INSTALLATION, OPERATION, SPARE

PARTS, AND MAINTENANCE MANUAL

MMD 150 SERIES

TWIN SHAFT SIZER
1500MM CENTRES
S150-0015*
(3 Tooth x 9 Ring, Double Drive, R630, 60:1 Gearbox)

CUSTOMER:

DRUMMOND COAL

* Please quote in all correspondence.

This number can be found on the identification plate, and
welded onto the machine side plate

THE MMD GROUP OF COMPANIES

MMD Mining Machinery Developments Limited
 MMD 150 SERIES
TWIN-SHAFT MINERAL SIZER
1500MM SHAFT CENTRES

CUSTOMER:
DRUMMOND COAL

MMD JOB NUMBER 18205

MACHINE SERIAL NUMBER S150-0015

VOITH COUPLING 750TVSC EPK 1108580

SERIAL NUMBER 1108581
S1797000-001
GEARBOX SERIAL NUMBER S1797000-002

G.A. DRAWING NUMBER 1500091

PREPARED BY :- N. SPENCER/S. RADFORD

POSITION :- C.A.D/MANAUL DEP’T
DATE COMPLETED :- 28 - 01 - 05

Company Registration Nº. 1382580

MMD 150 SERIES TWIN-SHAFT MINERAL SIZER
MACHINE CASE ASSEMBLY
TYPE 3 TOOTH x 9 RING CASE
PART NUMBER 341500110

BREAKER SHAFT ASSEMBLIES

TYPE 3 TOOTH x 9 RING
PART NUMBER (LEFT) 245010376
PART NUMBER (RIGHT) 245010377

GEARBOX ASSEMBLY
TYPE R630, 60:1 RATIO
PART NUMBER L/HAND 241797000L/H
PART NUMBER R/HAND 241797000R/H

FLUID COUPLING / DRIVE ASSEMBLY

TYPE VOITH 750 TVSC
PART NUMBER 141501432

INTERMEDIATE DRIVE ASSEMBLY

TYPE TO SUIT VOITH 750
PART NUMBER 245120000

GEAR COUPLING ASSEMBLY

TYPE TO SUIT R630 GEARBOX
PART NUMBER 111701147
MMD 150 SERIES TWIN-SHAFT MINERAL SIZER
UNDERSPEED SENSING ASSEMBLY
TYPE 110V CARLO GAVAZZI
PART NUMBER 143210032

GREASING ASSEMBLY
TYPE -
PART NUMBER 143060347

PLEASE NOTE:- ALL FIXINGS LISTED IN

THIS MANUAL ARE TO BS EN24014 GRADE 8.8
(UNLESS OTHERWISE STATED)
 PREFACE
This instruction/spare parts manual forms part of the equipment supplied on this contract,
and should be maintained for the life of the equipment, ensuring that any amendments are
incorporated. It is vital that any new user/holder of this equipment receives this manual.

The purpose of this manual is to give information and advise on the equipment supplied.

The design and manufacture of MMD products is subject to constant review, and the
information given may vary from that manufactured, due to improvements in design
techniques.

Before any commissioning or checking of the equipment is carried out, the manual should
be studied in its entirety, so that a better understanding of the operations of the equipment is
obtained.

PLEASE NOTE: THE INSTRUCTIONS IN THIS MANUAL ARE GIVEN

FOR INFORMATION AND GUIDANCE ONLY, AND MMD CANNOT
ACCEPT RESPONSIBILITY EITHER FOR THE MANNER IN WHICH
THEY ARE OBSERVED OR FOR ANY CONSEQUENCE THEREOF.

Copyright
This manual contains information and drawings which are confidential. Drawings and
information may not be used or disclosed, reproduced or transmitted in any form, or by any
means, electronic or mechanical, except with the written permission of, and in the manner
permitted by the proprietors:

MMD Mining Machinery Developments Limited, © 1999.

Cotes Park Lane,
Cotes Park Industrial Estate,
Somercotes,
Derbyshire. DE55 4NJ
England.
Telephone: +44 (0)1773 835533
Facsimile: +44 (0)1773 835593 or 837818 (Sales)
E-Mail: manuals@[Link]

All enquiries for spare parts should be directed to our purchasing department at the above
address. Technical queries or requests for further information should be directed to our
technical department.
In any correspondence or enquiry, please quote the serial number of the machine, which can
be found in two locations on Sizers: on the identification plate, and welded onto the side
plate, or on Plate Feeders, the serial number is stamped onto the identification plate.

Company Registration Nº. 1382580

ABCDEF
 SPARE PARTS ORDERING GUIDE
THE FOLLOWING INFORMATION IS PROVIDED TO ASSIST IN THE PURCHASE
OF SPARE PARTS, E.G. COMPONENT PARTS OR ASSEMBLIES OF COMPONENT
PARTS. WHEN ORDERING SPARE PARTS USING THIS MANUAL, THE
FOLLOWING INFORMATION IS REQUIRED BY OUR SALES DEPARTMENT.

MACHINE SERIAL NUMBER;

The serial number can be found in two locations on an MMD SIZER™, on the identification plate, and
welded onto the side plate. On Plate Feeders, the number can be found on the identification plate only.

PART NUMBER;
ITEM PART DESCRIPTION UNIT QTY
NUMBER MASS
1 0063817-01 Shaft End Cap 13.0 2
This nine figure part number is unique to every part sold by MMD, and is vital when ordering spare
parts.

COMPONENT DESCRIPTION;
ITEM PART DESCRIPTION UNIT QTY
NUMBER MASS
1 0063817-01 Shaft End Cap 13.0 2
The component description is required by MMD to act as a cross reference to the part number when
ordering spare parts. The description column can also contain other information, such as supplier’s part
numbers, bolt grades, etc.

UNIT MASS;
ITEM PART DESCRIPTION UNIT QTY
NUMBER MASS
13.0
1 0063817-01 Shaft End Cap 2
(28.66)
The unit mass is not required when ordering spare parts, but is provided for the purpose of on site lifting,
packaging, transportation etc. All masses are given in kilograms (kg), Where applicable/specified, the
unit mass is also given in pounds (lbs, shown in brackets).

QUANTITY;
ITEM PART DESCRIPTION UNITM QTY
NUMBER ASS
1 0063817-01 Shaft End Cap 13.0 2
Finally, the quantity of spare parts required must be included in the spare parts order.
 MMD MINING MACHINERY DEVELOPMENTS LIMITED

MMD 150 SERIES

TWIN SHAFT MINERAL SIZER
GENERAL ARRANGEMENT
DRAWING NUMBER - 1500091d

Section i – Revision 1 G.A. Drawing, Page 1 of 3

 MMD MINING MACHINERY DEVELOPMENTS LIMITED

CASE ASSEMBLY
PART NUMBER - 341500110

REVISION MODIFICATION DATE

1.0 FIRST ISSUE 25 - 02 - 05

Section 1 – Revision 1 Sizer Case Assembly, Page 1 of 19

 MMD MINING MACHINERY DEVELOPMENTS LIMITED
CASE ASSEMBLY
Part Number : 341500110

Section 1 – Revision 1 Sizer Case Assembly, Page 2 of 19

 MMD MINING MACHINERY DEVELOPMENTS LIMITED
CASE ASSEMBLY
Part Number : 341500110

Section 1 – Revision 1 Sizer Case Assembly, Page 3 of 19

 MMD MINING MACHINERY DEVELOPMENTS LIMITED
CASE ASSEMBLY
Part Number : 341500110

Section 1 – Revision 1 Sizer Case Assembly, Page 4 of 19

 MMD MINING MACHINERY DEVELOPMENTS LIMITED
CASE ASSEMBLY
Part Number : 341500110

Part
Item Description Unit Mass Qty
Number
1 1501413-85 SIDEPLATE 16,350.00 1
2 1501414-85 SIDEPLATE 16,350.00 1
3 1501415-85 FABRICATED BEARING HOUSING 19,165.00 2
4 1501416-85 D/DRIVE R630 GEARBOX MTG PLATE 10,020.00 1
5 1501417-85 FABRICATED BEARING CAPSULE 1,995.00 4
6 1501439-85 TOP COVER PLATE 700.00 1
7 1501440-85 BOTTOM COVER PLATE 510.00 1
8 1501441-84 INSPECTION COVER 28.80 2
9 1501448-85 SHAFT LIFTING EYE 89.20 1
10 1501464-84 D/END G/PIPE PROTECTION COVER 0.00 1
11 1501465-84 D/END G/PIPE PROTECTION COVER 0.00 1
12 1501466-84 ND/END G/PIPE PROTECTION COVER 0.00 1
13 1501467-84 ND/END G/PIPE PROTECTION COVER 0.00 1
14 1544239-84 INSPECTION COVER 9.50 4
Total Mass :- 90,424.80 Kg

Section 1 – Revision 1 Sizer Case Assembly, Page 5 of 19

 MMD MINING MACHINERY DEVELOPMENTS LIMITED

SIZER BOLT LIST

PART NUMBER - 14150-0012

REVISION MODIFICATION DATE

1.0 FIRST ISSUE 02 - 12 - 04

Section 1 – Revision 1 Sizer Case Assembly, Page 6 of 19

 MMD MINING MACHINERY DEVELOPMENTS LIMITED
BOLT LIST
Part Number : 14150-0012

Section 1 – Revision 1 Sizer Case Assembly, Page 7 of 19

 MMD MINING MACHINERY DEVELOPMENTS LIMITED
BOLT LIST
Part Number : 14150-0012

Section 1 – Revision 1 Sizer Case Assembly, Page 8 of 19

 MMD MINING MACHINERY DEVELOPMENTS LIMITED
BOLT LIST
Part Number : 14150-0012

Section 1 – Revision 1 Sizer Case Assembly, Page 9 of 19

 MMD MINING MACHINERY DEVELOPMENTS LIMITED
BOLT LIST
Part Number : 14150-0012

Part
Item Description Unit Mass Qty
Number
1 023991708 M64 X 4P HYD NUT(HTT.3828.000A) 0.00 16
2 030324080 M24 X 80 HEX BOLT EN24014 GR8.8 0.42 4
3 030324130 M24 X 130 HEX BOLT EN24014 GR8.8 0.60 4
4 030330150 M30 X 150 HEX BOLT EN24014 GR8.8 1.10 24
5 030348260 M48 X 260 HEX BOLT EN24014 GR8.8 0.00 20
6 030356320 M56 X 320 HEX BOLT 0.00 40
7 031316030 M16 X 30 HEX SET SCREW BS4168 GR8.8 0.09 16
8 031324050 M24 X 50 HEX SET SCREW BS4168 GR8.8 0.31 32
9 031336060 M36 X 60 HEX SET SCREW BS4168 GR8.8 0.94 6
10 031424000 M24 NYLOC NUT BS4929 0.11 8
11 032000873 RM0295-30 O RING 0.00 4
12 032742000 M42 HEX NUT 1XD THK BS EN 24032 GR8.8 0.80 64
13 032748000 M48 HEX NUT 1XD THK BS EN 24032 GR8.8 1.00 20
14 032756000 M56 HEX NUT 1XD THK BS EN 24032 GR8.8 1.00 40
15 032764000 M64 FULL HEIGHT NUT 2.20 80
16 035642000 M42 HV WASHER SPECIFICATION DIN 6916 0.16 64
17 035656000 M56 HV WASHER SPECIFICATION DIN 6916 0.38 80
18 035664000 M64 HV WASHER SPECIFICATION DIN 6916 0.62 80
19 1501163-01 M42 X 340 STUD GR10.9 0.00 32
20 1501461-01 M64 X 525 LONG STUD 0.00 32
21 1501462-01 M64 X 425 LONG STUD(M64X4 PITCH AT 1 END) 0.00 16
22 3992022-01 DOWEL 35MM DIA 0.00 8
23 3992023-01 RETAINING PLATE FOR DOWEL 0.00 8
Total Mass :- 471.24 Kg

Section 1 – Revision 1 Sizer Case Assembly, Page 10 of 19

 MMD MINING MACHINERY DEVELOPMENTS LIMITED

GEARBOX MOUNTING PLATE

LIFTING ASSEMBLY
PART NUMBER - 143992003

REVISION MODIFICATION DATE

1.0 FIRST ISSUE 21 - 02 - 05

Section 1 – Revision 1 Sizer Case Assembly, Page 11 of 19

 MMD MINING MACHINERY DEVELOPMENTS LIMITED
GEARBOX MOUNTING PLATE LIFTING ASSEMBLY
Part Number : 143992003

Item Part Number Description Unit Mass Qty

1 030342220 M42 X 220 HEX BOLT EN24014 GR8.8 0.00 8
2 031442000 M42 NYLOC NUT BS4929 0.62 8
3 035642000 M42 HV WASHER SPECIFICATION DIN 6916 0.16 16
4 3992003-85 LIFTING BRACKET-750 M/C-3T X 9R 0.00 2

Total Mass :- 7.52 Kg

Section 1 – Revision 1 Sizer Case Assembly, Page 12 of 19

 MMD MINING MACHINERY DEVELOPMENTS LIMITED

SIDE WEARPLATE
ASSEMBLY
PART NUMBER - 141501428
PART NUMBER - 141501430

REVISION MODIFICATION DATE

1.0 FIRST ISSUE 07 - 02 - 04

Section 1 – Revision 1 Sizer Case Assembly, Page 13 of 19

 MMD MINING MACHINERY DEVELOPMENTS LIMITED
SIDE WEARPLATE ASSY
Part Number : 141501428

Part
Item Description Unit Mass Qty
Number
1 031424000 M24 NYLOC NUT BS4929 0.11 14
2 031824160 M24 X160 CSK SKT SCREW BS4168 0.08 14
3 1501428-84 SIDE WEARPLATE 717.00 1
Total Mass :- 719.66 Kg

Section 1 – Revision 1 Sizer Case Assembly, Page 14 of 19

 MMD MINING MACHINERY DEVELOPMENTS LIMITED
SIDE WEARPLATE ASSY
Part Number : 141501430

Part
Item Description Unit Mass Qty
Number
1 031424000 M24 NYLOC NUT BS4929 0.11 10
2 031824160 M24 X160 CSK SKT SCREW BS4168 0.08 10
3 1501430-84 SIDE WEARPLATE 630.00 1
Total Mass :- 631.90 Kg

Section 1 – Revision 1 Sizer Case Assembly, Page 15 of 19

 MMD MINING MACHINERY DEVELOPMENTS LIMITED

END WEARPLATE
ASSEMBLY
PART NUMBER - 141501433

REVISION MODIFICATION DATE

1.0 FIRST ISSUE 10 - 02 - 05

Section 1 – Revision 1 Sizer Case Assembly, Page 16 of 19

 MMD MINING MACHINERY DEVELOPMENTS LIMITED
END WEARPLATE ASSEMBLY
Part Number : 141501433

Part
Item Description Unit Mass Qty
Number
1 031430000 M30 NYLOC NUT BS4929 0.21 4
2 031830160 M30 X160 CSK SKT SCREW BS4168 0.08 4
3 1501433-84 END WEARPLATE 1,060.00 1
Total Mass :- 1,061.16 Kg

Section 1 – Revision 1 Sizer Case Assembly, Page 17 of 19

 MMD MINING MACHINERY DEVELOPMENTS LIMITED

SIDE COMB
ASSEMBLY
PART NUMBER - 145061066

REVISION MODIFICATION DATE

1.0 FIRST ISSUE 05 - 02 - 05

Section 1 – Revision 1 Sizer Case Assembly, Page 18 of 19

 MMD MINING MACHINERY DEVELOPMENTS LIMITED
SIDECOMB ASSEMBLY
Part Number : 145061066

Item Part Number Description Unit Mass Qty

1 030342200 M42 X 200 HEX BOLT EN24014 GR8.8 2.90 4
2 031442000 M42 NYLOC NUT BS4929 0.62 4
3 5061066-85 FABRICATED SIDECOMB-1500 M/C-3T X 9R 305.00 1

Total Mass :- 319.08 Kg

Section 1 – Revision 1 Sizer Case Assembly, Page 19 of 19

 MMD MINING MACHINERY DEVELOPMENTS LIMITED

BREAKER BAR
ASSEMBLY
PART NUMBER - 145070186

REVISION MODIFICATION DATE

1.0 FIRST ISSUE 20 - 02 - 05

Section 2– Revision 1 Breaker Bar Assembly, Page 1 of 4

 MMD MINING MACHINERY DEVELOPMENTS LIMITED
BREAKER BAR ASSEMBLY
Part Number : 145070186

Part
Item Description Unit Mass Qty
Number
1 030348400 M48 X 400 HEX BOLT EN24014 GR8.8 5.30 12
2 030348500 M48 X 500 HEX BOLT EN24014 GR8.8 5.30 12
3 031448000 M48 NYLOC NUT BS4929 0.90 12
4 035648000 M48 HV WASHER SPECIFICATION DIN 6916 0.28 12
5 5070185-91 BREAKER BAR PACKER 25MM 0.00 16
6 5070186-85 BREAKER BAR 6,925.00 1
Total Mass :- 7,066.36 Kg

Section 2– Revision 1 Breaker Bar Assembly, Page 2 of 4

 MMD MINING MACHINERY DEVELOPMENTS LIMITED

BREAKER BAR CAP

ASSEMBLY
PART NUMBER - 145061069

REVISION MODIFICATION DATE

1.0 FIRST ISSUE 24 - 02 - 05

Section 2– Revision 1 Breaker Bar Assembly, Page 3 of 4

 MMD MINING MACHINERY DEVELOPMENTS LIMITED
BREAKER CAP ASSEMBLY
Part Number : 145061069

Part
Item Description Unit Mass Qty
Number
1 032748000 M48 HEX NUT 1XD THK BS EN 24032 GR8.8 1.00 1
2 035648000 M48 HV WASHER SPECIFICATION DIN 6916 0.28 1
3 5061069-84 BREAKER BAR CAP MMD501 155.00 1
4 5061119-84 INFILL PIECE FOR BREAKER BAP CAP 1.20 1
5 5110139-01 M48 X 450 SQ HEAD B/BAR CAP BOLT 7.20 1
Total Mass :- 164.68 Kg

Section 2– Revision 1 Breaker Bar Assembly, Page 4 of 4

 MMD MINING MACHINERY DEVELOPMENTS LIMITED

LEFT-HAND BREAKER SHAFT

ASSEMBLY
PART NUMBER - 245010376

REVISION MODIFICATION DATE

1.0 FIRST ISSUE 09 - 12 - 04

Section 3 – Revision 1 Left-Hand Shaft Assembly, Page 1 of 9

 MMD MINING MACHINERY DEVELOPMENTS LIMITED
BREAKER SHAFT ASSEMBLY
Part Number : 245010376

Section 3 – Revision 1 Left-Hand Shaft Assembly, Page 2 of 9

 MMD MINING MACHINERY DEVELOPMENTS LIMITED
BREAKER SHAFT ASSEMBLY
Part Number : 245010376

Part
Item Description Unit Mass Qty
Number
1 031336100 M36 X 100 HEX SETSCREW BS3692 GR8.8 1.25 20
2 035636000 M36 HV WASHER SPECIFICATION DIN 6916 0.10 20
3 141500111 FIXED BEARING ASSEMBLY 897.80 1
4 141500112 FREE BEARING ASSEMBLY 850.00 1
5 145010376 BREAKER SHAFT ASSY 21,513.00 1
6 1501418-01 SHAFT SPACER_OUTBOARD BEARINGS) 180.00 2
7 1501422-01 SHAFT END CAP-DRIVE END) 47.70 1
8 1501426-01 M400 THREAD LOCKNUT 86.00 1
9 1501427-01 SPACER 102MM 40.00 1
10 1501434-01 LOCKING WASHER(TO SUIT 1501426) 2.00 1
11 1501442-01 SHAFT END CAP(N/D/E) 55.00 1
12 1501447-01 M20 UNDERSPEED SENSING STUD 0.10 1
13 3992025-01 0.5MM THICK SHIM WASHER 0.00 2
14 3992026-01 0.1MM THICK SHIM WASHER 0.00 10
15 3992027-01 1.0MM THICK SHIM WASHER 0.00 2

Total Mass :- 23,878.60 Kg

Section 3 – Revision 1 Left-Hand Shaft Assembly, Page 3 of 9

 MMD MINING MACHINERY DEVELOPMENTS LIMITED

LEFT-HAND BREAKER SHAFT

ASSEMBLY
PART NUMBER - 145010376

REVISION MODIFICATION DATE

1.0 FIRST ISSUE 25 - 02 - 05

Section 3 – Revision 1 Left-Hand Shaft Assembly, Page 4 of 9

 MMD MINING MACHINERY DEVELOPMENTS LIMITED
BREAKER SHAFT ASSEMBLY
Part Number : 145010376

Part
Item Description Unit Mass Qty
Number
1 1501435-06 END COLLAR-EN 24 940.00 1
2 1501436-06 END COLLAR-EN 24 295.00 1
3 5010376-06 BREAKER SHAFT 11,583.00 1
4 5051225-06 3 TOOTH FORGED RING 970.00 8
5 5051451-06 3 TOOTH FORGED END RING 935.00 1
Total Mass :- 21,513.00 Kg

Section 3 – Revision 1 Left-Hand Shaft Assembly, Page 5 of 9

 MMD MINING MACHINERY DEVELOPMENTS LIMITED

FIXED BEARING
ASSEMBLY
PART NUMBER - 141500111

REVISION MODIFICATION DATE

1.0 FIRST ISSUE 13 - 12 - 04

Section 3 – Revision 1 Left-Hand Shaft Assembly, Page 6 of 9

 MMD MINING MACHINERY DEVELOPMENTS LIMITED
FIXED BEARING ASSEMBLY
Part Number : 141500111

Item Part Number Description Unit Mass Qty

1 030536120 M36 X 120 SKT CAP SCREW BS4168 1.30 20
2 032000870 500 X 460 X 20 R21 F1 VITON OIL SEAL 1.20 4
3 035000649 24180 ECA/W33 C3 EXPLORER BEARING 340.00 1
4 1501419-01 LABYRINTH-1500 M/C-3T X 9 RINGS 100.00 1
5 1501420-01 LABYRINTH RETAINING PLATE-1500 M/C 140.00 1
6 1501421-01 BEARING FIXING RING-1500 M/C-3T X 9R 23.50 2
7 1501423-01 SEAL RETAINING PLATE-1500 M/C-3T X 9R 185.00 1
8 1501425-01 SEAL PATH-1500 M/C-3T X 9 RINGS 0.00 1

Total Mass :- 842.80 Kg

Section 3 – Revision 1 Left-Hand Shaft Assembly, Page 7 of 9

 MMD MINING MACHINERY DEVELOPMENTS LIMITED

FREE BEARING
ASSEMBLY
PART NUMBER - 141500112

REVISION MODIFICATION DATE

1.0 FIRST ISSUE 20 - 12 - 04

Section 3 – Revision 1 Left-Hand Shaft Assembly, Page 8 of 9

 MMD MINING MACHINERY DEVELOPMENTS LIMITED
FREE BEARING ASSEMBLY
Part Number : 141500112

Item Part Number Description Unit Mass Qty

1 030536120 M36 X 120 SKT CAP SCREW BS4168 1.30 20
2 032000870 500 X 460 X 20 R21 F1 VITON OIL SEAL 1.20 2
3 035000649 24180 ECA/W33 C3 EXPLORER BEARING 340.00 1
4 1501419-01 LABYRINTH-1500 M/C-3T X 9 RINGS 100.00 1
5 1501420-01 LABYRINTH RETAINING PLATE-1500 M/C 140.00 1
6 1501424-01 BLANKING PLATE-1500 M/C-3T X 9 RINGS 220.00 1

Total Mass :- 828.40 Kg

Section 3 – Revision 1 Left-Hand Shaft Assembly, Page 9 of 9

 MMD MINING MACHINERY DEVELOPMENTS LIMITED

RIGHT-HAND BREAKER SHAFT

ASSEMBLY
PART NUMBER - 245010377

REVISION MODIFICATION DATE

1.0 FIRST ISSUE 21 - 02 - 05

Section 4 – Revision 1 Right Hand Breaker Shaft Assembly, Page 1 of 9

 MMD MINING MACHINERY DEVELOPMENTS LIMITED
BREAKER SHAFT ASSEMBLY
Part Number : 245010377

Section 4 – Revision 1 Right Hand Breaker Shaft Assembly, Page 2 of 9

 MMD MINING MACHINERY DEVELOPMENTS LIMITED
BREAKER SHAFT ASSEMBLY
Part Number : 245010377

Part
Item Description Unit Mass Qty
Number
1 031336100 M36 X 100 HEX SETSCREW BS3692 GR8.8 1.25 20
2 035636000 M36 HV WASHER SPECIFICATION DIN 6916 0.10 20
3 141500111 FIXED BEARING ASSEMBLY 897.80 1
4 141500112 FREE BEARING ASSEMBLY 850.00 1
5 145010377 BREAKER SHAFT ASSY 21,513.00 1
6 1501418-01 SHAFT SPACER_OUTBOARD BEARINGS) 180.00 2
7 1501422-01 SHAFT END CAP-DRIVE END) 47.70 1
8 1501426-01 M400 THREAD LOCKNUT 86.00 1
9 1501427-01 SPACER 102MM 40.00 1
10 1501434-01 LOCKING WASHER(TO SUIT 1501426) 2.00 1
11 1501442-01 SHAFT END CAP(N/D/E) 55.00 1
12 1501447-01 M20 UNDERSPEED SENSING STUD 0.10 1
13 3992025-01 0.5MM THICK SHIM WASHER 0.00 2
14 3992026-01 0.1MM THICK SHIM WASHER 0.00 10
15 3992027-01 1.0MM THICK SHIM WASHER 0.00 2

Total Mass :- 23,878.60 Kg

Section 4 – Revision 1 Right Hand Breaker Shaft Assembly, Page 3 of 9

 MMD MINING MACHINERY DEVELOPMENTS LIMITED

RIGHT-HAND BREAKER SHAFT

ASSEMBLY
PART NUMBER - 145010377

REVISION MODIFICATION DATE

1.0 FIRST ISSUE 21 - 02 - 05

Section 4 – Revision 1 Right Hand Breaker Shaft Assembly, Page 4 of 9

 MMD MINING MACHINERY DEVELOPMENTS LIMITED
BREAKER SHAFT ASSEMBLY
Part Number : 145010377

Part
Item Description Unit Mass Qty
Number
1 1501435-06 END COLLAR-EN 24 940.00 1
2 1501436-06 END COLLAR-EN 24 295.00 1
3 5010377-06 BREAKER SHAFT 11,583.00 1
4 5051225-06 3 TOOTH FORGED RING 970.00 8
5 5051451-06 3 TOOTH FORGED END RING 935.00 1
Total Mass :- 21,513.00 Kg

Section 4 – Revision 1 Right Hand Breaker Shaft Assembly, Page 5 of 9

 MMD MINING MACHINERY DEVELOPMENTS LIMITED

FIXED BEARING
ASSEMBLY
PART NUMBER - 141500111

REVISION MODIFICATION DATE

1.0 FIRST ISSUE 13 - 12 - 04

Section 4 – Revision 1 Right Hand Breaker Shaft Assembly, Page 6 of 9

 MMD MINING MACHINERY DEVELOPMENTS LIMITED
FIXED BEARING ASSEMBLY
Part Number : 141500111

Item Part Number Description Unit Mass Qty

1 030536120 M36 X 120 SKT CAP SCREW BS4168 1.30 20
2 032000870 500 X 460 X 20 R21 F1 VITON OIL SEAL 1.20 4
3 035000649 24180 ECA/W33 C3 EXPLORER BEARING 340.00 1
4 1501419-01 LABYRINTH-1500 M/C-3T X 9 RINGS 100.00 1
5 1501420-01 LABYRINTH RETAINING PLATE-1500 M/C 140.00 1
6 1501421-01 BEARING FIXING RING-1500 M/C-3T X 9R 23.50 2
7 1501423-01 SEAL RETAINING PLATE-1500 M/C-3T X 9R 185.00 1
8 1501425-01 SEAL PATH-1500 M/C-3T X 9 RINGS 0.00 1

Total Mass :- 842.80 Kg

Section 4 – Revision 1 Right Hand Breaker Shaft Assembly, Page 7 of 9

 MMD MINING MACHINERY DEVELOPMENTS LIMITED

FREE BEARING
ASSEMBLY
PART NUMBER - 141500112

REVISION MODIFICATION DATE

1.0 FIRST ISSUE 20 - 12 - 04

Section 4 – Revision 1 Right Hand Breaker Shaft Assembly, Page 8 of 9

 MMD MINING MACHINERY DEVELOPMENTS LIMITED
FREE BEARING ASSEMBLY
Part Number : 141500112

Item Part Number Description Unit Mass Qty

1 030536120 M36 X 120 SKT CAP SCREW BS4168 1.30 20
2 032000870 500 X 460 X 20 R21 F1 VITON OIL SEAL 1.20 2
3 035000649 24180 ECA/W33 C3 EXPLORER BEARING 340.00 1
4 1501419-01 LABYRINTH-1500 M/C-3T X 9 RINGS 100.00 1
5 1501420-01 LABYRINTH RETAINING PLATE-1500 M/C 140.00 1
6 1501424-01 BLANKING PLATE-1500 M/C-3T X 9 RINGS 220.00 1

Total Mass :- 828.40 Kg

Section 4 – Revision 1 Right Hand Breaker Shaft Assembly, Page 9 of 9

 MMD MINING MACHINERY DEVELOPMENTS LIMITED

GEAR COUPLING ASSEMBLY

PART NUMBER - 111701147

REVISION MODIFICATION DATE

1.0 FIRST ISSUE 10 - 01 - 05

Section 6 – Revision 1 Gear Coupling Assembly, Page 1 of 2

 MMD MINING MACHINERY DEVELOPMENTS LIMITED
GEAR COUPLING ASSEMBLY
Part Number : 111701147

Part
Item Description Unit Mass Qty
Number
1 030520110 M20 X 110 SKT CAP SCREW BS4168 0.32 4
2 031420000 M20 NYLOC NUT BS4929 0.06 4
3 032000857 RM6991-84 'O' RING 0.00 2
4 036000604 1/4 BSP GREASE NIPPLE 0.01 2
5 1701144-01 GEAR COUPLING HUB-R630 GEARBOX 208.00 2
6 1701145-01 SLEEVE O/D710 L351 265.00 1
7 1701146-01 GEAR COUPLING CLAMP 41.00 2
Total Mass :- 764.54 Kg

Section 6 – Revision 1 Gear Coupling Assembly, Page 2 of 2

 MMD MINING MACHINERY DEVELOPMENTS LIMITED

WELD-ON CAP
ASSEMBLY
PART NUMBER - 145061061

REVISION MODIFICATION DATE

1.0 FIRST ISSUE 22 - 02 - 05

Section 5 – Revision 1 Bi-Metal Cap Assembly, Page 1 of 2

 MMD MINING MACHINERY DEVELOPMENTS LIMITED
WELD ON CAP ASSEMBLY
Part Number : 145061061

Part
Item Description Unit Mass Qty
Number
1 5061053-06 HEAVY DUTY WELD ON TIP(EN24) 22.00 1
2 5061057-84 WELD ON TOP CAP 211.00 1
3 5061061-84 WELD ON BASE CAP 267.00 1
4 5061065-84 WELD ON BACK PLATE 33.00 1
Total Mass :- 533.00 Kg

Section 5 – Revision 1 Bi-Metal Cap Assembly, Page 2 of 2

 MMD MINING MACHINERY DEVELOPMENTS LIMITED

AUTOMATIC GREASING
ASSEMBLY
PART NUMBER - 143060347

REVISION MODIFICATION DATE

1.0 FIRST ISSUE 28 - 02 - 02

Section 9 – Revision 1 Centralised Greasing Assembly, Page 1 of 3

 MMD MINING MACHINERY DEVELOPMENTS LIMITED
GREASING ASSEMBLY
Part Number : 143060347

Section 9 – Revision 1 Centralised Greasing Assembly, Page 2 of 3

 MMD MINING MACHINERY DEVELOPMENTS LIMITED
GREASING ASSEMBLY
Part Number : 143060347

Item Part Number Description Unit Mass Qty

1 023307507 10MM O/D X 1.5MM WALL X 6MT LONG PIPE 1.30 4
2 023307509 1/4 BSP MALE - 10MM PIPE 0.10 10
3 023307510 10MM X 10MM ELBOW 0.10 10
4 023307512 10MM X 1/4 BSP BANJO 0.10 6
5 032000451 1/4" BSP BONDED SEAL BS4518 0.01 10
6 036000604 1/4 BSP GREASE NIPPLE 0.01 8

Total Mass :- 7.98 Kg

Section 9 – Revision 1 Centralised Greasing Assembly, Page 3 of 3

 MMD MINING MACHINERY DEVELOPMENTS LIMITED

UNDERSPEED
SENSING ASSEMBLY
PART NUMBER - 143210032

REVISION MODIFICATION DATE

1.0 FIRST ISSUE 03 - 08 - 04

Section 11 – Revision 1 Underspeed Sensing Assembly, Page 1 of 7

 MMD MINING MACHINERY DEVELOPMENTS LIMITED
UNDERSPEED ASSEMBLY
Part Number : 143210032

Part
Item Description Unit Mass Qty
Number
1 023210002 RELAY (REF.S114156115 -100RPM) 0.20 1
2 023210004 BASE (REF.S411) 0.06 1
3 023210036 SPEED SENSOR REF.1A 18 ELN 08 UC 0.01 1
4 1563010-01 SPEED SENSOR PLUG 0.10 1

Total Mass :- 0.37 Kg

Section 11 – Revision 1 Underspeed Sensing Assembly, Page 2 of 7

 MMD MINING MACHINERY DEVELOPMENTS LIMITED

CARLO GAVAZZI
SPEED SWITCH OPERATION &
INSTALLATION INSTRUCTIONS

The speed switch provided is a Carlo Gavazzi pulse continuity relay, part number
S114 156 115. This multiple function control relay operates as a motor speed monitor.
The relay receives a pulse from a Carlo Gavazzi proximity sensor, part number 1A 18
ELN 08 UC to monitor motor speed. The control operation of this relay includes two
selectable modes of operation, and four selectable time ranges.

SECTION 1 - BASIC OPERATION

This section covers basics connections and settings of DIP switches for the modes of
operation and time delay settings.

SECTION II - MOMENTARY START CIRCUIT OPERATION

This section covers the electric operation of the relay for a momentary start circuit,
and the required DIP switch setting for this operation.

SECTION III - MAINTAINED RUN CIRCUIT OPERATION

This section covers the electric operation of the relay for a maintained start circuit and
the required DIP switch setting for this operation.

Section 11 – Revision 1 Underspeed Sensing Assembly, Page 3 of 7

 I. BASIC OPERATION

This relay required 115 volts 50/60Hz control power connected to terminals 2 and 10.
To connect the proximity sensor connect the brown (+) positive wire to terminal 6 and
the blue (-) negative wire to terminal 7.

Pulse Continuity
115 V ~ 50/60Hz
S 114 156 115

Modes Of Operation:

DIP-SWITCH #1 ON; The relay operates and the time period starts when control
power is applied. If an input pulse is received before the end of the set time period, the
relay continues operating for a full new time period starting at the leading edge of the
input pulse. If the set time period expires before a new input pulse is received, the
relay releases.

DIP-SWITCH #1 OFF; The relay operates and the time period starts at the leading
edge of the first input pulse. If a new input pulse is received before the end of the set
time period, the relay continues operating for a full new time period starting at the
leading edge of the new input pulse. If the set time expires before a new input pulse is
received, the relay releases.

Time Settings:

Four (4) selectable time ranges 0.15 seconds to 800 seconds, with an adjustable scale
in percent of the maximum time setting.

DIP-SWITCH #2 ON #3 OFF time setting 0.15 sec to 3 sec.

DIP-SWITCH #2 OFF #3 ON time setting 0.6 sec to 12 sec.
DIP-SWITCH #2 ON #3 ON time setting 5 sec to 100 sec.
DIP-SWITCH #2 OFF #3 OFF time setting 40 sec to 800 sec.

Section 11 – Revision 1 Underspeed Sensing Assembly, Page 4 of 7

 II. MOMENTARY START CIRCUIT OPERATION

The speed switch relay contact (SSR) closes and the time period starts when the start
push button is pressed, applying 115 volt control power to the relay (SSR). When an
input pulse from the proximity sensor is received the relay continues operating for a
full new time period starting at the next impulse. When the set time period expires
before the next input pulse is received, the relay opens contact (SSR) and stops the
motor.

This operation requires the speed switch relay to be set for a time delay setting of 6
seconds. This allows for motor start up and provides a time delay for the motor to
recover from a potential stall condition. See figure below for required DIP switch set-
tings.

DIP switches for selecting function

and time are placed behind a small
removable plate on the front of the relay.

With the DIP switches set to provide a time range of 0.6 to 12 seconds, set the % time
adjustment to 50 percent for a time delay of 6 seconds.

Section 11 – Revision 1 Underspeed Sensing Assembly, Page 5 of 7

 III. MAINTAINED RUN CIRCUIT OPERATION

The speed switch relay contact (SSR) closes and the time period starts when the con-
trol switch is in the run position, applying 115 volt control power to the relay (SSR).
When and input pulse from the proximity sensor is received the relay continues oper-
ating for a full new time period starting at the next input pulse. When the set time
period expires before the next input pulse is received, the relay opens contact (SSR)
and stops the motor.

This operation requires the speed switch relay to be set for a time delay setting of 6
seconds. This allows for motor start up and provides a time delay for the motor to
recover from a potential stall condition. See figure below for required DIP switch set-
tings.

DIP switches for selecting function

and time are placed behind a small
removable plate on the front of the relay.

With the DIP switches set to provide a time range of 0.6 to 12 seconds, set the % time
adjustment to 50 percent for a time delay of 6 seconds.

Section 11 – Revision 1 Underspeed Sensing Assembly, Page 6 of 7

 BASIC SPEED
SENSOR CIRCUIT
The speed switch provided is a Carlo Gavazzi pulse continuity relay, part number S114 166
724 (24 V), S114 156 115 (110 V), or S114 156 230 (220 V). This multiple function control
relay operates as a motor speed monitor. The relay receives a pulse from a Carlo Gavazzi
proximity sensor, part number 1A 18 ELN 08 UC to monitor motor speed.

BASIC OPERATION
On pressing start, the push button contactor pulls in, C/1 closes. Power is applied to the
timer and closes contacts 1 and 3. When the sensor detects a pulse, the timer is reset and
waits for the next pulse. If there is no pulse, the relay drops out, stopping the motor.

Section 11 – Revision 1 Underspeed Sensing Assembly, Page 7 of 7

 MMD MINING MACHINERY DEVELOPMENTS LIMITED

MMD 150 SERIES TWIN

SHAFT MINERAL SIZER
PRINCIPLES OF OPERATION &
MAINTENANCE SCHEDULE

REVISION MODIFICATION DATE

1.0 FIRST ISSUE 25 - 03 - 04

Section 12 – Revision 1 Operation & Maintenance, Page 1 of 24

 MMD TWIN SHAFT
MINERAL SIZER

Principles Of Operation
The MMD Mineral SIZER accepts the product in through the top of the SIZER, delivery being from
any angle. The two rotating shafts have attached the appropriate sizing teeth which pass the total
product, undersize and oversize, down through the SIZER.

The undersized product is passed through the rotating teeth without further degradation, whilst the
oversized product is presented to the teeth in such a manner that the weakness of the material in
tension is exploited to the advantage. The size of the broken product can be controlled in all three
planes, giving an accurately sized product, which is then passed to the underside of the SIZER.

The SIZER is made of extremely robust construction and of adequate strength to withstand
continuous heavy duty operation.

The machined sideframes are of ribbed construction fabricated from structural steel with easily
replaceable steel wearplates covering all the inside area of the sizing chamber. Suitable drillings
readily accept the fitting of hopper and chute work.

The main shafts are machined from high strength alloy steel bar which are supported by self aligning
double row spherical roller bearings which are situated in heavy duty housings. The bearings are
lubricated by grease at both ends of the SIZER and are protected by heavy duty lip seals which are
further protected by a grease filled double labyrinth to prevent the ingress of water, dirt, etc.

The actual sizing elements are manufactured to MMD’s own specification, various specialist
materials have been developed to suit particular requirements.

Important Note On Operation

Running machines without load for extended periods is known to have serious detrimental
effects. This can cause damage to the bearings. It must therefore be part of the operating
procedure that when the machine is not being fed material for an extended period it must be
shut down.

Section 12 – Revision 1 Operation & Maintenance, Page 2 of 24

 SIZER Lifting Procedure

The MMD SIZER comes supplied with lifting lugs which are fixed to the top of the machine side plates to
allow for relevent lifting attachments to move and site the SIZER.

Note:- All local regulations must be adhered to and the correct safety regulations
enforced whilst lifting the equipment.

Once the SIZER has been correctly mounted in position, the lifting equipment can then be released and the
lifting lugs removed and stored in a safe place for future use.

Section 12 – Revision 1 Operation & Maintenance, Page 3 of 24

 Safe Operating Procedure

BEFORE ANY WORK IS CARRIED OUT ON THE SIZER OR ANY OF ITS ANCILLIARIES,
ISOLATE THE POWER SUPPLY, AND REMOVE THE CABLE FROM THE SIZER DRIVE
ELECTRIC MOTOR. UNLESS THE ABOVE OPERATION IS CARRIED OUT, NO PERSON OR
PERSONS SHALL STAND ON THE MACHINE.

O Installation of safety guards and hand rails shall be the responsibility of the customer at the time of
commissioning.

O During operation of the machine, no person or persons should violate the safety guards and hand rails in
its vicinity.

O Unless otherwise stated, MMD will not be responsible for the safe siting of the machine, and/or any
requirements appertaining to operating codes of practice.

O MMD will not be responsible for the use or operation of the machine for any purpose other that the
specified / accepted operation requirement in the official order.

O It is understood any maintenance carried out in accordance with this manual shall be by a person or
persons qualified to carry out such practice in compliance with the safety requirements of the operating
company.

NOTE: FAILURE TO COMPLY WITH ANY OF THE ABOVE PROCEDURES IS DONE SO AT THE
OPERATOR’S OWN RISK.

Commissioning Procedure
If the SIZER is removed from the working position for major overhauls or modifications, it will also be
necessary to re-commission it prior to re-starting.

O Carry out a full check of all items against manual parts list and drawings to ensure that everything is
installed correctly. This is a visual check only.

O Carry out a stall test to adjust the level in the fluid coupling, refer to the SIZER Stall Test section.

O For the recommended lubricant specifications/quantities, see the Maintenance Schedule.

O Run the machine under zero-load conditions for four (4) hours. Check for excessive noise, vibration, and
temperature. The normal operating temperature of the gearbox ranges between 55oC and 80oC. If any
adverse effects are evident, refer to the Trouble Shooting guide. Rectify as necessary.

O Run the machine under full-load conditions for eight (8) hours. Again check for any excessive noise,
vibration and temperature as before.

Section 12 – Revision 1 Operation & Maintenance, Page 4 of 24

 Pre-Start Check List
O Ensure visually that the machine is fully engaged in the working position.

O Check thoroughly to ensure that no person or persons can be injured when the machine starts.

O Check drive components for signs of obvious damage, leaks, etc.

O Check all oil levels, (gearbox & spur gears if fitted), check that the bearings are charged with grease.

O Check autolube system is set to run (if fitted).

SIZER Start-Up Procedure

O Carry out the specified pre-start checks.

O The machine can now start. If the motor starts, but the shafts do not rotate, then the machine is either
stalled, or a fusible plug has melted in one or both of the fluid couplings.

O Refer to the Stall Procedure.

MMD Equipment Storage Instructions

All MMD equipment is delivered in a stored condition, and is suitable to be stored inside or outside, in normal
temperatures for a period of approximately 12 months.

The cases supplied have a waterproof lining. On departure from MMD, the gearboxes are filled with lubricant
(for the lubricant specification, see the gearbox maintenance schedule). The input and output shafts of the
gearbox are wrapped in protective ‘Denso’ tape.

The containers supplied are covered in a Tarpaulin sheet with a slight apex incorporated to aid drainage, and
roped down accordingly around the base of the container. This must be checked periodically for rips or tears.

All exposed machined faces, such as the gearbox mounting plate are coated in ‘Tectil’ corrosion inhibitor.

THE SUPPLIED CONTAINERS, CASES, ETC. MUST NOT BE OPENED UNTIL MMD ARE NOTIFIED.

Section 12 – Revision 1 Operation & Maintenance, Page 5 of 24

 SIZER Stall Test

After every operating stall, and after any major overhaul, the fluid coupling must be reset to give optimum
performance. This is achieved by carrying out the following;

 Isolate the machine, by removing the cable from the electric motor. Use lockout procedures.

 Physically block the breaker shafts, so that they cannot rotate.

 Re-connect the power cable to the electric motor.

 The next operation requires and a tachometer, and is carried out as follows.

i Select the start position on the control switch, and run the motor until a steady speed reading is
obtained on the tachometer. It is imperitive that running time is kept to a minimum to avoid a build
of thermal energy in the coupling.

ii Stop the motor.

iii The objective is to obtain a steady reading of approximately 94% of synchronous motor speed.
i.e,
50Hz = 1410 RPM
60Hz= 1700 RPM

iv Add or remove a small amount of fluid as required

v Allow sufficient time for the coupling to cool before repeating the test.

 If the tachometer reading is below the desired speed, release fluid from the fluid coupling. If synchronous
speed is reached add fluid to the coupling. Repeat this process until a steady reading is achieved for the
motor of 94% synchronous speed.

 Remove the obstruction from between the SIZER shafts.

Section 12 – Revision 1 Operation & Maintenance, Page 6 of 24

 Trouble Shooting Guide
It is recommended that a daily check be made for any excessive noise, vibration, lubricant leaks, or obvious
damage. The following hints should help in determining the source of any unusual feature;

NOISE – When an unusual noise is heard, it is important to determine quickly what is causing the noise, so
that action can be taken. There are basically two noises to consider.

i High speed end (Electric Motor)

ii Low speed ends (Breaker Shafts)

The first step is to determine the frequency of the noise. It will be a regular noise in either the machine
aperture or the drive train. If it is a slow rhythmic noise, it is likely to come from the shafts. This could
indicate that there is a broken or loose bolt. Fully check the machine, the machine aperture, (with no material
passing through), to determine the cause.

If the noise is high frequency, it is possibly coming from the drive train. Starting from the motor, work along
the transmission to determine the cause of the noise. The obvious causes would be; faulty bearings in the motor,
fluid coupling, or gearbox; lack of lubricant or ingress of dust into rotating parts.

VIBRATION – A similar check list is used as when tracking down an unusual noise, however, most excessive
vibration is caused either by faulty main shaft bearings or faulty gearbox bearings. These items should be
checked first by checking the temperature on the frame of the machine adjacent to the shaft bearings and on the
casing of the gearbox.

LUBRICANT LEAKS – It is essential that all lubricants are corrected and replenished in accordance with the
service manual recommendations. If any leak is found, action must be taken immediately to correct it, i.e find
the source of the leak, determine the cause of the leak by reference to the spare parts manual, and identify the
parts required to rectify the leak. When this has been done, the machine must be stopped at the first opportunity
so that the work carried out.

OBVIOUS DAMAGE – 99% of the obvious damage occurring on MMD machines inside the machine
aperture is caused by tramp iron. Broken or cracked caps/segments and bolts are the most common form of
obvious damage. A visual inspection will determine the cause.

Section 12 – Revision 1 Operation & Maintenance, Page 7 of 24

 Underspeed Sensing Device
O Fitted at the non drive end of the SIZER™, is an underspeed sensing device. The purpose of the underspeed
sensing device is to isolate power to the main SIZER™ motor(s) and upstream supply systems when the rotors
have lost speed. This is achieved by a pulse stud on the breaker shaft(s) passing through the magnetic field of
a close proximity sensor, therefore inducing an electrical impulse to the monitoring system. Should the
breaker shafts stop rotating, the monitoring systems should be connected to ensure they trip the electric
motor(s) after seven seconds.
The Power supply to the electric motor(s) must be isolated
and a manual inspection can be carried out to identify the fault.

Replacing The Underspeed Sensor

Should the underspeed sensor become inoperative, it will be necessary to replace it. To do this the machine
must be isolated electrically together with any upstream supply systems, so that they cannot be started
accidentally whilst work is being carried out.

i Isolate power supply.

ii Disconnect electric leads.

iii Loosen the lock nuts, and unscrew the detector head.

iv Refitting is the reverse of the above procedure. However, care must be taken to ensure that the sensor
head is within 5 to 10mm of the stud in the end of the breaker shaft, which provides a pulse every
revolution.

Section 12 – Revision 1 Operation & Maintenance, Page 8 of 24

 Wear Plates - Replacing
The MMD SIZER™ has wear plates on the inside of the machine aperture to protect the side plates and bearing
housings. These wear plates must be replaced when excessive wear has been detected. Clearance of rotating teeth
on the side wear plates should be a minimum of 10mm. This clearance should be checked when side wear plates
have been replaced before starting the machine.

To remove wearplates, the following procedures must be followed;

Side Wear Plates:

O Where the machine has pyramids/side combs which are bolted through the side wear plate, it will be
necessary to remove them prior to attempting to remove the wear plate.
O Weld two temporary lifting lugs to each wear plate, (on smaller machines this procedure may not be
necessary).
O Remove the bolts retaining the side wear plates and pyramids to the side plates, and discard them.
O Attach lifting equipment to the lifting lugs.
O Remove the bolts retaining the side wear plates and discard them.
O Remove the wear plate.
O Thoroughly clean the inside of the machine where the new wear plate is to be fitted to ensure correct seating
of the new wear plate.
O Weld temporary lifting lugs to the new side wear plate.
O Lift the new wear plate into position, and line up with fixing holes.
O Bolt the new wear plate into position, using new bolts. MMD do not recommend the re-use of wearplate bolts
due to the wearing of the bolt tops.
O Tighten the bolts to the torque specified on MMD procedure T056.
O Remove the temporary lifting lugs and discard them.
O Check the clearance between tooth caps/segments and wear plates. Clearance should be a minimum of
10mm.

End Wear Plates:

O Thoroughly clean the top of the machine to expose the holes for the lifting eye bolts.
O Remove the fixings from the end wear plates, which attach the wear plate to the bearing housing. These
fixings are fitted into drilled and tapped holes.
O Fit lifting eye bolts into the top of the wear plates, and lift out.
O Thoroughly clean all faces to which the new wear plates fit, to ensure correct seating of the new wear
plate. Protect tapped fixing holes before cleaning.
O Attach lifting eye bolts to the new wear plate, and lift it into position.
O Bolt the wear plate into position using the existing set screws.
O Remove the lifting eyes.
O Tighten the bolts to the torque rating specified in MMD procedure T056. (Included at the back of this
manual).

Section 12 – Revision 1 Operation & Maintenance, Page 9 of 24

 Gearbox Fitting & Removal

Gearbox Fitting Procedure:

O Clean the output shaft of the gearbox and the gear coupling.

O Slide the coupling half onto the output shaft.

O Fit the end cap onto the output shaft. Threadlock should be applied to the bolts prior to fitting.

O Lift the gearbox into position, ensuring that the spigot on the gearbox mates with the recess on the gearbox
mounting plate. Fit the studs/bolts connecting the gearbox to the gearbox mounting plate, and torque to
the amount specified in MMD procedure T056.

O Align the teeth on the coupling half, with the teeth on the coupling sleeve, and slide the coupling sleeve
into position.

O Ensure ‘O’ rings are correctly seated on the coupling sleeve, and fit the two split clamping rings around
the coupling. Tighten bolts in accordance with MMD procedure T056.

O Fill the gearbox with the correct lubricant to the designated level. (See Maintenance Schedule for
Specification).

O Fill the gear coupling with grease. (See Maintenance Schedule for Specification).

Removal:

O Remove the motor (See Heading ‘Motor Removal’)

O Remove the fluid coupling. (See Heading ‘Fluid Coupling Replacement’).

O Note, that if fitted Oil cooler modules must have their pipes disconnected.

O Note, that when fitted the Gearbox Temperature Monitoring System must be removed from the gearbox

O Remove the motor mounting bracket or coupling housing from the gearbox.

O Remove the top cover plate to expose the gear coupling.

O Split the two clamping rings from the gear coupling, taking care not to damage the ‘O’ ring.

O Slide the coupling sleeve towards the gearbox.

O Attach lifting equipment to the gearbox lifting eyes.

O Remove the studs/bolts connecting the gearbox to the gearbox mounting plate.

O Slide the gearbox away from the mounting plate, until the gear coupling is clear of the mounting plate.
The gearbox can now be lifted out of position.

Section 12 – Revision 1 Operation & Maintenance, Page 10 of 24

 (Voith Turbo Fluid Coupling)
Description

O Mechanical overload protection is given by use of a fluid coupling, mounted on the input shaft of the
gearbox and the drive shaft motor.

O The fluid coupling is protected against excessively high operating temperatures by built-in fusible plugs,
which melt on thermal overloading, and allow the fluid to discharge, thereby interrupting the transmission
of torque and preventing damage.

O After a fusible plug failure, the fault must be corrected. The peripheral bolts must be re-torqued, (see fluid
couplng manual), new fusible plugs fitted, and the fluid coupling refilled with clean fluid in accordance
with the fluid coupling manual.

O There are three types of fusible plug ranging in different operating temperatures from 140/160/180ºc.
Under normal operating conditions the 160ºc type fusible plug should be used.

Preparation for Removal:

O Remove the motor (see heading ‘Motor Removal’)

O Where fitted, disconnect power supply to Voith MTS temperature monitoring device.

O Where fitted, remove the Voith MTS sensor bracket, complete with sensor.

Removal:

O The Voith fluid coupling may now be removed. See Voith installation and operating manual before
removing the coupling.

Installation:

O Clean gearbox input shaft and fit key.

O Fit Voith coupling, in accordance with Voith’s installation and operating manual using the proper tools.

O Where fitted, re-fit the Voith sensor bracket and sensor to the motor mounting bracket.

O Where fitted, connect power supply to Voith MTS temperature monitoring device.

O Refit the motor (See heading ‘Motor Installation’)

Section 12 – Revision 1 Operation & Maintenance, Page 11 of 24

 Voith Fluid Coupling Design Type: TVSC
Coupling At Stand-Still Coupling At Start-Up Coupling Running

VOITH DESIGN TYPE:

6 Filler Plug
TVSC

1 Flexible Connecting Cpl’g 7 Fusible Plug

2 Outer Wheel 8 Operating Fluid

3 Coupling Shell 9 Delayed Filling Chamber

4 Inner Wheel 10 Delay Chamber

5 Coupling Hub 11 ‘SC’ Chamber

Voith Fluid Coupling Design Type: TV

Coupling At Stand-Still Coupling At Start-Up Coupling Running

VOITH DESIGN TYPE: TV

1 Flexible Connecting Cpl’g 6 Filler Plug

2 Outer Wheel 7 Fusible Plug

3 Coupling Shell 8 Operating Fluid

4 Inner Wheel 9 Delayed Filling Chamber

5 Coupling Hub 10 Delay Nozzle

VOITH DESIGN TYPE: TV

1 Flexible Connecting Cpl’g 6 Filler Plug

2 Outer Wheel 7 Fusible Plug

3 Coupling Shell 8 Operating Fluid

4 Inner Wheel 9 Delayed Filling Chamber

5 Coupling Hub 10 Delay Nozzle

Section 12 – Revision 1 Operation & Maintenance, Page 12 of 24

Section 12 – Revision 1 Operation & Maintenance, Page 13 of 24
Section 12 – Revision 1 Operation & Maintenance, Page 14 of 24
 Breaker Shafts
O Move the SIZER into the maintenance position, if fitted onto wheels.

O Thoroughly clean the SIZER of all extraneous material, grease, oil, etc.

O Remove the end wearplates, and side combs (where fitted) from the machine. (See Heading ‘Wear Plates -
Replacing’).

O Remove the top cover plate from the machine. This is bolted to the machine side plates, the top bearing
housing and the gearbox mounting plate.

O Remove the clamping rings from the gear couplings and slide back the sleeve towards the gearbox. This
action disconnects the drive train from the breaker shafts. Care should be taken so as not to damage any ‘O’
Ring seals.

O Remove the shaft end cap, along with its fixings, and slide the remaining coupling hub off the shaft. Where
fitted, the spur gear can now be slid along the shaft, until it no longer meshes with the spur gear on the
driven shaft, care to be taken support its mass at all times.

O Where the bearings are flange mounted, remove the bolts securing the bearing capsule to the bearing
housing.

O Remove the bolts from the top bearing housing on each end of the machine.

O Using two appropriately sized eye bolts, lift out the top bearing housings. The shaft assemblies are now
exposed.

O The damaged shaft can now be lifted out by means of nylon webs slung at either end.

O Once the shaft is removed, the bearing assemblies, and labyrinth seals, can be removed, (refer to the bearing
removal sections).

O Replacement is a reversal of the above procedure.

Section 12 – Revision 1 Operation & Maintenance, Page 15 of 24

 Shaft Re-Timing Procedure

Where the machine is fitted with spur gears, the timing of the shafts can be altered as follows;

Spur Gears At Drive End:

O Isolate the machine electrically by removing the cable from the SIZER drive electric motor.

O Undo the bolts securing the top cover plate to the side plates, gearbox mounting plate, and top bearing
housing.

O Remove the top cover plate, along with the end wear plate,if still attached to the cover plate. (There is no
need to drain the oil).

O Remove the end cap from the driven (non-drive) shaft by unscrewing the fixings which secure it.

O Remove the shaft spacers.

O Slide the spur gear along the breaker shaft splines until it is clear of the spur gear on the drive shaft (until it
no longer meshes), taking care to support its mass.

O Rotate the driven shaft to the desired position.

O Move the spur gear back along the splines, and into position, so that it meshes with the other spur gear.

O Replace the spacers and end cap then replace the fixings using a threadlock.

O Refit the top cover plate and where applicable, the end wear plate, and refit the bolts which secure it to the
case.

Spur Gears At Non-Drive End:

O Isolate the machine electrically by removing the cable from the SIZER™ drive electric motor.

O Undo the bolts securing the top cover plate to the side plates, end cover and the top bearing housing.

O If desired drain the gear oil.

O Remove the top cover plate. (There is no need to drain the oil).

O Remove the end cap from the driven (non-drive) shaft by unscrewing the fixings which secure it.

O Slide the spur gear along the breaker shaft splines until it is clear of the spur gear on the drive shaft (until it
no longer meshes), taking care to support its mass.

O Rotate the driven shaft to the desired position.

O Move the spur gear back along the splines, and into position, so that it meshes with the other spur gear.

O Replace the shaft end cap, and replace the fixings, using a threadlock.

O Refit the top cover plate after applying sealant and refit the bolts which secure it.

Section 12 – Revision 1 Operation & Maintenance, Page 16 of 24

 Main Shaft Bearings

(Flange Located Type)

To replace a worn or damaged bearing, the following procedure must be followed:

O Follow the procedure for removing the shafts, see shaft removal.

O Using a bearing puller or similar device, plus a hydraulic jack, the complete bearing assembly must be
pulled from the end of the shaft, after first removing the end cap.

O This will leave the old labyrinth still attached to the shaft. It must be checked visually for excess wear. See
Things To Check.

O The damaged bearing assembly may now be dismantled as follows:

i Remove the retaining plate, complete with the two outer seals.

ii Remove the damaged bearing from the capsule.

Things to Check
O LABYRINTH - Check for wear grooves on the seal surface. Also, check for any significant wear on the labyrinth shoulders.
If there is any grooving on the seal surface, then the labyrinth must be replaced.

O SEALS - Check the condition of all lip seals. If there is any sign of damage, the seals must be replaced. As company policy
MMD recommend that all seals be replaced if they are removed for any reason.

O SEAL SPACER - If there is any grooving on the outside diameter of this spacer, it must be replaced.

O BEARING CAPSULE - If there is any obvious damage or any sign that the bearing has been turning in the capsule, then it
should be replaced.

Re-Assembly (Flange Located Type)

Should every item need replacing, the following procedure should be followed;

 Remove old labyrinth from the breaker shaft using oxy-acetylene cutting equipment to heat the labyrinth to
assist removal. Care must be taken to ensure that no damage is done to the shaft.

 Assemble the parts in the following order:-

i Labyrinth
ii Capsule
iii Seals
iv Bearing
v Seal Plate
vi Spacer
vii ‘O’ Rings

Section 12 – Revision 1 Operation & Maintenance, Page 17 of 24

 Warm the labyrinth in an oil bath or similar to 110oC. Remove from the oil bath and push onto the shaft
immediately. The labyrinth will stop at the raised shoulder.

 Fit the inner seals into the bearing capsule. Ensure the seals are seated correctly, (see the drawing in the
appropriate section).

 Coat the inside of the capsule sparingly with a light oil.

 Warm the bearing and capsule in an oil bath or similar to 110oC. Remove from the oil bath and
immediately push onto the shaft. Care must be taken as the seals engage the labyrinth spacer and the
assembly must be ‘eased’ into position. The assembly will seat fully home once engaged onto the seal
surface of the labyrinth spacer as the furthest extremity of the labyrinth locates against the inner race of
the bearing.

 Warm the spacer in an oil bath and heat to 110oC. When up to temperature remove and immediately push
onto the shaft.

 Re-assemble the machine in reverse sequence.

Main Shaft Bearings

(Dowel Located Type)
To replace a worn or damaged bearing, the following procedure should be followed;

 Follow the procedure for removing the shafts until the shafts are fully exposed, see shaft removal.

 Using a bearing puller or similar, plus a hydraulic jack, the complete bearing assembly must be pulled from the end
of the shaft, after first removing the end plate.

 This will leave the old labyrinth still attached to the shaft. It must be checked visually for excess wear.

 The damaged bearing assembly may now be dismantled as follows:

i Remove the retaining plate. This automatically removes the two outer seals, and the seal spacer.

ii Support the bearing capsule around the periphery, 200mm off floor level.

iii Apply heat to the outside of the bearing capsule.

iv The damaged bearing should fall out of the capsule.

Things to Check
 LABYRINTH - Check for wear grooves on the seal surface. Also, check for any significant wear on the labyrinth shoulders.
If there is any wear on the seal surface, then the labyrinth must be replaced.

 SEALS - Check the condition of all lip seals. If there is any sign of damage, the seals must be replaced. As company policy
MMD recommend that all seals be replaced if they are removed for any reason.

 SEAL SPACER - If there is any wear grooves on the outside diameter of this spacer, it must be replaced.

Section 12 – Revision 1 Operation & Maintenance, Page 18 of 24

 BEARING CAPSULE - If there is any obvious damage or any sign that the bearing has been turning in the capsule, then it
should be replaced.

 DOWEL - Check for any signs of damage on the sides of the dowel. If the capsule has been trying to turn, there will be
indentations approximately half way up its length. If these are evident, then the dowel must be replaced.

 Assemble all the parts required in the following order:-

i Labyrinth
ii Capsule
iii Seals
iv Bearing
v Dowel & Seal
vi Seal Retaining Plate
vii Spacer

Re-Assembly (Dowel Located Type)

Should every item need replacing, the following procedure should be followed;

 Remove the old labyrinth from the breaker shaft using oxy-acetylene equipment to apply heat to the labyrinth to
assist removal. Care must be taken to ensure that no damage is done to the shaft.

 Warm the labyrinth in an oil bath to 110oC. Remove from the oil bath and push onto the shaft immediately. Place up
to the abutment.

 Fit the inner seals into the bearing capsule. Ensure they are seated correctly, (see the drawing in the appropriate
section).

 Coat the inside of the capsule sparingly with a light oil.

 Fit the bearing into the capsule. This is a toleranced fit and a soft drift should be used.

 Warm the bearing and capsule in an oil bath or similar to 110oC. Remove from the oil bath and immediately push onto
the shaft. Care must be taken as the seals engage the labyrinth spacer and the assembly must be ‘eased’ into position.
The assembly will seat fully home once engaged onto the seal surface of the labyrinth spacer as the furthest extremity
of the labyrinth locates against the inner race of the bearing.

 Fit one of the bonded seals into the dowel location hole on the capsule and hold in with thick grease, ensuring the
remaining bonded seal is in the dowel location hole on the bottom bearing housing. Then place the dowel to the bottom
bearing housing.

 Warm the spacer in an oil bath and heat to 110oC. When up to temperature remove and immediately push onto the
shaft.

 Fit the two outer seals into the seal retaining plate ensuring that the seals are seated correctly as shown in the
appropriate section.

 Push the seal retaining plate into the capsule. Fit the retaining bolts and torque to the required amount as specified in
T056.

 Re-assemble the machine in reverse sequence.

Section 12 – Revision 1 Operation & Maintenance, Page 19 of 24

 Breaker Bar Adjustment
Adjustment of the breaker bar should be carried out as follows;

O Remove the bolts securing the breaker bar to the machine.

O Using the jacking screws, raise the breaker bar to the desired height.
O Adjust the breaker bar by removal/insertion of packers as required.
O When the height is satisfactory, refit the bolts, and tighten in accordance with MMD procedure T056.

Breaker Bar Cap Replacement

Breaker bar caps can only be replaced from the underside of the machine. They must be replaced when showing
signs of excessive wear. Replace the breaker bar caps immediately, or damage to the breaker bar will result.

Removal:
O Clean the area around the cap which is to be replaced.
O Remove the bolts securing the cap to the breaker bar.
O Remove the cap from the breaker bar.

Replacement:
O Clean the top surface of the breaker bar.
O Position the cap onto the breaker bar. Ensure that the cap is fitted in the correct orientation, as shown on
the drawing.
O Bolt the cap to the breaker bar using new bolts. All bolts must be tightened in accordance with MMD
procedure T056.

When carrying out any work on the breaker bar be sure to follow the safety
procedures in practice. The machine must be isolated electrically and mechanically,
use lifting gear where required and wear the appropriate protective clothing and eye
wear.

Cleaning Comb Adjustment

Standard Type:
Where specified, on larger machines, adjustable cleaning combs may be fitted to minimise build-up of material
between the tooth rings, and to prevent recirculation of any product attached to the shafts. These cleaning
combs will need periodic adjustment to compensate for wear. This is achieved by removing packers as follows;

O Check the actual cleaning comb clearance.

O Remove the cleaning combs. Each cleaning comb is secured to the side plate by two/four bolts. Remove
these bolts and withdraw the cleaning comb from the side plate.
O Remove necessary packers to give specified cleaning comb clearance. Thickness of packers to be
removed is the difference between actual cleaning comb clearance and the specified cleaning comb
clearance.
O Refit the cleaning combs into the side plates and move the packers from the ‘inside’ of the pyramid to
the ‘outside’ and bolt into position using existing bolts. These bolts must then be re-torqued.

Section 12 – Revision 1 Operation & Maintenance, Page 20 of 24

 Motor Installation
(Foot & Flange Mounted Type):
The electric motor cradle is designed such that foot mounting can be utilised, but still allowing the motor to
oscillate with the machine. Thus the problem which would be encountered with mounting to a separate base
would be avoided. The flange spigot is used to assist in gaining accurate concentricity and squareness.

O The motor should initially be sat on jacking screws, in the tapped holes through the cradle foot packs.

O Adjust until the motor spigot is engaged in the cradle spigot and then fit flange bolts and tighten.

O The packer height required under each foot must be measured individually. Packer sets must then be
made up or machined.

O Fit the packers under the correct feet and lower the jacking screws. Reference mark packs to their
position.

O The foot bolts should then be added, and all bolts tightened to the amount specified in MMD procedure
T056.

Motor Removal
(Foot & Flange Mounted Type):
The motor can sometimes be removed on the cradle to allow fluid coupling removal. This prevents
disturbance of the motor alignment.

Should just the motor need removing, the following procedure should be followed;

O Disconnect all electrical connections from the motor.

O Remove the cover plate(s) from the motor mounting frame.

O Remove the bolts connecting the motor flange and bolts connecting the motor feet to the mounting
bracket.

O The motor can now be removed. Carefully slide the motor out of the motor mounting bracket until the
drive boss on the motor shaft is clear of the motor mounting bracket. The motor can now be safely
lifted out of position.

O Remove the coupling half and spacer (where fitted) from the motor shaft.

O Remove the shims from the foot mountings, after identification to position.

Motor Installation
(Flange Mounted Type):
In this arrangement alignment is achieved automatically.

O Fit the motor spacer (if applicable).

O Fit the coupling and engage the drive boss.

O Lift the motor into position, fit the flange bolts and tighten to the amount specified in MMD
procedure T056.

Section 12 – Revision 1 Operation & Maintenance, Page 21 of 24

 Motor Removal
(Flange Mounted Type):
Should the fluid coupling need removing or replacing, the motor must be removed, the procedure for this is as
follows;

O Disconnect all electrical connections from the motor.

O Attaching lifting equipment to the motor.

O Remove the bolts connecting the motor flange.

O The motor can now be removed. Carefully slide the motor out of position, until the motor shaft is clear
of the coupling housing. The motor can now be safely lifted out of position.

Grease Lubrication;

MMD machines are fitted with the facility to allow bearing greasing. Grease can be pumped to the
labyrinth seals to prevent contamination. The bearing lubrication points can be served by either an
automatic lubrication pump or by the use of a grease gun or similar appliance. The quantity of grease for
the bearings is specified in MMD procedure T0132 to each bearing each week.

Lubricant is pumped from the reservoir into a distribution block, this distribution block ensures that each
bearing receives an equal amount of grease. The distribution block also includes an indicator pin to provide
a visual check that lubricant is being circulated. To ensure correct lubrication it is important that this
indicator pin is checked on a regular basis, i.e. weekly.

To check that the labyrinth seals are clear, and that the greasing system is functioning normally, grease will
be visible at the labyrinths.

Regular and correct greasing will increase the life of the bearings and help prevent damage to the bearing
casings.

NOTE: WHERE FITTED, THE AUTOMATIC CENTRALISED GREASING SYSTEM MUST

BE RUN WHENEVER THE MACHINE IS RUNNING. IT IS ALSO STRONGLY
RECOMMENDED TO RUN THE GREASE FEED FOR 2 HOURS AFTER EACH RUNNING
PERIOD. FOR FURTHER INFORMATION REFER TO THE AUTOLUBE SUPPLIER
MANUAL.

Section 12 – Revision 1 Operation & Maintenance, Page 22 of 24

Maintenance Schedule
Maintenance of the SIZER™ and its ancillaries is most important, and must be carried out in
accordance with this manual. Failure to do so could result in a reduction of operational efficiency, or
even a machine breakdown. Warranty maybe affected by improper maintenance.

Where the machine is fitted with breaker segments, after the first 24 hours of operation, check the
segment fixing bolts, and re-torque to the amount specified in MMD Procedure T056. then after 7 days
operation, check the segment fixing bolts again, and re-torque to the amount stated.

NOTE: Before any work is carried out on this machine, isolate the power supply, and
remove the cable from the electric motor.

Spur Gear Oil;

On SIZERS™ fitted with spur gears, MMD recommend that the spur gear oil should be renewed at
approximately every 4000 hours. Drainage is achieved by removing the drain plug which is fitted to the
bottom cover plate. Once this plug has been removed the oil can then be drained into the suitable catch
tray or other suitable containers. To replace the spur gear oil remove the inspection cover(s) and fill to
the required quantity through the top cover plate. Re-seal the top cover plate on refitting. Fill to the
level stick notch. The oil specification grade is listed in MMD procedure T0138.

Light Load Running;

When it is expected that the SIZER™ will not have any feed of material for a period in excess of 15
minutes, the SIZER™ motors should be shut down. The reason for this, is that the transmissions are
designed to carry high loads, and when loads are removed, the possibility of roller slip in the bearings
exists, which could result in long term damage.

Daily Maintenance;
Visual and audible examination for excessive vibration or noise.

Weekly Maintenance;
Where fitted, check the centralised greasing unit reservoir grease level, and top-up if required with the
recommended lubricant. Visually check for leaks.

Ensure (where fitted) the Autolube is functioning correctly. The distribution block indicator pin should
move up and down on a regular basis, (Speed is dependent on delivery volume).

Check the spur gear oil level, and top up as required, with the correct specification lubricant. Refer to
MMD procedure T0138a.

Section 12 – Revision 1 Operation & Maintenance, Page 23 of 24

Three Monthly Maintenance;
Grease the gear coupling at the ¼” BSPT grease nipple. Specification as per breaker shaft bearings. Where
fitted, check that the shut-down alarms are effective.

Annual Maintenance;
All bolts must be checked for tightness, and re-torqued to the amount specified in the (MMD Procedure T056)
if necessary.

Where fitted, grease the wheel carriage units at their respective grease points.

Section 12 – Revision 1 Operation & Maintenance, Page 24 of 24

 MMD MINING MACHINERY DEVELOPMENTS LIMITED

TECHNICAL SPECIFICATIONS

Section 13 – Revision 1 TO Specifications, Page 1 of 7

Member of the MMD Group of Companies

MMD Mining Machinery Developments Ltd

BOLT TORQUES - For approximately 85% proof stress in unlubricated coarse pitch bolts.

8.8 GRADE 10.9 GRADE 12.9 GRADE

Size Nm Nm Nm

M6 12 16 19

M8 29 39 47

M10 57 77 92

M12 99 134 161

M16 244 333 399

M20 476 649 779

M24 822 1121 1345

M30 1633 2227 2672

M36 2854 3891 4670

M42 4567 6227 7475

M48 6858 9351 11223

M56 11020 15025 18032

M64 16590 22620 27150

M72 24110 32873 39450

Nm x 0.74 = [Link] For EP2 Grease x 0.65

For cap bolts with EP2 Grease x 0.87

NUT AND BOLT COMBINATIONS

Bolt Grade 8.8 10.9 12.9
Nut Grade 8 12 12

Hydraulic tool pressure settings (PSI), applies HTD hydraulic tensioners:

M30 (8.8) M36 (8.8) M42 (8.8) M48 (8.8) M48 (10.9)
Small Jack (XL07) 12300 18000 — — —
Large Jack (XL09) — — 16500 21700 22000

Consult suppliers recommendations regarding pressure settings to achieve particular torque requirements. The torque procedure as
above, but excluding cover plates, and wear plates. Non critical structural, and location bolts, tighten these using electric nut runner
or hand tools. If in any doubt, consult the design department.

JACKET TYPE TIP ASSEMBLIES WITH SHANK IN 150M19 MATERIAL IN ‘R’ CONDITION TORQUE
DRY

Size Nm

M24 712

M30 1413

M36 2470

M42 3953

M48 5935

M56 9536

M64 14360

M72 20860

* Applied on thread, and between rotating faces. Where possible, torque up bolts dry.

Prepared By: ROB McGINN Approved By: R. P. BARBER

Procedure: T056 Page: 1 of 1 Date: 06-06-02 Issue No.: 9
Member of the MMD Group of Companies

MMD Mining Machinery Developments Ltd

PROCEDURE FOR SETTING AXIAL FLOAT ON INPUT SHAFTS.

1) Assuming gearbox is already assembled and with input shaft fitted, smear mating surface of input
shaft end plate “A” with sealant and fit end plate to gearbox, then fit and torque up studs “B” to
98 nm. Fit spacer “C” and end plate “D” without O ring “E” and seals “F”.

These are to be fitted upon completion, then fit and torque up studs “G” also to 98 nm.

2) Assemble setting frame “H” to gearbox around the input shaft “L” and not forgetting input shaft
end plate “J”, then tighten lock nut “M” with the gauge “I” taking a reading from end plate “J”
turn input shaft to find area on end plate “J” where movement of gauge needle is at a minimum
and then mark this area on the end plate “J”. Slack off the outer nut “P” on load screw “K” and
tighten the inner nut “N”, tapping the end of the load screw “K” lightly with a hammer and
periodically turning the input shaft “L” 360° back to the previously marked area on end plate “J”
continue to tighten nut “N” until the needle on the gauge will move no more. Then zero the
gauge, slack off the inner nut “N” on load screw, and again turning the input shaft “L”
periodically has you tighten nut “P” until gauge needle will move no more. This will then give
you the amount of float you have on the input shaft, and you will probably find that the spacer is
oversize by approximately 1.75 to 2.00 mm.

3) Whatever the amount of float is found to be, remove gauge “I” then slack off nuts “P”, “M” and
“N”, screw out load screw “K” and remove end plate “J”, then remove studs “G” and end plate
“D” along with spacer “C”. It may be necessary at this point to partially remove the setting frame
to allow removal of end plate “D” and spacer “C” depending on length of load screw “K”.
Machine 1 mm off the face of spacer “C” do not have anymore than 1 mm machined off the
spacer at the first attempt. After machining spacer fit back into gearbox along with end plate “D”
and studs “G” not forgetting to torque them back upto 98 nm,
re-assemble setting frame “H” and take another axial float reading following the same procedure
as before. What you have to achieve is a reading as below.

Total axial float for face to face taper roller bearing

shaft assemblies.

Refer to drawings, manuals or technical department. If this is not possible then use the
approximate formula below to obtain mm’s clearance.

a = D1 + D2
--------------------- D1 and D2 = Outer Diameter of bearings 1 and 2
2

b = (a x 4) +(Length x 2) Length = Distance Between Centre of each Bearing ( See

drawing)

Minimum Clearance = b x 0.00024

Maximum Clearance = Minimum Clearance + 0.05

Prepared By.: M. Bunce Approved By.: [Link]

Procedure.: T0114 Page.: 1 of 2 Issue No.: 1 Date.: 28/09/97

Member of the MMD Group of Companies

MMD Mining Machinery Developments Ltd

4) Whatever the reading is, the spacer will have to be removed for a second time for the remaining
amount to be machined off spacer “C” to give you the relevant reading for your particular gearbox.
When this has been completed, spacer “C” and end plate “D” will have to be refitted to gearbox, not
forgetting to torque up studs “G” again to 98 nm. Take another axial float reading and if it is within the
readings given for your gearbox the setting device can then be completely removed.

5) End plate “D” and spacer “C” will have to be removed once more to have O ring “E” and seals “F”
fitted into end plate “D”. Smear the faces with grease on both the end plate and spacer before refitting
them for the last time to the gearbox and torque studs “G” upto 98 nm.

Prepared By.: M. Bunce Approved By.: [Link]

Procedure.: T0114 Page.: 2 of 2 Issue No.: 1 Date.: 28/09/97

Member of the MMD Group of Companies

MMD Mining Machinery Developments Ltd

Scope

This specification covers quantities of grease to be fed to sizer bearings via automatic lubrication
system. Also types of grease.

Grease Types

For normal applications use

NLGI EP2
Lithium Complex, extreme pressure grease. (e.g., Shell Calithia EPT2)

If for a period of the year, the potential for ambient temperatures to be below -10°C exists, for that period use.

NLGI EP1 (eg., Shell Sterak 1)

If the temperature is likely to drop below -30°C pipe heating may be required.

Grease Quantities

Feeds to each bearing Feeds to each bearing

Feed to each labyrinth
when the labyrinth seal is when the labyrinth seal is
seal if applicable
not greased separately greased separately

m/c ctrs m/c ctrs m/c ctrs

cc/Hour cc/Hour cc/Hour
(m) (m) (m)

0.5 30 0.5 30 0.5 7

0.625 40 0.625 40 0.625 10
0.75 50 0.75 50 0.75 12
1.0 75 1.0 75 1.0 19
1.15 90 1.15 90 1.15 22
1.25 100 1.25 100 1.25 25
1.3 110 1.3 110 1.3 28
1.4 120 1.4 120 1.4 30
1.5 130 1.5 130 1.5 32

When bearings are greased by hand 200cc should be applied to each bearing each week.
Notes

When grease is fed by an autolube system, the grease must be fed continuously whenever the machine runs. It is
also strongly recommended to run the grease feed for 2 hours after each running period.

Prepared By: [Link] Approved By: [Link]

Procedure: T0132 Page: 1 of 2 Issue No: 4 Date: 13-08-2000

Member of the MMD Group of Companies

MMD Mining Machinery Developments Ltd

Information for setting pumps

Turns out for

M/C Ctrs Required Setscrew on
(M) cc/Hour Pump Element
(Centralube)
0.5 30 3 1/4
0.625 40 3
0.75 50 2 1/2
1.0 75 2
1.15 100 1
1.25 - 1.5 100 - 130 Fully in

Plate Feeders - Set to 3 1/4 turns for use with 4 way splitter
Set to 4 turns for individual feeds.

Do not exceed 4 turns or element may stop pumping

When seperate feeds are required for labyrinth and bearings a fifth pump element must be fitted and set to
same setting as other 4 elements. This outlet must be piped to a splitter valve and then to bearings. The
other 4 elements are to be piped individually to the labyrinths.

Prepared By: [Link] Approved By: [Link]

Procedure: T0132 Page: 2 of 2 Issue No: 4 Date: 13-08-2000

Member of the MMD Group of Companies

MMD Mining Machinery Developments Ltd

MMD SIZERS LUBRICANTS LIST

GEAR OIL

Ambient temperature -10°C and above

ISO VG 320 premium quality, heavy duty, Sulphur Phosphorous EP Gear Lubricant, 320 centistokes viscosity at
40°C, viscosity index IP226 85 to 95. The lubricant should have good water shedding (minimum FZG load stage 12).
e.g. SHELL OMALA 320

Ambient temperature 20°C to -20°C

ISO VG 220 premium quality, heavy duty, Sulphur Phosphorous EP Gear Lubricant, 220 centistokes viscosity at
40°C viscosity index IP226 85 to 95. The lubricant should have good water shedding (minimum FZG load stage 12).
e.g. SHELL OMALA 220

Ambient temperature 20°C to -50°C with heating

SAE 80W/140 SAE ASX 75W-90 SAE HD 320 Synthetic

Viscosity @ 40°C 210 cSt Viscosity @ 40°C 115 cSt Viscosity @ 40°C 320 cSt
Viscosity index 150 or Viscosity index 140 or Viscosity index 161
Pour point -29°C Pour Point -42°C Pour Point -45°C
Flash Point 210°C Flash Point 210°C Flash Point 268°C
e.g. SHELL ASX 75W-90

GREASE

Ambient temperature -15°C to 40°C

Lithium Complex EP NLGI No. 2

Mineral Base Oil Viscosity 160 cSt @ 40°C Change grease type
Timken (ASTM D2509) OK Load 45lbs
seasonally as necessary
Ambient temperature 20°C to -10°C or 20°C to -50°C with heating If in doubt use NLGI
No. 1 when supplying
Lithium EP NLGI No. 1 new machines
Mineral base oil viscosity 120 cSt @ 40°C
Timken (ASTM D2509) OK Load 45lbs

FLUID COUPLING OIL

Ambient temperature -15°C and above

Hydraulic Oil
ISO VG32 (32 cSt @ 40°C) or ISO VG22 (22 cSt 40°C)
Pour Point < -24°C
Flash Point >175°C

Ambient temperature 0°C to -50°C

Hydraulic Oil
12 - 25cSt viscosity @ 40°C
Pour Point , -54°C
Flashpoint >155°C

General
Lubricants to be compatible with flourocarbon and nitrile rubber.

Prepared By: [Link] Approved By: [Link]

Procedure: T0138 Page: 1 of 1 Issue No: 3 Date: 20/12/2001