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P.E.P. 8000

Operators Manual

Vibrator

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Table of Contents

egaPnoitceSIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Disclaimers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Installation and Start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Adjusting eccentric weights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Mounting vibrator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Connecting hydraulic hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Vibrator start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Filter changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Hydraulic fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Replacement oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Bearing grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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

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Introduction

General Engineered to provide long service life in rigorous, continuous-dutyapplications, the P.E.P. 8000 Vibrator is used on high-frequency screens from

Astec Mobile Screens, Inc.

References 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.

Safety All safety rules defined in the above documents and all owner/employersafety rules must be strictly followed when working on the P.E.P. 8000

Vibrator.

Symbols The following symbols are used in this manual:

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

WARNING!Warning: Hazards or unsafe practices that could result in personalinjury.

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

property damage.

IMPORTANTImportant: Instructions that must be followed to ensure proper

installation/operation of equipment.

NOTENote: General statements to assist the reader.

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Limited warranty Astec Mobile Screens, Inc. warrants the P.E.P. 8000 Vibrator against defectsin 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.

Disclaimers Astec Mobile Screens, Inc. hereby disclaims any liability for injuries ordamage 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.

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Installation and Start-up

IMPORTANTRead this entire section before beginning work.

NOTEWeights 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.

Adjustingeccentric 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

Washersfrom 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

IMPORTANTRemember 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.

Left Right

5

4

3

2

5

4

3

2

1

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Table I. Vibrator Settings and Force Output

*Gallons per minute (Liters per minute).

**Revolutions per minute of the hydraulic motor.

***Normal setting from factory.

Mounting vibrator

CAUTION!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).

IMPORTANTLoose vibrator mounting feet can adversely effect the speed of

the vibrator.

Connectinghydraulic hoses

CAUTION!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 ACASE 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).

gpm*(L/m) rpm**

EccentricWeightSetting

ForceOutputPercent

Unbalance(inch-lb)

ForceOutputPounds

3.00

(11.36)

4150

1 65 2.72 1331

2 75 3.14 1536

3*** 85 3.50 1713

4 95 3.92 1918

5 100 4.09 2001

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b. Contact Astec Mobile Screens, Inc. for case drain installation on

screens manufactured before May 1992.

Figure 2. Case Drain

Vibrator start-up

CAUTION!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.

NOTEVibrator 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.

Case Drain

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Maintenance

IMPORTANTRead entire section before beginning work.

Filter changes All hydraulic filters need to be changed after the first 50 hours and every 250hours thereafter.

Hydraulic fluid The hydraulic fluid will need to be changed after the first 500 hours and every

1000 hours thereafter with ISO 46 oil or equivalent.

NOTEEvery 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.

Bearing grease The P.E.P. 8000 Vibrator has been lubricated for life from the factory. Noperiodic lubrication is necessary. When replacing bearings use only Klber

Isoflex NBU15 grease.

NOTEKlber grease may be purchased from Astec Mobile Screens,

Inc. by calling 800-545-2125.

ISO 46 Properties

Viscosity @ 104F (40C) 46 cSt

Viscosity @ 212F (100C) 6.7 cSt

Viscosity Index 95

Gravity @ 60 degrees 31API

Flash Point, C.O.C. 421F (211C)

Pour Point 0F (-18C)

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Item Description Part No. Qty

100180CesaC1

2 Shaft Eccentric C08101 1

220180CgniraeB3

4 Seal Dual Lip Oil C08103 2

5 Weight Eccentric Fixed C08104 2

6 Weight Eccentric Adjustable C08105 2

9 Screw HHC 1/4-20NC x 7/8 ZP C02008 2

180180CpaCkcaB01

11 Spider Flexible C02128 1

12 Key 1/8 x 1/8 x 5/8 Lg C02129 1

13 Coupling L075 1/8 x 1/16 C02127 2

101180CrotoMegnalF41

15 Washer Compression 5/16 C02000 8

16 Screw HHC 5/16-24NF x 1-1/4 C02001 4

17 Motor Hydraulic 2HB C08111 1

18 Nut Hex 5/16-24NF ZP C02003 4

* SCHNORR Washer D8 C08106 10

* Screw SHC 5/16-18NC x 1 C08107 2

* Screw SHC 5/16-18NC x 3/4 C08109 8

* Washer Compression 5/8 C02006 2

* Manual Operators C08112 1

Item Description Part No. Qty

*Not Shown

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

Part Numbers

6

5

910 2 1 12

11

14

1516

1817

1343

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

Item Description Part No. Qty.

1 1/4-20 NC x 2-1/4 12 Point

Screw

C02029 8

2 7/16-20 SAE Steel Plug 2420113 1

3 Dowel Pin C02035 2

143020CniPevirD4

5 Woodruff Key C02038 1

6 Drive Shaft C02042 17 Steel Plug C02043 1

172020CgniR-O8

1

2

3

5

4

7

8

9

10

11

12

1315

1416

6

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

Replacement of parts not listed here will require

replacing entire hydraulic motor, P/N C08111.

NOTE

Item Description Part No. Qty.

162020CgnirpS9

152020CllaB01

11 Plastic Gasket Kit

(Amber, Silver, and Gold)*

C02136 1

12 Ball Bearing C02024 1

363020CgniRpanS31

144020CmihS4115 High-Pressure Oil Seal C02138 1

173020CgniRpanS61