Reference Manual
Service Manual
Nordberg HP® Series Cone Crusher Lubrication Supplement
FOREWORD This Instruction Manual provides guidance to first time operators of the Crusher as well as providing technical procedures as a reference for the experienced crusher operator. Read - study - and keep for future reference. Illustrations and instructions guide the operator through correct procedures for checking, installing, operating and maintaining the Crusher and accessories. Separate instruction manual supplements provide detailed instructions for the lubrication system, hydraulics and crusher drive in addition to the main Cone Crusher Instruction Manual. Operating techniques outlined in the book are basic. Operating skills and additional techniques will develop as the operator gains knowledge of the Crusher and its capabilities. Continuing improvement and advancement of product design may result in changes to your new machine which may not be included in this publication, however each publication is reviewed and revised, as required, to up-date and include appropriate changes in the later editions. The description and specifications in this manual were in effect at the time this manual was approved for printing. Nordberg reserves the right to discontinue models at any time and to change specifications or design, without notice and without incurring obligation. Whenever a question arises regarding your Crusher, or this publication, please consult your Nordberg representative for the latest available information. This manual is to be used as a general guide concerning technical information. All technical information required for correct installation of your crusher must be obtained from the installation drawings and technical data furnished for your particular Crusher.
SAFETY BASIC RULES REGARDING SAFETY IN AND AROUND A CRUSHING PLANT ARE OUTLINED IN SECTION 0, ENTITLED “SAFETY” OF THE MAIN CONE CRUSHER INSTRUCTION MANUAL. OPERATOR SAFETY AND THE SAFETY OF OTHERS DEPENDS UPON REASONABLE CARE AND JUDGEMENT IN THE OPERATION OF THIS CRUSHER. A CAREFUL OPERATOR IS GOOD INSURANCE AGAINST AN ACCIDENT. MOST ACCIDENTS, NO MATTER WHERE THEY OCCUR, ARE CAUSED BY FAILURE TO OBSERVE AND FOLLOW SIMPLE FUNDAMENTAL RULES OR PRECAUTIONS. FOR THIS REASON MOST ACCIDENTS CAN BE PREVENTED BY RECOGNIZING HAZARDS AND TAKING STEPS TO AVOID THEM BEFORE AN ACCIDENT OCCURS. REGARDLESS OF THE CARE USED IN THE DESIGN AND CONSTRUCTION OF THIS TYPE OF EQUIPMENT, THERE ARE CONDITIONS THAT CANNOT BE COMPLETELY SAFEGUARDED AGAINST WITHOUT INTERFERING WITH REASONABLE ACCESSIBILITY AND EFFICIENT OPERATION. WARNINGS ARE INCLUDED IN THIS INSTRUCTION MANUAL TO HIGHLIGHT THESE CONDITIONS.
TABLE OF CONTENTS LUBRICATION SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 1 OIL TANK AND HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 2 PUMP AND MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 3 OIL FILTER AND COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 4 RELIEF VALVES, PRESSURE AND TEMPERATURE SWITCHES . . . . . . . . . . . . . .SECTION 5 LUBRICATION — CHECK LIST & CONTROL LOGIC . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 6 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 7 TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 8
Section 1
DESCRIPTION LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3
INSTALLATION, OPERATION, AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4
LUBE OIL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4
OIL TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4
COLD WEATHER OPERATING RECOMMENDATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4
LUBRICATION OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4
LOWER LIMIT OF AMBIENT TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4
REGULATING THE OIL SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5
CHECK VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5
DESCRIPTION 1
10 8
9 4
7
3 1
5 15
6 11 14 12 2 13
1. 2. 3. 4. 5. 6. 7. 8.
Oil Tank Pump and Motor Assembly Oil Filter Screen Main Relief Valve Oil Filter By-Pass Relief Valve Oil Tank Breather Temperature Switch (High Oil Temp)
9. 10. 11. 12. 13. 14. 15.
Temperature Switch (Fan Control) Temperature Gauge Pressure Gauge Oil Tank Heater Oil Tank Drain Valve Differential Pressure Gauge Check Valve
FIGURE 1-1—SKID MOUNTED LUBE SYSTEM (AIR OIL COOLED)
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HP SERIES LUBRICATION SUPPLEMENT
1-1
DESCRIPTION 1
8
9
10 4
7
14 16
3 1 17
5
6 9
11 18 12 10 2 15
13
1. 2. 3. 4. 5. 6. 7. 8. 9.
Oil Tank Pump and Motor Assembly Oil Filter Screen Main Relief Valve Oil Filter By-Pass Relief Valve Oil Tank Breather Temperature Switch (High Oil Temp) Check Valve
10. 11. 12. 13. 14. 15. 16. 17. 18.
Temperature Gauge Pressure Gauge Oil Tank Heater Oil Tank Drain Valve Water Strainer Water Control Valve Heat Exchanger (Water) Heat Exchanger By-Pass Relief Valve Differential Pressure Gauge
FIGURE 1-2—SKID MOUNTED LUBE SYSTEM (WATER OIL COOLED)
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1-2
DESCRIPTION
DESCRIPTION 1 LUBRICATION SYSTEM Description The “skid mounted” lubricating oil systems shown in Figure 1-1 and 1-2 are typical systems. The lubricating systems as described in this section are designed for 8.6 Bars (125 PSI) maximum operating pressures; both oil and water. In these systems, oil is taken from the oil tank to the suction side of the oil pump. The oil pump forces the oil under pressure to the oil filter. A bypass relief valve is provided to protect the filter elements from excessive differential pressure which can occur if the filters are too dirty or the oil is too cold. A pressure differential gauge mounted on the filter housing provides a visual check of the pressure drop across the filter and indicates when the filter should be cleaned. The oil is then directed through a heat exchanger where the oil is cooled by circulating water or through a radiator where the oil is cooled by circulating air. A relief valve will divert the oil around the cooler when the oil is cold and becomes too viscous which will cause a pressure build-up. Thermometers on each side of the water type oil cooler provide a visual check of the oil temperature. For the air radiator type coolers, temperature gauges located at the radiator outlet and in the drain line are used for visual oil temperature checks.
A relief valve located right after the pump or at the Crusher prevents oil under excessive pressure from entering the Crusher. When an excessive oil pressure condition exists, the relief valve will open and divert part of the oil back to the tank. The oil is then directed into the main shaft at the bottom of the main frame. See Figure 1-3. The oil under pressure is then forced upward, through interconnecting passages in the main shaft, to the bearing surfaces of the eccentric and head bushings, then up through the socket to the bearing surface of the socket liner. The oil overflow from the socket liner and from out of the top of the head and eccentric bushing flow down through holes in the head, then down through large slots in the counterweight and collects in the frame under the eccentric gear. Oil also flows out the bottom of the head and eccentric bushings and through large slots in the counterweight and collects in the main frame under the gear. Oil flowing out the bottom of the eccentric bushing first has to pass through the thrust bearings located under the eccentric before collecting in the frame. The oil collects in the main frame, then flows around and spills over the gear and pinion teeth. A separate line simultaneously forces oil through the countershaft box to the countershaft bearings. The oil is finally collected in a sump at the underside of the main frame and is returned by gravity through piping to the supply tank.
FIGURE 1-3—INTERNAL OIL FLOW R
HP SERIES LUBRICATION SUPPLEMENT
1-3
DESCRIPTION 1 INSTALLATION, OPERATION AND MAINTENANCE The remainder of this section provides important information pertaining to the necessary components of the Lubricating System. Before attempting the installation or operation of a new crushing plant the following information must be carefully read and all instructions followed as specified.
LUBE OIL SPECIFICATIONS Use a high grade paraffin (not naphthalene) base industrial oil of viscosity specified, having high film strength, high adhesiveness to metal surfaces, and stable chemical and physical properties. The lubricant used must also have extreme pressure (E.P.) properties such as sulphur phosphorus or other antiweld agents which are compatible with the metals used in Crushers (bronze, babbitt, cast iron and steel). In addition, the lubricant should have a high viscosity index, rapid water separation, resist foaming, offer some rust and corrosion protection, resist oxidation and have anti-wear additives. E.P. lubricants also have much lower pour points than straight industrial oil and therefore are well worth their slightly higher cost.
Oil Temperature The oil temperature leaving the Crusher should be in the range of 16° C (60° F) to 60° C (140° F). How ever, the preferred range is 38° C (100° F) to 54°C (130° F). The Crusher should not be operated if this oil temperature reaches 60° C (140° F) or drops below 16° C (60° F). Higher temperatures warrant investigation as to proper operation or characteristics of the oil. Where ambient temperatures or operating conditions result in oil temperatures leaving the machine over 60° C (140° F), cooling facilities must be used. Thermostatically controlled electric heaters are suggested in cold weather when lubricant temperatures in the oil tank drop below 16° C (60° F). If at any time the Crusher is suspected of overheating, check the temperature difference between the oil going into the Crusher and the oil leaving the Crusher by installing thermometers in the feed and drain lines. Without the cooler operating, the temperature difference should be 5° C (9° F).or less. With the cooler operating, the temperature difference should be 8° C (15° F) or less. If the temperature difference is more than 5° C (9° F) without cooler on or 8° C (15° F) with cooler on, most likely the bearings within the Crusher have closed-in due to abnormal operating conditions.
The proper oil to use is ISO grade 150. The lubricant must have a viscosity of: 135 to 165 cSt (Centistokes) at 40° C 13 cSt or higher at 100° C or 680 to 850 SUS (Saybolt, Universal Seconds) at 100°F 70 SUS or higher at 210° F In addition the oil must have a viscosity Index of 90 or higher. Consult the factory for any special recommendations (supplying full information and data), when operating under abnormal conditions, such as when handling hot materials or when operating in extreme climates or atmospheric conditions or where heating or cooling facilities are not available. Correct lubricants meeting the above specifications are essential for the protection of the working parts of our Crushers. Improper lubricants can ruin the Crusher and their use will void any warranties pertaining to such Crushers. All major oil companies produce a product meeting these specifications. If a local supplier is unable to recommend a product based on the above properties, consult Nordberg for assistance.
COLD WEATHER OPERATING RECOMMENDATIONS Cold weather can adversely affect the operation of an HP Cone Crusher. The lubricating oil will become thicker at low temperatures and at extreme conditions may even gel or solidify. Lubrication Oil In order to provide adequate lubrication of crusher bearings, we recommend operation of the Crusher with a lube oil drain line temperature of at least 16° C (60° F). It is recommended that if the oil temperature drops below this temperature during a shutdown period, the electric immersion oil heaters, furnished with the Lube System, should be in operation to warm the oil. The oil temperature in the tank must be a minimum of 16° C (60° F) before the lube pump is started to prevent overloading of pump and motor assembly. However, to maintain 16° C (60° F) oil drain line temperature after oil starts circulating through Crusher, it may be necessary to wait until oil tank temperature is even higher before starting pump. At ambient temperatures below -20° C (0° F) it may be necessary to keep the oil heater and pump running any time the Crusher is not operating. Insulation around the oil tank and piping will also help maintain oil temperatures above 16° C (60° F). Lower Limit Of Ambient Temperature The minimum temperature at which the Crusher can safely be run using the above recommendations is -30° C (-25° F). Below this temperature the structural strength of the Crusher may be adversely affected. R
1-4
DESCRIPTION
DESCRIPTION 1 REGULATING THE OIL SUPPLY The oil pump capacity, pipe line sizes and bypass relief valve size have been selected and set to provide the Crusher with an ample supply of lubricating oil and to insure cooler operation. Field adjustments of the lubricating system should, therefore, be unnecessary as long as lubricant selection and crusher operation follow the instructions in this manual.
Crusher oil flow rate and operating pressure, at the countershaft box, for each size machine is shown in Table 1-1. Oil pressure will vary from the loaded to the unloaded condition.
CRUSHER SIZE
HP 200
HP 300
HP 400
HP 500
HP 700
Liters Per Minute (U.S. Gallons Per Minute)
95-114 (25-30)
114-132 (30-35)
190-210 (50-55)
227-246 (60-65)
473-492 (125-130)
Normal Operating Pressure-Bars (Pounds Per Square Inch)
1.4-2.8 (20-40)
1.4-2.8 (20-40)
1.4-2.8 (20-40)
1.4-2.8 (20-40)
1.4-2.8 (20-40)
TABLE 1-1—CRUSHER OIL FLOW RATE AND OPERATING PRESSURE
CHECK VALVE The main function of a check valve, which should be connected into the oil feed line near the oil tank, is to prevent the draining of feed line oil back into the tank. This draining back of the oil would cause the loss of the prime on the oil pump if the pump is located above the level of oil in the tank. A check valve is furnished as standard equipment on all Crushers. Care should be taken when installing the check valve, so it is positioned properly in the oil feed line, as the valve only operates in one direction. This direction is clearly marked on the valve itself.
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HP SERIES LUBRICATION SUPPLEMENT
1-5
DESCRIPTION 1
14 8
M M
15
DRAIN VALVES
TI PI PSV
PSL
TSH PSL TI PI PDI TC PSV LG
7
4
Temperature Switch Pressure Switch Temperature Gauge Pressure Gauge Pressure Differential Gauge Temperature Control Relief Valve Level Gauge
9 TSH
2
TI
14
PSV TSH
10
13
3
PDI
LG TC
TC
PI 12
11 PSV
5 M
6
1. 2. 3. 4. 5. 6. 7. 8.
1 Skid Mounted Lube System Oil Tank Oil Pump Pump Relief Valve Check Valve Relief Valve Set @ 3.4 Bars (50 PSI) Relief Valve Set @ 3.4 Bars (50 PSI) Skid Mounted Air Heat Exchanger
9. 10. 11. 12. 13. 14. 15.
High Temperature Radiator Fan Control Filter Heater Strainer Breather Blower
FIGURE 1-4—TYPICAL LUBRICATION SCHEMATIC (AIR)
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1-6
DESCRIPTION
DESCRIPTION 1
14
M 15
PI WATER OUT
WATER IN
TSH PSL TI PI PDI TC PSV LG
10
TC TI 7 4 8 PSV
9
PSL
TSH
TI
Temperature Switch Pressure Switch Temperature Gauge Pressure Gauge Pressure Differential Gauge Temperature Control Relief Valve Level Gauge
2
14
PSV 13 TI
3
PDI
LG TC
TC
PI 11
12 PSV
3
5 M
6
1
1. 2. 3. 4. 5. 6. 7. 8.
Skid Mounted Lube System Oil Tank Oil Pump Pump Relief Valve Check Valve Relief Valve Set @ 3.4 Bars (50 PSI) Relief Valve Set @ 3.4 Bars (50 PSI) Skid Mounted Air Heat Exchanger
9. 10. 11. 12. 13. 14. 15.
High Temperature Radiator Fan Control Filter Heater Strainer Breather Blower
FIGURE 1-5—TYPICAL LUBRICATION SCHEMATIC (WATER)
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HP SERIES LUBRICATION SUPPLEMENT
1-7
DESCRIPTION 1 This page left intentionally blank.
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1-8
DESCRIPTION
Section 2
OIL TANK AND HEATER OIL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1
OIL DRAIN LINE TRAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2
CRUSHER AIR BREATHER AND BLOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3
OIL TANK BREATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3
OIL IMMERSION HEATER AND THERMOSTAT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-4
ELECTRICAL RATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-4
MAGNETIC CONTACTOR AND TRANSFORMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5
ELECTRICAL RATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5
CHECKING THE THERMOSTAT SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5
OIL TANK AND HEATER 2 OIL TANK Description The oil tank is a simple, efficient reservoir for furnishing oil to the crusher lubricating system. Oil returning to the oil tank from the crusher drain line passes through a wire screen which removes any particles of foreign matter, 10 mesh or larger. Then flowing under and over a baffle arrangement for maximum settling of sludge, the oil enters the feed line to the oil pump. The level of oil can be seen on an oil level gauge located on the side of the tank. To assure proper lubrication the oil level must be kept within the range of the oil gauge glass. A thermometer located in the drain line at the oil tank readily provides the operator with the oil temperature leaving the Crusher. As the oil tank is sealed from contamination by dust and moisture, an air breather maintains atmospheric pressure inside the tank. The oil level gauge, thermometer and breather are shipped separately to avoid breakage.
Installation Locate the skid mounted lube system or oil tank below and as near the Crusher as possible. For sufficient flow of return oil, the bottom of the oil tank must be at least 1.3 meters (4 feet) below the bottom of the crusher mounting flange plus 25 mm (1 inch) for every 0.3 meter (1 foot) the tank is positioned horizontally away from the Crusher. See Figure 2-1. It is suggested that the tank be raised to provide suitable space below the oil tank drain plugs to facilitate draining and to assure complete air circulation around the tank. ON PORTABLE PLANTS IT IS OFTEN NOT POSSIBLE TO LOCATE THE OIL TANK ACCORDING TO THE ABOVE RULE. ON PORTABLE PLANTS LOCATE THE OIL TANK AS LOW AS PRACTICAL, WHILE PROVIDING AT LEAST 25 mm (ONE INCH) DROP FOR EVERY 0.3 METER (ONE FOOT) OF PIPE BETWEEN THE CRUSHER DRAIN OUTLET AND THE OIL TANK INLET.
1
1. Crusher 2. Minimum 1.3 Meters (4 Feet), Plus 25 mm (1Inch) For Every 0.3 Meter (One Foot) Tank Is Away From Crusher Horizontally 3. Oil Tank
2 3
FIGURE 2-1—LUBE TANK LOCATION
The crusher drain line should consist of properly pitched horizontal pipe runs. Minimum pitch should be 25 mm (1") per 300 mm (12") of pipe length. Vertical runs should be avoided. If vertical runs are unavoidable, a drain line trap may be required. Refer to the Oil Drain Line Trap section and Figure 2-2. Fill the oil tank with clean oil as described under MAINTENANCE below.
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HP SERIES LUBRICATION SUPPLEMENT
2-1
OIL TANK AND HEATER 2
1
2 1. Air Breather - Place Air Breather In A Relatively Dust Free Location And Where It Can Be Easily Maintained 2. 50 mm (2") Hose Minimum To Be Supplied By Customer 3. 1220 mm MAX. (48") 4. 305 mm (12") Minimum 5. Lube Oil Feed Line To Crusher 6. Crusher Lube Oil Drain Line 7. Trap Clean-Out Port 8. 305 mm (12") Minimum
8 3
4
5
7 6 FIGURE 2-
2—OIL DRAIN LINE TRAP
Oil Drain Line Trap IF CRUSHER DRAIN LINE HAS A VERTICAL DROP OF MORE THAN 1220 mm (48") MAX. TO THE OIL TANK, THEN A TRAP MUST BE INSTALLED. SEE FIGURE 2-2. IF THE TRAP IS NOT INSTALLED, THE RUSH OF OIL DOWN THE DRAIN LINE CAN PULL AIR AND DUST THROUGH THE SEALS AND CAUSE EXCESSIVE INTERNAL WEAR AND POSSIBLE BEARING FAILURE. Maintenance By lifting the inspection cover in the oil tank cover, the oil from the crusher drain line can be readily observed.
Change oil as experience dictates. Avoid operating with an oil that is dirty or gritty, or has lost its body. Sludge should be periodically drained from the tank and the oil screen cleaned. Filling the oil tank with the cover removed is the most convenient method, but it can also be done by lifting the inspection cover in the oil tank cover. ALWAYS DISCONNECT ELECTRICAL POWER TO IMMERSION HEATER BEFORE DRAINING THE OIL TANK. HEATER ELEMENTS CAN BURN OUT PREMATURELY IF EXPOSED TO AIR. Clean the tank and fill with the correct grade of oil, see LUBE OIL SPECIFICATIONS, with amount listed in Table 2-1. This is the required amount to adequately lubricate the Crusher and insure cooler operation. An additional 132 Liter (35 U.S. Gallons) to 208 Liters (55 U.S. Gallons) will be required to fill the Crusher, filter, cooler, pipe lines, etc.
CRUSHER SIZE
HP 200
HP 300
HP 400
HP 500
HP 700
Liters (U.S. Gallons)
170 (45)
170 (45)
300 (80)
300 (80)
1040 (275)
TABLE 2-1—OIL TANK CAPACITIES R
2-2
OIL TANK AND HEATER
OIL TANK AND HEATER 2 PERIODIC CLEANING OF THE OIL TANK BREATHER IS IMPORTANT, THE FREQUENCY OF WHICH DEPENDS ON THE AMOUNT OF DUST PRESENT. ONCE A WEEK OR MORE OFTEN, IF OPERATIONS ARE UNUSUALLY DUSTY, CLEAN THE BREATHER AS RECOMMENDED UNDER AIR BREATHER LATER IN THIS SECTION.
2
CRUSHER AIR BREATHER AND BLOWER For installation and maintenance instructions of the crusher breather, refer to the HP Series Cone Crusher Instruction Manual in Section 10 as outlined under Crusher Air Breather.
OIL TANK BREATHER As the oil tank is sealed from contamination by dust and moisture, an air breather is also mounted on the oil tank to maintain atmospheric pressure within the tank, as shown in Figure 2-3. Periodic cleaning is important, the frequency of which depends on the amount of dust present. Once a week, or more if operations are unusually dusty, remove the air breather or filter element and clean. When servicing the oil tank breather, which is commonly referred to as an “oil bath", observe the following instructions: 1. No tools are required to service the breather. Remove the oil tank breather top from the breather by unscrewing the wing nut on top of the breather. 2. Lift out top and element assembly. Then empty dirty oil from bowl and wipe out any accumulated sludge. 3. Remove screen filter element from top assembly and inspect. Element seldom needs replacing. 4. Clean dirty element by agitating in kerosene or some other cleaning solvent. 5. Allow element to dry, then dip in clean oil. Refill filter bowl with clean oil, SAE 10-30, up to the prescribed level on the side of the breather bowl (Indented Bead). Always install filter element with felt baffle at bottom. 6. Reassemble the breather and install on the oil tank.
1 1. Oil Tank 2. Oil Tank Breather FIGURE 2-3—AIR BREATHER INSTALLATION
OIL IMMERSION HEATER AND THERMOSTAT General A thermostatically controlled electric heater is required to enable oil flow in cold weather. Heaters are necessary when lubricant temperatures in the oil drain line are below 16° C (60° F). Oil tanks can be supplied complete with heaters. The heater is furnished as standard equipment with HP Cone package lube system. The immersion type heater is designed specifically for the type of lubricating oil used in a Crusher. These heaters have a special watt density of approximately 13 watts per square inch. This special wattage will prevent charring or carbonization of lube oil, whereas, immersion heaters with standard wattage (20 watts per square inch and above) will cause charring and carbonization. The recommended immersion heater is equipped with a built-in thermostat, -18°C (0°F) to 38°C (100°F) range, with the heater terminals and thermostat enclosed in a weatherproof housing. As the thermostat is mounted as an integral part of the heater, electrical connections are simplified. The heater wattage is 4kw (4000 watts). The rectangular oil tanks furnished with the Crushers have a 63.5 mm (2-1/2") pipe coupling welded into the side of the tank, thereby making the installation of an immersion heater a simple operation.
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HP SERIES LUBRICATION SUPPLEMENT
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OIL TANK AND HEATER 2 Installation See Figure 2-4 and install heater as follows:
2
1
1. Insert the heater through the pipe coupling in oil tank. DO NOT BEND THE HEATING ELEMENTS. 2. Use a pipe sealing compound on the threads.
3
3. Screw the heater into the pipe coupling, tighten sufficiently with a wrench applied to the HEX PORTION of the heater housing. 4. Position the electrical conduit opening on the heater housing on the side or at the bottom so that a drip loop can be installed as shown in Figure 2-4. A drip loop is recommended to minimize passage of moisture along the wiring onto the heater and/or thermostat terminals. Any moisture will then collect at the bottom of the drip loop and evaporate before seeping onto any terminals and corroding them.
4 5
Use moisture-proof flexible conduit. ALL WIRING SHOULD BE DONE IN ACCORDANCE WITH LOCAL AND NATIONAL ELECTRICAL CODES. BE SURE THE LINE VOLTAGE IS CONNECTED TO THE HEATER ELEMENT TERMINALS AND NOT TO THE THERMOSTAT TERMINALS, AS THE THERMOSTAT IS ONLY RATED FOR 115/230 VOLTS.
6 1. 2. 3. 4. 5. 6.
End View of Oil Tank Air Breather Magnetic Contactor by Customer Oil Immersion Heater Flexible Conduit Drip Loop
FIGURE 2-4—IMMERSION HEATER INSTALLATION
Electrical Ratings Immersion Heater: 380, 460, or 575 volt, 3 phase, 4 kilowatts, (4,000 watts) heating capacity, 6.0 amps (380 volts), 5.0 amps (460 volts), 4 amps (575 volts) per heater terminal. Thermostat: 115/230 volt, single phase, contacts: double pole, single throw. Contact Maximum A.C. Rating. 35 amps at 115 volts 25 amps at 230 volts
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OIL TANK AND HEATER
OIL TANK AND HEATER 2 MAGNETIC CONTACTOR AND TRANSFORMER A magnetic contactor, furnished by the customer, is to be electrically connected to the immersion heater which is required to switch the load from the thermostat to the heater, as the operating range of the thermostat is 115/230 volts and the heater elements are for 380, 460, or 575 volts. A magnetic connector is required to operate the 3 phase wired immersion heaters.
3. All immersion type oil heaters should be given a periodic cleaning since the oil that comes in contact with such heating elements tends to vaporize slightly. This causes a layer of carbon to build up on the surfaces of the elements and reduces efficiency. Removal of the heater from the oil tank is required for cleaning.
Electrical Ratings Magnetic Contactor: for 380 volt operation it is a 3 pole, 27 amps with a 380-115 volt control transformer; for 460 volt operation, it is a 3 pole, 27 amps with a 230/460-115 volt control transformer; for 575 volt operation, it is a 3 pole, 27 amps with a 600 volt primary and 115 volt secondary control transformer.
4. Remove sludge deposits from the oil tank. Always keep the heating elements above the sludge.
For the electrical wiring between the contactor and heater refer to the control circuit later in this supplement. Operation For proper operation of the heater the following general precautions should be observed: 1. The thermostat should be set at 27° C (80° F) for the proper operation of the lube system and Crusher. 2. An initial heat-up time of the oil could be as high as 6 to 7 hours. But once the 27° C (80° F) temperature is reached the heater will maintain the thermostat setting. 3. It is important that the oil level gauge on the end of the oil tank remains at least partially filled as any portion of the heating elements that are exposed to air will lead to premature burnout of the elements. 4. Do not allow excessively thick coating to form on the heating elements or heater burnouts can occur.
5. Clean the terminal ends of the heating elements and thermostat of all contamination. 6. Do not kink the thin capillary tubing that connects the heat sensitive bulb to the thermostat. Excess tubing should be coiled, not kinked or bent.
CHECKING THE THERMOSTAT SETTING Every thermostat was carefully calibrated and tested at the factory before shipment. However, if there is any reason to suspect that the thermostat is no longer operating properly, the thermostat can be checked as follows:.
Be sure the power to the heater has been disconnected before removing the thermostat. 1. Remove the thermostat and heat sensitive bulb assembly from within the heater housing.
5. Disconnect the power to the heater whenever draining the oil tank.
2. Place the heat sensitive bulb of the thermostat in a pan of water that has been heated to 276° C (80° F). Use a separate thermometer to accurately measure the temperature of the water. Take care not to kink the capillary tubing.
Maintenance Periodically perform the following maintenance procedures.
3. Allow the bulb to adjust to the temperature of the water for a few minutes before checking the thermostat.
DISCONNECT THE POWER TO THE HEATER BEFORE REMOVING THE HEATER FROM THE OIL TANK.
4. Turn the thermostat control knob slowly until the thermostat “clicks” off. Compare the temperature setting on the knob with the thermometer reading. The two readings should agree. If not, the thermostat requires re-calibration or replacement.
1. Drain the oil tank. 2. Remove the immersion heater from the oil tank periodically for inspection; check the heating elements for cracks and scale deposits.
WHILE A THERMOSTAT CAN BE RECALIBRATED IN THE FIELD IT IS RECOMMENDED THAT THE THERMOSTAT SIMPLY BE REPLACED.
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OIL TANK AND HEATER 2 This page left intentionally blank.
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OIL TANK AND HEATER
Section 3
PUMP AND MOTOR ASSEMBLY OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1
GENERAL INSTALLATION INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5
VACUUM GAUGE-SUCTION PORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5
PRESSURE GAUGE-DISCHARGE PORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5
TROUBLESHOOTING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-7
PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-9
PUMP REPAIR INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-9
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-9
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-9
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-12
GEAR REDUCER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-12
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-12
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-13
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-13
REDUCER REPAIR INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-14
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-14
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-14
PUMP AND MOTOR ASSEMBLY 3 OIL PUMP Description The oil pump is a low speed, internal gear, positive displacement pump that is supplied with all Crushers. It is furnished either as part of a package lube system or as part of a separate pump and motor assembly. The pump is driven by a totally enclosed electric motor, operating through a gear reducer to provide the correct pump speed. The correct oil pump and electric motor horsepower requirements are shown in Table 3-1.
THE PUMP IS MADE ESPECIALLY FOR THIS TYPE OF LUBRICATING SERVICE. HARDENED STEEL AND SPECIAL MACHINING TOLERANCES ARE USED ON THE INTERNAL PARTS OF THESE PUMPS TO PROVIDE TROUBLE FREE OPERATION AND LONG SERVICE. THEREFORE, SHOULD ANY SERVICING BE NECESSARY, IT IS IMPERATIVE THAT IDENTICAL PARTS BE USED FOR REPLACEMENT.
CRUSHER SIZE
PUMP LITERS/MINUTE (U.S. GALLONS/MINUTE)
PUMP RPM
MOTOR KILOWATTS (HORSEPOWER)*
HP 200
95-114 (25-30)
280
2.2 (3)
HP 300
114-132 (30-35)
280
3.7 (5)
HP 400
190-210 (50-55)
235
3.7 (5)
HP 500
227-246 (60-65)
280
5.6 (7.5)
HP 700
473-492 (125-130)
415
14.9 (20)
* Motor kilowatts (horsepower) based on maximum of 7.6 meters (25 feet) vertical height between oil pump and Crusher. TABLE 3-1—PUMP RPM AND MOTOR REQUIREMENTS General Installation Information - Pump Correct installation of the pump is the most important factor in proper pump operation. The correct pump may be selected to perform a given task but, if improperly installed, will give unsatisfactory performance. Before installation is started the following items must be considered. 1. Location - Always locate the pump as close as possible to the oil tank. Locate the pump below the oil level in the tank if at all practical. These oil pumps are self priming but the better the suction conditions the better the performance. 2. Accessibility - The pump should be located where it is accessible for inspection, maintenance and repair. Allow room to remove the rotor and shaft without removing the pump from the base.
B
2
A
1
1. Suction 2. Discharge FIGURE 3-1—OIL PUMP PORTS
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PUMP AND MOTOR ASSEMBLY 3 3. Suction/Discharge - Shaft rotation will determine which port is suction and which is discharge. Figure 3-1 shows how rotation determines which port is which; as the pumping gears come out of mesh (point "A" on the illustration) oil is drawn into the suction port as the gears come into mesh (point "B") the oil is forced out the discharge port. Reversing the rotation reverses the flow through the pump.
8. Piping Information - The cause of many pumping problems can be traced to the suction piping. It should always be as large and short as practical.
1
4. Electrical Rating - Check the motor nameplate for the correct voltage, frequency and phase; electrical connections are also shown on the nameplate. For proper operation and lubrication of the motor refer to the manufacturer's service bulletin. 5. Electrical Components - All fuse protection equipment is to be furnished by the customer to conform to local electrical codes. The starter for the pump motor is also to be furnished by the customer to meet the customer's specific needs, location and electrical interconnecting requirements. Attach a No. 8 or larger ground wire to the pump and motor assembly. 6. Foundation - Every pump should have a good foundation. It may be any structure sufficiently strong to hold the pump base rigid and to absorb any strain or shock that may be encountered. A concrete foundation built on solid ground is the most satisfactory. If a concrete foundation is provided, make it at least 50 mm (2") wider and longer than the base of the unit.
2 1. Use Straightedge, These Surfaces Must Be Parallel 2. Check Width Between These Surfaces With Inside Calipers To Be Certain The Faces Are An Equal Distance Apart And Parallel FIGURE 3-2—COUPLING ALIGNMENT
Before starting the layout and installation of the piping system consider the following points: 1.
Locate oil pump below oil level in tank, if possible.
2.
Never use piping smaller than the pump port connections.
7. Alignment - The pump and motor was shipped from the factory properly aligned. However, the alignment may have been disturbed in shipment or in mounting. For this reason it should never be taken for granted a unit just received from the factory is perfectly aligned. Therefore, when placing the unit on the foundation, the alignment should be carefully checked after installation as follows:
3.
Be sure the inside of the pipe is clean before hooking it up.
4.
Check Valve - When pumping with a suction lift, a check valve installed at the end of the suction piping will hold the oil in the line and make it easier for the pump to prime. Be sure the check valve is big enough so that it doesn't cause excessive line loss.
a. Check pump ports to be sure they are square and in proper position; shim or move pump as required.
5.
When approaching an obstacle in the suction line, go around the obstacle instead of over it as shown in Figure 3-3. Going over it creates an air pocket.
6.
Where practical, slope the piping so no air pockets will be formed. Air pockets in the suction line make it hard for the pump to prime.
7.
For a suction line with a long horizontal run, keep the horizontal portion below the oil level if possible. This keeps the pipe full so the pump does not have to remove so much air when starting; this is most helpful when there is no check valve.
When the unit is placed on the foundation it should be leveled and checked for position against the piping layout and then fastened down.
b. Remove the coupling guards and check alignment of the coupling halves. A straightedge placed across the coupling must rest evenly on both rims at the top, bottom and sides as shown in Figure 3-2. c. Make a final check on alignment after piping is hooked up as described next under PIPING INFORMATION.
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PUMP AND MOTOR ASSEMBLY 3 8.
pipe sealing compound or teflon tape will help assure leak free threaded joints. Leaks in the suction line permitting air to be drawn in may cause a noisy pump, and a reduction in capacity.
A strainer in the oil tank will keep foreign objects from going into the pump; without a strainer some would go through; others would cause a jammed pump, a broken part or a torn up drive. The strainer basket mesh should be fine enough to protect the pump. 12.
Check the alignment of the drive after the piping is hooked up. As a final check on pump alignment, remove the head of the pump and with a feeler gauge determine if there is clearance all the way around, between the rotor and casing. Because of manufacturing tolerances, bushing clearances, etc., the rotor may not be centered in the casing, but it should not drag; dragging would indicate unit misalignment or casing distortion from piping strain.
13.
A gate valve can be installed in the suction line between the oil tank and the pump to permit replacing the oil pump or any of its components without draining the oil tank. However, during normal operation the gate valve must be OPEN.
14.
Make sure the center of gaskets used on flanged connections are cut out.
15.
Record pump model number and serial number and file for future use.
Provision should be made for cleaning the strainer. Use of a strainer is particularly important at start up to help clean the system of weld beads, pipe scale and other foreign objects. A strainer mounted in the suction line is NOT recommended as there is the possibility of the strainer becoming plugged with foreign material and cutting off the flow of oil to the pump. 9.
The pump should not be used to support the piping. The weight of the pipe should be held by hangers, supports, stands, etc.
10.
When fastening the piping to the pump, do not impose any strain on the pump casing. “Springing” or “drawing” the piping up to the pump will cause distortion, possible misalignment and probable rapid wear of the pump. Do not use the pump to correct errors in piping layout or assembly.
11.
All joints of the piping system should be tight;
2
3
1
3 5
4 2 1 1. 2. 3. 4. 5.
Do This Not This Obstruction Go Around the Obstruction on the Horizontal Keep Long Horizontal Line Below Oil Level FIGURE 3-3—PUMP SUCTION LINE R
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PUMP AND MOTOR ASSEMBLY 3 Operation Before pushing the "start" button, check the following: 1. Is there a pressure gauge near the pump? This gauge is the quickest and most accurate way of finding out what is happening in the pump. 2. Make sure the gate valve between the tank and pump is open. 3. Make sure the valves on both the inlet and outlet side of the filter are open. 4. Rotate the pump shaft by hand to be sure it turns freely. 5. Jog motor to check rotation of the motor to be certain the pump is turning in the correct direction as shown in Figure 3-4. 6. Check pump gear reducer, motor, coupling, etc., for data plate instructions and lubricate as recommended. 7. Loosen packing gland nuts so gland can be moved slightly by hand. Adjust gland to reduce leakage only after pump has run long enough to reach constant temperature. Packing should leak a little to keep it cool and lubricated.
10. Do have spare parts, pumps or standby units available, as the pump is an essential part of a key operation or process. 11. Now push the "start" button. If the pump does not begin to deliver oil within one minute, push the "stop" button. Do NOT run the pump longer than one minute without oil in it. Review the steps just outlined, consider what the suction and discharge gauges, if used, indicate. If everything appears to be in order, put some oil in the pump. This will help it prime. Push the "start" button again. If nothing is flowing within two minutes, stop the pump. The pump is not a compressor, it will not build up much air pressure; it may be necessary to vent the discharge line until oil begins to flow. If the pump still does not deliver, the cause may be one or more of the following: 1. Suction line air leaks; vacuum gauge reading should help determine if this is the problem. 2. End of suction pipe not submerged deep enough in the oil. 3. Suction lift is too great or the suction piping is too small. If after consideration of these points, it still does not pump, read through TROUBLESHOOTING and try again.
3
1 2
1. Inlet
2. Rotation
3. Outlet
FIGURE 3-4—PUMP ROTATION
8. Check to be sure all guards are in place. 9. Don't run pump at speeds faster than recommended.
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PUMP AND MOTOR ASSEMBLY 3 Troubleshooting A pump which is properly installed and maintained will give long and satisfactory performance.
3. Fluttering, jumping, or erratic reading: a. Cavitation.
If trouble does develop, one of the first steps toward finding the difficulty is to INSTALL A VACUUM GAUGE IN THE SUCTION PORT AND A PRESSURE GAUGE IN THE DISCHARGE PORT. Readings on these gauges often will give a clue as to where to start looking for the trouble. Vacuum Gauge Suction Port 1. High reading would indicate:
b. Oil coming to pump in slugs. c. Air leak in suction line. d. Vibrating from misalignment or mechanical problems. Some of the following may also help pinpoint the problem:
a. Suction line blocked - gate valve closed. 1. Pump does not pump: b. Oil too viscous to flow through the piping. c. Lift too high.
a. Lost its prime - air leak, low oil level in tank.
d. Line too small.
b. Suction lift too high.
2. Low reading would indicate:
c. Rotating in wrong direction.
a. Air leak in suction line.
d. Motor does not come up to speed.
b. Oil level in tank too low to fill suction line.
e. Suction valves not open.
c. Pump is worn.
f.
d. Pump is dry - should be primed.
g. Any changes in the oil or operation that would help explain the trouble, such as changing oil supplier, added more lines, inexperienced operators, etc.
3. Fluttering, jumping, or erratic reading: a. Oil coming to pump in slugs, possibly an air leak or insufficient oil above the end of the suction pipe.
Pump worn out.
2. Pump starts, then loses its prime: a. Oil tank empty.
b. Vibrating from cavitation, misalignment or damaged parts. Pressure Gauge Discharge Port 1. High reading would indicate: a. High viscosity and small and/or long discharge line. b. Gate valve partially closed. c. Filter by-pass relief valve stuck shut. d. Line partially plugged from build-up on inside of pipe.
b. Air leaks or air pockets in the suction line; leaking air through the packing. c. Pump worn out. 3. Pump is noisy: a. Pump is being starved (heavy oil cannot get to pump fast enough). b. Pump is cavitating. Increase suction pipe size or reduce length; if pump is above the oil, raise the oil level closer to the pump; if the oil is above the pump, increase the head of oil.
e. Oil in pipe not up to temperature. c. Check alignment. f.
Oil in pipe has solidified.
2. Low reading would indicate:
d. May have a bent shaft or rotor tooth. Replace damaged part.
a. Too much extra clearance inside the pump.
e. May have to anchor pump to base or piping to eliminate or reduce vibration.
b. Pump worn.
f.
May be a foreign object trying to get into the pump through the suction port.
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PUMP AND MOTOR ASSEMBLY 3 4. Pump not up to capacity: a. Starving or cavitation - increase suction pump size or reduce length. Check oil level. b. Air leak in suction piping or along pump shaft. c. Running too slowly; is motor the correct speed and is it wired up correctly? d. Pump worn out. 5. Pump takes too much power: a. Running too fast - is correct motor speed, reducer ratio, sheave size, etc., being used. b. Is oil more viscous than unit sized to handle; heat the oil, increase the pipe size. c. Discharge pressure higher than calculated, check with pressure gauge. Increase size or reduce length of pipe. d. Packing gland drawn down too tight. e. Pump misaligned. f.
Check parts for evidence of drag or contact in pump and increase clearance where necessary.
6. Rapid Wear. On most applications, the pump will operate for many months or years before it gradually loses its ability to deliver capacity or pressure. Examination of such a pump would show a smooth wear pattern on all parts. Rapid wear, occurring in a few minutes, hours, or days, shows up as heavy grooving, galling, twisting, breaking or similar severe signs of trouble. 7. Troubleshooting Table. Additional troubleshooting data can be found on Table 3-2 and in the Preventive Maintenance paragraphs.
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PUMP AND MOTOR ASSEMBLY 3 Troubleshooting Data MALFUNCTION Loss of Flow or Low Capacity
POSSIBLE CAUSE
CORRECTION
System component malfunction
Inspect all system components and correct any malfunction. Make sure that suction and discharge lines are open and all valves are in proper order.
Pump not primed
Check reservoir oil level and fill as required.
Low pump speed
Make sure motor is receiving full electric power.
Incorrect pump rotation
Make sure motor leads are properly installed.
Obstruction in piping
Inspect suction and discharge piping and remove any obstruction.
Wear of rotors and/or housings
Replace worn rotors and/or housings.
System bypass
Check all system relief valves for leakage and replace as required.
Loss of Suction
Suction line closed, blocked or leaking
Verify that suction line valve is open. Inspect suction line piping, flanges and valves and remove any obstruction or repair any leakage.
Low Discharge Pressure
Low reservoir level
Check reservoir level and fill as required.
Air in system
Make sure suction lines are full of oil.
Wear of rotors and/or housings
Replace worn rotors and/or housings.
Low motor speed
Make sure motor is receiving full electric power.
Obstruction in piping
Inspect suction and discharge piping and remove any obstruction.
Relief valve leakage
Replace relief valve as required.
System bypass
Check all system relief valves for leakage and replace as required.
Misalignment
Check pump and motor alignment, correct as required.
Restricted suction line
Check suction line and remove any obstruction.
Air in system
Make sure pump suction lines are full of oil. Check reservoir level and fill as required. Check all lines, flanges, joints and connections for leakage and repair as required.
Relief valve chatter or leakage
Check relief valve pressure settings. Replace relief valves as required.
Excessive or Unusual Noise or Vibration
TABLE 3-2—TROUBLESHOOTING DATA
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PUMP AND MOTOR ASSEMBLY 3 MALFUNCTION Excessive or Unusual Noise or Vibration (cont.)
Rapid Wear of Pump
Excessive Power Usage
POSSIBLE CAUSE
CORRECTION
Internal rubbing of pump parts
Verify pump and motor alignment. Inspect pump wearing parts and replace as required.
Mechanical problems
Check for loose or mispositioned couplings, broken shaft or worn bearings and repair or replace as required
Oil contains abrasive foreign matter
Clean filter and strainer in oil reservoir. Collect samples of oil from drain line when Crusher is operating and test for foreign matter.
Oil contains water
Remove any water from reservoir.
Misalignment
Check pump and motor alignment and correct as required.
Insufficient oil
Check for low capacity and/or loss of suction.
Oil more viscous than specified
Heat oil to proper temperature.
Pump suction and/or discharge lines closed or blocked
Make sure suction and discharge lines are open. Check lines and remove any obstruction.
Internal rubbing of pump parts
Verify pump and motor alignment. Inspect pump wearing parts and replace as required.
Excessive pump speed
Reduce pump speed to design limitation.
Mechanical problems
Check for bent shaft, tight shaft packing or pipe strain and repair or replace as required.
TABLE 3-2—TROUBLESHOOTING DATA (CONTINUED)
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PUMP AND MOTOR ASSEMBLY 3 Preventive Maintenance Performing a few preventive maintenance procedures will extend the life of the pump and reduce the cost per liter (gallon) pumped. 1. Lubrication -Periodic external lubrication should be applied slowly with a hand gun at all lubrication fittings provided. A good quality of multipurpose grease is satisfactory. Suggested frequency of lubrication is once every 500 hours (3 months) of operation. DO NOT OVER GREASE. 2. Packing Adjustment - Occasional packing adjustment may be required to keep leakage to a slight leak; if impossible to reduce leakage by gentle tightening, replace packing. 3. End Clearance Adjustment - After long service, the running clearance between the end of the rotor teeth and the head of the pump may have increased through wear to the point where the pump is losing capacity or pressure. Resetting end clearance will normally improve pump performance. See PUMP REPAIR INSTRUCTIONS REASSEMBLY. 4. Examine Internal Parts - Periodically remove the head, examine idler and bushing and head and pin for wear. Replacing a relatively inexpensive idler bushing and idler pin after only moderate wear will eliminate the need to replace more expensive parts at a later date. Be sure idler does not slide off idler pin as head is removed and drop and hurt someone or damage the part. 5. Cleaning the Pump - A clean pump is easier to inspect, adjust and runs cooler; plus, it looks better. 6. Storage - If a pump is to be out of service or stored for along time, drain it and protect it from rusting inside and out. Apply a light coat of rust preventive oil to all internal parts.
Pump Repair Instructions General If it becomes necessary to rebuild the oil pump, refer to the oil pump assembly in your crusher parts book. The pump assembly shows various pump rebuild kits that are available for servicing your pump. 1. Don’t drop parts during disassembly, such as the idler which can slip from the pin as the head is removed from the pump; it may drop on someone’s foot, plus it may get nicked or gouged. 2. Don’t stick fingers in the ports of a pump! The close running parts may trim more than fingernails if the pump is rotated. 3. Don’t spin the idler on the idler pin! Fingers may be jammed between teeth and crescent. 4. Do remember that a few simple preventive maintenance procedures such as adjustment of end clearance, examination of internal parts, etc., will extend the service life of the pump. Disassembly Before starting disassembly, study Figure 3-5 to determine the parts relationship. The parts are shown in a logical sequence of disassembly and will prove to be a valuable aid in dismantling the pump. 1. Remove the head from the pump. When the head is being removed, the idler usually stays on the idler pin in the head, but it may fall off if the inside of the head is tilted downward. A fall on a hard surface can damage the idler. If the idler should fall, check carefully and file or stone all nicked or rough places before reassembly. 2. Remove the head gaskets. If a new set is not available, the original gaskets may be re-used provided they are not damaged. Coat these gaskets with grease or Vaseline to prevent drying and shrinkage if exposed to the atmosphere for any length of time.
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PUMP AND MOTOR ASSEMBLY 3
2
1
8
7
3
9
4
5
6
12
11 10
HP 700 CRUSHERS
16
17 15
14
11
9 2
3
17
5
13
4 HP 200, HP 300, HP 400 and HP 500 CRUSHERS
10
16
12 1. 2, 3. 4. 5. 6. 7. 8. 9.
Thrust Bearing Kit Packing Gland Packing Packing Retainer Washer Bushing Bracket Sub-assembly Bracket Gasket Pipe Flange Gasket Rotor and Shaft
10. 11. 12. 13. 14. 15. 16. 17.
Idler and Bushing Head Gasket Head Capscrews Packing Gland Studs and Nuts Pipe Plugs Casing Idler Pin
FIGURE 3-5—OIL PUMP - EXPLODED VIEW
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PUMP AND MOTOR ASSEMBLY
PUMP AND MOTOR ASSEMBLY 3 7. Remove the packing from the casing. Be sure to take out all of the packing.
3. With the head removed, the parts can be checked for wear with a feeler gauge. By comparing the actual clearances in the pump with the clearances shown on Figure 3-6, the approximate condition of the pump may be determined.
8. The sleeve bushing should be inspected and if it shows signs of wear, should be replaced. This bushing must be removed from the packing gland end of the casing.
4. Remove the idler from the idler pin. If the idler pin is worn, the idler, idler bushing and idler pin should be replaced. Remove the idler pin from the head with a press. When installing a new idler pin be sure it is started straight and pressed into place.
9. The casing should be examined for wear, particularly at the sealing area between the port openings as shown in Figure 3-7. If this surface is in good condition, the casing in all probability may be used. All parts should be checked for wear before the pump is put together. When making major repairs, such as replacing a rotor and shaft, it is usually considered advisable to also install a new head and idler. When making minor repairs, when only an idler bushing and idler pin are required, other new parts are usually not necessary.
If the idler bushing is worn, a new idler and idler bushing must be installed. 5. Remove the packing gland by removing the packing gland nuts. 6. Carefully remove the rotor and shaft from the casing. First remove the pipe plug from the drain hole in the back of the casing. This will break the vacuum between the rotor and casing and help in removing the rotor and shaft. Use a hardwood block or piece of soft bronze between the hammer and shaft and drive the rotor from the casing.
1
2 FEELER GAUGE CLEARANCE BETWEEN ROTOR AND CASING
FEELER GAUGE CLEARANCE BETWEEN IDLER AND CRESCENT
6 3
4
7
5
8
COMPARISON OF IDLER THICKNESS WITH LENGTHOF CRESCENT
FEELER GAUGE CLEARANCE BETWEEN IDLER PIN AND IDLER BUSHING
1. 0.178 mm (0.007") to 0.229 mm (0.009") On a Side 2. 0.178 mm (0.007") to 0.330 mm (0.013") 3. 0.051 mm(0.002") to 0.102 mm (0.004") On a Side
4. 5. 6. 7. 8.
0.000 mm (0.000") to 0.102 mm (0.004") Crescent Straightedge Idler Head
FIGURE 3-6—FEELER GAUGE CLEARANCES
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PUMP AND MOTOR ASSEMBLY 3 1
5. Pack the pump with new packing. Cut the packing into individual rings that wrap exactly around the shaft. Install and seat each ring, one at a time, staggering the ring joints from one side of the shaft to the other. Lubricate the packing rings with oil or grease to aid in assembly. A length of pipe or tubing slid over the end of the rotor shaft will help in seating the packing rings.
2
4 3
6. Install the packing gland and nuts. The gland must enter the casing at least 3 mm (1/8”) after tightening the packing gland nuts.
GEAR REDUCER 1. 2. 3. 5.
Sealing Area Rotor Crescent Idler
Installation Gear reducers are shipped completely assembled and ready for installation EXCEPT FOR THE ADDITION OF LUBRICANT. To replace the reducer, proceed as follows:
FIGURE 3-7—CASING SEALING AREA
1. Remove the flexible coupling halves and keys from the old reducer.
Reassembly See Figure 3-5 to determine parts relationship and proceed as follows:
2. Mount the reducer in the reducer bracket finger tight. The breather should be located on the top of the reducer and the magnetic drain plug on the bottom as shown on Figure 3-8.
1. Install the rotor and shaft. Before placing the rotor and shaft in the casing, remove all burrs or rough surfaces that could damage the bushing in the casing. Coat the inside of the casing bushing and the rotor shaft with a thin film of grease or oil. Place the end of the shaft in the casing bushing, turn the rotor slowly from right to left, and push the rotor into the casing as far as it will go. Be sure the drain plug is out of the casing; this opening will let the entrapped air escape. 2. Place the head gaskets on the head. The proper amount of gaskets should be used to provide the necessary end clearance within the pump so it turns freely with no appreciable end play. The rotor shaft must be free to move axially, in and out, 0.127 mm (0.005") to 0.229 mm (0.009"). 3. Put the idler on the idler pin in the head. 4. The head can now be assembled on the pump. Tilt the top of the head away from the pump slightly until the crescent enters the inside diameter of the rotor and rotate the idler until its teeth mesh with the rotor teeth. Do not damage the head gaskets. Note correct position of the idler and crescent as shown on Figure 3-7. Tighten the capscrews and then recheck the end clearance. If the pump shaft cannot be rotated, more gaskets must be added. If, however, the pump has any noticeable end play, remove enough gaskets so the pump has no appreciable end play but still turns freely.
2
1
6
3
5 4 1. Gear Reducer 2. Breather 3. Low Speed Or Pump Side 4. Reducer Bracket
5. Magnetic Drain Plug (Not Shown) 6. High Speed Or Motor Side
FIGURE 3-8—GEAR REDUCER
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PUMP AND MOTOR ASSEMBLY
PUMP AND MOTOR ASSEMBLY 3 4. Once each year drain and refill. If the reducer is outdoors, change to the proper lubricant each spring and fall.
1
2
Operation After the first few hours of operation, inspect the reducer for leaks. If leakage between the gear case and cover cannot be stopped by tightening the capscrews, the gasket should be replaced. Leakage around either shaft indicates a damaged lip seal which should be replaced. The operating temperature on the outside of the reducer case, after a few hours of operation, should not be more than approximately 24° C (75° F) higher than the surrounding air temperature. The oil within the reducer should never exceed a temperature of 93° C (200° F).
1. Use Straightedge, These Surfaces Must Be Parallel 2. Check Width Between These Surfaces With Inside Calipers To Be Certain The Faces Are An Equal Distance Apart And Parallel
1
FIGURE 3-9—COUPLING ALIGNMENT
3. Place the coupling halves on both the high and low speed reducer shafts. 4. Align the low speed coupling half with the coupling half on the pump. Use a straightedge to align the coupling as shown on Figure 3-9. A C-clamp, clamped over pieces of keystock, may be used to hold this alignment until the mounting bracket is securely bolted to the pump base. It may be necessary to shim the bracket to the exact center height of the pump. 5. Rotate the reducer in the “banana” slots of the bracket until the high speed coupling half is at the exact center height of the motor coupling half. 6. Tighten the reducer to the reducer bracket securely.
3 2 1. Breather (Oil Fill Hole) 2. Drain Plug 3. Lower Oil Level Plug FIGURE 3-10—REDUCER LUBRICATION
7. Align the high speed coupling and fasten the motor tightly to the pump base. Lubrication Before operating the reducer, be sure to add lubricant (oil) as follows: DO NOT OVER FILL.
Reducer Oil Specifications Reducer Size
Quantity
Automotive Type Oil
1. Remove the breather and fill the reducer to the lower oil level hole as shown on Figure 310 and in Table 3-2.
“B”
0.25 liter (8 oz.)
Use SAE 30 Above 0° C (32° F)
2. After the first 100 hours of operation, drain and refill with new oil.
“C”
1 liter (36 oz.)
Use SAE 10 Below 0° C (32°F)
3. Check the lubricant level every 2,000 hours of operation or every 6 months, whichever occurs first. Add lubricant as necessary.
Table 3-2—Reducer Oil Specifications
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PUMP AND MOTOR ASSEMBLY 3 Reducer Repair Instructions Disassembly Before starting disassembly, study Figure 3-11 to determine the parts relationship. The parts are shown in a logical sequence of disassembly and will prove to be a valuable aid in dismantling the reducer.
6. Use a conventional gear or bearing puller to remove the bearings from the gear shaft. Remove the beveled spacer and press shaft from gear. Save the square key. 7. Use a puller and remove the bearings from the pinion shaft. Remove spacer from 7.65 to 1 ratio, “B” reducer, pinion shaft.
1. Disconnect the couplings and remove the capscrews holding the mounting bracket to the pump base. Remove the coupling halves and bracket from the reducer.
8. Remove lip seals from the gear case and cover only if they show signs of deterioration or damage. Lip seals must be pressed or driven out from inside of gear case and cover.
2. Remove the breather and drain plugs. Drain all lubricant from the reducer. 3. Remove capscrews holding the cover to the gear case.
Reassembly See Figure 3-11 to determine parts relationship.
4. Tap firmly and alternately on gear shaft and pinion shaft. This will separate the reducer halves.
IF THE GEAR RATIO IS TO BE CHANGED FROM THAT OF THE DISASSEMBLED REDUCER, BE SURE TO SELECT A PINION AND GEAR OF A COMMON RATIO. A PINION FROM ONE RATIO CANNOT BE USED WITH A GEAR FROM A DIFFERENT RATIO.
With two screwdrivers at opposite sides, carefully pry the gear case cover loose from the internal ball bearings.
1. Be sure all parts are clean, and that gasket surfaces are free from burrs.
DO NOT FORCE! Be careful not to damage the gasket or gasket surfaces.
2. Install the ball bearings on the pinion shaft. Be sure the bearings are seated firmly against the shoulder on the pinion shaft.
5. Grasp the pinion and gear shafts and pull both assemblies simultaneously from the case or cover.
2
6.27 to 1 Ration Only - “B” Reducer 7.95 to 1 Ration Only - “C” Reducer
4
10
3 22
1
9
23
5
7
6
11 8
24
17 19
21
12
13 16 14
18 20 Lip Seal Snap Rig Capscrew Gear Case Cover Pinion Shaft Spacer (7.65 to 1 Ration Only - “B” Reducer) 7. Ball Bearing 8. Key
1. 2. 3. 4. 5. 6.
9. 10. 11. 12. 13. 14. 15. 16. 17.
Breather Hex Nut Gear Case Lip Seal Snap Ring Drain Plug Gasket Ball Bearing Gear Shaft
18. 19. 20. 21. 22. 23. 24.
15 Gear Spacer Dowel Pin Locating Pipe Plug Ball Bearing Snap Ring Ball Bearing
FIGURE 3-11—TYPICAL GEAR REDUCER - EXPLODED VIEW
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PUMP AND MOTOR ASSEMBLY
PUMP AND MOTOR ASSEMBLY 3 ON THE 6.27 TO 1 RATIO “B” REDUCERS, AND THE 7.95 TO 1 RATIO “C” REDUCERS, IT IS NECESSARY FIRST TO INSTALL A SNAP RING IN THE GROOVE ON THE PINION SHAFT BETWEEN THE TEETH AND INNER RACE OF THE BALL BEARING. THE BEARING SHOULD BE SEATED AGAINST THE SNAP RING.
10. Install the capscrews and nuts for the reducer. Tighten securely, alternating around the gear case to prevent distortion. 11. Install the drain plug. Be sure the reducer is filled with the proper lubricant.
ON THE 7.65 TO 1 RATIO “B” REDUCERS, ONE SPACER IS REQUIRED BETWEEN THE INNER RACE OF THE BALL BEARING AND THE TEETH ON THE PINION SHAFT AND ONE BETWEEN THE BALL BEARING AND THE GEAR. THE SPACER ON THE PINION AND SHAFT SHOULD BE INSTALLED WITH BEVELED EDGE TOWARD BEARING. 3. Install the square key in the gear shaft and press the gear into place. Be sure the gear seats against the shoulder on the shaft. 4. Place the spacer on the gear shaft with the beveled edge toward the gear. Install the ball bearings on the gear shaft. Be sure the bearings are seated firmly against the spacer and shaft shoulder. 5. If the lip seals were removed during disassembly, place the gear case and cover gasket faces down, on a surface which will not mar this face. Be sure the snap rings are in the case and cover. Put gasket sealer on the outside diameter of the lip seals. Drive the lip seals, with lip toward the inside of the reducer, in place against the snap rings. Use a wood block covering the entire lip seal and drive evenly. Apply a lubricant to the lip seal sealing surfaces. 6. Block the gear case, open side up, to provide at least 95 mm (3-3/4”) clearance between the case and work surface. 7. Make certain the pinion and gear shaft keyways are free of burrs and sharp edges to prevent damaging the lip seal sealing surfaces. Take the pinion and gear assemblies, mesh the gear teeth, and insert simultaneously into the gear case half. Rotate the gear shaft slightly as it is pushed through the lip seal. Tap the end of the pinion shaft and gear shaft with a hardwood block to seat the bearings in the counterbores. 8. Place the gasket on the gear case. If the gasket is the least bit damaged, discard it and use a new gasket. 9. Align the gear case cover with the ends of the pinion and gear shafts, and carefully press the cover into place. Rotate pinion shaft during assembly. Tap the cover with a hardwood block to seat the bearings in the cover.
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PUMP AND MOTOR ASSEMBLY 3 This page left intentionally blank.
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PUMP AND MOTOR ASSEMBLY
Section 4
OIL FILTER AND COOLER OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1
FILTER BY-PASS RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1
WHEN TO CLEAN OR REPLACE FILTER ELEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1
REPLACING CARTRIDGE TYPE FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2
VENTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2
MAINTAINING CLEANABLE TYPE FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2
OIL CONTAMINATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2
COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3
WATER COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4
WATER PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4
CONTROLLING THE WATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4
TEMPERATURE CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4
WATER PRESSURE REQUIRED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5
WATER FLUSHING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5
FREEZE-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5
WHEN NOT IN USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6
GALVANIC CORROSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6
REPAIR OF THE COOLER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6
MECHANICAL CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7
CHEMICAL CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7
USE OF STRAINERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7
COOLER BY-PASS RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7
AIR COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8
THE RADIATOR FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9
AIR SYSTEM RELIEF VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9
GATE VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9
MANUAL BY-PASS VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9
MANUAL BY-PASS VALVE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9
OIL FILTER AND COOLER 4 OIL FILTER
When To Clean or Replace the Filter Elements A differential pressure gauge is installed to clearly show when the filters require cleaning or replacing without remembering any pressures.
The oil filter or filters are either replaceable cartridge type or cleanable type. See Figure 4-1 which shows a typical filter arrangements. The filters provide a 50 micron filtration. The filter has been sized to provide the proper capacity, liters per minute (GPM) for adequately lubricating the Crusher.
When there is approximately a 1.7 Bars (25 PSI) a differential on the gauge, the filter element needs to be cleaned if cleanable type or replaced if the replaceable cartridge type.
The oil strainer inside the oil tank is NOT a filter and is not intended to remove particles of dust and dirt from the oil.
OIL MUST BE AT OPERATING TEMPERATURE WHEN CHECKING FOR PRESSURE LOSS, AS A GREATER AMOUNT OF OIL WILL BE BY-PASSED WHEN USING COLD OIL, THEREFORE REGISTERING A LARGE PRESSURE LOSS WITHIN THE FILTER.
Filter By-pass Relief Valve With the filtering arrangement, a relief valve set at 3.4 Bars (50 PSI) is also installed. When the oil is cold or if plugging of the filter occurs the relief valve would automatically by-pass the oil around the filter.
Valves can be installed at the inlet and outlet of the filter to shut off the flow of oil through the filter. This will keep the lubrication system in operation when servicing the filters.
1
2
3 9 8
4
5 7 6
1. Air Vents 2. Oil Filter 3. Differential Pressure Gauge
4. Quick-Turn Shut Off Valves To be used when replacing filter elements. 5. Oil Feed Line to Crusher
6. 7. 8. 9.
Filter Drain Oil Line from Oil Pump Filter Relief Valve Hose
FIGURE 4-1—TYPICAL OIL FILTER PIPING ARRANGEMENT R
HP SERIES LUBRICATION SUPPLEMENT
4-1
OIL FILTER AND COOLER 4 Replacing Cartridge Type Filter Observe carefully how the filter is assembled when it is taken apart the first time. To replace a typical filter, proceed as follows: 1. Shut off oil pump or close valves on each side of filter. 2. Open the air vent valve on top of the filter, then open the drain valve at the bottom of the filter or filter piping and completely drain the unit. 3. Remove the filter cover, then the pressure plate assembly and lift out the dirty element. Use the plastic bag the replacement element is shipped in for disposal of the dirty element.
By placing your hand against the side of the filter shell you can tell when air is trapped inside the filter; that portion of the filter that contains the air will feel cooler than the rest of the filter as the warm oil cannot penetrate that portion of the filter containing the trapped air. Maintaining Cleanable Type Filter The cleanable type filter element is cleanable up to five times but must be replaced after the fifth cleaning. Failure to replace or clean the element will allow damaging particles to enter the crusher with the oil. To remove the filter element from its housing follow this procedure: 1. Shut down the crusher.
4. Check the bottom seat to make sure there isn’t a gasket stuck to it from the old element.
2. Shut down the oil pump.
5. Place the new element in the filter shell, making sure it is properly seated on the inlet seat at the bottom of the shell.
3. Unscrew the top cover of the oil filter housing. (Take care not to damage the o-ring seal.)
6. Position the pressure plate assembly on top of the element, being careful that the tube on the pressure plate slides into the hole in the top of the element.
4. Lift the filter element straight up and out of the filter housing.
7. Place the filter cover over the filter itself. The large spring on the pressure plate will compress as the nuts on the swing bolts are turned down. Tighten all the cover bolts evenly and no tighter than necessary. Venting Periodically bleed the air from within the filter by opening the valve at the top of the filter. This will break the trap and allow the oil to flow through the entire filtering surface. A little oil will bleed out with the air, so observe the operation carefully as initially the air and oil mixture will sputter. Close the valve when the oil flows out in a steady stream. If air is continuously forced into the filter with the oil, unscrew the valve and connect a small tube from the top of the filter directly to the oil tank.
Copper (CU) Aluminum (Al) Iron (Fe) * Silica (Si) (Dirt) Chromium (Cr) Lead (Pb) Contamination Level (Total Solids) Water
A CHECK VALVE INSTALLED ON THE DISCHARGE SIDE OF THE FILTER WILL ELIMINATE THE NEED TO DRAIN THE FILTER HOUSING.
OIL CONTAMINATION If an unusual increase is seen over a 2 to 4 week period in any of the contaminants listed in chart “Oil Contamination Guidelines,” the Crusher should be checked to determine probable cause (ferrous or non-metallic may indicate whether cause is internal metallic contact or infiltration of dust or rock). On all crushers that are experiencing high bushing, socket liner or seal wear, the analysis of the oil will help indicate the possible source of the wear (ferrous, metallic, non-metallic).
ACCEPTABLE Below 100 PPM Below 5 PPM Below 20 PPM Below 25 PPM Below 0.5 PPM Below 70 PPM Below 0.1% Below 0.1%
HIGH Above 210 PPM Above 10 PPM Above 50 PPM Above 65 PPM Above 1.5 PPM Above 190 PPM Above 0.2% Above 1.0%
* Silica limits must be interpreted in relationship to copper and iron levels. If high silica is accompanied by high copper and/or iron, it is considered abrasive and the oil is rated unsatisfactory.
TABLE 4-1—OIL CONTAMINATION GUIDELINES
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OIL FILTER AND COOLER
OIL FILTER AND COOLER 4 COOLER As the construction of an air cooler depends on what the highest ambient temperature is, and the size of Crusher, this type of cooler in some cases must be designed to meet the particular Crusher cooling requirements. This kind of cooling system is as efficient as a tube type water cooler, refer to the paragraph in this section entitled AIR COOLER for installing and operating an air cooler. Piping drawings that show the proper method of installing an air cooler are furnished whenever an air cooling system is used.
The lubricating system is equipped with a cooler which will maintain an oil temperature from the Crusher between 38° C (100° F) and 54° C (130° F). There are two types of coolers available. One uses water circulating through a tubular cooler. This type of cooling is shown in Figure 4-2. In some areas or locations where water is in short supply, air can be used for cooling the oil. A large radiator, similar to an automobile radiator, through which the warm oil to the Crusher is circulated, is used. See Figure 4-3. Mounted on the radiator is a motor driven fan that forces the surrounding air past the radiator core and fins and cools the oil.
11
1. 2. 3. 4. 5. 6. 7.
1
8. 9. 10. 11. 10
Water Cooler Oil Pressure to Crusher Temperature Control Valve Overheated Water Discharged to Drain Oil Feed Line to Crusher Temperature Sensitive Bulb After Cooler Temperature and Oil Temperature to Crusher Oil Line from Oil Pump Cooler Relief Valve Hose Before Cooler Temperature
2 3
4 9 5
8 7
6
FIGURE 4-2—TYPICAL WATER COOLER PIPING ARRANGEMENT
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4-3
OIL FILTER & COOLER 4 Water Cooler (See Figure 4-2) The standard 152 mm (6") diameter cooler normally furnished will maintain an oil temperature to the Crusher of 46° C (115° F) or below, even with cooling water temperature as high as 27° C (80° F). For the quantity of water required to adequately cool the Crusher, refer to Table 4-2. For longer cooler life, it is recommended that the cooler be mounted VERTICALLY in the lubricating system as shown in Figure 4-2. Also, to provide for longer cooler life a special copper-nickel alloy is used in the tube construction of these coolers to resist any chemical action from using impure water.
Water Piping A continuous water system, that which can be obtained from a plant water system, should be used. Water is simply circulated through the cooler and discharged. When using such a system avoid operating in freezing temperatures unless precautions are taken to prevent the water from freezing. Controlling The Water To control the amount of water to the cooler, a globe valve can be installed in the system to manually regulate the amount of water through the cooler or a temperature control valve can be installed in the system to automatically control the cooling water to the cooler. Refer to Figure 4-2 and install either the globe valve or the temperature control valve in the location as shown. HP 700*
Quantity of Water Required Liters per Minute (U.S. Gallons per Minute)
190 (50)
151 (40) HP 400 & HP 500
113 (30)
HP 200 & HP 300
76 (20)
38 (10) 0 10° C (50° F)
15° C (60° F) 20° C (70° F) Water Temperature
27° C (80° F)
* HP 700 Crushers require two (2) coolers. Quantity of water shown on graph is water flow required for each cooler. TABLE 4-2—QUANTITY OF WATER REQUIRED
Manually controlling the water through the cooler means periodic checks by the crusher operator to see that the oil feed line temperature to the Crusher remains fairly constant. Adjustment to the globe valve may be required as water temperatures vary during the period that the Crusher is operating. Automatic controlling of the water through the cooler is preferred and is the arrangement that is shown in Figure 4-2. Temperature Control Valve Valve Location The temperature control valve should be mounted as close to the cooler as possible and should be installed in the cooling water OUTLET line as shown in Figure 4-2.
Check that the temperature control valve has been installed with the arrow on the valve body in the direction of the water flow. Valve Position If possible, let the capillary tubing run downward from the valve to the temperature sensitive bulb. Bulb Location This is perhaps the most important factor in a good installation. The entire bulb, not just part of it, must be exposed to the fluid of which the temperature is to be controlled. In this case the fluid to be controlled is the lubricating oil. The temperature sensitive bulb is to be installed in the oil feed line to the Crusher as shown in Figure 4-2.
This keeps the cooler filled with water which reduces corrosion of the cooler tubes and prevents the control valve from being affected by extreme variations of cooling water temperature. R
4-4
OIL FILTER AND COOLER
OIL FILTER AND COOLER 4 Temperature Setting The valve should be factory set to maintain a feed line temperature to the Crusher of 460°C (115°F). General Information Temperature control valves are instruments, not pipe fittings. A dent in the body or a sharp bend in the capillary tubing may prevent the valves from operating. Do not subject these controls to water-hammer conditions or excessive pressures. Temperature Adjustment To lower the oil temperature, turn the adjusting screw counterclockwise; to raise the temperature, turn clockwise. Since the valve controls the water flow through the cooler and the cooler cools the oil to the Crusher, it will probably require 5 to 10 minutes for an adjustment of the valve and water flow to show a change in oil temperature. Changes in valve settings should, therefore, be made 1/2 turn at a time with 10 minutes or so between changes. Operation Remember that this is a modulating control. It does not alternately open wide and shut tight like an electrical control device. In normal operation, the control valve remains in a constant, partially open position which is automatically adjusted whenever conditions require it. Maintenance The only servicing normally required is to keep the control clean. The valve can be inspected and cleaned by access through the inlet and outlet, without disassembly. The temperature sensitive bulb of the valve should be located where it will be most affected by the temperature changes of the lubricating oil. Accumulations of sludge or dirt will reduce its sensitivity. The bulb should be examined and cleaned whenever the oil is changed or if the oil temperature increases abnormally. Troubleshooting If the control does not appear to be holding temperatures steady, or if not enough cooling is obtained, first check for external conditions which may prevent the control from operating correctly. Examples are: low or fluctuating water supply pressure; damaged or obstructed valves, strainers or other accessories; supply piping too small; dirty bulb or poor bulb location; kinked or broken capillary tubing. If the valve will not close, check for dirt or foreign matter under the valve seat. The valve can be inspected through the inlet and outlet openings without disassembly, and can usually be cleaned out with an air hose.
If overheating results because a valve stays closed, regardless of the temperature at the bulb, the thermostat may have lost its ‘fill” and become inoperative. To check this, remove the valve and bulb from the line, set the control at about the middle range, and insert the bulb in water hotter than the maximum of the range. If the control does not open, factory repairs to the thermostat are required. If water leaks from the valve body, some part may be loose or partially disassembled. Otherwise, a seal bellows may be damaged requiring factory replacement. If the valve chatters, this usually means a loose or disassembled interior part. Chattering is sometimes caused by other devices near the control, and can sometimes be eliminated by changing piping, arrangements, valve position, or supply pressure. Water Pressure Required The amount of water pressure required for the Cooling system is dependent upon the quantity, Liters Per Minute (GPM) of water that is necessary to adequately cool the Crusher, however, the pressure loss within the cooler and through a temperature control valve is minimal, approximately 0.69 Bars (10 PSI). The maximum water flow that is allowed through the cooler is 190 Liters Per Minute (50 GPM). Water Flushing Valve Located adjacent to the cooler should be a water flushing valve (Gate Valve) that is to be opened once a day to flush the sediment that remains within the cooler from the generally slow moving water. The flushing valve water can be simply discharged into a drain. Opening the flushing valve directs the full force of the water through the cooler, dislodging any sediment or foreign particles that might remain in the cooler and lead to premature failure of the cooler tubes. Flushing for several minutes each day is all that is required. Flushing is strongly recommended in those installations where the cooling water cannot or is not strained, before entering the cooler. Freeze-up If there is a possibility that the water within the cooler will freeze and rupture the cooler, it must be thoroughly drained or an anti-freeze added prior to cold weather. A most effective method in the prevention of a freezeup would be the use of a commercially accepted solution of water and anti-freeze. It is recognized that this is not always possible under some of the circumstances in which these coolers are operated.
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OIL FILTER AND COOLER 4 It is, therefore, important that in case of potential freeze-up, the units are properly drained after use. In addition it is recommended that air pressure be applied to blow out any water which does not drain out normally. To assure that the water will drain out of the tubes of a cooler mounted “horizontally”, the cooler must be tipped approximately 50 mm (2”) toward the inlet and outlet bonnet. This will permit the water held in the tubes by surface tension to flow out of the tubes. Drain plugs located in the bottom of the cooler bonnet or in the bottom of the cooler piping are to be used for draining the cooler completely during cleaning or in freezing weather. When Not In Use Should the cooler not be in use for a month or more, the cooler must be thoroughly drained of water and allowed to dry. This is done by removing the end bonnets on the cooler and blowing out the tubes. Water in the cooler will stagnate and lead to corrosion of the tubes if water is allowed to stand in the tubes without any movement for a period of time. This procedure should also be followed if there is a seasonal shutdown. Galvanic Corrosion Each cooler is furnished with zinc anodes in order to minimize galvanic corrosion. In most fresh water applications, these anodes are not necessary and can be replaced with a pipe plug. In all salt water applications, it is advisable that the anodes be kept in the cooler. Anodes should be checked periodically, as they gradually erode away. How quickly the anodes will erode cannot be predetermined. Repair Of The Cooler Should any of the tubes within the cooler tube bundle begin to leak, the individual tube(s) can be repaired as follows; Leaking of the cooler will show up as water in the oil tank. The following procedures are offered only as suggestions in those instances where the cooler cannot be returned to the manufacturer or to an automobile radiator shop specializing in repair of such equipment. 1. For a temporary repair, drive wooden tapered plugs into each end of the leaking tube and seal the plugs with caulking compound. 2. For a more permanent repair, braze each end of the leaking tube shut, using silver solder. Do not use ‘soft’ solder. The brazing flux must be completely neutralized after the repair has been completed. If the flux has not been completely neutralized, accelerated corrosion of the remaining tubes within the cooler will take place.
3. If freezing of the cooler should occur, remove the end bonnets of the cooler and thoroughly inspect the circumferential seam between the tube sheet and the cooler shell for cracks. The tube sheet is the perforated plate of the cooler that the individual tubes are mounted in. Immerse the cooler in a barrel of water only exposing that area of the cooler that requires repairing. Proceed to repair the cracked seam with silver solder. Immersing the cooler in water removes some of the heat caused by brazing before the thermal expansion can cause additional damage to the cooler. Cleaning The greatest efficiency and longest life will be obtained from the cooler if it is kept clean. Periodic cleaning not only improves the heat transfer efficiency of the cooler, but also retards corrosion by removing corrosion - causing deposits and obstructions to smooth flow. Again, a definite schedule for cleaning the cooler cannot be predetermined, but inefficient cooling of the oil will determine when cleaning is necessary. To determine cooler efficiency, thermometers should be installed on the lube oil lines entering and leaving the cooler. The amount of heat transferred can then be seen at a glance. Whenever there is only a slight difference in oil temperature in and out of the cooler, the cooler may have become plugged with sediment or corroded and require cleaning. If any unusual cooling problems are experienced such as high ambient or water temperatures or highly corrosive water, consult the factory for special recommendations, giving full operating conditions and data. Regardless of the type of service and whether straining is practiced or required, the majority of all coolers benefit from periodic cleaning. A special alloy is used in the tube construction of these coolers to resist any chemical action when using impure water. The copper alloys, like most metals, depend for their corrosion resistance on a thin protective film of copper oxide laid down on the metal surface. Any local breaks in this film will leave adjacent areas of protected and unprotected metal, a possible starting point for severe corrosion. Tube cleaning methods used should therefore avoid disturbing this “protective film”. The choice between chemical and mechanical cleaning will usually depend on such factors as nature of the fouling material, construction of the cooler, relative effectiveness and costs.
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OIL FILTER AND COOLER 4 Mechanical Cleaning Mechanical cleaning is particularly adaptable for cleaning the INSIDE of the tube surfaces. Forcing high pressure water, or water and high pressure air, is effective in many instances. More thorough cleaning consists of forcing fiber brushes, or nylon brushes through the tubes. Water is particularly effective in providing a flushing action to remove the loosened material. Nylon brushes, which retain their stiffness in water, are somewhat more effective in removing more tightly adherent scale and dirt. Wire brushes are NOT recommended for cleaning copper alloys of this type. Chemical Cleaning On the shell or lube oil side, chemical cleaning provides the only method of cleaning the cooler. The chemicals used are to be selected for their effectiveness in dissolving all or parts of the scale or fouling material. In some cases an additional flushing action is necessary to remove the loosened solids. The selection of cleaning agent and method depend upon the nature of the scale or fouling material, cooler construction, facilities available, etc. There are hazards involved in using some of the most effective solvents, such as the chlorinated hydrocarbons, inhibited hydrochloric acid and many proprietary compounds. Cleaning of this type should always be done by or under the close supervision of specialists in this type of work. Use Of Strainers Foreign particles permitted to enter a cooler are capable, depending upon their size, nature and quantity, of partially or completely blocking the tubes. Similar objects too small to block the tubes may, by sticking to the tube walls, impair the heat transfer and also lead to that type of corrosion known as “deposit attack”. This can occur whether the deposits are organic or inorganic, although the decay of organic matter is frequently an accelerating factor. Therefore, it is strongly recommended that the water to the cooler be strained (100 mesh or finer) of all sediment prior to circulation through the cooler, however, the strainer must be of adequate size to prevent plugging the strainer and cutting off the water flow to the cooler. A 25 mm (1”) strainer is NOT large enough to assure constant water flow to the cooler. If the water supply cannot be strained with a large capacity strainer, it is suggested to operate without one. Conditions of the particular installation will usually dictate the size of strainer required and whether stationary or revolving strainers should be used. Cooler By-pass Relief Valve When using a cooler, a pressure relief valve is to be installed to automatically by-pass the oil around the cooler when operating with cold oil or if clogging of the cooler occurs. With cold oil, the pressure drop within the cooler increases, thereby forcing the cooler relief valve to open and causing the majority of the oil to by-pass around the cooler rather than go through it. See Figure 4-2. R
HP SERIES LUBRICATION SUPPLEMENT
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OIL FILTER AND COOLER 4
1
9 2
10 8
11
3
4
13
5 12 7 6 1. 2. 3. 4. 5. 6. 7.
Air Flow Air Cooler Electric Motor Hose Oil Temperature to Crusher Oil Feed Line to Crusher Oil Pressure to Crusher
8. 9. 10. 11. 12. 13.
Fan Rotation Oil Pressure to Crusher Oil Temperature to Crusher Air Cooler Oil Line from Oil Pump Cooler Relief Valve
FIGURE 4-3—TYPICAL AIR COOLER PIPING ARRANGEMENT
Aircooler (See Figure 4-3) An air cooler, which is a large radiator similar to an automobile radiator, through which the warm oil to the Crusher is circulated, is easy to install, since it is practically ready for operation when received. Piping to the radiator should be externally supported and not hung on the radiator itself. Flexible hose connections are recommended when piping to the radiator. The radiator should be installed between the oil pump and the Crusher. Piping drawings that show the proper method of installing an air cooler are furnished whenever an air cooling system is used. Never mount the radiator in an enclosed room as the air cooler depends on a continuing supply of moving air to cool the oil sufficiently. Before bolting the radiator to the foundation make sure that it is level.
Since mounted on the radiator is a large diameter motor driven fan that forces the surrounding air past the radiator core and fins and cools the oil, check the tightness of the fan motor hold down bolts.
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OIL FILTER AND COOLER
OIL FILTER AND COOLER 4 The Radiator Fan When wiring the fan motor, check the motor nameplate for the correct voltage, frequency and phase; electrical connections are also shown on the nameplate. For proper operation and lubrication of the motor, refer to the manufacturer’s service bulletin. All fuse protection equipment is to be furnished by the customer to conform to local electrical codes. The starter for the fan motor is also to be furnished by the customer to meet the customer’s specific needs, location and electrical interconnecting requirements. Attach a No. 8 or larger ground wire to the radiator and motor assembly. After the motor is connected to the power supply, check the motor and fan for correct rotation as shown on the cooler piping drawings.
To prevent serious bodily injury make sure the fan guard is in place, secured and not damaged before operating the radiator fan. The blowing air is to be taken from the fan side of the radiator, forced through the core and out of the front of the radiator. It is strongly recommended that the radiator be equipped with a core guard in order to protect the radiator core and fins from being damaged by flying rocks. The greatest efficiency and longest life will be obtained from the cooler if it is kept cleaned. Periodic cleaning improves the heat transfer efficiency of the cooler, therefore, clean the exterior surface of the cooling core whenever they become clogged with dust and dirt. Clean the core thoroughly with a fiber brush or blow out with compressed air. At least once a year, drain the oil from within the radiator and clean the radiator tubes thoroughly with either a fiber or wire brush.
GATE VALVES There is a gate valve mounted on the inlet and outlet of the radiator. These are to be kept open and only closed if a radiator is being removed for replacement. Manual By-Pass Valve This valve, which is kept normally closed, can be used to reduce the cooling capacity of the radiator by by-passing a portion of the oil flow. This is to avoid operating at low oil temperatures during winter operation. Manual By-Pass Valve Adjustment This valve is normally kept fully closed. The valve is only to be fully or partially opened as follows: If during cold winter weather the wind passing through the radiator, without the temperature switch calling for the fans to actuate, can cool the lube oil below the recommended operating drain line temperature of 38°C (100°F). To bring the crusher operating drain line temperature up to its proper temperature, open the by-pass valve in small increments, until the proper drain line temperature is obtained. Wait a minimum of 15 minutes after each incremental turn to allow the oil temperature to stabilize before turning the valve again. This procedure will allow some of the oil to by-pass the radiators and keep the Crusher at its proper operating temperature during cold weather operation. As the outside temperature warms, the by-pass valve is to be, again, fully closed, so that all the lube oil is circulated through the radiator.
Refer to the paragraph in this section entitled TEMPERATURE SWITCH for operating the cooler fan automatically. Air System Relief Valve The skid mounted air system is furnished with a relief valve, factory set at 3.4 Bars (50 PSI), to protect the radiators from overpressure due to either a plugged radiator or cold viscous oil.
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OIL FILTER AND COOLER
Section 5
RELIEF VALVES, PRESSURE & TEMPERATURE SWITCHES MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1
PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2
ELECTRICAL RATING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2
TEMPERATURE SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3
HIGH TEMPERATURE ALARM OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3
AIR COOLER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4
ELECTRICAL RATING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4
RELIEF VALVES, PRESSURE & TEMPERATURE SWITCHES 5 MAIN RELIEF VALVE A factory adjusted relief valve located near the countershaft box is provided to protect the Crusher from excessive pressure, see Figure 5-1. If the oil pressure exceeds the valve setting, the excess oil is returned to the oil tank. When starting in cold weather, oil may
be returned to the oil tank because of increased oil viscosity resulting in higher oil pressure. Removing the inspection cover in the oil tank cover will show if any oil is being returned to the tank from the relief valve.
2 1
RELIEF VALVE AND PRESSURE SWITCH CONNECTIONS HP 200, HP 300, HP400 AND HP 500 CRUSHERS
3
12
1. 2. 3. 4. 5. 6.
Main Relief Valve Countershaft Box Oil Hose to Countershaft Box Countershaft Drain Line from Crusher to Tank Connect Pressure Switch to Main Pressure Line as Shown 7. Tee 8. Pressure Gauge 9. Rubber Hose is Recommended - Keep Length to Minimum
11 4 10 5 7
12 9
10
6
8 15 8 13 10. Pipe Plug is Used for Venting the Piping Leading to the Pressure Switch Upon Initial Operation 11. Main Pressure Line to Crusher 2 12. Pressure Switch (Mount on Stationary Structure, Not on Crusher to Avoid Vibration) 13. Cross 14. Connect Pressure Switch to Main Pressure Line as Shown. Rubber Hose is Recommended - Keep Length to Minimum 15. From Pump
4 3 14
11
5
15 PRESSURE SWITCH CONNECTIONS - HP 700 CRUSHERS FIGURE 5-1—RELIEF VALVE AND PRESSURE SWITCH CONNECTIONS
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RELIEF VALVES, PRESSURE & TEMPERATURE SWITCHES 5 On the HP 700 Crushers, the main relief valve is located at the oil pump on the Package Lube System. By-passing oil from the relief valve is returned into the side of the oil tank. There is an inspection cover to observe the returning oil.
Connect the pressure switch and pressure gauge into the oil feed line leading to the countershaft box as shown in Figure 5-1. The switch should be located in a place where it is protected from dust and vibration. DO NOT ATTACH TO THE CRUSHER.
The proper relief valve setting is shown in Table 5-1. This setting is stamped on the body of the relief valve and indicates cracking pressure.
IF THE CRUSHER IS ALLOWED TO OPERATE AFTER THE LOSS OF OIL PRESSURE OR FLOW, SERIOUS DAMAGE CAN RESULT TO THE CRUSHER.
CRUSHER SIZE
VALVE SETTINGS
HP 200, HP 300, HP 400 and HP 500
2.4 Bars (35 PSI)
HP 700
10 Bars (150 PSI)
TABLE 5-1—MAIN RELIEF VALVE SETTINGS
It is normal for the temperature of the lubricating oil to reach 54°C (130°F) and still by-pass or return oil to the tank from the relief valve. PERIODIC INSPECTIONS OF THE RELIEF VALVE RETURN LINE IN THE OIL TANK SHOULD BE MADE, BOTH WHEN THE OIL IS COLD AND WHEN IT IS WARM, TO DETERMINE WHETHER OR NOT THE VALVE IS FUNCTIONING PROPERLY. AT SOME POINT THE VALVE MAY REQUIRE REPLACING. UNDER NO CIRCUMSTANCES ADJUST OR DISMANTLE THE VALVE - REPLACE IT INSTEAD!
PRESSURE SWITCH A pressure switch is provided to protect the Crusher in the event of oil pressure failure. Should the pressure in the oil feed line drop below the minimum safe operating pressure of the Crusher, the pressure switch is activated. An electrical warning signal and machinery shut-down interlocking arrangement connected to the pressure switch alerts the operator of such pressure loss. The pressure switch and a pressure gauge is furnished as standard equipment on all Crushers.
LOSS OF PRESSURE CAN BE CAUSED BY SEVERAL CONDITIONS; INSUFFICIENT OIL IN THE LUBRICATING SYSTEM, BROKEN OIL FEED LINE, OIL PUMP FAILURE OR EXCESSIVE BEARING WEAR IN THE CRUSHER. A CAREFUL INSPECTION WILL DISCLOSE THE TROUBLE. The pressure switch which has an adjustable range setting, is factory set for the minimum safe operating pressure of the Crusher, as shown on Table 5-2. This basic pressure setting presumes that the pressure switch is located at the same elevation as the crusher countershaft. Should the pressure switch be located below the countershaft, the following adjustment must be made: for every 3/4 meter (2-1/2 feet) the pressure switch is below the countershaft INCREASE the base setting 0.07 Bars (1 PSI). Piping leading to the switch must be vented before initial operation by opening the tee at the pressure switch using the pipe plug provided. For the proper operation of the pressure switch with electrical warning signals and machinery shut-down interlocking arrangements, refer to Section 6, Lubrication System Control Logic. Electrical Ratings Pressure Switch: Single pole, double throw. Contact Maximum A.C. Rating 10 amps at 230 volt 5 amps at 575 volt The switch is mounted in a weather-proof enclosure.
CRUSHER SIZE
PRESSURE SWITCH ACTIVATES AT BARS (PSI)
PRESSURE SWITCH DEACTIVATES AT BARS (PSI)
HP 200 & HP 300
0.56 (8)
0.85 (12)
HP 400 & HP 500
0.85 (12)
1.13 (16)
HP 700
1.06 (15)
1.41 (20)
No adjustment of the differential screw is required as this is factory set. TABLE 5-2—PRESSURE SWITCH BASE SETTING (LOW PRESSURE ALARM)
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RELIEF VALVES, PRESSURE & TEMPERATURE SWITCHES
RELIEF VALVES, PRESSURE & TEMPERATURE SWITCHES 5 TEMPERATURE SWITCH General Temperature switches are installed in the oil drain line to serve three functions as shown in Figure 5-2. One is to be used as a high temperature alarm, one is used as a minimum temperature interlock, the other is to operate a radiator type oil cooler fan motor automatically if the Crusher has this type of oil cooler. Should all three of these functions be desired, three temperature switches would have to be used. The temperature switches should be mounted in the drain line as near the oil tank as possible. A special pipe, with 13 mm (1/2”) half couplings welded into it or regular pipe tees, is furnished with tank. It is important to have the heat sensitive bulb of the temperature switch completely covered by the returning oil at all times and since the drain line is normally only half filled with oil, it is recommended that the temperature switch be mounted in the drain line upside down with the heat sensitive bulb entering the drain pipe from the bottom side.
When installing temperature switch, always screw in using a wrench on hex nut between probe and body. The high temperature switch is furnished as standard equipment on all Crushers. High Temperature Alarm Operation Once the switch is installed, it is to be electrically inter-locked with warning signals and machinery shutdown equipment. When the lube oil coming from the Crusher reaches the HIGH temperature setting, as shown on Table 5-3, the warning signal is activated and the crusher feeder is shut off by the switch, thereby warning of an abnormal crushing condition. The warning signal will continue to operate for either as long as the oil temperature remains above the HIGH setting or until it has been shut off manually. Once the difficulty has been corrected, the oil temperature must drop below the LOW setting, as shown on Table 5-3, before the temperature switch will again become deactivated. IF TEMPERATURE STAYS AT HIGH TEMPERATURE SPECIFIED IN TABLE 5-3 OR CONTINUES TO RISE WITHIN ONE MINUTE AFTER FEED IS SHUT OFF, SHUT OFF CRUSHER.
3
2
1
4 5
6
HIGH TEMPERATURE ALARM
1. Temperature Pipe 2. Drain Line Temperature 3. Temperature Switch (High Temperature Alarm)
HIGH TEMPERATURE ALARM AND AIR COOLER OPERATION
4. Temperature Switch (Air Cooler Fan Motor Operation) 5. Temperature Switch (High Temperature Alarm) 6. Oil Tank
FIGURE 5-2—TYPICAL TEMPERATURE SWITCH CONNECTIONS
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RELIEF VALVES, PRESSURE & TEMPERATURE SWITCHES 5
CRUSHER SIZE
TEMPERATURE SWITCH HIGH SETTING
TEMPERATURE SWITCH LOW SETTING
All Size HP Cones
60° C (140° F)
54° C (130° F)
TABLE 5-3—TEMPERATURE SWITCH BASE SETTINGS (HIGH TEMPERATURE ALARM)
Install the switch with the factory setting shown on Table 5-3. After beginning crushing operations, carefully observe and record the temperature in the oil drain line for several days. Once this oil temperature has stabilized, that is, reached a relatively constant temperature, it is recommended that the temperature switch is reset. Using this recorded temperature, turn the temperature switch range adjustment knob at bottom of switch until the switch setting is 6° C (10° F) above the temperature in the drain line, therefore, warning of impending trouble before any damage can result. Turning the range adjustment knob CLOCKWISE will RAISE the temperature, while turning the knob COUNTERCLOCKWISE will LOWER the temperature. No adjustment of the differential screw is required as this is factory set for 6° C (10° F). Crusher oil temperature usually remains constant after operation has begun. At what temperature the lube oil will stabilize depends upon such things as type of crushing, ambient temperature and crusher location.
Air Cooler Operation When air is used to cool the oil, a temperature switch which is furnished is to be used to control the fan motor on the oil cooler which would otherwise run unnecessarily. The switch will automatically start the fan motor when the oil temperature in the drain line reaches 52° C (125° F) and stop the motor when the temperature drops to 46° C (115° F). Therefore, the fan motor on the radiator type cooler will only operate when necessary, that is, when the lube oil temperature in the drain line is 52° C (125° F) and above. Electrical Ratings Temperature Switch: Single pole, double throw. Contact Maximum A.C. Rating 10 amps at 230 volt 3 amps at 575 volt The switch is mounted in a weather-proof enclosure.
Where cooling facilities must be used to bring the lubricant into the oil temperature range previously specified, careful regulating of the water supply or the fan motor, depending on type of cooling used, will give an even more constant oil temperature. Therefore, when using a cooler, the re-adjustment of the temperature switch HIGH setting, see Table 5-3, is most important as a Crusher with a cooler usuallyhas lower operating temperatures. The lower the operating temperature the more important it is that the switch be reset to within 6° C (10° F) of the oil temperature. High temperature can be caused by several conditions; insufficient oil in the lubricating system broken oil feed line, oil pump failure or excessive bearing wear in the Crusher. A careful inspection will disclose the trouble. For the proper operation of the temperature switch with either electrical warning signals and machinery shut-down interlocking arrangements, refer to the paragraph entitled INTERLOCKING SAFETY CONTROLS.
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Section 6
LUBRICATION — CHECK LIST & CONTROL LOGIC CHECK LIST FOR LUBRICATION SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1
LUBRICATION SYSTEM CONTROL LOGIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3
CRUSHER LUBRICATION PUMP MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3
CRUSHER INLET LINE LOW PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3
CRUSHER HIGH DRAIN LINE OIL TEMPERATURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . .
6-3
AIR FAN OIL COOLER TEMPERATURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3
LUBRICATION FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3
FILTER DIFFERENTIAL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4
LUBRICATION — CHECK LIST & CONTROL LOGIC 6 Satisfactory Unsatisfactory
A. PRE-START UP 1. Drain line pitch is ample 25 mm per 0.3 meter (min 1" per 12") 2. Specify brand name and type of oil in tank; (ISO Grade 150). Brand:
Type:
3. Piping has been installed per factory drawings. 4. Auxiliaries such as filter, cooler, immersion heater pressure switch, temperature switch and countershaft air breather have been installed properly. 5. Location of relief valve and piping is correct. 6. Oil pump is interlocked with crusher motor. 7. Pump is rotating in correct direction. 8. Oil pump gear reducer lubricant. 9. Coupling alignment is correct. 10. Filters have been vented. 11. Oil heater thermostat is set at correct valve. 12. Lube piping has been flushed. 13. Oil pump must be on before Crusher can start up.
B. START OIL PUMP 1. Oil temperature in tank must be at least 16° C (60° F) before starting pump. 2. Oil drain line temperature was at least 16° C (60° F) before starting Crusher.
C. JOG CRUSHER 1. Countershaft rotates clockwise.
D. START CRUSHER 1. Crusher was run no load until drain line temperature was at least 27° C (80° F) - 2 hours minimum. 2. Crusher has been checked for oil leaks from below Crusher. 3. Alarm system (pressure switch and temperature switch) has been checked (if so equipped) and oil pump interlock. 4. Relief valve stopped returning oil to tank at
°C(
° F).
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LUBRICATION — CHECK LIST & CONTROL LOGIC 6 Satisfactory Unsatisfactory
E. AFTER EIGHT HOUR INITIAL OPERATION 1. Temperature differential between feed and drain line is above ambient.
Drain line temperature is 2. Oil inlet pressure is 3. Crusher coast down time is oil drain.
.
PSI. seconds with
temperature
4. Customer has been advised of any recommended changes to his installation.
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6-2
LUBRICATION - CHECK LIST
LUBRICATION — CHECK LIST & CONTROL LOGIC 6 LUBRICATION SYSTEM CONTROL LOGIC The Crusher can be supplied with a packaged lubrication system that includes an oil tank, a pump with electric drive motor, filter and cooler. In addition, there are supplied alarm switches for high crusher drain line temperature and low crusher inlet line pressure. If the Crusher is supplied with an air fan oil cooler, there will also be included a temperature switch for control of the fan motor which will be activated by the drain line oil temperature. Optional RTD temperature probes can be used to monitor the temperatures at critical points. Optional pressure transducers can be used to monitor the inlet oil pressure. An optional flow meter can be used to monitor oil flow to the Crusher. See Figure 6-1 which shows a typical control circuit. The following details the crusher lubrication control logic that should be used to ensure proper operation. Nordberg does not provide the control equipment (hard-wired relays or PLC controllers) that would carry out the processing of alarm switch signals to produce the desired actions regarding control and protection of the Crusher but this control equipment should be incorporated into the plant control equipment. Crusher Lubrication Pump Motor The lubricating oil in the package lube tank must be a least 15° C (60° F) prior to starting the lubrication pump. This can be measured using an RTD temperature probe. The crusher lubrication pump must be running in order to allow the crusher drive motor to start. The crusher lubrication pump must be run for one minute minimum prior to starting the crusher drive motor. If the crusher lubrication pump motor is stopped (starter contact monitor) then the crusher drive motor must be stopped immediately. It is preferred that a hard wired interlock be used to prevent running the Crusher without having the lubrication pump motor running. (Some problems have been experienced by operators starting the Crusher in manual mode without first starting the lubrication system.) Crusher Inlet Line Low Pressure Switch The crusher drive motor cannot be started if the Low Pressure Switch indicates low pressure (As specified in Table 6-1).
Crusher High Drain LIne Oil Temperature Switch If the crusher drain line oil temperature reaches 60° C (140° F) the drain line high temperature switch will close and should be interlocked so that the crusher feeder is turned off and the drain line temperature monitored while operating no-load. If temperature stays at 60° C (140° F) or continues to rise within one minute after feed is shut off, shut off Crusher. It is recommended that after the Crusher has been operated for several months, the temperature switch be reset to a drain line oil temperature 6° C (10° F) over the normal operating temperature, but not to exceed 60° C (140° F). If a drain line RTD temperature probe is used, it can be used to shut off the feed to the Crusher and sound an alarm if the drain line oil temperature rises to 6° C (10° F) over the normal operating temperature, but not to exceed 60° C (140° F). If the temperature does not start to drop after the feed is shut off, the Crusher should be stopped to investigate why the temperature is so high. Air Fan Oil Cooler Temperature Switch If the Crusher is supplied with an air fan type oil cooler, the fan motor will be controlled by a second temperature switch in the crusher drain line at the package lubrication system. If the oil temperature reaches 52° C (125° F) the switch will close and the fan motor should run until the temperature drops below about 46° C (115° F). Optional RTD temperature probes can be used to monitor the temperature of the oil going to the cooler and the oil temperature going to the Crusher. This is a measure of the cooling being done by the Air Fan Cooler. If the temperature differential is too low, (depending on ambient temperature and oil inlet temperature) an alarm can be set to warn of dirt build-up on the cooler core. Lubrication Flow An optional flow meter is available to monitor the flow rate of oil from the package lubrication system to the Crusher. The flow meter should be mounted either between the package lube system and the air fan cooler if the air fan cooler option is chosen or between the package lube system and the Crusher for water type oil coolers. The minimum flow required is 80% of the rated flow rate. an alarm should be triggered at the 80% flow rate.
If during operation, the pressure drops below the preset pressure specified in Table 6-1, the crusher feeder and drive motor should be stopped. If a pressure transducer is used, an alarm should be signaled at 0.1 Bar (2 PSI) above preset pressure to warn of low pressure. We would recommend that the feed to the Crusher also be stopped at that pressure.
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LUBRICATION — CHECK LIST & CONTROL LOGIC 6
CRUSHER SIZE
PRESSURE SWITCH ACTIVATES AT BARS (PSI) PRESET PRESSURE
PRESSURE SWITCH DEACTIVATES AT BARS (PSI) LOW PRESSURE
HP 200 & HP 300
0.56 (8)
0.85 (12)
HP 400 & HP 500
0.85 (12)
1.13 (16)
HP 700
1.06 (15)
1.41 (20)
No adjustment of the differential screw is required as this is factory set. TABLE 6-1—PRESSURE SWITCH BASE SETTING (LOW PRESSURE ALARM) Filter Differential Pressure A pressure differential gauge is provided to monitor the oil filter differential pressure. When the pressure reaches 1.7 Bar (25 PSI), the filter should be changed. An optional pressure differential switch is available to signal when the pressure has reached this point. Another option is to mount pressure transducers on the inlet and outlet of the filter to measure the two pressures. When the difference reaches 1.7 Bar (25 PSI), an alarm condition should signal that the filters should be changed. If the pressure reaches 2.75 Bar (40 PSI), the feed to the Crusher should stop and after 30 seconds to allow the cavity to empty, the Crusher should be shut down. If the differential pressure drops to less than 0.2 Bar (3 PSI), there may be a damaged filter element and an alarm should be signaled to check the filters.
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6-4
LUBRICATION — CHECK LIST & CONTROL LOGIC
LUBRICATION — CHECK LIST & CONTROL LOGIC 6
L1 L2 L3
CB
1M
OL 1
CB
FM
OL 2
3
CB
LOH 4
5
CB
1. Hydraulic Power Unit Motor Located in Hydraulic Power Unit Console 2. Lube Oil Cooler Fan Motor 3. Skid Mounted Lube System
LPM
OL
4. Lube Oil Immersion Heater Located in Oil Tank 5. Lube Pump Motor
FIGURE 6-1—TYPICAL CONTROL CIRCUIT (SHEET 1 OF 2)
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6-5
LUBRICATION — CHECK LIST & CONTROL LOGIC 6
115V 50/60 HZ 1
1
60 SEC
START
STOP
2
LPMT
OL
M LPM
G
2 3
4
5
6 7
R HTS
8
10
9 OL
M 11 13 12
R LOPR
16 14 15 17
R RCPR
18
1. Lube Pump Motor 2. Lube Pump Motor On 3. This Switch is located in the Oil Immersion Heaters Mounted in the Lube Oil Tank. 4. Heater Temp Switch 5. Lube Oil Heater Contactor 6. Lube Oil Drain Line High Temp 7. Lube Oil Drain Line High Temp 8. This Switch is Mounted in the Drain Line. 9. Air Cooler Fan Motor 10. Fan Motor Temperature Switch 11. This Switch is Mounted in the Drain Line. 12. This Switch is Connected to the Oil Feed Line at the Countershaft Box. 13. Low Oil Pressure 14. Lube Oil Pressure Switch 15. These Switches are Located inside the Hydraulic Power Unit. 16. Release Cylinder Pressure 17. Release Cylinder Pressure Switch 18. Clamping Cylinder Pressure 19. Clamping Cylinder Pressure Switch 20. Feeder Motor 21. Crusher Motor
19 R CPR
20 START STOP
HTS
RCPR CPR CMT
M 21
START STOP
LOPR
LPMT
M CMT
CRUSHER
120 SEC
FIGURE 6-1—TYPICAL CONTROL CIRCUIT (SHEET 2 OF 2) R
6-6
LUBRICATION — CHECK LIST & CONTROL LOGIC
LUBRICATION — CHECK LIST & CONTROL LOGIC 6 ELECTRICAL SYMBOLS In order that there will be no confusion or misunderstanding of the symbols as they are shown in the control circuit, the symbols together with a description as to what they represent are given in Figure 6-2.
Circuit Breaker Thermo-magnetic (MCS & CD) Normally Open Contact (CR & M), Relay, Starter, or Timer Normally Closed Contact (CR & M) Relay, or Starter Overload Heater (OL), Starters, Power Magnetic Coil (CR, M, TR) Pushbutton Normally Closed Emergency Stop Pushbutton Normally Open Start Timed Contact (TR) Pressure Switch (PSI) Temperature TS (TS) Indicating Light (LT) Alarm Pushbutton Normally Closed Stop Timed Contact (TR) FIGURE 6-2—ELECTRICAL SYMBOLS
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LUBRICATION — CHECK LIST & CONTROL LOGIC
Section 7
MAINTENANCE INSPECTION AND MAINTENANCE PERIODS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1
MAINTENANCE 7 INSPECTION AND MAINTENANCE PERIODS Inspection time intervals will vary with differences in application and on site conditions. Inspection time periods are best chosen from operating experience.
DAILY CHECKS AND MAINTENANCE — LUBRICATION SYSTEM Item
Check List
1. Check oil tank level.
Normal Condition Within Oil Level Gauge Inlet: 38° C - 54° C (100° F -130 °F)
2. Check oil inlet and drain line temperatures.
Drain to Inlet Temperature: 0° - 5° C (0° - 9° F) without coolers 0° - 8° C (0° - 15° F) with coolers
3. Check oil pressure at countershaft box.
1.4 - 2.8 Bars (20-40 PSI)
4. Check oil filter differential pressure.
0.3 - 1.7 Bars (5-25 PSI)
5. Check for loose fasteners and connections. 6. Check for unusual noise, indications of wear. 7. Check oil flow and strainer basket. WEEKLY CHECKS AND MAINTENANCE — LUBRICATION SYSTEM Item
Check List
Normal Condition
1. Clean countershaft box blower and oil tank air breathers. 2. Check piping for oil leaks. 3. Inspect oil strainer in oil tank for metal chips and flakes. 4. Test all alarms, alarm lights and interlocks on lubrication system (pressure and temperature switches). MONTHLY CHECKS AND MAINTENANCE — LUBRICATION SYSTEM Item
Check List
Normal Condition
1. Check the lubricating oil for dirt and sludge. See Oil Contamination Guidelines
2. Analyze oil for contaminant levels. 3. Grease Lubrication Pump (Every 3 Months).
ANNUAL CHECKS AND MAINTENANCE — LUBRICATION SYSTEM Item
Check List
Normal Condition
1. Check all fasteners and piping connections for tightness. 2. Change oil in lube pump reducer. TABLE 7-1—INSPECTION AND MAINTENANCE PERIODS
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MAINTENANCE
Section 8
TROUBLESHOOTING TYPICAL LUBRICATION PROBLEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1
TROUBLESHOOTING 8 TYPICAL TROUBLESHOOTING PROBLEMS
Refer To: Crusher Problem Crusher Overheating
Possible Causes
Comments/Corrections
Main Manual Section
Lubrication Supplement Page
1.
Pump worn - not delivering enough oil.
1.
Check for proper oil flow LPM (GPM) in drain line.
10
3-1
2.
Oil not draining properly
2.
Check pitch in drain line from Crusher to oil tank. Minimum 25 mm (1") for every 305 mm (12").
10
2-1
Clean air breather connected to countershaft box or blower.
10
Drain line clogged with dirt or other debris.
None
3.
Insufficient oil supply
3.
5-1
Check main relief valve for malfunctioning due to wear, chips or stuck spring, oil bypassing Crusher. Check for the proper oil level in tank.
4.
Improper oil installed in Crusher
4.
Change to proper oil. Extreme pressure oil recommended.
5.
Lubrication holes in the main shaft plugged with dirt or other debris.
5.
Vertical holes in main shaft, inter-connecting horizontal holes in shaft must be cleaned using high pressure air.
6.
Oil cooler plugged with dirt, dust or other debris.
6.
If water cooler, clean tubes with wire brush. If air radiator, remove dust and other debris from radiator fins.
10
2-2
10
1-4
None
4-4
TABLE 8-1—TYPICAL LUBRICATION PROBLEMS
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8-1
TROUBLESHOOTING 8 Refer To: Crusher Problem Crusher Throwing OIl
Possible Causes
Comments/Corrections
Main Manual Section
1.
Faulty main relief valve.
1.
Incorrect setting of relief valve or relief valve spring stuck in closed position. Replace valve.
5-1
2.
Oil too cold.
2.
Install oil tank immersion heater and heat oil to 16° C (60° F).
1-4
3.
Improper oil installed in Crusher. Oil too heavy.
3.
Change to proper oil.
10
4.
Crusher not vented properly.
4.
Clean breather connected to countershaft box.
10
5.
Drain line clogged with dirt or other debris.
5.
Inspect drain line, clean if necessary
None
6.
Oil not draining properly.
6.
Check pitch in drain line from Crusher to oil tank. Minimum 25 mm (1”) per 305 mm (12”) or drain line piping too small.
10
Replace drain line with correct piping size.
1-4
2-1
None
Crusher Stalling
1.
Oil pressure, Bar (psi) too low.
1.
Check for correct operating pressure.
10
Seized or Broken Countershaft
1.
No lubrication or not enough lubrication to countershaft bushings.
1.
Check for some type of restriction between main oil supply line and entry hole in countershaft box. Remove any type of valve or some other means of restriction in the supply line.
None
2.
Oil groove in outer countershaft bushing in wrong position.
2.
V-belt drive should never pull countershaft into oil groove.
4
3.
No end float.
3.
Reset end float 1.0 mm (1/32") to 1.5 mm (1/16").
4
4.
Oil groove in outer countershaft bushing plugged with dirt or other debris.
4.
Clean oil groove.
4
1.
Water accumulating on top of counterweight cover.
1.
If no drain holes, drill holes and weld in drain tubes.
Water in Lube Oil
Lubrication Supplement Page
1-5
None
Clean out drain holes. 2.
Breather on lube tank is clogged.
2.
Replace breather.
2-3
TABLE 8-1—TYPICAL LUBRICATION PROBLEMS (Continued)
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TROUBLESHOOTING
TROUBLESHOOTING 8 Refer To: Crusher Problem Oil Leak at Sheave End of Countershaft Box
Dust and Dirt Getting Into Lube System
Possible Causes
1.
Comments/Corrections
Main Manual Section
Crusher not vented properly.
1.
2.
Oil not draining fast enough, from countershaft box or flinger housing, especially when oil is cold.
2.
Clean long, cored hole in countershaft box, which is directly below the countershaft.
3.
Worn piston ring between oil flinger and flinger cover.
3.
Replace piston ring and rework flinger cover, if necessary.
4
1.
No air breather on Crusher.
1.
Install breather connected to countershaft box.
10
2.
Breather connected to countershaft box or blower or oil tank not functioning properly.
2.
Clean both breathers. With Crusher operating, a piece of paper placed over the breather piping should move inward slightly.
10
3.
Crusher sheave swirling dust into the breather.
3.
Using hose, relocate breather away from crusher sheave.
10
4.
Dust and dirt falling into Crusher when Crusher has been dismantled for servicing or maintenance.
4.
Cover socket and eccentric area with canvas tarpaulin or polythylene (plastic) sheeting when servicing Crusher.
None
5.
Too great of a vertical drop in the crusher drain line between Crusher and oil tank.
5.
Dust and dirt will be sucked into socket area. Add an additional breather in crusher drain line in vertical pipe just below countershaft box elbow, coming from the horizontal pipe. Consult factory.
None
6.
No seals or gaskets between oil tank and oil tank cover.
6.
Replace seals or gaskets.
Excessively dirty oil.
1.
Replace oil and clean oil tank.
Gear and Pin- 1. ion Tooth Wear
Clean breather connected to countershaft box.
Lubrication Supplement Page
10 None
10
2-1
TABLE 8-1—TYPICAL LUBRICATION PROBLEMS (Continued)
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8-3
5
8
7 6
3
9
10
11
4
12
2
13
1
15 47
14
46
16
45
44
17 18
20 19
22
21
43 42 41
26
40
28
27
24 25
29 30 31 32 39
35
34
33
36 38 37 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.
Bowl Bowl Adapter Ring Adjustment Cap Hopper Socket Socket Liner Feed Plate Locking Bolt Driver Ring Mantle Head Head Ball Upper Head Bushing Clamping Ring Bowl Liner
16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30.
Dust Shell Main Frame Pin Adjustment Ring Dust Shell Seal Main Frame Counterweight Crusher Sheave Countershaft Box Flinger Cover Oil Flinger Outer Countershaft Bushing Countershaft Box Guard Countershaft Box Seal Inner Countershaft Bushing Countershaft
TYPICAL GENERAL ARRANGEMENT
31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45.
Pinion Upper and Lower Thrust Bearing Main Shaft Eccentric Bushing Gear Eccentric Arm Guard Counterweight Guard Clevis Pin Tramp or Cavity Release Cylinder Main Frame Liner “T” and “U” Seals Lower Head Bushing Clamping Cylinder Hydraulic (Motor) Adjustment Mechanism
Metso Minerals North and Central America 3073 South Chase Avenue Milwaukee, WI 53207 USA Phone: +1-414-769 4300 Fax: +1-414-769 4730 Metso Minerals South America Caixa Postal 272 18035-240 Sorocaba Brazil Phone: +55-152-191 300 Fax: +55-152-191 695 Metso Minerals Asia-Pacific Level 2, 1110 Hay Street West Perth, WA 6005 Australia Phone: +61-8-9420 5555 Fax: +61-8-9320 2500 Metso Minerals Europe, Middle East and Africa P.O. Box 4004 20311 Malmö Sweden Phone: +46-40-24 58 00 Fax: +46-40-24 58 78 Metso Minerals P.O. Box 307 33101 Tampere Finland Phone: +358 20 484 140 Fax: +358 20 484 141 www.metsominerals.com E-mail:
[email protected]
Service Manual No. 9000 0014-01-99-N-English
©2002 Metso Minerals
Printed in U.S.A.
