21052 VSI 1800-2100 O&M
Short Description
Cedarapids VSI Operations Manual...
Description
Operation & Maintenance Instructions
VSI 1800/2100 Operation & Maintenance Manual Form 21052 LJ1093200
A Terex Company
21052 (3/97)
Operation & Maintenance Manual
A Terex Company
Introduction
To the Owner & Operator: Cedarapids, Inc. tries to provide information that gives our customers a clear understanding of equipment construction, function, capabilities and requirements. This information is based on the knowledge and experience of qualified people at our company and in our field organization. Proper use of this information rewards users of Cedarapids equipment with high efficiency, maximum service life and low maintenance costs. That is why we strongly recommend that anyone using our equipment be familiar with this manual. This manual is not a bible. Information presented here should not be considered authoritative in every situation. Users will, as a matter of course, encounter problems and circumstances that raise questions not anticipated here. Such questions should be directed to Cedarapids, Inc. Anyone who uses this equipment for any purpose other than that for which it was intended assumes sole responsibility for dangers encountered and injuries sustained as a result of such misuse. Respectfully, Cedarapids Inc.
Danger - Federal, state and local safety regulations aim to protect both people and property from accident, injury and harmful exposure. When complied with, such regulations are often effective. Hazards to life, limb and property are further reduced when this equipment is used in accordance with all operation and maintenance instructions. Generally: 1) Read and heed all danger, warning, caution and notice decals. Know what guards and protective devices are included and see that each is installed and in operation condition. Additional guards and protective devices may be required and must be installed by the user (owner) before operating. 2) Never attempt to maintain, lubricate or adjust this equipment while it is running. Lock out and tag out all energy sources before doing maintenance, cleaning, adjusting or repairing this equipment. Make it impossible for anyone to start this machine while others are working on it or in it. 3) Wear protective clothing such as hard hats and safety shoes, and use protective equipment such as ear plugs and safety glasses when operating this equipment. Do not wear loose clothing or long hair. 4) Think safety and act safely. Stay alert at all times. Eliminate or neutralize potential hazards as soon as you spot them. Never allow anyone to engage in horseplay when near this equipment. Danger - Failure to take these precautions will result in death or severe personal injury.
16885 (3/99)
Operation & Maintenance Manual
A Terex Company
The following warning applies to Cedarapids equipment supplied with lead-acid batteries: Warning: Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling.
22388 (6/00)
Operation & Maintenance Manual
A Terex Company
22388 (6/00)
Operation & Maintenance Manual
A Terex Company
Section 1 Introduction and Contents About This Manual This manual is for owners and operators of a Vertical Shaft Impact rock crusher made by ElJay Division of Cedarapids Inc. The VSI is a precisely engineered, highly functional machine designed to provide years of excellent service. We strongly recommend that anyone involved with the operation or maintenance of the crusher take the time to become familiar with this manual. Warning! This manual contains vital information for the proper, safe operation of this equipment. Read the whole manual before beginning to operate the equipment. Failure to follow instructions and warnings contained in this manual could result in severe personal injury or death! It could also incur substantial property damage. Attention! Sometimes, at customer’s request, a VSI is shipped without certain features, such as the sheave. When this happens, Cedarapids/ElJay attaches a warning tag to alert installers that the belt guard, a safety feature, is missing. In such cases it is the customer’s responsibility to properly guard the machine while it is running. Keep this manual for your future reference. It can help you:
Experience shows it is to your advantage to have a copy of this manual on site at the crusher where operators can consult it as needed... and a copy on file in your office so that shift leaders or supervisors can conveniently refer to it. This manual is printed on high quality paper and bound in a tough, flexible three-hole binder so it can be read and handled many times in the field. Feel free to write notes or comments in it as needed. The manual is for your use. Additional copies can be ordered through your Cedarapids/ElJay Distributor. The Owner/Operator Manual may be bound with the VSI Parts Book. The Owner/Operator Manual is not intended as a source for ordering parts. Only your VSI Parts Book, identified with your serial number, can be relied on for accurate part numbers and part descriptions for your machine. Ongoing improvement of product design may result in future changes to some parts. When ordering replacement parts, please be as exact as possible in describing the part. Use part numbers, model numbers, and serial number to communicate with your Cedarapids Distributor. When you have a question, please consult your Cedarapids Distributor Representative. About Cedarapids/ElJay
• safely operate your VSI • understand how your crusher works • get highest production efficiency • perform regular maintenance and replace parts
Cedarapids/ElJay is proud to manufacture the superior VSI rock crusher for your use and profit. We also take pride in the quality of our service and replacement parts. We look forward to serving you.
• get maximum life from your wear parts • keep your downtime to a minimum.
21052 (3/97)
Page 1.1
LJ1093200
Operation & Maintenance Manual
A Terex Company
Table of Contents Section 1 Introduction and Contents
Installation Drawings 1800 VSI-GD .................................................... 3.7
About This Manual ........................................... 1.1
1800 VSI-VBD ................................................. 3.9 2100 VSI-GD .................................................. 3.11
Section 2 Safety Precautions
2100 VSI-VBD ............................................... 3.13
Personal Safety Hints and Rules ....................... 2.1 Cedarapids/ElJay Recommends ....................... 2.1 Work Area Safety Hints ................................... 2.2 Equipment and Tools Safety Hints ................... 2.3
Section 4 Daily Start-up and Check List Daily Start-up Detail ......................................... 4.1 VSI with CastRotor .......................................... 4.1
Section 3 Installation and Start-up
VSI Daily Start-up Inspection Form ................. 4.3
Leveling on a Sturdy Foundation ..................... 3.1
Daily Start-up Detail- Continued ...................... 4.5
Access ............................................................... 3.1
Expected Flow Rates ........................................ 4.6
Transporting Your VSI ..................................... 3.1
Cold Weather Start-up ...................................... 4.7
Lock Down the Throw Device ......................... 3.2
Hot Weather Start-up ........................................ 4.7
VSI with Table/Shoes ....................................... 4.5
Reinstall the Locking Bolts Before Travel ....... 3.2 Models .............................................................. 3.2 Types of Drive .................................................. 3.2 Component Weights Chart ............................... 3.3 Electrical System .............................................. 3.4 Start-up Controls .............................................. 3.4 Automatic Shutdown ........................................ 3.4 Optional Pre-wired Panel.................................. 3.5 Setting Up the Lubrication System ................... 3.5 Setting Up the Rock Material Feed .................. 3.5 Guards and Nearby Equipment......................... 3.5 Check Rotation Direction Before Starting........ 3.5 Maximum RPM ................................................ 3.6 First Start-up Check List................................... 3.6 Storage .............................................................. 3.6
Section 5 Changing Table/Shoe Wear Parts Balanced Running Important ............................ 5.2 Tables: Various Types Available ..................... 5.2 Shoes, Shoe Pins, Shoe Bolts ........................... 5.2 Weight-Balanced Shoe Sets.............................. 5.3 When to Change Shoes ..................................... 5.3 How to Remove Shoes ..................................... 5.5 How to Replace Shoes ...................................... 5.5 Shoe Brackets and Liners ................................. 5.6 When to Change Shoe Bracket Liners .............. 5.6 Changing Table Liners ..................................... 5.6 Changing Feed Disc ......................................... 5.7 Changing Table Rim Liners ............................. 5.7 6-Shoe Closed-Top Table ............................... 5.10 Cover Plate ..................................................... 5.10
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LJ1093200
Operation & Maintenance Manual
A Terex Company
Table of Contents Section 6 Changing CastRotor Wear Parts
Monitoring the Anvil Ring ............................... 7.5 Replacing Lid Liners ........................................ 7.7
Maintain Balance with Matching Sets .............. 6.2 Epps and Wear Tips .......................................... 6.2 Changing Exit Port Protectors (Epps) .............. 6.2 Changing Wear Tips ......................................... 6.2 How to Change Primary and Retaining Liners ............................................... 6.4 Changing Feed Disc ......................................... 6.5 CastRotor Tuning ............................................. 6.6 How to Change Trailing Angles ....................... 6.7 Changing the Feed Eye ..................................... 6.9
Replacing Tub Liner ......................................... 7.8 Replacing Flywheel Guard Wear Plates ........... 7.8 V-Belts .............................................................. 7.8 Installing New Belts ......................................... 7.8 Sheaves and Bushings ...................................... 7.9 Removing Sheaves and Bushings ..................... 7.9 Installing Sheaves and Bushings .................... 7.10 Check Alignment ............................................ 7.10
When to Change the Top Retaining Plates ....... 6.9
Section 8 Lubrication System
How to Change Top Retaining Plates .............. 6.9
Lubricant Oil Specifications ............................. 8.1
How to Remove the CastRotor ....................... 6.10
Oil Properties at Operating Temperature.......... 8.1
Changing Rim Liners ..................................... 6.11
Acceptable Lubricants ...................................... 8.1
Changing Side Plates ...................................... 6.11
Switching to Other Grades ............................... 8.1
When to Change the Bottom Retaining Plate . 6.12
Oil Analysis: When to Change Oil ................... 8.1
How to Change the Bottom Retaining Plate... 6.12
Taking Oil Samples .......................................... 8.2
Installing Rotor Studs ..................................... 6.12
Checking Oil Level with the Dip Stick ............ 8.3 How to Change Oil & Filter Element ............... 8.3
Section 7 Changing Stationary Wear Parts, Belts & Sheaves
Oil Flow Patterns .............................................. 8.4
The Feed Tube .................................................. 7.1
Oil Flow Monitoring System ............................ 8.6
Removing and Reinstalling the Feed Tube....... 7.2
Flow Meter/Switch Settings ............................. 8.7
Adjusting the Feed Tube Height ....................... 7.2
Expected Oil Flow Rates .................................. 8.7
Adjusting Feed Tube with an Open Table ........ 7.3 Adjusting Feed Tube with a Closed Table ....... 7.3
Section 9 Electrical System
Adjusting Feed Tube with a CastRotor ............ 7.4
Junction Box (J-Box) ........................................ 9.1
Removing the Lid Assembly ............................ 7.4
Oil Pump ........................................................... 9.1
Types of Impact Surfaces ................................. 7.5
Flow Switch and Warning Horn ....................... 9.1
Anvils ............................................................... 7.5
Vibration Switch ............................................... 9.2
Rock Shelf ........................................................ 7.5
Start Delay ........................................................ 9.2
21052 (3/97)
Lubricating Oil Capacities ................................ 8.6
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LJ1093200
Operation & Maintenance Manual
A Terex Company
Table of Contents Section 9 (con't) Electrical System
Table Requires Anvil Ring ............................. 10.7 VSI-GD (Gear Driven) ................................... 10.7
Monitor Delay and Simple Test........................ 9.2 Automatic Shutdown ........................................ 9.2
Changing Throw Device Rpm ........................ 10.7 Sheave and Rpm Combinations ...................... 10.8
Start-up Controls .............................................. 9.2 Wiring for Heater and Thermostat.................... 9.2 Wiring for Optional Pre-wired Panel................ 9.2 120 Volt Electrical Schematic (For Units Without Optional Lid-Lifter) .......... 9.3
Section 11 Troubleshooting Too Much Vibration ....................................... 11.1 High Operating Temperature .......................... 11.1
120 Volt Circuit Operation ............................... 9.4
Too Much Noise ............................................. 11.2
220 Volt Electrical Schematic (For Units Without Optional Lid-Lifter) .......... 9.5
Too Much Oil Consumption ........................... 11.2
220 Volt Circuit Operation ............................... 9.6
Uneven Wear .................................................. 11.2
220 Volt Electrical Schematic (For Units With Optional Lid-Lifter) ............... 9.7
Rapid Wear ..................................................... 11.2
Section 10 Applications
Wear Part Breakage ........................................ 11.3
How It Works: VSI Crushing Action ............. 10.1
Plugging of Hopper ........................................ 11.3
Characteristics of Rock ................................... 10.1
Horn Sounds ................................................... 11.3
Hardness ......................................................... 10.1
V-Belts ............................................................ 11.4
CastRotor Wear Tips Failing Too Soon ......... 11.2
Bearing Failure ............................................... 11.3 Low Production Tonnage ............................... 11.3
Abrasion ......................................................... 10.1 Friability ......................................................... 10.1
Section 12 Other Information
Application ..................................................... 10.1
Temperature Conversion Chart ...................... 12.1
Every Particle Crushed ................................... 10.2
U.S. Standard Sieve Series ............................. 12.2
Variables You Control to Meet Your Requirements................................ 10.3
Bolt & Nut Torque Chart ................................ 12.3 U.S.- Metric Conversions ............................... 12.6
Changing Speed .............................................. 10.3 Varying Throw Devices.................................. 10.3 Balancing a Circuit ......................................... 10.3 Varying Feed Size .......................................... 10.3 Power, RPM, Feed Rates & Sizes Chart ........ 10.4 Controlling Wear ............................................ 10.5 Factors Affecting Gradation ........................... 10.6 Adjusting Trailing Angle Position .................. 10.7 21052 (3/97)
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LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 2 Safety Precautions Personal Safety Hints and Rules Cedarapids/ElJay equipment is designed with the safety of all personnel in mind. Do not attempt to change, modify, or eliminate the accident prevention devices installed at the factory. Make sure that all personnel who regularly work or who might do work in the area of the equipment are familiar with the safety precautions. Owners and operators are responsible for reading safety information and following safe practices. Think safety! Act safely! Guards, covers, and shields are installed around moving parts at the factory whenever necessary to prevent accidental injury to operators and others working on or near the equipment. Do not remove them. Attention! Sometimes, at a customer’s request, a VSI is shipped without certain safety features, such as drive sheave guard or belt guard. When this occurs Cedarapids/ ElJay attaches a warning decal to alert installers that the safety feature is missing. In such cases it is the customer’s responsibility to properly guard the machine while running.
Warning: Whenever you see “Warning” in this manual, it means that severe personal bodily injury may result from improper procedures. Be on guard! Warning indicates that a serious hazard is present and severe injury is possible. Read all Warning messages carefully to prevent someone being hurt. Danger!, Warning: and Caution: messages are accompanied by the international alert symbol to help call your attention to situations where danger to persons is present. Caution! Whenever you see “Caution” in this manual, it means that if proper procedures are not followed, minor to moderate injury (small cut, bruise, etc.) may result. Do not neglect to care for even small cuts. Avoid infection by cleansing and covering wounds. Cedarapids/ElJay recommends the following basic safety practices
For your personal safety, this manual includes three levels of hazard and injury alert notices: Danger, Warning, and Caution. Each hazard alert notice is accompanied by an international alert symbol to help call your attention to dangerous or potentially dangerous situations. Read all alert notices carefully to prevent injury to yourself or others. Danger! Whenever you see “DANGER!” in this manual, it means that death or severe personal bodily injury can immediately result from improper procedures. Read all “Danger!” messages carefully to prevent accidents. Take immediate action!
• Read all warning, caution, and instruction signs. Warning! Lock out the power source to this crusher before attempting any maintenance. Always establish a positive lockout of the involved power source before performing maintenance, cleaning, adjusting, or repair. Secure the power source lockout to prevent start-up by other persons. • To help determine safe lifting conditions for VSI components and units, see the Component Weights Chart, pages 3.4 and 3.5. • Save your back. If the load is more than 18 kg (40 lbs), get help or use proper lifting procedures. Use your leg muscles, not your back, for lifting. Keep loads close to your body. Avoid twisting motions and overextensions when moving loads. • Do not remove any guards, covers, or shields when equipment is running.
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LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 2 Safety Precautions • Replace any guards, covers, or shields after adjustment or maintenance.
Work Area Safety Hints
• Never lubricate moving or running equipment. • Block parts as necessary to prevent unexpected motion while performing maintenance, adjustments, or repair. • Do not attempt to remove jammed product or other blockage from running equipment. Power must be shut off and locked out while doing so. Use adequate hearing protection devices when noise level is above acceptable limits. Wear an adequate protective breathing mask whenever dust and fumes are above acceptable limits. Wear adequate eye protection goggles or safety glasses with side shields to prevent flying particles from entering eyes. Hard hats are a good idea and are required at most field work sites. Wear yours. • Maintain safe work habits by dressing appropriately for the job. Do not wear loose sleeves, flowing hair, long coat tails, wrist watches or bracelets, or pockets full of tools, which could get caught in moving machinery. Thin-soled shoes without tread could cause falls or foot injury. Wear safe shoes. • Always look around equipment before startup to make sure no one is near moving parts, making adjustments, or performing maintenance. Keep alert to where your coworkers are. • Report defective machinery and unsafe conditions to your supervisor. • Know your equipment. Understand the machine and the conditions under which it operates. Do not limit playing it safe to only these few general rules. Think and act safely for your specific work environment and your particular equipment. 21052 (3/97)
Page 2.2
• Keep the work area as neat and as clean as practical. • Keep all warning and caution signs clear and up to date. Make certain that all electrical equipment is properly grounded. Wet spots near electric current are dangerous. Use ground-fault interruptible circuits wherever a potential shock hazard exists. • Store hazardous materials in restricted access areas and mark them clearly. United States Environmental Protection Agency federal regulations require special labeling of certain materials. • Make certain enough ventilation is present to safely run engines. Do not start an engine in an enclosed space without properly vented exhaust. Exhaust fumes from gasoline or diesel can kill! Do not smoke or allow smoking near flammable fuels or solvents. Use nonflammable solvents when possible for cleaning parts and equipment. Avoid electrical and static sparks and any open flame while handling, storing, moving or pouring fuels, electrolytes for batteries, hydraulic fluids, or coolants. Check for leaks in tanks or tubing with flashlights or other proper equipment. Never use an open flame to check for leaks. Know where fire extinguishers and other fire suppression equipment are located. Learn how to use them. Be alert and wary around any pressurized system: hydraulic or air. High pressure gases and oils can be very dangerous. Know your equipment and operate it properly.
LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 2 Safety Precautions Equipment and Tools Safety Hints • Clean and properly labeled tools are safer tools. Keep your equipment and tools in order. • Always use hoisting equipment for heavy loads. Regularly check hooks, cables, shackles, and chains for stretch and wear. Never overload the lifting capacity of hoists, cranes, and lifting devices. • Keep V-belts and sheaves in good condition. Frayed belts or cracked sheaves can be dangerous and cause downtime.
In addition, for your information, two other kinds of alert messages are included in this manual. Notice: Whenever you see “Notice” in this manual, it means that failure to follow proper procedures could lead to serious and expensive damage to your machine. Important: The “Important” messages in this manual help you to choose procedures that add to the efficiency and useful life of your machine.
• Keep your equipment clean and free of dirt and grease so it can be checked for loose, cracked or broken parts. Replace defective parts as soon as they are discovered.
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LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 2 Safety Precautions
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LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 3 Installation and Start-up Leveling on a Sturdy Foundation
• Lid Assembly
To operate correctly all VSI's must be installed level on a firm foundation. For stationary units, level the base frame on a vibration-free foundation. Check both east-west and north-south to be level. A solid, well-drained concrete or stone foundation is ideal, but compacted rock can work, too. If set up on compacted rock, regularly test the foundation to detect any movement or settling. Any supporting steel structure must be heavy and sturdy enough to support the total dynamic load of the operating crusher, conveyors and other related equipment with rock moving through it. Cross-bracing is recommended.
• Throw Device (Impeller) • Tub Assembly • Vertical Housing and Shaft Assembly • Drive Assembly • Lubrication Oil System • Electrical System • Miscellaneous Components
For plant-mounted units: use a carpenter’s level to check the plant frame. Use cribbing as needed to be sure the plant is level and firm. Do not operate with tires touching the ground.
On plant-mounted VSI's subcomponents of the lubrication and electrical systems, such as the oil pump and/or junction box, may be mounted on the plant’s frame. Since plant configurations vary, the exact placement of these subcomponents and their hose and line routings also vary. The installation drawings shown in this section describe typical locations for subcomponents.
Access
Transporting Your VSI
See appropriate installation drawing to help determine needed clearances for your VSI and site. Allow enough room all around for conveyors, loaders, maintenance cranes and other trucks. Allow enough clearance below crusher for discharge conveyor. Design safe overhead clearance, proper conduit for electrical power and communication lines, safe catwalks with handrails, and machine guards for every moving machine part to prevent accidents.
A typical method for tying down the VSI for transport is shown in Figure 3-1. Note that the heavy timbers are placed under the mounting pads and clearance below the mounting pads helps avoid damage to the under-crusher components. The cables are well-anchored and the sheave is protected from accidental impact.
VSI models are available in different drive systems, types of throw device (also called impeller), sizes, and impact surfaces. Each model performs excellently in the right application, but must be installed correctly to get best results. The different configurations require slightly different maintenance and replacement steps. The ability to conveniently service and maintain the VSI depends in part on how its installed so that all major systems and components are accessible. Eight major components or systems work together to make the VSI an effective rock crusher: 21052 (3/97)
Page 3.1
Figure 3-1 Typical Tie-downs for Transporting the VSI LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 3 Installation and Start-up Lock Down the Throw Device
Lid liner
1" (27mm) bolts
Throw device (table or rotor)
1) Open the inspection doors.
NOTICE
Feed tube
The VSI is shipped from factory with locking bolts in place to lock down throw device. The lock-down process prevents the possibility of flywheel bouncing up and down during transport, possibly damaging bearings. A decal is mounted near inspection access doors as a reminder (Figure 3-2)
Turn nut to wedge bolt in place
Locking nut
THROW DEVICE MUST BE LOCKED DOWN DURING TRANSPORT TO PROTECT CRUSHER BEARINGS. USE 2 BOLTS, ON OPPOSITE SIDES OF THROW DEVICE. Decal Part #01-871-372-0070
Figure 3-2 Lock Down the Throw Device Before Transport
2) Look for two or three bolts with yellow tags attached (Figure 3-2). Some throw devices have two, some have three locking bolts. Tables with even numbers of shoes and CastRotors have two. Tables with odd numbers of shoes have three.
3) Use two nuts on each bolt. Place two or three bolts to push evenly down on the throw device.
3) These locking bolts are installed vertically between the top of the throw device and the lid liners. The outer nuts are threaded out to apply pressure down against throw device. The second nut prevents the first nut from loosening.
5) Test the effectiveness of the locking bolts by attempting to rotate the throw device by hand. If you cannot dislodge the bolts by rocking the throw device back and forth, then the bolts are tight enough.
4) Loosen the nuts and remove the bolts. 5) Store these bolts where you can use them again the next time the VSI is to be transported.
4) Tighten these bolts firmly and evenly (but not too tightly!) by threading the nuts outward.
Notice: Do not overtighten these bolts. You could crack the lid liners with too much pressure. 6) Use the second nut to lock the outer nut in place.
Reinstall Locking Bolts Before Travel Notice: Do not ship or transport VSI until throw device is locked down to prevent bearing damage. Bearing damage may not be easily seen or immediately noticed, but it can cost valuable downtime and repairs. Installing lock-down devices before transport is easy and inexpensive.
Models The VSI is available in 1800 and 2100 models. Each size can be configured with table with shoes and anvils, with rotor and rockshelf, or with rotor and anvils, each driven by right angle gear (GD) or vertical belt drive (VBD).
1) Open the inspection doors.
Types of Drive
2) Install the locking bolts shipped with your VSI (Figure 3-2). If you need to use other bolts, use new bolts at least 27 mm (1") diameter bolts and paint them with a bright color or otherwise mark them to be sure they are noticed and removed at the end of the transport, before operation. Choose bolts that are slightly shorter than the distance from the top of the throw device to the lid liners.
The two types of drive system are right angle gear drive (GD) and vertical belt drive (VBD). GD models can be powered by diesel or electric motors while VBDs are driven by one or two vertically mounted electric motors.
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LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 3 Installation and Start-up Weights in lbs (kg)
1800 GD
1800 VBD 20,294 (9225) 2 mtr
Total with rotor & anvils
14,400 (6545)
Totals with rotor & rockshelf
13,250 (6022)
15,972 (7260) 1 mtr
2100 GD 1 1
19,144 (8702) 2 mtr 1 14,822 (6737) 1 mtr
1
2100 VBD 33,034 (15015) 2 mtr 2
26,000 (11818)
23,100 (10500)
27,812 (12642) 1 mtr
30,134 (13697) 2 mtr 2 24,912 (11324) 1 mtr
20,074 (9124) 2 mtr 1 14,180 (6727)
Total with flywheel, no rotor, no anvils, no rockshelf
11,000 (4990)
Lid Assembly
2,500 (1136)
2,500 (1136)
3,100 (1409)
3,100 (1409)
Anvils & Ring
2,100 (955)
2,100 (955)
2,900 (1318)
2,900 (1318)
Rockshelf (by itself)
950 (432)
950 (432)
1,080 (491)
1,080 (491)
Flywheel (by itself)
440 (200)
440 (200)
1,000 (455)
1,000 (455)
CastRotor
1,300 (591)
1,300 (591)
1,526 (694)
1,526 (694)
3-shoe Table
1,000 (455)
1,000 (455)
1,434 (652)
1,434 (652)
4-shoe Table
1,080 (491)
1,080 (491)
1,520 (691)
1,520 (691)
1 2
1
16,894 (7697) 2 mtr 1 12,572 (5715) 1 mtr
1
2
33,034 (15015) 2 mtr 2
Total with table, 4 shoes & anvils
15,752 (7160) 1 mtr
2
26,000 (11818)
21,580 (9789)
27,812 (12642) 1 mtr
2
26,614 (13006) 2 mtr 2 23,392 (10633) 1 mtr
2
Weights assume 250 hp (187 kw) electric motor(s). Weights assume 300 hp (224 kw) electric motor(s). Weights in lbs (kg)
1800 GD
1800 VBD
2100 GD
2100 VBD
5-shoe Table
1,160 (527)
1,160 (527)
1,606 (730)
1,606 (730)
6-shoe Table
1,475 (670)
1,475 (670)
1,975 (898)
1,975 (898)
Uppter Tub with Rock
4,200 (1909)
4,200 (1909)
5,400 (2455)
5,400 (2455)
Lower Tub
1,370 (623)
1,370 (623)
1,700 (773)
1,700 (773)
Gear Box Drive Module
2,750 (1250)
N/A
3,410 (1550)
N/A
Housing Assembly VBD
N/A
1,300 (591)
N/A
1700 (773)
VBD Motor Mount with Bracket
N/A
1,680 (764)
N/A
1680 (764)
Feed Disc (flat)
86 (39)
86 (39)
129 (57)
129 (57)
Feed Disc (cone-shaped)
N/A
N/A
94 (43)
94 (43)
Typical Anvil
60 (27)
60 (27)
86 (39)
86 (39)
Typical Shoe
57 (26)
57 (26)
82 (37)
82 (37)
Anvil Ring (by itself)
542 (246)
542 (246)
893 (406)
893 (406)
6-shoe Cover Plate
125 (57)
125 (57)
175 (80)
175 (80)
Hopper
460 (209)
460 (209)
630 (286)
630 (286)
Feed Tube Table
98 (45)
98 (45)
170 (77)
170 (77)
Feed Tube Rotor
98 (45)
98 (45)
130 (59)
130 (59)
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Page 3.3
LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 3 Installation and Start-up Electrical System
Start-up Controls
The electrical system for all VSI models includes a vibration-sensitive shut-off switch, an electric oil pump with timer, a flow meter/switch (also called the flow monitor) connected to a warning horn, and a thermostatically controlled oil heater.
A properly wired VSI assures that the drive cannot be started unless the oil pump is running and the proper amount of oil is flowing through the pump. The horn sounds momentarily (1-2 seconds) then turns off when you first start the oil pump. This assures you that the horn and flow meter/switch are working properly. Always be sure the oil pump starts before the drive shaft turns.
See the Electrical Schematics in Section 9. Note particularly the importance of the vibration switch and the flow meter/switch. Warning! The vibration switch must be connected correctly and be in good working order whenever the VSI is operating. Failure of the vibration switch to shut down the VSI if high vibration develops during operation could be very dangerous to operators or other people nearby. Death or serious injury could result!
On electrically powered models check the power supply to be sure its voltage, frequency, and phasing agree with that shown on the electric motor nameplate(s).
Notice: Refer to the electrical schematic for proper connection at the junction box. The flow meter/ switch must be tied into the warning horn, the shutdown circuit and the feed device to prevent serious machine damage in the event of lubrication failure.
Wire the oil flow meter/switch to the warning horn and main power source (Figure 9-4 & 9-4). This step is a simple but very important protection for your crusher. Your VSI must have full lubricant supply at all times during running.
Electrically ground the crusher mount or trailer frame with standard grounding rod or earth/grounding devices, according to local electrical code.
If the oil flow rate is too low, the warning horn sounds and the crusher shuts down. If this happens, find out why the oil flow was too low before restarting the VSI.
Warning! Failure to lock out the power source before performing maintenance can result in serious injury or death. Because of the danger of accidental start-up of the VSI while maintenance is being performed, you must set up a system for positive lockout of the power source during cleaning, maintenance, adjustment, or repair. Prevent accidental start-up of the crusher by another person. Make sure your lockout and tagout system is well-known and respected by every member of your work crew. See the safety comments in Section 2 of this manual.
21052 (3/97)
Be certain that line voltage is within 10% of nameplate value and that frequency is within 5% of nameplate value. The combined variation of voltage and frequency must not exceed 10%.
Automatic Shutdown
If the vibration detection switch trips, the crusher drive shuts down, but the warning horn does not sound. Momentum continues to keep the flywheel rotating for awhile. After the flywheel and throw device stop rotating, find out why the vibration detection switch tripped. To restart the crusher, turn the oil pump off, then back on. This resets the vibration switch. You can tell the difference between a shutdown caused by the oil flow switch and one caused by the vibration detection switch by whether or not the horn sounds.
Page 3.4
LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 3 Installation and Start-up Optional Pre-wired Panel An optional pre-wired electrical panel is available from your Cedarapids/ElJay Distributor. It contains circuit breaker, fuses, step-down transformer, relays, timers, lube pump start and stop switches, and indicator lights for lube pump and heater.
Center feed fall into crusher hopper. Off-center feed can cause excessive wear, uneven wear, and decreased production. To help center feed, rotate feed box to angle needed to mate with feed conveyor. Warning! The VSI generates high velocity air flow through the discharge ports. Wear dust masks or other breathing protection.
Setting Up the Lubrication System Important: If the oil supply fails during operation for any reason, immediately shut down, determine the cause and fix it before restarting.
To reduce dust levels, ElJay Division advises dust suppression devices, such as covered conveyors or water injection at crusher discharge.
Check the dip stick for adequate lubricant level.
Guards and Nearby Equipment
If oil is old, dirty, or sticky, select a proper lubricant and change the oil. Verify that the oil pump operates continuously when the crusher drive is on.
Read all of Section 2 on safety and safe practices. Caution! Read all warning, caution and instruction signs. Know what guards and protective devices are included with the crusher and see that each is securely in place. Operating without each of these guards is a violation of federal safety codes and a threat to the safety of operators and observers. Do not remove these guards.
Notice: Failure to run the oil pump at all times while the crusher is running voids the warranty. The external, electrically driven pump is the only oil pump on the VSI. See the Acceptable Lubricants Chart (Figure 8-2), Lubricating Oil Capacities (Figure 8-10) and the Oil Flow Charts (Figures 8-6 through 8-9 and 8-11).
Warning! Do not operate until all guards, protective devices and systems are in place and operative.
Setting Up the Rock Material Feed Oversize feed material can cause serious damage to the crushing chamber. Notice: Damage to crusher chamber components resulting from tramp iron passing through the crushing chamber voids the warranty. The VSI crusher has no built-in tramp iron protection. Tramp material, especially heavier metal pieces, entering the crushing chamber cause severe damage to your crusher. If your crushing site or feed system generates frequent tramp iron problems, install metal detectors and/or removal devices (such as a belt magnet) in the feed system well ahead of the VSI in your production circuit. This reduces the chance that tramp iron can enter the crusher. Set up rock feed system so feed rate to VSI is even and steady. Uneven feed rate can have a negative effect on gradation and increase wear rate. 21052 (3/97)
Warning! Never stand on the VSI lid when it is operating. Warning! If any part of the throw device is allowed to come loose during operation, a serious accident could occur, endangering operators and other people nearby! Do not start the VSI with any loose parts on the throw device. Especially check after transporting the VSI. Check Rotation Before Starting Notice: Serious damage to your crusher can result if the shaft rotation direction is wrong. The oil pump does not properly lubricate when the shaft turns the wrong direction. Rock does not properly strike the wear surfaces.
Page 3.5
LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 3 Installation and Start-up 1) Briefly engage the diesel engine or electric motor(s) without the V-belts installed. 2) On GD models check that the pinion shaft rotates in the direction of the rotation arrow above the shaft. See Installation drawings for GD models. On VBD models, be sure motors and vertical shaft rotate counterclockwise (viewed from top). Maximum RPM On diesel drive models the maximum recommended diesel engine speed is 1800 rpm. Verify that the governor is not allowing the diesel to operate beyond this limit. On electric drive models the maximum shaft rotation speed is shown in charts in Section 10. Check rpm specifications in Section 10. Caution! Do not exceed the stated rpm for the configuration of your crusher.
13) Is the discharge area clear? 14) Are tramp iron (metal detection) removal devices installed and in working condition? 15) Is the vertical shaft rotating in the proper direction? 16) Is the crusher feed tied to the emergency shutdown circuit? 17) Is the vibration detection switch working properly? Important: After the first hour at the initial startup, shut down the conveyors, the screen(s) and the crusher to reinspect the VSI crusher chamber. Varying crushing conditions and the great variety of abrasive content in rock can significantly affect the crushing capabilities of the VSI. At a new site you can save time and money by an early check into the wear characteristics your VSI is experiencing. Also see the daily inspection form in Section 4. Storage
First Start-up Check List 2) Is the Operation Manual present and available?
Once a month during storage, or when running VSI infrequently:
3) Has the operator reviewed the safety precautions in the Owner/Operator Manual?
Notice: Do not immediately start the VSI or the oil pump if the VSI has been idle for a month or more.
1) Are all the components properly installed?
4) Is the equipment mounted level?
1) Check the dipstick.
5) Is oil reservoir filled with the proper lubricant?
2) After determining that oil can be properly pumped, run the oil pump for 10 minutes to pre-lubricate the bearings.
6) Are the automatic shutdown systems working? 7) Does the warning horn sound correctly? 8) Does the flow meter indicate proper oil flow? 9) Are all wear castings properly secured? No loose parts?
3) Turn the vertical shaft two complete revolutions by hand to coat the bearings and/or gears with lubricant.
10) Is the flywheel guard installed at the proper height? 11) Is the feed tube adjusted to the proper height? 12) Have the locking bolts that prevent the throw device from moving during transport been removed? 21052 (3/97)
Page 3.6
LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 3 Installation and Start-up Installation 1800 VSI-GD
Notes on callouts:
Top and Bottom View this page.
1) Clearance necessary to remove pinion shaft assembly.
Front and Side View opposite page.
2) Inspection doors. 3) Keep this area clear for crusher lubrication components. 4) Do not block discharge areas.
1
838 mm (33")
2032 mm (80")
1111 mm (433/4")
2
3
92 mm (33/4") 1702 mm (67") 1321 mm (52")
4 1321 mm (52")
711 mm (28")
1219 mm (48")
1422 mm (56")
1702 mm (67")
1003 mm (391/2") 1175 mm (461/4 ")
48 mm (17/ 8")
Figure 3-4 1800 VSI-GD Installation
21052 (3/97)
Page 3.7
LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 3 Installation and Start-up 9) Pinion shaft 88.9 mm (3-1/2") diameter with 22,2 mm (7/8") x 11.1 mm (7/16") keyway. Metric conversions are approximate and are given only for convenience. Standard bore metric sheaves do not fit the pinion shaft.
5) Minimum heights required to gain access to anvil ring. 6) Pinion rotation direction arrow. 7) Oil drain plugs. 8) Keep area above and around lid clear for access to inspection doors.
10) Standard sheave is 12 groove 8V 312 mm (12.3") PD x 318 mm (12.5") O.D. (other sheaves available).
1080 mm (421/2 ") 356 mm (14")
5
6
3
7 692 mm (271/4 ")
8
762 mm (30")
724 mm (281/2")
2140 mm (841/4 ")
2197 mm (861/2")
1416 mm (55 3/4 ")
203 mm (8")
1010 mm (39 3/4 ")
9
537 mm (211/8 ")
10
359 mm (141/8")
1016 mm (40")
1219 mm (48")
57 mm (21/4 ")
1340 mm (52 3/4 ") 2356 mm (92 3/4 ")
Figure 3-4 1800 VSI-GD Installation Continued
21052 (3/97)
Page 3.8
LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 3 Installation and Start-up Installation 1800 VSI-VBD
Notes on Callouts:
Top and Bottom View this page
1) Motor rotation direction arrows.
Front and Side View opposite page
2) Inspection doors. 3) Area used for crusher lubrication components. Keep clear for access. 4) Oil drain plug.
3181 mm (1251/4")
2 1
1021 mm (40 3/16")
92 mm (33/4")
1054 mm (411/2")
3 4331 mm (1701/2")
48 mm (17/ 8")
1320 mm (52") 1003 mm (391/2")
4
1320 mm (52") 762 mm (30") 1190 mm (467/8")
5
1676 mm ± 64 (66" ± 21/2)
3352 mm ± 127 (132" ± 5)
Figure 3-5 1800 VSI-VBD Installation
21052 (3/97)
Page 3.9
LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 3 Installation and Start-up 5) Do not block discharge areas. 6) Minimum heights required to remove anvil ring. 7) Not used if shipped in the single drive configuration. 8) Keep area above and around lid clear for access to inspection doors.
9) 1500 to 1700 mm (59 to 67") - dimension depends on the motor used. 10) 1638 to 1842 mm (64-1/2 to 72-1/2")- dimension depends on the motor used. 11) Clearance for sheave removal. 12) Clearance for belt removal.
1054 mm (411/2") 721 mm (28 3/8") 368 mm (141/2")
1416 mm (553/4")
3
997 mm (391/4")
6
546 mm (211/2")
57 mm (21/4")
2032 mm (80") 762 mm (30") 381 mm (15")
7
2148 mm (849/16")
343 mm (131/ 2")
8
9 10 978 mm (381/2")
762 mm (30")
143 mm (5 5/ 8")
11 610 mm (24")
762 mm (30")
254 mm (10")
12
11
Figure 3-5 1800 VSI-VBD Installation Continued 21052 (3/97)
Page 3.10
LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 3 Installation and Start-up Installation 2100 VSI-GD
Notes on callouts:
Top and Bottom View this page
1) Inspection Doors.
Front and Side View opposite page
2) Clearance necessary to remove pinion shaft assembly. 3) Keep this area clear for crusher lubrication components. 4) Do not block discharge areas.
2 1067 mm (42")
1
171 mm (63/ 4")
3 1575 mm (62")
94 mm (311/16 ")
762 mm (30")
5
4
318 mm (121/ 2") 1575 mm (62")
190 mm (7 1/2") 787 mm (31")
6 213 mm (83/ 8")
213 mm (83/ 8") 1187 mm (463/ 4")
48 mm (17/ 8")
Figure 3-6 2100 VSI-GD Installation
21052 (3/97)
Page 3.11
LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 3 Installation and Start-up 5) Oil drain plugs. 6) Pinion shaft 88.9 mm (3-1/2") diameter with 22.2 mm (7/8") x 11.1 mm (7/16") keyway. Metric conversions are approximate and are given only for convenience. Standard bore metric sheaves do not fit the pinion shaft.
7) Minimum height required to gain access to anvil ring. 8) Pinion rotation direction arrow. 9) Area around and above lid to be kept clear for access to inspection doors. 10) Standard sheave 12 groove 8V 452 mm (17.8") PD x 457 mm (18") O.D. (other sheaves available).
1003 mm (391/ 2") 952 mm (371/ 2") 381 mm (15")
7
8 3
787 mm (31") 2057 mm (81") 2705 mm (1061/2 ") 1143 mm 1143 mm (45") (45") 508 mm 508 mm (20") (20")
9 2517 mm (991/8") 2832 mm (1111/2 ") 1565 mm (615/8") 521 mm (201/2 ") 1254 mm (493/8")
432mm (17")
10
492 mm (193/8") 314 mm (12 3/8 ")
Figure 3-6 2100 VSI-GD Installation Continued
21052 (3/97)
Page 3.12
LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 3 Installation and Start-up Installation 2100 VSI-VBD
Notes on Callouts:
Top and Bottom View this page
1) Motor rotation direction arrows.
Front and Side View opposite page
2) Area used for crusher lubrication components. Keep clear for access. 3) Inspection doors. 4) Oil drain plug.
171 mm (63/4")
3559 mm (1401/8")
2 1
1056 mm (419/16")
3 1
4832 mm (190 /4") 1575 mm (62")
4
48 mm (17/ 8")
1181 mm (461/2")
5
1575 mm (62") 762 mm (30") 1422 mm (56")
2
1930 mm ± 64 (76" ± 21/2)
3861 mm ± 127 (152" ± 5)
Figure 3-7 2100 VSI-VBD Installation
21052 (3/97)
Page 3.13
LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 3 Installation and Start-up 5) Do not block discharge areas. 6) Minimum heights required to remove anvil ring. 7) Not used if shipped in the single drive configuration. 8) Keep area above and around lid clear for access to inspection doors.
9) 1700 mm (67")- dimension depends on the motor used. 10) 1842 mm (72-1/2")- dimension depends on the motor used. 11) Clearance for sheave removal. 12) Clearance for belt removal.
1054 mm (411/2") 953 mm (371/2") 381 mm (15")
2 6 546 mm (211/2")
1564 mm (619/16") 1254 mm (493/8")
57 mm (21/4")
2286 mm (90") 1016 mm (40") 508 mm (20")
7
2572 mm (1011/4")
343 mm (131/ 2")
8
9 10 1276 mm (501/4")
762 mm (30")
143 mm (5 5/ 8")
762 mm (30")
11 610 mm (24")
254 mm (10")
12
11
Figure 3-7 2100 VSI-VBD Installation Continued 21052 (3/97)
Page 3.14
LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 4 Daily Start-up and Check List Keep VSI operating properly with maximum “uptime” in crushed rock production. Use the Daily Inspection Form on page 4.3 to provide a routine and a record that helps monitor conditions and keep crusher performing at its best. Photocopy the Daily Inspection Form to help better maintain VSI. The Daily Start-up Detail helps you decide when parts have worn to the point they need changing and provides more detailed information about the steps in the Daily Inspection Form. See the Bolt and Nut Torque chart in the Appendix. Notice: Do not exceed recommended torque values on the bolts holding cast wear parts. Cast wear parts are more brittle than mild steel. A part that breaks loose at high rpm inside the crushing chamber can do serious damage to your VSI. Daily Start-up Detail Warning! Lock out the power source, including power to the oil pump, before attempting any maintenance. Before starting any VSI for the workday or shift, do the following pre-start checks: 1) Check oil level with dipstick at oil tank. Lift dipstick and be sure oil is at proper level. Check that oil drips from stick. If oil is too thick to drip, it can damage oil pump and not lubricate bearings. Be sure oil tank is full. 2) Check the discharge openings. Be sure they are clear and unobstructed. Notice: If your site has material such as sticks and clay that can bridge and block the discharge openings, check the openings more often. 3) Check all visible oil fittings for leaks. 4) Check for loose bolts on the outside of the VSI. 5) Check that crusher V-belts are tight enough and aligned. Check them for signs of wear. 6) Clean out all dust and dirt buildup on crusher sheave and motor sheave. This buildup can cause vibration and early wear. 21052 (3/97)
7) Open the inspection doors to see the throw device. Remove the locking pin from the door locking wedge. Drive the wedge out with a hammer. Drive the locking bar out (Figures 41, 4-2 and 4-3). If you have a VSI with table/shoes, go to the instructions on page 4.6. VSI with CastRotor 8a) Inspect rotor assembly. Check all wear parts and liners for excessive wear (Figure 4-4). 8b) Check all wear tip assemblies for damage and excessive wear. Note especially the condition of the primary wear tips. Some CastRotors have primary carbide wear tips of an earlier design that are 13 mm by 13 mm (1/2" by 1 /2") when new. Later designs of primary carbide wear tips are 9.5 mm by 22.2 mm (3/8" by 7/8"). The backup carbide wear tips are all 13 mm by 13 mm (1/ 1 2" by 1- /2"). If you are in doubt as to the extent of wear, check the carbide tip with a straightedge (Figure 4-5). A 140 mm (5-1/2") straight edge works well for the 1800 CastRotor. A 190 mm (7-3/8") straight edge works for the 2100 model. Bridge the straight edge vertically from an unworn portion at the top to an unworn portion at the bottom of the carbide face (Figure 4-5). Measure wear from the straight edge to the deepest wear point of the carbide. If you have primary wear tips that are 13 mm (1/2") thick and Dimension A = 8 mm to 9.5 mm (5/16" to 3/ 8"), immediately replace the wear tip. If you have primary wear tips that are 9.5 mm (3/8") thick and Dimension A =17.5 mm to 19 mm (11/16 to 3 /4"), immediately replace the wear tip. 8c) Check the area of the tips in front (to the inside) of the carbide for undermining of the wear tip holder (Figure 6-7). Some undermining, up to 3 mm (1/8"), is expected and is not likely to harm your VSI. 4.7 mm (3/16") or more is too
Page 4.1
LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 4 Daily Start-up and Check List much undermining. If there is too much undermining, consult local Cedarapids/ElJay distributor before making any adjustments. After consulting your distributor, follow steps for adjusting trailing angles in Section 6. 8d) Inspect anvils or rockshelf, as equipped, and tub liner for wear. Check all wear parts for excess wear. See steps for changing wear parts in Sections 5, 6, or 7.
Figure 4-1 To open the inspection doors in the lid, remove the locking pin
8e) Check for any loose fasteners on rotor and all liners. Be sure bolts holding liners are snug. Check the torque chart in the Appendix. Do not overtighten the bolts. The liners are very hard, high chrome parts and can crack if bolts holding them are too tight, but, due to grit and dirt getting under or behind the liners, they can also sometimes loosen during operation. Important: Liners and other rotor parts that are too loose or too tight can damage or wear quickly. Check for any loose bolts or other rotor parts. 8f) Check the position of feed tube to be certain it is even with but not more than 13 mm (1/2") above bottom of the feed eye (Figure 7-8).
Figure 4-2 Remove locking wedge
Figure 4-3 Drive the locking bar out
21052 (3/97)
Figure 4-4 Looking at the Rotor through the Inspection Doors Page 4.2
LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 4 Daily Start-up and Check List
VSI Daily Inspection Form Warning: Lockout the power source, including power to the oil pump before inspecting the VSI.
Today’s date Serial number Machine ID number
Before Start-up Inspect:
✔ Check Boxes
1. Undercrusher discharge area for blockage ❐ proper level ❐ viscosity OK 2. Oil 3. Visible oil fittings for leaks 4. Outside of VSI for loose bolts, wedges 5. Drive V-belts for wear, fraying, slipping 6. Sheaves for material buildup
❐ OK ❐ Cleaned ❐ cleanliness OK ____Amount added ❐ OK ❐ Replaced ❐ OK ❐ Tightened ❐ OK ❐ Adjusted ❐ Replaced ❐ OK ❐ Cleaned
Operator’s Initials
7. Open the inspection doors to check throw device: Table
✔
Shoes Shoe bracket liners Shoe pins Feed tube Feed disc Table liner Rim liners Anvils
❐ OK ❐ OK ❐ OK ❐ OK ❐ OK ❐ OK ❐ OK ❐ OK
Hours or Tons run
❐ Replaced
Rotor
✔
Feed tube Tips Epps Primary liners Retaining liners Feed disc Feed eye Trailing angles Side plates Rim liners Top wear plates Bottom wear plates Anvils or rockshelf
❐ OK ❐ OK ❐ OK ❐ OK ❐ OK ❐ OK ❐ OK ❐ OK ❐ OK ❐ OK ❐ OK ❐ OK ❐ OK
Hours or Tons run
Important: Do not replace one (1) part on table or CastRotor without also replacing similar parts in similar positions. Maintain balanced weight condition at all times. Notes on wear parts condition:
21052 (3/97)
Page 4.3
LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 4 Daily Start-up and Check List
Warning: Look carefully around before start-up! Sound the usual warning for your site. Be sure no one is working on related equipment or might be injured by start-up!
✔ Check Boxes
Start-up time ______
Operator’s Initials
After start-up, running empty, inspect: 8. Low oil warning horn system 9. Oil filter indicator for restricted flow ❐ Green ❐ White 10. Flow meter: write down the reading 11. Ammeter: write down the amperage 12. Diesel motor rpm
❐ OK
❐ Not working
❐ Red ❐ Replaced filter element ____ Liters per minute (gallons per minute) flow ____ Motor 1 ____ Motor 2 ____ RPM
After crushing begins, inspect: 13. Feed rate 14. Ammeter for amp draw under full load 15. Flow meter reading after oil is warm 16. Diesel rpm
❐ Choke fed ____ Tonnes (tons) per hour ____ Motor 1 ____ Motor 2 ____ Liters per minute (gallons per minute) flow ____ RPM
Total crushing hours this date Downtime this date Total tonnes (tons) this date
________ ________ ________
Did you take an oil sample today?
❐ Yes
❐ No
Comments:
21052 (3/97)
Page 4.4
LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 4 Daily Start-up and Check List
4
3
2
1
1
Figure 4-5 Measure Wear from a Straight Edge to Deepest Wear Point of the Carbide Tip
Figure 4-6 Looking at Table through Inspection Doors
8g) Slowly rotate rotor and note clearance between the feed tube and feed eye. Center feed tube as much as possible for feed efficiency and to avoid rotating parts contacting each other.
Important: Liners and other rotor parts that are too loose or too tight can damage or wear quickly. Check that bolts are snug.
8h) Check the feed eye for wear paths. As the feed eye wears out, paths wear in the eye and the adjacent wear liners. To increase liner life, lift out the feed eye and rotate it 90°.
8d) Check the position of the feed tube. See that it is even with the tops of the shoes. Readjust the feed tube downwards when it has worn to 13 mm (1/2") above the tops of the shoes.
Go to Daily Start-up Detail- Continued, this page, to complete the daily inspection of your VSI.
8e) Slowly rotate the table and note the clearance between the feed tube and each shoe. Be sure no shoes hit the feed tube.
VSI with Table/Shoes
Daily Start-up Detail - Continued
For a VSI model with table/shoe/anvil configuration: 8a) Inspect all shoes and shoe bracket liners for wear. Inspect the shoe-holding pins. Be certain they are in place and not bent (Figure 4-6). 8b) Inspect anvils, table liners, table rim liners, tub liner, and feed cone for wear. Refer for details of wear minimums to Section 5. 8c) Check for loose fasteners on table and all wear liners. Be sure wear liner bolts are snug. Do not overtighten. Check the bolt and nut torque chart at the end of this section.
9) Close the inspection doors. Reinstall the locking bar (Figure 4-7). Drive in the locking wedge and install the locking pin. 10) Unlock the power source to the oil pump only and tell fellow workers you are about to test the warning horn before starting up. 11) Turn on the oil pump switch. It is normal for the warning horn to sound for a few seconds until the oil flow reaches a rate above the preset warning level. Sounding the warning horn serves two functions: • It lets you know the warning system is working to protect your VSI from low oil flow.
21052 (3/97)
Page 4.5
LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 4 Daily Start-up and Check List 14) Check screens and conveyors feeding the VSI to be sure no tools or hardware have been left on them. Warning! Look carefully around; check your radio; sound usual warning for your site, or use other communications methods to be sure no one is working on related equipment or may be injured by starting up! 15) Unlock power source to crusher drive. 16) Turn on under-crusher conveyor. Figure 4-7 Drive Locking Wedge In and Replace Locking Pin
• It lets workers in the surrounding area know you are nearing start-up. 12) Check the flow meter. The oil flow rate varies during the course of the day, depending on the oil temperature. After the VSI has operated, the oil warms and flows easier. The flow meter shows this tendency. For approximate oil flow rates, both cold and warm (Figure 4-8). Important: To prevent damage to bearings, leave the oil pump on at all times during crusher operation. Do not shut off pump until crusher has come to a complete stop. 13) Check to be sure all guards and protective devices are securely in place. Model
Warm
liters/min
4.7 to 5.7
2.8 to 3.3
Gallons/min
1.25 to 1.5
.75 to .875
liters/min
2.8 to 3.8
1.4 to 1.9
Gallons/min
.75 to 1
.625 to .5
liters/min
5.7 to 6.6
3.3 to 4.3
Gallons/min
1.5 to 1.75
.875 to 1.125
liters/min
4.7 to 5.7
2.8 to 3.3
Gallons/min
1.25 to 1.5
.75 to .875
1800 VSI-VBD
2100 VSI-GD
2100 VSI-VBD
17) For diesel driven crushers, start diesel and warm it up according to diesel manufacturer’s instructions. Bring diesel to about 1000 to 1100 rpm. Bump power takeoff (PTO) handle several times to engage power takeoff gradually. Important: Do not move handle to full engagement until VSI speed increases. If VSI is brought up to full speed too quickly, it can damage your drive belts, causing them to wear too quickly. New belts need frequent tightening for several operating days after being installed. 18) For electrically driven VSI's, engage drive motor(s) and bring VSI to full rpm. 19) Monitor drive and VSI for any excessive vibration. Normal conditions produce very little vibration.
Cold
1800 VSI-GD
Important: Never run VSI without under-crusher conveyor also running.
Important: If using a VSI with a rotor and have cleaned rock buildup out of rotor, fill rotor and rockshelf with 30 to 60 seconds of 19 mm and smaller (3¦4" minus) feed before feeding larger rock into VSI. Without this buildup at start-up, large rock can damage wear tips. 20) Start feeding material to the crusher.
Figure 4-8 Oil Flow Rates 21052 (3/97)
Page 4.6
LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 4 Daily Start-up and Check List Important! Do not run CastRotor VSI's more than 15 minutes immediately after exit port protectors or wear tips have been changed or serviced. Stop machine and Open inspection door in lid. Inspect rotor, carbide wear tips, and all wear points. Again tighten exit port protector (epp) bolts to 190 n•m (140 ft-lbs). Adjust trailing angles as needed to control material buildup. Any time rock material characteristics are changed (such as size, rate of feed, rock material), it pays to look carefully at crushing chamber for changes in wear rates. Improperly adjusted trailing angles or other VSI parts can be costly in creating unnecessary wear. It pays to check! 21) Start normal feed. Cold Weather Start-up Check dip stick to see that oil drips freely from stick. If oil cannot drip from dip stick, it is too thick to lubricate VSI. Important: Do not start crusher if oil is too thick to drip from dipstick. Either warm crusher with a propane heater before starting or change to a lighter oil.
The VSI is equipped with an oil heater and thermostat which is set to switch on at 15.5°C (60°F) oil temperature and go off when oil is at 26.7°C (80°F). With oil pump continuously circulating oil, heater is effective down to an ambient temperature of about 9°C (15°F), but is not very effective when weather conditions are below -9°C (15°F). For cold weather operation, cover crusher at night and pre-warm it with an external heater (propane, for example) before morning start up. Important: Do not start crusher if oil does not flow freely. Oil must be free flowing to properly lubricate bearings (and gears on gear drive models). Hot Weather Start-up Keep VSI oil temperature gauge reading below 115.5°C (240°F). If readings are nearing 115.5°C (240°F), consult Acceptable Lubricants Chart to select an oil designed for higher temperature conditions. Important: Maximum allowable oil temperature under any conditions is 115.5°C (240°F) at temperature gauge!
See the Acceptable Lubricants Chart, page 8.1, for proper oil specifications for your operating and weather conditions.
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Page 4.7
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Operation & Maintenance Manual
A Terex Company
Section 4 Daily Start-up and Check List
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Page 4.8
LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 5 Changing Table/Shoe Wear Parts The VSI’s structural members are protected from abrasive wear. Some wear surfaces collect rock material to protect structure. Some areas of crushing chamber, input and discharge areas include replaceable, bolt-on wear parts. Highly wearresistant, each wear part armors VSI to protect it from damage (Figure 5-1). Wear parts also efficiently shape the flow of rock for crushing large volumes.
Warning! Lock out the power source to this crusher before attempting any maintenance. Turn off diesel power plant (if diesel is used.) Notice Regarding Wear Part Fasteners: Except where noted, most fasteners used to attach VSI wear parts use anti-seize lubricant on the threads. Cast wear parts are very abrasion-resistant, but are more brittle than milder, softer steels. Standard torque values of the recommended Grade 8 bolts 4
2
5 3
1
6
7
8
9
11
10 1. Shoe bracket 2. Flywheel bolt 3. Feed disc 4. Shoe pin 5. Shoe 6. Shoe bracket liner
7. Table liner 8. Special (Allen-head or shortened hex) table liner bolt 9. Rim liner 10. Flywheel spacer ring 11. Table weldment (includes shoe brackets) Figure 5-1 Wear Parts Identified
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LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 5 Changing Table/Shoe Wear Parts may be so high as to crack or break the cast part. Except where a torque value is specifically noted, always tighten wear part fasteners firmly to a “snug fit.” Except where noted in this manual, do not tighten the bolts holding wear parts to their full, standard, lubricated torque value.
1
Balanced Running Important Balanced running is very important to the table and shoes. Whenever you change wear parts, be sure to replace them in matching, weight-balanced sets. Tables: Various Types Available
2
The open-topped table is available with 3, 4, or 5shoes. A 6-shoe table is available with a closed top. You can refit your VSI with any one of the table options. Find instructions for removing and reinstalling tables later in this section. Table options allow you to choose the best one to fit your crushing needs. Generally, the more shoes, the finer the crushed product and the more shoe life.
3
Figure 5-2 shows you the four table/shoe options. Replacing the individual wear parts is essentially the same for each table type. Under normal operating conditions, shoes are first parts to need replacing due to wear. These and shoe bracket liners can be changed while working through access doors in lid. To change other table/shoe wear parts best practice is to remove lid. See Removing Lid Assembly in Section 7. Changing table rim liners requires removing table from VSI. See Changing Table Rim Liners, page 5-10 for instructions on removing and replacing table.
4
Shoes, Shoe Pins, Shoe Bolts Shoes are easily removed and replaced. They are attached to table’s shoe brackets with either shoe pins or shoe bolts. Pins can be mounted either vertically or diagonally, depending on type of shoe. A pin stop is welded to each shoe bracket. This determines which type of shoe and pin your table requires. See Figure 5-3 for both types of pins. 21052 (3/97)
Page 5.2
1. 3-shoe, open top 2. 4-shoe, open top 3. 5-shoe, open top 4. 6-shoe, closed top Figure 5-2 Available Table Types
LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 5 Changing Table/Shoe Wear Parts Tables with even-numbered shoes (4 and 6-shoes) can tolerate different weight shoes as long as they balance 180° apart, across table. Tables with oddnumbers of shoes (3 and 5-shoes) require all shoes to be more closely matched in weight (Figure 5-5). Even-number of shoes on the table
Odd-number of shoes on the table 1. Diagonal Pin 2. Vertical Pin
A
A
B
B A
A
A
A
A
A
B
A
B
B A
A
Figure 5-3 Two Types of Shoe Pins
A
A
Weight-Balanced Shoe Sets Important: Balanced running is very important with the VSI. Whenever you change wear shoes, be sure to replace them in matching, weight-balanced sets. Allow a maximum weight variation of only 0.45 kg (1.0 lb). Always replace shoes in matching, weight-balanced sets all around the table. The better balanced running you have, the longer bearing life you can expect. See the specifications for weight-balanced sets (Figure 5-4).
Model
1800
2100
Typical Shoe
26 kg (57 lbs)
37 kg (82 lbs)
B
A
Figure 5-5 Even and Odd Shoe Balance Sets
When to Change Shoes To inspect shoes, reach in through access door to check inner edge of shoe. Feel inner edge of shoe to be sure it has more than 6 mm (1/4") thickness remaining (Figure 5-6). A pocket worn by rock passage weakens shoe. If pocketing has occurred, change when bottom of the pocket is within 13 mm (1/2") of back side (Figure 57). Change shoes when worn to within 6 mm (1/4") of back side at discharge (outer) edge, or if cracked.
Figure 5-4 Weight Specifications for Shoes
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Operation & Maintenance Manual
A Terex Company
Section 5 Changing Table/Shoe Wear Parts Caution: Wear Safety glasses or goggles. Brittle metals can shatter dangerously.
6 mm (1/4") minimum
3) Rap on the face of the shoe with a hammer to jar it slightly loose. 4) Use a pry bar to lift while pulling with locking pliers to remove the pin. Figure 5-8 shows the vertical-pin type shoe. 5) If the pin is solidly cemented by rock material, you can use a torch to cut it loose, but carefully avoid cutting into the shoe bracket! 6) If removing shoes of bolt-type, remove bolt and backing plate. If shoe is solidly cemented by rock material, rap face of shoe with a hammer to jar shoe loose (Figure 5-9).
Inner edge
Figure 5-6 Check the Inner Edges of the Shoes
How to Replace Shoes 1) Clean all surfaces where shoes have contact.
inner edge
2) Inspect shoe bracket for weld integrity, cracks or erosion (Figure 5-10). See also Shoe Brackets and Liners.
13 mm (1/2") minimum 6 mm (1/4") minimum
outer edge Figure 5-7 Pocketing Wear Shows It Is Time to Change Shoes Figure 5-8 Removing Shoe Pin
How to Remove Shoes 1) Clean away the rock material around the shoes, shoe brackets, and pins or bolts. 2) Inspect the shoes for erosion.
21052 (3/97)
Page 5.4
Caution: Always replace shoe pins or bolts when you replace shoes! A bent or worn shoe pin or a poor condition bolt can be very dangerous because it can fail at high rpm! A LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 5 Changing Table/Shoe Wear Parts Bolt
Backing plate
Shoe bracket erosion Figure 5-10 Look for Shoe Bracket Erosion Figure 5-9 Removing Bolt-type Shoe
shoe bracket wear from the pin
failed pin or bolt can also very rapidly cause extensive damage to your VSI by letting a shoe come loose during operation. 3) Place shoe against front of bracket with stob through bracket. 4) Insert new pin through hole in shoe stob. A properly fitting pin slips into place and does not require driving into place. Notice: Clearance must be no more than 1.6 mm (1/16") (Figure 5-11). If shoe pin has worn a low spot in back of shoe bracket, gap between pin and bracket is too large. Pin can bend and cause shoe stob to crack and break out. Serious damage to crusher chamber may occur. If table has an even number of shoes and pin seems too tight, try trading shoe directly opposite across table. Sometimes minor variations in shoe fit can occur. Be sure to keep weight balanced. Allow a maximum weight variation of only 0.45 kg (1.0 lbs). Important: ElJay/Cedarapids factory-original shoe pins are stress-proof. Use no substitutes.
Figure 5-11 Pin Wear in the Shoe Bracket
5) Check to be sure pin is fully seated against the pin stop. Use only correct length pin. When fully and correctly seated, pin is even with top of shoe. 6) For bolt-type shoes, check backing plate. Reuse a backing plate that is not bent or badly worn. 7) Install shoe bolts dry, without any lubrication. 8) Tighten the bolt to 203 N•m (150 ft-lbs).
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LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 5 Changing Table/Shoe Wear Parts Important: Do not use an impact (pneumatic) wrench to tighten the shoe bolts. 9) Turn the table by hand to check for any clearance problems. Shoe Brackets and Liners The portion of the table weldment called the shoe bracket is not itself a wear part, but can erode where the shoe pins contact the bracket and at the side members (Figure 5-10). If the shoe bracket is worn in the area of the pin, fill the worn area with mild steel weld and grind it flush (Figure 5-11).
Figure 5-12 Install Shoe Bracket Liner
Side members of bracket can also show wear.
that are threaded into the table unless they are damaged or worn. Other table liners use shorthead bolts under the shoes. These hex-head bolts, part number 02-382-510-0030, have shorter heads so the shoe seats properly over the table liner. The heads of these bolts are machined to 9.5 mm (0.375") high. Some types of table liners have 3 bolt holes; some have 4. As long as you keep the table weightbalanced, you can interchange the table liners types as they are available.
Important: Heavy welding activity can distort the roundness of the table and unbalance it. Always rebalance the table after major maintenance. Important: When wear has advanced enough that bracket might bend, replace table itself. Always maintain shoe brackets in like-new condition. When to Change Shoe Bracket Liners Change shoe bracket liners when worn to 5 to 6 mm (3/16" to 1/4") thick, or if cracked. Both high chrome and heat treated shoe bracket liners are available. See your Cedarapids distributor.
3) Lift off the old liners.
1) Remove bolts holding liner. Remove old liner.
4) Thoroughly clean flat areas of table, clean bolt holes and threads, and blow out holes with air.
2) Clean rock material from liner seat area. Check liner’s mating surface area for proper fit.
5) Set liners in position. 6) Apply anti-seize lubricant to bolt threads.
3) Set new liner in place (Figure 5-12).
7) Install bolts with shortened heads (as needed) in shoe area and standard bolts in open area (Figure 5-13). If bolts supplied with liners are lost, replace them with Grade 5 or higher.
4) Use anti-seize lubricant on bolt threads. Attach liner with bolts. Tighten to 67.8 N•m (50 ftlbs) lubed. Do not overtighten. Changing Table Liners
8) Hand tighten bolts in shoe area.
1) Remove the shoes.
9) Hand tighten bolts in open area.
2) Remove the appropriate table liner bolts (Figure 5-13). Some table liners have Allenhead bolts acting as guide pins under the shoes. You do not need to remove these bolts 21052 (3/97)
10) Tighten all table liner bolts to 135.6 N•m (100 ft-lb). Do not overtighten.
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Section 5 Changing Table/Shoe Wear Parts 3) Clean off the feed disc seat area.
Important: Centrifugal force during operation locks the liners into place. If you overtighten the bolts, they can be nearly impossible to remove. Also, if a casting is just slightly warped, overtightening can crack it. A cracked casting could become dangerous if it were to fly apart during operation.
4) Center the feed disc in the counter-bore in the table. Casting tolerances permit from 1.5 to 3 mm (1/16 to 1/4") total clearance between the feed disc and the hole in the table, so it is possible in rare cases for the feed disc to be off center by up to 3 mm (1/4"). If you notice vibration after installing a new feed disc, stop the crusher and check for centering by measuring from the inside edges of the shoe brackets. If disc is off center, pry into centered position. Fill space around feed disc with fine rock material to hold the position until it seats.
Changing Feed Disc Change the feed disc when hole first appears in surface, or if cracked. If you allow feed disc wear to go on, costly damage can occur to table, flywheel and the vertical shaft. When the disc is worn, the outer edge in front of shoe becomes rounded off (Figure 5-14). Rotate feed disc so worn sections are under shoes and sharp edges of disc are in front of shoes. Rotate the feed disc a small amount each time you change shoes to get even wear of feed disc and to promote even shoe wear.
Changing Table Rim Liners
1) Remove the shoes.
Change the table rim liners when they are worn to 9 mm (3/8") thick , or when top surface wears to within 6 mm (1/4") of top of table, or if any are cracked (Figure 5-16).
2) Pry under the outer edge of the disc and lift (Figure 5-15).
To change the rim liners, first remove the lid assembly. See section 7 for instructions.
1
2
1
2
1. Standard length bolts. 2. Shortened bolts for use under shoes (some table liners use Allen-head bolts. See Figure 5-1). Figure 5-13 Table Liners with Bolts
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Operation & Maintenance Manual
A Terex Company
Section 5 Changing Table/Shoe Wear Parts
1
2
1
2
3
4 3 Typical table wear patterns 1. Shoe wear 2. Feed disc wear 3. Rim liner wear 4. Table liner wear
4
5 1. Do not remove large flywheel locknut. 2. Top of shaft 3. Flywheel bolts 4. 6 mm (1/4") minimum to top of table 5. 9 mm (3/8") minimum thick
Figure 5-14 Feed Disc and Table Rim Liner Wear
Figure 5-16 Table Rim Liner Wear
Figure 5-15 Pry Up on Feed Disc
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Figure 5-17 Lift Table from Flywheel
Page 5.8
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Operation & Maintenance Manual
A Terex Company
Section 5 Changing Table/Shoe Wear Parts
Figure 5-20 Clean the Underside of the Table
3) Attach lifting device through shoe brackets (Figure 5-17). 4) See the Component Weights Chart in Section 3. Remove table from flywheel. Place table so chains can be repositioned to lift the table from the center (Figure 5-18).
Figure 5-18 Turn the Table Upside Down
5) Turn table upside down (Figure 5-19). 6) Remove the bolts from each liner. 7) When you have removed the rim liners, clean the flat underside of the table. Clean the bolt holes and threads (Figure 5-20). 8) Obtain a weight-balanced set of table rim liners. Not more than 0.227 kg (0.5 lbs) weight variance is allowed. Set the replacement liners in place (Figure 5-21). 9) Apply anti-seize lubricant to bolts. Install the bolts in each liner. 10) Hand tighten bolts. Hand-tightening helps assure proper alignment of the cast parts.
Figure 5-19 Remove Table Rim Liner Bolts
1) Remove the shoes and feed disc. 2) Remove the bolts holding table to flywheel, but do not remove the large flywheel locknut.
21052 (3/97)
11) Tighten bolts on 1800 VSI's with 3, 4, or 5 shoe tables to 190 N•m (140 ft-lbs). On 6-shoe 1800s and all 2100 VSIs tighten bolts to 298 N•m (220 ft-lbs). Do not overtighten (Figure 5-22).
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Operation & Maintenance Manual
A Terex Company
Section 5 Changing Table/Shoe Wear Parts
Figure 5-23 Tighten Table to Flywheel Bolts
Figure 5-21 Rim Liners Carefully Weighed and Placed to Balance Load
14) Tighten table bolts to 540-680 N•m (400-500 ft-lb) (Figure 5-23). 15) Install feed disc and shoes. 16) Reinstall the lid assembly. 17) Rotate the table to check clearances. 6-Shoe Closed-Top Table Most maintenance tasks are the same on the 6-shoe table as on other, open-topped tables, such as the 5shoe and 4-shoe tables. The main difference is in the cover plate and its retainers and bolts. Cover Plate To replace or maintain cover plate, remove lid assembly. See Section 7 for removing lid assembly.
Figure 5-22 Tighten Rim Liner Bolts
Caution! Use eye protection!
Important: Centrifugal force during operation locks liners into place. If bolts are overtightened, they can be nearly impossible to remove. If a casting is just slightly warped, overtightening can crack it. A cracked casting could become dangerous if it were to fly apart during operation 12) Place table on flywheel. 13) Use anti-seize lubricant on table bolt threads. If original bolts become lost, replace with Grade 8 or higher.
21052 (3/97)
1) Protect eyes from flying particles. Blow dust out of cover plate bolt retainers (Figure 5-24). 2) Use a 1-1/8" socket wrench to remove 3/4" diameter bolt from each retainer. Retainers protect bolt heads from abrasive wear during operation. 3) Shoes can be changed without removing cover plate if using shoes that have vertical shoe pins or bolt in place. However, it may be more convenient to remove cover plate.
Page 5.10
LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 5 Changing Table/Shoe Wear Parts 1
2
Bosses
3
Figure 5-25 Detail of the Bosses
1. Cover plate 2. Cover plate retainer 3. Cover plate bolts Figure 5-24 Six-Shoe, Closed -Top Table
4) Remove all six bolts and retainers. The retainers can be reused if they are not worn too much. Caution! Plate is very heavy! A new plate weighs 50-55 kg (110-120 lbs). Do not strain your back! Get help or use a mechanical lift to handle the cover plate. 5) Lift off the cover plate. You can turn the cover plate upside down and rotate it to extend its use if it is not too worn. The plate can be safely reused if 1/3 or less of the original thickness of the plate has been eroded away. A new plate is 38 mm (1-1/2") thick.
21052 (3/97)
6) Check bosses at top of each shoe holder to see that they are flat, in good condition, and all same height. If wear has occurred to bosses, add hard-facing weld to protect them. Avoid distorting or damaging threads (Figure 5-25). 7) Replace the cover plate. You can also rotate it to a new position. 8) Replace the bolt retainers. Rotate each retainer so the thickest portion faces the table’s direction of rotation. If you are in doubt about whether to reuse worn retainers, replace them. 9) Tighten cover plate bolts to 136 N•m (100 ft-lbs). 10) Reinstall the lid assembly.
Page 5.11
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Operation & Maintenance Manual
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Section 5 Changing Table/Shoe Wear Parts
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Operation & Maintenance Manual
A Terex Company
Section 6 Changing CastRotor Wear Parts The CastRotor’s structural members are protected from abrasive wear with replaceable, bolt-on wear parts. Some wear surfaces collect rock material to protect the structure. Highly wear-resistant, each wear part armors the rotor to protect it from damage.
wear parts use anti-seize lubricant on the threads. Cast wear parts are very abrasion-resistant, but are more brittle than milder, softer steels. Standard torque values of the recommended Grade 8 bolts may be so high as to crack or break the cast part. Except where a torque value is specifically noted, always tighten wear part fasteners firmly to a “snug fit.” Except where noted in this manual, do not tighten the bolts holding wear parts to their full, standard, lubricated torque value.
Warning! Lock out the power source to this crusher before attempting any maintenance. Turn off diesel power plant (if diesel is used.) Notice Regarding Wear Part Fasteners: Except where noted, most fasteners used to attach VSI Direction of rotation
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.
Exit path of rock material
9
10
Backup wear tip Primary wear tip Exit port protector Exit port rim liner Feed tube Feed disc Rim liner Side plate Bottom retaining liner Bottom primary liner Trailing angle Feed eye Top retaining plate Metal shim Top primary liner Top retaining liner Rubber shim Bottom retaining plate
1 11
2 3 4
12 5
7
6
13
14 15, 16
8 9, 10 17 7 18 Figure 6-1 Wear Parts of the CastRotor 21052 (3/97)
Page 6.1
LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 6 Changing CastRotor Wear Parts Maintain Balance with Matching Sets
Lid assembly
Exit port
Lid liner
Balanced running is very important to the throw devices. Whenever you change wear parts, be sure to replace them in matching, weight-balanced sets. Epps and Wear Tips At the outer edge of the CastRotor replaceable carbide wear tips at each exit port protect the throw point from excessive erosion. Under normal operating conditions the epps (exit port protectors) and the wear tip assemblies are the first parts to need replacing due to wear. These parts can be changed through the access doors in the lid. After the first 4 hours of rotor operation with new parts, check the wear tips and the buildup, the exit port protectors, the primary liners, the feed eye and feed tube (Figure 6-2). After that check once every shift (or 8 hours of operation).
Exit port protector (epp)
Anvils
Figure 6-2 Check the Rotor Often
Changing Exit Port Protectors (Epps) Change epps when they are damaged or when they are worn too thin (Figure 6-3). Look at the epp retaining nuts. Replace the epps when epp material has worn so much that 25% (1/4) of the retaining nut has worn away. Always replace bolts, nuts, and lockwashers when replacing epps.
Nuts
Caution! If any part of the CastRotor is allowed to come loose during operation, a serious accident could occur, endangering operators and other people nearby! Do not start the VSI with any loose parts on the throw device. Notice: If the retaining nuts get worn too thin, they could allow epps to fly off the rotor assembly. This could cause serious damage to your crusher. 1) With the VSI at a complete stop, and after locking out the power, open the access doors in the lid. 2) Remove nuts from the epps (Figure 6-3). 3) Remove the worn epps (Figure 6-4).
21052 (3/97)
Figure 6-3 Nuts Holding the Epps
Changing Wear Tips For typical recommended feed sizes, change wear tips when worn to 3 mm (1/8") thick minimum. Larger feeds often require changing them sooner. New wear tip carbide is 22 mm (7/8") thick on primary carbide tips and 13 mm (1/2") thick on backup tips. Check the tips on both sides for undermining of the holder. If you find undermining, adjust the trailing angles according to instructions in
Page 6.2
LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 6 Changing CastRotor Wear Parts
Figure 6-4 Removing an Epp
How to Change Trailing Angles. Check carbides carefully for cracks. If hairline cracks are found, run crusher but check them often. Cracked carbides may indicate other problems to watch for. See Troubleshooting, item 5.
Primary wear tip
Backup wear tip
Figure 6-5 Remove the Primary Wear Tip
1) After removing the epps, remove the primary wear tip (Figure 6-5). 2) Drive the bolts out (Figure 6-6). If you are changing your primary carbide tips at proper intervals and controlling feed to avoid oversized feed material, you may not need to change backup tips at this time. Whether or not you change backup tips, drive the bolts out and change them every time you replace the primary carbide tips. Never reuse the epp bolts or nuts! 3) Check the wear tip condition (Figure 6-7). Look for undermining in the holder and cracks in the carbides. If any tip has more than 3 mm (1/8") of carbide is exposed (undermined), see CastRotor Tuning, How to Change Trailing Angles, and Troubleshooting, Item 5. Check carefully any tip where more than 50% of carbide is exposed by undermining. Determine and fix the cause. Then frequently monitor the carbide condition. You may soon need to change these tips. Replace any wear tips that have more than hairline cracks. 21052 (3/97)
Page 6.3
Figure 6-6 Drive the Epp Bolts Out
4) Clean the seating area for both backup and primary tips. Caution! Use only Grade 8 fasteners. Never reuse an epp bolt. 5) Install the backup tip, then the bolts, then the primary tip (Figure 6-8). Replace the epps only as a set of three. When replacing the epps, be sure all parts are fully seated. 6) Torque the epp nuts to 190 N•m (140 ft-lbs.) 7) Close and secure the access doors. Clear the immediate area for start-up. LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 6 Changing CastRotor Wear Parts 1. Good wear. No more than 3 mm (1/8") of carbide exposed. 1
2
1
3 mm (1/8") Backup Wear Tip Surface 1 slips in back of surface 2
2. Too much undercuttingmore than 50% of carbide exposed (x/y). 3. Too much backdooring, where support for the carbide tip is worn away.
Figure 6-8 Backup Tip Comes Out Last, Goes In First
Top primary liner
Top retaining liner
3
x y
2
Figure 6-7 Check Carbide Wear Tips Carefully
8) Follow safe start-up procedures and bring VSI up to operating speed. 9) After reaching full operating speed for five minutes, shut down the VSI again briefly to recheck bolt torques. Warning! Always lock out and tag out power source. 10) Re-torque the epp nuts to 190 N•m (140 ft-lbs).
21052 (3/97)
Bottom Primary Liner
Bottom Retaining Liner
Figure 6-9 Primary and Retaining Liners
11) The first material fed to the VSI after cleaning and replacing parts should be 19 mm and smaller (3/4 minus) to provide initial protection to the wear tips and to fill the rotor. 12) Again start and operate as usual, being alert to possible vibration imbalance in the first few minutes of crushing.
Page 6.4
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A Terex Company
Section 6 Changing CastRotor Wear Parts Change Primary and Retaining Liners The CastRotor has top and bottom primary liners at each exit port (Figure 6-9). Primary liners are each held in place by secondary, or retaining, liners. Bolts hold top and bottom retaining liners in place. Always change primary and retaining liners in matched, weight-balanced sets.
Feed disc clip
1) Remove lid assembly. 2) Dig out and remove rock material as needed to remove retaining liner bolts. 3) Remove retaining liners. 4) Remove primary liners. Worn feed disc
5) Clean up seating area for all liner sets (Figure 6-10).
Wear pattern in feed disc
Figure 6-11 Feed Disc and Clips
Changing Feed Disc Change feed disc when a hole first appears in surface, or if it cracks. If feed disc wear is allowed to continue, costly damage can occur to rotor, flywheel or vertical shaft.
Seating areas
When disc is worn, outer edge becomes rounded off (Figure 6-11). Rotate feed disc so worn segments are in a different position relative to exit ports. Rotate feed disc a small amount each time change epps are changed to promote even wear of disc.
Figure 6-10 Clean Seating Area for Liner Sets
1) Loosen and remove bolts holding feed disc clips. Remove clips.
6) Install primary liners.
2) Pry under outer edge of disc and lift. A new feed disc weighs about 45 kg (100 lbs).
7) Install retaining liners. 8) Pull or tap liners outward to assure a lock fit. 9) Install bolts and tighten to 136 N•m (100 ft-lbs). 10) Reinstall lid assembly.
21052 (3/97)
Page 6.5
3) Clean off feed disc seat area. 4) Center new feed disc. If there is vibration after installing a new feed disc, stop crusher and check for centering by measuring from inside edges of primary liners.
LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 6 Changing CastRotor Wear Parts 5) If disc is off center, pry into centered position. Fill space around feed disc with fine rock material to hold position until it seats.
Direction of rotation
6) Replace feed disc clips and tighten bolts to 67.8 N•m (50 ft-lb.) CastRotor Tuning Trailing angle positions and conditions are very important in maintaining efficient crushing and crushed material specifications (Figures 6-12 and 613). Inside CastRotor each trailing angle controls rock material buildup in rotor segment traveling ahead of angle. The angle trails (or follows) wear tip in same rotor segment.
C A B
During crushing, material collects at leading face of trailing angles and builds out to carbide tips at three exit ports. This material buildup at each rotor segment prevents or slows wear and affects finished material specifications. Buildup is controlled by position, length and shape of trailing angle irons.
Trailing angle A = Buildup just right B = Buildup too big C = Buildup too small Figure 6-13 Three Types of Buildup
Buildup also varies with material type, moisture content, and revolutions per minute (rpm) of rotor. Figure 6-13 shows three different buildup conditions illustrated in one rotor. In actual practice buildup would result in rotor imbalance and very poor operation. For best conditions, position all three trailing angles equally and adjust them so that buildup between each wear tip and its trailing angle are as shown in the A portion of figure. Both too much and too little buildup prevent good VSI performance. Replace or modify trailing angles when: • buildup can not be controlled by trailing angle position 2 1. Leading Face 2. Trailing Face
• trimming or increased depth of trailing angle is needed
1
• hardfacing must be renewed on angle toe. Figure 6-12 Trailing Angle Controls Buildup 21052 (3/97)
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Operation & Maintenance Manual
A Terex Company
Section 6 Changing CastRotor Wear Parts 1
2
Toe of the angle
Note the dimensions of 1 and 2 to within 1.6 mm (1/16"). Figure 6-15 Measuring Trailing Angle Position Figure 6-14 Trailing Angle Modification to Control Buildup
Check to see that trailing angles are hard-faced at toe (Figure 6-14). Check both inside and outside carbide tips for undermining of wear tip holder. Too little buildup can undermine wear tips and/or break them by allowing material to “stream” past trailing angles.
Important: Small changes in trailing angle position and shape can make big changes in VSI performance and in wear rates. Do not change trailing angle position or profile without reading the whole section on CastRotor Tuning.
Some undermining, up to 3 mm (1/8"), is expected and is not likely to harm VSI. 5 mm (3/16") or more undermining is too much. If there is too much undermining, consult your local Cedarapids/ElJay distributor before making any adjustments. How to Change Trailing Angles 1) Showing a typical trailing angle position (Figure 6-15). First, measure carefully position and angle of each trailing angle before loosening bolts holding them. Note their positions to within 1.6 mm (1/16"). Write dimensions down for later use. This helps correctly position replacement parts. 21052 (3/97)
Page 6.7
2) Dig out rock material packed around trailing angles. 3) After measuring and recording position of trailing angles, loosen and remove the bolts that hold trailing angles. Remove feed disc retaining clips. 4) Remove trailing angles. 5) Replace trailing angles as a set. Make sure parts are fully seated. 6) Adjust trailing angles to their previous position unless a different buildup performance is desired (Figure 6-16). If you want to change performance, read all of this section before choosing a new position for trailing angles.
LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 6 Changing CastRotor Wear Parts
Figure 6-16 Adjust Angles to their Proper Position
Place all three trailing angles in matching positions so rock material buildup is even and balanced. Wear patterns in epps are another indicator to suggest adjustments to trailing angles. Figure 6-17 shows three typical trailing angle positions and associated wear pattern in epps. The shaded area represents the wear in epp. The top image indicates trailing angles need to be adjusted because epp is wearing too fast at top. The bottom image shows a good wear pattern in epp. This wear pattern provides longest wear life for epp. 7) Tighten trailing angle bolts. 8) Replace feed disc retaining clips and tap them down firmly against feed disc. 9) Tighten trailing angle bolts to 67.8 N•m (50ft-lbs). Caution! Do not overtighten bolts on cast wear parts. Cast parts are more brittle than mild steel. They can crack and break under too much stress from the bolt torque. If a large piece breaks and flies loose during operation, it can be dangerous.
21052 (3/97)
Page 6.8
Epp wear patterns
Trailing angle positions
Figure 6-17 Epp Wear Related to Trailing Angle Position
LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 6 Changing CastRotor Wear Parts Changing the Feed Eye
Change Top Retaining Plates
As feed eye wears out, wear paths occur in eye and adjacent wear liners. Regularly inspect feed eye to note progress of wear paths. To increase liner life, lift out feed eye and rotate it 90°.
Change top retaining plates if they are (Figure 6-19): • worn to 4 or 5 mm (3/16") thick, or 1/4 the original thickness of 19 mm (3/4"). • cracked or chipped
1) To remove feed eye, first remove lid assembly.
• worn to minimum dimension of 102 mm (4") shown in Figure 6-19. Note this dimension on new top wear plates is 108 mm (4-1/4")
2) Remove four socket-head screws and lift out feed eye (Figure 6-18). 3) To extend feed eye’s wear life, rotate it 90° so an unworn portion of eye lines up with each exit port. 4) Make sure feed eye is completely seated in rotor. 5) Replace four bolts and tighten to 81 N•m (60 ft-lbs). 6) After replacing lid assembly or hopper and feed tube, inspect rotor for clearance by turning the rotor by hand with lid on and access doors open. See Adjusting Feed Tube Height in Section 7.
Important: Do not allow top wear plates to wear so much that holes can be seen or studs in the rim liners. If you can see these holes or studs, you have let wear plates go too far. Replace immediately to avoid costly damage to VSI. How to Change Top Retaining Plates The top retainer plates help armor top side of rotor, but also help retain rim liners around upper rim (Figure 6-20).
Feed eye bolts
2) Lift old plates out. Replace plates in balanced sets around rotor. 102 mm (4")
Feed eye
Figure 6-19 Minimum Dimension for Wear of Top Retaining Plates
Figure 6-18 Worn Feed Eye and Bolts 21052 (3/97)
1) To change top wear plates, remove two sockethead bolts holding each plate in place.
Page 6.9
LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 6 Changing CastRotor Wear Parts 3) Be sure each part is fully seated. Replace bolts as needed. Do not reuse worn or damaged bolts. Apply a thread-locking agent, such a Loctite 242, to bolt threads. Tighten bolts t 136 N•m (100 ft-lb). How to Remove the CastRotor Changing many CastRotor wear parts requires that rotor be removed from the flywheel and set outside VSI. Working on upper liners inside rotor and on those on bottom of rotor requires rotor be turned upside down. The job can be done in mud and water, but is more likely to be done correctly in good conditions. A good idea is to prepare a clean, dry work area near VSI or prepare to move rotor to a work area with good conditions. 1) Remove lid and set it aside. 2) Dig rock material out from around feed disc. Also dig out feed eye.
6) Remove six bolts holding rotor to flywheel. 7) With all liners installed, 1800 model CastRotor weighs about 591 kgs (1300 lbs), 2100 model CastRotor weighs about 694 kgs (1526 lbs). Use appropriate lifting device to lift rotor and set it in a clean, dry work area. The following instructions on changing rotor wear parts all assume you have removed rotor from VSI. Changing Rim Liners The rim liners protect outer rim of rotor at both top and bottom edges (Figure 6-21). The same rim liners fit both upper and lower positions. Each rim liner fits over studs and is retained by one or more plates that are bolted in place. A metal shim fits between top retaining plates and upper rim liners. A rubber shim fits between lower set of rim liners and bottom retaining plate. The top retaining plates are not interchangeable with bottom retaining plate. The
3) Remove bolts holding feed eye and lift clear. 4) Dig out and remove three angle clips that hold feed disc. These clips keep the feed disc in place when rotor is running empty at start-up. 5) Pry up the edge of feed disc and lift out of rotor. Feed disc weighs about 45 kg (100 lbs).
B Change rim liner when B = 8 mm (5/16") or less
Figure 6-20 Changing Top Retaining Plates 21052 (3/97)
Figure 6-21 When to Change Rim Liners Page 6.10
LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 6 Changing CastRotor Wear Parts rim liners above and below exit ports are longer and fit over more studs than rim liners between exit ports. To change lower rim liners, turn rotor upside down. Usually, upper rim liners wear faster than lower. Change rim liners when dimension B is 8 mm (5/16") or less. Any time a rim liner is removed, look carefully at studs that rim liners fit over. Immediately replace any that are bent, loose, chipped, dented, or damaged in any way. 1) To change rim liners, remove the bolts holding retaining plates. 2) Carefully remove shim between retaining plates and rim liners. If replacing upper rim liners, shim is metal. Lift out and set aside. If replacing lower rim liners, shim is rubber. Peal off rubber shim without damaging it, if possible. 3) Examine studs for looseness and wear. If loose or worn, replace studs. See Installing Rotor Studs. 4) Replace liners in balanced sets around rotor. Be sure each rim liner is fully seated and that metal shim fits cleanly onto upper rim liners. Replace rubber shim on lower rim liners if the rubber is brittle or torn. Replace metal shim if it is worn, bent or broken. 5) Replace retaining plates and torque bolts to 136 N•m (100 ft-lb). Changing Side Plates Side plates can often be used until a hole is worn through. Wear near top or bottom of side plate is more common than wear in middle. 1) Remove top retaining plates.
Caution! Wear goggles and dust mask. Fine airborne abrasive particles can be hazardous. 5) Blow out all dust. Side plates can be turned upside down or have their order changed to increase wear life. If worn side plates are kept in service, position new ones behind epps, so new plates follow exit ports as rotor rotates. Always replace side plates in sets of three to maintain weight balancing. If changes are made to one segment, it must be done to all. Weight range among side plates must not vary more than 57 grams (2 oz.). 6) Replace side plates. 7) Before replacing rim liners or top retaining plates check alignment studs. Be sure they are sound. If not, replace them. See Installing Rotor Studs. 8) Replace rim liners. 9) Replace metal shim. 10) Replace top retaining plates and tighten bolts to 136 N•m (100 ft-lb). When to Change Bottom Retaining Plate Look through gap between lower rim liners and the flywheel guard liners (Figure 6-22). Note how usage and wear have caused lower edge of bottom retaining plate to recede. If bottom retaining plate appears to have been extensively worn, remove CastRotor from VSI and measure diameter of wear plate (Figure 623). If diameter is less than 762 mm (30"), change retaining plate. This can only be seen clearly with rotor removed and turned upside down.
2) Remove metal shim. 3) Remove upper rim liners. 4) Remove worn (or cracked) side plates.
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Page 6.11
LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 6 Changing CastRotor Wear Parts How to Change Bottom Retaining Plate 1) To change bottom retaining plate, turn rotor upside down (Figure 6-23). Remove bolts holding bottom retaining plates.
Gap Between Lower Rim Liners and Flywheel Guard Liners
2) Replace rubber shim if rubber is brittle or torn. 3) Replace plate (Figure 6-24). Bottom retaining plate
Flywheel Guard
Bottom Retaining Plate
Rubber shim
Figure 6-22 Gap Between Lower Rim Liners and Flywheel Guard Liners
762 mm (30") minimum
Rotor shown upside down. Figure 6-24 Replacing Bottom Retaining Plate
Rotor shown upside down. Figure 6-23 Measure Diameter of Bottom Retaining Plate
21052 (3/97)
4) Be sure rim liners and retaining plate are fully seated. Replace bolts as needed. Tighten to 136 N•m (100ft-lb).
Page 6.12
LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 6 Changing CastRotor Wear Parts Installing Rotor Studs CastRotor studs are not actually a wear part, but are included here because they are important in properly holding rim liners and side plates.
The fourth stud in each of these groupings is behind a portion of rotor weldment called “epp mounting plate” and is harder to see, but must be checked carefully (Figure 6-26).
The rotor requires 72 Grade 8 studs, p/n 02-382-7190000, 3/4 -10. 36 studs are at top of rotor; 36 are at bottom (Figure 6-25).
1
3
Stud
4
2
Rotor
1 1. Exit port rim liners 2. Epp 3. Fourth stud ends hidden 4. Visible stud ends
Grind flush any portion of stud that extends through the rotor. Figure 6-25 CastRotor Studs
Before mounting studs, check condition of both male and female threads. If female threads in rotor weldment are damaged, consult factory for proper repairs. Reject studs that are damaged and use only studs in good condition. Apply Loctite 271 or similar thread-locking agent. Tighten each stud to full extent of threads, but do not distort slotted head of stud.
Figure 6-26 Fourth Stud behind Epp Mounting Plate
After tightening fully, be sure that studs are flush with surface inside rotor weldment. Do not allow stud to project into epp area. If any studs project inside surface, from above or below epp, grind them flush before attempting to mount tip brackets.
Note that special attention must be paid to studs above and below three epps. At each epp (exit port protector), four studs are at top and four are at bottom. These eight studs must be checked closely after being tightened fully. Of these eight, three at top and three at bottom are fully visible from outside of rotor.
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Page 6.13
LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 6 Changing CastRotor Wear Parts
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Page 6.14
LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 7 - Changing Stationary Wear Parts, Belts, Bushings & Sheaves Maintaining condition of stationary (non-rotating) wear parts in VSI is just as important as with moving wear parts. From hopper, through feed tube, past flywheel guard plates and on through discharge openings, every surface that is impacted or abraded by rock material must be maintained and protected in order to keep whole machine functioning well.
torque values of recommended Grade 8 bolts may be so high as to crack or break cast part. Except where a torque value is specifically noted, always tighten wear part fasteners firmly to a “snug fit.” Except where noted in this manual, do not tighten bolts holding wear parts to full, standard, lubricated torque value.
This section also helps maintain other moving parts involved in driving VSI.
The Feed Tube
Notice Regarding Wear Parts Fasteners: Except where noted, most fasteners used to attach VSI wear parts use anti-seize lubricant on threads. Cast wear parts are very abrasion-resistant, but are more brittle than milder, softer steels. Standard
1. Tub liner 2. Anvil 3. Wedges 4. Lid liners 5. Lid 6. Hopper
The feed tube works same for both table/shoe and CastRotor options (Figure 7-2). It is made to adjust downward as wear occurs by removing adjusting rings until all rings have been removed. Feed tubes are installed at factory in pairs, one tube pointing down and one up. When one pointing down wears to
7. Feed tube 8. Ring shims 9. Rotor option 10. Table option 11. Flywheel guard 12. Upper tub assembly
6 7
8 4
5
9
3
10
2
11
12
1
Figure 7-1 Stationary Wear Parts 21052 (3/97)
Page 7.1
LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 7 - Changing Stationary Wear Parts, Belts, Bushings & Sheaves 8) Fit feed tube with ring shims at desired height into lid assembly. See Adjusting Feed Tube Height.
point that no further downward adjustment is possible, turn pair over so worn tube is on top and new one faces down. A new wear surface is then ready for use.
9) After you have adjusted tube to proper height, lift lid assembly and replace it. Bolt hopper back onto lid. Tighten locking wedges in opposite direction of throw device rotation.
Removing and Reinstalling Feed Tube 1) Unbolt feed hopper and attach appropriate lifting device (Figure 7-3). Also see Component Weights Chart. Note that component weights are stated without rock material in VSI. Actual weights can be heavier, depending on how much material is trapped on component. 2) Lift hopper clear. Feed tube remains in lid. Rock material usually jams feed tube tightly in place. Set hopper down on ground. 3) Knock lid-locking wedges free (Figure 7-4). 4) Attach appropriate lifting device (Figure 7-5). Lift lid with feed tubes still in place. Warning! Stand clear when swinging lid assembly free of VSI and to the side! 5) Set lid down with a heavy enough action to loosen feed tube. 6) With feed tube un-jammed from lid, re-remove feed tube.
Adjusting Feed Tube Height Warning! Lock out power source before opening access doors. Use a positive lockout system. The feed tube has four rings for height adjustment. Three are 13 mm (1/2") thick; one is 19 mm (3/4") thick (Figures 7-2 and 7-7 through 7-10). Select rings needed to match feed tube height you need and put them on ledge of lid. To adjust feed tube downwards, remove one or more rings. If removing all rings does not bring feed tube down within 13 mm (1/2") of feed eye or shoes, turn tube over to unused half and replace all rings. If both ends of tube are worn, replace it.
.
7) Clean out lid so seating surfaces of feed tube mate and tube can sit level in lid.
Figure 7-2 Feed Tube and Ring Shims 21052 (3/97)
Figure 7-3 Removing Hopper Page 7.2
LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 7 - Changing Stationary Wear Parts, Belts, Bushings & Sheaves
Figure 7-4 Remove Lid Wedges.
Figure 7-7 Feed Tube Too High Above Table
Figure 7-5
Adjusting Feed Tube with Open Table Figure 7-8 Feed Tube Just Right Above Open Table
1) Open access doors in lid to check tube height. 2) With an open table, measure from top of shoe to lowest point of feed tube. Keep this dimension at 13 mm (1/2") or less. The best position is when bottom of tube is flush with top of shoes. If you find more than 13 mm (1/ 2") gap, adjust feed tube down until gap is less than 13 mm (1/2") (Figures 7-7 and 7-8).
5) Close and secure the access doors. Adjusting Feed Tube with Closed Table
3) Keep feed tube centered over throw device. If feed tube is worn on one side or you see a wear pattern in shape of a scallop in tube, check to be sure tube is centered above throw device.
1) Open access doors in lid to check tube height. 2) With a closed table, measure from bottom of cover plate to lowest point of feed tube. Keep this dimension at 13 mm (1/2") or less. The best position for bottom of tube is flush with top of shoes. If you find more than 13 mm (1/2") gap, adjust feed tube down until the gap is less than 13 mm (1/2") (Figure 7-9).
4) Rotate throw device by hand to check clearance all around feed tube. 21052 (3/97)
Page 7.3
LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 7 - Changing Stationary Wear Parts, Belts, Bushings & Sheaves Adjusting Feed Tube with CastRotor 1) Open access doors in lid to check tube height. 2) With rotor, reach through exit port to feel lower edges of feed eye and feed tube (Figure 7-10). The feed tube must not be lower than feed eye. If feed tube is worn more than 13 mm (1/2") higher than feed eye, lower feed tube. 3) Keep feed tube centered over throw device. If feed tube is worn on one side or you see “scalloping” in tube, check to be sure tube is centered above throw device. 4) Rotate throw device by hand to check clearance all around feed tube.
Figure 7-9 Feed Tube Just Right Above Closed Table
5) Close and secure access doors. Removing the Lid Assembly Several checks can be done through access doors in lid assembly. For other procedures, entire lid assembly must be removed. It can be removed with feed hopper in place or remove hopper first. See Component Weights Chart. To remove lid assembly with hopper in place, chains or cables are needed that are about 3 meters (8 to 9 feet) long. Cedarapids recommends a three point lifting device to remove lid (Figure 7-11). Warning! Lock out the power source before removing the lid assembly. Use a positive lockout system.
Figure 7-10 Feed Tube Just Right Above Rotor
3) Keep feed tube centered over throw device. If feed tube is worn on one side or you see “scalloping” in tube, check to be sure tube is centered above throw device.
1) Remove locking pins from wedges. Drive wedges from wedge brackets. 2) Attach lifting device at three equally spaced points on lid (Figure 7-11).
4) Rotate throw device by hand to check clearance all around feed tube.
3) Lift lid high enough to clear wedge brackets and bottom of feed tube.
5) Close and secure the access doors.
4) Carefully swing lid away from crusher and place it on blocks on ground. Interior wear parts of the VSI are now accessible.
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Page 7.4
LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 7 - Changing Stationary Wear Parts, Belts, Bushings & Sheaves Monitoring the Anvil Ring A set of anvils generally shows greatest wear at a point not quite opposite end of feed conveyor. To even out wear and extend wear life of anvils, rotate anvil ring 180° halfway through anvil wear life. If anvil wear pattern is not centered vertically on anvil faces, adjust height of anvil ring as needed. Warning! Lock out power source before beginning maintenance! Change anvils when worn to within 6 mm (1/4") of back side. This is often about every 4 to 8 shoe changes. Wear pattern should be a cup shape, surrounded on 3 sides by face of anvil (Figure 7-12). Do not allow wear to break through far side of anvil face. Change if cracked.
Figure 7-11 Removing Lid Assembly
Types of Impact Surfaces The impact-resistant, stationary surfaces mounted around inner surface of upper tub also are available in two separate options. Anvils The anvil ring option contains a set of replaceable, white iron, high-chromium alloy castings, called anvils or anvil blocks. These fit into holding brackets around inside of upper tub. With proper lifting equipment anvil ring can be lifted as a unit out of VSI and tipped upside down for quick change of anvils. Rock Shelf
To change anvils:
The rock shelf option is a simple, reinforced steel ring mounted inside upper tub where rock accumulates. After shelf area of ring fills with first few hundred pounds or kilograms of rock through crusher, following rock flung by rotary action hits accumulated rock mass held on shelf area, creating a rock-on-rock crushing effect.
21052 (3/97)
Figure 7-12 Worn Anvil
1) Remove bolts holding hopper. 2) Remove hopper from lid and place on ground using appropriate cables or changing. Note: If cables are 3 meters (8-9 ft), you don't need to remove feed hopper before lifting lid.
Page 7.5
3) Remove wedges from lid wedge brackets by driving out with a hammer. LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 7 - Changing Stationary Wear Parts, Belts, Bushings & Sheaves 4) Attach cables or chains with lifting hooks though holes in lid gussets at three points. 5) Raise lid high enough to clear wedge brackets and feed tub. 6) Swing lid away from crusher and place on ground. 7) Remove wedges from upper tub wedge brackets by driving out with a hammer. 8) Attach lifting hooks at three points through wedge brackets on upper tub. 9) Raise upper tub high enough to clear wedge brackets.
Figure 7-13 Place Anvils in Brackets
10) Swing upper tub away from crusher. 11) Tip upper tub assembly upside down on ground. Caution! Wear eye protection! 12) Tap anvils lightly with hammer until anvils fall to ground. 13) Turn upper tub with empty anvil ring right side up on ground. 14) Place anvils into anvil brackets. Place the narrow end of dovetail on back of anvil toward bottom (Figure 7-13). Note: Keeping a spare ring with anvils in stock can make for quick changes, keeping downtime to a minimum (Figure 7-14). Anvil ring removed from crusher can be refitted with anvils in shop while crusher continues to run.
Figure 7-14 Spare or Replacement Anvil Ring
15) Set upper tub in place with slots over wedge brackets. Lower into position. Upper tub must be kept level to avoid hanging up on wedge brackets. 16) Drive in wedges securely (Figure 7-15). Install locking pins. Warning! Drive wedges in clockwise direction to prevent loosening. 21052 (3/97)
Page 7.6
Figure 7-15 Drive Wedges Clockwise
LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 7 - Changing Stationary Wear Parts, Belts, Bushings & Sheaves Replacing Lid Liners Warning! Stand Clear! Lid assembly can drop quickly when turning upside-down! To remove liners: 1) Remove the hopper and then lid. See Removing and Reinstalling the Feed Tube. 2) Swing lid away from crusher and place on blocks on ground to prevent damage to feed tube. 3) Remove lid liner bolts. 4) Drive bolts through with drive punch. 5) Allow old liners to fall to ground. To install new liners: 1) Turn lid upside down and place on support stands strong enough to support weight of lid assembly (Figure 7-16). 2) Set new liners in place (Figure 7-17). Begin with liners furthest from inspection doors, crowding liners at first to give extra space for manipulating liners near doors.
Figure 7-16
1
2
3
Note: Different manufacturers of lid liners put the mounting bolts in different places and you may not be able to mix brands within a concentric ring of liners (inner ring, middle ring, and outer ring). Fit up all liners before tightening bolts. 3) On inspection doors a 13 mm (1/2") spacer is required between door and liner. 4) Install new bolts. Do not tighten bolts until all liners are in place to permit small adjustment of liners. 5) Tighten bolts. Snug only- do not overtighten. 6) Turn lid right side up. 7) Reinstall lid and hopper.
21052 (3/97)
4 1. Outer ring liner 2. Middle ring liner 3. Inner ring liner 4. Door spacer- 13 mm (1/2") thick Figure 7-17 Replacing Lid Liners
Page 7.7
LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 7 - Changing Stationary Wear Parts, Belts, Bushings & Sheaves Replacing Tub Liner
Replacing Flywheel Guard Wear Plates
When to change: Change before worn through, or if cracked. If tub liner wears completely through, deformation of broken-out area may make liner difficult to remove. If tub liner is worn only on one side, it can be rotated 180° to even out wear. If tub liner is worn only on top, it can be inverted.
Warning! Lock out the power source before beginning maintenance! Change flywheel guard wear plates before worn through, or if cracked. Wear plates do not need to be changed as a set. 1) See Section 5 for steps in removing table from flywheel or Section 6 on removing CastRotor.
To remove tub liner:
2) Remove two bolts from each liner.
1) Remove lid, anvil ring, and upper tub assembly. See Monitoring the Anvil Ring.
3) Set replacement liner in place.
2) Remove channel rubber from top edge of tub. Remove silicone sealant between tub and tub liner.
5) Install two bolts in each liner. Tighten bolts to 81 N•m (60 ft-lbs).
3) Attach appropriate cables or chains with lifting hooks to three lifting eyes on tub liner. If lifting eyes are worn off or unusable, replace with new ones. Caution! Welds to AR plate are brittle. Use caution when lifting liner. 4) Raise high enough to clear tub wedge brackets. Swing liner clear of crusher and set on ground. To install new liner: 1) Attach cables or chains with lifting hooks to 3 lifting eyes on new tub liner. 2) Lift liner, position over tub, and set in place. 3) Fill any large gaps (greater than 6 mm (1/4")) between tub and liner with pieces of polyurethane foam or similar material. Seal all around space between tub and liner with silicone caulking. Caulking prevents dust from building up in space between tub and liner. Liner can be installed without it, but will may become cemented in place by packed dust.
4) Apply anti-seize lubricant to bolts.
V-Belts Danger! Stand clear of running belt drive. Warning! Shut down and lock out the power source before beginning maintenance! Attention: Sometimes, at customer request, a VSI is shipped without certain features, such as drive sheave. When this happens, Cedarapids/ElJay attaches a warning tag to alert installers that belt guard, an important safety feature that must be fitted to sheave size, is missing. In such cases it is customer’s responsibility to properly guard machine while it is running. Installing New Belts Important: Do not use belt dressing of any kind. Do not pry belts. Always use a matched set of belts. Never mix belts from different manufacturers, worn and new belts, or belts of the same manufacturer that are from different lots.
4) Set upper tub in place, drive in wedges, install pins. Set lid in place, drive in wedges, install pins.
21052 (3/97)
Page 7.8
1) Check sheaves carefully for worn grooves or other damage. Worn grooves can shorten belt life by as much as 50%. See Sheaves and Bushings, next page.
LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 7 - Changing Stationary Wear Parts, Belts, Bushings & Sheaves 2) Remove all grease, rust and dirt from grooves in sheaves.
1
2
3
3) Be sure sheaves are aligned and shafts are parallel. See Sheaves and Bushings. 4) If belts do not slip easily onto sheaves, shorten distance between sheaves (center distance or span) until they go on easily. Do not pry belts onto sheaves. 1. Belt touches bottom of sheave 2. Worn belt or sheave 3. Proper fit
5) Place belts on sheaves. 6) With belts still loose, rotate the drive so all slack is on one side.
Figure 7-18 Belt Fit
7) Tighten belts with threaded adjustments at motor mount. General guidelines for getting and maintaining proper belt tension:
Warning! Standard iron sheave rim speed must not exceed 1981 meters per minute (6500 feet per minute, fpm). Standard iron sheaves can explode when run at excessive speeds! If rim speed exceeds 1981 meters per minute (6500 fpm), ductile iron or steel sheaves are required.
• The best tension is lowest at which the belts will not slip under highest load. Too much tension shortens belt and bearing life! • Check tension often in first day operating with new belts • Check belt tension on a regular schedule • Keep belts and sheaves free of material that may cause slippage (oils, grease, silicone, etc.)
Removing Sheaves and Bushings 1) Loosen and remove three hub bolts from sheave.
• If a V-belt slips, tighten it!
2) Insert the three bolts in threaded jackscrew holes in sheave hub.
8) New belts stretch after installation. Check tension periodically and readjust as necessary.
3) Start with bolt farthest from busing saw slot. Tighten all jack screw bolts in small equal amounts, progressing around the circle, until tapered hub and sheave disengage.
Sheaves and Bushings Check sheaves carefully for worn grooves or other damage. Worn grooves can shorten belt life by as much as 50% (Figure 7-18). Caution! To check by feel, protect fingers from cuts by using gloves or a rag. Replace sheave if grooves are dished out.
Important: Sheaves are cast iron and fragile. Excessive or unequal pressure on jack screws can break bushing flange, making removal difficult without destroying sheave. Use care when handling.
To check by gauge, use sheave groove gauge. Replace sheave if sidewall wear exceeds 0,635 mm (0.025").
21052 (3/97)
Page 7.9
4) Remove sheave and bushing. If bushing does not slip off shaft, wedge screwdriver in saw cut to loosen, being careful not to damage shaft or bushings.
LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 7 - Changing Stationary Wear Parts, Belts, Bushings & Sheaves Installing Sheaves and Bushings 1) Consult dealer when using sheaves other than those listed in Section 10. 2) Make sure tapered outer surface of bushing and bore of sheave are clean. 3) Place key on shaft. Slide bushing into place with flange toward crusher. 4) Line up unthreaded holes in sheave with threaded holes in bushing. Position threaded jack screw holes as far from busing saw slot as possible to lessen chance of bushing breakage at next removal. 5) Insert bolts and lock washers through sheave into busing, engaging only two or three threads. Notice: Sheave manufacturers do not recommend use of anti-seize bolt lubricant on bolts or mating surfaces. It can cause sheave breakage.
8) Tighten set screw in bushing flange to hold key securely during operation. 9) Check to see that drive and driven shafts are parallel. Check by measuring distance between shafts at three or more points. If distances are equal, shafts are parallel. 10) Check alignment between the two sheaves. Check Alignment • by placing straight edge across face of both sheaves. Sheaves are aligned if straight edge touches sheaves at two points on each sheave • Or by tying a piece of string to one shaft, then stretching it across the faces of both sheaves. Check alignment at minimum of two positions: across tops of sheaves and across bottoms of sheaves. Rotate sheaves 90° and check again. Adjust alignment if needed.
6) Position sheave and bushing assembly for good belt alignment. 7) Carefully tighten bolts in small equal amounts, progressing around the circle just until the tapers are seated. Torque bolts to 136 N•m (100 ft-lb) dry. This normally leaves a gap between bushing flange and sheave. Notice: Overtightening can cause sheave and/or bushing breakage.
21052 (3/97)
Page 7.10
LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 8 Lubrication Lubricant Oil Specifications VSIs run at high rpm to effectively crush rock. They are sensitive to oil temperature changes near upper end of oil performance range. Take frequent oil samples and base an oil and filter change schedule on data from those samples. This is most reliable way to assure long bearing, shaft, and/or gear life for a VSI. This practice is efficient and cost effective over time and can greatly extend life of VSI.
Above 66°C (150°F) ISO 68 thins out below minimum viscosity of 100 SUS. At this point replace it with heavier oil. However, even lighter weight oils may require heaters for cold weather start-up. Before starting the crusher in cold climates, be sure the oil in the sump and external lines is fluid. The oils shown can be used as long as specifications are met (Figure 8-2).
VSIs are filled with ISO 150 oil at factory when tested. This oil protects gears and bearings to a maximum operating temperature of 115.5°C (240°F). This oil minimizes cold weather start-up problems and still supplies adequate viscosity for bearing lubrication. Use only extreme pressure (EP) rated oils. Oil Properties (at Operating Temperatures) Minimum Viscosity (Saybolt Universal Seconds) Centistrokes
100 SUS
55 lb
Minimum Viscosity Index
90
Amoco
Amogear EP 150
Chevron
Ultra Gear ISO 150
Exxon
Spartan EP 150
Gulf
Gulf EP HD 150
Mobil
Mobilgear 629
Shell
Omala 150
Texaco
Meropa 150
Switching to Other Oil Grades Notice: Maximum allowable oil temperature under any condition is 116°C (240°F) at gauge!
Figure 8-1
Notice: Using a lubricant that does not meet these specifications voids warranty. Cedarapids has found, for conditions above -18°C (0°F) with no wind chill, internal bearing temperature is independent of outside (ambient) temperature and can reach 82°C (180°F) in any size VSI (Figure 8-1). In cold weather operation with ISO 150 grade oil an oil heater may be needed to keep oil fluid and prevent damage to lubrication pump. Continuous operation in very cold temperatures may allow use of lighter oils. For example, ISO 68 oil may be used to maintain lubricant liquidity in climates where temperatures are commonly well below freezing, as long as oil temperature does not exceed 66°C (150°F).
21052 (3/97)
Brand Name/Grade
Figure 8-2 Acceptable Lubricants
20.58
Minimum Timken OK Load
Oil Company
If oil temperature reading for crusher exceeds 104°C (220°F) with ISO 150 grade oil, Cedarapids recommends installation of ISO 220 or equivalent. This does not make crusher run any cooler, but oil is able to maintain an adequate oil film thickness at higher operating temperatures. If VSI is run at 80-100% of maximum recommended speed, changing to a heavier oil is likely to raise operating oil temperature. Oil Analysis: When to Change Oil Cedarapids/ElJay recommends that oil be periodically sampled and analyzed in a qualified lab. The data from a proper analysis indicate:
Page 8.1
• condition of oil • what contaminants are in oil • when it should be changed LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 8 Lubrication VSIs built in 1989 and after have an oil sampling valve fitted conveniently near filter. Usually, oil should be changed every 1000 operating hours. You may get longer service from your oil. The best indicator of oil condition is Total Acid Number, the TAN. It is a measurement of how much the oil has degraded. The TAN rises as oil degrades. Generally, a 100% increase in TAN indicates that you should change lubricating oil. As TAN continues to increase, oil carries more contaminants and viscosity increases, decreasing lubricant effectiveness.
Keep a record of lab reports to develop a history of oil consumption, metal concentrations and other useful data for preventative maintenance. If oil sample analysis is not available, or if no machine history data exists on which to schedule preventive maintenance, use following schedule for oil changes.
A good lab analysis shows concentrations of wear metal elements in parts-per-million. Typical concentrations and limits are shown (Figure 8-3).
Notice: Dirty oil can damage bearings.
1) Change oil after first 500 hours of operation, then every 1000 hours or every 6 months. In very dirty conditions, change the oil more often. See oil sampling program recommended in Taking Oil Samples. 2) Change oil at end of shift when oil is warm. 3) Change oil filter element at same time as the oil change. Do not run clean oil through a dirty filter.
Aluminum
Typical Concentration 0-10
Copper
0-15
50
Taking Oil Samples
Nickel
0-5
10
Chrome
0-5
10
Lead
0-20
50
The oil sampling valve allows you to take oil samples for lab testing while still crushing (Figures 8-4 and 8-5).
Iron
30-50
150
Silicon (dirt)
10-30
75
Wear Metal
Upper Limit –
1) Unscrew the protective cap. 2) Lightly push on the sampler needle assembly. Allow a small amount of oil to escape into a spare container to avoid possible contamination from dirt near the sampling valve.
Figure 8-3 Metal Concentration Upper Limits
A good oil sample report shows a viscosity number, expressed in centistokes, Saybolt Universal Seconds, or Minimum Viscosity Index.
3) Holding the open tube end in a sampling bottle, fill the sample bottle and cap it tightly.
If you are using an oil with a rating of 140 SUS at 40°C (104°F) for SAE 80W-90 when it is clean and fresh, a report might show 168 SUS at 40°C (104°F) for SAE 80W-90. 168 SUS is an increase of 20% in the oil’s base viscosity level at same temperature and SAE rating. In this case, report tells you it is time to change oil. To protect your VSI from damage caused by inadequate lubrication is to continue taking periodic oil samples, sending them for analysis, and depending on that analysis to assess effectiveness of your oil. 21052 (3/97)
Page 8.2
Figure 8-4 Oil Sampling Valve LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 8 Lubrication 4) Replace the protective cap.
1
5) Label oil sample. Write date, machine ID number, oil type, number of hours run, and other useful data on label. Make a copy to keep with your records. Send sample and data to your analysis lab.
2 3
Checking Oil Level with Dipstick
1. Oil sampling valve 2. Indicator 3. Housing 4. Cannister 5. Nut
To be sure your VSI has enough oil, check dipstick every day. See Figures 8-6 through 8-9 for the dipstick location on your machine. 1) Clean top of oil filler cap (which is welded to dipstick) and clean surrounding area before unscrewing cap. 2) Unscrew dipstick/oil filler cap and remove it. Look at oil on stick. Note oil characteristics. If oil is too thick to drip, it can damage oil pump and not properly lubricate bearings.
5
Figure 8-5 Oil Filter
Change filter element: • After first 500 hours of operation, then every 1000 hours or every 6 months. Samples may indicate need for more frequent filter changes
3) Wipe dipstick on a clean cloth.
• At each oil change
4) Place dipstick/oil cap on top of filler pipe (without threading it down).
• When oil flow is slowed by blockage of filter. Change element when indicator shows a change is needed
5) Lift dipstick a second time and read oil level. 6) Add clean oil as needed and replace dipstick/ oil filler cap tightly.
• When samples show a particulate count that is too high
How to Change Oil and Filter Element To ensure only clean oil flows over bearings, each VSI is equipped with an external oil filter (Figure 85). The filter is designed to have high dirt-holding capacity and to filter harmful particles out of lubricating oil.
4
Notice: Use of filter element with particle removal rating coarser than 25 microns absolute voids warranty. 1) Before draining oil, make sure it is warmed to operating temperature. 2) Take an oil sample from sampling valve.
The filter has a replaceable element. It is important to use proper replacement element in filter. An element that is too fine plugs quickly and one that is too coarse allows too many particles to pass.
3) Remove drain plug(s). Each model has a different configuration and location of oil drain plugs. All plugs are magnetic with 25.4 mm (1'') square heads.
Check filter element indicator every shift.
1800 GD: Two oil drain plugs, both on drive-shaft face of base below drive sheave. Removing upper plug drains outer tank and removing lower plug drains inner tank (Figure 8-6). 21052 (3/97)
Page 8.3
LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 8 Lubrication 1. From external oil system 2. Dipstick (not shown) 3. In-line oil filter 4. Pinion bearing spray nozzle 5. Suction strainer 6. To external oil system 7. Outer tank drain plug 8. Inner tank drain plug
1 2 3
4
5
6
8
7
Figure 8-6 Oil Flow Pattern 1800 VSI-GD
1. Dipstick 2. From external oil system 3. Oil level 4. Oil tank 5. Drain Plug 6. To external oil system
1
2
3 4
6
5 Figure 8-7 Lubrication Flow Pattern 1800 VSI-VBD
21052 (3/97)
Page 8.4
LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 8 Lubrication
2 1
1. From external oil system 2. Pinion bearing spray nozzle 3. Dipstick 4. Lower tank drain plug 5. To external oil system 6. Belly pan access cover 7. Inner tank drain plug
3
4 7
6 5 Figure 8-8 Oil Flow Pattern 2100 VSI-GD
1. From external oil system 2. To external oil system 3. Dipstick 4. Cover plate 5. Oil drain Plug
3
1 2
5
4
Figure 8-9 Lubrication Flow Pattern 2100 VSI-VBD
21052 (3/97)
Page 8.5
LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 8 Lubrication 1800 VBD: Plug in bottom of oil tank (Figure 8-7).
Lubricating Oil Capacities
2100 GD: Two plugs. Remove belly pan access cover (14 bolts). Remove plug from inner tank. Remove lower tank plug (Figure 8-8).
Notice: Oil capacities shown in accompanying chart are guidelines only, based on averages. Actual capacity of VSI may differ from that stated in chart.
2100 VBD: One plug. Remove cover plate from lower (secondary) motor mount. Slide a collecting bucket up between belts. Remove plug from bottom of oil tank (Figure 8-9). 4) Drain oil from reservoir(s). Replace drain plugs. 5) Remove filter cannister with an open end, box, or socket wrench. Filter housing remains fixed.
Crusher Model
Liters
U.S. Gallons
1800 GD
45
12
1800 VBD
26
7
2100 GD
49
13
2100 VBD
28
7.5
Figure 8-10 Approximate Lubricating Oil Capacities
6) Take out white indicator ring and set aside. 7) Drain old oil from cannister and remove element. Dispose properly.
15) Check dipstick to be sure of correct oil level before restarting VSI.
8) Clean cannister.
Notice: Take precautions to prevent water from getting in oil. Store oil barrels where rain and condensation cannot get in.
9) Replace seal that fits inside lip of filter housing. 10) Install a new element.
Oil Flow Monitoring System
11) Replace indicator ring.
Oil flow monitoring system includes:
12) Fill cannister with new, approved lubricant.
• a flow meter
13) Reinstall cannister.
• a flow switch
14) See Lubricating Oil Capacities, Figure 8-10. Add clean oil, about half volume required for total system, through oil filler pipe. Start pump to fill oil sump (gearbox on gear-driven VSIs) and circulate oil through system. Add remaining half of total required oil while pump continues to run. Important: Protect the filter housing from contamination. Dirt particles in oil can damage bearings.
• a warning horn If a breakdown in oil flow occurs, flow monitoring system can alert operator that a malfunction needs to be corrected. It is recommended to have flow monitor switch shut down feed to crusher if oil flow is interrupted (Figure 8-11). Notice: Continued operation of crusher with insufficient oil flow severely damages bearings. Use flow monitoring system to prevent costly repairs and downtime resulting from insufficient oil flow. Failure to properly interlock flow monitoring system to protect crusher voids warranty! Figures 8-6, 8-7, 8-8, and 8-9 show the internal oil flow in the various VSI models.
21052 (3/97)
Page 8.6
LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 8 Lubrication Expected Oil Flow Rates 1
2
3
4
Flow in liters per minute (lpm) and U.S. gallons per minute (gpm). Model
Cold
Warm
liters/min
4.7 to 5.7
2.8 to 3.3
Gallons/min
1.25 to 1.5
.75 to .875
liters/min
2.8 to 3.8
1.4 to 1.9
Gallons/min
.75 to 1
.625 to .5
liters/min
5.7 to 6.6
3.3 to 4.3
Gallons/min
1.5 to 1.75
.875 to 1.125
liters/min
4.7 to 5.7
2.8 to 3.3
Gallons/min
1.25 to 1.5
.75 to .875
1800 VSI-GD
5 1800 VSI-VBD
2100 VSI-GD
2100 VSI-VBD
Figure 8-12 Oil Flow Rates
8
For other lubrication questions, call your Cedarapids/ ElJay Distributor, or call Cedarapids at (319) 3633511 for location of your nearest distributor.
6
1. Warning horn 2. Temperature gauge 3. Oil sampling valve 4. Filter 5. To crusher 6. From crusher 7. Pump 8. Flow meter/switch
7
Figure 8-11 External Oil Flow
Flow Meter/Switch Settings Flow meters are set at factory to activate warning horn when oil flow rate descends to: • 1.9 liters per minute (0.50 U.S. gpm) on models 1800 GD and 2100 VBD • 1.4 liters per minute (0.375 U.S. gpm) on model 1800 VBD • 2.8 liters per minute (0.75 U.S. gpm) on model 2100 GD 21052 (3/97)
Page 8.7
LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 8 Lubrication
21052 (3/97)
Page 8.8
LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 9 Electrical System The electrical system for all VSI models includes an electric oil pump, a flow switch activated by flow meter and electrically connected to a warning horn, a vibration switch, transformer, and a thermostatically controlled oil heater. Wiring for each of these electrical components is routed to a junction box (sometimes called the j-box). See appropriate, suggested wiring diagram for your operating voltage, Figures 9-3 or 9-4. The oil pump circulates oil from the sump through the filtering system and to the bearings.
Oil Pump The electric oil pump of VSI is its only source of lubrication. The VSI has no mechanical oil pump, so it is very important that electric pump be wellmaintained and always in working condition. The 1800 and 2100 VSI pumps have different sized outlet ports. The 1800 model has a 9.5 mm (0.375") port with an output of 1.9 lpm (0.5 U.S. gpm). The 2100 model has a 12.7 mm (0.5") port with an output of 2.84 lpm (0.75 U.S. gpm). Flow Switch and Warning Horn
The flow switch protects crusher bearings by sounding warning horn, cutting off power to crusher and feed conveyor at any time oil flow rate drops below preset value.
Cedarapids recommends that flow switch also be wired to feed source, so that if bearing lubrication is inadequate, load is immediately taken off bearings. See suggested wiring diagram.
The warning horn sounds to alert operators that oil flow to bearings has become too low.
The switch point (oil flow rate at which an internal cam in flow meter throws a switch, activating warning horn and cutting off power to crusher and feed conveyor) is preset at factory.
The vibration switch protects crusher and nearby people by shutting down power to crusher whenever too much vibration occurs. The transformer converts incoming voltage to appropriate levels for electrical components.
Note: Attempting to reset switch point voids warranty. Switch point settings for 60Hz systems:
The thermostatically controlled heater warms oil in sump to help assure proper oil flow to bearings.
lpm = liters per minute, gpm= U.S. gallons per minute.
Junction Box (J-Box)
1800 GD is set at 1.9 lpm (0.5 gpm).
Inside each junction box Cedarapids attaches a wiring schematic to help users set up and maintain proper wiring for their VSI (Figures 9-3 or 9-4).
1800 VBD is set at 1.1 lpm (0.3 gpm) 2100 GD model is set at 2.8 lpm (0.75 gpm) 2100 VBD model is set at 1.9 lpm (0.5 gpm)
List of components terminating in J-box:
Switch point settings for 50Hz systems:
• Oil pump
1800 GD is set at 1.5 lpm (0.4 gpm).
• Flow switch
1800 VBD is set at 0.83 lpm (0.22 gpm)
• Warning horn
2100 GD model is set at 2.3 lpm (0.6 gpm)
• Vibration switch
2100 VBD model is set at 1.5 lpm (0.4 gpm)
• Transformer • Heater and thermostat An electrical outlet is located at J-box, wired at factory to match voltage requirements of region. 21052 (3/97)
Page 9.1
LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 9 Electrical System Automatic Shutdown If oil flow rate is too low, warning horn sounds and crusher shuts down. If this happens, find out why oil flow was too low before restarting VSI. If vibration detection switch trips, crusher drive shuts down, but warning horn does not sound. Momentum continues to keep flywheel rotating for awhile. After flywheel and throw device stop rotating, find out why vibration detection switch tripped. To restart crusher, turn oil pump off, then back on. This resets vibration switch.
Figure 9-1 Vibration Switch
Vibration Switch The factory normally ships VSI with 220 or 120 volt 50/60 Hertz (Hz) circuitry with vibration switch set at 4.5 (4.5) gravities. Other voltage packages must be stated at time machine is ordered. A transformer is supplied for vibration switch to step voltage down from 220 to 120 volts. Start Delay When you first start VSI after power has been shut off, a 30 second delay circuit prevents vibration switch from reacting to any vibrations during that period. Monitor Delay and Simple Test After 30 seconds of operation monitor circuit is activated. It also has a delay of 5 seconds. This is to prevent unnecessary shutdowns for brief, intermittent, mild vibrations, but allows quick shutdown for any violent or long-duration vibrations. A simple test of monitor-delay circuit is to hit base frame mounting bolt with a 1 kg (2 lb) hammer. Then listen for vibration switch to trip first relay. If system is working correctly, the physical/electrical contacts open, starting timer. After 5 seconds you can hear them close. If you hit mounting bolt continually to make vibration last longer than 5 seconds, VSI should shut down.
21052 (3/97)
The difference between a shutdown caused by oil flow switch and one caused by vibration detection switch is whether or not warning horn sounds. Start-up Controls A properly wired VSI assures that drive cannot be started unless oil pump is running and proper amount of oil is flowing through pump. The horn sounds momentarily (1-2 seconds) then turns off when first starting oil pump. This assures that horn and flow meter/switch are working properly. Always be sure oil pump starts before drive shaft turns. Wiring for Heater and Thermostat 1800 models have a cast heater with radiating vanes. 2100 models have a tube-type heater. Both have built-in thermostats. Wiring for Optional Pre-wired Panel An optional pre-wired electrical panel is available containing circuit breaker, fuses, step-down transformers, relays, timers, lube pump start/stop switches, and indicator lights for lube pump and heater.
Page 9.2
LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 9 Electrical System
L1 L2
L3 Main Breaker 70 A
Circuit Breaker 20 A 5 KVA Transformer X1
40 A
M1
480 V X2
F4
F2
F3
20 A
7A
20 A
F1
120 V 60Hz
20
120 V Outlet 20 X2 (12 Ga) R2
6
14
(12 Ga)
14
14
Red
14
M2
Lube Pump 1 HP 120 V
M1 15 HP U/C Conveyor
X2
R2 Green Flow Switch 18 N.O. 21
18
22 F5 (Fast) KTK 1.5 A
21
R2
22
V.S.
23
X2
23
CR1
X2
Sup
18
Flow Switch N.C.
R4
15
(12 GA)
16
X2
16
16
R4
16
T¡
1
1
Horn
19
19
1
1
0X
5
0X
4
4
U/C Conveyor
Crusher junction box terminations.
R4
R2
Vibraswitch Power Supply
V.S.
Items in gray boxes are standard equipment on VSIs.
X2
Start
Stop 1
X2
Amber 17
17
Lube Pump
Heater 600 W
51
50
O.L.
Items shown as black lines are supplied on plants ordered with the electrical package.
M1
M1
EQUIPMENT FEEDING VSI CRUSHER
1
Feed Stop
CR1 1
26
Feed Start
Items shown as dotted lines are not supplied by Cedarapids.
O.L.
26
Feed Feed
ELECTRIC DRIVE
1
Crusher Stop
CR1 1
27
1.5 mm2 (16 gauge) wire used except where noted.
Crusher Start O.L.
27
C C
X1
X2
Figure 9-2 VSI Electrical Schematic - 120 Volt (For Units without Optional Lid-Lifter) 21052 (3/97)
Page 9.3
LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 9 Electrical System 120 Volt Circuit Operation
Heater Fuse Chart
The lube pump switch energizes Relay R2 and vibraswitch power supply (VS). Relay R2 contacts energize lube pump motor’s starter (M2) and flow switch circuit. The horn blows momentarily until Normally Closed (N.C.) flow switch contact opens. The Normally Open (N.O.) flow switch contacts close, energizing CR1. When CR1 is energized, you can start electric drive (or engage PTO of a running diesel) and start feed equipment.
The G-force of vibration switch is preset. Continuous G-forces greater than this setting for more than five (5) seconds opens vibration switch’s Normally Closed contact (VS), de-energizing CR1, This stops crusher drive (diesel or electric) and equipment feeding VSI, It does not sound warning horn. Reset vibration switch by momentarily interrupting power to lube pump or by installing a reset button on Vibraswitch terminal strip locations #3 and #4.
2000 W
F2
10 amp
20 amp
14
4 25
17
16 27
26
19
18 X2
X2
21
20 X2
X2
23
22
24
GND GND
GND GND
120 V VSI Crusher J-Box Terminal Strips 120 V
X2
1
2
3
120 V
4
22
23
5
6
Reset
Vibraswitch Terminal Strip
Cummins Clutch Limit Diesel Battery Supply From Fuel Solenoid
+24 VDC
To Fuel Solenoid
CR1 24
24
25
25 LS1
24
24
25
25
Clutch Limit Opens Circuit When Clutch is Engaged
Caterpiller Clutch Limit Diesel Battery Supply From Fuel Solenoid
The clutch limit switch, LS1, lets you warm up diesel without VSI lube pump running. It stops diesel if Power Take Off (PTO) is engaged without oil flow and/or if vibration switch is tripped.
21052 (3/97)
600 W
1
In case of loss of oil flow when using an electric drive, flow switch’s Normally Open contacts open, de-energizing CR1. This stops drive motor and the equipment feeding crusher. The Normally Closed flow switch contacts also close, sounding horn to alert operator. In case of loss of oil flow when using a diesel drive, flow switch’s Normally Open contacts open, deenergizing CR1. This shuts off diesel fuel solenoid, stopping diesel engine and equipment feeding crusher. The Normally Closed flow switch contacts also close, sounding horn to alert operator.
Fuse
Page 9.4
+24 VDC
24
24
To Fuel Solenoid LS1
28
CR1
25
25
Clutch Limit Closes Circuit When Clutch is Engaged
LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 9 Electrical System L1 L2
L3 Main Breaker 70 A
40 A
15 A
380/416 V 50 Hz
5 KVA Transformer
M1
M2
220 V 50-60 Hz X2
X1
20
20 (12 Ga)
M1
M2
15 HP U/C Conveyor
1 HP Lube Pump
4
4
Amber
T2 T3
F6 5A
F5
F4 15 A
F3
F2
5A
15 A
F1
T1
220 V Outlet
3
R4 15
(12 Ga)
16
Heater
16
3
R4 1
1
T¡
1
17
17
2
R4
50 VA Transformer 220 V 50-60 Hz 1
2 X1A
120 V 50-60 Hz
0.5 A On Transformer
2
X2A
X2A
Vibraswitch Power Supply 22 X2A V.S.
Green X1A
X2A
23
Lube Pump
0X
V.S.
22
22
23
X2A
CR1 Sup
Crusher junction box terminations.
Red Lube Pump
1
0X
M2
U/C Conveyor
51
50
Items shown in gray boxes are standard equipment on VSI crushers.
Lube Pump- 3 Phase
Start
Stop 1
O.L.
14
O.L. M1
M1 EQUIPMENT FEEDING VSI CRUSHER
1
Start
Stop
CR1
1
C
26
26
Items shown as black lines are supplied on plants ordered with the electrical package.
O.L.
CR2 Feed
Crusher Starter Interlock
Feed Electric Drive
Diesel Drive ELECTRIC DRIVE
M2 18
Flow Switch N.O. 18
21
21
Stop
CR1 27
O.L.
27
Aux
C C
Flow Switch N.C.
Items shown as dotted lines are not supplied by Cedarapids.
Start
Crusher Motor Horn
19
19
2
2
1.5 mm2 (16 gauge) wire used except where noted.
Figure 9-4 VSI Electrical Schematic - 220 Volt (For Unit Without Optional Lid-Lifter) 21052 (3/97)
Page 9.5
LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 9 Electrical System 220 Volt Circuit Operation For both electric and diesel drives, lube pump switch energizes Vibraswitch power supply (VS), CR1 and lube pump motor starter M2.
The clutch limit switch, LS1, warms up the diesel without VSI lube pump running. It stops diesel if Power Take Off (PTO) is engaged without oil flow and/or if vibration switch is tripped. Heater Fuse Chart
Contact C is optional as shipped from factory. Cedarapids recommends installing Contact C as appropriate to prevent feeding any rock to VSI if loss of oil flow or overload conditions occur. For VSIs with diesel drive use CR2 contacts to stop feed.
Fuse
600 W
2000 W
F2
5 amp
10 amp
F5
5 amp
10 amp
3
For VSIs with electric drive, horn blows momentarily until Normally Closed (N.C.) flow switch contact opens. If CR1 contacts are closed, Normally Open (N.O.) flow switch contacts close, enabling (usersupplied) Relay C and Contact C to start electric drive and feed equipment. If vibration switch is tripped, CR1 does not close.
X1A
X2A
X2A
For VSIs with diesel drive, oil flow switch operates same as with electric drive except that CR1 contact energizes CR2 relay, which controls operation of diesel’s fuel solenoid. In a loss of oil flow condition with an electric drive, flow switch’s Normally Open contacts open, deenergizing (user-supplied) Relay C. This stops drive motor. The flow switch’s Normally Closed contacts close, sounding warning horn. In a loss of oil flow condition with a diesel drive, flow switch’s Normally Open contacts open, deenergizing CR2. This shuts off diesel fuel solenoid, stopping diesel. The flow switch’s Normally Closed contacts close, sounding horn. G-force of vibration switch is preset. Continuous Gforces greater than setting for more than five seconds open vibration switch’s Normally Closed contact (VS), de-energizing CR1 (CR2 for diesel), This stops crusher drive (diesel or electric) and equipment feeding VSI, It does not sound horn. Reset vibration switch by momentarily interrupting power to lube pump or by installing a reset button on Vibraswitch terminal strip locations #3 and #4.
16
18
21
4
17
19
23
25
27
22
24
GND GND
GND GND 1
26
2
20
T1
1
2
T3
T2
220 V VSI Crusher J-Box Terminal Strips 22
X2A
1
2
3
22
23
5
6
4
120 V
Reset
Vibraswitch Terminal Strip Diesel Drive 1
M2 18
18
Flow Switch N.O.
CR1 21
27
CR2
27
2
2
Aux Flow Switch N.C.
Horn 19
19
2
2
Cummins Clutch Limit Diesel Battery Supply From Fuel Solenoid
+24 VDC
To Fuel Solenoid
CR2 24
24
LS1
24
24
25
25 25
25
Clutch Limit Opens Circuit When Clutch is Engaged
Caterpiller Clutch Limit Diesel Battery Supply From Fuel Solenoid
+24 VDC
24
24
To Fuel Solenoid LS1
28
CR2
25
25
Clutch Limit Closes Circuit When Clutch is Engaged
21052 (3/97)
Page 9.6
LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 9 Electrical System L1 L2
L3 Main Breaker 70 A
Circuit Breaker 20 A 5 KVA Transformer X1
15 A
40 A
M1
480 V X2
7A
F4 20 A
F2
F1
120 V 60Hz
20
20 (12 Ga)
120 V Outlet
R4
15
Heater
16
M1
M2
2 HP Lube Pump
15 HP U/C Conveyor
Amber
Red Start
Stop 2
1
M1
4
M1 VS
51
50
M2
U/C Conveyor
Feed to Impact
Stop
CR1
Vibration Switch
U/C Start
Stop
1
Lube Pump
Feed
26
Thermostat R4
17
1
Off On Lid Lifter
Up Up
M1
OX
14
33
32
Down Down 31
Green XO
21
18
F5 1.5 A
22
V.S.
23
Suppressor
27
4
#22
#23
5
6
Reset
Vibraswitch Terminal Strip X2
Cummins Clutch Limit XO
3
19 Horn
24
2 120 V
1
From Fuel Solenoid
X2
1 CR1
Sup Stop
#4
25
1
1 4 14 16 17 18 19 20 21 22 23 24 25
To Diesel Fuel Solenoid
Clutch Limit Switch
26 27 31 32 X2 X2 X2 X2 GND GND GND T1 T2 T3 24
CR1
25
120 V VSI Crusher J-Box Terminal Strips
Figure 9-4 Electrical Diagram for Units Equipped with Optional Lid-Lifter. Refer to Lid-Lifter Addendum 21052 (3/97)
Page 9.7
LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 9 Electrical System
21052 (3/97)
Page 9.8
LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 10 Applications How It Works: VSI Crushing Action
Abrasion
The VSI is a machine for volume production of cubically fractured crushed rock. The drive system rotates vertical shaft and rotating throw device (rotor or table with shoes) at top of vertical shaft.
Tests for chemicals with known abrasive compounds can determine abrasion characteristics of specific rocks. Silica dioxide (SiO2), iron oxide (FeO) and aluminum oxide (Al2O3) are commonabrasive compounds in rock. Magnesium carbonate (MgCO3) and calcium carbonate (CaCO2) are also associated with abrasive effects. Abrasiveness and toughness are different. Some basalts are tough materials, performing very well in soundness tests, but are moderate on an abrasion scale.
Rock is continuously fed through a hopper into crushing chamber, where its caught by high speed rotating throw device and thrown outwards, striking and rebounding from impact-resistant, stationary surfaces mounted inside upper portion of tub. Rock pieces shatter in crushing chamber, then fall through discharge area. A significant percent of rock is cubically fractured by high speed impacting inside crushing chamber.
Abrasion and friability test data are needed when considering impact crushing. A high abrasive content causes more liner wear.
Characteristics of Rock
Friability
In any rock crushing operation physical characteristics of raw material affect output product achieved. The characteristics of rock of most interest in the industry are hardness, abrasion, friability, toughness, and specific gravity. Cedarapids’ testing facility is equipped to test samples using several tests to quantify or compare rocks on basis of these characteristics. Tests follow American Standards Testing Methods (ASTM) standard procedures.
Friability indicates how well rock shatters or crumbles when impacted. Friability can be contrasted with toughness of rock. The Burbank Paddle Test used on a rock sample shows where sample lies on a continuum from a high degree of toughness to high degree of friability, as compared with other samples of the same rock type.
Hardness Some practical testing of hardness that can be done in the field is based on Mohs Scale of Hardness. Talc has a hardness value of one, diamond value of ten. talc = 1 gypsum = 2 alcite = 3 fluorite = 4 apatite = 5
orthoclase = 6 quartz = 7 topaz = 8 corundum = 9 diamond = 10.
With this scale a rock that can be scratched with: fingernail = about 2 copper coin = about 3 pocket knife = over 5 window glass = 5-1/2 steel file = 6-1/2 21052 (3/97)
For more extensive information about types and characteristics of rock, consult a Cedarapids Dealer and Cedarapids Pocket Reference Guide. Application VSI's suit a variety of applications. For a particular application judge how VSI suits need by considering overall operating costs and production capability of VSI’s specific configuration. Here are some guidelines to help make the appropriate adjustments to VSI to adapt to varying friability, hardness, and abrasion conditions. Good VSI applications include producing:
Page 10.1
• Base materials • Asphalt rock with a high percentage of fines • Chips (also called topping rock or chippings) • Winter sanding material (applied when roads are icy or snow-covered) LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 10 Applications VSIs are also good at: • Getting more minus 4.75 mm (#4) mesh product • Preparing a ballmill feed • Beneficiating to remove softer stone from harder stone
With a VSI even these smaller particles are fractured. Regardless of size,each rock particle passes through the throw device to be thrown against impact surface (anvil ring or rock shelf). Every particle of rock is likely to be crushed during its path through crusher. Use VSI to:
• Increasing asphalt stability by adding fractured faces to smaller gravel sizes • Cleaning up a particle shape problem by: • improving results of ASTM C-131 test (sometimes known as Los Angeles Abrasion or “LA Rattler” test) • improving the ability of particles to pass skid resistance tests • improving concrete pumpability by reducing chance of blockage in pump • improving screening efficiency with more cubical particle shape • Balancing a circuit where a compression-type crusher is struggling to crush material that is already nearly sized to crusher’s setting. The VSI can stabilize recirculating load, preventing tendency to increase, and maintain screening efficiency Since more friable materials crush easier in VSI, you may be able to slow speed of throw device (also called impeller) and still get a satisfactory gradation. This also can help wear rate.
• Relieve near-size problems in a compression crushing circuit that can cause bumping • Put fractured faces on smaller material that is already near to your product size • Reduce material beyond the efficient closed size settings of compression crushers Because aggregates crush differently in a VSI than in compression crushers, VSI may be useful in material with high compressive strength. Rocks with high compressive strength may also be brittle (friable) and crush more efficiently in a VSI. Particles that are flat or long and narrow usually break across their shorter, thinner dimensions when impacted, providing a more cubical product. Some materials tend to break to a natural grain size when impacted, giving reduction ratios very different from (and in some cases improved beyond) compression methods. Use this tool to:
If there is tough rock mixed with friable rock, use a slower throw device speed and a rock shelf to help remove some of the softer stone. Every Particle Crushed Many producers find VSIs helpful in solving troublesome production problems occurring with compression crushers because impacting is a dramatically different method of crushing. With a cone or roll crusher, particles that enter crushing chamber at or near the desired product size or slightly smaller than closed side setting can pass through without being broken. 21052 (3/97)
Page 10.2
• Get more fines when a compression circuit is showing deficiencies • Improve the percentage of harder, more durable materials by crushing softer undesirable materials to fines and screening them out • Improve the typical particle shape for superior asphalt stability, better concrete pumping, and better skid resistance of aggregates
LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 10 Applications Controling Variables to Meet User Requirements Changing Speed VSI offers many variables that you can use to match machine capabilities to changing needs. Changing rotation speed is the most commonly used variable. Use throw device (impeller) speeds 50-80% of maximum for making coarse-graded products (such as chips, with few fines) and for improving physical properties of output product. Use slower speeds for putting fractured faces on particles of gravel while minimizing fines production. Use higher speeds (80-100% of maximum) for greatest reduction when producing dense graded products with lots of fines, like base mix, asphalt mix, and when supplementing sand production. See charts showing sheave and engine/motor speed combinations to get desired throw device speeds and maximum speeds for each model. Remember: Higher speeds cause faster wear. Notice: When running near maximum rpm, Cedarapids suggests reducing the maximum size of feed material by 13 mm (1/2"). Varying Throw Devices VSI can be equipped with either a 3, 4, 5, or 6-shoe table, or a rotor (Figure 10-1). Field studies show that fewer shoes on a table give a coarser output gradation when run at same speed. More shoes gives a finer gradation. Using rotor may be desirable to reduce wear cost in very abrasive materials, because rotor uses a rock-on-rock strategy for reducing wear costs. The rotor usually gives a coarser gradation, so be sure trade-off is justifiable. Use throw device most efficient and effective for site. Aggregate producers often use a table with more shoes to extend life of each set of shoes. If a 4-shoe table gives reduction of aggregate that is desired, replacing it with a 5-shoe table and slowing speed down can usually match crushing action and give wear savings of a slower speed. 21052 (3/97)
If using a rotor in VSI, there is the option of using a rock shelf for autogenous crushing (obtained by crushing a rock with a rock) or an anvil ring assembly. Depending on needs, rock shelf may be a costeffective option. Crushing against an anvil ring assembly usually results in better reduction and a finer gradation. If reduction offered by rotor and rock shelf is acceptable, or if trying to shape material with less reduction, this offers the added feature of reduced wear cost. Balancing a Circuit VSIs are high production machines, well suited to finishing, or final sizing applications. As compression crusher closed side settings are pinched down, throughputs diminish. VSI's, when properly powered, retains their throughput rating even with smaller product sizes. A three-stage circuit having extra capacity at primary and secondary stages but which is limited at tertiary stage by capacity may benefit from high throughput capability of a VSI. Balancing a circuit in this way gives producer better return on money invested in entire crushing plant. Varying Feed Size Cedarapids establishes maximum sizes of feed material for all VSI models. These are published as maximum “cubed” size, the size square opening in screen cloth that feed to crusher must fit through. Feeds that are graded from maximum size down to closed circuit size result in an output gradation that are more evenly distributed along gradation curve (Figure 10-2). If wanting to produce a narrow band of sizes, for example, 13 mm by 4.75 mm (1/2" x 4M), an optimum feed size is slightly larger than product band, for example 25 by 13 mm (1 x 1/2"). Slowing throw device and/or using a table with fewer shoes, or a rotor, can concentrate more product in a narrower coarse-product band, rather than distributing product evenly throughout gradation.
Page 10.3
LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 10 Applications Model
1800 3-4-5 Shoe Table
1800 6-Shoe Table
1800 Rotor
2100 3-4-5 Shoe Table
2100 6-Shoe Table
2100 Rotor
Feed Rate Tonnes per hour (Tons per hour)
136-181 (150-200)
136-181 (150-200)
136-181 (150-200)
227-318 (250-350)
227-318 (250-350)
181-227 (200-250)
Maximum Feed Size
57 mm (2-1/4")
57 mm (2-1/4")
51 mm (2")
76 mm (3")
76 mm (3")
63.5 mm (2-1/2")
1535
1426
1920
1316
1206
1700
1400
1300
1750
1200
1100
1550
813 mm (32")
889 mm (35")
864 mm (34")
940 mm (37")
1041 mm (41")
864 mm (34")
Tip Speed at Maximum RPM meters/minute (feet/minute)
3575 (11,729)
3631 (11,912)
4748 (15,577)
3543 (11,624)
3599 (11,807)
4205 (13,797)
Suggested Nominal Power
224 kW (300 hp)
224 kW (300 hp)
298 kW (400 hp)
298 kW (400 hp)
298 kW (400 hp)
373 kW (500 hp)
2
Maximum Pinion RPM
4
Maximum Throw Device RPM Diameter of Throw Device
4, 5
6
Diesel Power Range
7
Electric Motor Power Range
1
1
149-373 kW (250-500 hp)
224-448 kW (300-600 hp)
75, 112, 149 or 187 kW Twin (100, 150, 200 or 250 hp Twin)
112, 149, 187 or 224 kW Twin (150, 200, 250 or 300 hp Twin)
Notes
7) De-rated for altitude.
1) High-output version is available on some models. Consult ElJay for information. 2) When operating near maximum RPM ElJay suggests reducing the maximum feed size of material by 13 mm (1/2").
Warning! Do not attempt to observe throw device's operating rpm directly through access doors. Any small particle of rock can be ejected at any moment, causing serious injury or death!
3) VSI-GD models only. 4) Warning! Do not allow cast iron sheave rim speed to exceed 1981 meters/minute (6500 fpm). Exceeding this rim speed requires ductile iron sheave.
Point of exit
5) Same as VBD crusher sheave rpm. 6) Table and rotor outside dimensions refer to actual throw diameter at point of exit where rock is thrown from table or rotor. Figure 10-1 Power, Rpm, Feed Rates & Sizes 21052 (3/97)
Page 10.4
LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 10 Applications 100%
1 3 Percent passing
2
4
0% Larger product size
Smaller product size Critical Product Band 1. Feed size just larger than the critical product band 2. Larger percent of crusher output in the critical product band
3. Feed size up to maximum 4. Smaller percent of crusher output in the critical product band
Figure 10-2 Output at Slow Throw Device Speed
Controlling Wear
Following adjustments can help control wear cost:
Annual cost for high chrome iron wear parts in a VSI is higher than manganese cost in a cone crusher. But, considering low initial investment cost of a VSI coupled with high production rate, VSI can actually improve overall plant cost per ton. This is of most importance in situations where labor costs are high. Depending on amount of rock being processed and on hardness, silica content, moisture, and other factors, wear parts need periodic replacement. Section 6 explains how often wear parts must be changed. The strategy for controlling wear is to reduce chances for abrasive action and increase chances of breaking rock on impact.
21052 (3/97)
Page 10.5
• Use appropriate throw device and impact surface configuration for your application. • Use an efficient vibrating screen ahead of crusher to scalp out excessively slabby material and oversize rock, and to prevent as much abrasive sand and fines as possible from entering crushing chamber. • Reduce or eliminate water with feed. More water usually means more wear. Water increases wear to parts such as shoes, liners, and anvils. Water causes fine particles to cling to coarse particles, making coarse particles more abrasive and increasing scouring effect on surfaces contacted by moving rock. LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 10 Applications • Feed crusher more than 50% of maximum feed rate. Light tonnage rates (below 50%) can aggravate wear on lower parts of table shoes. A symptom of this condition is slotting in shoes (Figure 10-3). If allowed to continue, slotting increases operating costs by prematurely wearing out shoes.
• Shape and size of feed is a factor. Large, round uncrushed rock is generally less abrasive than rock with broken edges. Small, crushed rock is generally more abrasive. Recirculating alreadysized rock or oversize rock which has been partially fractured can increase wear. • Table or rotor speed is important. Higher rotor or table rpms, create greater wear on cast liner parts, shoes, anvils, or exit port protectors. A moderate change in rpm can have little effect on gradation, yet increase wear rate.
1
• On table/shoes/anvils VSIs, number of shoes affects wear life. Generally, more shoes on the table means longer wear life of each shoe. • The rock shelf is used with CastRotor only. Adjust rock shelf to height where rock strikes the buildup in shelf as low as possible without damaging shelf. Adjust not higher than 13-25 mm (1/2"-1") below exit port of rotor.
2
• Too little buildup can undermine wear tips and/or break them by allowing material to stream past trailing plates. Field-cut trailing plates to desired depth and then hardface as detailed in Section 6.
1. Minimum 1/2" 2. Slot Figure 10-3
Factors Affecting Gradation
• Keep feed tube properly adjusted. Letting feed tube wear too high can cause scuffing on forward edge of top of shoes, poor gradation, and possibly cause lid liner breakage. • Feed to center of feed tube. Feeding to side of feed tube can cause uneven wear around anvil ring. Anvil ring can be turned to compensate, but feeding straight down to center of feed tube allows throw device to distribute feed more evenly to anvils.
Product gradation is varied primarily by throw device speed. Gradation is also affected by adjusting feed tube, varying feed size and varying feed rate. Increasing rpm generally increases percentage of fines. Decreasing rpm generally decreases percentage of fines. See Changing Table RPM.
• Keep anvils adjusted to proper height to avoid slotting. Cedarapids/ElJay VSI's are designed for vertical adjustment of anvils to maximize anvil wear life.
21052 (3/97)
Page 10.6
• When using table with anvils, using a table with more shoes generally increases percentage of fines. Tables with fewer shoes generally have a smaller percentage of fines. • Decreasing input volume generally increases percentage of fines.
LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 10 Applications • Properly adjusting feed tube can increase percentage of fines. If feed tube is too high above a table, rock goes over tops of shoes, missing anvils and giving a lower percentage of fines. If feed tube is too high above a rotor, wear rate increases and results poorer gradation.
Changing Throw Device RPM Warning! Lockout power source before beginning adjustment. Warning! Standard cast iron sheaves can explode when run at excessive speeds. Sheave rim speed must not exceed 1981 meters per minute (6500 fpm). Ductile iron or steel sheaves are required when speeds greater that 6500 fpm are required.
Adjusting Trailing Angle Position Trailing angles control pattern of material buildup in CastRotor (Figures 6-12, 6-13, and 6-14). Buildup is controlled by tilt of trailing angle, distance from wear tip, depth and profile. Too much material buildup wears both feed tube and feed eye quickly. Too little buildup can undermine wear tips. Always adjust trailing angles as a set. See Section 6 for details of how to adjust trailing angle position. Table Requires Anvil Ring To crush rock efficiently, table/shoes option requires anvil ring stationary impact surface. Use of rock shelf with table/shoe throw device is not recommended. VSI-GD (Gear Driven) Cedarapids developed gear driven (GD) model for applications that demand:
For VSIs with diesel drive, adjust diesel engine throttle. The upper limit is controlled by a governor, preset at factory. On VSIs with electric drive: 1) Change crusher sheave or crusher and motor sheaves to change throw device rpm. The following charts show sheave sizes required to give designated speeds. Stock sheave sizes are 457.2 mm (18.0") diameter on crusher and 508 mm (20.0") diameter on electric motors. (The metric equivalents are calculated for convenience and may not represent available metric sheaves, nor will a metric sheave fit pinion/drive shaft on a VSI.) 2) Consult your Cedarapids/ElJay distributor when using sheaves other than those listed.
• Low overall height • Using horizontal electric motors
3) See Sheaves and Bushings, in Section 7 for correct removal and installation procedures.
• Using a diesel engine When electrically powered, speed changes are easier on gear driven (GD) models because sheaves are more accessible. On diesel powered units, users can change sheaves to allow even slower throw device speeds while still keeping engine in proper rpm operating range.
21052 (3/97)
Page 10.7
LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 10 Applications 1800 RPM (1775 Actual RPM) Electric Motors-Sheave Combinations GD Throw Device RPM
VBD Throw Device RPM
1710 (18 Rrs*)
GD Pinion RPM
GD Pinion or VBD Sheave
Motor Sehave
1876
12.5"
13.2"
1618
1775 (18 Rrs*)
1775
13.2"
13.2"
1525 (18 Ra, 21 R*)
1672
1672
14.0"
13.2"
1422 (18 T5*)
1559 (18 Ra, 21 R*)
1559
15.0"
13.2"
1332
1460
1460
16.0"
13.2"
1252 (21 T5*)
1374 (18 T5*)
1374
17.0"
13.2"
1182 (21 T5*)
1296
1296
18.0"
13.2"
1119
1227 (18 T6*)
1227
19.0"
13.2"
1063 (21 T6*)
1165 (21 T5*)
1165
20.0"
12.5"
20.0"
13.2"
1103 (**) 1002
1099
1099
21.2"
13.2"
948
1039 (21 T6*)
1039
22.4"
13.2"
22.4"
12.5"
983 855
938
24.8"
13.2"
809
888
24.8"
12.5"
* Maximum RPM for different configurations: 18=1800 VSI. 21=2100 VSI. R=Rotor. rs=Rock Shelf. a=Anvil Ring. T5=3, 4, or 5-shoe Table with Anvil Ring. T6=6-shoe Table with Anvil Ring ** Largest and smallest sheave combination for an 1800 VSI 1800 RPM Diesel-Sheave Combinations GD Throw Device RPM
GD Pinion RPM
GD Pinion Sheave
Motor Sheave
1735 (18 Rrs)
1902
12.5"
13.2"
1641
1800
13.2"
13.2"
1546 (18 Ra, 21 R*)
1696
14.0"
13.2"
1442 (18 T5*)
1581
15.0"
13.2"
1350
1481
16.0"
13.2"
1270 (18 T6*)
1393
17.0"
13.2"
1199 (21 T5*)
1315
18.0"
13.2"
1135
1245
19.0"
13.2"
1078
1182
20.0"
13.2"
1016 (21 T6*)
1114
21.2"
13.2"
961
1054
22.4"
13.2"
867
951
24.8"
13.2"
820
900
24.8"
12.5"
21052 (3/97)
Page 10.8
LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 10 Applications 1200 RPM (1185 Actual RPM) Electric Motor-s-Sheave Combinations GD Throw Device RPM
VBD Throw Device RPM
GD Pinion RPM
GD Pinion or VBD Sheave
Motor Sehave
1739 (18 Rrs*)
1908
12.5"
20.0"
1646
1805
13.2"
20.0"
12.5"
18.0"
14.0"
20.0"
13.2"
18.0"
15.0"
20.0"
14.0"
18.0"
16.0"
20.0"
15.0"
18.0"
17.0"
20.0"
16.0"
18.0"
18.0"
20.0"
17.0"
18.0"
1715 (18 Rrs*) 1550 (18 Ra. 21 R*)
1700 1623
1445 (18 T5*)
1585 1528 (18 Ra, 21 R*)
1354
1485 1425 (18 T5*)
1274 (18 T6*)
1397 1335
1202 (21 T5*)
1318 1250 (18 T6*)
1138
1248
19.0"
20.0"
1080
1185
20.0"
20.0"
1185 (21 T5*)
18.0"
18.0"
1118
18.0"
17.0"
1019 (21 T6*)
1117
21.2"
20.0"
964
1057
22.4"
20.0"
1052 (21 T6*)
18.0"
16.0"
996
19.0"
16.0"
24.8"
20.0"
946
20.0"
16.0"
933
19.0"
15.0"
24.8"
19.0"
892
21.2"
16.0"
870
19.0"
14.0"
24.8"
18.0"
843
22.4"
16.0"
826
20.0"
14.0"
24.8"
17.0"
790
22.4"
15.0"
778
20.0"
13.2"
373
22.4"
14.0"
736
20.0"
12.5"
870
954
826
906
782
857
738
21052 (3/97)
809
Page 10.9
LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 10 Applications 1500 RPM (1480 Actual RPM) 50 hz Electric Motors-Sheave Combinations GD Throw Device RPM
VBD Throw Device RPM
GD Pinion RPM
GD Pinion or VBD Sheave**
Motor Sehave**
1733 (18 Rrs*)
1901
12.5"
16.0"
1640
1799
13.2"
16.0"
1545 (18 Ra, 21 R*)
1694 (18 Rrs*)
1694
14.0"
16.0"
1440 (18 T5*)
1580 (18 Ra*)
1580
15.0"
16.0"
1349
1480 (21 R*)
1480
16.0"
16.0"
1269 (18 T6*)
1392 (18 T5*)
1392
17.0"
16.0"
1198 (21 T5*)
1314
1314
18.0"
16.0"
1134
1244 (18 T6*)
1244
19.0"
16.0"
1077
1181 (21 T5*)
1181
20.0"
16.0"
1015 (21 T6*)
1114
1114
21.2"
16.0"
20.0"
15.0"
22.4"
16.0"
1032
20.0"
14.0"
987
22.4"
15.0"
972
20.0"
13.2"
24.8"
16.0"
920
22.4"
14.0"
919 (**)
20.0"
12.5"
24.8"
15.0"
22.4"
13.2"
24.8"
14.0"
22.4"
12.5"
24.8"
13.2"
1106 960
1053 (21 T6*)
867
1053
951
812
890 867
757
830 820
713
21052 (3/97)
782
Page 10.10
LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 10 Applications 1000 RPM (985 Actual RPM) 50 Hz Electric Motors-Sheave Combinations GD Throw Device RPM
GD Pinion RPM
GD Pinion Sheave
Motor Sheave
1699 (18 Rrs*)
1864
13.2"
24.8"
1601
1756
14.0"
24.8"
1493 (18 Ra, 21 Rrs*)
1637
15.0"
24.8"
1398 (18 T5*)
1534
16.0"
24.8"
1315 (21 Ra*)
1442
17.0"
24.8"
1241 (18 T6*)
1361
18.0"
24.8"
1175 (21 T5*)
1289
19.0"
24.8"
1116
1224
20.0"
24.8"
1052 (21 T6*)
1154
21.2"
24.8"
995
1091
22.4"
24.8"
898
985
24.8"
24.8"
810
889
24.8"
22.4"
767
841
24.8"
21.2"
723
793
24.8"
20.0"
* Maximum RPM for different configurations: 18=1800 VSI. 21=2100 VSI. R=Rotor. rs=Rock Shelf. a=Anvil Ring. T5=3, 4, or 5-shoe Table with Anvil Ring. T6=6-shoe Table with Anvil Ring ** Largest and smallest sheave combination for an 1800 VSI
21052 (3/97)
Page 10.11
LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 10 Applications
21052 (3/97)
Page 10.12
LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 11 Troubleshooting Too Much Vibration
For gear-driven VSIs:
Warning! If VSI vibrates, shut down immediately and determine cause. Too much vibration can be dangerous,. Do not allow persons near a VSI that has violent vibrations.
• Broken gear teeth • Defective pinion shaft bearing For VSIs with CastRotor: • Trailing angles not adjusted properly
Notice: If VSI vibrates, shut down immediately and determine cause. Too much vibration can cause serious damage to VSI, incurring downtime and unnecessary expense. Possible Causes of Excessive Vibration:
• Bridging of material inside rotor where material blocks an exit port • Oversize rock knocks out material buildup For VSIs with diesel drive:
• Feed cone or feed eye is off-center
• Defective Power Take Off (PTO) bearing. To check for diesel-associated vibration or noise, run VSI up to operating speed, release clutch and shut off diesel engine. As crusher coasts to a stop, noise and vibration can be listened to without noise from diesel drive
• Oversize rock or branch is stuck on throw device • VSI is not level • Improper installation of throw device (Bolts into flywheel are too long; throw device is not set down over lip in flywheel) • Broken, worn, or unbalanced wear parts (parts not installed in balanced sets on throw device) • Loose bolts in vertical shaft assembly • Worn vertical housing (can be a cause or result of too much vibration) • Dirt buildup on sheaves • Loose bushing in sheave
High Operating Temperature Indication: If oil temperature gauge reads above 110°C (230°F), be alert to possible damage to VSI. Notice: If oil temperature gauge reads 115°C (240°F) or above, shut down immediately. Find cause and fix before starting up for normal operation. Possible Causes of High Operating Temperature:
• Drive belt tension is too loose • Loose motor mount bolts
• Defective bearing
• Defective drive take-up
• Defective seal at flywheel flinger and vertical housing top cover plate (sometimes known as a labyrinth seal)
• Defective seal at flywheel flinger and vertical housing top cover plate (sometimes known as a labyrinth seal) • Defective seal (on gear drive models) at pinion inner and outer flinger or cover (also sometimes known as a labyrinth seal)
• Defective seal (on gear drive models) at pinion inner and outer flinger or cover (also sometimes known as a labyrinth seal)
• Bad drive motor bearing (likely with VBD)
• Operating in very high ambient temperature conditions (See hot weather start-up Sec. 4)
• VSI not bolted firmly enough to stand or trailer
• Using improper oil
• Bad bearing 21052 (3/97)
Page 11.1
LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 11 Troubleshooting Too Much Noise
Anvils Worn at Top:
• Defective bearing
• Feed tube adjusted too low
• Defective seal at the flywheel flinger and vertical housing top cover plate (sometimes known as a labyrinth seal) • Defective seal (on gear drive models) at the pinion inner and outer flinger or cover (also sometimes known as a labyrinth seal)
Anvils Worn at Bottom: • Feed tube adjusted too high Shoes Worn at Top: • Feed tube adjusted too high • Feed size too large
• Broken wear part
• Feed cone is worn
• Broken gear tooth
Shoes Worn at Bottom:
• Too much gear tooth backlash
• High percentage of fines in feed
• Bad motor bearing
• Low rate of feed (low tonnage)
• Worn vertical housing assembly
• Feed cone is worn Rapid Wear
Too Much Oil Consumption
Possible Causes of General Wear:
• Leaking seal
• Surges in feed rate
• Broken oil line
• Recirculation of already-sized material
CastRotor Wear Tips Failing Too Soon
• High percentage of fines
• Check tips for undermining of holder material in front of carbide. If you find undermining, adjust trailing plates according to instructions in How To Change Trailing Angles, Section 6 • Check carefully for cracks. A slightly cracked tip can be run but should be checked carefully at end of shift and every four hours of operation Uneven Wear
• Wet feed • Feed tube adjusted too high • Trickle feed or not choke fed Wear to Shoe or shoe bracket: • Loose shoe Wear to Feed Tube:
Uneven wear is typical for stationary parts, but if rotating parts wear unevenly they cause vibration. All VSI parts that come in contact with rock wear much faster if material is too wet. Water causes smaller rock particles to cling to surfaces and increase abrasive wear. A broken cast part anywhere can cause uneven wear
• Crusher feed is off center • Feed tube adjusted too high • Feed tube adjusted too low Wear to Feed Eye: • Feed tube adjusted too low Wear to Lid Liners:
Possible Causes of Uneven Wear Anvils:
• Feed tube adjusted too high Wear to Upper Tub and Ring behind Anvil:
• Worn shoes
21052 (3/97)
• Feed tube adjusted too high
Page 11.2
LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 11 Troubleshooting Bearing Failure
Low Production Tonnage
Indications:
Possible Causes of Low Production:
• Too much vibration could indicate bearing failure or could lead to bearing failure
• Feed rate not constant
• Abnormally high amperage draw in electric motor
• Feed tube adjusted too high
• Recirculation of already-sized material • Throw device rpm too high
• Oil temperature higher than normal
• Worn shoes and/or anvils
• Noise: A change in the normal sound which could be in pitch (higher or lower) or in volume • Abnormal oil sample readings, that include brass or other metal particles
• See Section 10 Plugging of Hopper Possible Cause of Plugging: • Oversize rock or branch stuck on throw device
Possible Causes of Bearing Failure: • Contamination of lubrication system. Not starting with clean oil. Getting dirt in oil when disassembling or reassembling parts. Not changing filter elements when needed. Not using proper filter elements
Horn Sounds Possible Causes of Horn Sounding: • Low oil level • Broken oil line
• Oil level too low or oil too old
• Defective oil pump
• Rotor or table imbalance
• Faulty horn wiring
• Too much vibration
V-Belts
• Faulty installation or removal procedures. Jamming or cocking bearing or part of bearing on shaft. Hammer blows during installation or removal
Broken Drive Belts:
• Rust and corrosion of bearing surfaces. See Section 3 for VSI storage procedures
• Too much tension
Wear Part Breakage Possible Causes of Wear Parts Breaking:
• Belts damaged during installation. Do not pry belts over sheave. See Section 7 for installation. • Loose tension, causing shock load • Foreign object between belt and sheave Belts Wearing Too Quickly:
• Oversize feed
• Worn sheave; belts riding too low in groove.
• Tramp iron in circuit
• Dirty or rusty sheave
• Warped castings
• Belts mismatched
• Overtightened bolts • Seating surface of wear parts not cleaned when last replaced
21052 (3/97)
• Loose tension
Page 11.3
• Too much abrasive dust
LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 11 Troubleshooting Possible Cause of Split Belts: • Too much tension Possible Causes of Belts Turning Over: • Worn sheave • Motor and crusher sheaves misaligned • Loose tension • Broken cord caused by prying onto sheave • Too much belt vibration caused by loose mounting Possible Cause of Belts Squealing: • Belts too loose Causes of Belts Stretching Too Soon: • Worn sheave • Too tight Causes of Belts Misaligned at Installation: • Not a matched set • Using a mix of old and new belts, or different manufacturers • Motor and crusher shafts not parallel
21052 (3/97)
Page 11.4
LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 12 Other Information Temperature Conversion Chart To convert from Centigrade to Fahrenheit, locate C in center column and read F value in column to left. To convert from Fahrenheit to Centigrade, locate F in center column and read C value in column to right. For other temperatures: C = 5/9 (F - 32); F = 9/5 C + 32 F -40 -36.4 -32.8 -29.2 -25.6 -22.0 -18.4
C F -40 -38 -36 -34 -32 -30 -28
F 75.2 78.8 82.4 86.0 89.6 93.2 96.8
C F 24 26 28 30 32 34 36
C -40.0 -38.9 -37.8 -36.7 -35.6 -34.4 -33.3
-14.8 -11.2 -7.6 -4.0 -0.4 3.2 6.8 10.4 14.0 17.6 21.2 24.8 28.4 32.0 35.6 39.2 42.8
-26 -24 -22 -20 -18 -16 -14 -12 -10 -8 -6 -4 -2 0 2 4 6
46.4 50.0 53.6 57.2 60.8 64.4 68.0 71.6
F 190.4 194.0 197.6 201.2 204.8 208.4 212
C F 88 90 92 94 96 98 100
C -4.4 -3.3 -2.2 -1.1 0 1.1 2.2
-32.2 -31.1 -30.0 -28.9 -27.8 -26.7 -25.6 -24.4 -23.3 -22.2 -21.1 -20.0 -18.9 -17.8 -16.7 -15.6 -14.4
100.4 104.0 107.6 111.2 114.8 118.4 122.0 125.6 129.2 132.8 136.4 140.0 143.6 147.2 150.8 154.4 158.0
38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70
8 10 12 14 16 18 20
-13.3 -12.2 -11.1 -10.0 -8.9 -7.8 -6.7
161.6 165.2 168.8 172.4 176.0 179.6 183.2
22
-5.6
186.8
F 30.56 309.2 312.8 316.4 320.0 323.6 327.2
C F 152 154 156 158 160 162 164
C 31.1 32.2 33.3 34.4 35.6 36.7 37.8
C 66.7 67.8 68.9 70.0 71.1 72.2 73.3
3.3 4.4 5.5 6.7 7.8 8.9 10.0 11.1 12.2 13.3 14.4 15.6 16.7 17.8 18.9 20.0 21.1
215.6 219.2 222.8 226.4 230.0 233.6 237.2 240.8 244.4 248.0 251.6 255.2 258.8 262.4 266.0 269.6 273.2
102 104 106 108 110 112 114 116 118 120 122 124 126 128 130 132 134
38.9 40.0 41.1 42.2 43.3 44.4 45.6 46.7 47.8 48.9 50.0 51.1 52.2 53.3 54.4 55.6 56.7
330.8 334.4 338.0 341.6 345.2 348.8 352.4 356.0 359.6 363.2 366.8 370.4 374.0 377.6 381.2 384.8 388.4
166 168 170 172 174 176 178 180 182 184 186 188 190 192 194 196 198
74.4 75.6 76.7 77.8 78.9 80.0 81.1 82.2 83.3 84.4 85.6 86.7 87.8 88.9 90.0 91.1 92.2
72 74 76 78 80 82 84
22.2 23.3 24.4 25.6 26.7 27.8 28.9
276.8 280.4 284.0 287.6 291.2 294.8 298.4
136 138 140 142 144 146 148
57.8 58.9 60.0 61.1 62.2 63.3 64.4
392.0 395.6 399.2 402.8 406.4 410.0 413.6
200 202 204 206 208 210 212
93.3 94.4 95.6 96.7 97.8 98.9 100
86
30.0
302.0
150
65.6
Figure 12-1
21052 (3/97)
Page 12.1
LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 12 Other Information U.S. Standard Sieve Series for Wire Cloth- Selected Sizes Size (English)
Nominal Sieve Opening
Nominal Wire Diameter
Size (SI)
Size (English)
Nominal Sieve Opening
Nominal Wire Diameter
Size (SI)
4"
4"
6.30 mm
100 mm
3/8"
0.375"
2.27 mm
9.5 mm
3-1/2"
3.5"
6.08 mm
90 mm
5/16"
0.312"
2.07 mm
8.0 mm
3"
3"
5.80 mm
75 mm
1/4"
0.250"
1.82 mm
6.3 mm
2-1/2"
2.5"
5.50 mm
63 mm
4M
0.187"
1.54 mm
4.75 mm
2"
2"
5.05 mm
50 mm
5/32" (5M)
0.157"
1.37 mm
4.0 mm
1-3/4"
1.75"
4.85 mm
45 mm
8M
0.0937"
1.00 mm
2.36 mm
1-1/2"
1.5"
4.59 mm
37.5 mm
10M
0.0787"
0.900 mm
2.00 mm
1-1/4"
1.25"
4.23 mm
31.5 mm
16M
0.0469"
0.650 mm
1.18 mm
1"
1"
3.80 mm
25.0 mm
30M
0.0234"
0.390 mm
0.60 mm
7/8"
0.875"
3.50 mm
22.4 mm
40M
0.0165"
0.290 mm
0.425 mm
3/4"
0.750"
3.30 mm
19.0 mm
50M
0.0117"
0.215 mm
0.30 mm
5/8"
0.625"
3.00 mm
16.0 mm
100M
0.0059"
0.110 mm
0.15 mm
1/2"
0.500"
2.67 mm
12.5 mm
200M
0.0029"
0.053 mm
0.075 mm
Figure 12-2
21052 (3/97)
Page 12.2
LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 12 Other Information Standard Bolt and Nut Torque Specifications To prevent standard threaded bolts and nuts used on Cedarapids equipment from being overstressed when tightened, use torque chart on pages 12.4, and 12.5. Follow these specifications unless other specific torques are given in this manual. Cedarapids uses grade 5 as standard. Grades 2 and 8 are used when required and are identified in the manual. The maximum torque values are based on 75% of specified minimum proof strength of the bolt steel in order to provide a safety factor. The term “Lube” in the chart includes applying thread lubricants and cadmium plating.
21052 (3/97)
Notice Regarding Wear Parts Fasteners: Except where noted, most fasteners used to attach VSI wear parts use anti-seize lubricant on the threads. Cast wear parts are very abrasion-resistant, but are more brittle than milder, softer steels. Standard torque values of the recommended Grade 8 bolts may be so high as to crack or break the cast part. Except where a torque value is specifically noted, always tighten wear part fasteners firmly to a “snug fit.” Except where noted in this manual, do not tighten the bolts holding wear parts to their full, standard, lubricated torque value.
Page 12.3
LJ1093200
21052 (3/97)
Page 12.4
20 28 18 24
16 24 14 20
13 20 12 18
11 18 10 16
9 14 8 14
7 12 7 12
6 12 6 12
5 4.5 4.5 4
4 4
(inches)
1/4 1/4 5/16 5/16
3/8 3/8 7/16 7/16
1/2 1/2 9/16 9/16
5/8 5/8 3/4 3/4
7/8 7/8 1 1
1-1/8 1-1/8 1-1/4 1-1/4
1-3/8 1-3/8 1-1/2 1-1/2
1-3/4 2 2-1/4 2-1/2
2-3/4 3
5590 7385
1370 2060 3015 4125
655 745 865 975
350 395 495 550
165 180 245 270
97 110 170 190
49 55 70 79
20 23 32 36
5 6 11 12
4300 5680
1055 1585 2320 3170
500 570 665 750
270 305 380 425
125 140 190 210
75 85 130 145
38 42 54 60
15 17 25 27
4 5 9 10
Lube
122010 147750
47020 61870 80430 99000
28580 32540 34770 39120
18880 21180 23980 26550
11430 12590 14990 16400
9320 10560 13770 15380
5850 6590 7500 8370
3190 3620 4380 4890
1310 1500 2160 2390
Clamp Load (lbs)
9320 12310
2285 3435 5025 6875
1465 1670 1945 2190
790 890 1120 1240
425 470 640 700
150 170 265 295
75 85 109 121
31 35 49 55
8 10 17 19
Dry
7165 9470
1755 2640 3865 5285
1130 1285 1495 1685
610 685 860 950
330 360 495 540
115 130 200 225
58 65 84 93
24 27 38 42
6 7 13 15
Lube
203360 246260
78370 103120 134060 165000
64100 72980 77970 87740
42340 47500 53770 59550
29450 32440 38630 42260
14400 16320 21290 23770
9040 10190 11600 12940
4940 5590 6770 7560
2020 2320 3340 3690
Clamp Load (lbs)
Torque (ft-lbs)
Dry
Torque (ft-lbs)
ASSUMPTIONS: (1) The maximum torque values are based on 75% of the specified proof strength. (2) The term "lube" includes the application of thread lubricants, cadmium plating, and the use of hardened washers; regardless of whether standard or lock nuts are used.
N
(threads/in.)
Diameter
S. A. E. Grade 5 S. A. E. Symbol
S. A. E. Grade 2 S. A. E. Symbol
17790 23500
4985 7500 10960 15000
2380 2710 3160 3555
1285 1440 1815 2010
605 665 905 990
210 240 375 415
106 120 150 170
44 49 70 78
12 14 25 27
Dry
13680 18080
3835 5765 8435 11530
1830 2085 2430 2735
990 1110 1395 1545
465 510 695 765
160 180 285 320
82 92 115 130
34 38 54 60
9 11 19 21
Lube
Torque (ft-lbs)
388230 470130
170990 225000 292500 360000
103950 118350 126450 142290
68670 77040 87210 96570
41580 45810 54540 59670
20340 23040 30060 33570
12770 14390 16380 18270
6970 7900 9560 10680
2860 3270 4710 5220
Clamp Load (lbs)
S. A. E. Grade 8 S. A. E. Symbol
Recommended Maximum Torque Values (±5%) Use "LUBE" column values
Operation & Maintenance Manual
A Terex Company
Section 12 Other Information
Use the following torque chart to avoid overstressing standard nuts and bolts used on Cedarapids equipment. These specifications should be followed unless specific torques are given in our equipment manual. Cedarapids uses Grades 2, 5, and 8. The maximum torque values are based on 75% of the specified minimum proof strength of the bolt steel in order to provide a safety factor. The term "lube" includes the application of thread lubricants, cadmium plating, and the use of hardened washers. Steel type and hardness range are as follows: For SAE Grade 2 plain low carbon (1018 or 1020) steel, hardness is Rockwell "B" 85-100. For SAE Grade 5 plain medium carbon (1035, 1038, & 1045), hardness is Rockwell "C" 19-30. For SAE Grade 8 medium carbon alloy (4140, 8642 & 5147), hardness is Rockwell "C" 32-38. All SAE bolt head symbols are listed on the Torque Chart next to the SAE grade.
LJ1093200
21052 (3/97)
Page 12.5
1.5
1.25
1.75
1.25
2
1.5
2
1.5
2.50
1.5
2.5
1.5
2.5
1.5
3
2
3
2
10
10
12
12
14
14
16
16
18
18
20
20
22
22
24
24
27
27
949
879
654
600
519
473
385
347
276
246
190
178
124
115
78
72
43
41
Dry
730
676
503
461
399
364
296
267
212
189
146
137
95
88
60
55
33
32
Lub.
53540
49616
41517
38070
35970
32767
29322
26438
23353
20787
18063
16920
13451
12467
9944
9101
6609
6263
Clamp Load (lbs)
Property Class = 8.8
1387
1286
956
877
759
692
563
507
403
359
277
260
181
168
115
105
63
60
Dry
1067
989
736
674
584
532
433
390
310
276
213
200
139
129
88
81
49
46
Lub.
78302
72563
60719
55678
52606
47922
42884
38665
34154
30401
26417
24746
19672
18234
14543
13310
9666
9159
Clamp Load (lbs)
Property Class = 10.9
ASSUMPTIONS: (1) The maximum torque values are based on 75% of the specified proof strength. (2) The term "lube" includes the application of thread lubricants, cadmium plating, and the use of hardened washers; regardless of whether standard or lock nuts are used.
Pitch (mm)
Diameter (mm)
8.8
Property class is noted on bolt head.
1627
1508
1122
1029
891
812
660
595
473
421
325
305
212
196
134
123
74
71
Dry
1252
1160
863
791
685
624
508
458
364
324
250
234
163
151
103
95
57
54
Lub.
91854
85122
71228
65315
61711
56216
50306
45357
40066
35663
30989
29029
23077
21389
17060
15614
11339
10745
Clamp Load (lbs)
Property Class = 12.9
Recommended Maximum Torque Values (+/- 5%) Use "Lube" values
Operation & Maintenance Manual
A Terex Company
Section 12 Other Information
Use the following torque chart to avoid overstressing metric nuts and bolts used on Cedarapids equipment. These specifications should be followed unless specific torques are given in our equipment manual. Cedarapids uses Class 8.8, 10.9, and 12.9 metric bolts. The maximum torque values are based on 75% of the specified minimum proof strength of the bolt steel in order to provide a safety factor. The term "lube" includes the application of thread lubricants, cadmium plating, and the use of hardened washers.
LJ1093200
Operation & Maintenance Manual
A Terex Company
Section 12 Other Information Inches- Millimeters Inches
1/16"
1/8"
3/16"
1/4"
5/16"
3/8"
7/16"
1/2"
9/16"
5/8"
11/16"
Millimeters
1.59
3.18
4.76
6.35
7.94
9.53
11.11
12.7
14.29
15.88
17.46
Inches
3/4"
13/16"
7/8"
15/16"
1"
1-1/4"
1-1/2"
1-3/4"
2"
3"
4"
Millimeters
19.05
20.64
22.23
23.81
25.4
31.75
38.1
44.45
50.8
76.2
101.6
Figure 12-4 Millimeter Equivalents of Common Sizes in Inches
Millimeters- Inches Millimeters
1
2
3
4
5
6
7
8
9
10
11
Inches
0.03937
0.07874
0.11811
0.15748
0.19685
0.2362
0.2756
0.3150
0.3543
0.3937
0.4331
Millimeters
12
13
14
15
16
17
18
19
20
25
30
Inches
0.4724
0.5118
0.5512
0.5906
0.6299
0.6693
0.7087
0.7480
0.7874
0.9843
1.1811
Millimeters
35
40
45
50
60
70
80
90
100
200
300
Inches
1.3780
1.5748
1.7127
1.9685
2.3622
2.7559
3.1496
3.5433
3.937
7.874
11.811
Figure 12-5 Inch Equivalents of Common Sizes in Millimeters
Common Conversion Factors English-Metric (SI)
Metric (SI)-English
1 inch = 25.4 millimeters (mm)
1 millimeter (mm) = 0.03937 inches (")
1 gallon = 3.785 liters (l)
1 liter (l) = 0.2644 U.S. gallons (gal)
1 pound (force) = 4.448 Newtons (N)
1 Newton (N) = 0.2248 pounds (lb)
1 pound (mass) = 0.4536 kilograms (kg)
1 kilogram (kg) = 2.2046 pounds (lb)
1 ton (2000 lbs.) = 0.9072 tonnes
1 tonne (1000 k) = 1.1023 tons
1 foot-pound (ft-lb) = 1.356 newtonmeters (N•m)
1 newtonmeter (N•m) = 0.7376 foot-pounds (ft-lb)
1 horsepower (hp) = 0.746 kilowatts (kW)
1 kilowatt (kW) = 1.341 horsepower (hp)
1 pound/inch2 (psi) = 6.895 kilopascals (kPa)
1 kilopascal (kPa) = 0.145 pound/inch2 (psi)
1 pound/inch2 (psi) = 0.06895 bars
1 bar = 14.504 pound/inch2 (psi)
(note: 1 bar = 100kPa)
21052 (3/97)
Page 12.6
LJ1093200
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