MasterFlo OM en

operator’s manual Doc. no. S 241.
010 en
MASTER-FLO™
This document is valid for:
Serial no. / Machine no. Sign.
MASTER-FLO™
© Copyright 2005 Sandvik SRP AB.
All rights reserved. No parts of this document may be reproduced or
copied in any form or by any means without written permission from
Sandvik SRP AB. All data and information in this manual may be
changed without further notice. Reservations for misprints.
Document number: S 241.010 en

Issue: 20061127
Version: 1
Sandvik SRP AB
Stationsplan, SE-233 81 Svedala, Sweden
Tel: +46 (0)40 409000, Fax: +46 (0)40 409260
www.sandvik.com
Table of contents
1. Introduction
1.1 Equipment information.......................................................... 8
1.2 Document information........................................................... 9
1.2.1 Document conventions ............................................ 9
1.2.2 Document compliance ............................................. 9
1.2.3 Enclosed dimension drawing ................................... 9
1.2.4 Technical publications .............................................. 9
1.3 Product description ............................................................. 10
1.3.1 Orientation convention ........................................... 10
1.3.2 Rotation directions ................................................. 11
2. Safety precautions
2.1 Hazard information ............................................................. 14
2.1.1 Warning signs ........................................................ 14
2.1.2 Prohibition signs..................................................... 14
2.1.3 Mandatory signs..................................................... 14
2.2 Personnel............................................................................ 15
2.3 General safety precautions................................................. 16
2.3.1 Electrical safety...................................................... 16
2.3.2 Pressurized systems (hydraulics) .......................... 16
2.3.3 Machine safety guards........................................... 17
2.3.4 Equipment for lifting and moving loads .................. 17
2.3.5 Welding .................................................................. 18
2.3.6 During operation .................................................... 18
2.3.7 During inspection and maintenance....................... 19
3. Technical data
3.1 Physical specifications........................................................ 22
3.1.1 Foundations and framework .................................. 22
3.1.2 Dimensions ............................................................ 22
3.1.3 Weight.................................................................... 23
3.1.4 Electrical specifications.......................................... 23
3.1.5 Noise level ............................................................. 23
4. Operating the Master-Flo

4.1 General ............................................................................... 26
4.2 Starting the Master-Flo ....................................................... 26
Master-Flo © Sandvik SRP AB – Doc. no. S 241.010 en Ver. 1 3

Table of contents
4.2.1 Precautions ............................................................ 26

4.2.2 Starting the Master-Flo ........................................... 26
4.3 Operating the Master-Flo .................................................... 27
4.3.1 Normal operation.................................................... 27
4.4 Stopping the Master-Flo...................................................... 27
4.4.1 Precautions ............................................................ 27
4.4.2 Normal stopping ..................................................... 27
4.4.3 Emergency stopping .............................................. 27
4.4.4 Long idle period...................................................... 27
5. Inspection and maintenance

5.1 Routine inspection and care ............................................... 30
5.1.1 Continuous checks................................................. 30
5.2 Lubrication .......................................................................... 31
5.3 Setting the speed and stroke .............................................. 31
5.3.1 General .................................................................. 31
5.3.2 Recommendations and rules ................................. 32
5.3.3 Measuring the stroke.............................................. 32
5.3.4 Changing the stroke ............................................... 33
5.3.5 Changing the speed ............................................... 35
5.4 Oil leaks .............................................................................. 35
5.4.1 Corrective actions .................................................. 35
5.5 Changing screening elements ............................................ 36
5.6 Maintanance of mechanism ................................................ 36
5.7 Changing spare parts.......................................................... 36
5.8 Adjusting the belt tension.................................................... 36
5.9 Using the log book .............................................................. 36
5.9.1 Content................................................................... 37
5.9.2 Requirement during the warranty period................ 37
5.9.3 Recommendation ................................................... 37
5.9.4 Checklists in this manual........................................ 37
5.9.5 The importance of being honest............................. 37
6. Lubrication
6.1 General ............................................................................... 40
6.2 Oil quality and specification ................................................ 40
6.3 Filling the oil ........................................................................ 40
6.4 Changing the oil .................................................................. 41
4 © Sandvik SRP AB – Doc. no. S 241.010 en Ver. 1 Master-Flo

Table of contents
6.4.1 Changing the oil brand........................................... 41
7. Screening media
7.1 The side tensioned system ................................................. 46
7.2 Changing wear parts of the side tensioned media.............. 48
7.2.1 Work from the feed end ......................................... 48
7.2.2 Checklist ................................................................ 49
8. Mechanism
8.1 The parts of the mechanism ............................................... 52
8.1.1 Torques .................................................................. 52
8.2 Double mechanisms ........................................................... 54
8.3 Maintaining the mechanism ................................................ 54
8.3.1 Precautions with the shaft...................................... 55
8.3.2 Recommendation at disassembling ....................... 55
8.3.3 Differences between the 2 ends ............................ 55
8.3.4 Taking out the shaft................................................ 55
8.3.5 Before disassembling the mechanism ................... 55
8.3.6 Disassembling the mechanism .............................. 57
8.3.7 Assembling the mechanism ................................... 59
8.3.8 After assembling the mechanism........................... 62
9. Changing spare parts

9.1 General ............................................................................... 64
9.1.1 Torques .................................................................. 64
9.2 Changing the springs.......................................................... 64
9.2.1 Changing one spring or all springs ........................ 65
9.3 The belt tension .................................................................. 65
9.3.1 Calculating the force to tension the belt................. 66
9.3.2 Calculating the deviation........................................ 66
9.4 Changing the belts.............................................................. 67
9.4.1 Taking out the old belts .......................................... 67
9.4.2 Install the new belts ............................................... 68
9.5 Changing the motor ............................................................ 69
9.5.1 Disassembling the motor ....................................... 70
9.5.2 Putting the motor in place ...................................... 71
9.6 Changing the synchronisation belt...................................... 73

Table of contents
10. Troubleshooting
10.1 Damage reports .................................................................. 76
10.2 Faults and suggested actions ............................................. 77
10.2.1 Orientation list ........................................................ 77
10.2.2 Master-Flo does not start, or stops while running .. 77
10.2.3 Master-Flo does not run properly ........................... 78
10.2.4 The motor vibrates ................................................. 78
10.2.5 The framework bends or vibrates too much........... 78
10.2.6 Abnormal noise while running ................................ 78
10.2.7 Bearings overheat .................................................. 79
10.2.8 Bearings broken or worn out .................................. 79
10.2.9 Oil leak ................................................................... 79
10.2.10 Belts worn out ........................................................ 79
10.2.11 Pegging or low performance .................................. 81
10.2.12 Blinding .................................................................. 81
10.2.13 Low accuracy ......................................................... 81
10.2.14 Material mainly on one side of the Master-Flo ....... 82
10.2.15 Media wear out or break, abnormal wear out......... 82
10.2.16 Material falls out from the feed end onto platform .. 82
10.2.17 Springs too compressed......................................... 82

1. Introduction
To ensure maximum safety, always read section 2. Safety precautions before
doing any work on the equipment or making any adjustments.

1. Introduction
1.1 Equipment information

Purpose
The purpose of this Sandvik equipment is to be a screen component in a
crushing and screening unit. This equipment has been exclusively designed
for the application – as defined by the application equipment manufacturer. It
is therefore not the responsibility of Sandvik SRP AB to secure the design
and usage for the complete application. Sandvik SRP AB will not accept any
liability for damage to equipment or injury to personnel caused by
unauthorised or improper use or change of this equipment.
Manufacturer
This Sandvik equipment has been manufactured by:
Sandvik CFBK S.A.S.
Rue Louis Blanc
02300 Chauny
France
Telephone +33 3 23 52 14 61
Telefax +33 3 23 39 57 78
For maintenance
Contact the nearest Sandvik company, agent or representative or directly:
Sandvik SRP AB
Service Dept.
SE-233 81 Svedala
Sweden
Telephone +46 40-40 90 00
Telefax +46 40-40 92 64
Identification
The figure below shows an example of the screen identification plate. The
identification plate contains data needed when contacting Sandvik SRP AB
concerning this specific equipment.
Please enter the serial number of the associated machine in the intended field
on the first page of this manual (the copyright page).
1 Machine
2 Machine type
3 Serial number
4 Mass (kg)
5 Order number
6 Manufacturer
7 Year of manufacture
8 CE mark
CE marking
This equipment complies with the basic health, environment and safety
regulations of the European Union and European Economic Area.

1. Introduction
1.2 Document information

Purpose of this Operator’s manual
The purpose of this Operator’s manual is to provide the operator with
information on how to handle and operate this Sandvik equipment before,
during, and after operation. It also provide information about maintenance.
It is important to:
• keep the manual for the lifetime of the equipment
• pass the manual on to any subsequent holder or user of the equipment.
1.2.1 Document conventions

Figures in this manual
Figures in this manual showing principals rather than details, and can differ
slightly from the screen model in question.
Cross references
The text of this manual include references to other sections within this
document, and to other documents normally including more detailed
information. References are presented as follows:
• References to other sections within a single manual are presented in
italic and with blue text.
• References from one document to another document is presented in italic
and with black text.
Examples:
Refer to section 2. Safety precautions for more detailed information.
Refer to the Product Documentation (PD) for more detailed information.
1.2.2 Document compliance

The instructions in this document are in accordance with the design and
construction of the equipment at the time it was delivered from the Sandvik
manufacturing plant.
1.2.3 Enclosed dimension drawing

The Master-Flo is delivered with a dimension drawing containing
information specific to your screen. This manual refers to it, so it is useful to
keep the dimension drawing together with this manual.
1.2.4 Technical publications

The customer technical publications for this equipment are:
• Installation manual
• Operator’s manual
When ordering technical publications, always specify the language and quote
the machine serial number.

1. Introduction
1.3 Product description

The Master-Flo can be a CS (classification screen) or an XS (extra heavy
screen). The screen can have 2, 3, or 4 decks and 1 or 2 mechanism. The
number of electrical motors is the same as the number of mechanisms.
Master-Flos with 2 mechanisms, and therefore with 2 electrical motors, also
have a synchronisation system.
The illustration below shows a typical Master-Flo, explaining the screen
nomenclature and components.
A Feed end
B Discharge end A
1 Decks
2 Springs
3 Mechanism
4 Spring mounting blocks
B
1
R
2
Item Name Function
A Feed end Material input
B Discharge end Material outputs
1 Decks Support the screening media
2 Springs Enables the Master-Flo to vibrate &
isolates the framework from the vibrations
3 Mechanism Moves the Master-Flo
4 Spring mounting blocks Supports the Master-Flo
(bolted or welded to the framework)
1.3.1 Orientation convention

This manual makes reference to:
• The right side and the left side of the screen
• The feed end and the discharge end of the screen.

1. Introduction
The top view below shows these references.
Discharge end
Left side Right side
Feed end
1.3.2 Rotation directions

This manual makes reference to 2 rotation directions:
When the rotation direction is… ...the mechanism rotates so that its top moves
forward in the same direction as the material
backwards in the opposite direction to the material
NOTE! As the he motor can be on the left side or on the right side of the Master-Flo,
reference to clockwise or counter clockwise directions are not made. The
only reference is the direction of the material flow.
The illustration below shows how to understand these references.
Forward
Forward
Backward
Backward

1. Introduction
This page is intentionally left blank

To ensure maximum safety, always read this section carefully before doing
any work on the equipment or making any adjustments.

2.1 Hazard information

2.1.1 Warning signs
General danger Dangerous voltage Risk of crushing
Heavy load Flying fragments
Warning signs are accompanied with an additional panel marked either

“DANGER” or “WARNING” depending on their state:
Failure to observe information marked “DANGER!” puts your life in

danger!
DANGER!
Failure to observe information marked “WARNING!” can result in
personal injury and/or serious damage to, or destruction of,
equipment!
WARNING!
CAUTION! Failure to observe information marked “Caution!” can result in damage
to equipment!
2.1.2 Prohibition signs
Do not remove
guards
2.1.3 Mandatory signs
Disconnect current Read the manual

before any work

2.2 Personnel
Only skilled or instructed personnel are allowed to work on the equipment.
According to Sandvik a skilled person is:
– An individual with technical knowledge or sufficient experience to
enable that individual to avoid hazards which this equipment can
create (e.g. operators or service staff).
According to Sandvik an instructed person is:
– An individual adequately advised or supervised by a skilled person to
enable that individual to avoid hazards which this equipment can
create (e.g. operators or service staff).
The manufacturer declines all responsibility for injury or damage if the

instructions in this manual are not followed.
Personnel are responsible for:
• the equipment and the work area around the equipment
• all personnel in the vicinity of the equipment
• following local or national safety regulations
• making sure that all safety devices are fully operational
Sandvik strongly recommends that personal safety protection is always worn

when working in the vicinity of the equipment.
Sandvik recommendation for personal safety protection includes:
Ear protection Safety helmet Eye protection
Protective gloves Safety boots Mask or breathing

apparatus when
appropriate

2.3 General safety precautions

Always switch off power to the equipment before any maintenance work is
started. Also secure that it is not possible for anyone else to switch on power
while maintenance work is being done.
Dangerous work
Never touch the screen during operation. Never put hands, arms or
feet between moving parts and framework.
WARNING!
CAUTION! Clear the feed arrangement and the screen decks from processing ma-
terial before any maintenance work is carried out inside or below the
screen, to prevent fragments from falling down.
2.3.1 Electrical safety

Dangerous voltage
Personnel must regard all electrical equipment as live until it is proven
dead by proper test procedures.
DANGER!
Check, repair and replace broken or damaged electrical cables and
connectors before starting the equipment.
Check that electrical connections are properly and securely connected before
starting the equipment.
2.3.2 Pressurized systems (hydraulics)

Hydraulic systems
Pressurized oil is dangerous if released incorrectly. Relieve all
pressure before carrying out maintenance or repair work on the
WARNING! pressurized system.
Hydraulic oil can get very hot in operation. Allow the oil to cool before
working on the hydraulic system.
Check, repair and replace defective hoses, valves or fittings before starting
the equipment.

2.3.3 Machine safety guards

Do not remove guards
Make sure that all guards are in place and functioning, to prevent
exposure of flying fragments and rotating or vibrating parts.
PROHIBITION!
Rotating parts
All rotating parts of the equipment shall be protected by guard. Always
attach guards after maintenance work.
WARNING!
Flying fragments
Upward ejected fragments may fall down close to the screen. Provide
adequate guards and warning signs at appropriate places around the
WARNING! danger zone.
Never remove guards while the equipment is in operation.

Check, repair and replace defective guards and dust seals if any before
starting the equipment.
2.3.4 Equipment for lifting and moving loads

Hanging load
Make sure that the capacity of the lifting equipment is adequate and
that the equipment itself is in good working order.
WARNING!
Hanging load
Do not stand under, or allow anyone else to stand under equipment
that is being hoisted or suspended.
WARNING!
If lifting tackles has to be joined to make up the necessary lengths, make sure
that the joints are secure and have the same lifting capacity as the rest of the
tackle.
NOTE! Always use lifting tackles certified in accordance to local conditions.

Always engage the safety clip on lifting hooks to prevent the tackle from
slipping off.
Use ropes or poles to steady and manoeuvre loads. Do not use hands or feet.
Make sure that the route and the destination are free from obstacles before
moving a suspended load. It must be possible to lower the load to the floor
quickly and safely in an emergency.
When depositing loads, keep the lifting equipment in place until the stability
of the load has been checked.

2.3.5 Welding
CAUTION! Always consult with the manufacturer before any welding operation be-
gins on the jaw crusher.
CAUTION! Never let the welding current pass through a bearing or another vital
part. If earthed on the wrong side of the bearing, the latter can be so se-
riously damaged that bearing replacement is necessary.
If welding an item to the screen, the earth must be attached to the item itself.
If a screen component is to be welded, the earth should be attached as near to
the welding area as possible.
Toxic gases
Inhalation of welding fumes can be a dangerous to health. Always
follow instructions provided by the welding equipment supplier.
WARNING! Several parts of the jaw crusher is made of manganese steel. Long
term exposure to manganese oxide can effect the nervous system.
2.3.6 During operation

Flying fragments
Upward ejected stones and fragments may fall down close to the
screen. Wear safety helmet and eye protection.
WARNING!
High sound levels
Harmful sound levels can occur if working close to the equipment for
longer period of times. Use ear protection.
WARNING!
Dust emissions
Harmful dust emissions can occur if working within sight of the
equipment. Use mask or breathing apparatus when appropriate.
WARNING!
Dangerous work
Never touch the steel coil springs during operation.
WARNING!
During screening, the main hazards are ejected stones, dust and noise
emissions. The following can be supplied by Sandvik Rock Processing to
reduce these hazards:
• partially or completely encapsulated screens
• non-metallic screening elements to reduce noise levels
• rubber-lined feed boxes and discharge lips
Noise levels
For noise levels, refer to section 3.1.5 Noise level.

2.3.7 During inspection and maintenance

Risk for cut injuries
Sharp edges can be exposed when working with screening elements
and surrounding components. Always wear protective gloves.
WARNING!


3. Technical data

3. Technical data
3.1 Physical specifications

3.1.1 Foundations and framework
Design rules
Design the foundations and framework so that:
• they support the static and dynamic loads
• they meet the local building regulations
• their natural frequencies are far from the screens operating speed.
Where to find the loads?
The dimension drawing gives you the static and dynamic loads.
3.1.2 Dimensions
For the dimensions, see the general drawing. It can be useful to copy theses
values into the table below.
Tolerance
The tolerance on the dimensions is 3 mm
Dimension Value in mm
x
y
z

3. Technical data
3.1.3 Weight
For the weight, see the general drawing.
NOTE! The weight of the Master-Flo varies with the type of media, the various
options (feed box, spraying equipment…).
3.1.4 Electrical specifications

The standard electric supply is 3 phases 400 V, 50 Hz. Other voltage and
frequencies are available as an option.
The electric motor nominal speed is about 1,500 rpm.
For the power draw, see the general drawing.
3.1.5 Noise level

The noise level of the Master-Flo, as measured in Sandvik’s factory, is less
than 85 dB without material and between 90 and 100 dB with material.
Causes of variations
Noise level can vary with:
• the presence of housing
• the installation type
• the feed type
• the material size
• the material work index
• the motor size
• the screening media
• etc.

3. Technical data

This chapter contains step by step instructions to operate the Master-Flo. It is
assumed that commissioning has been achieved successfully.

4.1 General
NOTE! A functional test should be performed during preparation for commissioning.
Make sure this is done, and that any faults are corrected. Refer to the
Installation Manual.
4.2 Starting the Master-Flo

4.2.1 Precautions
Usual precautions
Before starting the Master-Flo, check that:
– the Master-Flo is completely stopped
– the oil level is correct. Refer to section 6.3 Filling the oil
– the media is neither loose, nor worn out, nor broken
– no loose objects are left on the screen
– all safety and warning devices, such as guards and dust enclosures are
in place, well fastened and fully functional
– no service or inspection personnel are working on, in, near, or
downstream of the Master-Flo
– the downstream equipment is in operation
– there are no unauthorized people or animal close to the Master-Flo.
Precautions after a long idle period

If the Master-Flo has remained idle during more than 2 weeks, check the
tension of the belts. Refer to section 9.4.1 Taking out the old belts.
4.2.2 Starting the Master-Flo

Start the Master-Flo, and check the following:
– that the Master-Flo has started normally and is running smoothly
– Listen for any abnormal noise or vibration.

4.3 Operating the Master-Flo

4.3.1 Normal operation
During operation, check:
– that the flow of material in and out of the Master-Flo is smooth
– that no material jumps off the media and gets into places where it
could cause damage
– the end product to ensure that the screening accuracy is adequate, and
that no media is broken
– if possible, that the power draw of the Master-Flo remains constant.
4.4 Stopping the Master-Flo

4.4.1 Precautions
Watch the clearance between the Master-Flo and the surrounding structures
as it slows down.
4.4.2 Normal stopping

Here is how to stop the Master-Flo:
a) Shut off the feed to the Master-Flo.
b) Wait for the Master-Flo to be empty of material.
c) Stop the Master-Flo.
4.4.3 Emergency stopping

Here is how to stop the Master-Flo in case of emergency:
a) Hit the emergency stop.
b) Reset the emergency stop.
4.4.4 Long idle period

If the Master-Flo is to remain idle during more than 2 weeks, release the
tension of the belts. Refer to section 9.4.1 Taking out the old belts


5. Inspection and
maintenance
This section describes the routine inspection and maintenance instructions
for the Master-Flo.

5.1 Routine inspection and care

NOTE! Every screen must be subjected to regular systematic checks. This will
result in fewer and smaller repairs, less downtime and thus lower overall
running costs.
Keep a written log including the screen’s operating conditions, important

data, details of adjustments made and any repairs carried out. For more
information, see section 5.9 Using the log book
5.1.1 Continuous checks

When walking or working near the Master-Flo, listen for any abnormal noise
and look for any unusual situation. Do not wait to take corrective actions.
Interval Action Remarks See Section
Daily look for oil leaks 5.4
Daily check the oil level 6.3
Daily look and listen for loose bolts -
Daily look for blinding of the screening element -
Daily look for pegging of the screening element -
Weekly Check the breather -
Weekly Check the screening element for wear -
Weekly Check for build up of material underneath -
the screen
Weekly Check the nozzles of the spraying -
system, if relevant
Monthly The belts: 9.4
- tension
- condition
- foreign material build up in the grooves
- oil or grease on the belts
Monthly Check condition of the housings -
Monthly Check condition of the rubber protections -
Monthly Check the tidiness of the mechanism -
Quarterly Change the oil every 500 h of operation 6.4
Quarterly Inspect the Master-Flo for damaged or loose -
parts
Quarterly Check the tightening of all bolts every 500 h -
of operation (including the bolts securing the
mechanism pulley and flywheels)
Quarterly Check the alignment and adjustment of the The dimen-
pivoting motor base sion drawing
Quarterly Check the condition of all guards -
Quarterly Check the condition of the springs -

Interval Action Remarks See Section

Quarterly Check the condition of the feed and dis- -
charge chutes
Quarterly Check the motor temperature and current -
draw (amps)
Quarterly Check the stroke with a stroke card in all Check when media is 5.3.3
four corners changed
5.2 Lubrication
Correct Lubrication of the Master-Flo is absolutely essential. Follow the
instructions in this chapter for a trouble-free operation of the Master-Flo.
CAUTION! Incorrect lubrication may cause breakdown of the Master-Flo.
For lubrication instructions, refer to section 6. Lubrication.
5.3 Setting the speed and stroke

5.3.1 General
Setting the speed and stroke optimize the function, the reliability, and the
lifetime of the Master-Flo.
NOTE! Material and screen media may change during the life span of the Master-
Flo. These changes impact the stroke and speed settings and may put your
Master-Flo out of its designed work-range. In such a case, call Sandvik for
advice.
In case of doubt
In case of doubt on the correct settings, please contact Sandvik.
Always switch off the power to the equipment before maintanance. Secure
that it is not possible for anyone else to switch on power while maintenance
work is being done.
Dangerous work
There is a risk of crushing when setting the speed and the stroke of
the Master-Flo
WARNING!
Do not remove guards
Make sure that all guards are in place and functioning, to prevent
exposure of flying fragments and rotating or vibrating parts.
PROHIBITION!
Rotating parts
All rotating parts of the equipment shall be protected by guard. Always
attach guards after maintenance work.
WARNING!
You must ensure maximum safety before doing any work on the Master-Flo
or making any adjustments. For more information, see section 2. Safety
precautions.

Factory settings and spares

Counterweights are already mounted on the mechanism in the factory. Spare
counterweights enable you to adjust the stroke.
5.3.2 Recommendations and rules

Use the lowest values
For extended Master-Flo and bearing life, use the lowest stroke and speed
required for the application.
Rule on the acceleration
The Master-Flo operates best at an acceleration between 3 and 4 G. If the
acceleration is out of this range, call Sandvik.
Calculating the acceleration
To calculate the acceleration apply this formula:
stroke (mm) x speed2 (rpm)

Acceleration (G) =
1.800.000
Rules on the number of counterweights

• You must mount the same number of additional counterweights on the
flywheels on each side of the screen.
• You must not mount more counterweights than delivered by Sandvik.
5.3.3 Measuring the stroke

A stroke card is used to determine the actual stroke (mm) of the screen
(circular vibration movement).
1 The blue circle has a white

circle in its center 1
2 The blue circle looks sharp and Too Small 2
gives the actual stroke
3 The blue circle looks blurred Actual Stroke 3
STROKE CARD Too Large
15 14 13 12
2 11 10 9 8,5
5 8 7,5 7 6,5
7
6 5,5 5 4,5
8
Stroke
9 4 3,5 3 2,5
10

To measure the stroke:

a) Put the stroke card against one of the sides of the Master-Flo while it is
running.
b) Record the value printed on top of the sharp circle (2).
NOTE! The stroke of the screen should be the same at corresponding points on both
sides of the screen.
5.3.4 Changing the stroke

• When you observe pegging or blinding, increase the stroke.
• When the Master-Flo is working out of its range, correct the stroke.
The illustration below shows the counterweights.
1 Washer
2 Nut
3 Bolt
4 Counterweights (4 shown)
2
3

Detail view, counterweight

1 Washer
2 Nut
3 Bolt
4 Counterweights
(4 shown)
1
2
To change the stroke:

a) Stop the Master-Flo. Wait until it has come to a complete stop.
b) Swich off the power. Secure the machine to avoid accidental start.
c) Disassemble the guards.
d) Loosen the nuts (2).
e) Take out the nuts (2) and the washers (1).
Add or take out one counterweight as follows:
If you want to… Then...
Increase the stroke add one counterweight
decrease the stroke take out one counterweight
f) Put back in place the nuts and the washers.

g) Tighten the nuts.
h) Re-install the machine guards.
i) Repeat the same operation on each end, of each mechanism.
j) Start the Master-Flo.
k) Measure the stroke. For more information, see section 5.3.3 Measuring
the stroke.
l) Check the acceleration. For more information, see section
5.3.2 Recommendations and rules.

5.3.5 Changing the speed

To change the speed:
a) Stop the Master-Flo. Wait until it has come to a complete stop.
b) Swich off the power. Secure the machine to avoid accidental start.
c) Take out the belts. For more information, refer to section 9.4.1 Taking
out the old belts.
d) Take out the motor pulley.
e) Select a new pulley as follows:
If you want to… Then...
Increase the speed use a larger motor pulley
decrease the speed use a smaller motor pulley
f) Reassemble the new pulley

g) Reinstall the belts. For more information, refer to section 9.4.2 Install
the new belts.
h) Re-install the machine guards.
i) Start the Master-Flo.
j) Measure the speed.
k) Check the acceleration, refer to section 5.3.2 Recommendations and
rules.
5.4 Oil leaks

Look for oil leaks every time you are near the Master-Flo and at least every
day, before starting the Master-Flo.
5.4.1 Corrective actions

In case of oil leak, execute the following actions:
If the oil leak is from… Then...

a nut tighten the nut
If the coil continues leaking, change the seal
the transparent tube change it
Look for the origin of the leak and proceed as follows:
a) If necessary, complete the oil level. For more information, see section
6.3 Filling the oil.
b) Clean spilled oil with a rag.

Checklist
Step Action Done/Checked
1 Oil level reaches the Normal mark
2 If clogged, breather is cleaned or changed
3 Breather back in place
5.5 Changing screening elements

To change or replace screening elements and wear parts, refer to section
7. Screening media.
5.6 Maintanance of mechanism

For maintenance on the mechanism, such as exchange of bearings, refer to
section 8. Mechanism.
5.7 Changing spare parts

To change or replace spare parts such as belts, motors or springs, refer to
section 9. Changing spare parts.
5.8 Adjusting the belt tension

The belt tension needs to be checked at regular intervals, and might need to
be sdjusted. Refer to section 5.1 Routine inspection and care and section
9.3 The belt tension.
5.9 Using the log book

It is recommended to use a log book for recording events, observations, and
actions.
The log book helps the owner, the operators, Sandvik engineering, and
maintenance staff to:
• track events
• better forecast the purchase of wear and spare parts
• ensure that the maintenance instructions are followed
• understand the sequence of events and make the right decisions to
improve products in case of problem.

5.9.1 Content
The log book as a minimum must specify:
• when the work was done (date and, if possible, operating hours)
• who did the work
• what work was done
• any measurements and observations
• signature of foreman or supervisor.
5.9.2 Requirement during the warranty period

As a condition of the warranty, Sandvik requires that during the warranty
period, the owner of the Master-Flo records all service, maintenance and
repair work done in the log book.
The log book must be available for inspection by Sandviks´ representatives.
5.9.3 Recommendation
Sandvik recommends that the owner of the Master-Flo maintains the log
book during the whole life time of the Master-Flo.
If you follow this recommendation, the log book must be available for
inspection by Sandvik representatives.
5.9.4 Checklists in this manual

This manual contains many checklists. Use them as a model for your log
book. You can use them as they are by making direct copies. You may also
adapt them to your local or company rules.
5.9.5 The importance of being honest

It is important to fill the log book so that it reflects the hard facts.
An error is always possible. Should you make an error, correct it. Take
measures to prevent it from happening again, and record exactly what
happened in the log book.
On the long term, recording exact information in the log book will make
your Master-Flo more reliable and more available.


6. Lubrication
This section describes when and how to how to lubricate the vibrator
mechanism. It also specifies which oil to use.
or making any adjustments. Refer to section 2. Safety precautions

6. Lubrication
6.1 General
Lubrication is absolutely essential to your Master-Flo. It is important to keep
the mechanism correctly lubricated.
CAUTION! A low oil level can cause overheating and damage to the bearings. A
high oil level can cause seal leakage and increase the operating temper-
ature.
NOTE! All mechanisms are lubricated in an oil bath.
Following the instructions of this chapter will ensure a trouble free operation
of your screen.
Dangerous work
Always remember that hot oil can cause severe burns.
WARNING!
or making any adjustments. For more information, refer to section 2. Safety
precautions.
6.2 Oil quality and specification

The quality of oil is important. Always use oil of good quality. Sandvik
recommends an oil having specifications showed in the table below.
Oil specification
Note that it depends on the ambient temperature.
Ambient < 4° C (40 °F) From 4 ° C (40° F) > 25° C (77° F)
temperature to 25° C (77° F)
Characteristic
Min flash point ° C/° F 205/400 205/400 205/400
Viscosity 104° F cSt 100 150 220
Viscosity 100° F SSU 450 750 1,375
Viscosity 210° F SSU 55 75 100
Viscosity index > 95 > 95 > 95
Timken test lb 50 50 50
Extreme pressure agent yes yes yes
Anti foaming agent yes yes yes
Copper strip yes yes yes
Corrosion test ok ok ok
6.3 Filling the oil

Check the oil during installation, commissioning, and every day during the
life of the Master-Flo. Fill it whenever the level is below the Mini mark. Fill
the oil after maintaining the mechanism.

6. Lubrication
The drawing below shows the oil circuit, indicating oil levels and parts you
need to know in order to complete the oil:
Breather
Normal
Normal
Mini
Mini
To fill the oil:

Remove the breather on one side of the Master-Flo
c) Add oil through the breather hole until the oil level reaches the Normal
mark.
d) If the breather is clogged, clean it or change it.
e) Put the breather back in place.
Checklist
6.4 Changing the oil

Change the oil every 500 hours.
NOTE! After commissioning, you must change the oil after the first 40 hours of
operation.
6.4.1 Changing the oil brand

If the oil brand is to be changed, proceed as follows:
a) Drain the mechanism.
b) Flush out the bearings.
c) Refill with new oil.
NOTE! Unless there is a special request, the Master-Flo is shipped with
Total EP150 oil.

6. Lubrication
Table of equivalence
Use this table of equivalence to select another brand:
Ambient < 4° C (40 °F) From 4 ° C (40° F) > 25° C (77° F)
temperature to 25° C (77° F)
Supplier
Antar Antar EP 80W Antar EP 80 W 30 —
BP GR XP 100 GR XP 150 GR XP 220
Elf Reduct Elf Spigo Reduct Elf 150 Reduct Elf SP220
Esso Spartan EP ICO Spartan EP150 Spartan EP220
Mobil Mobilgear 626 Mobilgear 629 Mobilgear 630
Comdat Mecanic EP 100 Mecanic EP 150 Mecanic EP 220
Shell Omala 100 Omala 150 Omala 220
Total Carter EP 100 Carter EP 150 Carter EP 220
The drawing below shows the oil circuit, indicating oil levels and the
nomenclature of the parts involved at oil change:
1 Cap 3
2 Nut
3 Breather
Normal
Normal
Mini
Min.
Change the oil

Run the Master-Flo to warm up the oil, as warm oil flows more easily.
Recommended tools Complete the following step (a-h) on both sides of the Master-Flo:
A spindle a) Put the container under the cap (1).
Rags b) Remove the breather (3) and the cap (1).
2 containers to c) If the breather (3) is clogged, clean it or change it.
collect the old oil
d) Wait until the oil stops dripping.
NOTE! This may take as long as 2 hours
e) Remove the cap (2).
f) Clean the interior of the tube indicating the oil level using a spindle and
rags.
g) Put back in place the 2 nuts (parts 1 and 2).

6. Lubrication
h) Put one of the breathers (part 3) back in place.

Complete the following step (i-k) on one side of the Master-Flo:
i) Refill the mechanism through the breather pipe until the oil level reaches
the Normal mark
NOTE! See the general drawing for an approx. quantity of oil.
j) When the oil level is stable, complete if necessary.
k) Put the last breather (part 3) back in place.
Checklist

6. Lubrication

7. Screening media
This section describes side tensioned media only. For other media, please see
the manufacturer’s documents.
or making any adjustments. Refer to section 2. Safety precautions.

7. Screening media
7.1 The side tensioned system

Before you read the instructions on changing the media, read the following
explanations to help you understand how a side tensioned system works.
The illustration below shows a tensioning system:
3 4 7
2 5 8
9
6 8 9
The table explains the function of the parts of the side tensioning system:
1 550 304 Clamping screw Pulls the clamping bars
2 550 180 Clamping nut —
3 550 308 Bevel washer —
4 567 464 Washer —
5 Screen specific Clamping bar Pulls the draw hooks
6 — Draw hook Tensions the media
7 — Master-Flo side plate —
8 500 562 Rubber capping Protects the longitudinal members
9 — Longitudinal members Supports the media when it is properly
tensioned

7. Screening media
The illustrations below show detail views of the tensioning system.

In below illustration, there is no central hold down for widths < 2.100 mm:
The illustration below shows a central hold down for widths ≥ 2.100 mm. It
keeps the media against the deck.
1 Central hold down

7. Screening media
7.2 Changing wear parts of the side

tensioned media
Look for a worn part of the media every time the Master-Flo produces a
material out of tolerance.
To look for a worn part of the media, you can:
• use visual inspection
• see the log book where the recording of previous events can orientate
you to parts of the media sensitive to wear
• use a gauge to measure the apertures of the media.
CAUTION! When a media is not held down firmly over the longitudinal support
members, it hits the deck during operation. This leads to premature fail-
ure of the media and of the deck. A broken deck frame can lead to se-
vere structural damage to the whole Master-Flo.
7.2.1 Work from the feed end

Media can normally be inserted and removed from the feed end. The
inclination of the Master-Flo makes inserting media from the feed end and
sliding them into position simple and convenient.
Exception
Use the discharge end when the discharge chute is equipped with a trolley
that you move before changing the media.
To change the media (referring to illustration in section 7.1 The side
tensioned system):
a) Loosen the clamping nuts (item 2).
b) Remove:
• the clamping nuts (item 2)
• the bevel washers (item 3)
• the washers (item 4)
• the clamping screws (item 1)
• the clamping bars (item 5).
c) Lift the media from the deck.
d) If the rubber protections of the deck are not in good condition, replace
them.
e) Install the new sections of media beginning from the discharge end.
f) Put back in position, without tightening them:
• the clamping bars (item 5)
• the clamping screws (item 1)
• the washers (item 4)
• the bevel washers (item 3)

7. Screening media
• the clamping nuts (item 2).

g) Ensure that the draw hooks (item 6) are locked under the clamping bars
(item 5).
h) Tighten the nuts (item 2) evenly on both sides of the Master-Flo.
The screw has an index to help you set its orientation with a screwdriver
(see illustration below).
CAUTION! The media must fit tight over the crown of the deck and rest firmly on
the rubber protection.
i) Check the tensioning of the media by lightly tapping its surface with a
hammer and listening for the sound to have the same pitch over the
whole area.
CAUTION! Do not tension the media beyond the manufacturer’s recommenda-
tions.
j) Run the machine for a few minutes, preferably with material
If necessary, adjust the tensioning of the media.
7.2.2 Checklist
Step Action Done or
checked
1 Draw hooks (item 6) locked under the clamping bars (item 5)
2 Nuts (item 2) tightened evenly on both sides of the Master-Flo
3 Media tension

7. Screening media

8. Mechanism
This section describes the nomenclature and the parts of the mechanism and
its parts. It also describes how to disassemble, and re-assemble it at
maintenance.

8. Mechanism
8.1 The parts of the mechanism

The mechanism is rather complex. Refer to the breakdown view and the
sectional view in this chapter.
8.1.1 Torques
When tightening screws, apply the following torques given in daNm
(decanewton x meter)
Diameter Quality class 8.8 Quality class 10.9 Quality class 12.9
12 8.11 11.41 13.70
14 12.87 18.11 21.73
16 19.59 27.56 33.07
20 38.2 53.71 64.46
24 65.60 92.24 110.70
27 95.80 134.71 161.66
30 120 168.75 202.50
NOTE! The counterweights are not commented here because they do not impact the
mechanism maintenance.

8. Mechanism
Breakdown view of the mechanism

This view shows the mechanism seen from the motor side:
22
5
11
13
12
9
7 8
6
4
3
2
1
14
20
19
17
16
15
18
10
1 Shaft end screw 9 Bearing cap, double sealing 17 Bearing housing
2 Shaft end lock washer 10 2 oil seals 18 Bearing
3 Shaft end washer 11 Bearing cover O-ring oil seal 19 Spacer tube O-ring oil seal
4 Grooved flywheel 12 Wear ring 20 Shaft
5 Flywheel key 13 Deflector baffle 21 Spacer tube (mechanism tube)
6 External labyrinth spacer 14 Bearing housing screw 22 Spacer tube rubber protection
7 Bearing cap screw 15 Bearing housing locking nut
8 Bearing cap lock washer 16 Bearing housing washer Note: item 21 not visible in view

8. Mechanism
8.2 Double mechanisms

If the Master-Flo has two identical mechanisms, each mechanism is driven
by its own electric motor. The two motors are identical. A synchronisation
belt synchronises the two mechanisms.
The illustration below shows the synchronisation system.
1
1 Synchronization
pulley
2 Idlers support
3 Idlers
4 Synchronization belt
2
4
8.3 Maintaining the mechanism

Dangerous work
Heavy parts can cause crushing.
WARNING!
When maintaining the mechanism, apply these safety precautions:

• Be careful not to damage the shaft’s bearing seats or the bearing housing.
• Be careful when handling heavy and or oily parts.
• Be careful with the mechanism and the flywheels which are unbalanced.
• Warm or hot oil can cause severe burns.
• If it is necessary to remove the shaft, Sandvik recommends to attach a
threaded bar to its end to support it from both ends.

8. Mechanism
8.3.1 Precautions with the shaft

Critical damage to the shaft can be caused by:
• accidental impact at disassembly or re-assembly
• corrosion
• contaminations
• bearing failures.
Damaged shaft
A shaft with severe damages must be replaced.
8.3.2 Recommendation at disassembling

The following procedures tell you how to disassemble and to reassemble the
whole mechanism.
You need to decide how far to go on the basis of the real situation you are
facing. Stop the disassembly procedure when you have reached the part
which needs attention. Likewise, start reassembling the mechanism from
where you need.
8.3.3 Differences between the 2 ends

These are the differences between the 2 ends:
Flywheels
• On the motor side, the flywheel is grooved.
• On the other side, the flywheel is smooth.
Bearings
• On the motor side, the bearing is fixed.
• On the other side, the bearing is floating.
Marking
• On the motor side, the shaft is marked with a B.
• On the other side, the shaft is marked with a L.
8.3.4 Taking out the shaft

To take out the shaft, you need to execute the procedures at both ends.
8.3.5 Before disassembling the mechanism

Before disassembling the mechanism:
• If possible, run the Master-Flo to warm up the oil. A warm oil will flow
more easily.
• Remove the guard and the belts.

8. Mechanism
• Drain the oil. For more information, refer to section 6.4 Changing the
oil.
• If you need to disassemble the mechanism on the synchronisation side,
first disassemble the synchronisation system. For more information,
refer to section 9.6 Changing the synchronisation belt.
Sectional view of the mechanism

The illustration below shows a sectional view of the mechanism at the
motor side.
13
12
9
6
5
4
3
2
22
1 21
20
14
17
16
15
18
10
1 Shaft end screw 9 Bearing cap, double sealing 17 Bearing housing
2 Shaft end lock washer 10 2 oil seals 18 Bearing
3 Shaft end washer 11 Bearing cover O-ring oil seal 19 Spacer tube O-ring oil seal
4 Grooved flywheel 12 Wear ring 20 Shaft
5 Flywheel key 13 Deflector baffle 21 Spacer tube (mechanism tube)
6 External labyrinth spacer 14 Bearing housing screw 22 Spacer tube rubber protection
7 Bearing cap screw 15 Bearing housing locking nut
8 Bearing cap lock washer 16 Bearing housing washer Note: item 7, 8, 11 and 19 not
shown in view

8. Mechanism
Detail
1 6 9 12 13 18
Detail of the labyrinth oil seals
10 10
8.3.6 Disassembling the mechanism

Here is how to disassemble the mechanism
a) Remove:
• the shaft end screw (item 1)
• the shaft end lock washer (item 2)
• the shaft end washer (item 3).

8. Mechanism
b) Extract the grooved flywheel (item 4).

CAUTION! Take care of the flywheel key (item 5).
c) Remove the external labyrinth spacer (item 6).
d) Remove:
• the bearing cap screws (item 7).
• the bearing cap lock washers (item 8).
• the bearing cap (item 9), using the threaded holes.
NOTE! The 2 labyrinth oil seals (10) come with the bearing cap.
e) Remove the oil level assembly by loosening the reducing nipples shown
by the arrows:
Reducing
nipples Normal
Normal
Mini
Min
f) Warm the wear ring (item 12) with a torch and remove it.
g) Remove the deflector baffle (item 13).
h) Support the shaft end vertically.
NOTE! Use the screw at the end of the shaft and a belt
Remove:
• the bearing housing lock nuts (item 15)
• the bearing housing washers (item 16).
i) If you need to change the bearing housing screws (item 14), pull them
from the inside of the screen.
j) Using the 2 threaded extraction holes, and remove together:
• the bearing housing (item 17)
• the bearing (item 18).
NOTE! Check that the bearing number faces the upper side of the bearing housing.
Any discrepancy must be recorded.
Check the surface of the bearing housing. Change it if necessary.
k) When the bearing and the housing are almost taken out, relieve the load
of the shaft on the bearing.

8. Mechanism
l) Support the shaft in the mechanism tube.

NOTE! You can use wooden wedges
m) Extract the bearing (item 18) from the bearing housing (item 17) by:
• placing the bearing housing on a rigid workbench
• striking the external collar of the bearing with a tube or muff coupling.
8.3.7 Assembling the mechanism

Here is how to assemble the mechanism
a) Clean:
• the bearing housing (item 17)
• all mechanical parts
• the internal tube.
b) Change and grease the:
• bearing cover O-ring oil seal (item 11)
• spacer tube O-ring oil seal (item 19).
c) Heat the bearing housing (item 17).
NOTE! Sandvik recommends an induction heating at 70 - 80° C (130 - 150°F).
You can also use an oil bath at 90 - 100° C (190 - 210° F) or a torch at
70 - 80° C (130 - 150° F).
d) Remove the bearing (item 18) from its protective packaging.
• Turn it so that the number engraved on its face remains visible on the
upper side so that a later inspection can check that it did not turn in its
housing.
• Slide it immediately into the bearing housing (item 17) evenly until it
sits on the lower inner edge of the bearing housing.
e) Lightly tap the outer face of the bearing with a rubber mallet on a brass
rod so that the bearing is all the way down.
f) Cover the bearing and the bearing housing to avoid contaminants until
final assembly on the shaft.
g) If the shaft has been removed, put it back in place.
CAUTION! Take care of its direction. It has a B on the motor side and a L on the
opposite side
h) Make sure that:
• the shaft is clean and free of scratches
• the attachment for the grooved pulley is on the correct side
• if work has been done on the bearing seat, the bearing can slide
smoothly.
i) Slide one bearing housing on the end of the shaft.
• Clean the reinforcement plate.
NOTE! Use RCI SH 58 or equivalent. The housing can then act as a lifting device for
the shaft.

8. Mechanism
j) Screw the bolts of the bearing housing and tighten them.

k) If both bearings have been disassembled, reassemble the 2nd one.
• Execute steps i) and j) for this bearing.
NOTE! Slightly pull the shaft to make the access to the end easier. Push the shaft
back in place.
l) Clean the bearing housing outer surfaces.
m) Put in place:
• the bearing housing screws (item 14)
• the bearing housing washers (item 16)
• the bearing housing lock nuts (item 15).
n) Tighten the bearing housing lock nuts (item 15).
o) Check that the shaft can slide on the bearings.
p) Install the deflector baffle (item 13).
• Check the contact between the deflector and the bearings on the motor
side
• Check the contact between the deflector and the shaft on the opposite
side.
q) Coat the machined surface of the shaft on which the spacer will sit with
RCI Fix 88 or equivalent.
r) Warm up and slide the wear ring (item 12) as shown here:
Marking of the external

labyrinth spacer
The marking on the

external labyrinth
spacer is in the upper
position
.
The unbalanced weight
of the shaft is in the
lower position
s) Clean the double sealing bearing cap (item 9).

t) Remove the old labyrinth oil seals (item 10).
u) Coat the new labyrinth oil seals with a film of oil or grease.

8. Mechanism
v) Check the direction of the seal according to this sketch:
w) Place the seal into its housing using a muff coupling with a diameter
slightly smaller than the seal. Make sure it presses against the metallic
part of the seal.
NOTE! Take care of the spring embedded in the seal.
x) Put a little grease on the outer side of the dust resistant lip of the
labyrinth oil seal.
y) Install a new bearing cover o-ring seal (item 11) on the bearing housing
(item 17).
• Put a little grease on the seal.
NOTE! Take care not to pinch the seal
z) Install on the bearing housing (item 17):
• the double sealing bearing cap (item 9)
• lock washers (item 8)
• the bearing cap screws (item 7).
NOTE! Make sure not to damage the labyrinth oil seals (item 10).
aa) Slip the external labyrinth spacer (item 6) over the shaft.

8. Mechanism
ab) Re-install the oil level assembly by tightening the reducing nipples
shown by the arrows:
Reducing
nipples Normal
Normal
Mini
Mini
NOTE! Put RCI ETA 27 or equivalent on the threading

ac) Re-install:
• the grooved flywheel (item 4)
• the shaft end washer (item 3)
• the shaft end lock washer (item 2)
• the shaft end screw (item 1).
ad) Tighten to the proper torque. Refer to section 8.1.1 Torques.
8.3.8 After assembling the mechanism

After assembling the mechanism:
• Put the belts and the guards back in place. For more information, refer to
section Installing the belts in the Installation manual (IM).
• Complete the oil. For more information, refer to section 6.3 Filling the
oil.
• If you need to assemble the mechanism on the synchronisation side,
assemble the synchronisation system. For more information, refer to
section 9.6 Changing the synchronisation belt.

This section describes how to change the spare parts (belts, electrical motors
and the support springs), and how to calculate the belt tension.

9.1 General
This chapter refers to previous sections in this manual. For a general
description of the Master-Flo, and its nomenclature, refer to section
1.3 Product description.
Always switch off power to the equipment before any maintenance work is
started. Also secure that it is not possible for anyone else to switch on power
while maintenance work is being done.
9.1.1 Torques
When tightening screws, apply the following torques given in daNm
(decanewton x meter):
Diameter Quality class 8.8 Quality class 10.9 Quality class 12.9
12 8.11 11.41 13.70
14 12.87 18.11 21.73
16 19.59 27.56 33.07
20 38.2 53.71 64.46
24 65.60 92.24 110.70
27 95.80 134.71 161.66
30 120 168.75 202.50
9.2 Changing the springs

Dangerous work
Disconnect the motors before working on the belts
DANGER!
Change the springs when they are either broken or have lost their original
stiffness.

The illustration shows 2 springs, their sleeves, and the nipples.
9.2.1 Changing one spring or all springs

If one spring is broken, change it.
If the springs of a corner have lost their original stiffness, change all the
springs of this corner.
Recommended tools To change several springs, repeat steps (a) to (e) below for each spring. Lift
A crane the relevant end of the Master-Flo until the spring comes loose.
Lifting tackles a) Pull horizontally the broken spring with its protection sleeve.
b) Pull out the protection sleeve.
c) Put the protection sleeve around a new spring.
If necessary, use a new one.
d) Put the new spring with its protection sleeve in place.
e) Lay down the Master-Flo.
9.3 The belt tension

CAUTION! The belts must have the proper tension to avoid slippage under load
and damage to the belts.
The belt tension for each belt needs to be correctly set when changing the
belts. The tension must also be checked periodically. For more information,
refer to section section 6.1 Routine inspection and care.

If the belt tension is not recorded in the log book, the procedures in sections
9.3.1 and 9.3.2 (below) needs to be carried out.
9.3.1 Calculating the force to tension the belt

Before tensioning the belt, you need to calculate the force to be applied to it
as follows. Apply the force (F) perpendicular to the belt.
Belt deviation
F Mechanism
pulley
Motor
pulley
a) Record the motor pulley diameter

b) Apply this formula to calculate the belt linear speed:
Belt linear speed (in m/s) = 0.077 x pulley diameter (in mm)
c) find out the force F in Newtons to be applied to the belt in below tables:
Belt linear speed Motor pulley diameter < 355 Motor pulley diameter ≥ 355
< 10 72 - 102 102 - 132
10 - 20 60 - 90 90 - 120
20 - 30 50 - 80 80 - 110
Belt linear speed Motor pulley diameter < 250 Motor pulley diameter ≥ 250
< 10 38 - 56 56 - 72
10 - 20 32 - 50 50 - 64
20 - 30 28 - 42 42 - 58
NOTE! Record calculated force F to apply at belt change in the log book.
This value is needed whenever the belts are changed or when the belt tension
is to be checked.
9.3.2 Calculating the deviation

Now that you have calculated the force to be applied, you need to calculated
the deviation of the belt as follows:
a) Measure the distance D between the pulley centres
b) Apply this formula to calculate the belt deviation:
Belt deviation = 0.015 x D
NOTE! Record calculated belt deviation in the log book.
This value is needed whenever the belts are changed or when the belt tension
is to be checked.

9.4 Changing the belts

Dangerous work
Disconnect the motors before working on the belts.
DANGER!
Dangerous work
You risk crushing when the Master-Flo is being put into position.
WARNING!
Hanging load
Do not stand under, or allow anyone else to stand under equipment
that is being hoisted or suspended.
WARNING!
You need a lifting device to lift the pivoting motor base.
NOTE! You must change all belts together.
9.4.1 Taking out the old belts

To take out the old belts:
a) Loosen the counter-nut (1) and the nut welded to the belt tension bolt (2)
shown below.
1 Counter-nut
2 Nut welded to the bolt

b) Lift the pivoting motor base, indicated by the arrow below.
c) Pull out the belts.
9.4.2 Install the new belts

NOTE! Before installing the new belts, the force (F), and the belt deviation needs to
be taken note of. See the log book for previously recorded values, or re-
calculate the values. For more information refer to section 9.3 The belt
tension.
To install the belts:
a) Lift the motor base enough to be able to put the belts in place.
b) Put the belts in place.
c) Lay the motor base down in place.
d) Apply the force (F) recorded in the log book (or calculated in section
9.3.1) perpendicular to the middle of one of the belt.
Belt deviation
F Mechanism
pulley
Motor
pulley

e) Tighten the nut welded to the rod (2), shown below, until the belt
deviation reaches the value recorded in the log book (or calculated in
section 9.3.1).
f) Tighten the counter-nut (1), shown below.
1 Counter-nut
g) Check that the tension is the same for the other belts.
h) Put the belt guard in place.
9.5 Changing the motor

Dangerous work
Disconnect the motors before working on the belts
DANGER!
You need a lifting device to lift the pivoting motor base.

Change the motor if:
• the power consumption becomes very different from what has been
measured and recorded during commissioning

• you observe an alteration of the performance with relation with the

motor.
9.5.1 Disassembling the motor

To disassemble the broken down motor:
a) Switch off the power supply.
b) Disconnect the motor.
a) Loosen the counter-nut (1) and the nut welded to the belt tension bolt (2)
shown below.
1 Counter-nut
b) Lift the pivoting motor base, indicated by the arrow below.
c) Pull out the belts.

d) Unscrew the 4 bolts fixing the motor to the motor base, shown below:
3 Bolts
e) Lift the motor and put it away.

f) Disassemble the motor pulley.
9.5.2 Putting the motor in place

To put in place the new motor:
a) Assemble the pulley on the new motor.
b) Install the new motor with its pulley on the pivoting motor base.

c) Check that the grooves of the motor pulley and the grooves of the
mechanism pulley are in the same plane.
Both pulleys must be

in the same plane
Mechanism
pulleys
Belt
Motor pulleys
Both pulleys must be

in the same plane
d) Make the electrical connections.

e) If possible, jog the motor to ensure that it turns in the correct direction.

9.6 Changing the synchronisation belt

Dangerous work
Disconnect the motors before working on the belts.
DANGER!
Change the synchronisation belt when it is worn out or partially or totally

destroyed.
The illustration below shows the synchronisation side of the Master-Flo with
the guard taken out:
To change the synchronisation belt:

a) Take the guard out.
b) Disassemble the pulley flanges.
c) Pull out the synchronisation belt.
d) Ensure that the shafts are in the same position.
e) Slide the new belt in.
f) Assemble the pulley flanges.
g) Put the guard in place.


10. Troubleshooting
This section is a guide for solving interruptions in production. Checking the
Master-Flo regularly will help you increase its reliability, and optimize its
life span.

10. Troubleshooting
10.1 Damage reports

When a damage occurs to the Master-Flo, you must send a damage report to
Sandvik.
A damage report has the following advantages:
• It is a condition to have the damage approved as a warranty claim.
• It helps us assist you.
• It helps us increase the quality of our products and of our service level.
Content
The damage report must contain at least the following information:
• Serial number of the Master-Flo.
• The date the damage was first noticed (operating hours if available).
• Description of the damage.
• A copy of the maintenance log for the preceding period, if possible.
• Any measurements and observations.
• Photos or drawings showing the exact location of the damage.
• Description of any work done to repair/reduce the damage.
• Signature of foreman or supervisor.

10. Troubleshooting
10.2 Faults and suggested actions

If you have to change a part after a failure, always try to find the reason of
the failure and correct it whenever possible. If you cannot correct it, contact
the manufacturer.
10.2.1 Orientation list

Use this table to quickly find out corrective actions:
No Problem Check See section
1 Master-Flo does not start, or 10.2.2
stops while running.
2 Master-Flo does not run prop- 10.2.3
erly.
The motor vibrates abnormally. 10.2.4
3 The framework bends or 10.2.5
vibrates too much.
4 Abnormal noise while running. 10.2.6
5 Bearings overheat. 10.2.7
6 Bearings broken or worn out. 10.2.8
7 Oil leak. 10.2.9
8 Belts worn out. 10.2.10
9 Pegging or low performance. 10.2.11
10 Material mainly on one side of 10.2.14
the Master-Flo.
11 Media wear out or break, abnor- 10.2.15
mal wear out.
12 Material falls out from the feed 10.2.16
end onto platform.
13 Springs too compressed. 10.2.17
10.2.2 Master-Flo does not start, or stops while running

No. Potential cause Proposed action See section
14 Electrical system failure. Check and correct.
15 Belts not tensioned or worn out. Check tension and appear- Refer to section 9.3 The belt tension.
ance of the belts.

10. Troubleshooting
10.2.3 Master-Flo does not run properly

16 Master-Flo hits something hard. Check the clearances. Refer to the Installation Manual, sec-
tion Installing the Master-Flo.
17 Pulleys or belts worn out. Change the parts. Refer to section 9.4.2 Install the new
belts.
18 Motor not installed in line with Install the motor as per Refer to section 9.5.2 Putting the
the mechanism. instructions. motor in place.
10.2.4 The motor vibrates

19 Fixing screws loose. Tighten the fixing screws. Refer to the Installation Manual, sec-
tion Installing the Master-Flo
10.2.5 The framework bends or vibrates too much

20 Framework too light or assem- Reinforce the supporting -
bly too weak. framework.
21 Framework foundations too Reinforce the foundations -
weak. or the framework.
10.2.6 Abnormal noise while running

22 Loosened or broken parts in the Tighten, repair or change -
Master-Flo. the parts. Find out the rea-
son to eliminate it.
23 Master-Flo hits something hard. Check the clearances. Refer to the Installation Manual, sec-
tion Installing the Master-Flo.
24 Media loosened. Tighten the media as per Refer to section 7. Screening media.
instructions.
Note: Long, coarse or thick

media can be hard to
secure with sufficient hold-
down force.
25 Bearing broken. Change the bearing. Refer to section 8.3 Maintaining the
mechanism.
26 Spring broken. Change the spring. Refer to section 9.2 Changing the
Find out the reason to elimi- springs.
nate it.

10. Troubleshooting
10.2.7 Bearings overheat

27 Not enough or too much oil. Check the oil level. Refer to section 6.3 Filling the oil.
28 Incorrect oil type. Change the oil. Refer to section 6.4 Changing the oil.
Oil too old.
29 Bearing broken. See point below. -
30 Ambient or material temperature Make sure there is enough Refer to section 6.4 Changing the oil.
too high. airing. Choose oil for high
temperatures.
10.2.8 Bearings broken or worn out

31 Bearing is worn out. Change the bearing. Refer to section 8.3 Maintaining the
Find out the reason to elimi- mechanism.
nate it.
32 Not enough lubrication. Check the periodic mainte- Refer to section 5.1 Routine inspection
nance intervals. and care.
Check the log book.
Look for leaks.
33 Incorrect oil type. Change the oil type. Refer to section 6.2 Oil quality and
specification.
34 Foreign material in oil. Find out the reason to elimi- -
nate it (broken parts, dirty
working environment).
35 Master-Flo position prevents Check the Master-Flo levels Refer to section 6.4 Changing the oil.
proper oil distribution between as per instructions.
the bearings.
10.2.9 Oil leak

36 Breather is clogged. Change the breather and -
clean it regularly.
37 Seals worn out or damaged (for Change them. -
instance during installation).
10.2.10 Belts worn out
Cut belt
38 Damage to the belt during Install a new belt as per Refer to section 9.4 Changing the
installation. instructions. belts.
39 Hard objects in pulleys. Check the guards. -

10. Troubleshooting
Belts slip in the pulleys or motor vibrates

40 Tension too low. Check the belt tension. Set Refer to section 9.3 The belt tension.
tension as per instructions.
41 Belts are installed unevenly in Set the pulleys as per Refer to section 9.5.2 Putting the motor
the pulleys. instructions. in place.
42 Belts touch fixed parts. Check the belt tension. Refer to section 9.3 The belt tension.
Belt surface wears out quickly

43 Tension too low. Set tension as per instruc- Refer to section 9.3 The belt tension.
tions.
44 Tension too high. Set tension as per instruc- Refer to section 9.3 The belt tension.
tions.
45 Belts are installed unevenly in Set the pulleys as per Refer to section 9.3 The belt tension.
the pulleys. instructions.
Scratched belt surface

46 Cracks or holes in the pulleys Check the pulleys. Refer to section 9.3 The belt tension.
groove. Tighten the belts.
47 Low motor performance. Check the motor. -
Burnt rubber in the grooves

48 Tension too low. Set tension as per instruc- Refer to section 9.3 The belt tension.
tions.
49 Tension too high. Set tension as per instruc- Refer to section 9.3 The belt tension.
tions.
50 Belts are installed unevenly in Set the pulleys as per Refer to section 9.5.2 Putting the motor
the pulleys. instructions. in place.
51 Low motor performance. Check the motor. Tighten Refer to section 9.3 The belt tension.
the belts.
52 Lubricant or fuel on the belts. Clean the motor. -
Eliminate leaks.
53 High ambient temperature. Reinforce airing. -
Cracks and breaks on the surface of the belts

54 Belts touch fixed parts. Check the clearance. Refer to section 9.3 The belt tension.
Check the tension.

10. Troubleshooting
Sticky belt surface, rubber on the belts and the pulleys

55 Lubricant or fuel on the belts. Clean the motor. -
Eliminate leaks.
Hard belt surface, cracked rubber

56 Direct sunshine, welding, hot air Check protection and air- -
draft. ing.
57 High ambient temperature. Reinforce airing. -
10.2.11 Pegging or low performance

58 Stroke too small. Set stroke as per instruc- Refer to section 5.3 Setting the speed
tions. and stroke.
59 Speed too low. Set speed as per instruc- Refer to section 5.3 Setting the speed
tions. and stroke.
60 Media unsuitable (for instance Change media. Refer to section 7. Screening media.
holes too small).
61 Material containing clay, mud or Wash material before -
other impurities. screening.
10.2.12 Blinding
62 Stroke too small. Set stroke as per instruc- Refer to section 5.3 Setting the speed
tions. and stroke.
63 Media unsuitable. Change screening media: Refer to section 7. Screening media.
-To a more flexible media.
-To a media with more open
area.
-To thinner wire media.
-From regular steel to stain-
less wire media.
10.2.13 Low accuracy

64 High bed depth. Check the travel speed. Refer to section 5.3 Setting the speed
Increase speed or stroke. and stroke.
65 Low bed depth. Check hole size and toler- -
ance. Check hole shape.
Decrease speed or stroke.

10. Troubleshooting
10.2.14 Material mainly on one side of the Master-Flo

66 Incorrect Master-Flo feed. Check the foundations and -
the framework. Feed the
Master-Flo so that the
material spreads evenly on
the surface of the media.
67 Incorrect position of the Master- Check the supports as per Refer to the Installation Manual, sec-
Flo. the installation instructions. tion Installing the Master-Flo.
10.2.15 Media wear out or break, abnormal wear out

68 Media tension incorrect in Tension the media as per Refer to section 7. Screening media.
places or over all the deck. instructions.
69 Material falls on the media and Set the feed. -
not on the reception surface.
70 Media is not suitable for the Change the media type. Refer to section 7. Screening media.
application.
10.2.16 Material falls out from the feed end onto platform
71 Feed chutes not installed cor- Install the chutes correctly. -
rectly.
72 Media totally worn out, material Check the feed and dis- -
falls from the feed or the discharge end protections.
charge end.
10.2.17 Springs too compressed

73 Springs have lost their stiffness. Change the springs. Refer to section 9.2 Changing the
springs.

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operator’s manual Doc. no. S 241.

Serial no. / Machine no. Sign.

Document number: S 241.010 en

4. Operating the Master-Flo

Master-Flo © Sandvik SRP AB – Doc. no. S 241.010 en Ver. 1 3

4.2.1 Precautions ............................................................ 26

5. Inspection and maintenance

4 © Sandvik SRP AB – Doc. no. S 241.010 en Ver. 1 Master-Flo

6.4.1 Changing the oil brand........................................... 41

9. Changing spare parts

Master-Flo © Sandvik SRP AB – Doc. no. S 241.010 en Ver. 1 5

6 © Sandvik SRP AB – Doc. no. S 241.010 en Ver. 1 Master-Flo

Master-Flo © Sandvik SRP AB – Doc. no. S 241.010 en Ver. 1 7

1.1 Equipment information

8 © Sandvik SRP AB – Doc. no. S 241.010 en Ver. 1 Master-Flo

1.2 Document information

1.2.1 Document conventions

1.2.2 Document compliance

1.2.3 Enclosed dimension drawing

1.2.4 Technical publications

Master-Flo © Sandvik SRP AB – Doc. no. S 241.010 en Ver. 1 9

1.3 Product description

1.3.1 Orientation convention

10 © Sandvik SRP AB – Doc. no. S 241.010 en Ver. 1 Master-Flo

The top view below shows these references.

Left side Right side

1.3.2 Rotation directions

Master-Flo © Sandvik SRP AB – Doc. no. S 241.010 en Ver. 1 11

This page is intentionally left blank

12 © Sandvik SRP AB – Doc. no. S 241.010 en Ver. 1 Master-Flo

Master-Flo © Sandvik SRP AB – Doc. no. S 241.010 en Ver. 1 13

2.1 Hazard information

General danger Dangerous voltage Risk of crushing

Heavy load Flying fragments

Warning signs are accompanied with an additional panel marked either

Failure to observe information marked “DANGER!” puts your life in

2.1.2 Prohibition signs

2.1.3 Mandatory signs

Disconnect current Read the manual

14 © Sandvik SRP AB – Doc. no. S 241.010 en Ver. 1 Master-Flo

The manufacturer declines all responsibility for injury or damage if the

Sandvik strongly recommends that personal safety protection is always worn

Ear protection Safety helmet Eye protection

Protective gloves Safety boots Mask or breathing

Master-Flo © Sandvik SRP AB – Doc. no. S 241.010 en Ver. 1 15

2.3 General safety precautions

2.3.1 Electrical safety

2.3.2 Pressurized systems (hydraulics)

16 © Sandvik SRP AB – Doc. no. S 241.010 en Ver. 1 Master-Flo

2.3.3 Machine safety guards

Never remove guards while the equipment is in operation.

2.3.4 Equipment for lifting and moving loads

NOTE! Always use lifting tackles certified in accordance to local conditions.

Master-Flo © Sandvik SRP AB – Doc. no. S 241.010 en Ver. 1 17

2.3.6 During operation

18 © Sandvik SRP AB – Doc. no. S 241.010 en Ver. 1 Master-Flo

2.3.7 During inspection and maintenance

Master-Flo © Sandvik SRP AB – Doc. no. S 241.010 en Ver. 1 19

This page is intentionally left blank

20 © Sandvik SRP AB – Doc. no. S 241.010 en Ver. 1 Master-Flo

Master-Flo © Sandvik SRP AB – Doc. no. S 241.010 en Ver. 1 21

3.1 Physical specifications

22 © Sandvik SRP AB – Doc. no. S 241.010 en Ver. 1 Master-Flo