S154-1209 Iom

TM
Installation, Operation &

Maintenance Manual
MMD Twin Shaft Sizer
SR Drive Application - To run at motor speed of

1485rpm and this may only change with written
approval from MMD Technical Department.
Adjusting the speed or altering the Voith Fill Level

will require other adjustments and may cause
CAUTION
mechanical damage.
www.mmdsizers.com © MMD Design and Consultancy Ltd.

MAN SIZER-IOM MMD Ltd
Sales and Support

Contact Information
MMD Mining Machinery Developments Ltd provides Sales and Technical Support, world-wide. If you
need Sales information or you require Technical Support, please contact our main office listed below or
refer to our website.
MMD Mining Machinery Developments Limited Tel: +44(0)1773 835533
Cotes Park Lane Fax: +44(0)1773 835593 or 837818(sales)
Cotes Park Industrial Estate info@mmdsizers.com
Somercotes
www.mmdsizers.com
Derbyshire
DE55 4NJ
United Kingdom
Revision details
Revision Modification Section Revised Date
7.0 Title Caution Note Added Title 11-11-15
Manual Details
Installation, Operation & Maintenance Manual
Manual Number: MAN SIZER-IOM
Version/Publication Date: Version 0.10, 14th April 2015
Original Instructions
2 © MMD Ltd 2013

MMD Ltd MAN SIZER-IOM
Safety, Regulatory & Legal Information

Before using any MMD product, please read the safety,
regulatory and legal information provided.
CAUTION
Important Information
This equipment works safely and reliably if qualified, experienced and trained operators follow the
installation, operating and maintenance procedures described in this manual.
If you do not follow the manual instructions and information, you will be responsible for the
consequences and may invalidate the warranty.
The MMD Group of Companies accepts no liability for unauthorised modifications to MMD supplied
equipment.
This manual pays particular attention to Health and Safety. Appropriate safety icons are used and
warning messages are given where special precautions are required by the user due to the nature of the
equipment or product. Special attention should be made to "Note Conventions", where all such
messages are summarised.
The CE Certification provided under EU Directives 2006/42/EC Machinery and 2004/108/EC
Electromagnetic Compatibility covers all MMD equipment as delivered; any subsequent upgrades or
modifications that change the equipment function or attribute new functionality that are not carried
out by an MMD Company will not be covered by the attached CE certification.
MMD Sizers™ also comply with European Union Waste Electrical and Electronic Equipment WEEE
Directive 2002/96/EC (UK, Waste Electrical and Electronic Equipment (WEEE) Regulations 2006 - UK
SI.2006 No. 3289 amended 2007):
The equipment supplied by MMD under this contract contains EEE (Electrical and Electronic Equipment)
and is considered to be 'fixed plant', and as such as the obligations for re-use, recycling and/or safe
disposal is the responsibility of the user.
For further clarification regarding disposal contact your local MMD Company Customer Support.
All local and national safety regulations must be complied with when carrying out any operation or
maintenance function on the equipment.
Warranty
All products supplied by the MMD Group of Companies, are carefully designed, manufactured and
inspected. We will replace or repair any part found to be defective in material or workmanship as
described in your contract.
We do not accept liability for defects arising from neglect, misuse or accidents.
This warranty does not affect your legal rights.
End of life statement

At the end of its life, contact MMD before you dispose of or scrap your product.
© MMD Ltd 2013 3

Note Conventions
The following note conventions are used throughout this manual:
Text in this format highlights useful or important information.
Text in this format is a caution notice to the user and indicates

a situation that can cause minor injury and/or damage to the
CAUTION
product.
Text in this format is a warning to the user and indicates a
situation that may cause severe injury or death, and/or severe
WARNING
product damage.
Text in this format is a danger notice to the user and indicates a
situation that will almost certainly cause severe injury or
DANGER
death.
Copyright & Trademarks

While reasonable efforts have been made to ensure the accuracy of this manual, MMD Group of
Companies assumes no liability resulting from any omissions in this document, or from the use of the
information obtained therein. MMD Group of Companies reserves the right to revise this document and
to make changes from time to time in the content hereof without obligation of MMD Group of
Companies to notify any person of such revision or changes.
Electronic versions of this manual may be read online, downloaded for personal use, or referenced in
another document. The content itself may not be published commercially in print or electronic form,
edited, translated, or otherwise altered without the permission of MMD Group of Companies.
It is possible that this publication may contain reference to or information about MMD Group of
Companies products or services that are not available. Such references or information must not be
construed to mean that the MMD Group of Companies intends to announce such products or services.
MMD, the MMD logo, Mineral Sizer and all other trademarks indicated as such herein are trademarks of
MMD Design and Consultancy Ltd. All other product or service names are the property of their
respective owners.
©Copyright 2013 MMD Mining Machinery Developments Ltd. All rights reserved.
4 © MMD Ltd 2013

Contents
1 Operating Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.1 Principles of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
1.2 Safe Operating Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
1.3 Lifting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
1.4 On Site Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
1.4.1 On Arrival. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
1.4.2 Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
1.4.3 Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
1.4.4 Voith Fluid Coupling (keyed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
1.4.5 Electric Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
1.4.6 Motor to Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
1.5 Pre Start Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
1.6 Start Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
1.7 Stall Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
2 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.1 Trouble Shooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
2.1.1 Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
2.1.2 Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
2.1.3 Lubricant Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
2.1.4 Obvious Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
2.2 General Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
2.2.1 Replacing Underspeed Sensing Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
2.2.2 Wear Plates Replacement Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
2.2.3 Bolt On Cap Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
2.2.4 Segment Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
2.2.5 Pick Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
2.2.6 Breaker Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
2.2.7 Side Cleaning Comb Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
2.2.8 Bottom Cleaning Comb Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
2.3 Breakdown Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
2.3.1 Electric Motor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
2.3.2 Electric Motor Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
2.3.3 Voith Fluid Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
2.3.4 Gearbox Fitting and Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
2.3.5 Breaker Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
2.3.6 Breaker Shaft Adjustable Centres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
2.3.7 Shaft Re-Timing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
2.3.8 Main Shaft Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
2.3.9 Tooth Ring Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
2.4 Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
© MMD Ltd 2013 5

2.4.1 Gearbox Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

2.4.2 Gearbox Coolers (Optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
2.4.3 Grease Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
2.4.4 Maintenance Inside Sizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
2.5 Sizer Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
3 T.O. Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.1 T. O. 56 Bolt Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
3.1.1 Bolt Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
3.1.2 Hydraulic Bolt STRETCHING Tool Pressure Settings (PSI) . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
3.1.3 Hydraulic NUT Pressure Settings (PSI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
3.1.4 Bolt Torques for Tapered Type Tip Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
3.1.5 Spill Plate Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
3.1.6 ‘CAT’ Undercarriage Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
3.2 T.O.132 Grease Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
3.2.1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
3.2.2 Grease Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
3.2.3 Grease Quantities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
3.2.4 Pump Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
3.3 T.O.138 MMD Lubricant List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
3.3.1 Gear Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
3.3.2 Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
3.3.3 Fluid Coupling Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
3.3.4 General Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
6 © MMD Ltd 2013

Figures
1.1: Sizer Lifting Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
1.2: Case Drawing1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
1.3: Case Drawing2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
1.4: Gearbox Drawing1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
1.5: Gearbox Drawing2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
1.6: Gearbox Drawing 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
1.7: Gearbox Drawing 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
1.8: Gearbox Drawing 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
1.9: Voith Coupling Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
1.10: Motor to Gearbox Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
2.1: Under speed Sensing Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
2.2: Wear Plates Drawing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
2.3: Bolt on Cap Drawing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
2.4: Segment Section Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
2.5: Segment Weld Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
2.6: Pick Installation/Removal Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
2.7: Breaker Bar Adjustment Drawing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
2.8: Breaker Bar Cap Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
2.9: Side cleaning comb (standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
2.10: Side cleaning comb (standard) sectioned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
2.11: Side Cleaning Comb Drawing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
2.12: Bottom Cleaning Comb Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
2.13: Fusible Plug Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
2.14: Adjustment in/out Drawing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
2.15: Adjustment bars Uppermost Drawing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
2.16: Spur Gear at Drive End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
2.17: Flange Located Type Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
2.18: Dowel Type Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
2.19: Fixed Bearing Assembly (lift out style). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
2.20: Removal/Fitting Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
2.21: Standard Greasing Layout.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
2.22: Maintenance inside the Sizer (Caps). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
2.23: Maintenance inside the Sizer (Segments). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
3.1: Grease Adjustment Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
© MMD Ltd 2013 7

Tables
2.1: Weld Procedure According to Segment Material. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
8 © MMD Ltd 2013

Chapter 1: Operating Procedures
Revision Modification Date

1.0 First Issue 07-03-14
1.1 Principles of Operation

The MMD Mineral Sizer™ accepts the material in through the top of the Sizer. The two rotating shafts
pass the material down through the Sizer.
The smaller material is passed straight through the rotating teeth and the larger material is broken down
by the teeth.The size of the broken material can be controlled in all three planes, giving accurately sized
material, which is then passed to the next stage.
The Sizer is robustly made and able to withstand continuous heavy duty operation.
The machined side frames are fabricated from structural steel and ribbed for strength.
Easy replaceable steel wear plates cover all the inside area of the sizing chamber. It is designed to accept
the fitting of hopper and chute work.
The main shafts are machined from high strength alloy steel bar. Self-aligning double row spherical
roller bearings fitted in heavy duty housings are attached to each end of the shafts. The bearings are
lubricated by grease at both ends of the Sizer. The bearings are protected by heavy duty lip seals, which
are protected by a grease filled double labyrinth to prevent water, dirt, and other foreign bodies
entering and damaging the bearings.
The actual sizing elements are manufactured to MMD own specification. Various specialist materials
have been developed to suit particular requirements.
Shut down the Sizer when not in use. Extended running with
no material load causes damage to bearings.
1.2 Safe Operating Procedure

Isolate the power supply and remove the cable from the Sizer
drive electric motor before any persons can work on the Sizer.
WARNING
Installation of safety guards and hand rails are the responsibility of the customer at the time of
commissioning.
During operation of the machine, safety guards and hand rails must remain in place.
Unless otherwise stated, MMD is not responsible for the safe siting of the machine, and/or any
requirements appertaining to operating codes of practice.
MMD is not responsible for the use or operation of the machine for any purpose other than the specified
/ accepted operation requirement in the official order.
Any maintenance carried out in accordance with this manual shall be by a person or persons qualified
to carry out such work in compliance with the safety requirements of the operating company.
Failure to comply with any of the above procedures is done so
at the operator's own risk.
This machine becomes unstable when maintaining the Sizer if

care is not taken when removing assemblies. For example, if
WARNING
you remove the shafts with gearboxes and motors attached,
the Sizer will tip over. Use proper supports.
10 Chapter 1: Operating Procedures © MMD Ltd 2013

It is the legally appointed person's responsibility to ensure that

safe operating procedures are in place for all the equipment
that is in operation at the sizing plant and that these
procedures are adhered to at all times.
1.3 Lifting Procedure

The MMD Sizer is supplied with four lifting lugs that are bolted to the top of the machine side plates to
facilitate the safe lifting of the Sizer.
The supplied lifting lugs must only be used in the specified
positions and affixed properly with the supplied nuts and
WARNING
bolts.
Do not attempt to lift the machine with these lifting lugs while
the gearbox and motor are still bolted to the machine frame.
WARNING
The supplied lifting lugs have been designed for lifting only
the Sizer case assembly!
Only use lifting equipment designed for and rated to the
specific load.
WARNING
When the Sizer has been safely lowered and secured into position, the lifting equipment can be released
and the lifting lugs can be removed. Store the lifting lugs in a safe place for future use.
Figure 1.1: Sizer Lifting Drawing
60°
Failure to follow the safety requirements as specified in this

manual may result in serious injury to personnel or damage to
WARNING
equipment.
© MMD Ltd 2013 Chapter 1: Operating Procedures 11

Lifting of heavy equipment is a specialized task and should

only be carried out by qualified personnel. All local regulations
WARNING
and site safety requirements must be adhered to while lifting
the equipment.
1.4 On Site Assembly

When MMD equipment is delivered to site the Sizer is stripped for transportation and must be rebuilt.
The following procedure is a typical build pattern for a single or double drive Sizer.
1.4.1 On Arrival
Check the inventory and make sure you have all the component parts to build in the correct sequence.
• Clear and prepare the working area where the machinery is to be finally sited.
• Unpack the equipment as it is needed. (Mating faces are coated with a protective substance.)
1.4.2 Case
Case Assembly
• Remove inspection covers from the top cover.
• Remove any transportation covers from the front of the gearbox mounting plate.
• If the Sizer case was transported on beams. Remove the beams from underneath the Sizer.
• Clean down and remove the Tectil coating from all the mating surfaces on the gearbox mounting
plate.
• Fitting the gear coupling sleeve:
1. Check that the ‘O’ rings are fitted to the gear coupling sleeve with 2 greasing nipples.
2. Slide the sleeve onto drive hub already attached to the drive shaft of the Sizer.
(There are 2 sleeves if this is a double drive machine.) See Figure 1.3 on page 13.
Figure 1.2: Case Drawing1
MATING SURFACE
3
1
2
A
2
A 3
FIT 2 OFF ITEM 3 TO ITEM 1
MATING SURFACE FIT 2 OFF ITEM 2 TO ITEM 1
FIT ASSEMBLED ITEM 1 OVER HUB ON SHAFTS -ARROW A
ITEM 1 SLEEVE
ITEM 2 'O' RING
ITEM 3 GREASE NIPPLE

Fig 1.3 is an overview showing the sleeve(s) fitted onto the drive hubs already attached to the
breaker shaft(s).
Figure 1.3: Case Drawing2
TOP VIEW SHOWING SLEEVE FITTED

ONTO BREAKER SHAFT ASSEMBLIES
1.4.3 Gearbox
Preparation
Next to be fitted is the gearbox:
1. Fit the gearbox output seal housing ‘O’ ring in place and apply grease to the ‘O’ ring surface.
2. If required fit the spigot ring to the output seal housing.
3. Tighten the grub screws in the spigot ring onto the output seal housing.
4. Fit the ‘O’ ring to the spigot ring and apply grease to the ‘O’ ring surface.
5. Thoroughly clean mating faces on gearbox(es).

Figure 1.4: Gearbox Drawing1

‘O’ Ring
Output Housing
A EXPLODED VIEW ON 'A'
‘O’ Ring
Spigot Ring
A EXPLODED VIEW ON 'A'
Fig 1.5 shows the spigot ring in its fitted position and the mating surfaces to be cleaned before
fitting of gearbox to case.
Figure 1.5: Gearbox Drawing2
MATING SURFACES
MATING SURFACES
SPIGOT RING SHOWN FITTED
1. Using suitable lifting equipment attached to the gearbox.

2. Lift the gearbox into position and fit onto gearbox mounting plate.
3. Secure in position with the supplied bolts. (For double drive machines, step 1, 2 and 3 are
repeated for second gearbox.)
Tighten bolts up in accordance with MMD procedure TO56. See Section 3.1 on page 57.

Figure 1.6: Gearbox Drawing 3
Fig 1.6 shows the gearbox moving into position, aligning mating faces and spigot through
gearbox mounting plate opening.
GEARBOX SHOWN FITTED
Fig 1.7 shows the gearbox bolted in its final position.

1. When bolted into position the coupling sleeve(s) can be slid into position engaging the hub on
the gearbox. Slight rotation might be required to align the splines.
2. Fit gear coupling clamps over sleeve(s).
3. Fit gear coupling clamping bolts so as to lock the drive hubs together.
4. Tighten all bolts in accordance with TO56. See Section 3.1 on page 57.

GEAR COUPLINGS SHOWN FITTED
Fig.1.8 shows a double drive machine with the gear couplings in their final drive position and gear
coupling clamps attached.
1.4.4 Voith Fluid Coupling (keyed)

To fit the fluid coupling:
1. Remove Voith fluid coupling from its packaging.
2. Attach suitable lifting equipment and raise Voith into position level with input shaft.
3. Align Voith key-way with key on input shaft of gearbox.
4. Apply a light oil coating to the input shaft.
5. By hand slide the Voith fluid coupling onto input shaft as far as possible.
6. Place Voith end plate over Voith fitting tool.
7. Screw Voith fitting tool through Voith and into end of input shaft.
8. Using the attached nuts on fitting tool, push the Voith fully onto the input shaft.
9. Remove fitting tool.
10. Apply loctite to the fixing bolt threads and secure the Voith end plate with the fixing bolt.
The fluid coupling can now be filled with either oil or water dependant on its application. See Voith
coupling manual.

Figure 1.9: Voith Coupling Drawing
VOITH COUPLINGS SHOWN PARTLY FITTED

VOITH FITTING TOOL SHOWN READY TO FULLY FIT VOITH COUPLING
1.4.5 Electric Motor

Preparation
Make sure the motor feet and/or flange is clean and free of burrs.
1. If needed fit motor spacer over motor shaft.
2. Fit drive boss to motor drive shaft.
3. Using suitable lifting equipment, lift the motor and align with motor mounting frame, bolting to
the flange.
Steps 4, 5 and 6 are usually completed at MMD before sending
to customer.
4. Attach a dial test indicator (dti) to the drive boss and check concentricity before final tightening
of flange bolts.
5. Measure under each foot individually and fit suitable packers to the underside of the motor feet
and tighten bolts.
6. Tighten foot and flange bolts in accordance to MMD T.O.56 Procedure. See Section 3.1 on
page 57.
The motor mounting frame and motor are now ready to be fitted to the gearbox.
1.4.6 Motor to Gearbox

1. Using suitable lifting equipment attached to the motor mounting frame, lift aligning drive boss
with Voith coupling.
2. Manoeuvre the motor drive boss into the Voith coupling until the motor mounting frame is
nearly tight to gearbox.

3. Align motor mounting frame spigot onto spigot ring of gearbox.

4. Fit the bolts supplied and bolt into place.
5. Tighten all bolts in accordance with MMD T.O.56 Procedure. See Section 3.1 on page 57.
The main machine components are now fully assembled.
If required, you can now attach ancillaries. These include the following.
• Speed sensors to the rear or non drive end of machine.
• Auto greasing pump to the machine or mounting frame.
• Auto greasing lines from the pump to machine lines.
• Temp monitoring/heaters and or grease heating system.
Figure 1.10: Motor to Gearbox Drawing
FIXING HEX BOLTS

NYLOC NUTS AND HV WASHERS
VOITH COUPLING/MOTOR MOUNTING ASSEMBLY
(TOP COVER REMOVED FOR REFERENCE ONLY)
ELECTRIC MOTOR
• Check all oil levels (gearbox, spur gears if fitted.)

• Check all safety covers are attached.
The machine is now ready to accept Power.
1.5 Pre Start Checks

• Check that the machine is fully engaged in the working position.
• Check thoroughly to ensure that no person or persons can be injured when the machine starts.
• Check drive components for signs of obvious damage, leaks, etc.
• Check all oil levels (gearbox and spur gears if fitted).
• Check that the bearings are charged with grease.
• If fitted check that the greasing system is set to run.

1.6 Start Up Procedure

1. Complete the specified pre-start checks, see Section 1.5 on page 18.
2. Start the machine.
3. 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. Refer to the stall test procedure. See
Section 1.7 on page 19.
1.7 Stall Test Procedure

After every operating stall, and after any major overhaul, the
fluid coupling must be reset to give optimum performance.
The object is to obtain a steady tachometer reading of

approximately 94% of synchronous motor speed (50Hz = 1410
RPM, 60Hz = 1700 RPM).
1. Isolate the machine, by removing the cable from the electric motor. Use lockout procedures.
2. Physically block the breaker shafts, so that they cannot rotate.
3. Re-connect the power cable to the electric motor.
4. Use the tachometer to measure motor speed.
4.1 Select the start position on the control switch, and run the motor until a steady speed
reading is obtained on the tachometer.
Running time is kept to a minimum to avoid a build of thermal energy in the coupling.
4.2 Stop the motor.
5. Add or remove a small amount of fluid as required.
5.1 If the tachometer reading is below the desired speed, release fluid from the fluid coupling.
5.2 If synchronous speed is reached add fluid to the coupling.
6. Repeat steps 4 and 5 until a steady reading is achieved for the motor of 94% synchronous speed.
Allow sufficient time for the coupling to cool before repeating test.
This oil/water gets very hot. Repeated stall testing without
cooling periods will result in the fusible plug blowing and the
WARNING
coupling emptying its hot contents.
7. Remove the obstruction from between the Sizer shafts.
The stall test is complete and the machine is now ready to be run.

Chapter 2: Maintenance

3.0 Bottom Cleaning Comb Section Added 15-01-15
2.1 Trouble Shooting Guide

MMD recommended that you check daily for any excessive noise, vibration, lubricant leaks or obvious
damage. The following hints should help in determining the source of any unusual feature:-
2.1.1 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.
• High speed end (Electric Motor).
• 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.
2.1.2 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.
• 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.
2.1.3 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 shall be taken to correct.
1. Find the source of the leak.
2. Determine the cause of the leak by reference to the spare parts manual.
3. 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 can be
carried out.
2.1.4 Obvious Damage

Broken or cracked caps or segments and bolts are the most common cause of obvious damage to 99%
of MMD machines inside the working aperture. A visual inspection will determine the cause.
© MMD Ltd 2013 Chapter 2: Maintenance 21

2.2 General Maintenance

The machine must be isolated electrically together with any
upstream supply systems so that it cannot be started when
WARNING
work is being carried out.
The shafts roll uncontrolled if they are not restrained when
working on the breaker shafts. Removing of caps or segments
WARNING
creates a situation when the shafts become unbalanced so
shafts rotate uncontrolled resulting in severe injury to
person(s) working on the shafts.
2.2.1 Replacing Underspeed Sensing Device

Underspeed sensing device(s) are fitted at the non drive end. The purpose of the device is to isolate
power to the main Sizer motor(s) and upstream supply systems when the shafts have lost speed. This is
done by a pulse stud on the breaker shaft(s) passing through the magnetic field of a close proximity
sensor, 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 6 seconds.
If the Underspeed sensor becomes inoperative, it will be necessary to replace it.
1. Isolate power supply.
2. Disconnect electric leads from under speed sensor assembly.
3. Loosen the lock nuts, and unscrew the detector head.
4. Refitting is the reverse of the above procedure.
Take-care to ensure that the sensor head is within 8+/- 1mm of the stud in the end of the breaker shaft,
which provides a pulse every revolution.
Figure 2.1: Under speed Sensing Drawing
50
8
1563010-01
8± 1 Nom. Gap
M 18
SPEED SENSOR
SENSING STUD
MOUNTING PLATE
22 Chapter 2: Maintenance © MMD Ltd 2013

2.2.2 Wear Plates Replacement Procedure

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.
Rotate the shafts by hand through 360 degrees to make sure they are clear.
Figure 2.2: Wear Plates Drawing
SIDE WEARPLATE
END WEARPLATE
Replacing Side Wear Plates

If the machine has pyramids/side combs which are bolted through the side wear plate, remove them
prior to attempting to remove the wear plate.
1. Fit eye bolts to wear plate lifting lugs.
2. Attach lifting equipment to the eye bolts.
3. Remove the bolts retaining the side wear plates.
4. Remove the wear plates.
Thoroughly clean the inside of the machine where the new wear plate is to be fitted to allow correct
seating of the new wear plate.
5. Fit eye bolts to new wear plate lifting lugs.
7. Lift the new wear plate into position, and line up with fixing holes.
8. Bolt the new wear plate into position, using new fixings.
MMD recommend you do not re-use wear plate bolts due to the
wearing of the bolt tops.

9. Remove the lifting equipment from the eye bolts.

10. Tighten the bolts to the torque specified on MMD procedure T056. See Section 3.1 on page 57.
11. Remove the eye bolts from the lifting lugs.
12. Check the clearance between tooth caps/segments and wear plates.Rotate the shafts by hand.
Clearance should be a minimum of 10mm.
13. If previously removed, re-fit the pyramids/side combs.

This operation is now complete.
Replacing End Wear Plates
Thoroughly clean the top of the machine to expose the holes for the lifting eye bolts.
1. Fit eye bolts to wear plate lifting lugs.
3. Remove the bolts retaining the end wear plates.
4. Remove the wear plates.
Thoroughly clean the inside of the machine where the new wear plate is to be fitted to allow correct
seating of the new wear plate.
5. Fit eye bolts to new wear plate lifting lugs.
7. Lift the new wear plate into position, and line up with fixing holes.
8. Bolt the new wear plate into position, using new fixings.
MMD recommend you do not re-use wear plate bolts due to the
wearing of the bolt tops.
9. Remove the lifting equipment from the eye bolts.

10. Tighten the bolts to the torque specified on MMD procedure T056. See Section 3.1 on page 57.
11. Remove the eye bolts from the lifting lugs.
2.2.3 Bolt On Cap Replacement Procedure

upstream supply systems, so that it cannot be started while
WARNING
1. With the Sizer now isolated and shafts locked, clean out the area around the caps to be removed.
2. Remove the nut, washer (If fitted) and bolt.
3. If the caps are also welded into position then remove any weld.

4. Remove the caps.

Care should be taken when removing caps as they are
extremely heavy.
5. Thoroughly clean the ring or horn where the cap fits, checking for any damage or wear.
6. Place the new cap in position.
7. Thread the bolt through the hole in the cap. Place the washer (If required) over the bolt with the
chamfer downward and screw on the nut.
8. Rotate each shaft manually to ensure that no interference exists between teeth.
Figure 2.3: Bolt on Cap Drawing
BREAKER CAP
M64 BOLT M64 NUT
RING SHOWN FOR REFERENCE
9. With a calibrated wrench, such as a hydraulic torque wrench, tighten the nuts to the correct
torque setting.
The nuts have a non-standard metric thread. Please refer to
TO56 or TO150 for the correct torque setting.
2.2.4 Segment Replacement Procedure

You can replace segments in any order, but be aware that
imbalance may cause sudden rotation of the shafts.
1. Clean out the area in the segment bolt counter bores.

2. Remove the nuts along the length of the segment.
3. With the nuts removed, the washers and the spangles (small plate with a hole) can be removed.
See Figure 2.4 on page 26
4. Rotate the bolts counter clockwise through 90° and remove the bolts.
5. If the segments are welded into position then remove any weld.

The segment can now be removed.

Take care when removing the segment as they are extremely
heavy.
CAUTION
Figure 2.4: Segment Section Drawing
NUT AND BOLT

SEGMENT
SPANGLE
WASHER
SECTION VIEW
6. Clean the area where the segment fits, especially the lugs for the bolt retention.
7. Place a new segment in position. (In some cases careful dressing of the locating surfaces may be
required to obtain a good fit.)
8. An ideal segment fit should be seated flat/flush with the barrel.
9. Place the bolt through the segment slots and engage in its locating lug by a clockwise rotation
through 90°.
10. Place the spangle into position with the small hole uppermost alongside the bolt. (The spangles
are important to prevent the bolt from falling out of position.)
11. Place the washer over the bolt with the chamfer downward.
12. Screw on the nut with the skirt downward. Repeat the process for the remaining positions.
13. Rotate each shaft once to ensure that no interference exists between teeth.
14. With a calibrated torque wrench, tighten the nuts to the correct torque setting. T.O.56 Procedure
see Section 3.1 on page 57.


Refer to TO56 or TO150 for the correct tightening setting.
The segments may come loose during operation due to

hardness of materials. A weld can be applied along the back
edge and around the locating lugs of the segment to stop this
happening. See Figure 2.5 on page 27.
Table 2.1: Weld Procedure According to Segment Material
Segment Material Welding Procedure

MMD 101 TO30
MMD 505 TO63
MMD 501 TO55
Figure 2.5: Segment Weld Positions
IF BOLTS COME LOOSE STITCH WELD HERE
CUT HERE TO REMOVE CUT HERE TO REMOVE
2.2.5 Pick Procedure

Installation of the PICK into a TWIN style sleeve
To install the pick.
1. Make sure that the internals of the breaker shaft pick block are clean and free from foreign
bodies or damage. This is to make good contact on all surfaces and that the sleeve will sit firmly in
position when installed.

2. Fit the CR Clip into the machined grove on the lower portion of the sleeve.
3. Insert the sleeve into the pick block. You may need to use a copper hammer to fit the sleeve into
position.
4. Rotate the sleeve 180° in both directions so that there is good contact with the underside of the
sleeve collar and the top of the pick block. Make sure that there is good contact on all surfaces
inside the pick block.
5. Using the 9244 retainer kit that is supplied with the sleeve, install the retainer halves in the
groove that is machined into the base of the sleeve.
6. Using suitable pliers, install the snap ring into position on the base of the sleeve.
This locks the retainer halves and the sleeve into position within the breaker shaft pick block.
7. Fit the anti rotational clip to the base of the pick.
8. Use a copper hammer to fit the pick into position within the sleeve.
With the pick in the correct position you should be able to rotate the pick within the sleeve.
Figure 2.6: Pick Installation/Removal Drawing
5
10
PICK
163
89
SLEEVE
BLOCK
SPLIT RING AND CIRCLIP RETAINER
SUPPLIED WITH SLEEVE
Removal of the PICK from the TWIN style sleeve

To remove the pick.
1. Clean the area around the base of the sleeve of all foreign bodies to access the hole that runs
through the centre of the sleeve.
2. Also clean out the hole to gain access to the base of the worn pick within the sleeve.
3. Using an appropriate tool/drift, insert the tooling into the hole that runs through the sleeve until
it is in position at the base of the pick.

4. When in position strike the tooling with a copper hammer until the pick is driven free from the
sleeve.
5. Once the pick has been extracted from the sleeve please refer to "Installation of the PICK into a
TWIN style sleeve" on page 27.
In the event that the sleeve and pick are to be replaced as a complete unit.
1. Clean all foreign bodies away from the 9244 retainer so as to gain access to the snap ring.
2. Using a circlip pliers locate correctly into the holes of the snap ring so that the snap ring can be
compressed and removed.
3. Next remove the retainer halves from their position.
4. With the use of a copper hammer strike the base of the sleeve until the sleeve and pick have been
driven from the breaker shaft pick block as one complete unit.
Refer to "Installation of the PICK into a TWIN style sleeve" on page 27.
Failure to follow these recommendations will result in sleeves
and pick blocks becoming damaged reducing serviceable life.
Picks must be changed when any are found to be damaged,
cracked or missing a carbide tip or any signs of non rotation.
2.2.6 Breaker Bar

Breaker Bar Adjustment
Adjustment of the breaker bar should be carried out as follows:-
1. Remove the bolts securing the breaker bar to the machine.
2. Using the jacking screws provided, raise the breaker bar to the desired height.
3. Adjust the breaker bar height by removal or insertion of packers as required.
4. When the required height is achieved, remove jacking screws and refit the bolts and tighten in
accordance with MMD procedure T056. See Section 3.1 on page 57.

Figure 2.7: Breaker Bar Adjustment Drawing
Fit Spare or Removed

Remove Packers Packers Here
From Here or Add
Jacking Studs fit on

both sides. jack to the
correct height fit or
remove packers.
Breaker Bar Cap Replacement

Breaker bar caps can only be replaced from the underside of the machine. Replace damaged or worn
breaker bar caps immediately. If not replaced these could result in damage to the breaker bar.
Removal
Isolate the power source before commencing work.
WARNING
1. Clean the area around the cap which is to be replaced.
2. If welds are surrounding the infill piece/bolt cover, remove them using an appropriate process.
3. Remove the bolt(s) and nut(s) securing the cap to the breaker bar.
4. Strike the cap forcibly to release it from it’s seating.
5. Remove the breaker bar cap.
Replacement
Prepare breaker bar mounting surfaces. Care must be taken not to damage breaker bar during clean up.
1. Locate the cap onto the breaker bar. Make sure that the cap is fitted in the correct orientation, as
shown in drawing Fig 2.8.
2. Bolt the cap to the breaker bar using new bolts. All bolts must be tightened in accordance with
MMD procedure T056. See Section 3.1 on page 57.
3. Where Required place the new infill piece/bolt cover over the bolt and weld in to position in
accordance with MMD Procedure TO71/TO96/TO128


Figure 2.8: Breaker Bar Cap Replacement
Welded Infill Piece
Breaker Bar Cap
to be Removed
Bolt
Breaker Bar
Nut and Washer
2.2.7 Side Cleaning Comb Adjustment

Standard Type Side Comb
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 material attached to the shafts.
These cleaning combs will need periodic adjustment to compensate for wear. This is achieved by
removing packers as follows:-
1. Check the actual cleaning comb clearance.
2. To remove the cleaning comb.
1. Undo the two/four bolts securing cleaning comb to side plate.
2. Withdraw the cleaning comb from the side plate.
Some side cleaning combs will require lifting equipment
attached because of their sheer weight.
3. Remove necessary packers to give cleaning comb clearance. (Approx 10mm.)

4. Refit the cleaning combs into the side plates.
5. The packers taken out should be fitted to the outside of the comb so the existing bolts can be re
used. These bolts must then be tightened in accordance with MMD Procedure TO56. See

Figure 2.9: Side cleaning comb (standard)
SIDE CLEANING
COMB
SIDE
CLEANING
COMB
Figure 2.9 shown fitted in machine, Figure 2.10 shown as a section view.
Figure 2.10: Side cleaning comb (standard) sectioned
SIDE WEARPLATE
SIDEPLATE
CLEANING COMB
NUT AND BOLT

Figure 2.11 Showing the infill box style cleaning comb.

Figure 2.11: Side Cleaning Comb Drawing
PACKERS
INFILL BOX
CLEANING COMB
2.2.8 Bottom Cleaning Comb Assembly

Removal
Isolate the power source before commencing work.

WARNING
Bottom Cleaning Comb Assembly will require supporting

before any Bolts are removed.
1. Remove the Nuts and Bolts securing the Cleaning Comb Assembly to the Sizer Case Assembly.
2. Remove the Cleaning Comb Assembly and place in a safe working area.
3. Remove the Nuts and Bolts securing the Clamp Plates.
4. Remove the Nuts and Bolts securing the Cleaning Comb.
5. Remove the worn Cleaning Comb.

Figure 2.12: Bottom Cleaning Comb Drawing
REMOVE THESE BOLTS SECOND
REMOVE THESE BOLTS FIRST
CLEANING COMB SUPPORT
CLEANING COMB
REMOVE THESE BOLTS THIRD
Replacement
Prepare Cleaning Comb mounting surface.
Care must be taken not to damage Cleaning Comb during clean

up.
1. Locate the Cleaning Comb onto the Cleaning Comb Support.

2. Using new Nuts and Bolts loosely tighten Cleaning Comb to Cleaning Comb Support.
3. Using new Nuts and Bolts loosely tighten the Clamp Plates to the Cleaning Comb Support.
4. Tighten the Bolts securing the Comb to the Support. (Ensure the Combs remain square to the
Beam.
5. Tighten the Bolts securing the Clamping Plates to the Cleaning Comb Support.
6. Refit the Cleaning Comb Assembly to the Sizer Case
.
All Bolts must be tightened in accordance with MMD Procedure
TO56. See Section 3.1 on page 57.

2.3 Breakdown Maintenance

2.3.1 Electric Motor Installation
Foot and flange type motors:
Make a safe and clear area to work.
Appropriate lifting equipment required.
1. The motor should initially be sat on jacking screws, in the tapped holes through the cradle foot
packs.
2. Adjust jacking screws until the motor spigot is engaged in the cradle spigot bore and then fit
flange bolts and lightly hand tighten.
3. With a dial test indicator on the motor shaft, check that the total indicated run-out on the
mounting face of the motor cradle does not exceed 0.2mm.
4. Measure each foot for shim heights individually.
5. Fit the required shims under the correct feet and lower the jacking screws.
6. Fit foot bolts and tighten to the amount specified in MMD procedure T056. See Section 3.1 on
page 57.
This stage is now complete.
Flange type motors
In this arrangement alignment is achieved automatically
1. Fit the spacer (if needed).

2. Fit the drive boss (coupling) to the motor shaft.
3. Lift the motor into position, engaging the drive boss (coupling).
4. Fit the flange bolts and tighten to the amount specified in MMD procedure T056. See Section 3.1
on page 57.
2.3.2 Electric Motor Removal

Foot and flange 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.
upstream supply systems, so that it cannot be started
WARNING
accidentally whilst work is being carried out.
1. Disconnect all electrical connections from the motor.
2. Remove the cover plate(s) from the motor mounting frame.
3. Connect suitable lifting equipment to take the weight of the motor.

4. Remove the bolts connecting the motor flange and bolts connecting the motor feet to the
mounting bracket.
5. 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.
6. The motor can now be safely lifted out of position.
7. Remove the drive boss (coupling).
8. Remove the spacer (if needed) from the motor shaft.
9. Remove the shims from the foot mountings.
This is complete.
Flange type
WARNING
Should the fluid coupling need removing or replacing the motor must first be removed, the procedure
for this is as follows:
1. Disconnect all electrical connections from the motor.
2. Attach appropriate lifting equipment to the motor.
3. Remove the bolts connecting the motor flange.
4. Carefully slide the motor out of position, until the motor shaft is clear of the coupling housing.
5. The motor can now be removed.
This is now complete.
2.3.3 Voith Fluid Coupling

Description
• Mechanical overload protection is given by use of a fluid coupling mounted on the input shaft of
the gearbox and the drive shaft motor.
• 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 interrupting the
transmission of torque and preventing damage.
• After a fusible plug failure, the fault must be corrected. The peripheral bolts must be re-tightened,
(see fluid coupling manual), new fusible plugs fitted, and the fluid coupling refilled with clean fluid
in accordance with the fluid coupling manual.
• There are three types of fusible plug for the oil filled coupling ranging in different operating
temperatures from 140/160/180ºc.
Under normal operating conditions for an oil filled Voith
coupling the 160ºC type fusible plug should be used. (110ºC
when water filled.)
Hot oil and water can cause serious injury when it comes in
contact with the eyes or skin. Suitable protective equipment
DANGER
must be worn.

Figure 2.13: Fusible Plug Drawing

PLUG
FUSIBLE ALLOY
Refer to the Voith Manual for full instructions. Filling, Fitting,

Troubleshooting.
Preparation for Removal

1. Remove the motor, see Section 2.3.2 on page 35.
2. If fitted, disconnect power supply to Voith MTS temperature monitoring device.
3. If fitted, remove the Voith MTS sensor bracket, complete with sensor.
Removal
1. Remove fixing bolt and holding disk.
2. Support the Voith fluid coupling using suitable lifting equipment.
3. Apply lubricant to thread of Voith removal tool (MMD Part number: 3991325-01(Voith 487).
3991307-01(Voith 562/650)).
4. Insert the Voith removal tool into thread of the Voith coupling hub.
5. Turn the head of removal tool to remove Voith fluid coupling.
6. When the fluid coupling is removed from the input shaft, remove Voith removal tool.
This is now complete. The Voith can be inspected for damage or leaks if required.
2.3.4 Gearbox Fitting and Removal

Fitting Procedure
1. Clean the output shaft of the gearbox and the gear coupling.
2. Slide the coupling half onto the output shaft and fit end cap.
3. Apply thread-lock to bolts. Tighten the bolts to the amount specified in MMD procedure T056.
See Section 3.1 on page 57.
4. Make sure the coupling sleeve is fitted onto the other coupling half attached to your Sizer shaft.
5. Lift the gearbox into position, checking that the spigot on the gearbox mates with the recess on
the gearbox mounting plate. Fit the studs or bolts connecting the gearbox to the gearbox
mounting plate and tighten to the amount specified in MMD procedure T056. See Section 3.1 on
page 57.

6. Align the teeth on the coupling half with the teeth on the coupling sleeve and slide the coupling
sleeve into position.
7. Make sure '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. See
8. Fill the gearbox with the correct lubricant to the designated level. (See Gearbox manual for oil
specification and correct fill level.)
9. Fill the gear coupling with grease. (See maintenance schedule for grease specification.)
Removal
1. Remove the motor. See Section 2.3.1 on page 35
2. Remove the motor mounting bracket or coupling housing from the gearbox.
3. Remove the fluid coupling. See Section on page 37.
4. If oil cooler modules are fitted then the pipes must be disconnected.
5. If temperature monitoring is fitted then this must be disconnected and removed from gearbox.
6. Remove the top cover plate to expose the gear coupling.
7. Split the two clamping rings from the gear coupling, taking care not to damage the 'O' rings.
8. Slide the coupling sleeve away from the gearbox till it disengages with the gearbox coupling hub
on the gearbox.
9. Attach appropriate lifting equipment to the gearbox lifting eyes.
10. Remove the studs/bolts connecting the gearbox to the gearbox mounting plate.
11. Move the gearbox away from the mounting plate until the gear coupling hub is clear of the
mounting plate.
The gearbox can now be lifted clear out of position.
This is now complete.
2.3.5 Breaker Shafts

WARNING
Removal
1. Unbolt top chute from top of sizer.
2. Support top chute.
3. Move the sizer into the maintenance position. If fitted on wheels pull out of position.
4. Thoroughly clean the sizer of all extraneous material, grease, oil, overspill material.
5. Remove the end wear plates and side cleaning combs (where fitted) from the machine. See
Section 2.2.2 on page 23.
6. Remove the top cover plate(s) at the drive end from the machine. These are bolted to the
machine side plates, the top bearing housing and the gearbox mounting plate.

7. Now the drive end gear coupling clamps are exposed.

8. Remove the gear coupling clamps from the gear coupling(s) and slide back the sleeve towards
the gearbox. This action disengages the drive train from the breaker shafts. Care should be taken
not to damage the ‘O’ ring seals.
9. Remove the bolts securing the top bearing housing to the bottom at each end of the machine.
10. Disconnect any grease piping if applicable.
11. Use appropriate rated lifting eye bolts attached to the top bearing housing and appropriate rated
lifting equipment and lift off the top bearing housings.
The shaft assemblies are now exposed.
12. Remove the shafts using appropriate rated web slings fitted at either end.
Take care to attach slings correctly and lift out evenly. The spur gear and coupling hub are still
attached at one end so it will be overbalanced.
13. Remove the shaft end cap along with its fixings and slide the remaining coupling hub off the
shaft.
14. If the shaft has a spur gear fitted this can now be slid along the shaft and removed. The shaft may
need supporting on appropriate stands to obtain ground clearance to remove spur gear.
Care should be taken to support the mass of the Spur Gear at
all times.
CAUTION
15. The bearing assemblies can now be removed from the shaft. See bearing removal/fitting
procedure Section 2.3.8 on page 42.
Replacement is the reversal of the above procedure make sure all mating faces/surfaces are thoroughly
cleaned and prepared before commencing re assembly.
2.3.6 Breaker Shaft Adjustable Centres

Adjustment In/Out
Preparation for moving into a maintenance position is as follows.
WARNING
1. Unbolt and support top chute.
2. If the sizer is fitted with wheel carriages move the sizer into the maintenance position.
3. Thoroughly clean the sizer of all extraneous material, grease, oil, overspill material.
4. Where applicable loosen the fixings connecting the wheel carriage unit with the slotted holes to
the side plate.
5. Loosen the adjusting bar nuts to expose about 50mm of the adjustment bar on one side of the
sizer case. (If wheel carriages are fitted then this has to be the side the wheel carriage fixing bolts
were loosened on so to move without disrupting wheel carriage centres.

Figure 2.14: Adjustment in/out Drawing

ADJUSTMENT BAR NUTS
ADJUSTMENT BAR NUTS
6. Using appropriate rated jacks slide the free case half away from the fixed case half until the
approximate desired gap is created between the bearing housings of each shaft at each end.
7. Remove the uppermost adjusting bar on both the drive and non drive end of the sizer case. This
is the bar which is going through the packer.
Figure 2.15: Adjustment bars Uppermost Drawing
UPPERMOST ADJUSTMENT
AJUSTMENT BAR PACKERS
8. In the gap created between the bearing housings place the correct amount of packers to set the
position of the shaft centres.Take care to place the slot of the packers over the top of the
remaining adjusting bars.
If decreasing the space remove the appropriate amount of packers.
9. Replace the adjusting bars previously removed making sure they pass through the locating hole
in each packer.
10. Attach the relevant washers and nuts.
All the adjustment bar nuts must be tightened up equally until the gap in the centre of the sizer
has closed and all packers have seated correctly.
11. Tighten wheel carriage fixings where applicable. See TO56 for all relevant torque settings.
12. Return machine to the working position.
13. Fit all guards and safety covers, hoppers, chutes.

The power can now be put back on the machine.
2.3.7 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
WARNING
If the end wear plates are bolted through the top then they need to be removed.
1. Undo the bolts connecting the top cover to the side plate/gearbox mounting plate/top bearing
housing and remove the top cover plate.
2. Remove the end wear plate if attached separately from top over plate. (There is no need to drain
the spur gear oil.)
3. Remove the end cap from the driven (non drive) shaft by unscrewing the fixings which secure it
in place.
4. Remove the shaft spacers.
5. If required, fit a dummy short shaft to assist with the movement of the spur gear.
6. Taking care to support its weight, slide the spur gear along the shaft splines until it is clear of the
spur gear on the drive shaft.
Figure 2.16: Spur Gear at Drive End
SPUR GEAR SLID OUT OF POSITION
7. Rotate the driven shaft to the desired position.

8. Move the spur gear back along the splines and into position so it meshes with the other spur
gear.
9. Replace the spacers and end cap, apply thread-lock to the fixings before inserting and tightening
fixings.
10. Refit the top cover plate and end wear plate where applicable and fit the bolts which secure it in
place. Tighten in accordance with MMD T.O. 56 Procedure See Section 3.1 on page 57.
Spur Gears at Non Drive End
WARNING
If the end wear plates are bolted through the top then they need to be removed.
1. Undo the bolts securing the top cover to the side plates, end cover and top bearing housing.
2. Remove the top cover.There is no need to drain the spur gear oil unless desired.
3. Remove the end cap from the driven (non-drive) shaft by unscrewing the fixings which secure it
in place.
4. If required, fit a dummy short shaft to assist with the movement of the spur gear.
5. Taking care to support its mass, slide the spur gear along the breaker shaft splines until it is clear
of the spur gear on the drive shaft.
6. Rotate the driven shaft to the desired position.
7. Move the spur gear back along the splines and into position so it meshes with the other spur
gear.
8. Replace the end cap, apply thread-lock to the fixings before inserting and tightening fixings.
9. Re fit the top cover plate after cleaning and applying sealant and refit bolts which secure it in
place. Tighten in accordance with MMD T.O.56 Procedure See Section 3.1 on page 57.
2.3.8 Main Shaft Bearings

Flange Located Type
To replace a worn or damaged bearing the following procedure must be followed:
1. Follow the procedure for removing the shafts. See Shaft Removal Section 2.3.5 on page 38.
2. If still fitted remove any end caps on side where bearing requires replacing.
3. Using a bearing puller or similar device plus hydraulic jacks, pull the complete bearing assembly
away from the shaft.
4. The labyrinth is still attached to the shaft. Check for excess wear. Remove if excessively damaged.
See heading Things to check on next page.
5. The damaged bearing assembly can now be dismantled as follows:
1. Remove retaining plate complete with the 2 outer seals.
2. Remove the damaged bearing from 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 grooving on the seal surfaces then the labyrinth must be
replaced.
• Seals— Check the condition of all the lip seals. If there is any sign of damage then the seal must be
replaced. MMD recommend that the seals are replaced if they are removed for any reason.
• Seal Spacer— If there is any obvious grooving on the outside diameter of this spacer then it must
be replaced.
• 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 maybe indentations approximately half way up its length. If these are evident then
the dowel must be replaced.
Re Assembly Flange Located Type
If every item needs replacing then the following procedure should be followed:
1. If the labyrinth has not already been removed then do so now. Take care not to damage the
breaker shaft.
2. Clean and prepare the shaft ready to fit bearings and new labyrinth.
3. Assemble the parts in the following order.
1. Heat up Labyrinth to110°C using a bearing heater or appropriate equipment and fit to
shaft. Labyrinth will stop at the raised shoulder.
2. Fit inner seals to bearing capsule. Make sure seals are seated correctly. See spare parts
manual for breakdown of parts and orientation.
3. Warm the capsule slightly so it is not cold and fit bearing to bearing capsule.
4. Heat the bearing and capsule on a bearing heater to 110°C, remove and immediately fit
onto shaft make sure that the seals engage on the labyrinth and ease the assembly into
position. The assembly will seat fully home once engaged onto the seal surface of the
labyrinth as the furthest extremity of the labyrinth locates against the inner race of the
bearing.
5. Warm the spacer on a bearing heater to110°C. When up to temperature remove and
immediately push onto shaft right up to inner race of the bearing.
6. Fit seals to seal plate and attach seal plate to bearing capsule.
7. Repeat for opposite end of shaft. If seal plate is for a blind end bearing then there will be no
seals to fit.
8. Re-assemble the shaft in reverse sequence. See shaft removal/assemblySection 2.3.5 on
page 38.

Figure 2.17: Flange Located Type Bearing

BEARING
LABYRINTH HOUSING
“O”RING
SEAL PLATE
SEAL PATH
LIP SEALS
LIP SEALS BEARING
Dowel Located Type

To replace a worn or damaged bearing the following procedure should be followed:
1. Follow the procedure for removing the shafts. See Shaft Removal in Section 2.3.5 on page 38
2. If still fitted remove any end caps on side where bearing requires replacing.
3. Using a bearing puller or similar device plus hydraulic jacks, pull the complete bearing assembly
away from the shaft.
4. The labyrinth is still attached to the shaft. Check for excess wear. Remove if excessively damaged.
See heading Things to check on previous page.
5. The damaged bearing assembly can now be dismantled as follows.
1. Remove the retaining plate. This automatically removes the 2 outer seals.
2. Support the bearing capsule around the periphery about 200mm off the floor level.
3. Apply heat to the outside of the bearing capsule till the damaged bearing falls out.

Re Assembly Dowel located type

If every item needs replacing then the following procedure should be followed:
1. If the labyrinth hasn’t been removed in previous section then do so now. Taking care not to
damage the breaker shaft.
2. Check for damage to breaker shaft.
3. Heat up Labyrinth to110°C using a bearing heater or appropriate equipment and fit to shaft.
Labyrinth will stop at the raised shoulder.
4. Fit inner seals to bearing capsule. Ensure seals are seated correctly. See spare parts manual for
breakdown of parts and orientation.
5. Warm the outside of the bearing capsule and fit bearing. This is a tolerance fit and a soft drift
should be used to ensure bearing is fully seated in capsule.
6. Heat the bearing and capsule on a bearing heater to 110°C, remove and immediately fit onto
shaft make sure that the seals engage on the labyrinth and ease the assembly into position. The
assembly will seat fully home once engaged onto the seal surface of the labyrinth as the furthest
extremity of the labyrinth locates against the inner race of the bearing.
7. Warm the spacer on a bearing heater to110°C. When up to temperature remove and immediately
push onto shaft right up to inner race of the bearing.
8. Fit seals to seal plate and attach seal plate to bearing capsule. See MMD procedure TO56 for all
bolt torque settings. See Section 3.1 on page 57.
9. Repeat assembly sequence for opposite end of shaft.
10. Fit one of the bonded seals into the dowel locating holes on the bearing capsule and hold in
place with thick grease. Fit the remainder of bonded seals with the dowels into the bottom
bearing housings. The shaft is now ready to be re assembled into the machine.
11. Assemble the shaft in the reverse sequence. See Section 2.3.5 on page 38

Figure 2.18: Dowel Type Bearing.

BEARING
CAPSULE BEARING SEAL
PLATE
“O”RING
SEAL PATH
LIP SEALS
BONDED
LABYRINTH CUT BACK TO DOWEL SEAL
SHOW HOW SEALS SIT
Lift out Shaft Bearings

Bearing Assembly
Wear suitable P.P.E. when working with heated bearings.
CAUTION
When assembling this style bearing remember to check the bearing capsule for damage.
1. Clean bearing capsule.
2. Fit lip seals to both seal plate and labyrinth seal plate. (See Spare Parts Manual for orientation of
seals.)
3. Fit labyrinth seal plate to back of bearing capsule.
4. Tighten bolts. See Section 3.1 on page 57.
5. Warm bearing capsule slightly and fit bearing into capsule.
Fixed bearing has 2 additional fixing rings. 1 installed before
bearing and 1 after. (See Figure 2.19 on page 47.)
6. Fit seal plate to outer face of bearing capsule.

7. Tighten bolts. See Section 3.1 on page 57.
8. Heat shaft spacer to 110°C and fit onto shaft right up to screwed collar.
9. Heat labyrinth to 110°C and fit onto shaft right up to spacer.

10. Fit lifting eyes to top of bearing capsule.

11. Attach lifting equipment to top of bearing capsule and place on bearing heater or similar and
heat to 110°C.
12. Fit heated bearing to breaker shaft. Make sure seals fit onto labyrinth seal body.
13. Heat seal path to 110°C and fit onto breaker shaft pushing it right up against bearing inner race.
14. Repeat for other side of shaft.
Each shaft has a fixed and free bearing. Fixed bearing at drive
end unless it has spur gears then it goes to the spur gear end.
Figure 2.18 shows typical fixed bearing assembly.

Figure 2.19: Fixed Bearing Assembly (lift out style).
LABYRINTH SEAL PLATE
BEARING CAPSULE
BEARING
LIP SEALS LABYRINTH
SEAL PATH
LIP SEALS
FIXED BEARING SPACERS
BEARING CAPSULE SHOWN GHOSTED A IT IS

SEAL PLATE PART OF CASE ASSEMBLY AND NOT BEARING
ASSEMBLY.
Always check the spare parts manual for correct components for each bearing assembly.
All bearing assemblies shown are typical for MMD machines. Check to see which type are fitted to your
shafts.

2.3.9 Tooth Ring Removal

It is very rare the tooth rings become damaged due to their robust construction but in the event that
damage does occur to the tooth rings then the following procedure must be followed.
Removal
Follow the procedure for the removal of the Breaker Shafts. See Section 2.3.5 on page 38
1. Remove both fixed and floating bearing assemblies from the breaker shaft.
2. Remove all breaker caps from each tooth ring.
3. Each tooth ring is welded to the next ring. This weld has to be removed to proceed further.
4. Remove the screwed collar(s). Apply force to the screwed collar to break it free from the mating
thread. The breaker shaft has right and left threads where the screwed collars mount.
5. Once all the weld and the screwed collar(s) have been removed, the tooth rings are ready for
removal. A suitable hydraulic press or pullers will be required to apply enough pressure to
remove the tooth ring.
Tooth rings are shrink fitted therefore care must be taken
when being removed.
CAUTION
6. Repeat these steps for any other rings which are to be replaced.
Fitting
To fit a new tooth ring proceed as follows:
1. Clean up around the exposed breaker shaft and the mating faces of any remaining tooth rings.
2. With the aid of an oil bath or similar appliance, apply sufficient heat to warm the tooth ring to
help it onto the shaft. See TO72 as a guide.
3. Supporting its mass, align the new ring with the shaft key making sure it is scrolling in the correct
direction.
4. Slide the new ring onto the shaft until it is flush with the mating face of the existing tooth ring.
5. Repeat from step 2 for further tooth rings until the required number have been replaced.
6. When all the tooth rings which required changing have been replaced the shaft is now ready for
welding.
• The weld preparation on each tooth ring will form a butt weld.
• This is usually done by submerged arc welding process.
7. When the shaft has sufficiently cooled the breaker caps can be fitted.
8. Completely rebuild the shaft with bearings and fit into the machine case.

Figure 2.20: Removal/Fitting Ring.
1. REMOVE THE SPUR GEAR AND GEAR COUPLING HUB 5.

TO LIFT THE SHAFT FROM THE MACHINE CASE REMOVE THE TOOTH CAPS FROM THE DAMAGED RING
DIRECTION OF PRESS
2. WITH THE SHAFT OUT OF THE MACHINE CASE,

PROCEED TO REMOVE BOTH THE BEARING ASSEMBLIES
6. WITH THE WELD DETAIL REMOVED, A SUITABLE HYDRAULIC
PRESS OR PULLER SHOULD BE EMPLOYED TO PRODUCE
ENOUGH FORCE TO MOVE THE RING FROM THE SHAFT
PUSH ONTO SHAFT APPLY HEAT TO INSIDE

FACE OF TOOTH RING
3. NEXT REMOVE THE SCREWED COLLARS AND SPACER
7. AFTER HEATING THE TOOTH RING TO 120°C, ALIGN THE

NEW RING WITH THE SHAFT KEY AND PUSH ONTO THE SHAFT
4. MACHINE OR BURN AWAY THE
WELD BETWEEN THE TOOTH RINGS.
8. WELD THE RINGS TOGETHER USING

SUBMERGED ARC WELDING PROCESS

2.4 Preventative Maintenance

WARNING
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 reduction of operational efficiency or even a machine
breakdown. Warranty maybe affected by improper maintenance.
If the machine is fitted with breaker segments, after the first 24 hours of operation check the segments
fixing bolts and tighten to the amount specified in MMD Procedure TO56 in Section 3.1 on page 57.
After 7days operation check the segment fixing bolts again and tighten to the amount stated.
Spur Gear Oil
We recommend that the oil is warm when draining the spur
gear end.
Hot oil can cause serious injury if it comes in contact with the
eyes or skin. Suitable protective equipment must be worn.
DANGER
On Sizers fitted with spur gears, MMD recommend that the spur gear oil is renewed every 4000 hours.
• To drain the oil remove the drain plug which is fitted to the bottom cover plate. Once this plug has
been removed the oil can then be drained into a 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 on dipstick
notch. The oil specification grade is listed in MMD procedure T0138 See Section 3.3 on page 63.
Remove the containers with the old oil.
Discard old oil in accordance with the requirements of the local
environmental regulations.
Light Load Running

If it is expected that the Sizer will not have any feed of material for a period of 4 hours, shut down its
motors. This is because 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 and or noise. Visually check for signs of wear on
machine.
Weekly Maintenance
• Greasing Unit (If fitted)
Check the centralised grease units level, top-up if required with the recommended lubricant.
• Visually check for leaks.
Repair as necessary.
• Check the Auto greasing is functioning correctly.

The distribution block indicator pin should move up and down on a regular basis. Speed is
dependent on delivery volume.
• Bearing Void Clearance.
Check the void between the breaker chamber and bearing capsule by removing the void covers
and clear if necessary. Clean out with either high pressure airline or pressure washer.
The void must be kept clear or the consequence will be ingress
of dirt into the shaft bearings causing bearing failure.
Grease should flow freely from the bearing labyrinth.

Void covers must be re-fitted to the sizer for safety reasons.
• Check the spur gear oil level.
Top up as required with the correct specification lubricant. See T0138 Chapter 3.3 on page 63.
Three Monthly Maintenance
• Grease the gear coupling at the ¼”BSPT grease nipple. See TO132 Section 3.2 on page 61.
• If fitted, check that the shut-down alarms are working.
Annual Maintenance
• All bolts must be checked for tightness, and tightened to the amount specified in the MMD
Procedure T056 if necessary. See Section 3.1 on page 57.
• If fitted, grease each wheel bearing on the wheel carriage unit by the grease nipples provided.
2.4.1 Gearbox Maintenance

Daily
• Check the oil level daily. Remove dipstick, oil should be midway on the machined portion.
• Top up the oil level if necessary with the correct specific lubricant. See TO138 Section 3.3 on
page 63
• Visually check for leaks. All leaks should be traced and rectified immediately.
2,000 Operational Hours
• The input shaft seals should be checked.
• Check seal housing is clean and is fitted perfectly and free from burrs.
• Tighten all bolts. See Section 3.1 on page 57.
6,000 Operational Hours
• The output shaft seals should be checked.
• Check seal housing is free from burrs and damage.
• Tighten all bolts. See Section 3.1 on page 57.
Oil Analysis
MMD recommend that the oil change period should be determined by sample analysis.
• Maximum analysis period should not exceed 250 operating hours.

• If oil sample analysis is not carried out then oil must be changed every 1,500 operating hours, or 6
month period at a maximum.
All bolts should be tightened in accordance with MMD

Procedure TO56. All lubricants are to MMD Procedure TO138.
Always check with MMD for latest TO Specification. These are
available from MMD on request.
• For further information please refer to Gearbox Manual.
2.4.2 Gearbox Coolers (Optional)

The purpose of the unit is to filter and cool the oil. The cooler filter modules must run while the machine
is running.
Maintenance Required
Daily
• Check to see if the basket filters require cleaning
• Look around the module for leaks, rectify if necessary.
Weekly
• Check the cooler radiator is not blocked.
• Check the pump gland packing seals, tighten if necessary.
6 Monthly
• Thoroughly clean the unit.
• If the unit is fitted with a thermostat to control the fan motor, check the thermostat on and off.
Set-points are between 50 and 60°C. The 'on' setting should be higher than the 'off ' setting.
2.4.3 Grease Lubrication

MMD machines have 2 lubrication points, bearings and labyrinth.
Each bearing and labyrinth has its own feed source.
Lubrication 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 a grease
gun or similar appliance.
The quantity of grease to be supplied to each bearing each week is specified in MMD procedure T0132.
See Section 3.2 on page 61.

Figure 2.21: Standard Greasing Layout.

NON-DRIVE END DRIVE END
GREASE PUMP
RESERVOIR
FLOW/BLOCKAGE
GREASE FEED TO INDICATOR
LABYRINTH 1 (DRIVE END)
GREASE FEED TO
LABYRINTH 1 (NDE)
GREASE FEED TO
LABYRINTH 2 (NDE)
GREASE FEED TO
LABYRINTH 2 (DRIVE END)
GREASE FEED TO SPARE OUTLETS

BEARING 2 (NDE) GREASE FEED TO (OPTIONAL FEEDER ETC.)
BEARING 2 (DRIVE END)
FLOW
INDICATOR
PIN
GREASE FEED TO ZP-A

BEARING 1 (DRIVE END) DISTRIBUTION BLOCK
GREASE FEED TO
BEARING 1 (NDE)
Automatic lubrication pumps supply grease from the reservoir into a distribution block. This makes sure
that each bearing receives an equal amount of grease. The distribution block has an indicator pin to
provide a visual check that grease is being circulated. It is important that this indicator pin is checked on
a regular basis.
• Grease will be visible at the labyrinth seals if the system is functioning normally.If there is no grease
at the labyrinths then clear debris.
• Regular and correct greasing increase the life of the bearings reducing damage to the bearing
casings.
Automatic greasing system must be run whenever the

machine is running and for 2 hours after each running period.
Refer to the greasing supplier manual.
2.4.4 Maintenance Inside Sizer

The Sizer must be completely electrically isolated before any
person is allowed to enter into the Sizer cavity (the area around
WARNING
shafts and breaker bar).
Movement of the breaker shafts must be mechanically controlled. This is because whilst removing the
teeth or segments a situation may arise where the shaft reaches a state of imbalance. This could cause
the shaft to rotate without control resulting in severe injury to the person working on the shaft. This
must be prevented at all cost.
This can be done by with either chain blocks or pull lifts and slings around the shaft to either brake or
rotate the shaft when necessary. This method of restraint is preferred to completely locking the shaft(s)
because it allows full access for maintenance all around the shaft.

Figure 2.22: Maintenance inside the Sizer (Caps)
PULL LIFT
OR
CHAIN BLOCK
DRAWING IS AN EXAMPLE ONLY

Figure 2.23: Maintenance inside the Sizer (Segments)
CHAIN BLOCKS
OR
PULL LIFT
DRAWING IS AN EXAMPLE ONLY
2.5 Sizer Storage

When delivered, MMD equipment can be stored inside or outside for a period of 12 months.
The cases have a waterproof lining to aid protection. Gearboxes are filled with lubricant (for the
lubricant specification, see the gearbox maintenance schedule). Exposed machined surfaces are coated
and wrapped in 'Denso' tape and a ‘Tectil’ corrosion inhibitor.
The containers supplied are covered in a Tarpaulin sheet and roped down accordingly around the base.
This must be checked periodically for rips or tears.
Any further queries please do not hesitate to contact MMD.

Chapter 3: T.O. Procedure
T.O. Procedures are correct at date of Manual compilation.

Check with MMD for latest revisions.
Bolt Torques are to be used on MMD Equipment only.

CAUTION

4.0 Bolt Torque Caution Note Added. 14-04-15
3.1 T. O. 56 Bolt Torque

3.1.1 Bolt Torques
For approximately 85% proof stress in non lubricated coarse pitch bolts.
Size 8.8 GRADE 10.9 GRADE 12.9 GRADE

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=lb.ft
If greasing fastenings (Grease both thread and the surface under the Bolt Head) (Mobil Temp 78 or
equivalent) the following applies:
• If Greased x 0.65
• If Greased MMD Cap Bolts x 0.75
Nut and Bolt Combination
Bolt Grade 8.8 10.9 12.9
Nut Grade 8 12 12
Prepared By: M.Duthie Approved By: R.P.Barber

Procedure: TO56 Page 1 of 5 Issue No.18 Date:31/07/13
© MMD Ltd 2013 Chapter 3: T.O. Procedure 57

3.1.2 Hydraulic Bolt STRETCHING Tool Pressure Settings (PSI)

This applies to the Tentec HTT hydraulic tensioners.
Bolt Metric Size Pitch Grade Tool Tightening Tightening

Pressure (PSI) Pressure (BAR)
30 3.5 8.8 HTT.3045.000D 13348 920
36 4 8.8 HTT.3045.000D 19446 1341
42 4.5 8.8 HTT.3043.000E 16713 1152
48 5 8.8 HTT.3043.000E 21964 1514
48 5 10.9 HTT.6476.000B 30478 2101
56 5.5 8.8 HTT.4155.000B 23493 1620
64 6 8.8 HTT.4015.000C 23347 1610
64 6 10.9 HTT.4015.000C 32826 2263
72 6 8.8 HTT.4232.000A 32269 2225
The above torque are to be used with assigned tool ONLY. the above tools are special and custom made
for MMD use only.
The above excludes cover plates and wear plates. Non critical structural and location bolts to be
tightened using an electric nut runner or hand tools.
If in any doubt, consult the MMD UK design department.

3.1.3 Hydraulic NUT Pressure Settings (PSI)

This applies to the Tentec HTT hydraulic nuts.
Bolt Metric Size Pitch Grade Tool Tightening Tightening

Pressure (PSI) Pressure (BAR)
36 4 8.8 HTT.3682.000A 32726 2256
42 4.5 8.8 HTT.3756.000B 32843 2264
42 4.5 10.9 HTT.6253.000A 32728 2256
48 5 8.8 HTT.3638.000A 32928 2270
56 5.5 8.8 HTT.5734.000A 33000 2275
64 6 8.8 HTT.5718.000A 33000 2275
64 4 8.8 HTT.3818.000A 33000 2275
The above torque are to be used with assigned tool ONLY. the above tools are special and custom made
for MMD use only.
The above excludes cover plates and wear plates. Non critical structural and location bolts to be
tightened using an electric nut runner or hand tools.
If in any doubt, consult the MMD UK design department.

58 Chapter 3: T.O. Procedure © MMD Ltd 2013

3.1.4 Bolt Torques for Tapered Type Tip Assemblies

(Figures allow for a thread undercut)
Torques for 8.8 Grade or ‘T’ condition material.
Size DRY
Nm
M24 667
M30 1323
M36 2311
M42 3699
M48 5555
M56 8924
M64 13439
M72 19526
• Torque up bolts dry.
Always specify a minimum thread length when issuing any bolts or studs. This applies to all bolts of all
sizes.
3.1.5 Spill Plate Bolts

• Bolt torques for M24 spill plate bolts used for the securing of segments should be 822Nm.


3.1.6 ‘CAT’ Undercarriage Bolts

These bolts are actually made to SAE Grade 8, though the head markings do not conform.
For reference their mechanical properties are approximately 88% of 10.9 grade metric bolts, and higher
than 8.8 grade. So it could loosely be said they are about 10.9 grade.
Per SAE grade 8, mechanical Properties are:
• Minimum tensile strength 1034 MNm¯²
• Minimum 0.2% proof stress 827 MNm¯²
• Minimum yield strength 896 MNm¯²
Correct Tightening Torque is given by:
• Torque = 1.35582 x 10b+m x log(d)
With b = 2.983, m = 3.095, d = bolt diameter (inches), the log function is base 10.
Tightening Torques per above are as follows, Bolt sizes in inches.
SIZE DRY
Inches Nm
½ 153
⅝ 304
¾ 535
⅞ 862
1 1304
1⅛ 1877
1¼ 2601
1⅜ 3493
1½ 4573
1⅝ 5859
1¾ 7369
1⅞ 9123
2 11140


3.2 T.O.132 Grease Specification

3.2.1 Scope
This specification covers the types and quantities of grease to be fed to the Sizer and to the feeder
bearings via an automatic lubrication system.
3.2.2 Grease Types

For normal applications use: NLGI EP2 Lithium Complex, extreme pressure grease.
If for a period of the year the potential for the ambient temperature to be below -10°C exists, then for
that period use: NLGI EP1
If the temperature is likely to drop below -30°C, pipe heating may be required.
3.2.3 Grease Quantities

Feeds to each bearing when Feed to each labyrinth Feeds to each bearing when
the labyrinth seal is not seal if applicable. the labyrinth seal is greased
greased separately. separately.
Sizer Shaft cc/hour Sizer Shaft cc/hour Sizer Shaft cc/hour
centres centres centres
(m) (m) (m)
0.5 30 0.5 15 0.5 3.5

0.625 40 0.625 20 0.625 5
0.75 50 0.75 25 0.75 6
0.85 60 0.85 30 0.85 8
1.0 75 1.0 37.5 1.0 9.5
1.15 90 1.15 45 1.15 11
1.25 100 1.25 50 1.25 12.5
1.3 110 1.3 55 1.3 14
1.4 120 1.4 60 1.4 15
1.5 130 1.5 75 1.5 16
Feeder D4 10
Feeder D7 20
Feeder D9 50
When Sizer bearings are greased by hand, apply 200cc to each bearing each day.
Prepared By: M.Duthie. Approved By: R.P.Barber.

Procedure: TO132 Page 1 of 2 Issue No: 8 Date: 08/12/2010

When grease is fed by an auto lubrication system, the grease

must be fed continuously whenever the machinery runs. It is
also strongly recommended to run the grease feed for 2 hours
after each running period.
3.2.4 Pump Settings

Required Turns out for Set
cc/Hour screw on Pump
Element
(Centralube)
30 3¼
40 3
50 2½
75 2
100 1
100 - 130 Fully In
Do not exceed 4 turns or the element may stop pumping.
When separate feeds are required for labyrinth and bearings a fifth pump element must be fitted and
set to the same settings as the other 4 elements. This outlet must be piped to a splitter valve and then
to bearings. The other 4 elements are piped individually to the labyrinths.
Figure 3.1: Grease Adjustment Drawing
Prepared By: M.Duthie. Approved By: R.P.Barber.

Procedure: TO132 Page 2 of 2 Issue No: 8 Date: 08/12/2010

3.3 T.O.138 MMD Lubricant List

3.3.1 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
properties (minimum FZG load stage 12).
e.g. SHELL OMALA 320
Ambient temperature -20°C to +45°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
properties (minimum FZG load stage 12).
e.g. SHELL OMALA 220
Ambient temperature 45°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
Some gearboxes require cooling under certain circumstances.
3.3.2 Grease
Ambient temperature -15°C to +40°C
Lithium Complex EP NLGI No.2 Change grease type seasonally
Mineral Base Oil Viscosity as necessary.
160cSt@40°C If in doubt use NLG1 No.1 when
Timken (ASTM D2509) OK Load 45lbs supplying new machines.
Ambient temperature 20°C to -10°C or 20°C to -50°C with heating

Lithium EP NLGI No.1 Change grease type seasonally
Mineral Base Oil Viscosity as necessary.
120cSt@40°C If in doubt use NLG1 No.1 when
Timken (ASTM D2509) OK Load 45lbs supplying new machines.
Prepared By: R.P.Barber Approved By: G.R.Nowell


3.3.3 Fluid Coupling Oil

Ambient temperature -15°C and above
Hydraulic Oil
ISO VG32 (32cSt@40°C) or ISO VG22
(22cSt@40°C)
Pour Point < -24°C
Flash Point > 175°C
Ambient temperature 0°C to -50°C
Hydraulic Oil
I2 - 25cSt viscosity@40°C
Pour Point < -54°C
Flash Point > 155°C
3.3.4 General Notes
Ensure ALL grease pipes are purged and clean prior to and
during assembly.
Lubricants to be compatible with fluorocarbon and nitrile

rubber.
Prepared By: R.P.Barber Approved By: G.R.Nowell



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TM

Installation, Operation &

SR Drive Application - To run at motor speed of

Adjusting the speed or altering the Voith Fill Level

www.mmdsizers.com © MMD Design and Consultancy Ltd.

Sales and Support

2 © MMD Ltd 2013

Safety, Regulatory & Legal Information

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© MMD Ltd 2013 3

Text in this format is a caution notice to the user and indicates

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© MMD Ltd 2013 5

2.4.1 Gearbox Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

6 © MMD Ltd 2013

© MMD Ltd 2013 7

8 © MMD Ltd 2013

Chapter 1: Operating Procedures

Revision Modification Date

1.1 Principles of Operation

1.2 Safe Operating Procedure

This machine becomes unstable when maintaining the Sizer if

10 Chapter 1: Operating Procedures © MMD Ltd 2013

It is the legally appointed person's responsibility to ensure that

1.3 Lifting Procedure

Failure to follow the safety requirements as specified in this

© MMD Ltd 2013 Chapter 1: Operating Procedures 11

Lifting of heavy equipment is a specialized task and should

1.4 On Site Assembly

12 Chapter 1: Operating Procedures © MMD Ltd 2013

TOP VIEW SHOWING SLEEVE FITTED

© MMD Ltd 2013 Chapter 1: Operating Procedures 13

Figure 1.4: Gearbox Drawing1

1. Using suitable lifting equipment attached to the gearbox.

14 Chapter 1: Operating Procedures © MMD Ltd 2013

Figure 1.6: Gearbox Drawing 3

GEARBOX SHOWN FITTED

Fig 1.7 shows the gearbox bolted in its final position.

© MMD Ltd 2013 Chapter 1: Operating Procedures 15

Figure 1.8: Gearbox Drawing 5

GEAR COUPLINGS SHOWN FITTED

1.4.4 Voith Fluid Coupling (keyed)

16 Chapter 1: Operating Procedures © MMD Ltd 2013

Figure 1.9: Voith Coupling Drawing

VOITH COUPLINGS SHOWN PARTLY FITTED

1.4.5 Electric Motor

1.4.6 Motor to Gearbox

© MMD Ltd 2013 Chapter 1: Operating Procedures 17

3. Align motor mounting frame spigot onto spigot ring of gearbox.

FIXING HEX BOLTS

• Check all oil levels (gearbox, spur gears if fitted.)

1.5 Pre Start Checks

18 Chapter 1: Operating Procedures © MMD Ltd 2013

1.6 Start Up Procedure

1.7 Stall Test Procedure

The object is to obtain a steady tachometer reading of

© MMD Ltd 2013 Chapter 1: Operating Procedures 19

Revision Modification Date