XL500 Instruction Manual Rev 2_warranty Included

Raptor XL500 Instruction Manual

October 2011

XL500 Cone Crusher Section 1

Safety

Section 2

General Crusher Information

Section 3

General Installation Information

Section 4

Main Frame Assembly Adjustment Ring Assembly Tramp Release Assembly

Section 5

Countershaft Box Assembly Countershaft Assembly Sheave Assembly

Section 6

Eccentric Assembly

Section 7

Socket Assembly

Section 8

Head Assembly Mantle Assembly Feed Plate Assembly

Section 9

Bowl Assembly Bowl Liner Assembly Hopper Assembly

Section 10

Bowl Adjustment Mechanism Assembly

Section 11

Lubrication System

Section 12

Hydraulic Systems

Section 13

Operating Instructions Warranty

Section 14

XL500 Cross Section with Component Call Outs Index

Section 1

Safety General Safety Instructions............................................................................................................................. 1-2 Slip and Trip Hazards......................................................................................................................................... 1-2 High Pressure Hydraulics/Gas Charged Accumulator ................................................................................ 1-3 Clearing the Crusher Cavity ............................................................................................................................. 1-3 Lifting and Moving Heavy Components ....................................................................................................... 1-4 Flying or Falling Objects ................................................................................................................................... 1-4 Confined Spaces ................................................................................................................................................ 1-5 Respiratory Concerns ....................................................................................................................................... 1-5 High Noise Levels ............................................................................................................................................... 1-5 Crusher Con trol System Operating and Safety Interlocks ........................................................................ 1-6 General Housekeeping ..................................................................................................................................... 1-6 Proper Training and Indoctrination ............................................................................................................... 1-7

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General Safety Instructions This Instruction Manual discusses only the basic safety concerns related to the operation and maintenance of the Raptor Cone Crusher. As with all machinery having moving parts, attention to personal safety is of the utmost importance. The Raptor Cone Crusher is designed with safety factors with respect to structural steel, high pressure hydraulic components, electrical components, and drive components. FLSmidth provides all of the static and dynamic load requirements, as well as the clearance dimensions necessary to design a safe and sound platform for the operation and maintenance of the Crusher. The actual installation of the Crusher with respect to plant layout is the responsibility of the customer or agents of the customer. The Safety Section of this Instruction Manual is not to be construed to supersede any of the safety policies of the customer and applicable government agencies. Instead, the safety topics and recommendations should only be regarded as an aid in assisting the customer to write their own safety procedures pertaining to the operation and maintenance of the Raptor Cone Crusher. There are specific safety concerns related to the operation and maintenance of the Raptor Cone Crusher, and FLSmidth has outlined these concerns in the following paragraphs.

appropriate guarding is usually the scope of the customer or agents of the customer. •

The Hydraulic Adjustment Mechanism operates with a rotating pinion and a large ring gear. The interface between the pinion and gear has a guard to protect workers’ hands. An alarm should sound to warn workers whenever the adjustment mechanism is about to be actuated. Workers must be instructed to stand clear.

•

Crushing activity can result in the rapid vertical movement of the Crusher Adjustment Ring Assembly during a major tramp event. Work platforms about the Crusher and overhead feed chutes must be designed to take this into consideration. Workers must be made aware of the potential for sudden, rapid movement of the Adjustment Ring during crushing operations. Note: A tramp event is when a large, uncrushable object passes through the crushing cavity.

•

Ensure that all guards are mounted in their proper position prior to operation of the Crusher.

•

Though proper guarding should protect the individual worker, it is still important that workers do not wear loose fitting clothing, ties, or jewelry, or have exposed long hair that can get caught up in machinery. Local safety procedures will apply in all instances.

Moving Components and Potential Pinch Points: As with all mechanical equipment with exposed movable components, workers must be made aware of the dangers and adequately protected from these dangers. Following is a list of areas that must be guarded: •

The Raptor Cone Crusher requires the gyrating motion of the Head Assembly in conjunction with the Bowl Assembly to provide the forces necessary to crush rock. The crushing cavity of the Raptor Cone Crusher is large enough for a worker to fall into. Needless to say, the areas above the Crusher must be guarded against the possibility of someone falling into the crushing cavity.

•

Drive power to the Crusher is normally transmitted from an electric motor through a drive sheave, drive V-belts, and a driven sheave. This entire area of power transmission must be guarded to protect workers falling or placing ora limb intofrom pinchaccidentally points of the driveinto arrangement against high speed rotating elements. As FLSmidth is normally not involved in the layout of the Crusher drive, the manufacture and installation of the

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Slip and Trip Hazards Working around the Crusher can present a number of potential slip and trip hazards. Rock spillage can cause slip and trip hazards. Oil leaks, from either the hydraulic system or the lubrication system, can cause slip hazards. During liner changes and other maintenance activities, it is frequently necessary to climb down into the internal area of the Crusher for maintenance and clean up. The interior of the eccentric assembly and the gear well areas will be wet with lubricating oil, which presents a serious slipping hazard. •

Clean up all oil spills that may drain off on major Crusher components that have been removed from the Crusher or that may have developed from system leaks.

•

Use particular care when entering the oil wetted areas of the Crusher. Also, use care in keeping this area clean. Part of the maintenance procedure at every liner change is to clean the old grease from

the Adjustment Ring Assembly threads and the Bowl Assembly threads. Ensure that this grease is collected and disposed of properly. •

Rock spillage can occur around a Crusher. Ensure that spillage is cleaned up promptly to eliminate potential slip and trip hazards.

•

Wet Crusher feed conditions and excessive dust suppression water sprays can cause wet fines to accumulate on walkways. Wet fines tend to be very slippery, so this condition should be guarded against.

circuits dumped of pressure, and that hydraulic hoses and connections be avoided. •

The local control panel for the Hydraulic Power Unit has a red “panic” button type switch, that can be used to de-energize the hydraulic system in the event of major leak or fire. Workers must be instructed concerning the location and function of this switch. At no time should this switch be used as the means of electrically isolating the Hydraulic Power Unit for maintenance purposes.

•

Only workers trained in the maintenance and operation of the Hydraulic Power Unit should be allowed to work on the system.

•

Only workers trained in the maintenance of pressure vessels should be allowed to work on the nitrogen charged accumulators.

•

The lubrication system must be shut down, electrically isolated, and locked out whenever maintenance work involves removing the Crusher Head Assembly or working on the lubrication system by itself. This is particularly important when the lubricating oil is to be changed out.

•

Workers must be fully trained in the maintenance and operation of the Raptor lubrication system.

High Pressure Hydraulics/ Gas Charged Accumulator The Raptor Cone Crusher uses an FLSmidth-supplied Hydraulic Power Unit with hydraulic oil pressure up to 3,000 psi (204 bar). The hydraulic system maintains consistent crushing forces, allows for release of the crushing forces during a tramp event, provides clearing (lifting of the Adjustment Ring) when the Crusher is stalled with a full cavity, provides clamping forces to keep the Bo wl Assembly from rotating during crushing, and provides for setting adjustment as necessary by rotating the Bowl Assembly within the Adjustment Ring Assembly. The tramp release system uses nitrogen charged accumulators to absorb the energy involved in vertical movement of the Adjustment Ring during a major tramp event and uses the stored energy to return the Adjustment Ring to the normal crushing position.

Clearing Crusher It is possible forthe the Crusher to stop Cavity (stall) while crushing.

The Raptor Cone Crusher operates with a lower pressure, high volume lubrication system that incorporates pressure relief valves, a filtration system, and either water or air heat exchangers.

This is normally due to power bumps or outages, or an uncrushable object that wedges in the crushing cavity. The Raptor Cone Crusher has a Clearing function that is designed to allow for the easy removal of rock product or tramp material in the event that the Crusher stops with material in the crushing cavity. The clearing function works with the Hydraulic Power Unit to dump the Tramp Release Pressure and pressurize the Tramp Cylinders to lift the Adjustment Ring and Bowl Assemblies and increase the clearance (gap) between the Bowl Liner and the Mantle on the Head. This increased clearance should allow material in the crushing cavity to fall through. The procedure for clearing the Crusher is described in the Hydraulic Systems portion of this instruction manual.

Crusher workers must be instructed to be aware of the following potential dangers: •

Oil under high pressure presents a considerable danger when accidentally released by maintenance personnel. Workers must be instructed to electrically isolate and lockout the hydraulic power system and dump the hydraulic pressure whenever maintenance is to be carried out on the system.

•

Hydraulic oil is very flammable. Special care must be taken when doing hot work around the Crusher. It is imperative that the hydraulic power unit be electrically isolated, locked out, and all hydraulic

Refer to Section 12

Clearing a Crusher presents potential safety hazards that workers must be made aware of. Safety concerns relating to clearing a Crusher cavity are:

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•

Workers must be aware that a Clearing cycle will result in the Adjustment Ring being lifted approximately 6 inches (152 mm).

•

Workers will require safe access to look into the crushing cavity to verify that the crushing cavity is clear.

•

It may be necessary to support the Adjustment and Bowl Assemblies with safety blocks included in the Tools Assembly.

•

It is possible that an item of tramp material will be so large that it cannot be released in a Cavity Clearing cycle. In this case, it will be necessary to mechanically hook the item and pull it out with an overhead crane, or burn (reduce in size) the object with an oxy-acetylene lance or magnesium rod burning bars.

Detailed procedures for carrying out a Crusher Clearing cycle are described in the Hydraulic Systems Section of this instruction manual. It is highly recommended that a crushing plant site have a written safety procedure to address the removal of tramp material.

Lifting and Moving Heavy Components

be available when major Crusher maintenance is performed. •

Most of the major components of the Raptor Crusher are made up of machined castings. The weights shown are nominal. As castings, the actual weights can vary by as much as ±5%.

•

Many pieces that make up the various Crusher assemblies are at, or just over, what would be considered safe weight for a worker to lift. Again, workers are instructed to check with the Parts Manual to determine the actual weight of the piece and to use proper lifting procedures. Weight lifting restrictions are the responsibility of the customer’s safety program and governmental agencies and are thus not addressed in this manual.

Flying or Falling Objects Gravity is used to introduce rock into the Crusher cavity. Overflow, worn chutes, or other possibilities for spillage can cause falling rock to present a safety hazard. Crushing action can cause rock to be ejected from the crushing cavity, particularly as rock is first being introduced into the cavity. •

The Raptor Cone Crusher has a number of very heavy assemblies that must be removed and installed during the change out of wear liners, and other maintenance routines. Crusher workers must be instructed about the following heavy lifting concerns: •

•

•

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The weights of major Crusher assemblies are listed in the General Crusher Information. The weights of individual piece parts that make up a Crusher assembly can be found in the Parts Manual. FLSmidth supplies a Tool Assembly consisting of parts specifically designed for the installation and maintenance of the Raptor Crusher. Often, there is only one Tool Assembly per group of Crushers supplied. This Tool Assembly has all of the lifting fixtures and specifically sized ring bolts necessary to maintain the Raptor Crusher. Workers must be made aware of the importance of keeping the tools in an environmentally protected and secure storage area. Trained riggers and crane operators along with suitably sized lifting capacity and rigging must

A safety skirt, normally made of flexible rubber, can be mounted between the feed chute and the Crusher feed hopper to keep rock from being ejected out or from spilling out if the Crusher cavity becomes overfilled. This ejected or falling rock can present a serious safety hazard. The rubber skirt also serves as part of the system to control fugitive dust from the Crusher. The skirting is part of the feed chute arrangement and is not part of the scope of supply for the Ra ptor Crusher.

•

Spillage can accumulate on a lower deck and present slip and trip hazards for workers. Good housekeeping is absolutely essential for safe Crusher operations.

•

As crushing systems often involve a gravity flow design with screening applications before or after the Crusher, it is not uncommon to have one or more decks above and below the Crusher. Workers must be aware of any time people are working above them and likewise, any time people are working below them. Work should be coordinated to eliminate the potential for dropped tools and parts, areas under workers cordoned off, or adequate overhead protection should be provided.

Confined Spaces The Crusher discharge area is normally considered a confined space and should be treated as such. As routine maintenance procedures require the visual inspection of the underside of the Crusher, the Crusher lubrication lines, and the discharge cavity, the following concerns must be addressed. •

Confined space work permits and procedures must be utilized whenever maintenance work is to be carried out under the Crusher or in the discharge cavity.

•

Electrically isolate and lockout the Feed Conveyor, the Crusher and the Discharge Conveyor.

•

The discharge area must be designed in such a way as to provide safe and easy access to the area under the Crusher. This is always an engineering challenge as the discharge area must be designed to eliminate spillage and allow for adequate dust control.

programmed to interlock with the Raptor Crusher Automated Control System provided by FLSmidth. •

Water type dust suppression systems must be designed to not provide too much moisture. Too much moisture tends to cause Crusher product fines to stick to the Head Assembly and this can lead to ring bounce. Too much moisture can also lead to crushed product material build up on the arms and in the discharge cavity, which can lead to serious damage to the Crusher.

•

Often the true seriousness of a dust control problem cannot be determined until after the Crusher has been in operation for a short period of time. Therefore, it is often necessary to over design for dust control system to insure proper control at the onset of crushing.

•

Working in the discharge area of the Crusher may agitate (kick up) respirable dust.

•

The epoxy based backing compound used with the Raptor Crusher wear liners has a caustic agent that is both caustic by skin contact and by respirable fumes. Adequate personal protective equipment and ventilation is necessary when working with these chemicals.

Respiratory Concerns The comminution (crushing) of rock produces rock dust. Rock dust is often fine enough to be carried into the lungs during normal breathing. All rock dust presents some health hazards, with some rock presenting especially serious health hazards. It is the responsibility of the customer to provide a system to control the escape of respirable rock dust or to provide personal protective equipment to protect the workers. Work on or around the Crusher often involves welding, thermal cutting, and the use of chemical reagents, and can present respiratory issues. The following items must be addressed: •

•

During installation of the Crusher, the area under the Countershaft Box along with the areas between the Crusher mounting pads and the foundation needs to be sealed to contain dust in the discharge area. The area around and between the feed chute and the feed hopper of the Crusher should also be sealed. FLSmidth service technicians will be present during the installation of the crusher to assist the customer or the customer’s agent in sealing these areas. Vacuum type dust collections systems and moisture type dust suppression systems should be

High Noise Levels The very nature of crushing rock generates high level of noise. The actual noise generated is determined by the type of rock being crushed, the amount of energy being put into the rock and the type of structure that the Crusher is mounted on. Typically, the decibel readings will be found to be in the 85 to 105 dB range. As it is very difficult to abate this noise from the area around the Crusher, it is often necessary to require the use of noise protection devices for workers. Following are some concerns: •

The actual noise generated by a Raptor Crusher will have to be determined by measurement during normal crushing operations. The customer will then have to determine what personal hearing protection is required for the worker as well as what time exposure limits may have to be put in place.

•

Exceeding the Crusher force limits for the Raptor Crusher will generate extremely high noise levels. Therefore, it is incumbent upon the operators to operate the Crusher within the design limitations.

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FLSmidth has a system of accelerometers mounted on the Crusher adjustment ring that alert the operator to periods when the crushing forces are being exceeded (ring bounce).

•

The air impact tool is frequently used to turn jacking bolts that remove interference fit parts. In this case, it is important the part be removed as rapidly as possible, before heat can soak into the mating part. It is advisable that more than one person be assigned to a tool, so that the tool can be utilized without excessive fatigue to an individual worker.

•

Some fasteners used in the Raptor Crusher require high torque values to establish proper pre-load. These high torque values can require the use of torque multipliers. Workers need to be trained in the

Crusher Control System Operating and Safety Interlocks The Raptor Crusher comes with an Automated Control System (ACS) that monitors the vital signs of the Crusher as well as assists in operating the Crusher within the design limitations. Altering or isolating (jumper out) the interlocks of this system not only affects the mechanical well being of the Crusher, it can seriously effect the safety of the workers about the Crusher. •

Never make changes to the Automated Control System without prior approval of FLSmidth.

•

If it becomes necessary to make temporary changes to the Automated Control System and FLSmidth cannot be contacted in a timely manner, insure that approval has been provided by local mine opera tional and safety management and that any changes are well documented. Tools used to maintain the Raptor Crusher: Many components that make up assemblies of the Raptor Crusher are assembled with interference fits. Therefore maintenance workers will be required to use open flame and/or cryogenic agents in the installation and removal of

safe utilization of these tools. •

It is common to have to weld on feed and discharge chutes about a Crusher, as well as to weld lifting rings (D-rings) to Crusher wear materials to facilitate lifting the components into position. The Maintenance Section of this Instruction Manual lists specific cautions with respect to welding to manganese and high chrome white iron wear materials.

•

Under no circumstances should any welding be done on the cast components of the Crusher, with the exception of worn liners for maintenance. Though such welding does not present any particular safety hazard, the high carbon steel alloy of these castings can be seriously compromised by improper welding techniques. It is imperative that FLSmidth be contacted before any such welding is undertaken.

various parts. Following is a list of safety concerns: •

•

•

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Open flames present obvious safety concerns for the workers. Because some parts have to be heated rapidly and thoroughly, it is important that more than one heating torch is used at the same time (two torches, two workers). It is imperative that workers be trained in the safe use of open flame heating devices. Liquid nitrogen and dry ice are commonly used to chill components for assembly. Working with cryogenics presents unique safety hazards and workers must be trained in the safe use of these agents and appropriate personal protective equipment. Air impact tools are frequently used for assembly and disassembly work. Because of the size of the fasteners, these tools are frequently large and cumbersome. Workers need to be trained in the proper use of these compressed air tools.

General Housekeeping Though housekeeping concerns have been mentioned with respect to Slip and Trip Hazards above, it is still important to reiterate this concern: •

Always correct the causes of spillage as they occur and clean up spillage as soon as possible.

•

Clean up all oil spills or other types of spills that would result in slip hazards.

•

Pick up and put away tools, cable rigging, wash down water hoses, air pressure hoses and acetylene torch equipment immediately after they are used.

Proper Training and Indoctrination As working with the Raptor Crusher presents many unique safety issues as described above, it is very important that workers receive proper hazard awareness training relating to these issues. Following are topics of job specific training: •

All workers should become familiar with the general operation and maintenance of the Crusher.

•

Workers must be made aware of the specific safety hazards related to working about the Crusher.

•

Workers need to be trained in the safe use of tools and materials used in the installation, maintenance, and operation of the Crusher.

As mentioned at the onset, this Section on Safety is only to be utilized as a guide to assist the customer in developing there own safety program with respect to working on and about the Raptor Crusher. Any questions and concerns related to the safe operation and maintenance of the Crusher should be directed to the Engineering and Sales Department of FLSmidth, located at:

FLSmidth Engineering and Sales Office 543 A. J. Allen Circle, Suite B Wales, Wisconsin, 53183, USA Phone: 1-262-968-9095 Fax: 1-262-968-9112

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Section 2

General Crusher Information Introduction

Information Furnished

This manual provides information for properly installing, operating and maintaining the Raptor XL500 Cone Crusher.

The following information for your Raptor XL500 Cone Crusher is provided by the factory and includes:

It is recommended that this manual be read before installing and operating the machine.

Initial Inspection A complete inspection is recommended as soon as possible following delivery of the Raptor Cone Crusher. Look for any damage that might have occurred during transit. Also verify that all “shipped loose” items listed on the Bill of Lading, Freight Bill or Manifest are accounted for. Notify the carrier immediately of any damage or shortages.

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Mounting and Clearance drawing.

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Index for Field Connections drawing.

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Operation and maintenance information for equipment not manufactured by FLSmidth.

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Crusher Parts Book.

Repair Parts FLSmidth carries an extensive supply of replacement parts. To avoid delay and incorrect parts being furnished, the following information is required when ordering: 1. Crusher size 2. Crusher serial number 3. Name of part, part number and the quantity of parts ordered

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Section 3

General Installation Information Crusher Clearance Dimensions .................................................................................................................... 3-2 Foundation ...................................................................................................................................................... 3-2 Weight of Complete Crusher an d Assemblies Table 3-1 ......................................................................... 3-2 Belt Types Figure 3-1 ...................................................................................................................................... 3-3 Crusher and Subassembly Weights.............................................................................................................. 3-3 Discharge Arrangement ................................................................................................................................. 3-3 Feed Arrangement .......................................................................................................................................... 3-3 V-Belt Drive ...................................................................................................................................................... 3-3 Crusher Motor .................................................................................................................................................. 3-4 Hydraulic System Information ..................................................................................................................... 3-4 Piping Information .......................................................................................................................................... 3-4 General Assembly & Disassembly Information .......................................................................................... 3-5 Welding and Weld Repair of Major Castings .............................................................................................. 3-5 Bolt Torque Table 3-2 .................................................................................................................................... 3-5 Special Tools Furnished with the Raptor Crusher Figure 3-2 ................................................................ 3-6

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Foundation

Crusher Clearance Dimensions

The Mounting and Clearance Drawing, furnished by FLSmidth, will provide you with mounting position of the foundation bolts, drive motor location and various clearances required to mount the Crusher onto the foundation. A durable, solid and level foundation is critical to the safe operation of the Crusher.

Success of the operation and maintenance of the Crusher relies on a well planned installation. Crusher clearances must be considered when designing the foundation. Clearance must be provided above the Crusher for the installation and removal of the Head and B owl Assemblies. Clearance should also be provided for the feed equipment such as; chutes, feed hoppers, conveyors and other related equipment. Adequate area is also required in front of the foundation for the removal of the Countershaft Assembly. Another requirement is the room needed under the Crusher for a discharge conveyor and/or chute.

Important Information data sheets with Crusher foundation loads are available from FLSmidth. The foundation must be designed to accept these loadings. The customer is responsible for the design of the foundation.

Refer to the Mounting and Clearance drawing along with the Dimensional Data Sheets available from FLSmidth to determine the clearances required in designing your foundation.

Weight of Complete Crusher and Weight of Assemblies That Require Frequent Handling XL500 Pounds (Kilograms)

Complete Crusher

110,833 (50,274)

Main Frame Assembly

35,203 (15,968)

Bowl Assembly (with Bowl Liner and Hopper)

24,588 (11,153)

Adjustment Ring Assembly

17,829 (8,087)

Head Assembly (with Mantle and Feed Plate)

14,202 (6,442)

Countershaft Box Assembly

1,470 (667)

Eccentric Assembly (Includes Counterweight)

8,133 (3,689)

Mantle

5,132 (2,328)

Bowl Liner

5,097 (2,312)

Hydraulic Power Unit

1,370 (621)

Lube Package

2,075 (941)

Air Cooler Assembly

1,900 (862) Table 3-1

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Crusher and Subassembly Weights Another consideration must be the weights of the Crusher and components. Sizing of overhead lifting equipment such as cranes, chain hoists or a mobile crane must take into consideration the weights associated with handling of the entire Crusher during installation. The lifting equipment must also be able to lift the various Crusher assemblies and individual replacement parts. Refer to Table 3-1 for the weights of the Crusher and assemblies. These weights are also furnished on a Crusher informational data sheet available from FLSmidth.

Feed Arrangement

Proper design of the Crusher feed arrangement is critical in maximizing the crushing circuit efficiency. This involves providing an adequate amount of feed material to the Crusher. It also requires an even distribution of blended material sizes within the crushing cavity. Proper control of the feed material into the Crusher maximizes capacity, product size and life of components. Inadequate amount of feed material will cause the Crusher to run underpowered resulting in uneven distribution of forces across the Bushings. FLSmidth recommends that feed circuits for Crushers in Short Head applications be designed to provide a build-up of material above the Feed Plate (referred to as a “Choke Fed” condition). When possible, it is beneficial to run a Standard Crusher in this “choke fed” condition as well. Use of a level sensor is required to monitor the feed level. The feed size should be thoroughly mixed and evenly distributed around the crushing cavity. Uneven feed distribution will result in oversize product, reduced capacity and “ring bounce”.

Crusher in the circuit to remove fine or sticky material. This will help avoid conditions such as bridging and ring bounce. Installation of a metal detector or magnet is recommended to remove any non-crushable items (called “Tramp”) before they get into the crushing cavity. Excessive amounts of tramp material passing through the Crusher can cause ring bounce, damage Crusher parts and possibly stall the Crusher drive motor.

Discharge Arrangement The construction recommendations shown on the Mounting and Clearance drawing should be followed. Replaceable wear material should be used to line the discharge compartment. Within the compartment, a shelf or ledge should be incorporated to make a “dead bed” for the Crusher discharge material to fall on. The dead bed is designed to absorb most of the energy of the falling material before cascading onto the conveying equipment. If a discharge chute is used, it must be positioned at an angle of 45° or grea ter from horizontal. If wet discharge material is present then the chute angle should be increased. As shown on the mounting and clearance drawing, adequate clearance is to be maintained between the discharge equipment and the Crusher. The proper amount of clearance will stop material from building up under the Crusher and eventually interfering with its operation.

V-Belt Drive Driving the Crusher is accomplished using a set of 8V-Belts. They reduce shock loads from being transmitted to the Crusher drive motor. Various combinations of Sheave diameters are used to change the speed of the Countershaft to fit different a pplication requirements. There are two types of belts available, single or banded. Refer to Figure 3-1

Note: Ring bounce occurs when the Adjustment Ring lifts or bounces quickly on and off the Main Frame Seat Liners. Extended periods of “ring bounce” will damage the Adjustment Ring, Main Frame Seat Liners, Main Frame and other associated Crusher components. Figure 3-1

A feed box mounted over the Crusher can serve as a backstop to ensure the ma terial falls vertically onto the Feed Plate. A feed mounted on thea box and centered over the Feed Platespout will aid in providing uniform distribution of feed around the crushing cavity. It is recommended that a screen be placed ahead of the

Belt Types

Either type of belt can be used on a standard sheave. The advantage of banded belts is that they reduce the chance of rollover or belt whip. For V-Belt installation and adjustment, refer to the belt manufacturers instructions. It is important to follow these

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instructions as belts adjusted too tight will cause high Countershaft Box and/or drive motor bearing temperatures with the possibility of bearing failure. Belts adjusted too loose will cause belt slip and possible stalling of the Crusher. FLSmidth recommends using slide rails or a stand-alone idler system, that can be supplied upon request, as proper means of tightening. Mounting the motor Sheave below the Countershaft and within 45° of the vertical centerline will require a change in the mounting position of the outer Countershaft bushing oil groove. Contact FLSmidth if either of these mounting positions are going to be used so the bushing can be installed correctly prior to shipment of the Crusher.

Crusher Motor The drive motor should be a squirrel cage induction motor; continuous duty rated, with normal starting torque (approximately 125%) and normal breakdown torque (approximately 200%) within ±10% acceptable voltage variance. It is recommended that the Crusher be equipped with a reduced voltage starter.

Piping Information The type of oil to be used to lubricate the Crusher is outlined in detail in Section 11. The lubrication system is designed to operate at a maximum of 150 PSI (10.3 Bars). Refer to the Crusher piping and lubricating system and Mounting and Clearance drawings provided by FLSmidth for piping connection size and locations. Factors listed below should be addressed when laying out the piping of the feed and drain lines as follows: 1. The slope of the drain piping from the Crusher to the Lube Package must be at least 1” (25 mm) of vertical change for every 12” (305 mm) of horizontal change. 2. The supply and drain piping should be as direct and short as possible with a minimum amount of turns, dead pockets and any other obstructions. 3. A flexible coupling is supplied between the drain connection at the Crusher and the piping to accommodate Crusher movement.

To maintain a continuous horsepower level, an electric motor with a 1.15 service factor is required. If a service factor of 1.0 is used, the horsepower rating appearing on the motors nameplate should be approximately 15% higher than the recommended operating horsepower. The Crusher power draw however has to be held to 500 horsepower.

4. The use of pipe unions is helpful in the removal of any piping or lubricating equipment when required.

With the use of a V-Belt drive, the following considerations should be addressed when ordering the motor:

6. Prior to initial Crusher startup, all piping connections should be checked for leaks.

1. Motor bearings to be sized to handle overhung loads for the sheave and belt pull. 2. The motor is to have 360° radial belt pull capacity. 3. Motor shaft diameter must be able to withstand peak torque and simultaneous bending due to belt pull and Sheave weight. 4. The motor shaft must be a proper length to accommodate the motor Sheave bushing or hub and also provide clearance between the motor housing and the rim of the Sheave.

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5. All oil piping should be cleaned (remove chips and cuttings) before operating the lubrication system so as to avoid introducing this material into the Crusher bearings and oil pump.

Hydraulic System Information Refer to the Hydraulic Power Unit and Index for Field Connections drawings supplied by FLSmidth for information regarding the Power Unit to Crusher connection locations. The type of oil to be used in the hydraulic system is specified in Section 12. The Power Unit should be placed in a protected area no more than 50 feet (15 meters) from the Crusher. Its placement should also allow the operator to observe the Crusher during the lifting of the Adjustment Ring (called “Clearing the Crusher”) and setting adjustments. The hoses used to connect the Hydraulic Power Unit to the Crusher are 50 feet (15 meters) long. Reusable couplings are attached to the end of each of these hoses for adjusting the lengths. This eliminates them from being coiled into a pile and causing a safety hazard.

General Assembly & Disassembly Information

Bolt Torque Bolt Sizes

The XL500 Cone Crusher is shipped in subassemblies. The following sections in this book will provide detailed 6 instructions for assembling the crusher as well as 8 disassembly and assembly of various subassemblies and 10 parts that make up the Crusher. Cap screws within the assemblies should be torqued per the values listed in 12 16 Table 3-2 unless otherwise noted in the parts manual. 20 In the following sections there are instructions and 24 illustrations that refer to the lifting and turning of various 30 subassemblies and parts that make up the Crusher. 36 For good safety practices follow these instructions and 42 illustrations. When required, use the special tools furnished with the Crusher. See Figure 3-2 48

Welding and Weld Repair of Major Castings The Main Frame, Bowl, Head and Adjustment Ring are critical components in the function of the Crusher. These specific parts are cast using high alloy steel that has special welding requirements. It is recommended that before doing any welding on these specific parts that you contact FLSmidth engineering to obtain the appropriate WPS (Weld Procedure Specification).

Pitch (N*M)

1

Torque

(FT.*LBS.)

3.9

2.9

1.25

9.4

6.9

1.5

19

14

1.75

33

2

86

24 64

2.5

160

120

3

270

200

3.5

540

400

4

950

700

4.5

1,500

1,100

5

2,300

1,700

56

5.5

3,700

2,700

60

5.5

4,600

3,400

64

6

5,500

4,100

72

6

8,000

5,900

80

6

11,000

8,300

90

6

16,000

12,000

6

23,000

17,000

100

NOTE: Multiply torque values by 0.70 when loctite or anti-seize is applied. Table 3-2

3-5

1 2 3 4 5 6 7

Ring Bolts Washers Head Lifting Plate Safety Block Line-up Stud Jackscrew Lockbolt Wrench

8 9 10 11 12

Thread Template Hoist Ring Eccentric Lifting Ring Bowl Turning Pin Head Stub/Ball Lifting Plate

13

Heading Turning Plates

Figure 3-2 Special Tools Furnished with the Raptor Crusher

3-6

Section 4

Main Frame, Adjustment Ring and Tramp Release Assemblies Main Frame Assembly Figure 4-1 .................................................................................................................. 4-3 Crusher Grouting Figure 4-2 ........................................................................................................................... 4-4 Crusher Installation on a Concrete Foundation .......................................................................................... 4-4 Crusher Installation o n a Steel Structure ..................................................................................................... 4-5 Epoxy Grouting Requ irements Table 4-1 ..................................................................................................... 4-5 Main Frame Flange Spacers Figure 4-4 ........................................................................................................ 4-6 Main Frame Liners and Arm Guards ............................................................................................................... 4-6 Replacing the Main Shaft ................................................................................................................................. 4-6 Replacing the Lower Thrust Bearing and Sh ims ......................................................................................... 4-6 Main Frame Arm Guard Figure 4-5 ................................................................................................................ 4-7 Main Frame Liner Figure 4-6 ........................................................................................................................... 4-7 “U” Seal Replacement ....................................................................................................................................... 4-7 Lower Thrust Bearing and Shims Figure 4-7 ............................................................................................... 4-8 U-Seal Replacement Figure 4-8 ..................................................................................................................... 4-8 Main Frame Pin Replacement ......................................................................................................................... 4-8 Main Frame Pin Figure 4-9 .............................................................................................................................. 4-9 Main Frame Pin Bushing Replacement ......................................................................................................... 4-9 Main Frame Seat Liner and Fulcrum Bar....................................................................................................... 4-9 Main Frame Seat Liner and Fulcrum Bar Figure 4-10 .............................................................................. 4-10 Determining Main Frame Seat Liner Wear.................................................................................................. 4-10 Determining Adjustment Ring Wear............................................................................................................ 4-10 Maximum Vertical Seat Liner Wear Table 4-2 ............................................................................................ 4-10 Determining Seat Liner Wear Figure 4-11 .................................................................................................. 4-11 Installing the Main Frame Seat Liner and Fu lcrum Bar ............................................................................ 4-11 Main Frame Seat Liner and Fulcrum Bar Figure 4-12 .............................................................................. 4-12 Adjustment Ring Assembly Removal ........................................................................................................... 4-12 Adjustment Ring Placement Figure 4-13 ................................................................................................... 4-13 Clamp Ring Spacers and Capscrews Figure 4-14 ...................................................................................... 4-13 Installing the Adjustment Ring Assembly................................................................................................... 4-13 Removing the Tramp Release Cylinder ....................................................................................................... 4-14 Tramp Release Cylinder Assembly Figure 4-15 ......................................................................................... 4-14 Installing the Tramp Release Cylinder ......................................................................................................... 4-14 Accumulator Depressurization Figure 4-16............................................................................................... 4-15 Replacing the Accumulator........................................................................................................................... 4-15

4-1

Accumulator Mounting Figure 4-17 ............................................................................................................ 4-16 Removing the Clamping Ring ....................................................................................................................... 4-16 Installing the Clamping Ring ......................................................................................................................... 4-16 Clamp Cylinder Travel Figure 4-18 ............................................................................................................... 4-17 Checking for Thread Wear Figure 4-19 ....................................................................................................... 4-17 Determining Adjustment and Clamping Ring Thread Wear.................................................................... 4-17

4-2

Description

Cylinders are mounted in the Clamping Ring and position it above the Adjustment Ring. The Clamping Ring also has internal threads. When the Clamping Cylinders are pressurized, the Clamping Ring lifts slightly and locks the Bowl Assembly in place. This prevents the Bowl from turning during crushing.

Refer to Figure 4-1 This section covers descriptions of the Main Frame, Adjustment Ring, and Tramp Release Assemblies along with installation and removal instructions.

The Main Frame is typically bolted to a foundation and provides a rigid support for the Crusher components while transmitting the crushing force to the foundation.

Two Dust Shells with bolt-on seals are bolted to the Adjustment Ring. The Dust Shells and their seals protect the Clamping Ring, Clamping Cylinders and Bowl threads from dust and dirt.

To protect the inside of the Frame from wear, Main Frame Liners are attached to blocks welded to the Frame, and Arm Guards protect the three arms of the Frame.

Hydraulic Tramp Release cylinders are used to hold the Adjustment Ring to the Main Frame. One end of each cylinder is bolted to the Adjustment Ring while the other end is held under the upper Main Frame flange by a bracket. An uncrushable item (tramp) passing through the crushing

An Adjustment Ring with internal threads sits on the conical surface of the Frame. The threads provide the means for installing or removing the Bowl Assembly, along with the adjustment of the Crusher closed side setting. Clamping

1. 2. 3. 4. 5.

Main Frame Adjustment Ring Clamping Ring Clamping Cylinder Dust Shell

6. 7. 8. 9. 10.

Dust Shell Seal Main Shaft Lower “U” Seal Arm Guard Main Frame Liner

11. 12. 13. 14. 15.

Tramp Cylinder Main Frame Pin Fulcrum Bar Main Frame Pin Bushing Seat Liners

16. Main Frame Ring 17. Lower Thrust Bearing

Figure 4-1 Main Frame, Adjustment Ring and Tramp Release Assemblies

4-3

cavity or overloading the Crusher will cause the Adjustment Ring to lift off the Frame. The ring lift will extend the cylinder and force oil from the rod side of the cylinder to one of two Accumulators, mounted on the Main Frame, compressing the pre-charged nitrogen gas in the Accumulator. When the non-crushable item has passed through the crushing cavity and the Crusher overload condition has passed, the compressed nitrogen in the accumulator will force the oil back into the Tramp Release cylinders, retracting them, and reseating the Adjustment Ring on the Main Frame. The Main Shaft is secured in the Main Frame hub by use of an interference fit. The Eccentric Assembly rotates around the fixed Main Shaft. The Socket Assembly is mounted on the top of the Main Shaft and supports the Head Assembly. A thrust bearing is bolted to the top of the Main Frame hub and supports the rotating Eccentric Assembly. Shims located under the thrust bearing can be inserted or removed and are used to adjust the position of the Gear and Pinion relative to one another. Pins mounted in the Main Frame match up with holes in Bushings located in the Adjustment Ring and prevent the Adjustment Ring from turning during crushing. The pins also serve as guides to properly reseat the Adjustment Ring on the Main Frame following the passing of tramp material. Mounted around the top of the Main Frame gear well is a replaceable “U” shaped seal. This seal, along with its mating “T” shaped seal in the Eccentric Assembly, form a labyrinth to prevent oil leakage and the infiltration of dust into the Crusher.

Crusher Installation on a Concrete Foundation FLSmidth recommends the use of grout when mounting the Crusher on a concrete foundation. There are two types of grouting material a vailable: cementitious and epoxy. Epoxy grouting is a tough, vibration resistant and resilient material that requires less preparation before pouring than concrete grouting. This makes epoxy grouting the better choice. To grout the Main Frame Assembly onto a concrete foundation, do the following: 1. Select the grout material. a)

If epoxy grouting is going to be used, torchcut four washers 10mm (0.4”) thick and place them over the four foundation bolts.

b) If cementitious grout is going to be used, make four hardwood blocks. These blocks are to support the Main Frame 50mm (2.0”) to 60mm (2.4”) above the foundation. Cementitious grout material shrinks when it sets and the wood blocks will shrink with it. Refer to Figure 4-2 2. Attach the proper lifting equipment to the Frame lifting holes located on the outside of the upper Main Frame flange. Refer to Figure 4-3

Warning Before lifting the Crusher, make sure the Bowl and Head Assemblies have been removed. It is not necessary to remove the Tramp Release Cylinders. 3. Place the Main Frame on the foundation and on top of the steel washers or wood blocks.

1.

Crusher

2. Foundation 3. Epoxy Grout 4. Foundation Bolt 5. Wood Forms

Figure 4-2 Crusher Grouting

4-4

4. If cementitious grouting is used, go to Step 5. If epoxy grouting is used, place customer supplied “C” shaped steel shims on top of the steel washers. This will provide the approximate desired 13mm (0.5”) to 20mm (0.8”) epoxy thickness between the Main Frame and foundation. 5. Construct and install wood forms around the inside and outside of the lower Main Frame flange to contain the epoxy or cementitious grouting material while it’s being poured. Refer to Figure 4-2

2. When the grouting has hardened to the manufacturer’s recommendations, tighten the nuts on the foundation bolts to safely secure the Crusher. b) Follow the instructions cementitious grouting.

below

for

pouring

1. The foundation surface should be cleaned and in a rough condition in the areas where the grouting is to be poured, according to the manufacturer’s recommendations. The areas must also be kept completely saturated with water to prevent water from being absorbed from the grout mix. Remove any standing water from the foundation just before pouring.

1. Main Frame 2. Lifting Hooks in Main Frame

3. 4.

Adjustment Ring Lifting Cables

Figure 4-3 Lifting the Crusher

Coat the forms with several layers of paste wax prior to installation to prevent the grouting material from adhering to the forms. These forms should be kept 13mm (0.5”) to 20mm (0.8”) from the outside of the Main Frame flange. Place the forms against the inner underside of the foundation and Main Frame flange. Use a caulking material to seal all seams and joints to prevent grout leakage when being poured. 6. If cementitious grouting is to be used, go to 6b. a)

Follow the instructions below for pouring epoxy grouting. 1.

Follow the epoxy grout manufacturer’s mixing and pouring instructions. Pour the epoxy in one area at a time and allow it to spread approximately 0.6 meters (2 feet) on either side of the spot that’s being poured. This will prevent air from being trapped under the flange. Next, move to another area where the previous pour has stopped and pour again. Repeat this process until the grouting has been completed. The epoxy should not be poured into more than one place at a time. The amount of epoxy grout needed to install the Crusher with a 13mm (0.5”) to 20mm (0.8”) grout thickness, with a 20mm (0.8”) gap around the four corner pads, is approximately 195 kg (430 lb).

2. When the grouting has hardened to the manufacturer’s recommendations, tighten the nuts on the foundation bolts to safely secure the Crusher.

Crusher Installation on a Steel Structure If the Crusher is to be mounted on a steel structure or trailer, the Frame must be shimmed because of discontinuities of the Crusher and the steel structure surfaces. For mounting the Crusher on a steel structure, do the following: 1. All weld spatter and slag is to be removed from the area wherewelds the Crusher is the to be mounted. Ground all protruding flush on adjacent surfaces. 2. Torch cut four 6.4mm (0.25”) thick spacers to the same contour as the Main Frame flange. Refer to Figure 4-4 Dimensions for fabricating a spacer can be found on the Mounting and Clearance Drawing available from FLSmidth. The spacers are then to be placed onto the steel structure and over the anchor bolts or bolt holes. 3. Attach the proper lifting equipment to the special lifting eye bolts, which can be installed on the outside of the upper Main Frame flange. Refer to Figure 4-3

Warning Before lifting the Crusher, make sure the Bowl and Head Assemblies have been removed. It is not necessary to remove the Tramp Release Cylinders.

4-5

4. Lift the Main Frame and place it on the steel structure above the shims.

If the Main Frame Liners are worn to the point of replacement, do the following:

5. Level the Crusher by inserting shims the same shape as the ones torch cut in Step 2 but with slots to clear the anchor bolt when they are slid between the spacers and Main Frame flange.

1. Weld a lifting eye to the worn Main Frame Liner. Be sure to preheat parts to 39°C (70°F) to 56°C (100°F) above ambient. Stainless Steel rod or equivalent should be used to attach the lifting eye to the worn Main Frame Liner. Support the Main Frame liner with a suitable lifting device.

6. Tack weld the spacer and shims to the steel structure to avoid them from working loose due to vibration. 7. Firmly seat the Crusher on the structure by tightening the anchor bolts. The anchor bolts should be long enough to pass through the entire depth of the support beam, as well as the Main Frame flange, shims, and spacers. 8. After the Crusher has been firmly anchored to the structure, recheck to make sure the Crusher is still level. 9. Check the anchor bolts for tightness after one day, one month, six months and one year and tighten if necessary.

Main Frame Liners and Arm Guards

2. Cut the welds using a grinder or Acetylene torch at the top of the worn Main Frame Liners holding them to the Main Frame (be careful not to undercut into the Main Frame). 3. Remove the worn liner. Caution: Do NOT be under the suspended load. Serious injury can occur. 4. Place each section of the new Frame Liner sections into the Main Frame relative to the Arm Guards to allow for welding. Refer to Figure 4-5 When welding the new Main Frame Liners to the Main Frame preheat the Main Frame 39°C (70°F) to 56°C (100°F) above ambient.

Replacing the Main Shaft

The Main Frame Liners and Arm Guards should be checked for wear during every Mantle and Bo wl Liner change. With the Head Assembly out of the Crusher, the Arm Guards are easily accessible for inspection and changing if required. Refer to Figure 4-5

Replacement of a Main Shaft requires a proper fit between the Shaft and Main Frame hub. Installing a Shaft should only be done by an FLSmidth trained technician. Contact FLSmidth customer service department in such a situation. Note: During the annual check, inspect the fit of the Main Shaft in the hub of the Main Frame.

Use a feeler between the Shaft and bore at the top of the hub. The fit should be feeler tight all the way around. Use a feeler gauge between the Shaft and bore at the bottom of the hub. Measure at four points 90° apart and calculate the average clearance. This value should not exceed 0.060mm (0.0023”). If there is clearance at the top or the bottom clearance exceeds the value listed, contact FLSmidth customer service department immediately.

Replacing the Lower Thrust Bearing and Shims Shims 2.1. Steel Structure or Trailer

3. 4.

Main(305mm) Frame Flange 12” x 12” (305mm) Square Spacers

Figure 4-4 Main Frame Flange Spacers

4-6

To replace the Lo wer Thrust Bearing due to damage or wear or to add or remove shims to adjust Gear/Pinion backlash, do the following: 1. To access the lower thrust bearing, remove the Bowl, Head, Socket and Eccentric Assemblies. Removal

1.

Main Frame

2.

Main Frame Liner

Figure 4-6 Main Frame Liner

the shim stack, making sure the Bearing and shims are seated properly and that the holes in these parts are aligned with the tapped holes in the Main Frame.

1.

Liner Welded to Main Frame 2. Main Frame Liner 3. Arm Guard

4. 5.

Main Frame Liner Welded to Arm Guard

Figure 4-5 Main Frame Arm Guard

6. Insert the socket head capscrews, along with new spring washers, through the Thrust Bearing and shims and screw them into the tapped holes in the Main Frame. Using a crossing pattern, tighten all the capscrews to 151 N-m (111 ft-lbs). Recheck torque after all components have returned to ambient temperature.

“U” Seal Replacement instructions can be found in the respective sections of this manual. 2. Remove the socket head capscrews and spring washers that retain the thrust bearing to the frame hub. Refer to Figure 4-7 3. Use the two M10 ring bolts supplied by FLSmidth in the special tools to lift the Thrust Bearing out of the Crusher. 4. Inspect and remove any burrs or upset edges on the new Thrust Bearing and shims that would not allow flat contact on the top surface ofthe Main Frame hub. 5. To determine the correct amount of shims to be placed between the Main Frame and Thrust Bearing, see 6, Checking Backlash the GearSection and Pinion . If additional shimsBetween are required, place them on top of the existing shim stack. If a new Thrust Bearing is to be installed, lift and lower the Thrust Bearing (using the same M10 ring bolts) on

There is a “U” shaped seal located in a groove around the top of the Main Frame gear well. Refer to Figure 4-8 This seal can only be inspected whenever the Eccentric Assembly or Counterweight is out of the Crusher. Seal replacement is required if any damage is found. This seal not only prevents oil from leaking out of the Crusher, but keeps contaminants out of the Crusher as well. To replace the seal, do the following: 1. Remove the damaged seal and scrape out any old glue residue left in the seal groove. 2. Completely clean the groove with an oil free solvent such as acetone or alcohol and let dry. 3. If the new seal is shiny on the bottom and is coated with a mold release agent, use a coarse sand paper to remove just enough material from the bottom and sides of the seal to completely remove the shine. It is important that the release agent be completely removed so the adhesive used to hold the seal in the Eccentric groove will adhere to the seal.

4-7

closed side setting, using a different liner configuration, or properly distributing the feed around the feed opening. Adjustment Ring movement will cause wear to the Main Frame Pins and Pin Bushings, which are mounted in the Adjustment Ring. This wear can be seen by looking at the underside of the Adjustment Ring and at the top and bottom of the Pin Bushings. The rotation of the Head while the Crusher is under load will be counterclockwise. For that reason, the Bowl and Adjustment Ring will want to turn in the same direction, causing the Pins and Pin Bushings to wear more on one side. To replace the Main Frame Pins, do the following: 1. 2.3. 4. 5. 6.

Socket Head or Hex Head Capscrew Lower ShimsThrust Bearing Main Frame Spring Washer Main Shaft

Figure 4-7

Lower Thrust Bearing and Shims

The seal could become loose and work itself out of the groove during Crusher operation if the release agent is not completely removed.

1. Remove the Bowl Assembly from the Crusher following the instructions in Section 9, Bowl Removal. 2. Remove the Adjustment Ring from the Crusher following the instructions detailed later in this section under Adjustment Ring Assembly Removal. 3. Remove the hex bolt and washers from the bottom side of each Main Frame Pin that needs replaced. Refer to Figure 4-9

4. Apply a very thin coat of activator to the bottom and sides of the seal. Too much activator will result in a partial cure that may not provide complete bond of the adhesive. 5. Apply a thin coat of adhesive to the bottom of the groove in the Main Frame. Apply just enough adhesive to the seal groove to obtain a minimal squeeze out when the seal is pressed in place in Step 6. 6. After the adhesive has been applied, quickly place the seal into the frame groove. Place a steady force on the bottom of the seal to maintain contact between the bottom of the groove and the seal. A satisfactory handling bond will occur in approximately three minutes.

Main Frame Pin Replacement The Main Frame Pins are pressed into the Main Frame and serve two purposes. They stop the Adjustment Ring from rotating the FrameRing during crushing operation guide theonAdjustment back into position whenand ringthey lift occurs due to a tramp event or overpowering the Crusher. Adjustment Ring lift, sometimes called “Ring Bounce,” is not normal and can usually be corrected by adjusting the

4-8

1. Apply Activator to Bottom and Sides of “U” Seal 2. “U” Seal 3. Apply Adhesive to Sides and Bottom of Frame Seal Groove 4. Apply Seal 5. Main Frame

Figure 4-8

U-Seal Replacement

4. To remove the pins, heat the Main Frame pin boss while driving the pin out the top of the Main Frame. An aid to removing the pin would be to lance the pin prior to heating the Main Frame and driving it out. 5. To install the replacement Main Frame Pins, cool the Pins and heat the Main Frame to create a temperature difference of 115°C (207°F). 6. After the pins have been installed and are bottomed out in the counterbored hole in the Main Frame, reinstall the hex bolts and washers. If there are pin bushings that require replacing, then follow the instructions Replacing the Main Frame Pin Bushing later in this section. Otherwise, install the Adjustment Ring back onto the Frame following the instructions Installing the Adjustment Ring Assembly described later in this section.

Main Frame Pin Bushing Replacement To replace the Main Frame Pin Bushings, do the following: 1. Remove the Bowl Assembly from the Crusher following the instructions in Section 9, Bowl Removal. 2. Remove the Adjustment Ring from the Crusher following the instructions Adjustment Ring Assembly Removal described later in this section. 3. Remove the set screws, located at the Adjustment Ring, and the caps from those bushings that are being replaced. 4. Heat the Adjustment Ring pin bushing bosses and drive the bushings out of the bottom of the Adjustment Ring. 5. The replacement bushings are to be packed in dry ice for at least two hours before being installed. 6. The following instructions are to be conducted at each bushing location where the bushing is being replaced. Just prior to installing a cooled pin bushing, heat the Adjustment Ring boss for 10 to 15 minutes. The temperature difference between the Adjustment Ring boss and Pin Bushing should be at least 56°C (101°F). Drop the cooled Pin Bushing quickly into the Adjustment Ring bore, making sure the holes

1. Main Frame Pin 2. Adjustment Ring 3. Main Frame Pin Bushing 4. Pin Retainer

Figure 4-9 Main Frame Pin

in the Pin Bushing line up with the tapped holes in the Adjustment Ring. After the bushings have been installed, reinstall the caps and hardware. Before mounting the Adjustment Ring back onto the Main Frame, check for wear on the Main Frame Pins to determine if any or all need replacing. If there are Pins that require replacing, follow the instructions Main Frame Pin Replacement described earlier in this section. Otherwise, install the Adjustment Ring onto the Frame following the instructions Installing the Adjustment Ring later in this section.

Main Frame Seat Liner and Fulcrum Bar Welded to the top of the Main Frame are a Seat Liner and Fulcrum Bar. Refer to Figure 4-10 These parts should be regularly checked for wear. Deviations in feed to the Crusher along with slight movement between the Adjustment Ring and Main Frame can cause small amounts of wear. This wear will increase if an excessive amount of Adjustment Ring movement (Ring Bounce) is allowed. The bronze Seat Liner provides a replaceable seating surface for the Theand bronze is a softer material than the steelAdjustment in the MainRing. Frame Adjustment Ring.

There should always be clearance between the top of the Fulcrum Bar and the underside of the Adjustment Ring.

4-9

The clearance is greatest when the Main Frame Seat Liners are replaced. Even though it rests on a bronze Seat Liner, over long periods of operation, the seating surface of the Adjustment Ring will wear. The seating surface of the Adjustment Ring should be reconditioned when the required clearance between the top of the Fulcrum Bar and the Adjustment Ring is no longer achievable after replacing the Main Frame Seat Liners. There is a possibility of Adjustment Ring failure (i.e. cracking) if the Adjustment Ring is allowed to directly contact the Fulcrum Bar during crushing operations.

Determining Main Frame Seat Liner Wear The Main Frame Seat Liner needs to be inspected weekly or after every major tramp event. This requires doing a Crusher clearing to lift the Adjustment Ring. The Safety Blocks should be installed and the Seat Liner segments inspected for detachment or cracked welds. To determine the amount and rate of Seat Liner wear, do the following: 1. Number each of the four Main Frame Pin bosses in a clockwise direction, by painting or stamping, starting with the boss to the left of the Countershaft Box. Refer to Figure 4-11 2. Measure and record the gap between the top of the Main Frame pin boss and the bottom of the Adjustment Ring at that point. Refer to Figure 4-11 3. Every six months or after a known period of excessive ring bounce, take gap measurements at these |points and compare them with the srcinal

Maximum Vertical Seat Liner Wear

5/16” (8mm) Seat Liner Wear Example Original Recorded Measurement

1-9/16” (40mm)

Periodic Dimensional Check Measurement

1-1/4” (32mm)

Difference

5/16” (8mm) Table 4-2

4-10

1. 2.

Fulcrum Bar Seat Liner

3. 4.

Seating Surface Main Frame

Figure 4-10 Main Frame Seat Liner and Fulcrum Bar

measurements from Step 2. The difference in the measurements will tell you how much if any wear has taken place. Due to casting variations, this gap is the only place to take accurate measurements. 4. The maximum allowable difference between the srcinal and a check measurement is 8.0mm (0.31”). The Seat Liner and Fulcrum Bar need replacing when the wear has reached this amount of drop, as there is only 1.5mm (.06”) thickness left on the Seat Liner. Refer to Table 4-2 If the gap measurements from one side of the Crusher to the other vary by 6.4mm (.25”) after subtracting them from the srcinal measurements, the Seat Liner has worn on one side and the Adjustment Ring is tilted. This scenario is caused by an uneven distribution of feed to the Crusher. When the ring tilt is between 6.4mm (0.25”) to 10mm (0.4”), the Seat Liner and Fulcrum Bar need to be replaced. The Fulcrum Bar must be replaced at the time the Seat Liner is replaced. Replacement procedure for installing a new Seat Liner and Fulcrum Bar can be found later in this section.

Determining Adjustment Ring Wear When a new Fulcrum Bar is installed, there is a gap between the top of the Fulcrum Bar and the underside of

the Adjustment Ring that must be held. Refer to Figure 4-10 As previously mentioned, the Adjustment Ring seating surface will wear over a long period of time. The Adjustment Ring seating surface will eventually wear enough to where the desired gap will not be able to be held even with the installation of new Seat Liner and Fulcrum Bar. For the Adjustment Ring to seat properly on the Main Frame, holding the desired gap between the Adjustment Ring and Fulcrum Bar after new ones have been installed is very important. To determine the gap between the Adjustment Ring and Fulcrum Bar, do the following: 1. If not already done, remove and replace the Main Frame Seat Liner and Fulcrum Bar as instructed in Installing the Main Frame Seat Liner and Fulcrum Bar later in this section. 2. Insert balls of clay or putty at various spots on top of the Fulcrum Bar. 3. Place the Adjustment Ring on the Main Frame, making sure it’s properly seated. 4. Lift the Adjustment Ring off the Frame and measure the thickness of the clay or putty. a) If the thickness of the clay or putty measures the minimum clearance allowed, 1.0mm (0.04”) or less, machine the top of the Fulcrum Bar to obtain the proper clearance. b) If the thickness of the clay or putty measures the maximum clearance allowed, 4.0mm (0.16”) or more, use weld to build up the top of the Fulcrum Bar, then machine to obtain the proper clearance. Contact FLSmidth customer service for dimensions and welding and machining procedures.

1. 2. 3. 4. 5. 6. 7. 8.

Adjustment Ring Main Frame Pin Paint or Stamp Numbers 1, 2, 3, etc. Here Measure and Record Wear Dimensions Here Seat Liner Main Frame Fulcrum Bar 1/32” (1mm) to 5/32” (4mm) Clearance required after new seat liners are installed

Figure 4-11 Determining Seat Liner Wear

The Adjustment Contact Ring seating surfacecustomer will have service to be reconditioned. FLSmidth department for welding and machining procedures.

Installing the Main Frame Seat Liner and Fulcrum Bar To install new Main Frame Seat Liners and Fulcrum Bars, do the following: 1. Remove the Bowl Assembly following the instructions in Section 9, Bowl Removal.

5. If the measurement varies from one side of the Crusher to the other by 6.4mm (0.25”) or more, this indicates the Adjustment Ring seating surface has worn excessively on one side and that the ring is

2. Remove the Adjustment Ring following the instructions Adjustment Ring Assembly Removal later in this section.

tilted on the Main Frame. This is usually caused by uneven feed distribution.

3. Remove the worn Seat Liners and Fulcrum Bar segments from the Main Frame by grinding off the welds. Do not use air arc, as this can infuse carbon into the steel of the Main Frame and cause embrittlement.

Installing a new Main Frame Seat Liner and Fulcrum Bar WILL NOT correct this problem.

4-11

Adjustment Ring Assembly Removal To remove the Adjustment Ring Assembly from the Crusher, do the following: 1. Remove the Bowl Assembly from the Crusher following the instructions in Section 9, Bowl Removal. 2. Remove the Drive Ring from the Adjustment Ring as instructed in Section 10, Bowl Adjustment Mechanism Assembly.

1. Fulcrum Bar 2. Bronze Main Frame Seat Liner 3. Gap Between Fulcrum Bar Segment 4. Gap Between Main Frame Seat Liner Segments .75” (20mm)

Figure 4-12 Main Frame Seat Liner and Fulcrum Bar

4. The Seat Liner consists of segments and each segment is to be welded to the Frame individually. The vertical joints are not to be butt welded. Refer to Figure 4-12 Use welding rod Ø4mm (0.16”) AMPCO ROD #10 or AWS #E CU AL-A2 or #R CU AL-A2. These rods require an amp setting between 130A and 190A and reverse polarity. The welding surfaces must be preheated between 39°C (70°F) to 56°C (100°F) above ambient to remove all moisture and ensure proper weld penetration. 5. The Fulcrum Bar is also made of segments and made to be welded to the Main Frame individually. Use 7018 Weld Rod to mount the Fulcrum Bar to the Main Frame. The welding surfaces must be preheated between 39°C (70°F) and 56°C (100°F) above ambient to remove all moisture and ensure proper weld penetration. Refer to Figure 4-12 6. Check the clearance between the Fulcrum Bar and the underside of the Adjustment Ring as outlined Determining under earlier in this section. Adjustment If the gap is Ring found Wear to be correct, then install the Adjustment Ring back onto the Frame following the instructions Installing the Adjustment Ring Assembly later in this section.

4-12

3. Electrically isolate the Hydraulic Power Unit and depressurize the Tramp Release Cylinders as instructed in Section 12, Hydraulic Systems. Make sure the tramp circuit pressure is zero by checking the value displayed on the tramp circuit pressure transducer. 4. Depressurize all the Clamping Cylinders as instructed in Section 12, Hydraulic Systems. Make sure the clamp circuit pressure is zero by checking the value displayed on the clamp circuit pressure transducer. A. Lockout Hydraulic Power Unit. B. Bleed Adjust Motor Hose Connections. 5. Unscrew the nuts that secure the top of the Tramp Release Cylinders to the Adjustment Ring. These nuts were factory installed with Loctite and must be heated to 250°C (482°F) to be able to remove. 6. Again, check that the Clamping Circuit Pressure is zero. Opposite the Countershaft on the adjustment ring, disconnect the hose that supplies hydraulic oil to the clamping cylinders from the hydraulic power unit. Refer to Figure 4-13 7. Unbolt the Dust Shell and remove it from the top of the Adjustment Ring. 8. Disconnect the hydraulic setting adjust motor and proximity sensors. 9. Remove the Vibration Sensors mounted on the Drive Ring Retainers. Be careful not to damage the cords as they are permanently secured to the Sensors. 10. Remove the Adjustment Ring Assembly using the ring bolts provided with the Tools Assembly. 11. Check the Adjustment Ring, Clamping Ring and Bowl threads as instructed in Adjustment and Clamping Ring Thread Wear later in this section.

Ring and Clamping Ring threads will not be correctly oriented and the Bowl will not screw into the Adjustment Ring. 3. Insert the tube spacers into the holes in the Clamping Ring followed by the cap screws with washers mounted on them. Refer to Figure 4-14 4. Connect the hydraulic supply hose (vertical hose section coming from the Adjustment Ring) to the Clamping Cylinder hose loop. Check all the clamp cylinder hose connections to make sure they are tight before proceeding to Step 5. 5. Lift and place the Dust Shell on the top of the Adjustment Ring and bolt in place. 1.

Clamping Cylinder Hose Connection 2. Indexing Hole Location on Adjustment Ring 3. Countershaft Centerline 4. Indexing Hole in Clamping Ring 5. Indexing Hole in Adjustment Ring

Figure 4-13 Adjustment Ring Placement

6. Thread the spherical nuts onto the top of the tramp release cylinders following the instructions Installing the Tramp Release Cylinder later in this section. 7. Lift and place the Drive Ring and its support brackets, as instructed inSection 10, on the Drive Ring Support. 8. Connect the setting adjust motor hydraulic connections and proximity sensor cables.

Installing the Adjustment Ring Assembly To install the Adjustment Ring onto the Main

Frame do

the following: 1. Install the Adjustment Ring using the ring bolts provided with the Tools Assembly, making sure that the Adjustment Mechanism motor mount is located opposite the Countershaft. If the Tramp Release Cylinders were left attached to the Main Frame, carefully lower the Adjustment Ring and guide the cylinder rods into the mating holes. Refer to Figure 4-13 If the Clamping Ring was not removed, skip to Step 5. 2. Install the Clamping Ring using the ring bolts provided with the Tools Assembly, making sure that the indexing holes in the Adjustment Ring and Clamping Ring are aligned. Refer to Figure 4-13 If the indexing holes are not aligned, the Adjustment

1. Clamping Ring 2. Capscrew 3. Flat Washer

4. 5.

Tube Spacer Adjustment Ring

Figure 4-14 Clamp Ring Spacers and Capscrews

4-13

9. Connect the Vibration Sensors to the Drive Ring Support Brackets. 10. Apply a liberal coat of molybdenum disulfide grease to the Adjustment Ring and Clamping Ring threads.

Removing the Tramp Release Cylinder When a leaking Tramp Release Cylinder is found, it should be replaced or removed and rebuilt immediately. A leaking cylinder will allow excessive Adjustment Ring movement. A leaking condition can also be indicated by excessive repressurization of the tramp circuit by the Control System. External leaks can be observed by oil leaking out from between the cylinder bearing and the cylinder tube or from between the cylinder rod and rod bearing. An internal leak (not visibly detectable) involves hydraulic oil bypassing the piston seals from the rod side to the piston side. This will result in the constant loss of tramp circuit pressure causing excessive pressurization. Pressure test the cylinder to verify internal leaking. To remove a Tramp Release Cylinder from the Crusher for replacement or reconditioning, do the following: 1.

Shut off power to the Hydraulic Power unit and lock it out.

2.

Depressurize the tramp release circuit pressure as instructed in Section 12, Hydraulic Systems. Make certain the tramp release system pressure is zero.

3. Remove all the hoses from the tramp release cylinder. 4. Attach a sling around the cylinder to be removed and to a suitable lifting device. The sling should pass between the cylinder and bypass tube so the tube will not be damaged when the cylinder assembly is being lifted off the Crusher. 5. Remove the nut from the top of the Tramp Release Cylinder. These nuts secure the cylinders to the Adjustment Ring and were factory installed with Loctite. They must be heated to 250°C (482°F) to remove. Refer to Figure 4-15 6. Remove the Upper Spherical Washer from the top of the Tramp Release Cylinder. Heat may need to be applied locally to loosen the washer.

4-14

1. Clamp Collar 2. Main Frame 3. Adjustment Ring 4. Tramp Release Cylinder Assembly 5. By-pass Tube 6. Nut and Cylinder Cap 7. 20mm (.75”)

Figure 4-15 Tramp Release Cylinder Assembly

7. Unbolt and loosen the Tramp Cylinder Bracket from under the upper Main Frame flange. Also remove the Clamp Collar from under th Adjustment Ring. 8. Slowly lower the cylinder assembly, with bracket resting on top of the cylinder, while guiding the cylinder rod down through the Adjustment Ring hole, being careful not to damage the cylinder threads and hydraulic fittings. Once the cylinder assembly is clear of the Crusher, lift it up and out of the way. 9. The Tramp Release Cylinder has rebuild kits referenced in the Parts Books under the Tramp Release Cylinder Assembly.

Installing the Tramp Release Cylinder To install a new or rebuilt Tramp Release Cylinder, do the following: 1. Attach a sling around the cylinder so the cylinder hangs as vertical as possible. The sling should pass between the tramp release cylinder and the integral bypass tube so the tube will not be damaged when the cylinder assembly is being lifted. 2. With the Tramp Cylinder Bracket (and Lower Spherical Washer and Cup) resting on top of the cylinder, carefully lift the cylinder and guide the cylinder rod up through the Adjustment Ring so as not to damage the rod threads.

3.

Bolt the bracket into place on the bottom of the upper Main Frame flange and install the Upper Spherical Washer on the top of the Cylinder rod.

4.

Clean the threaded portion of the rod and the M72 hex nut threads with an oil free solvent such as acetone or alcohol and coat the threads with Loctite 277.

5.

Install the hex nut onto the rod until a distance of 15.0mm (0.59”) between the groove in the cylinder rod and the bottom of the Adjustment Ring is achieved. Refer to Figure 4-15

Tools. The screw on top of the bleeder valve must be closed. Screw the air chuck swivel onto the Accumulator valve stem until hand tight and then a quarter turn to compress the seal. Do not over tighten the swivel more than a quarter turn. Over tightening can twist off the Valve Stem and/or damage the copper washer causing leakage.

5. Turn the T-handle down until its internal shaft depresses the valve core stem on the Accumulator. Slowly open the screw on the bottom of the bleeder valve until the nitrogen gas starts to escape. Allow

6. Connect the hoses to the cylinder. 7. Bleed the tramp release system of any trapped air following the instructions in Section 12. After bleeding, pressurize the tramp release system and check the distance between the bottom of the Adjustment Ring and rod groove and correct if necessary. Refer to Figure 4-15

Replacing the Accumulator A defectiv e Accumulator requires immedi ate a ttention. It is typically a result of a damaged internal bladder and results in the inability to maintain pre-charge pressure. This condition can result in the Accumulator filling with hydraulic oil. Since oil is normally displaced from the tramp release cylinders into the Accumulator during tramp events or overload conditions, with no nitrogen gas to compress, the tramp release system will not operate as designed and excessive forces will be produced within the Crusher components.

1. Accumulator 2. Gas Valve Stem

3. Valve Guard

The pre-charge in the Tramp Release Accumulator should be checked at a minimum of every 40 hours of operation (approximately once a week). If the pressure is not at the specified precharge pressure or the pre-charge pressure cannot be held, then the Accumulator should be replaced. To replace the accumulator, do the following:

1.

Shut off power tothe HydraulicPower Unitand lock it out.

2.

Depressurize all the Tramp Release Cylinders as instructed in Section 12, Hydraulic Systems . Make certain the tramp release circuit pressure is at zero. 1.

3. Remove the valve guard from the top of the Accumulator. Refer to Figure 4-16 4. Turn the T-Handle on the air chuck all the way out on the Charging Assembly supplied with the Special

Screw

2. r Valve Valve 3. Bleede Gas Charging 4. Pressure Gauge 5. Handle

6.

Air Chuck

7. Swivel 8. Gas Valve Stem 9. Accumulator

Figure 4-16 Accumulator Depressurization

4-15

the gas to escape until the pressure gauge on the charging valve reads zero. Then remove the charging assembly and return it back with the rest of the tools.

1.

Accumulator Clamp 2. Accumulator 3. Accumulator Base 4. Hose Fittings

6. Remove the hoses from the tee at the bottom of the Accumulator. Refer to Figure 4-17 7. Remove the Accumulator clamp securing the Accumulator to the Main Frame and lift it off its base. 8. Remove the fittings from the bottom of the old accumulator and install them on the new one. 9. Lift and set the new Accumulator on the base and install the clamp. 10. Connect the hoses to the tee at the bottom of the Accumulator.

Figure 4-17 Accumulator Mounting

11. Pre-charge the accumulator following the instructions in Section 12, Hydraulic System Pre-Start Tramp Release System. Damage can occur to the Accumulator bladder if the tramp release system is pressurized before the accumulator is precharged. 12. Bleed the tramp release system of any trapped air following the instructions in Section 12. After bleeding, pressurize the tramp release system and check for leaks.

Removing the Clamping Ring To remove the Clamping Ring, do the following: 1.

Remove the Bowl Assembly following the instructions in Section 9, Bowl Removal.

2.

Remove the Drive Ring from the Adjustment Ring Assembly as instructed in Section 10.

3. Electrically isolate the Hydraulic Power Unit and depressurize the Tramp Release Cylinders as instructed in Section 12, Hydraulic Systems . Make sure the tramp circuit pressure is zero by checking the value displayed on the tramp circuit pressure transducer.

b) Bleed Adjust Motor Hose Connections. 5. Disconnect the hydraulic setting adjust motor and proximity sensors. 6. Unbolt the Dust Shell and remove it from the top of the Adjustment Ring. 7. Disconnect the Clamping Cylinder hose from the Clamping Cylinder hose system. 8. Remove the cap screws, washers and spacers that hold the Clamping Ring in place. Refer to Figure 4-14 9.

From the Tools Assembly obtain the ring bolts and thread them into the tapped holes in the top of the Clamping Ring. Then attach proper lifting equipment to the ring bolts and lift the Clamping Ring off the Adjustment Ring.

Installing the Clamping Ring To install the clamping ring on the adjustment ring, do the following: 1. Install the Clamping Ring on the Adjustment Ring

4. Depressurize allHydraulic the Clamping Cylinders as instructed in Section 12, Systems . Make sure the clamp circuit pressure is zero by checking the value displayed on the clamp circuit pressure transducer. a) Lockout Hydraulic Power Unit.

4-16

using the ring bolts provided with the Tools Assembly, making sure the indexing holes in the Adjustment and Clamping Rings are aligned. Refer to Figure 4-13 If the indexing holes are not aligned, the Bowl will not screw into the Adjustment Ring.

2. Insert the tube spacers into the holes in the Clamping Ring, followed by the cap screws with washers mounted on them. Refer Figure to 4-14 3. Connect the loose end of the Clamping Cylinder hose system to the 90° elbow mounted in the top of the Adjustment Ring. Check all the Clamp Cylinder hose connections to make sure they are tight. Repressurize the system.

Determining Adjustment and Clamping Ring Thread Wear Whenever the Bowl Assembly is removed from the Crusher,

combined thread wear approaches the maximum travel of the Clamping Cylinders, the Bowl will become progressively more difficult to hold in position during crushing. Eventually, if the threads are not refurbished, it will become impossible to maintain the desired closed side setting. To check the Adjustment Ring, Clamping Ring and Bowl threads for wear, do the following: 1. Clean the threads thoroughly by removing all grease and dirt. 2. Use the thread checking template supplied with the Tools Assembly to check the Adjustment Ring, Clamping Ring and Bowl threads .

the Adjustment Ring, Clamping should be checked for galling and Ring wear. and Bowl threads

Refer to Figure 4-19 3.

Measure the gap between the thread template and each of the thread flats. Refer to Figure 4-19 Add the gap measurements taken from the Bowl, Adjustment Ring, and Clamping Ring threads to the designed thread clearance of 4.1mm (0.16”). If the sum of these measurements matches or exceeds the maximum allowable Clamping Cylinder travel of 15.0mm (0.59”), the threads should likely be reconditioned. Contact FLSmidth customer service for welding and machining procedures before reaching this condition.

4.

Dress off all upsets and gouged steel caused by galling of the Bowl, Adjustment Ring and Clamping Ring threads.

1.

Adjustment Ring and Clamping Ring Threads

The clamping system consists of a set of Clamping Cylinders Refer to Figure 4-18 installed in the Clamping Ring, which is mounted on top of the Adjustment Ring. When pressurized, the cylinders raise the Clamping Ring slightly and lock the Bo wl Assembly in place. The extreme crushing forces passing through the threads will inevitably result in thread wear. As the condition of

1. Piston 2. Piston Retainer 3. Cylinder 4. Piston Seal

Note: Cylinder is shown upside down for clarity

Figure 4-18 Clamp Cylinder Travel

2. Bowl Threads 3. Thread Checking Template 4. Distance to be Measured

Figure 4-19 Checking for Thread Wear

4-17

Section 5

Countershaft Box, Countershaft and Sheave Assemblies Countershaft Box Assembly Figure 5-1........................................................................................................ 5-2 Countershaft Box Installation......................................................................................................................... 5-2 Countershaft End Float Figure 5-2................................................................................................................ 5-3 Countershaft Assembly Installation (Method-A) Figure 5-3 ..................................................................... 5-3 Countershaft Box Temperature Sensor Installation .................................................................................. 5-4 Forcing Countershaft Box into Main Frame Figure 5-4 ............................................................................ 5-4 Countershaft Box Assembly Removal ........................................................................................................... 5-4 Temperature Probe Figure 5-5....................................................................................................................... 5-5 Countershaft Box Removal Figure 5-6 ......................................................................................................... 5-5 Crusher Sheave Removal ................................................................................................................................. 5-5 Crusher Sheave Installation............................................................................................................................. 5-6 Crusher Sheave Assembly Figure 5-7............................................................................................................ 5-6 Countershaft Removal ..................................................................................................................................... 5-6 Countershaft Installation................................................................................................................................. 5-7 Holding the Countershaft Figure 5-8............................................................................................................ 5-7 Pinion Replacement .......................................................................................................................................... 5-8 Countershaft Bushing Removal ..................................................................................................................... 5-8 Pinion Location Figure 5-9 .............................................................................................................................. 5-8 Bushing Removal Plate Figure 5-10 .............................................................................................................. 5-9 Countershaft Bushing Installation................................................................................................................. 5-9 Removing the Countershaft Bushing by Ramming Figure 5-11 ............................................................. 5-9 Countershaft Bushing Removal by Jacking Figure 5-12 ......................................................................... 5-10 Countershaft Bushing Figure 5-13 .............................................................................................................. 5-10 “Inner” Countershaft Bushing Oil Groove Location Figure 5-14 ............................................................ 5-11 “Outer” Countershaft Bushing Oil Groove Positions Figure 5-15 .......................................................... 5-11 Oil Leakage Out of the Drive End of the Countershaft ............................................................................ 5-11 Drive Motor Positioned Below Motor Sheave Figure 5-16 ..................................................................... 5-11

5-1

Description Refer to Figure 5-1 This section covers descriptions of the Countershaft Box, Countershaft and Crusher Sheave Assemblies along with installation and removal instructions. A power source (electric motor) transmits power to the Countershaft via a set of V-Belts or direct drive equipment. The Countershaft has a bevel pinion gear mounted on one end and drives a gear that is mounted on the underside of the Eccentric Assembly. Supporting the Countershaft are two bronze sleeve bushings that are inserted in each end of the Countershaft Box. Dowels in the Countershaft Box prevent any rotation of the bushings in the Countershaft Box bores. The bushing flange absorbs thrust loads from either the pinion or the Oil Flinger. An Oil Flinger is pressed on the drive end of the Countershaft. The centrifugal force of the rotating Oil Flinger prevents oil from leaking past the drive end bushing. This oil then collects in the end of the Countershaft Box and drains back to the C rusher sump area through a passage in the Countershaft Box. A piston ring type oil seal is held in place by a tight fit in the cover. The

1. Pinion 2. Countershaft 3. Oil Flinger 4. Cover (Installed with Salastic)

piston ring groove in the Oil Flinger forms a labyrinth seal and rotates around the piston ring to keep oil from leaking past the running clearance between the Countershaft and cover bore. The Countershaft Box is held in the Main Frame by an interference fit and a set of capscrews around the outer flange

Countershaft Box Installation To install the Countershaft Box Assembly in the Crusher, do the following: 1. The Countershaft Box is factory assembled with “end float” or clearance to allow for in and out movement to Figure of Countershaft Box. Refer 5-2theWhen installingin athe repaired or replacement Countershaft Box Assembly, FLSmidth recommends checking the end float by doing the following:

a)

Pull on the Pinion until the Flinger contacts the outer Countershaft Bushing. Refer to Figure 5-2

5. Outer Countershaft Bushing 6. Inner Countershaft Bushing 7. Countershaft Box 8. Piston Ring Seal

Figure 5-1 Countershaft Box Assembly

5-2

If the end float measurement is too large, insert a feeler gauge of appropriate thickness (defined in Step B) between the Pinion and inner Bushing flange. Clamp the Pinion tight against the Bushing and heat the Flinger to the temperature specified above. Refer to Figure 5-8 Then push the Flinger against the outer Bushing flange and allow the Flinger to cool before removing the clamp and feeler gauge. 1. 2. 3. 4. 5. 6. 7.

2. The Countershaft Box Assembly should be inserted in the Main Frame using a sling. Place a long piece of pipe over the Sheave end of the Countershaft to balance the assembly.Refer to Figure 5-3 Lift the assembly and insert it as far as it will go through the outer Main Frame bore while carefully positioning the box centering lug on the Main Frame guide plate.

Inner Countershaft Bushing Countershaft Outer Countershaft Bushing Oil Flinger Sheave Bushing No Clearance Measure End Float Here

Figure 5-2 Countershaft End Float

b) Measure the gap between the Pinion and the inner Countershaft Bushing flange with a feeler gauge. If the end float is not correct, go to Step C. If it’s correct, go toStep 2. Min. End Float Max. End Float XL5000 0.020” (0.51 mm) 0.025” (0.64 mm)

c)

Loosen the Sheave Bushing capscrews and

3. Apply Anti–Seize to the jackscrews provided with the special tools. The Anti-Seize protects the threads from damage caused by the pulling forces. Insert the jackscrews equally spaced through the holes located in the outer Countershaft Box flange until they thread into the tapped holes in the Main Frame. 4. In small increments, alternately tighten the jackscrews to prevent binding of outer Main Frame bore and the corresponding surface of the Countershaft Box. Tighten the jackscrews until they bottom out in the tapped holes of the Main Frame.

slide the Bushing off the Countershaft. If the Bushing is tight on the Countershaft, a wedge can be used in the cut section of the Bushing (making sure not to damage the Bushing) to spread it apart enough to slide it off the shaft. If there is a safety set collar mounted on the Countershaft, just loosen and slide it off. d) Remove the Cover from the Countershaft Box. e) If the end float gap is smaller than specified, then heat the flinger and tap the Countershaft on the sheave end to obtain the correct end float measurement. 1. Lifting Sling 2. Add Counterbalancing Pipe Here 3. Centering Lug on Countershaft Box

Oil Flinger Temperature Difference Above Ambient o

XL500

o

187 F (104 C)

4.5. Guide/Rest (Main Frame) Pinion

Figure 5-3 Countershaft Assembly Installation (Method-A)

5-3

5. Once the jackscrews have bottomed out in the tapped holes in the Frame, remove them and place washers or spacers on the jackscrews. Refer to Figure 5-4 Step 2 Repeat the small incremental tightening until they bottom out. 6. Remove the jack screws. Place the Lock Washers on the cap screws that hold the Countershaft Box Assembly in the Main Frame. Apply Anti-Seize to the cap screws. Install the cap screws into the Main Frame. 7.

Press the Countershaft Box Assembly into the Main Frame by alternately tightening the capscrews until the Countershaft Box flange is tight against the Frame. Refer to Figure 5-4 Step 3

8. Install the Crusher Sheave onto the Countershaft as instructed in Crusher Sheave Installation that can be found later in this section.

Countershaft Box Temperature Sensor Installation An analog temperature sensor is mounted near the Countershaft Box and measures the outer box bushing temperature. The signal from this sensor is monitored by a control system. The system will signal an alarm when the temperature goes above the 130° F (54° C) setpoint in the control system. The most common cause of high outer box bushing temperature is over tensioning the drive belts. This sensor is shipped loose to a void damage in transit. To install the Countershaft Box bushing temperature sensor, do the following: 1. Remove the pipe plug from the tapped hole that the sensor will mount in and install the Mounting Adaptor. Refer to Figure 5-5 2. Locate the sensor and its cover from one of the shipping crates along with the associated temperature probe, mounting adapter, mounting clamp and cable. Refer to the Crusher Oil Piping Assembly in the parts book to help with proper part number identification. 3. Slide the temperature probe into the adapter until the probe contacts the Countershaft Box Bushing. Tighten the nut on the mounting adapter to secure the probe in place. Do not over tighten the nut. This can cause damage to the probe cable.

5-4

Step 1

Step 2 Step 3 1. 2. 3. 4. 5. 6. 7.

Main Frame Washer Spacers Jackscrew Countershaft Box Lockwasher Regular Countershaft Box Hex Head Capscrews No Clearance

Figure 5-4 Forcing Countershaft Box into Main Frame

4. Using the mounting clamp supplied, locate the sensor near the Crusher in an easily accessible area. This will provide easy viewing of the local display on the sensor.

Countershaft Box Assembly Removal To remove the Countershaft Box from the Main Frame do the following: 1. Remove the outer box bushing temperature sensor by loosening the mounting adapter nut and sliding the probe out of the box making sure not to damage the probe and/or cable. Refer to Figure 5-5 2. Attach a lifting sling around the Crusher Sheave and lift just enough to take the slack out of the sling. This will keep the Sheave from sliding off the Countershaft when it breaks loose from the tapered fit of the Sheave Bushing. 3. Follow the instructions in the Crusher Sheave Removal section (located later in this section) and remove the Sheave from the Countershaft.

To Control System

1. Main Frame 2. Jackscrews 3. Countershaft 1. Temperature Sensor Cable 2. Temperature Sensor

3. 4.

Mounting Adapter Countershaft Box

4. Cover 5. Countershaft Box

Figure 5-6 Countershaft Box Removal

Figure 5-5 Temperature Probe

Crusher Sheave Removal To remove the Crusher Sheave, do the following: 4. Remove all the oil piping attached to the Countershaft Box and plug the openings. 5. Remove the capscrews that secure the Countershaft Box to the Main Frame. 6. Using the jackscrews provided in the tools, thread them into the three equally spaced tapped holes in the Countershaft Box flange until they bottom out. Refer to Figure 5-6 7. Attach a lifting sling around the Sheave end of the Countershaft Box and lift to just take the slack out of the sling. Refer to Figure 5-3 The sling will keep the Countershaft Box from falling when the Box isremoved from the Main Frame bore as instructed inStep 8. 8. Alternately tighten the jackscrews in small increments to prevent binding of the Box in the Frame bore. Continue jacking until the box is free of the Frame. 9. Place a long piece of pipe over the Sheave end of the Countershaft to offset the heavier pinion end and remove the assembly.Refer to Figure 5-3

1. Wrap a lifting sling around the Crusher Sheave and lift just enough to take the slack out of the sling. This will keep the Sheave from sliding off the Countershaft when it breaks loose from the tapered fit on the Sheave Bushing. 2. Remove the combination take-up and back-up capscrews from the hub of the Sheave. Refer to Figure 5-7 3.

Take two of the cap screws that were just removed. Lubricate the threads of the two cap screws and thread them into the tapped holes in the sheave hub. Alternately, tighten the cap screws against the sheave bushing flange until the sheave breaks loose. If there is difficulty in breaking the sheaves loose, hit the end of the Counter Shaft with a Babbitt hammer while applying pressure to the sheave bushing flange. If force does not work, heat the sheave with propane torches to expand the bore. First, heat the outside of the sheave in the area of the belts. Then heat will be applied to the center hub. Once the sheave

5-5

2. With the end float checkedand corrected ifnecessary, gently tap the Sheave key int o the Countershaft keyway. 3. Check the tapered surface and bore of the Sheave Bushing as well as the tapered bore in the Sheave and remove any dirt, paint, rust, lubricants and scratches. The Bushing and Sheave bore surfaces must be clean to ensure the Sheave is secure to the Countershaft. Do not lubricate the bushing or the sheave bore. 4. Loosen the Sheave Bushing clamp screw and slide the Bushing onto the Countershaft until it’s tight against the oil flinger. Then tighten the clamp screw to lock the Bushing in place on the Countershaft. Use a wedge or screwdriver in the split of the Bushing to install on the Countershaft if required. 1. Oil Flinger 2. Sheave 3. Sheave Hub 4. Countershaft

5. 6. 7.

Combination Take-up and Back-off Capscrews Bushing Flange Set Screw

Figure 5-7 Crusher Sheave Assembly

is expanded, hit the end of the Counter Shaft with a Babbitt hammer. This action should break the sheave free. 4.

When removing the Countershaft Box Assembly from the Crusher, do not remove the Sheave Bushing from the Countershaft. This will ensure that the Countershaft and Pinion do not slide out of the Box while handling the assembly. The Bushing can be safely removed after the Countershaft Box Assembly is set on appropriate cribbing by removing the clamp screw and sliding the bushing off the Countershaft. If the Bushing is difficult to remove, insert a wedge or screwdriver in the split of the Bushing to enlarge the bore.

Crusher Sheave Installation

5. Lift and slide the Crusher Sheave on the Sheave Bushing and align the holes in the Sheave with the tapped holes in the Bushing Flange. 6. Install the capscrews in the Sheave and screw them into the tapped holes in the Sheave Bushing flange. Alternately tighten the bolts in small increments until the torque value defined on the Drive Assembly drawing in the parts book is achieved. Over tightening could cause the Sheave to crack. When correctly assembled, there should be a clearance of approximately 0.375” (10mm) between the Sheave hub and Bushing flange. Do not try the make up this clearance. This gap is designed to attain a proper grip of the tapered fit between the Bushing and Sheave. Be sure to follow the torque requirements of the bushing manufacturer as over tightening the capscrews could cause the Sheave to crack.

Countershaft Removal To remove the Countershaft and Pinion from the Countershaft Box, do the following:

To mount the Crusher sheave onto the Countershaft, do the following:

1. Remove the Countershaft Box Assembly from the Crusher as instructed in Countershaft Box Assembly Removal earlier in this section.

1. Before mounting the Sheave onto the Countershaft,

2. Loosen the Sheave Bushing clamp screw and

check the end float by following the Countershaft Box Installation instructions, Steps 1 and 2 earlier in this section. If the Sheave Bushing was not removed from the Countershaft, proceed to Step 5.

slide the Bushing off the Countershaft. A wedge or screwdriver used in the split of the Bushing can help open the Bushing bore. Then remove the Sheave key from the Countershaft keyway.

5-6

3. Remove the Countershaft Box cover from the Countershaft Box. 4. There is a slight interference fit between the oil flinger and Countershaft. The oil flinger must first be heated to the proper temperature above ambient before it can be properly removed from the Countershaft.

XL500

Temperature Difference Above Ambient 187°F (104°C)

Position a pry bar between the flinger and the Countershaft Box and apply pressure. When the flinger starts to move, apply force to both sides of the flinger and slide it off the Countershaft. 5. The Countershaft and Pinion are now free to be slid out of the Countershaft Box. 6. With the Countershaft removed, check the shaft run out. If the measured value exceeds 0.004” (0.102mm), the Shaft must be replaced. Also check the Shaft for any twisting. Operating the Crusher with a bent or twisted Countershaft will cause excessive vibration and the potential for premature box bushing failure.

XL500

Temperature Difference Above Ambient 187°F (104°C)

Slide the flinger onto the Countershaft until it bumps the Countershaft Bushing Flange. 5. There is a piston ring seal mounted in a groove in the oil flinger which provides an oil seal with the cover. Make sure the ring is free to turn in the flinger groove. Apply a light coat of grease before installing the seal. 6. Check the inner bore of the cover and make sure it’s smooth and has no grooves worn into it by the piston ring. If a groove is starting to sho w, machine the bore to clean-up. A ring that is allowed to wear too deep into the cover will make removing the cover difficult. 7. Remove any old Silastic from the cover and the cover mounting surface on the Countershaft Box. Next place a bead of Silastic RTV (see parts book for FLSmidth part number) on the cover and inside the bolt circle. 8. Slide the cover onto the oil flinger and bolt it to the Countershaft Box.

Countershaft Installation To install the Countershaft and Pinion into the Countershaft Box, do the following: 1. Use an emery cloth to remove any burrs and buff any scratches found on the Countershaft, the inside of the Countershaft Box and the surfaces of the Countershaft Box Bushings. 2. Coat the Countershaft Bushings with lube oil and carefully slide the Countershaft into the Countershaft Box until the Pinion contacts the Countershaft Bushing Flange. 3. Place a 0.020” (0.51 mm) to 0.025” (0.64 mm) thick shim between the Pinion and Countershaft Box Bushing Flange to establish the required end float. Then clamp the Pinion to the Countershaft Box. Refer to Figure 5-8 4. There is a slight press fit between the oil flinger and Countershaft. The oil flinger must first be heated to the proper temperature of above ambient before it can be properly installed on the Countershaft.

END FLOAT

1. 2.

C-Clamp Countershaft Box Bushing

3. Pinion 4. No Clearance 5. Shim

Figure 5-8 Holding the Countershaft

5-7

9. Install the Sheave Bushing onto the Countershaft by following the instructions Crusher Sheave Installation, Step 2, 3 and 4 described earlier in this section. 10. Remove the clamp holding the Pinion to the Countershaft Box and spacer. 11. The Countershaft Box assembly is now ready to be installed back into the Crusher. Follow the instructions Countershaft Box Installation detailed earlier in the section.

Pinion Replacement The Pinion should be inspected for wear and damage any time the Countershaft assembly is removed from the Crusher. Excessive Pinion wear typically includes pitting and galling of the teeth surfaces. Damage may include broken teeth. The causes of such conditions may be:

1. Pinion 2. Countershaft 3. Measurement “A” .20” (5mm)

1. Incorrect Gear/Pinion backlash setting which will cause damaging tooth contact.

Figure 5-9 Pinion Location

2. Dirty lube system oil. 3. Operating the Crusher in an overloaded condition. Worn Pinions will likely experience tooth breakage which in turn will cause excessive vibration. These conditions will eventually lead to damage of other internal Crusher components. An excessively worn Pinion should be replaced. To maximize the benefits of installing a new Pinion, it’s recommended that the Eccentric Gear be replaced at the same time. Use of a new Pinion with an existing Gear requires checking the contact pattern and backlash and adjusting if necessary. Follow the instructions Checking Backlash in section 6. To replace the Pinion, do the following: 1. Remove the Countershaft Box assembly from the Crusher following the instructions Countershaft Box Assembly Removal described earlier in this section. 2. Remove the Countershaft and Pinion from the Countershaft Box following the instructions Countershaft Removal described earlier in this section. 3. Using a torch, evenly heat the Pinion to create the proper temperature difference as compared to the Countershaft.

5-8

XL500

Temperature Difference Above Ambient 242°F (135°C)

When the specified temperature has been reached, continue to apply heat while bumping the Pinion. When the Pinion starts to move, slide it off the Countershaft. 4. Heat the new Pinion to the above temperature difference and quickly slide the Pinion onto the correct end of the Countershaft so the end of the shaft is sticking out of the Pinion the specified by measurement “A” distance. Refer to Figure 5-9

Countershaft Bushing Removal If either of the two Countershaft Box Bushings are found to be loose in the Countershaft Box as a result of wear, first remove the Bushing(s) and check the Box bore(s) to verify that they are within factory specifications and then change the loose Bushing(s). Operating the Crusher with inadequate lubrication, in an overloaded condition or with over tensioned V-Belts could cause the Bushings to over heat, fail and seize in the Countershaft Box making them difficult to remove. To remove Bushings that are tight in the Countershaft Box, do the following: 1. Remove the Countershaft Box assembly from the Crusher following the instructions detailed in

Countershaft Box Assembly Removal described earlier in this section.

2. Remove the Countershaft from the Countershaft assembly following the instructions listed in Countershaft Removal earlier in this section. 3. A steel bushing removal plate is to be fabricated by the customer. Refer to Figure 5-10 4. The narrow part of the removal plate is to be slid into the Bushing until it’s positioned behind the Bushing. Refer to Figure 5-10 Turn the plate 90° until it contacts the Bushing. 5. Hold the plate in place and thread a 1” (25mm) diameter rod (threaded on both ends) into the nut that was welded to the removal plate. Make the rod a few inches longer than the Bushing. Refer to Figure 5-11

6. Drill a 1.12” (30mm) hole in the center of a 1” x 3” x 12” (25mm x 75mm x 305mm) steel bar. Place the bar onto the threaded rod and hold it in place with a 1” hex nut. Refer to Figure 5-12 Slide a timber or a piece of pipe into the opposite end of the box and ram it against the removal plate to force the Bushing out of the box bore. If ramming will not move the bushing, then go to Step 7. 7. Thread a longer rod than the one previously used in Step 6 into the removal plate nut. Mount the steel bar onto the new rod and place wood blocking between the steel bar and the Countershaft Box flange. Refer to Figure 5-12 Tighten the 1” hex nut on the rod as a jackscrew until the Bushing is pulled against the steel bar. Place additional blocking under the bar and tighten the hex nut until the bushing is again drawn to the bar. Repeat this procedure until the bushing is pulled free of the Countershaft Box bore.

Countershaft Bushing Installation To install a new Countershaft Bushing do the following: 1. First measure the Bushing and Countershaft Box inside and outside diameters. Countershaft bushings are manufactured to provide a 0.001” (0.025 mm) tight to 0.002” (0.051 mm) loose fit in the Box bore. If the measurements indicate that a tighter interference fit than 0.001” (0.025 mm), then the

1. 2. 3. 4. 5. 6. 7.

Slide Centering Plate through Bushing and turn 90 ° to Bear against end of Bushing Countershaft Bushing Bushing Removal Plate Flats to be narrower than Inside Diameter of Bushing Diameter of Plate to be larger than inside of Bushing 1” (25mm) Weld 1” (25mm) Hex Nut to Plate

Figure 5-10 Bushing Removal Plate

1. 2. 3. 4. 5. 6. 7.

Countershaft Box Bushing Removal Plate Dowel Flat Bar Countershaft Bushing Threaded Rod Timber

Figure 5-11 Removing the Countershaft Bushing by Ramming

5-9

b) Position of the oil groove in the outer bushing, Sheave end, is normally at the bottom of the Countershaft Box bore or at the 6:00 o’clock position. This oil groove position accommodates all applications in which the drive motor is positioned horizontally on either side of the Crusher along with applications in which the motor is located above the Crusher while not more than 45° on either side of the vertical centerline.

4. Countershaft Box 1. Flat Bar 5. Bushing Removal Plate 2. Blocking 3. Countershaft Bushing 6. Threaded Rod

Figure 5-12 Countershaft Bushing Removal by Jacking

Countershaft Box bore must be machined to obtain the proper fit between the Bushing and Countershaft Box bore. If the interference fit is too tight, the Bushing bore will collapse when the Bushing is installed. This will reduce the running clearance between the Bushing

If the drive motor is positioned 45° below the Crusher on either side of the vertical centerline, the bushing oil groove must be located at the top center or at the 12:00 o’clock position. Refer to Figure 5-15 and 5-16 5. The new Bushing must be chilled to create the proper temperature difference between the Bushing and Box.

Temperature Difference Between Bushing & Box XL500 78°F (43°C) 6. With the Bushing diameter sufficiently reduced, quickly slide the Bushing into the Countershaft Box bore using the rods (installed in Step 3) as guides. If the Bushing is not installed quickly enough and it gets stuck in the Countershaft Box bore, place a block of wood across the face of the Bushing (for protection of the Bushing) and use two clamps to pull the Bushing the rest of the way in. Evenly tighten

bore and Countershaft causing premature failure with the possibility of the BushingBushing seizing to the Countershaft. Excessive heat can reduce the Countershaft Box bore diameter. 2. Remove the two dowels from the face of the Countershaft Box flange. 3. Make two rods the same diameter as the removed dowels and 1” (25 mm) longer than the Bushing. Insert the rods in the dowel holes. Refer to Figure 5-13 4. The inner and outer Countershaft Bushings are identical. The position of their longitudinal oil groove in the Countershaft Box bore is what changes. To determine the oil groove position, do the following: a) Position the inner Bushing (Pinion end) with the oil groove at the top of the of the Countershaft Box bore, or at the 12:00 o’clock position. Refer to Figure 5-14

5-10

1. Steel Guide Rods 2. Countershaft Bushings 3. Countershaft Box

Figure 5-13 Countershaft Bushing

the clamps to ensure the Bushing does not cock in the Countershaft Box bore. 7. Remove the guide rods and replace them with the dowel pins. Set the end float and complete the assembly of the Countershaft Box per Countershaft Installation procedures outlined earlier in this section. 8. The Countershaft Box assembly is now ready to be installed back into the Crusher. Follow the instructions Countershaft Box Installation located earlier in the section. 1. Inner Oil Groove is at 12:00 o’clock Position 2. Countershaft Bushing 3. Countershaft Box

Figure 5-14 “Inner” Countershaft Bushing Oil Groove Location

Oil Leakage Out of the Drive End of the Countershaft There are many causes of oil leaking from the drive end of the Countershaft. One cause may be an incorrect pitch of

1.

Normal 6:00 O’clock Position for Horizontal Drive or Vertical Drive Pulling Upward 2. Oil Groove 3. 12:00 o’clock Position for Vertical Drive Pulling Downward 4. Outer Countershaft Bushing 5.

Countershaft Box

Figure 5-15 “Outer” Countershaft Bushing Oil Groove Positions

1. Crusher Vertical Centerline 2. Motor Sheave

3. Crusher Sheave 4. 45°

Figure 5-16 Drive Motor Positioned Below Motor Sheave

5-11

the oil drain line creating a condition in which the oil cannot properly drain from the Countershaft Box. Other possible conditions are as follows: 1. Check for a worn or damaged Piston Ring Seal in the Oil Flinger groove. To replace the Piston Ring Seal, Refer to Figure 5-1 and do the following: a)

Remove the Crusher Sheave following the instructions Crusher Sheave Removal earlier in this section.

b) Remove the Countershaft Box cover and Sheave bushing following the instructions Countershaft Removal, Steps 2 and 3 , found earlier in this section. c)

Remove the worn or damaged Piston Ring Seal from the groove in the Oil Flinger. Clean the groove and install the new Piston Ring Seal.

d) Install the Oil Flinger Cover and Sheave Bushing following the instructions Countershaft Installation, Steps 5 thru 9 , earlier in this section. e)

Mount the Crusher Sheave following the instructions Crusher Sheave Installation, Steps 5 and 6, earlier in this section.

2. Check the long cored passage in the lower section of the Countershaft Box f or sludge build-up. Build-up will limit oil flow to the Flinger area and cause oil to leak out from between the Countershaft and Flinger Cover. 3. Check the pitch of the Crusher oil drain line. The drain line should have a minimum pitch of 1” (25mm) vertical rise for every 12” (305 mm) of horizontal run. If the pitch is too shallow, the oil will not flow properly out of the Crusher and leak out from between the Countershaft Box area. This problem will be increased with cold oil conditions. 4. Check the inside of the drain line for dirt, sludge build-up or a collapsed hose. Any restriction to proper oil flow will cause oil leakage.

5-12

Section 6

Eccentric Assembly Counterweight Assembly Figure 6-1 ............................................................................................................ 6-2 Eccentric Assembly Installation...................................................................................................................... 6-2 Backlash and Root Clearance Figure 6-4 ..................................................................................................... 6-3 Checking Backlash and Contact Between the Gear and Pinion............................................................... 6-3 Lifting Eccentric Assembly Figure 6-2 .......................................................................................................... 6-3 Countershaft and Backlash Tool Figure 6-3 ................................................................................................ 6-3 Optimal Contact Pattern Figure 6-5.............................................................................................................. 6-4 Contact Pattern Corrections Figure 6-6 ....................................................................................................... 6-4 Shim Thickness vs. Backlash Table 6-1 .......................................................................................................... 6-4 Eccentric Assembly Removal .......................................................................................................................... 6-5 Replacing the Counterweight Guard ............................................................................................................. 6-5 Upper Thrust Bearing ....................................................................................................................................... 6-5 Upper Thrust Bearing Wear Figure 6-7 ......................................................................................................... 6-5 Upper Thrust Bearing Figure 6-8 ................................................................................................................... 6-5 “T” and “U” Seal Replacement Figure 6-9 ..................................................................................................... 6-6 “T” and “U” Seal Replacement ........................................................................................................................ 6-6 Bushing Lock Removal Figure 6-10 ............................................................................................................... 6-6 Eccentric Bushing .............................................................................................................................................. 6-7 Removing the Eccentric Bushing ................................................................................................................... 6-7 Eccentric Bushing Removal Figure 6-11....................................................................................................... 6-7 Eccentric Bore Inspection ................................................................................................................................ 6-8 Main Shaft Inspection ....................................................................................................................................... 6-8 Eccentric Bushing Alignment Figure 6-12.................................................................................................... 6-8 Eccentric Bushing Alignment Figure 6-13.................................................................................................... 6-8 Eccentric Bushing Installation ........................................................................................................................ 6-9 Adjusting the Gear Backlash for Wear .......................................................................................................... 6-9 Gear Replacement ............................................................................................................................................. 6-9 Removal of the Gear and Counterweight .................................................................................................... 6-9 Lifting Counterweight and Eccentric Figure 6-14 .................................................................................... 6-10 Assembling the Gear and Counterweight .................................................................................................. 6-10 Gear Mounting H oles Figure 6-15 ................................................................................................................ 6-11 Capscrew Torque and Gear Heating Table 6-2 .......................................................................................... 6-11

6-1

Description Refer to Figure 6-1 This section covers description of the Eccentric Assembly and related components along with installation and removal instructions.

seals. These seals, along with adjoining seals in the Head and Main Frame, form a labyrinth to prevent oil leakage and the infiltration of dust into the Crusher.

Eccentric Assembly Installation The Eccentric with its tilted and out-of-round outside diameter rotates around the Main Shaft, which is fixed in the Main Frame. The Head has a bore that matches the outside diameter of the Eccentric and follows an elliptical path as the Eccentric is rotated. Locked in the Eccentric bore is a bronze bushing which provides a bearing for the Main Shaft. Bolted to the bottom of the Eccentric is a bevel gear that is driven by the Countershaft Pinion. The Eccentric Assembly rests on a set of Thrust Bearings. The rotating bronze Upper Thrust Bearing is bolted to the bottom of the Eccentric and the fixed steel Lower Thrust Bearing is bolted to the Main Frame. Shims are placed between the Lo wer Thrust Bearing and Main Frame to adjust the backlash between the Gear on the Eccentric and Pinion on the Countershaft. Bolted to the Eccentric is a Counterweight consisting of a heavy and light side. The heavy side of the Counterweight is located opposite the heavy side of the Eccentric to reduce the unbalanced forces associated with the rotating Eccentric and Head Assemblies. A Guard is bolted to the outside of the Counterweight to protect it from wear caused by the discharge material. Mounted around the top and bottom of the counterweight are replaceable “U” and “T” shaped

1. Eccentric 2. Eccentric Bushing 3. Counterweight 4. Counterweight Guard 5. Gear

6. 7. 8. 9. 10.

To install the Eccentric Assembly in the Crusher, do the following: 1. Thoroughly clean the top of the Main Shaft, Main Frame gear well, Eccentric Bushing bore, Upper Thrust Bearing (bolted to the underside of the Eccentric) and Lower Thrust Bearing (bolted to the Main Frame). Remove any scratches, burrs or nicks. 2. Make sure the cap screws that secure the Upper and Lower Thrust Bearings are tight. 3. From the Tools Assembly, attach the Eccentric Lifting Plate with the ring bolts to the Eccentric using the hex head cap screws. Refer to Figure 6-2 4. Apply a light coat of oil to the Main Shaft, Upper and Lower Thrust Bearings and Eccentric Bushing bore. 5. Carefully lower the Eccentric Assembly onto the Main Shaft while making sure to position one of the large cast slots in the Counterweight above the

Upper Thrust Bearing Upper U-Seal Lower T-Seal Caulking Alignment Dowel

Figure 6-1 Counterweight Assembly

6-2

Pinion. Continue to lower the Eccentric Assembly until seated on the Lower Thrust Bearing. Note: Apply contact paste to the pinion before lowering if Pinion and Gear contact needs to be checked. Refer to Figure 6-2 6. The backlash between the Gear and Pinion should now be checked. Follow the instructions outlined in the next section. Checking Backlash and Contact Between the Gear and Pinion.

1. Countershaft Box 2. Countershaft Box Cover 3. Backlash Tool

4. Adjustment Tab 5. Main Frame 6. Countershaft

Figure 6-3 Countershaft and Backlash Tool

(light side of the Counterweight). Use only enough force to push the Eccentric Bushing against the Main Shaft. If too much force is used, the Eccentric will tip slightly and the backlash measurement will not be accurate. 1. Lifting Cables 7. Main Frame 2. Ring Bolts 8. Lower Thrust Bearing 3. Heavy Side of Eccentric 9. Upper Thrust Bearing 4. Main Shaft 10. Eccentric 5. 6.

Gear Pinion

5. Place a backlash measuring tool on the Countershaft (or remove a bolt from the sheave and add a tool

11. LiftingU-Seal Ring 12. Upper

Figure 6-2 Lifting Eccentric Assembly

Checking Backlash and Contact Between the Gear and Pinion It is important to maintain proper backlash and contact to minimize wear of the Gear and Pinion teeth. To check and/ or adjust the backlash and contact, do the following: 1. Loosen the drive belts or direct drive coupling. 2. Apply contact paste to the pinion. 3. Pull outward on the Countershaft until the pinion is tight against the inner Countershaft Bushing. 4. Remove all bearing clearance between the Eccentric Bushing and the Main Shaft by placing a hydraulic jack between the inner wall of the Main Frame and Counterweight at thickest section of the Eccentric

1. Gear 2. Backlash 3. Gear Tooth Must be Vertical to take an Accurate Measurement 4. Root Clearance 5. Pinion

Figure 6-4 Backlash and Root Clearance

6-3

Shim Thickness vs. Backlash

Shim Thickness

LOW HEEL CONTACT

Approximate Change in Backlash

XL500 0.03” (0.79mm)

0.022” (0.56mm)

0.06” (1.59mm)

0.044” (1.12mm)

.0125” (3.18mm)

0.088” (2.24mm)

HIGH TOE CONTACT

HIGH HEEL CONTACT

1. Gear 2. Pinion

LOW TOE CONTACT

Table 6-1 The pinion should be shimmed out of mesh. It may be necessary to shim the gear into mesh t o obtain the proper backlash.

HIGH TOE CONTACT

LOW HEEL CONTACT

LOW TOE CONTACT

1. Gear 2. Pinion

HIGH HEEL CONTACT

1. Gear 2. Pinion

Typical range of Spiral Bevel Contact Patterns

Figure 6-5 Optimal Contact Pattern

for measuring). Drawings for such a tool can be provided by FLSmidth if needed. Using light force, rotate the Countershaft in a clockwise direction until the Pinion stops against the gear. Refer to Figure 6-3 6. Place a dial indicator with the stylus at the scribed mark on the backlash tool and zero the dial indicator. This mark represents the pitch radius of the pinion, which is 5.495” (139.56 mm). 7. Rotate the Countershaft in a counter-clockwise direction until the Pinion touches the Gear. The reading on backlash. the dial indicator will givenecessary you the transverse It is sometimes to take multiple readings and average the results. Record the readings and compare with the specified backlash range.

6-4

The pinion should be shimmed into mesh.It may be necessary to shim the gear out of mesh to obtain the proper backlash.

Figure 6-6 Contact Pattern Corrections

Transverse Backlash = 0.061” – 0.074” (1.54mm – 1.88mm)

8. Lift the Eccentric Assembly out of the crusher and check the contact pattern on the Gear. Compare the contact pattern to Figure 6-5. 9. The backlash is increased by adding shims under the Lower Thrust Bearing on the Main Frame or by rotating the Countershaft Box Clockwise. The backlash is decreased by removing shims or by rotating the Countershaft Box counter-clockwise. (Note: Countershaft Box rotation is for fine adjustment.) For changes in backlash vs. shim thickness. Refer to Table 6-1 10. Study the contact pattern, compare to Figure 6-6, and follow the recommended adjustments by moving the Countershaft Box in or out of the Main frame using shims.

1. Minimum Groove Depth 2. Original Groove Depth 3. Upper Thrust Bearing

1. Upper Thrust Bearing 2. Socket Head Capscrew 3. Spring Washer

Figure 6-8 Upper Thrust Bearing

Figure 6-7 Upper Thrust Bearing Wear

11. Carry out another measurement of backlash and check of contact pattern. Repeat as needed. 12. Once the correct backlash and contact pattern is obtained, tighten the Countershaft box screws.

Eccentric Assembly Removal To remove the Eccentric Assembly, do the following: 1. Attach the Eccen tric Lifti Ring usin g theRing hex head cap screws. Position theng Eccentric Lifting with an eye bolt in the center of the thickest portion of the Eccentric. Any other position will create Eccentric tip due to unbalanced load. Refer to Figure 6-2 2. Carefully lift the Eccentric Assembly using adequate hoisting equipment. Refer to Table 3-1 for weights. 3. Once the Eccentric Assembly is out of the machine, place it on wood blocking or other protective material.

Replacing the Counterweight Guard The Counterweight is protected from discharge material wear by a bolt on replaceable Counterweight Guard. If the Guard is not regularly checked and replaced, wear will occur to the Counterweight requiring costly repair. Unwanted wear of the Counterweight can also create an out-of-balance condition causing foundation problems. To replace the Counterweight Guard, do the following:

4. Eccentric Bushing 5. Eccentric 6. Gear

1. Remove the cap screws holding the Guard on the Counterweight. It may be necessary to use a moderate amount of heat because of the Loctite used by the factory when installing the Guard hardware. 2. Lift and remove the old Guard from the Counterweight Assembly. 3. Install the new Guard on the Counterweight and bolt in place, using Loctite 277. A daily inspection of the Crusher discharge area will ensure that there is no material build-up or bridging occurring on the Main Frame arms or foundation discharge area that can create wear to the bottom of the Counterweight

Upper Thrust Bearing The bronze Upper Thrust Bearing mounted to the underside of the Eccentric Assembly, should be checked for wear any time the Eccentric Assembly is removed from the Crusher. Nicks and scratches should be buffed out as well. Bearing wear will eventually cause the following two major problems: a)

As the Upper Thrust Bearing wears, the position of the Gear bolted to the bottom of the Eccentric will lower relative to the Pinion teeth resulting in a change to the backlash. This is corrected by placing shims under the steel Lower Thrust Bearing which raises the Gear relative to the Pinion and reestablishes the proper backlash setting. Refer to Checking

6-5

Backlash outlined earlier in this section.

b)

Normal wear of the bronze Upper Thrust Bearing reduces the size and shape of the oil grooves which limits the amount of lubrication eventually resulting in excessive heat and bearing failure. Replace the Bearing when the minimum groove depth value is reached. Original Groove Depth = 0.39” (10 mm) Minimum Groove Depth = 0.35” (8.8 mm)

Never allow either the Upper or Lower Thrust Bearings to wear to point in which contact of the capscrews securing the bearings occurs.

To replace the upper thrust bearing proceed as follows: 1.

Turn the Eccentric Assembly upside down on wood blocking to access the Upper Thrust Bearing.

2.

Remove the socket head cap screws and lock washers that bolt the Upper Thrust Bearing to the Eccentric. Refer to Figure 6-8

3.

Use the ring bolts supplied with in the Tools Assembly to lift and remove the Upper Thrust Bearing from the Eccentric.

1. Counterweight 2. Upper U-Seal 3. Clean bottom of seals using course sand paper to remove surface “Shine” before applying activator and adhesive to bottom of groove in counterweight 4. Lower T-Seal

Figure 6-9 “T” & “U” Seal Replacement

6-6

4.

Before installing thenew Thrust Bearingin the Eccentric, check it for burrs or upset edges to ensure it will sit flat on the Eccentric.

5.

Using thesame ring boltsused toremove theold Bearing, lift and install the new Bearing onto the Eccentric making sure the mounting holes line up. Use a feeler gauge between the Bearing and Eccentric to check that the Bearing is seated flat against the Eccentric.

6.

Tighten the socket head cap screws that fasten the Bearing to the Eccentric using a crisscross pattern.

“T” and “U” Seal Replacement

A replaceable “T” shaped seal is located in a groove on the underside of the Counterweight while a replaceable “U” shaped seal is located in a groove around the top of the Counterweight. Refer to Figure 6-9 They are designed to prevent dust from getting into the Crusher. Inspect them for damage, wear or build-up of oil and dust anytime the Counterweight is removed. They are to be replaced as follows: 1. Remove the damaged seal and scrape out any residue from the groove.

1. Locking Material 2. Eccentric Bushing 3. Drill a Series of Holes in Locking Material in Cored Pockets 4. Cored Pockets 5. Eccentric

Figure 6-10 Bushing Lock Removal

2. Completely clean the groove with an oil free solvent such as acetone or alcohol and let dry. 3. If the new seal is coated with a shiny mold release agent used in its manufacturing process, use coarse sandpaper to remove just enough of the coating from the bottom and sides of the seal so as to completely remove the shine. The adhesive will not adhere to any parts of the seal containing the release agent. The seal may fall out of the Counterweight groove during operation if the release agent is not completely removed from the seal.

4. Apply a thin coat of activator to the bottom and sides of the seal. Too much activator will create a partial cure of the adhesive. 5. Apply a thin coat of adhesive to the bottom of the Counterweight groove. Apply just enough to obtain a minimal squeeze out. 6. After the adhesive has been applied, quickly place the seal into the Counterweight groove. Apply a steady force to the bottom of the seal to maintain

contact between the bottom of the groove and the seal. A handling bond will occur in approximately three minutes.

Eccentric Bushing FLSmidth recommends checking the Eccentric Bushing for wear to the inside diameter and/or looseness in the Eccentric bore whenever the Eccentric Assembly is removed from the Crusher. There are four pockets in both the top inside diameter of the Eccentric and the top outside diameter of the Bushing. When factory assembled, the pockets are aligned and filled with an epoxy locking compound. This prevents the Bushing from turning in the Eccentric. If the Bushing has turned in the Eccentric bore, it must be removed and checked. Measure the inside and outside diameters in three places (top, middle and bottom) to make sure the I.D. has not changed or that the Bushing diameter has not “pulled in”. Contact FLSmidth with the measurements to see if the Bushing is useable or if it must be replaced.

Removing the Eccentric Bushing To remove the Eccentric Bushing, do the following: 1. Remove the Counterweight following instructions listed in Removal of the Gear and Counterweight located later in this section. 2. The epoxy locking compound that fills the pockets must be removed by drilling holes and removing any material that would prevent the Bushing from being removed. Refer to Figure 6-10 3. Turn the Eccentric upside down on wood blocking high enough to allow the Bushing to be lowered clear of the Eccentric. Refer to Figure 6-11 4. Manufacture a round plate from 1” (25mm) thick steel with a diameter slightly smaller than the Eccentric bore that will be used to remove the Bushing from the Eccentric. The outside diameter of the plate should be smooth and tapered so it does not damage the Eccentric bore. Refer to Figure 6-11

Wooden Blocking Eccentric Bushing

5. Set the plate on the bottom of the Bushing making sure it does not contact the Eccentric bore.

Figure 6-11 Eccentric Bushing Removal

6. Apply force to the plate until the Bushing is free of the Eccentric.

1. Eccentric 2. Wooden Timber 3. Steel Plate

4. 5.

6-7

Main Shaft Inspection Inspection of the Main Shaft is recommended whenever the Eccentric is removed from the Crusher. This is especially important if the condition of the Eccentric Bushing requires replacement. Remove any bronze or lead using only a fine emery cloth by rubbing in a circular and horizontal direction. Measure the O.D. of the Main Shaft every 60 degrees of angle and at 4 inch intervals top to bottom, starting in the middle of the socket fit area. Contact FLSmidth to determine if the condition of the Main Shaft requires replacing. If the Eccentric Bushing is seized on the Main Shaft, extra effort will be required to remove the Eccentric Assembly. Consult the factory for suggested instructions. To remove an Eccentric Bushing that has seized on the Main Shaft, do the following: 1.

Mark lines along side and top of Bushing above the oil holes 2. Small Oil Hole 3. Oil Holes 4. Eccentric Bushing 5. Large Oil Hole

Figure 6-12 Eccentric Bushing Alignment

Note: If the Bushing will not come out following the steps listed above, cutting through the Bushing wall using a heavy duty circular saw as detailed in Section 8, Replacing the Lower Head Bushing, Steps 3 to 5 may be necessary.

1. Located on the inside of the Bushing is a longitudinal oil groove that is centered on the large oil hole. The oil hole is visible from the outside of the Bushing and is vertically centered on the Bushing. 2. Using a heavy duty circular saw and metal cutting blade, cut around the Bushing wall at the longitudinal oil groove location. Set the depth of the cut at 0.75” (20mm). Do not exceed 1” (25mm) depth. It is critical not to damage the Main Shaft. Scoring of the Shaft can result in required replacement. 3. Using a pry bar, spring the Bushing open and off the Main Shaft.

Eccentric Bore Inspection The Eccentric bore is to be inspected for rough spots and smoothed out prior to the installation of a new Eccentric Bushing. The Eccentric bore should be measured top to bottom every 4“ and 60° apart at each location. These measurements will show: • Any high spots in the bore • If the bore has worn to an oversize condition • If the bore has pulled in due to excessive heat Contact FLSmidth to verify the bore measurements. High spots can be ground off a bore that has shrunk unevenly. However, if the bore has pulled in to the point that hand grinding is not practical, the bore should be machined back to srcinal size. Machining is also required if the bore is found to be worn out of round. It’s recommended to contact FLSmidth prior to any machining.

6-8

1. Ring Bolts and Washers Will Hold Bushing 2. Bushing Lock 3. Eccentric Bushing 4. Eccentric

Figure 6-13 Eccentric Bushing Alignment

Eccentric Bushing Installation The Eccentric Bushing is designed to have a loose fit in the Eccentric bore. To install an Eccentric Bushing do the following: Note: A tight fit is the result of a pulled in or out-ofround Eccentric bore. Improperly storing or shipping the Bushing can result in a out-of-round Bushing.

1. Clean, inspect and measure the Bushing. Remove any scratches and burrs. 2. Thoroughly clean the pockets in the Eccentric of any epoxy locking compound. Inspect the Eccentric bore for scratches, nicks and gouges. Smooth out any upsets found. 3. Cool the Bushing to create the proper minimum temperature difference between the Bushing and Eccentric.

NOTE: Do not remove the lifting rings until the epoxy has cured. The lifting rings prevent the bushing from dropping. 7. After the epoxy has fully cured, remove any excess locking compound by grinding flush with the top of the Bushing and Eccentric. Whenever a new Eccentric Bushing is installed, it is important to follow Item D of the Check List for Starting a New Crusher defined in Section 13, Operating Instructions.

Adjusting theWear Gear Backlash for To adjust the root clearance and backlash follow the instructions in Eccentric Assembly Installation and Checking Backlash Between the Gear and Pinionas outlined earlier in this section.

Gear Replacement Temperature Difference between Eccentric / Bushing XL500 57°F (32°C) 4. Mark lines on both sides and top of the Bushing adjacent to the oil hole locations. Refer to Figure 6-12 Do the same for the two holes in the Eccentric bore. Make sure to extend the lines up to the top surfaces. These lines will be used to align the oil holes in the Bushing and Eccentric. 5. Using the lifting rings supplied with the tools assembly in the top of the Bushing, lift and center the Bushing above the Eccentric. With the oil hole lines and locking pockets aligned, quickly lower the Bushing into the Eccentric making sure the top of the Bushing is flush with the top of the Eccentric. It is very important that the oil passage holes in the bushing are aligned with the mating holes in the Eccentric. Due to casting variations, this may not provide exact alignment of the locking pockets. However, it is critical that the oil holes in the bushing match-up with the oil holes in the Eccentric. 6. Ensure that the Eccentric and Eccentric Bushing have warmed to ambient (60° to 80°F (16° to 27°C) is desired). Mix the Locking Compound per the manufacturer’s instructions and fill each locking pocket to the top.

The bevel gear mounted on the underside of the Eccentric should be inspected whenever the Eccentric Assembly is removed from the Crusher or if there is a concern regarding excessively worn or broken gear teeth. Excessive gear wear is indicated by a step worn in the profile of the teeth or pitting and galling of the profile. This can be caused by the following conditions: • Incorrect amount of shims under the Lower Thrust Bearing resulting in the wrong backlash setting. • Operating the Crusher in an overload condition for extensive periods of time. • Operating with excessively dirty lubrication oil. If it’s determined that the Gear has worn to the point requiring replacement, follow the instructions outlined in Removal of the Gear and Counterweight.

Removal of the Gear and Counterweight Remove the Eccentric as instructed in Eccentric Assembly Removal found earlier in this section. To remove the Gear and Counterweight do the following: 1. Place the EccentricAssembly on wood blocking. Make sure the blocking is positioned under the Gear and not under the Counterweight. Refer to Figure 6-14 2. There are cap screws that run through the Counterweight and Eccentric flange into tapped holes in the Gear that must be removed. These cap

6-9

Eccentric flange and a counter bore in the top of the Gear. Install ring bolts from the Tools Assembly into the Eccentric Assembly lifting ring. 7. Attach proper equipment to the Eccentric ring bolts and lift the Eccentric 1.5” (38mm) above the wood blocks. With a torch, evenly heat the Gear all around until the Gear expands enough to fall off the Eccentric onto the wood blocking. 8. If the Upper Thrust Bearing is to be removed, place the Eccentric on its side on wood blocks to protect the machined surfaces and go to Step 10. If the Upper Thrust Bearing is not to be removed, place the Eccentric on wood blocks to protect the machined surface of the Upper Thrust Bearing. 9. To remove the Upper Thrust Bearing from the Eccentric, first remove the cap screws that hold the thrust bearing to the Eccentric. Then remove the thrust bearing.

1.

Counterweight Cover to 6. Counterweight Capscrew 7. 2. Counterweight 3. Eccentric 8. 4. Eccentric Bushing 9. 5. Eccentric to 10. Gear Capscrew

Wooden Timber Upper Thrust Bearing Gear Alignment Dowel Eccentric Lifting Ring

Figure 6-14 Lifting Counterweight and Eccentric

screws are factory installed with Loctite and will require heating to remove.

Assembling the Gear and Counterweight To assemble the Gear and Counterweight as part of the Eccentric Assembly, do the following: 1. If the Upper Thrust Bearing was removed, turn the Eccentric upside down and place on wood blocks. If the thrust bearing was not removed, go to Step 4. 2. Place the Thrust Bearing on the bottom of the Eccentric with its mounting holes aligned with the tapped holes in the Eccentric. Install the cap screws with new spring washers and tighten. 3. Turn the Eccentric right side up and place it on wood blocks

3. Install the ring bolts supplied in the tools assembly into the tapped holes in the flange of the counterweight. 4. Using the proper equipment, lift the Counterweight off the Eccentric. NOTE: There are tapped holes in the Counterweight flange to be used with jacking screws if needed. 5. Remove the cap screws running through the Eccentric flange into tapped holes in the Gear. These cap screws were also installed with Loctite requiring heat to be removed. 6. There is a slight interference fit between the

6-10

to protect the machined surface of the Thrust Bearing.

4. Place the Gear on wood blocks with the teeth down. Clean all the tapped holes in the Gear with an oil free solvent such as alcohol or acetone. Loctite will be applied to these holes later. Refer to Figure 6-14 5. With the Eccentric lifting ring and lifting ring bolts attached to the top of the Eccentric, lift the Eccentric until it is safely suspended above the Gear approximately 12” (305mm) while centered over the Gear counter bore. 6. Measure the Eccentric flange diameter and the Gear counter bore for use later.

Note: If the bolts required heating to remove, they must be replaced.

10. Assemble the cap screws and hardened washers into the holes and tighten them using a crisscross pattern to the torque specified in Table 6-2. 11. If a new Gear was installed, check and adjust the backlash as detailed in Checking Backlash Between the Gear and Pinion outlined earlier in this section. 12. Install the ring bolts from the tools assembly into the Counterweight hole locations. Refer to Figure 6-14 1. Gear Mounting Holes 2. Counterweight Locating Dowel 3. Eccentric Flange

Figure 6-15 Gear Mounting Holes

7. Using a torch, evenly heat the Gear all around the counter bore area to the temperature listed. Temperature Difference between Gear / Eccentric XL500 71°F (39°C) It is critical that the gear be evenly heated and that the supply of heat is not concentrated in one spot or area. Heating in one spot or area could destroy the heat treatment of the gear. A ch emical marking device designed to melt at a specified temperature can be used to make sure over heating doesn’t occur. An infrared pyrometer or digital contact thermometer can also be used.

8. Measure the Gear counter bore while it is being heated. Once the counter bore has expanded to a diameter slightly larger than the Eccentric flange, quickly lower the Eccentric into the counter bore in the Gear while making sure to align the Eccentric mounting holes with the tapped holes in the Gear. Refer to Figure 6-15

13. Lift and lower the Counterweight onto the Eccentric flange making sure to line-up the dowel in the Eccentric with the matching hole in the Counterweight. 14. Clean the threads on the Counterweight to Gear cap screws with an oil free solvent such as acetone or alcohol. Apply Loctite 271 to the cap screw threads and install them in the tapped holes in the Gear. 15. Assemble the cap screws and hardened washers into the Eccentric flange holes and tighten them using a crisscross pattern to the torque specified. Refer to Table 6-2 16. Rotate the Countershaft to check the Pinion teeth for damage or wear before installing the Eccentric back into the Crusher. 17. Install the Eccentric and check the gear backlash, following the instructions detailed in the Eccentric Assembly Installation procedure outlined earlier in this section. Note: FLSmidth recommends checking the torque with a torque wrench on all the capscrews that hold the Gear to the Eccentric during each liner change.

Capscrew Torque and Gear Heating Crusher Size

XL500

Capscrew Torque

9. Clean the threads on the Eccentric to Gear cap screws with an oil free solvent such as acetone or alcohol. Apply Loctite 271 to the cap screw threads and install them in the tapped holes in the Gear. Refer to Figure 6-15

1,096 Ft-lbs (1485 N-m)

Table 6-2

Warning: An impact gun may break the Loctite and allow the bolts to back out.

6-11

Section 7

Socket Assembly Socket and Socket Liner Installation ............................................................................................................. 7-2 Socket Installation Heating Temperature and Socket Capscrew Torque Requirements Table 7-1 ..................................................................................................................... 7-2 Socket Assembly Figure 7-1............................................................................................................................ 7-2 Socket Installation Figure 7-2 ........................................................................................................................ 7-2 Checking Socket Contact Figure 7-3 ............................................................................................................. 7-3 Measuring Socket Liner Oil G roove Depth Figure 7-4 ................................................................................ 7-3 Socket Liner Removal and Replacement ...................................................................................................... 7-3 Socket Liner Removal Figure 7-6 ................................................................................................................... 7-4 Socket Liner Installation Figure 7-5 .............................................................................................................. 7-4 Socket Removal ................................................................................................................................................. 7-4 Socket Removal Figure 7-7 ............................................................................................................................. 7-5

7-1

Description Refer to Figure 7-1 This section covers the Socket Assembly, which consists of the Socket, Socket Liner, and associated hardware. These parts are mounted on the top of the Main Shaft and support the Head Assembly. They transfer the crushing force to the Main Frame through the Main Shaft. The Socket is held in place on the Main Shaft by a press fit and a series of bolts. The Socket Liner, which is mounted in a counter bore of the Socket and set in place with dowel pins, provides a bearing surface for the Head Ball. Pressurized lubricating oil is supplied to the grooves located in the spherical surface of the Socket Liner to provide lubrication between the Socket Liner and Head Ball.

Socket and Socket Liner Installation To install the Socket and Socket Liner in the Crusher, do the following: 1. Inspect the Main Shaft and bottom of Socket. Ensure all burs or pulled ma terial has been removed.

1. Capscrew 2. Lockwasher 3. Ring Bolt

2. Install the Eccentric Assembly as instructed in Section 6.

4. Main Shaft 5. Alignment Studs 6. Socket

Figure 7-2 Socket Installation

3. Install the alignment studs from the Tools Assembly in the top of the Main Shaft. Refer to Figure 7-2

Use a chemical marker, which melts at a specified temperature, to help determine when the Socket has reached the proper temperature from the table.

4. Insert the ring bolts from the Tools Assembly into the Socket. Refer to Figure 7-2

6. With the Socket suspended above the alignment

5. Evenly heat the lower flange of the Socket all around, to the temperature specified. Refer to Table 7-1

studs, quickly lower it onto the Main Shaft, making sure it is firmly seated. Use a feeler gauge to check that the web of the Socket has seated flat on the Main Shaft. Refer to Figure 7-3 There should be no clearance. 7. Remove the alignment studs and install the cap screws with lock washers through the Socket into the Main Shaft. Alternately tighten the cap screws in small increments until the torque value specified is reached. Refer to Table 7-1 Socket Installation Heating Temperature and Socket Capscrew Torque Requirements Temperature Difference

Socket Capscrew

(between Socket & Mainshaft)

1. Straight Pin 2. Socket Flange 3. Main Shaft

Size 4. Capscrew with Lock Washer 5. Socket Liner

Figure 7-1 Socket Assembly

7-2

Crusher Fahrenheit

XL500

91

°

Centigrade

Size & (N-m) Length Ft-lbs

164° M20x70 Table 7-1

Torque

456 (618)

1.

Socket

3.

Main Shaft

2.

Tight

4.

Feeler Gauge

Figure 7-3 Checking Socket Contact

Recheck the torque after the Socket has cooled for one hour.

8. Install the ring bolts from the Tools Assembly into the tapped holes located around the outside diameter of the Socket Liner. Refer to Figure 7-5 9. Cool the Socket Liner to achieve a temperature difference of 55°C [99°F] as compared to the Socket. 10. Lower the Socket Liner over the locating dowels in

1. 2. 3. 4. 5. 6.

Original Contour of Socket Liner XL500 Minimum Groove Depth = 2.1mm (0.082”) Socket Liner Oil Groove Socket Liner Wear XL500 Vertical Travel from Wear = 4.0mm (0.157”) Depth Gauge

Figure 7-4 Measuring Socket Liner Oil Groove Depth

the Socket, making sure the Liner has firmly seated on the web of the Socket, and remove the ring bolts.

Socket Liner Removal and Replacement The Socket Liner is typically removed from the Socket for one of two reasons: • Replacement due to oil groove wear • To be able to remove the Eccentric Assembly If the Socket Liner is being replaced due to wear, start with Step 1. If the Socket Liner and Socket are being removed to pull the Eccentric Assembly, start with Step 2. 1. Use the depth of the oil grooves in the spherical surface of the Socket Liner to determine if the Liner needs to be replaced. Measure the depth. Refer to Figure 7-4 Changing liners provides a good opportunity to check the Socket Liner groove depth.

2. Install the ring bolts from the Tools Assembly in the tapped holes located around the outside diameter of the Socket Liner. Refer to Figure 7-5 3. Lubricate the jack screws from the Tools Assembly and install them into the Socket Liner until they bottom out on the Socket. Refer to Figure 7-6 4. Alternately tighten each jackscrew in small increments to avoid cocking the Socket Liner in the Socket during removal. A small amount of heat applied to the upper portion of the Socket may be required to aid in removing the Liner. 5. Lift the Socket Liner out of the Crusher using the ring bolts around the sides of the Liner. 6. Inspect the interior bore for any damage. Grind or remove any pulled material or burrs. Ensure all the dowels have not become unseated.

7-3

7. To install a new or existing Socket Liner, follow Steps 7 thru 9 located in Socket and Socket Liner Installation found earlier in this section.

Socket Removal To remove the Socket, do the following:

1. Socket Liner 2. Ring Bolt 3. Main Shaft 4. Capscrew and Lockwasher

1.

Remove the cap screws and washers that attach the Socket to the Main Shaft.

2.

Lubricate the jack screws from the Tools Assembly and install them into the Socket until they bottom out on the top of the Main Shaft.Refer to Figure 7-7

3.

Thread the ring bolts into the Socket. Refer to Figure 7-7

4.

Heat the lower flange of the Socket evenly to achieve the required temperature difference. Alternately tighten each jackscrew in small increments. If the jackscrews start to push the Socket off the Main Shaft, keep the heat on the Socket and keep alternately tightening the jackscrews in small increments until the Socket is free of the Main Shaft. It is important that the jackscrews be tightened in small increments so the Socket does not tilt and jam on the Main Shaft. If, after heating the Socket lower flange to the required temperature difference the jackscrews will not move the Socket, increase the temperature difference and try again. Continue increasing the applied heat until the Socket is able to be removed from the Main Shaft.

5.

With the Socket lifting rings attached, quickly lift the Socket off the Main Shaft.

6.

Inspect the Main Shaft and bottom bore of the Socket. Remove any pulled material or burrs. If material is not removed and Eccentric is pulled, a groove will be made in the Eccentric Bushing.

7.

To install the Socket, follow the instructions defined in Steps 1 thru 6 of Socket and Socket Liner Installation located earlier in this section.

5. Socket 6. Web of Socket 7. Straight Pin

Figure 7-5 Socket Liner Installation

1. Socket Liner 2. Jackscrew 3. Heat Upper Portion of Socket to Achieve Required Temperature Difference with Socket 4. Main Shaft 5.

Socket

Figure 7-6 Socket Liner Removal

7-4

1. Jackscrews 2. Socket 3. Main Shaft

4. 5.

Heat Lower Portion of Socket to Aid in Removal Socket Lifting Ring Bolts

Figure 7-7 Socket Removal

7-5

Section 8

Head, Mantle and Feed Plate Assemblies Head, Mantle, and Feed Plate Assembly Figure 8-1.................................................................................... 8-2 Head Removal .................................................................................................................................................... 8-2 Cutting the Torch Ring Figure 8-4 ................................................................................................................. 8-3 Installing and Removing Head Assembly Figure 8-2 .................................................................................. 8-3 Mantle Replacement Figure 8-3 ...................................................................................................................... 8-3 Mantle Replacement ......................................................................................................................................... 8-3 Locking Nut Wrench Figure 8-5 ..................................................................................................................... 8-4 Mantle Lifting Figure 8-6 .................................................................................................................................. 8-4 Installing the Mantle Figure 8-9 ...................................................................................................................... 8-5 Lifting Lug Figure 8-7 ........................................................................................................................................ 8-5 Seating the Mantle Figure 8-8 ......................................................................................................................... 8-5 Head Stub / Ball Replacement ........................................................................................................................ 8-5 Installing Head Ball Figure 8-11 ....................................................................................................................... 8-6 Removing Head Ball Figure 8-10 ..................................................................................................................... 8-6 Handling the Head............................................................................................................................................. 8-6 Handling the Head Figure 8-12 A-E ................................................................................................................ 8-7 Replacing the Lower Head Bushing ...............................................................................................................8-7 Lower Head Bore Inspection ........................................................................................................................... 8-7 Lower Head Bushing Installation ................................................................................................................... 8-8 Sawing Head Bushing Wall Figure 8-14 .........................................................................................................8-8 Replacing the Upper Head Bushing ............................................................................................................... 8-8 Upper Head Bore Inspection ........................................................................................................................... 8-8 Head Bushing Installation Figure 8-15........................................................................................................... 8-9 Upper Head Bushing Installation .................................................................................................................... 8-9 “T” Seal Replacement ........................................................................................................................................ 8-9 Replacing the “T” Seal Figure 8-16.................................................................................................................. 8-9 Head Assembly Installation ........................................................................................................................... 8-10

8-1

Description Refer to Figure 8-1 This section covers descriptions of the Head, Mantle and Feed Plate Assemblies along with installation and removal instructions. The Head and Mantle in combination with the Bowl and Bowl Liner make up the major components of the crushing chamber. Mounted on the top surface of the Mantle is a Torch Ring. Both the Mantle and Torch Ring are held in place by the Locking Nut. Mounted on top of the Locking Nut is the feed plate. The Feed Plate protects the Locking Nut from wear and helps distribute ma terial around the crushing cavity.

A molded polyurethane “T” shaped seal is adhered to a groove in the Head. This T-seal runs parallel with a similar “U” shaped seal mounted in the adjoining Counterweight. Together they form a labyrinth seal that protects the inside of the Crusher from dust infiltration and prevents excessive oil leakage.

Head Removal To remove the Head Assembly from the Crusher, do the following: 1. Remove the Feed Plate from the Locking Nut.

A Head Stub/Ball is secured in the Head with an interference fit and sits in the Socket Liner mounted on top of the Main Shaft. There are two Bushings contained in the Head: an Upper and Lower Head Bushing. The flanged Lower provides the bearing surface with the Eccentric. The Upper provides bearing support for the top of the Head during no-load (non-crushing) operation.

1. Feed Plate 2. Locking Nut 3. Upper Head Bushing

2. Secure the hoist ring (supplied in the Tools Assembly) in the off-centered hole on the top of the Head lifting plate. Bolt the Head lifting plate to the Locking Nut using the capscrews supplied in the Tools Assembly. Refer to Figure 8-2

4. Head 5. Upper T-Seal 6. Head Stub/Ball

7. Lower Head Bushing 8. Mantle 9. Torch Ring

Figure 8-1 Head, Mantle, and Feed Plate Assembly

8-2

1. Feed Plate 2. Fill with Silastic 3. Mantle 1.

Head Lifting Plate

2.

Thick Side of Eccentric

4. 5.

Torch Ring Locking Nut

Figure 8-3 Mantle Replacement

Figure 8-2 Installing and Removing Head Assembly

3. Making sure the ring bolt in the Head Lifting Plate is positioned toward the closed side of the crushing cavity and the lifting equipment is centered over the Head, slowly lift the Head Assembly straight up and out of the Crusher. The off-center position of the ring bolt slightly tilts the Head into a position that will not damage the Lower Head Bushing when removing the Head. If the ring bolt is not correctly positioned, Lower Head Bushing damage will occur.

2. Obtain the Locking Nut wrench from the Tools Assembly and mount it on the Locking Nut with the wrench pins engaging the holes in the Locking Nut. Use the cap screws, also from the Tools Assembly, to hold the wrench in place on the Locking Nut. Refer to Figure 8-5 With the wrench firmly attached, strike the side of the wrench with a sledge hammer or suspended weight so the Locking Nut turns in a counterclockwise direction. Continue this until the Locking Nut can be tur ned by hand.

4. Place the Head Assembly on suitable cribbing.

Mantle Replacement Refer to Figure 8-3 The procedure for replacement of a worn Mantle is the following:

1. Grind off all welds between the Mantle, Torch Ring, and Locking Nut. Next, cut through the Torch Ring. Refer to Figure 8-4 Care should be taken not to damage the Locking Nut or Head. Once the Torch Ring is cut through, the Locking Nut should easily turn off of the Head Stub by hand. If there is damage to the threads of the Locking Nut or Head Stub and the nut cannot be turned by hand, then go to Step 2. If the Locking Nut is easily removed, go to Step 3.

1. Torch Ring 2. Direction of Cutting Torch (to avoid damaging the Locking Bolt or Head)

Figure 8-4 Cutting the Torch Ring

8-3

c)

1.

Mantle

2. Locking Bolt 3. Locking Bolt Wrench

4. 5.

Torch Ring Head

Figure 8-5 Locking Bolt Wrench

3. The Mantle is now free to be removed from the Head. Lift the Mantle off the Head using the two equally spaced and welded lifting lugs on the Mantle. Refer to Figure 8-6 4. Chip off all backing material left on the Head after removing the Mantle. 5. Clean the Locking Nut threads along with the mating threads on the Head Stub/Ball. Inspect both sets of threads and remove any nicks or burrs found. Inspect the Locking Nut where the torch ring seats and remove upsets proper contact.grease. Then coat the threads withtoa ensure moly based anti-seize 6. Inspect the Mantle seating surface on the Head and grind any ridges to provide a smooth surface. If the seating surface of the Head has worn to the point that it is flush with the wear indication groove, the Head should be refurbished. Contact FLSmidth for instructions.

Turn the Locking Nut down until it is close to the Torch Ring. Refer to Figure 8-8 The distance between the Torch Ring and Locking Nut should be the same all around to ensure that the Mantle is centered on the Head. This will also ensure that it will seat properly on the Head when the Locking Nut is tightened. If the distance is not even, do not try to even it out by tightening the Locking Nut. Even the distance out by either bumping the top of the Mantle to reposition it on the Head or by lifting the bottom of the Mantle on the low side. (Keep in mind that the Mantle must also seat properly on the Head seating surface. See Step 11 Once an even distance has been achieved, tighten the Locking Nut down snug on the Torch Ring.

9. Mount the Locking Nut wrench to the Locking Nut as outlined in Step 2. 10. With the wrench firmly attached to the Locking Nut, strike the side of the wrench with a sledge hammer or suspended weight to turn the Locking Nut in a clockwise direction. Keep ramming the wrench until the Locking Nut turns 1mm (0.04”) or less per strike. 11. Use a 0.25mm (0.010”) feeler gauge at least 80% of the way around the bottom of the Mantle to check that it’s seated tightly against the Head. If there are openings due to Head seat wear, fill these areas with caulking to keep the backing material from leaking out when poured. Refer to Figure 8-9 12. Scribe a vertical line down through the lower flange of the Locking Nut, Torch Ring and upper section of the Mantle. Heat the outside of the Mantle in the seating surface area to 55°C (130°F). Sledge the Wrench again until the Locking Nut has moved an additional 25mm (1”).

7. Coat the Mantle seating surface on the Head lightly with grease or oil to prevent new backing material from adhering. 8. A loose or improperly seated (cocked) Mantle will damage the Head seating surface. To correctly seat the Mantle, do the following: a)

Lower the Mantle onto the Head using the lifting hooks on the bottom of the Mantle.

b) Place the Torch Ring on the Mantle.

8-4

1. Lifting Cables 2. Mantle

3.

Lifting Lugs Welded to Mantle

Figure 8-6 Mantle Lifting

1. 2. 3.

4” (100mm) 2” (50mm) 2” (50mm)

4. R 2” (50mm) 5. 2” (50mm)

Note: Make Lifting Lug from .38”(10mm) Thick ASTM A36 Steel Plate

1. Locking Bolt 2. Equal Distance All Around 3. Head

Figure 8-8 Seating the Mantle

Figure 8-7 Lifting Lug

13. Weld the Locking Nut to the Torch Ring and theTorch Ring to the Mantle with four 100mm (3.9”) long welds equally spaced around the perimeter of the parts. 14. Fill the space between the Head and Mantle to the top of the pouring holes in the Mantle with high performance epoxy. Refer to Figure 8-9 Carefully follow the epoxy backing manufacturer’s mixing, pouring, and safety instructions. A pouring trough made from any flexible sheet material such as cardboard can be used to pour the epoxy into the holes in the Mantle. The epoxy backing material kits should be stored at room temperature, or in a temperature range between 16° and 33°C (60° and 90°F). The head and mantle also need to be in the same temperature range prior to pouring the backing material. If the metal is too cool, the exothermic reaction may stop and the backing material will not set properly. If the metal is too hot, the backing material may set prior to flowing to the bottom of the void between the mantle and head. If the mantle and/or head are colder than 16°C (60°F), heat should be applied to each component prior to adding the backing compound. Heat may need to be continually added if the ambient temperature is very low.

Head Stub / Ball Replacement Normal Crusher operation should not involve significant wear between the Head Ball and the mating surface of the Socket Liner. However, if the lube oil is excessively contaminated or if there is a loss of oil supply flow or pressure and the Head Ball is worn to the point of replacement, do the following: 1. The Head Stub/Ball has an interference fit in the Head. To drive the Stub/Ball out of the Head, do the following: a)

Place wood blocking under the Head Stub/Ball. Refer to Figure 8-10 The blocking should be

15. Install the Head Assembly in the Crusher as outlined in Head Assembly Installation later in this section. Cure time for the epoxy backing material is normally about 8 hours. However, this cure time can be up to 24 hours if the ambient temperature is low in the 16°C (60°F) range.

4. Mantle 5. Torch Ring

4. 1. Head Mantle 2. 3. Feeler Gauge

0.010” (0.25mm) Maximum Clearance Allowed 5. Pouring Trough 6. Epoxy Backing Material

Figure 8-9 Installing the Mantle

8-5

making sure to line up the dowel pins with the holes in the Head. Then quickly lower it into the Head, engaging the dowels and making sure the Head Stub/Ball is fully seated in the bore of the Head. Refer to Figure 8-11

high enough to allow the Stub/Ball to just clear the bore in the Head when it drops. Allowing the Stub/Ball to drop through the Lower Head Bushing risks damage to the Bushing. b) Using a sledgehammer, strike the Stub/Ball on one side and then on the other to drive it out of the Head. If the Stub/Ball will not move during sledging, heat the Head to a maximum of 300°F (149°C) in the area and keep sledging. It may also be helpful to pack dry ice into the inside of the Head Stub/Ball. Refer to Figure 8-10 2. With the worn Head Stub/Ball removed, check the bore for burrs and pulled material. Next, turn the Head upside down using the handling instructions outlined further on in this section. 3. Cool the replacement Head Stub/Ball to achieve a temperature difference of 91°C (163°F) compared to the Head. This will shrink it enough to be set in the Head. It’s suggested that the bore in the Head and the Head Stub/Ball diameter are measured to make sure enough shrinkage has occurred before installing the Stub/Ball in the Head. 4. With the Head Ball sufficiently cooled, attach the Head Stub/Ball Lifting Plate from the Tools Assembly to the Head Stub/Ball and position it above the Head,

1. Steel Round Bar 4. Head Ball 2. Heat this area if necessary 5. Blocking 3. Clearance 6. Upper Head Bushing

Figure 8-10 Removing Head Ball

8-6

5. The Head Stub / Ball should have 25 mm ±1 mm (0.94” ± 0.04”) penetration through the head. This measurement can be taken from the machine flat of the head to the machine flat of the Head Stub / Ball. 6. Using the handling instructions below, turn the Head back upright after the parts come back to Ambient temperature. Failure to do so will result in the Head Stub / Ball falling out.

Handling the Head The following instructions are to be used to turn the Head upside down for Stub/Ball, Bushing, or seal replacement: 1. If the Mantle is on the Head, install the Head lifting plate as outlined in Step 4 under Head Assembly Installation found later in this section. If the Mantle is not on the Head, make sure the Locking Nut is securely screwed onto the Head Stub/Ball and the Head lifting plate is bolted to the Locking Nut. 2. Place the Head on suitable cribbing. Refer to Figure 8-12A

1. 2.

Head Ball Ring Bolt

3. 4.

Steel Ring Steel Frame

Figure 8-11 Installing Head Ball

3. Attach the Head Turning Plates from the Tools Assembly to the bottom of the head using the appropriate cap screws. Refer to Figure 8-12B 4. Connect lifting cables to the Head Turning Plates. Lift the Head off the blocking while slowly and carefully turning the Head.

measure the bore to determine if it has shrunk undersize due to an overheating condition or has worn oversize. Measure the bore at the top, center and bottom 90° apart at each location. Contact FLSmidth to verify that the measurements are within factory specifications. If they are not, FLSmidth will provide further instructions.

5. The Head may be set down on either the floor (for removing Bushings) or a customer supplied steel frame for installing a Head Stub/Ball or Bushings. Refer to Figures 8-12C and D. If on the floor, place blocking on both sides of the Head so it will not roll when the lifting equipment is removed.

Replacing the Lower Head Bushing The Lower Head Bushing is secured in the Head using an interference fit, Retaining Ring and cap screws. To remove the Lower Head Bushing, do the following: 1. First turn the Head on its side as instructed under Handling the Head, outlined earlier in this section. 2. Remove the cap screws and lock washers that secure the Retaining Ring to the Head and the Bushing. The cap screws into the Head were factory installed with Loctite, so heat will likely be required to remove them. Remove the Retaining Ring. 3. With a heavy duty circular saw equipped with a metal cutting blade, make a cut along the inside of the bushing. (If sparks are appearing, the saw blade is set too deep.) Set the saw blade depth to slightly less than the thickness of the Bushing, so the saw blade does not contact the Head bore. Make a sample cut to be sure the saw blade is correctly set and adjust if necessary. Note: The Lower Head Bushing is made from leaded bronze. It is important to wear a dust respirator whenever cutting or grinding leaded bronze bushings. Refer to Figure 8-13 4. Place a chisel against the Bushing saw cut and hit it with a hammer. This will pop that portion of the Bushing out from the bore allowing the Bushing to collapse. The Bushing can now be easily lifted out of the Head bore.

Lower Head Bore Inspection With the Lower Head Bushing removed, inspect the bore for any rough areas or scoring and smooth them out. Also

Figure 8-12 A-E Handling the Head

8-7

Lower Head Bushing Installation To install a new Lower Head Bushing, do the following: 1. Using a wire brush, clean the outside diameter of the Bushing and Head bore. 2. Cool the Bushing to establish a 23°C (41°F) temperature difference with the Head bore. Important: Do not try to install a bushing in a bore that is undersize or pulled in due to a high heat event (burnt bushing, weld repairs).

3. After the temperature difference has been achieved, measure the Head bore and the Bushing outside diameter to verify that the Bushing has shrunk enough to be inserted in the Head bore. 4. Install the ring bolts supplied with the Tools Assembly in the Retaining Ring. 5. With the Bushing positioned above the Head bore, use customer supplied threaded aligning bolts to quickly lower it into the Head until the Retaining Ring bottoms on the Head. Make sure the clearance holes in the Retaining Ring are lined up with the mating tapped holes in the Head. Refer to Figure 8-14 6. Once the Bushing has returned to ambient temperature, use Loctite (available fromwashers FLSmidth) to install the eight cap screws and lock in the Head. Torque the cap screws to 90 N-m (66 ftlbs). 7. With the Lower Head Bushing installed, turn the Head right side up, following the Head handling procedures outlined in this section.

Replacing the Upper Head Bushing The Upper Head Bushing is secured in the Head using an interference fit along with keys. To remove the Upper Head Bushing do the following:

1. Circular Saw 2. .50” (12mm) to .75” (20mm) Between Saw Cuts 3. Lower Head Bushing 4. Blade Depth

Figure 8-13 Sawing Head Bushing Wall

been heated should be replaced.) Heat may be required as the cap screws were factory installed using Loctite 277. Extract the Upper Head Bushing from the Head bore by use of two small Porta Power position between the head ball and the underside of the Upper Head Bushing using a small piece of rubber to protect the Head Ball surface. Jack out the Upper Head Bushing by moving the Porta Power evenly around the bushing. If a Porta Power is not available, a similar procedure to Countershaft Bushing Removal in Section 5 can be used to extract the Upper Head Bushing. Refer to Figure 5-13 Note: It may be possible to remove the Upper Head Bushing by hand if it has been damaged as a result of a high heat event due to a lack of proper lubrication.

First turn the Head on its side as instructed under Handling the Head, outlined earlier in this section. Remove the four keys used to hold the Upper Head Bushing by unbend the wire on the cap screws in the Lock Plates, loosening and removing the cap screws. (Bolts that have

8-8

With the Upper Head Bore Bushing Inspection removed, inspect the bore Upper Head for any rough areas or scoring and smooth them out. Also measure the bore to determine if it has shrunk undersize due to an overheating condition or has worn oversize.

perpendicular ring bolts will not allow the Upper Head Bushing to be lowered into the Head Assembly.Washers may be added to correctly orientate the ring bolts.

5. With the Upper Head Bushing positioned above the head. Align the bushing key slots with the Key Retainers in the Head. Quickly lower the Upper Head Bushing into the Head until the Lower Head Bushing seats firmly into the Head. 6. Using Loctite 277 (available from FLSmidth),install the Hex Head Cap screws and Lock Washers in the Keys. After firmly securing the Hex Head Cap screws, install the wire in pairs of the HHCS in a figure 8 pattern. 7. With the Upper Head Bushing installed, turn the Head right side up following Handling the Head procedures outlined in this section. 1. Lower Head Bushing 2. Head

3. 4.

Steel Ring Steel Frame

Figure 8-14 Head Bushing Installation

Measure the bore at the top and bottom at 60° apart a t each location. Contact FLSmidth to verify that the measurements are within factory specifications. If they are not, FLSmidth will provide further instructions.

Upper Head Bushing Installation To install a new Upper Head Bushing, do the following:

“T” Seal Replacement The “T” Seal located in a groove on the underside of the Head will typically see very little wear. It is important to check it every time the Head Assembly is removed from the Crusher and reattach or replace it if the seal is ever loose or damaged. The seal prevents dust from infiltrating the inside of the Crusher. To replace the “T” Seal, do the following: 1. Turn the Head upside down following the Handling the Head Procedure outlined earlier in this section. 2. Remove the seal and scrape out any old glue residue left in the seal groove. Refer to Figure 8-15

1. Using a wire brush, clean the outside diameter of the Bushing and Head bore. 2. Cool the Bushing to establish the proper temperature difference with the Head bore.

XL500

Temperature Difference Between Head & Upper Head Bushing 26°C (47°F)

Important: Do not try to install a bushing in a bore that is undersize or pulled in.

3. After the temperature difference has been achieved, measure the Head bore and the Bushing outside diameter to verify that the Bushing has shrunk enough to be inserted in the Head bore. 4. Install the ring bolts, supplied with the Tools Assembly, in the Upper Head Bushing. Ensure the ring bolt eyes are not perpendicular to the Upper Head Bushing. The

1.

Head

2.3. “T” Seal Clean bottom of seal using coarse sand paper to remove surface shine before applying activator and adhesive to bottom of groove in head.

Figure 8-15 Replacing the “T” Seal

8-9

3. Completely clean the groove with an oil free solvent such as acetone or alcohol and let dry. 4. If the new seal is coated with a shiny mold release agent, use coarse sand paper to remove just enough off the sides of the seal that will be contacting the Head to completely remove the shine. It is important that the release agent be completely removed so the adhesive used to hold the seal in the Head groove will adhere to the seal. The seal could become loose and work itself out of the groove during Crusher operation if the release agent is not completely removed.

5. Apply a very thin coat of activator to the Head contact sides of the seal. Too much activator will result in a partial cure that may not provide complete bond of the adhesive. 6. Apply a thin coat of adhesive to the groove in the Head. Then apply just enough adhesive to the contact sides of the seal to obtain a minimal squeeze out when pressure is applied in Step 7. 7. After the adhesive has been applied, quickly place the seal into the groove in the Head. Apply a steady force to the seal. A satisfactory handling bond will occur in approximately three minutes. 8. Turn the Head right-side-up following the Handling the Head Instructions detailed earlier in this section.

Head Assembly Installation To install the Head Assembly in the Crusher, proceed as follows: 1. With the Head assembled and the Mantle mounted per the instructions shown earlier in this section, install the Head Lifting Plate to the Locking Nut. Refer to Figure 8-2 2. Properly clean the Eccentric, Socket, Socket Liner, Head Bushing bores and Head ball. Also make sure all oil passages have been cleaned. Any scratches or nicks in the Upper and Lower Head Bushings should be smoothed out with fine emery paper. 3. Using the same lube oil used in the lubrication system, coat all the bearing surfaces on the Eccentric, Socket Liner, Head Bushing bores and Head Ball.

8-10

4. Making sure the ring bolt in the Head Lifting Plate is positioned toward the thick portion of the Eccentric and center the Head Assembly over the crusher. Slowly lower the Head Assembly down into the crusher. The off-center position of the ring bolt slightly tilts the Head into a position that will not damage the Lower Head Bushing when installing the Head Assembly. If the ring bolt is not correctly positioned, Lower Head Bushing damage will occur. 5. After seating the Head Assembly on the Socket Liner, lift the Head Assembly up approximately 1” (25 mm) and suspend the Head Assembly in the crusher and run the lube pump for 10 minutes. This operation will wash away any contamination and lubricat the critical bearing surfaces in the crusher. 6. Lower the Head Assembly on to the Socket Assembly. 7. Remove the Head Lifting Plate and mount the Feed Plate onto the Locking Nut. Refer to Figure 8-3 8. After securing the Feed Plate mounting bolts, fill the four areas around the bolts with Silastic. This operation will prevent dust and water packing around the bolts, making removal of the bolts easier at the next removal. Refer to Figure 8-3

Section 9

Bowl, Bowl Liner and Hopper Assemblies Bowl Assembly Installation ............................................................................................................................. 9-2 Bowl, Bowl Liner & Hopper Figure 9-1 .......................................................................................................... 9-2 Bowl Removal .................................................................................................................................................... 9-3 Lifting the Bowl Figure 9-2 ............................................................................................................................. 9-3 Bowl Wedge and Liner Parts Figure 9-3 ....................................................................................................... 9-3 Bowl Liner Removal .......................................................................................................................................... 9-4 Wedge Assembly Figure 9-4 ........................................................................................................................... 9-4 Bowl Liner Installation...................................................................................................................................... 9-4 Helix High Point Location Figure 9-5 ............................................................................................................ 9-5 Installation of Bowl Liner Figure 9-6............................................................................................................. 9-5 Checking Bowl Liner Seating Surface Figure 9-7 ........................................................................................ 9-6 Bowl, Bowl Liner Seating Surface .................................................................................................................. 9-6 Changing the Bowl Adaptor Ring................................................................................................................... 9-6 Determining Bowl Thread Wear ..................................................................................................................... 9-6 Bowl Adapter Ring Figure 9-8 ........................................................................................................................ 9-7

9-1

Description Refer to Figure 9-1 This section covers descriptions of the Bowl, Bowl Liner and Hopper Assemblies along with installation and removal instructions. The outside diameter of the Bowl consists of greased heavy-duty right-hand threads that mate with corresponding threads in the Clamping and Adjustment Rings and provide vertical adjustment of the Bowl position in the Crusher. The Bowl is rotated counterclockwise to open the closed side setting of the crushing cavity and clockwise to close it. The Adjustment Cap is mounted to the top of the Bowl and contacts a rubber seal on the Dust Shell (which is bolted to the Adjustment Ring). The seal, Adjustment Cap and Dust Shell protect the greased threads from dust contamination. When pressurized, Clamping Cylinders (spaced around the top of the Adjustment Ring) provide a locking mechanism for holding the Bowl in position during crushing. The Bowl Assembly is turned by a hydraulic Adjustment Mechanism mounted on the Adjustment Ring. The Feed Hopper is designed to direct the feed into the crushing cavity. The flat bottom of the Hopper provides a shelf for the incoming feed to collect and form a dead bed that contributes to wear protection of the Hopper. The Bowl Liner is secured in the Bowl using Wedges, Wedge

1. Bowl Liner 2. Adjustment Cap 3. Bowl

4. 5.

Bolts and an Adapter Ring designed to accommodate various Liner configurations.

Bowl Assembly Installation To install the Bowl and Hopper Assemblies in the Crusher, proceed as follows: 1. Thoroughly clean the Bowl, Adjustment Ring and Clamping Ring threads. Note: Assemblies shipped to customers that are not factory installed in the Crusher (e.g. spare or replacement assemblies) will have a protective coating material such as Cosmoline applied to the threads, which must be removed. 2. Liberally apply a coat of FLSmidth supplied 3% moly grease to the Bowl, Adjustment Ring and Clamping Ring threads. 3. Lift the Bowl Assembly, with the Hopper installed, using the lifting ears on the Adjustment Cap. Slowly set the Bowl Assembly in the Crusher on the Clamping Ring threads, being sure to match the thread starts of both components. Refer to Figure 9-2 4. With the threads of the Bowl Assembly resting on the threads of the Clamping Ring, turn the Bowl Assembly clockwise into the Crusher as follows:

Adaptor Ring Wedge Bolt

Figure 9-1 Bowl, Bowl Liner & Hopper Assemblies

9-2

6. Wedge 7. Upper Hopper

5. Refer to the Automated Control System (ACS) Instruction Manual for instructions on calibrating the Crusher closed side setting.

Bowl Removal To remove the Bowl Assembly from the Crusher during inspection or a Liner change, do the following: 1. Turn the “Local / Remote” selector switch located on the Remote Mounted Hydraulic Power Unit Control Panel to the “Local” position. 1.

Feed Hopper

2. Lifting Cable 3. Anchor Shackle 4. Adjustment Cap Lifting Lug

5.

Adjustment Cap

2. Turn the “High / Low” selector switch located on the Remote Mountedposition. Hydraulic Power Unit Control Panel to the “High”

6. Bowl Liner 7. Bowl

Figure 9-2 Lifting the Bowl

a) Turn the selector switch labeled “Local / Remote” located on the Remote Mounted Hydraulic Power Unit Control Panel to the “Local” position.

3. Open the Clamping Circuit pressure dump valve before installing or removing the Bowl Assembly. This is to insure that the Bowl or Adjustment Ring threads are not damaged during minimal thread engagement by automatic pressurization of the Clamping Circuit.

b) Turn the selector switch labeled “High / Low” located on the Remote Mounted Hydraulic Power Unit Control Panel to the “High” position. c)

Open the Clamping Circuit pressure dump valve before installing or removing the Bowl Assembly. This action is to ensure that the Bowl or Adjustment Ring threads are not damaged during minimal thread engagement by automatic pressurization of the Clamping Circuit.

d) Turn and hold the selector switch labeled “Open / Close” in the “Close” position. There will be a brief delay as the Hydraulic Power Unit depressurizes the clamping circuit pressure. The Bowl will then begin to turn in a clockwise direction. Note: When the selector switch is released, the Hydraulic Power Unit will automatically pressurize the clamping circuit. Turn the Bowl down until the desired closed side setting is achieved. e)

Turn the “High / Low” selector switch to the “Low” position.

f)

Turn the “Local / Remote” selector switch to the “Remote” position.

1. 2. 3. 4. 5. 6.

Bolt Stop Loosen Nut 0.5” (12mm) Cotter Pin Wedge Bowl Liner Epoxy Backing

7. 8. 9. 10. 11.

Spherical Nut Square Head Bolt Bowl Lock Plate Wood Blocking

Figure 9-3 Bowl Wedge and Liner Parts

9-3

Turn and hold the “Open / Close” selector switch located on the Remote Mounted Hydraulic Power Unit Control Panel to the “Open” position. The Bowl will then begin to turn counter-clockwise out of the Crusher. Turn the Bowl until the end of the bottom thread of the Bowl just passes the start of the top thread on the Clamping Ring. At that point, release the “Open / Close” selector switch to stop the turning of the Bowl.

4. Remove the cotter pins and lock plates from each of the wedges. Refer to Figure 9-4

5. Attach suitable lifting equipment to the lifting ears located on the top of the Adjustment Cap and lift the Bowl Assembly out of the Crusher and onto wood blocking. Refer to Figure 9-3

7. With all the wedges loose, unscrew all the spherical nuts far enough to allow for removal of the square head bolts and wedges.

4.

Bowl Liner Removal To remove the Bowl Liner from the Bowl, proceed as follows: 1. Support the Bowl Assembly with the bottom of the Bowl Liner resting on wooden blocking. This will support the Bowl Liner when removing the Bowl. Refer to Figure 9-3 2. Remove all the old grease, rust and dirt from the Bowl threads. Inspect the threads for galling and repair as defined in Determining Bowl Thread Wear later in this section. 3. Attach suitable lifting equipment to the two lifting holes spaced 180° at the top of the Hopper and lift it out of the Bowl. This will provide access to the wedges that hold the Bowl Liner in place.

5. Unscrew the spherical nuts (used to hold the wedges tight against the Liner) approximately 13mm (0.5”). 6. If any of the wedges do not loosen when the spherical nut is backed off, strike the wedge with a hammer and blunt chisel.

Warning Backing material may have broken up during operation. Avoid standing close to the Bowl as it is lifted off the liner. 8. With all the Liner retention hardware removed, lift the Bowl off the Bowl Liner. Note: Factory installation of the Bowl Liner includes the application of a light coat of oil to the Bowl in the area of the backing material prior to pouring. This ensures that the backing material will not stick to the Bowl. If someone other than FLSmidth should improperly install the Bowl Liner, and some of the backing material remains attached to the Bowl, it may be necessary to use a heavy object to remove the backing material from the Bowl Liner. After removing the Bowl free of the Liner, set the Bowl on wood blocking. 9. Inspect the seating surface of the Bowl for ridges or steps caused by the removed Bowl Liner. Grind any discontinuities to maintain a continuous conical Bowl Liner seating surface in the Bowl. If the ridge or step is abnormally deep, refer to the Bowl Liner Installation later in this section.

Bowl Liner Installation To install a Bowl Liner, do the following: Note: If the Bowl Liner configuration is being changed (e.g. Standard to Short Head), the Adapter Ring may require changing as well. 1. Lockplate 2. Bolt Stop 3. Square Head Bolt

4. Spherical Nut 5. Wedge 6. Cotter Pin

Figure 9-4 Wedge Assembly

9-4

1. Place the Bowl Liner on wood blocking making sure the blocking will allow the Bowl to fully seat on the Bowl and remove all the paint from the seating surface.

2. Place chalk marks at the high points of the helix on the Bowl Liner. Refer to Figure 9-5

wedge. Add or remove shims under the wedges to obtain the desired contact points on the helix, with the shim height not to exceed 25mm (0.94”). Once the proper wedge contact on the helix is established, tack weld the shim(s) in place. Refer to Figure 9-6

3. Apply a light coat of oil or grease on the inside of the Bowl to prevent the epoxy backing from adhering to the Bowl. 4. Lower the Bowl onto the Bowl Liner, making sure the chalk marks on the Bowl Liner from Step 2 are centered between the stop blocks on the adapter ring. 5. Take a measurement between the Bowl Liner flange and the inside of the Bowl at four places 90° apart. This is to make sure the Bowl Liner is properly centered in the Bowl. If these measurements are not fairly equal, lift the Bowl or use a large pry bar to bump the Bowl and reseat it on the Bowl Liner until they are equal. Refer to Figure 9-7 A cocked Bowl Liner can loosen during operation and cause damage to the Bowl seating surface.

9. Place the square head bolts with attached spherical nuts (see Step 6) behind the wedges making sure the bolt heads are under the bolt stops welded in the Bowl slots. The bolt stops hold the heads of the bolts in place. If the bolts slide up, the Bowl Liner will come loose. Note: The Liners are castings. Casting variances causes the bolt stops need to be relocated. Refer to Figure 9-6 10. With an open end wrench, alternately tighten each spherical nut in a crisscross pattern until all the wedges are tight in the Bowl Liner helixes. Ensure the spherical nuts sides are in a vertical orientation.

6. After applying anti-seize compound to the thread of the square head bolts, screw on the spherical nuts, making sure that the spherical side faces away from the head of the bolt. Refer to Figure 9-6 7. Inspect the inclined surface on the nose of each wedge to make sure there are no gouges. Any gouges should be smoothed out to eliminate possible (point) contact problems between the Bowl Liner helix and the wedge. Place the wedges on the adapter ring between the stop blocks and push the wedges forward until they contact the Bowl Liner. Refer to Figure 9-6 8. Each of the wedges should contact the helix of the Bowl Liner midway up the inclined surface of the

1. 2. 3. 4. 5. 6. 7. 8. 1. Bowl Liner 2. Chalk Mark Above High Point of Helix 3. High Point of Helix

Figure 9-5 Helix High Point Location

Lock Plate View Showing Lockplate Bolt Stop, Welded to Bowl Wedge Inclined Midpoint Bowl Adapter Ring Must Have Clearance Bowl Liner

9. Bowl 10. Tack Weld Shim on this surface, if required 11. Square Head Bolt

Figure 9-6 Installation of Bowl Liner

9-5

NOTE: DO NOT BACK OFF the spherical nut to achieve the vertical orientation. 11. Use a 0.25mm (0.010”) feeler gauge around the bottom of the Bowl Liner to check that the Bowl Liner is seated tightly against the Bowl. Any openings caused by Bowl seating surface wear should be packed with caulking to prevent the backing material from leaking out when poured. Refer to Figure 9-7

14. Using fiberglass insulation, cover the entire area above the wedge bolt assemblies all the way around. This will prevent dirt and dust from accumulating around these parts and make it easier to remove them during the next Liner change. Place a bead of caulk or silicone on top of the bowl liner. Refer to Figure 9-7 15. Lift and place the Hopper into the Bowl, making sure the Hopper engages the bars in the top of the Adjustment Cap.

12. Fill the entire space behind the Bowl Liner with high performance epoxy just below the level of the Adapter Ring. Carefully follow the epoxy

16. Following the steps defined in the Bowl Assembly Instructions detailed earlier in this section, lubricate

backing manufacturer’s mixing, pouring and safety instructions. Refer to Figure 9-7

the Bowl, Clamping Ring and Adjustment Ring threads prior to installing the Bowl in the Crusher.

13. Place the lock plates over the spherical nuts and attach them to the wedges using cotter pins. The lock plates prevent the spherical nuts from loosening which in turn prevents the Bowl Liner from coming loose. Refer to Figure 9-6

Note: If any of the threads have been refurbished (e.g. weld repaired), it is important to apply the same break-in grease used by the factory to the threads. This material is available from FLSmidth and has a significant affect on the wear of new or rebuilt threads.

Changing the Bowl Adaptor Ring If a change is made to the type of Liner (e.g. Short Head Medium changed to a Standard Fine), a change to the adapter ring located in the Bowl may also be required. To change the adapter ring, do the following: 1. Remove the socket head ring capscrews and lock washers holding the adapter in the Bowl. Refer to Figure 9-8 2. Lift the existing adapter ring out of the Bowl and replace it with the new one. 3. Reinstall the socket head capscrews and lock washers.

Bowl, Bowl Liner Seating Surface Extended periods of crushing operation will eventually cause wear of the Bowl seating surface requiring weld repair and machining. Contact FLSmidth for reconditioning instructions.

1.

Bowl

2. Fiberglass Insulation 3. Bowl Liner 4. Epoxy Backing Material

5. 6. 7.

Blocking Feeler Gauge 0.010” (0.25mm) Maximum Clearance

Figure 9-7 Checking Bowl Liner Seating Surface

9-6

Determining Bowl Thread Wear During every Liner change, the threads on the Bowl, Adjustment Ring and Clamping Ring should be checked for excessive wear. Follow the instructions outlined in Section 4, Determining Adjustment and Clamping Ring Thread Wear, to check the Bowl threads.

1. Bowl Adapter Ring 2. Stop Blocks (Part of Adaptor Ring) 3. Socket Head Capscrew & Lockwasher 4. Bowl

Figure 9-8 Bowl Adapter Ring

9-7

Section 10

Bowl Adjustment Mechanism Assembly Adjustment Mechanism Installation............................................................................................................ 10-2 Hydraulic Adjustment Mechanism Assembly Figure 10-1 ...................................................................... 10-3 Drive Ring Removal ......................................................................................................................................... 10-3 Drive Assembly................................................................................................................................................. 10-3 Hydraulic Adjust Drive Oil Specifications .................................................................................................... 10-4 Drive Ring Support System ............................................................................................................................ 10-4 Drive Ring Support Figure 10-2 .................................................................................................................... 10-4 Positioning Bowl A djust Pinion Figure 10-4 .............................................................................................. 10-4 Jacking Bolts Figure 10-5 .............................................................................................................................. 10-4

10-1

Description Refer to Figure 10-1 This section covers the description of the adjustment mechanism along with installation and removal instructions.

Adjustment Mechanism Installation To install the adjustment mechanisms, do the following:

The XL500 Crusher is equipped with an Adjustment Mechanism consisting of a hydraulic drive assembly, two Idler Assemblies, a Drive Ring with four Turning Brackets, and four Drive Ring Support Brackets. Refer to Figure 10-1 These parts allow the Bowl to be turned for closed side setting adjustment, and for Bowl removal or installation during Liner changes. To turn the Bowl, the clamping circuit is depressurized to release the Bowl threads from the Adjustment Ring and Clamping Ring threads. After a brief delay to ensure the clamping circuit pressure is completely released, the hydraulic drive motor mounted on the Adjustment Ring turns a pinion that is mounted on the drive assembly. The teeth of the Pinion engage teeth in the Drive Ring. Mounted to the top of the Drive Ring are turning brackets that match with lugs welded to the outside of the Adjustment Cap, which is bolted to the Bowl. The drive turns the Bowl in either direction to increase or decrease the closed side setting of the Crusher.

1. Bolt the hydraulic drive assembly to the mounting adapter. Refer to Figure 10-1

Two proximity sensors are mounted to the cover that protects the drive pinion. They are used to count the pinion teeth. The count is used to monitor the changes in setting along with liner life.

6. Set the Drive Ring with attached Turning Brackets on the Drive Ring Support Pads, making sure the teeth in the Drive Ring engage with the teeth in the three pinions. Refer to Figure 10-3 Turn the jacking bolts

9

2. Lift and place the drive assembly and mounting adapter onto the mounting wel dment, which is part of the Adjustment Ring Assembly, and bolt it in place. Do not completely tighten the bolts. 3.

Lift and place the two Idler Pinion Assemblies on the idler mounting weldments not completely tighten the and bolts.bolt them in place. Do

4.

Bolt the Drive Ring Support Brackets to the Adjustment Ring. If the Drive Ring Retainers are attached, remove them.

5. Remove the pinion shields protecting the drive pinion and idler pinions.

7

10

11

1. Drive Ring 2. Hydraulic Drive Assembly 3. Hydraulic Mounting Motor Adapter 4. 5. Pinion 6. Mounting Weldment

7.

Drive Ring Retainer and Support

8. Cover Turning Bracket 9. Shield 10. Proximity Switches 11. Brake

Figure 10-1 Hydraulic Adjustment Mechanism Assembly

10-2

on the mounting adapters to achieve the required root clearance. Tighten the locking bolts along with the bolts that secure the mounting adapters to the mounting weldments. Refer to Figure 10-4 7. Lift and set the Bowl Assembly, as instructed in Section 9, onto the Clamping Ring threads, making sure the square vertical bars welded to the outside diameter of the Adjustment Cap engage in the four turning brackets bolted to the top of the drive ring. 8. Connect the hydraulic lines to the hydraulic adjust motor and brake. See the adjustment mechanism hose assembly in the customer Parts Manual. 9. Rotate the Drive Ring 360° in both directions to make sure the pinion and Drive Ring teeth do not bind or slip. If binding or slippage occurs while turning the Bowl Assembly, adjust the pinion to drive ring root clearance to eliminate the problem. Adjust the bolts in the turning brackets and pinion to Drive Ring root clearance using the jacking screws.Refer to Figure 10-4 Directions for turning the Bowl Assembly into the Adjustment Ring can be found in Section 9, Bowl Assembly, Steps 1 thru 4.

Drive Assembly The drive assembly consists of a hydraulic motor, Planetary drive housing, Brake and pinion. Refer to the customer Parts Manual for replacement component part numbers.

Hydraulic Adjust Drive Oil Specifications The hydraulic adjust drive lubricant level should be checked every 1,000 hours of Crusher operation. Gear Box Lubricant Lubricant Type Grade GL-5 EP 80/90 Quantity 2.5 Pints (1.2 Liters) Brake Lubricant Lubricant Type ATF-Type F Quantity 2 FL. OZ (0.06 Liter)

Drive Ring Support System As the Drive Ring rotates, it is kept in the same plane as the Adjustment Mechanism pinions by four Drive Ring Support Brackets, each with a replaceable urethane Support Pad. Drive Ring Retainers keep the Drive Ring on the Support Pads. Refer to Figure 10-2

Directions for turning the Bowl Assembly out of the Adjustment Ring can be found in Section 9, Bowl Removal, Steps 1 thru 3. 10. Re-install the pinion shield to protect the pinion and drive ring teeth.

Drive Ring Removal The Drive Ring will sometimes need to be removed to perform other maintenance, particularly on the Adjustment Ring. To remove the Drive Ring, do the following: 1. Unbolt and remove the pinion shields from the drive pinion and idler pinions. 2. Unbolt and remove the Drive Ring Retainers from the Drive Ring Support Brackets mounted on the Adjustment Ring. 3. Attach ring bolts from the Tools Assembly to the lifting holes in the Drive Ring and remove it. 4. To reinstall the Drive Ring, follow the Adjustment Mechanism Installation instructions in this section.

1.

Drive Ring Support

2. Turning Drive Ring Retainer 3. Bracket 4. Adjustment Ring

5.

Drive Ring

6. Centering Drive RingBolts Support Pads 7.

Figure 10-2 Drive Ring Support

10-3

1. 2.

Drive Ring Drive Pinion

3. .25” (6mm) 4. Pinion

Figure 10-3 Positioning Bowl Adjust Pinion

1.

Jacking Bolts

2.

Locking Bolts

Figure 10-4 Jacking Bolts

10-4

Section 11

Lubrication System Lubrication System (Water Cooled) Figure 11-1 ....................................................................................... 11-2 Lubricating Oil Specifications........................................................................................................................ 11-3 Lubrication System (Air Cooled) Figure 11-2 ............................................................................................. 11-3 Air Oil Cooler Figure 11-3 ............................................................................................................................... 11-4 Crusher Operating Oil Temperature ............................................................................................................. 11-4 Drain Oil Temperature .................................................................................................................................... 11-4 Reservoir Oil Temperature ............................................................................................................................. 11-4 Supply Oil Temperature .................................................................................................................................. 11-4 Oil to Water Cooling ........................................................................................................................................ 11-4 Air Cooled .......................................................................................................................................................... 11-5 Lube System Placement and Installation ................................................................................................... 11-5 Skid Mounted Lube System ........................................................................................................................... 11-5 Air Cooler System ............................................................................................................................................ 11-5 Oil Supply Regulation...................................................................................................................................... 11-5 Tank Location Figure 11-4 ............................................................................................................................. 11-5 Piping Information .......................................................................................................................................... 11-5 Crusher Air Breather Figure 11-5 ................................................................................................................. 11-6 Countershaft Box Blower .............................................................................................................................. 11-6 Oil Tank Breather ............................................................................................................................................. 11-6 Oil Filtration ..................................................................................................................................................... 11-6 Oil Contamination............................................................................................................................................ 11-6 Lubrication Filter Figure 11-6 ....................................................................................................................... 11-7 Oil Contamination Guidelines Table 11-1 .................................................................................................... 11-7 Oil Coolers ......................................................................................................................................................... 11-7 Air Cooler .......................................................................................................................................................... 11-7 Water Cooler .................................................................................................................................................... 11-8 Water Control Valve Troubleshooting ......................................................................................................... 11-8 Water Cooled Lube System Components ................................................................................................... 11-8 Water Strainer Cleaning ................................................................................................................................. 11-8 Low Oil Level ..................................................................................................................................................... 11-8 Oil Heater........................................................................................................................................................... 11-8 Oil Pressure Sensor.......................................................................................................................................... 11-8

11-1

positioned electric drive motor, which is mounted to the top of the oil reservoir

Description Refer to Figure 11-1 This section covers the description of the Package Lubrication System (PLS) and its related components along with installation and removal of those compone nts. There are two lubrication packages available. Selection depends on the oil cooling requirement. Figure 11-1 shows the parts of a water cooled lube system. Figure 11-2 shows the parts of an air cooled lubrication package. Both systems are designed to operate at a maximum pressure of 125 psi (8.6 Bars). The Package Lubrication Systems (PLS) are skid mounted and consists of the following:

•

Main system relief valve set at 125 psi (8.6 bars)

•

20 micron filter system with 50 psi (.34 bars) internal bypass monitored by two separate filter differential pressure switches

•

Various isolation valves

•

Temperature Transducer in the oil return line

•

Water cooled systems have the heat exchanger mounted on the Lube skid

• •

Reservoir with an oil level sensor and a thermowell mounted oil heater

•

Submerged oil pump attached to a vertically

Air cooled systems have a remote mounted (radiator type) heat exchanger

The oil supply is piped to the bottom of the Crusher Main Shaft. A small portion of oil is tapped off of the Crusher

1. 2. 3. 4. 5.

Oil Reservoir Oil Reservoir Clean Out Cover Heat Exchanger (Oil to Water) Water Control Valve Water Strainer

9. 10. 11. 12. 13.

Inspection Screen Oil Pump Oil Pump Motor Oil Reservoir Breather Oil Reservoir Temperature Transducer

6. 7. 8.

Check Valves Oil Filter Oil Heater

14. Drain Oil Temperature Transducer 15. Oil Level Sight Gauge 16. Pressure Relief Valve

17. 18. 19. 20. 21.

22. Crusher Pressure Relief Valve Return Connection

Figure 11-1 Lubrication System (Water Cooled)

11-2

Oil Level Sensor Water Inlet Connection Water Outlet Connection Drain Oil Connection Supply Oil Connection

1. 2. 3. 4. 5. 6.

Oil Reservoir Oil Reservoir Clean Out Cover Check Valves Oil Filter Oil Heater Inspection Screen

7. 8. 9. 10. 11. 12.

Oil Pump Oil Pump Motor Oil Reservoir Breather Oil Reservoir Temperature Transducer Drain Oil Temperature Transducer Oil Level Sight Gauge

13. Pressure Relief Valve 14. Oil Level Sensor 15. Drain Oil Connection 16. Supply Oil Connection 17. Crusher Pressure Relief Valve Return Connection

Figure 11-2 Lubrication System (Air Cooled)

Oil Piping to lubricate Countershaft Box Assembly. Oil flows through a verticalthe opening at the center of the Main Shaft, where it lubricates the Head Ball, Socket Liner, and (during no load operations) the Upper Head Bushing. The Main Shaft has an intersecting cross ports that carries the bulk of the oil flow to lubricate the eccentric bushing and the lower head bushing. The majority of oil flow for this system is designed to provide cooling (heat transfer) from the bearing surfaces within the Crusher. Oil exiting the bearing surfaces gravity flows through the slots in the counterweight and lubricates the Gear and Pinion on its way to the gear well and Main Frame sump. The oil then flows back to the Package Lube System (PLS) reser voir. There is a port in the Crusher Oil Piping in the 2-1/2 inch lube oil supply line, located near the crusher that supplies oil to lubricate the Countershaft Box bushings. The correct oil flow to the Countershaft Box is determined by the size of the flexible supply line and fittings. The oil flow drains from the Countershaft Box into the Main Frame oil sump, where it combines with the rest of the lubricating oil and returns to the Package Lube System (PLS) reservoir.

Lubricating Oil (not Specifications Use high grade paraffin naphthalene) based ISO VG 150 gear oil that meets the following requirements: 1. High film strength 2. High adhesiveness to metal surfaces 3. Stable physical and chemical properties 4. Must have extreme pressure (E.P.) properties such as sulfur phosphorus or other anti-weld agents which are compatible with metals used in the Crusher. The E.P. oil is preferred over straight industrial oil because of the higher pour point. 5. High viscosity index 6. Rapid water separation 7. Resist foaming 8. Provides rust and corrosion protection 9. Includes anti-wear additives

11-3

ISO VG 150 Viscosity:

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 Viscosity Index of 90 or Higher

If the Crusher is to operate under abnormal conditions such as crushing hot materials or operating in extreme climates, contact FLSmidth’s customer ser vice for special lubricating oil recommendations. It is very important that Crusher lubricating oil meet the above requirements to protect its working parts. Not using the proper oil can damage the Crusher in a short period of time and void any warranties. Any major oil company makes oil that meets the above requirements. If your local oil supplier cannot furnish oil that meets the above requirements, contact FLSmidth’s customer service for assistance.

Crusher Operating Oil Temperature The preferred operating temperature of the lube oil supplied to the Crusher is 100° F (38° C) to 130° F (54° C). Do not operate the Crusher if the drain line temperature reaches 140° F (60° C). There are two temperature transducers mounted on the oil reservoir. The transducers are wired to the junction box and monitor oil temperatures from two locations on the lube system. Refer to Figure 11-1 for the lube system transducer locations.

1. Air to Oil Cooler 2. Fan Motor

3.

Supply Oil Temperature Transducer 4. Pressure Relief Valve

Figure 11-3 Air Oil Cooler

Drain Oil Temperature

If the Crusher oil is cooled by an air t o oil cooler, the fan motor is controlled by the drain line temperature sensor located in the lube package. There is an optional supply oil temperat ure transducer mounted on the cooler assembly in the outlet piping. Refer to Figure 11-3 for the transducer location on the air cooler.

A temperature sensor probe mounted in the Crusher drain line connection on the side of the reservoir is connected to the Return Temperature transducer and is used by the Control to activate high oil temperature warning and alarm conditions.

Reservoir Oil Temperature

The type of cooling system will dictate the location of the Crusher supply oil temperature sensor. The following is a description of those systems and locations:

A temperature probe is mounted in the reservoir and connected to a temperature transducer in the electrical control panel. The analog signal from the temperature sensor is used by the Control System to control the Oil Heater and to monitor the “start permissive” for the Lube Oil Pump.

11-4

Supply Oil Temperature

Oil to Water Cooling The Supply Oil Temperaturesensor is mounted adjacent to the 2-1/2” Flange connection on the Package Lube

System and is wired to the transducer in the electrical box. The sensor provides an analog signal to the Control System.

Air Cooled The Supply Oil Temperature sensor is mounted in the outlet piping of the Air Cooler Assembly and wired to the Control System. Refer to Figure 11-3

Oil Supply Regulation The Package Lube System (PLS) is designed and sized to provide the necessary supply of clean and cooled lubrication oil. It should not be modified. Normal supply oil flow to the Crusher is XL500 75-80 GPM (284-303 LPM). Normal supply oil pressure at the Crusher should be: XL500 20-40 psi (1.4-2.8 Bars) The amount of oil to fill the lubrication system reser voir: XL500 175 U.S. Gallons (662 Liters)

Lube System Placement & Installation Skid Mounted Lube System Locate the lube system below and as near the Crusher as possible. To obtain the proper flow of drain oil f rom the Crusher to the lube system reservoir, the bottom of the reservoir must be at least 6 feet (1.8 meters) below the underside of the

Crusher mounting flange. Make sure that the Package Lube Skid is level before attaching to the foundation, using shims if necessar y. Refer to Figure 11-4

Before wiring the pump motor, check the motor name plate for the voltage, frequency, phase and electrical connection requirements. All electrical equipment required to operate the pump motor (motor starter, fuse protection, etc.) is to be furnished by the customer and must meet local electrical code requirements. With the pump motor properly wired, check the direction of rotation by briefly starting the motor. There is an arrow mounted on the top of the motor to indicate the correct direction of rotation.

Air Cooler System Crushers using an air to oil heat exchanger (radiator type, air cooler assembly) are supplied with a skid mounted heat exchanger assembly with a by-pass relief valve already piped in place. Refer to Figure 11-3 The air to oil heat exchanger (air cooler assembly) is best located between the Package Lube System and the Crusher. If the air cooler assembly is installed in a lube room, the room needs to be properly vented to provide an in-flow of ambient air necessary to efficiently cool the oil. The air cooler assembly (skid) can be mounted by overhead suspension or fastened to a foundation. Make sure that the air cooler assembly is not subjected to excessive vibrations and is mounted level. Before wiring the air cooler motor, check the motor name plate for the voltage, frequency, phase and electrical connection requirements. All electrical equipment required to operate the air cooler motor (motor starter, fuse protection, etc.) is to be furnished by the customer and must meet local electrical code requirements. After the air cooler motor has been properly wired, start the motor and check its rotation. It should rotate the fan so air is forced through the radiator from the motor side. Refer to Figure 11-3 for air flow direction. If the motor is rotating the fan in the wrong direction, change the fan motor wiring and re-check the direction of air flow.

Piping Information 1. Crusher 2. Minimum 4’ (1.3 Meters) plus 1” (25mm) for every 12” (0.3 Meters) tank is away from the crusher horizontally 3. Oil Tank

Figure 11-4 Tank Location

The factors listed below should be addressed when laying out the supply and drain oil piping to and from the Lube Package and Crusher: 1. The drain line should have a minimum pitch of 1 inch (25mm) of vertical change for every 12 inches (305mm) of horizontal change. Refer to Figure

11-5

11-4 for minimum vertical distance between the Lube Tank and Crusher.

Countershaft Box Blower

2. The piping should be as direct and short as possible with a minimum amount of turns, dead pockets and similar obstructions.

A Blower is connected by hose to the Countershaft Box to provide positive pressure inside the Crusher. This device is required to allow the lube oil to drain freely from the Crusher. Locate the Breather away from the Crusher in a relatively dust free area. Refer to Figure 11-5

3. Install flexible couplings or short hoses between the piping from the Lube Package and the Crusher to accommodate Crusher movement.

To verify that the Crusher is brea thing properly, remove the hose from the breather and place a piece of light paper at the opening. The paper should be pulled slightly inward.

4. Install unions or bolted, flanged joints to aid at various locations in the removal of any piping or lubricating equipment when necessary.

If not, it could be that the cored passage that runs the length of the Countershaft Box is plugged with dirt. This can usually be corrected by blowing pressurized air into the Countershaft Box at the hose connection to blow out the dirt. This method does not require the removal of the Countershaft Box Assembly from the Crusher. The more common problem is a dirty or plugged Breather element.

5. Avoid long vertical drops in the drain line. This will create an excessive vacuum inside the Crusher and cause dust to be pulled into the Crusher past the labyrinth “T” and “U” seals. If a vertical drain line cannot be avoided and vertical drop is more than 4 feet (1220 mm) long, contact FLSmidth’s customer service department for instructions for installing and maintaining a drain line trap.

Important The lube supply oil piping and return oil piping must be cleaned of rust, scale, cutting chips, and other debris prior to assembly. The supply oil piping should then be disconnected at the Crusher and, with a flexible hose or other suitable means, connected to the return line. The lubrication pump is then operated for approximately 10 minutes to flush the supply oil line and return oil line.

These paper elements are not considered cleanable and should be changed out as needed.

Oil Tank Breather The oil reservoir is sealed from dust and moisture and includes a breather mounted on top surface of the tank. This breather allows the reservoir to maintain atmospheric pressure. Refer to Figures 11-1 and 11-2 A weekly check should be made to make sure dust and debris does not build up around the brea ther. The reservoir breather is not cleanable and should be replaced.

Oil Filtration The Package Lube System (PLS) includes a full flow oil filter with integral pressure relief, a replaceable 20 micron filter element and two pressure switches used to indicate dirty and plugged filter element conditions. These signals are sent to and processed by the Automated Control System (ACS). To replace the filter element, disconnect the electrical connector and unscrew the top cover of the filter. The element includes a handle for ease of removal. Refer to Figure 11-6 Under the oil tank cover is a removable/cleanable strainer basket designed to catch large particle contamination as the drain oil falls back into the tank.

1. Countershaft Box 2. Hose (15 feet long) 3. Air Breather

Figure 11-5 Crusher Air Breather

11-6

Oil Contamination Use of contaminated oil or oil that has lost its properties will accelerate bearing wear and create expensive parts replacement requirements.

Oil samples should be taken and analyzed on a regular basis. Most Crusher operators use a one month interval. If, over the oil sample interval, there is an unusual increase in any of the contaminants listed in Table 11-1, a thorough inspection of the Crusher should be made to find the source(s). The type of contamination may indicate whether the source is internal (e.g. metallic contact) or a result of dust infiltration. Oil analysis can also provide possible sources of contamination causing excessive bushing and socket liner wear. 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

1. Cover 2. Element 3. Filter Housing

rated unacceptable.

Oil Coolers The lubrication system includes an oil cooler designed to maintain the drain oil temperature of the Crusher between 100°F (38°C) and 130°F (54°C). Figure 11-6 Lubrication Filter

The two most common types of cooling are oil to air (radiator type cooler) and oil to water (tube and shell type cooler). There is a relief valve located in a bypass line around either of the cooler designs. This allows pressure by-pass due to plugged internal passages or cold thick oil. This valve is factory set and should not be adjusted. If there is a change in cooler efficiency, check the relief valve to make sure it is not stuck open allowing un-cooled oil to by-pass the cooler. If so, it should be replaced immediately.

Air Cooler The oil to air cooler is a radiator type cooler that transfers the heat of the oil to air by use of a fan. This stand-alone assembly is best mounted between the Crusher and Lube Package. Refer to Figure 11-3 To maximize the efficiency of the air cooler, FLSmidth recommends periodically cleaning the cooler to remove dust and dirt that builds up in the core.

Oil Contamination Guidelines ACCEPTABLE

HIGH

COPPER (Cu)

Below 100 PPM

Above 210 PPM

ALUMINUM (Al)

Below 5 PPM

Above 10 PPM

IRON (Fe)

Below 20 PPM

Above 50 PPM

SILICA (Si)

Below 25 PPM

Above 65 PPM

CHROMIUM (Cr) LEAD (Pb)

Below 0.5 PPM Below 70 PPM

Above 1.5 PPM Above 190 PPM

CONTAMINATION LEVEL (TOTAL SOLIDS) WATER

Below 0.1% Below 0.1%

Above 0.2% Above 1.0%

Table 11-1

11-7

Water Cooler The Lube Package mounted oil to water cooler is a tube and shell design that transfers the heat of the oil (circulated through the shell) into the water (circulated through the tubes). Refer to Figure 11-1 Contact FLSmidth customer service for operation and maintenance instructions for the water heat exchanger. FLSmidth recommends using an uninterrupted water supply from the plant water system. Using this system in freezing temperatures should be avoided unless safeguards are incorporated to keep the water from freezing. The water supply and discharge connection for the heat exchanger are 1 inch NPT fittings. The supply and discharge lines are the supply of the customer and are to be installed once the Package Lube System is properly installed. Refer to Figure 11-1

Water Cooled Lube System Components The required flow of water (gallons per minute or liters per minute) is dictated by the water temperature. This is accomplished using a water control valve that is mounted on the oil outlet port of the oil to water coolers on the Lube Package. The valve automatically controls the flow of water by use of a non-electrical temperature sensor mounted in a thermowell on the side of the lube tank that increases the water flow as the temperature of the oil in the tank (source of supply) increases. The water control valve must be set to provide 110°F (43°C) supply oil temperature. If for some reason, the valve needs adjusting, contact FLSmidth customer service for instructions. Keeping the control valve clean is the only maintenance that’s required. Regular inspection and cleaning of the valve can be done through its inlet and outlet. FLSmidth recommends cleaning the temperature sensor part of the control valve during every oil change to maintain a consistent control of the supply oil temperature.

Water Control Valve Troubleshooting If the control valve does not seem to be holding a steady temperature or the oil is not being cooled enough, do the following: 1. Check the water strainer located on the water inlet side of the cooler for any debris. Refer to Figure 11-1

11-8

2. Check for any external conditions which may cause the control valve to operate improperly such as low and/or fluctuating water supply or pressure, damaged or blocked valves or other components in the water circuit, too small of a supply line, kinked or broken control valve capillary tube or a dirty bulb. 3. Check for foreign material under the control valve seat possibly causing the valve not to close. 4. If after cleaning the bulb, the water control valve will not open, there is a possibility that the gas in the temp sensor bulb has escaped requiring replacement of the bulb. This can be checked by placing the bulb in hot water to see if the valve opens. 5. Water leaking from the valve body may indicate a loose part in the valve or damaged bellows. Either condition will require replacement of the valve. 6. Chattering of the water control valve may indicate loose parts within or near the valve.

Water Strainer Cleaning Depending upon the quality of the cooling water, it may be necessary to clean the strainer weekly. Refer to Figure 11-1 for its location. To clean the strainer screen, shut off the water supply, remove the strainer cap and screen, clean the screen, reassemble the screen and cap and turn the water back on.

Low Oil Level A sensor mounted on the side of the reservoir monitors the oil level and provides a switch signal to the Control System.

Oil Heater The Lube System includes an oil heater mounted in the tank used to maintain oil temperature in cold operating conditions. Equipment required for heater operation such as magnetic contactor and fuse protection is to be furnished by the customer and must meet local electrical code requirements.

Oil Pressure Sensor An analog pressure sensor is supplied as standard equipment and provides Crusher protection in the case of lost oil pressure. The sensor is wired to the Control System. The control logic programmed into the Control System activates low oil pressure warning and alarm conditions.

Section 12

Hydraulic Systems Hydraulic Power Unit Installation ................................................................................................................ 12-2 Tramp Release and Clamping Cylinders Figure 12-1 ................................................................................ 12-2 Crusher to Power Unit Hose Co nnections ................................................................................................. 12-2 Hydraulic Power Figure 12-2 ........................................................................................................................ 12-3 Hydraulic Power Unit Hose Connections Figure 12-3 .............................................................................. 12-3 Release and Clearing System Hose Connections Figure 12-4 ................................................................ 12-4 Hydraulic Adjust Drive Hose Connections Figure 12-4A .......................................................................... 12-4 Remote Mounted Push Button Control Panel Installation .................................................................... 12-4 Hydraulic Oil Specifications ........................................................................................................................... 12-4 Cold Weather Oil Specifications .................................................................................................................... 12-5 Hydraulic System Pre-Start Tramp Release System ................................................................................ 12-5 Accumulator Valve Figure 12-5 .................................................................................................................... 12-5 Charging and Gauging Assembly Figure 12-6 ........................................................................................... 12-6 Clamping Circuit System ................................................................................................................................12-7 Hydraulic Power Unit Controls .....................................................................................................................12-7 Hydraulic Power Unit Operations and Control Logic ...............................................................................12-7 Remote Pu sh Button Panel Figure 12-7 ..................................................................................................... 12-7 Description of Lights and Switches on the Local Control Panel ............................................................12-8 Description of Operating the Hydraulic Power Unit from the Local Control Pan el .......................... 12-9 Operating in Service Mode ............................................................................................................................ 12-9 Hydraulic Power Unit Start-up and Operation .......................................................................................... 12-9 Power Un it Pressure Table 12-1 ................................................................................................................ 12-10 Power Un it Service Switches Figure 12-8 ................................................................................................ 12-10 Bleeding and Pressure Testing the Tramp Release and Clamping Systems ...................................... 12-10 Bleeding the Tramp Release System .........................................................................................................12-10 Bleeding the Clamping System ................................................................................................................... 12-11 Power Unit Oil Filter Figure 12-9................................................................................................................ 12-12 Changing the Oil Filter ..................................................................................................................................12-12 Hydraulic Oil Changing ................................................................................................................................. 12-12 Cleaning the Hydraulic System ................................................................................................................... 12-12 Troubleshooting Procedures ...................................................................................................................... 12-13

12-1

Description This section covers the description of the hydraulic circuits and related components along with installation and removal of those components. All XL500 Crushers are furnished with hydraulic tramp release, cavity clearing and clamping circuits, and hydraulic Bowl adjust drive system. Tramp Release Cylinders hold the Adjustment Ring firmly to the Main Frame. The rod of each Cylinder is attached to the Adjustment Ring by a hex nut and spherical washer. The top of each cylinder is secured to the Main Frame by a spherical nut. A non crushable item passing through the crushing cavity or adjusting the closed side setting too tight will cause the Adjustment Ring to lift off the Main Frame. Lifting of the Adjustment Ring will extend the Tramp Release Cylinders and force oil from the rod side of the cylinders to an accumulator mounted on the Crusher. When the non crushable item has passed through the crushing cavity or the setting has been forced larger, the compressed nitrogen in the bladder of the Accumulator will force the oil back into the tramp release cylinders and resea t the Adjustment Ring on the Main Frame. If for any reason the Crusher stops with material in the crushing cavity, the Adjustment Ring and Bowl Assemblies can be raised off the Main Frame to open the crushing cavity and clear the Crusher. This task is accomplished by depressurizing the rod side of all the Tramp Release Cylinders and pressurizing the piston side. This action extends the Cylinders and lifts the Adjustment Ring and Bowl Assembly off of the Main Frame. The clamping system consists of a set of ten Clamping Cylinders installed in the Clamping Ring which is mounted on top of the Adjustment Ring. Refer to Figure 12-1 When the Clamping Cylinders are pressurized, the Clamping Ring raises slightly and locks the Bowl threads in the Adjustment Ring during operation. Control of these systems is done by a Hydraulic Power Unit (HPU) consisting of a cabinet with an integral oil tank with replaceable breather, vertically mounted electric motor, submerged hydraulic pump, solenoid valves, oil filters and pressure transducers. All protected by a removable cover with door. Included the HPUtoisthe a remote mounted button control panelwith connected Hydraulic Powerpush Unit by a 30 foot (9 meter) long cable. Refer to Figure 12-2 The HPU can be controlled locally at the push button pendent or at the Control System.

12-2

1. Clamping Ring 2. Clamping Cylinder 3. Adjustment Ring 4. Tramp Release Cylinder

Figure 12-1 Tramp Release and Clamping Cylinders

Hydraulic Power Unit Installation The Hydraulic Power Unit (HPU) should be carefully placed in an area that is protected from falling rock and no more than 50’ (15 M) from the Crusher. The remote mounted push button panel should be placed in a location that will allow the operator to observe the Crusher during clearing or while turning the Bowl (setting adjustment). There are six hydraulic hoses that connect the Crusher to the HPU. These hoses are shipped loose for field installation. The hoses include reusable couplings on one end providing the customer with the ability to change the length of the hoses to fit the installation. The remote mounted push button panel is prewired to the terminal box located inside the Hydraulic Power Unit. The remote mounted push button panel is pre-wired to the terminal box located inside the Hydraulic Power Unit.

Crusher to Power Unit Hose Connections 1. Connect the Clamping Circuit hose to the connection on the Hydraulic Power Unit (HPU). Refer to Figure 12-3 for the clamping system HPU connection

1. 2. 3. 4. 5. 6. 7.

Oil Reservoir Oil Reservoir Clean Out Cover Oil Level Sight Gauge Oil Filters Junction Box Reservoir Oil Fill Cap Reservoir Breather

8. Accumulator 9. Oil Level/Temp. Switch 10. Electric Motor 11. Clamping System Manifold and Valves 12. Tramp Release System Manifold and Valves

13. 14. 15. 16. 17.

Clamp Circuit Pressure Transducer Tramp Release Circuit Pressure Transducer Reservoir Drain Plug Manual Dump Valve (Clamp) Manual Dump Valve (Tramp)

Figure 12-2 Hydraulic Power

location. Connect the other end of this hose to the clamping system connection on the Adjustment Ring. Refer to Figure 4-15 in Section 4 Main Frame, Adjustment Ring and Tramp Release Assemblies. 2. Connect Tramp Release hose to the connection on the HPU. Refer to Figure 12-3 Connect the other end to the inner connection on the Tramp Release Cylinder located opposite of the Countershaft on the Main Frame. Refer to Figure 12-4 3. Connect Clearing hose to the connection on the power unit. Refer to Figure 12-3 Connect the other end of this hose to the outer connection on the release cylinder located opposite of the Countershaft on the Main Frame. Refer to Figure 12-4 4. Connect the Brake hose to the “Brake” port connection at the Hydraulic Power Unit. Refer to Figure 12-4 Connect the other end of this hose to “Brake” port on the Hydraulic Adjust Drive. Refer to Figure 12-4a 5. Connect the “open” hose to the “open” port connection at the Hydraulic Power Unit. Connect the other end of this hose to “open” port on the Hydraulic Adjust Drive. Refer to Figure 12-4a 6. Connect the “close” hose to the “close” port connection at the Hydraulic Power Unit. Connect the other end of this hose to “close” port on the Hydraulic Adjust Drive. Refer to Figure 12-4a

1. Clearing Circuit Hose Connection 2. Tramp Release Circuit Hose Connection 3. Clamping Circuit Hose Connection

4. 5. 6.

Close Open Brake

Figure 12-3 Hydraulic Power Unit Hose Connections

12-3

1. Tramp Release Hose to Power Unit 2. Clearing Hose to Power Unit 3. Adjustment Ring 4. Clamping Hose to Power Unit

Figure 12-4

Release and Clearing System Hose Connections

Remote Mounted Push Button Control Panel Installation The remote mounted push button panel includes a 30 foot (9 meter) long multi-conductor electrical cord attached to it for connecting to the electrical box located inside the hydraulic power unit. Panel should be located so as to provide direct line-of-sight to the bowl adjust mechanism. FLSmidth recommends shortening this cable to suit the installation. Use the Hydraulic Power Unit electrical schematic drawing furnished in the Parts Manual to make the proper connections.

Hydraulic Oil Specifications Thoroughly inspect the inside of the reservoir for any contaminants before filling the hydraulic power unit tank with oil. Remove any material with lint free rags. Also check the suction strainer for any material that may be stuck to the screen and clean if necessary. Use a high grade paraffin, not naphthalene, industrial hydraulic oil with high film strength, high adhesiveness to metal surfaces and stable chemical and physical properties. The oil should also have a high viscosity index, rapid water separation, resist foaming, include corrosion protection, resist oxidation and contain anti-wear additives. ISO VG 32 Viscosity: 29 to 35 cSt (Centistrokes) at 40°C 6 cSt or Higher at 100°C or 135 to 165 SUS (Saybolt, Universal Seconds) at 100°F

45 SUS or Higher at 210°F Viscosity Index of 140 or Higher Fire resistant hydraulic oil should not be used. This type hydraulic oil may not be compatible with packing seals, accumulator bladders, hoses and other parts of the power unit. It will adversely damage the special paint used inside the reservoir as well as reduce the life of the pump. 1. Gearbox Fill Plug 2. Brake Port 3. Port B Close

4. 5.

Port A Open Gearbox Drain Plug

Figure 12-4A Hydraulic Adjust Drive Hose Connections

12-4

The reservoir is to be filled to the top of the oil level gauge. Approximately 100 US gallons (379 Liters) will be required. An additional 30 gallons (114 liters) of oil will be required to initially fill and bleed the Clamp, Tramp Release and Clear systems.

The oil level should be kept at the center of the oil level gauge during normal operation and regularly monitored.

Cold Weather Oil Specifications Cold oil will not flow freely through the hydraulic system causing it to be almost solid. This situation is a particularly bad for the Tramp Release circuit in which the oil must flow freely to and from the accumulator when the Crusher passes tramp or stalls. If the correct oil for a cold weather environment is not used, the Hydraulic Power Unit and/or Crusher components could be damaged. If the ambient temperature will be 0°F (-20°C) or less for more than a few days, FLSmidth recommends changing the entire hydraulic system oil to a cold weather type as specified below.

using the dump valve located in the front of the cabinet. Make sure the pressure on the Tramp Release Circuit Pressure Transducer reads zero before going any further. Refer to Figure 12-2 for the dump valve and Tramp Release Circuit Pressure Transducer locations. 4. Push the machine stop button down on the remote push button panel. This will turn all power off to the Hydraulic Power Unit (HPU). With the power unit shut off, the control system will not pressurize the Tramp Release Circuit Pressure if someone should turn the Operation - Service selector switch in the Operation position during this process. A. Lockout the HPU motor.

ISO VG 10 10 cSt (Min) at 130°F (54.4°C) 500 cSt (Max) at -40°F (-40°C) Pour Point of -75°F (-59.4°C) Max

5. Remove the valve guard, cap and washer from the accumulator. Refer to Figure 12-5

FLSmidth does not recommend using the above cold weather oil all year round. Since the oil is designed for use in cold ambient conditions, occasional leakage past the Tramp Release Cylinders and Clamping Cylinders may occur during warmer conditions.

6. Locate the charging assembly supplied with the tools from FLSmidth. Turn the T-handle on the air chuck all the way out or until it bottoms out. The screw on the bottom of the bleeder valve must be closed. Screw the air chuck swivel onto the valve stem until hand tight and then a quarter turn to compress the seal. Refer to Figure 12-6

Hydraulic System Pre-Start Tramp Release System (Checking Pre-Charge and Charging the Accumulator)

The two 5-gallon Tramp Release Accumulators are mounted on the Main Frame and contains a bladder that needs to be charged with nitrogen gas to a 1500±50 PSI (103±3 bar). This pressure needs to be regularly checked monthly. The pre-charge pressure can only be checked when the Tramp Release pressure is zero. With no pressure in the Tramp Release Circuit and needle valve is turned out, so the accumulator bladder is free to expand inside the accumulator and thereby give you an accurate reading of the pressure in the bladder. To check and pressurize (pre-charge) the Tramp Release System Accumulator, do the following:

Do not over tighten the swivel more than a quarter turn. Over tightening can twist off the valve stem and/ or damage the copper crush washer causing leakage.

7. Turn the T-handle in on the air chuck so the shaft completely depresses the valve core in the accumulator stem. The pressure gauge on the gas charging valve should read 1500 psi (103 bars) +/50 psi (3 bars). If the pressure is within this range, proceed to Step 12. If the pressure is above the

1. At the remote mounted push button panel, turn the Local - Remote selector switch to Local. 2. At the Hydraulic Power Unit (HPU), open the service Operation-Service selector switch to door. Turn the the Service position. Refer to Figure 12-2 and 12-8 for the Operation-Service selector switch location.

3. Eliminate all the Tramp Release Circuit pressure

1. Accumulator 2. Gas Valve Stem 3. Valve Cap

Figure 12-5

4. Valve Guard 5. Washer

Accumulator Valve

12-5

on the top of a nitrogen bottle. Use commercially available “oil pumped dry nitrogen“. 9. Slowly open the valve to push any residual oxygen out of the hose. Hand tighten the swivel end of the hose. Slowly open the valve on the nitrogen bottle to allow the nitrogen to pass into the accumulator bladder at a controlled rate. Close the nitrogen bottle valve at frequent intervals to let the gas charging pressure gauge settle. When the pressure defined in Step 7 has been reached, quickly close the valve on the nitrogen bottle. 10. Turn the T-handle on the air chuck out until itbottoms out. This action will decompress the valve core and allow it to seat in the accumulator stem. 11. Bleed the residual nitrogen from the hose. Disconnect the hose assembly from the nitrogen bottle and the swivel connector from the end of the hose from the gas charging valve. 12. Disconnect the air chuck from the accumulator valve stem. 13. Store the hose assembly, gauging assembly and nitrogen bottle in a dust free atmosphere that is out of the weather. Plug the ports on the gauging assembly and both ends of the hose assembly to keep them free of dust and contaminates.

1. 2. 3. 4. 5. 6. 7. 8.

Accumulator 9. Screw 10. Bleeder Valve 11. Swivel Connector 12. Gas Charging Valve 13. Pressure Gauge 14. T-Handle 15. Air Chuck 16.

Swivel Gas Valve Stem Hose Assembly Coupling Gland Gland Nut Pressure Regulator Valve Nitrogen Bottle

Figure 12-6 Charging and Gauging Assembly

range, slowly open the bleeder valve on the bottom of the gas charging valve to exhaust excessive nitrogen gas out of the accumulator bladder. When the pressure falls into the range, quickly close the bleeder valve and go to Step 12. If the pressure is below the specified limits then proceed to Step 8. 8. Attach the swivel end of the hose to the gas charging valve. This connection just needs to be loose. Connect the other end of the hose assembly to the regulator

12-6

14. Brush a soapy solution on the accumulator gas valve to check for any leakage of gas. Depress the core once or twice to seat it if any leaks are found. If the leakage continues, either tighten the core or replace it altogether. 15. Thread the valve cap onto the valve stem. 16. Thread the valve guard onto the accumulator. 17. Close the Tramp Release Circuit Pressure dump valve. a) Unlock HPU pump motor and energize motor contactor. 18. Lift up on the machine stoppanel. push Press buttonthe located on the remote mounted control machine enabled/reset button. This action should cause the Hydraulic Power Unit (HPU) to pressurize the Tramp Release Circuit back to its working pressure. Refer

to Service Switches later in this section for instructions on how to manually pressurize the Tramp Release Circuit. 19. Once the Tramp Release Circuit has been pressurized and checked, then install the cover back onto the HPU. 20. For a new or repaired Tramp Release Accumulator, the pre-charge pressure should be checked Monthly.

Clamping Circuit System (Checking Pre-Charge and Charging the Accumulator)

FLSmidth recommends regularly checking the clamping circuit accumulator pre-charge pressure. The 1-gallon accumulator is located inside the Hydraulic Power Unit. (HPU) Follow the same procedure used to check and charge the 5-gallon tramp release accumulators on the 1 gallon clamping circuit accumulator. The only difference is that the pre-charge pressure must be 1000 psi (69 bars) ± 50 psi (3 bars). Figure 12-7

Remote Push Button Panel

Hydraulic Power Unit Controls crushing forces. This is a dead headed circuit that will be pressurized up to 2800 psi (193 bars). Once the circuit is fully charged with oil, there will be minimal oil flow as the oil is introduced to make up for loss of pressure due to oil leakage. Repressurization occurs automatically and is quite rapid, being in the 2 to 5 second range. There is a 3.8 liter accumulator in the circuit to dampen hydraulic pressure spikes and provide make up oil to reduce the repressurization cycles. There is a pressure transducer that monitors the Clamping Circuit pressure.

Refer to Figure 12-7 Do not operate the Hydraulic Power Unit (HPU) until after reading the following information.

Warning Pressing the Machine Power Button located on the remote push button panel will only turn off the electric power to the controls. Use caution when troubleshooting the HPU or making any adjustments. Always lock out the main power supply and the electrical controls before ser vicing the HPU and the Crusher.

•

Clamping Cylinder Circuit: This circuit provides a clamping force to keep the Bowl Assembly from rotating under load and working in the Adjustment

Tramp Release System Circuit: This is a system of 8 large, two-way hydraulic cylinders (cylinders perform both Tramp Release and Clearing functions) that provide a force to keep the Adjustment Ring pulled down tight to the Main Frame. The circuit is deadheaded with an operating pressure range from 1600 to 1800 psi (110 to 124 bars). There are two 5 gallon accumulators which absorbs the energy of displaced oil from the Tramp Release Cylinders as crushing forces lift the Adjustment Ring during a tramp event. A tramp event is when an uncrushable object passes through the crushing

Ring Assembly threads. mounted in the Clamp Ring, liftHydraulic the ClampCylinders, Ring and this in turn lifts the Bowl Assembly and jams the bowl threads against the Adjustment Ring threads and keeps the Bowl Assembly from rotating due to

cavity. Repressurization however, due to the greateroccurs volume automatically; of oil flow, it takes a considerably longer period of time to achieve the proper pressure. There is a pressure transducer that measures Tramp Release pressure.

Hydraulic Power Unit Operations and Control Logic The XL500 Hydraulic Power Unit is designed to provide the hydraulic flows and pressures to activate the various hydraulic circuits necessary to operate the XL500 Cone Crushers. These circuits (functions) are: •

12-7

• Clearing Circuit: This is a system of 8 hydraulic cylinders (the same two-way cylinders used for Tramp Release) that lift the Adjustment Ring when energized. The system lifts until it is dead headed and can operate up to the maximum pressure of 3,000 psi (207 bars) that the Hydraulic Power Unit is designed for. This circuit cannot be energized until the Tramp Release Circuit is depressurized and an open channel is made for the oil to displace from the Tramp Release Cylinders during a Clearing cycle. The pressure is monitored by the system pressure Transducer. •

•

•

•

12-8

Close Bowl Adjustment: In this circuit, the HPU provides a flow of oil under pressure to the Hydraulic Drive Assemblies (hydraulic motors with gear reducers and hydraulic brake). The circuit operates with the lower flow of just one of two stacked pumps in the power unit. The oil makes a complete circuit through the hydraulic motors and back to the HPU reservoir. There is no pressure or flow monitored on this circuit. When the circuit is actuated, a bi-directional valve sends the oil flow in the appropriate direction to turn the hydraulic motors in a direction that screws the threaded Bowl Assembly into the Adjustment Ring and thus makes changes in the crusher setting. Open Bowl Adjustment: In this circuit, the HPU provides a flow of oil under pressure to the Hydraulic Drive Assemblies (hydraulic motors with gear reducers and hydraulic brake). The circuit operates with the lower flow of just one of two stacked pumps in the power unit. The oil makes a complete circuit through the hydraulic motors and back to the HPU reservoir. There is no pressure or flow monitored on this circuit. When the circuit is actuated, a bidirectional valve sends the oil flow in the appropriate direction to turn the hydraulic motors in a direction that screws the threaded Bowl Assembly out of the Adjustment Ring and thus makes changes in the crusher setting.

by turning the Bowl into the Adjustment Ring until the bowl liner makes hard contact with the mantle mounted on the Head Assembly. The hard contact creates a resistance to Bowl rotation that in turn creates a hydraulic power spike (rapid rise in system pressure). A bowl drive pressure light on thehydraulic power unit turns on at 750 psi (52 bars) signaling hard contact. This function can be controlled by an automation system which can automate this calibration. The control logic marks this point as zero and reverses the direction of Bowl rotation. There are two proximity switches set up on one of the two drive pinions of the adjustment drive mechanism. By counting these teeth, and knowing the change in closed-side-setting per tooth of adjustment, the automation system can establish an accurate measurement of the actual Closed Side Setting. Actuation of the Hydraulic Power Unit is carried out in either Local or Remote mode. Local mode control uses fixed and temporary switches mounted on the face of a remote pushbutton panel door. As the Clamping and Tramp Release Circuits pressurize automatically, there is no switches for this function (one only needs the power on indicator to be lit green). Following is the Control Logic at the Manuel Control Panel; for the six functions listed above:

Description of Lights and Switches on the Local Control Panel Power On: Light is on while Power Unit is operating. Service Mode: Light is on while selector switch is turned to service. Service Mode is normally used by technicians to troubleshoot the HPU. Low Tramp Pressure: Light is on when tramp pressure is below operating pressure. Note: Light is on during clearing. Low Clamp Pressure: Light is on when clamp pressure is below the desired operating pressure. Note: Light is on while opening or closing the bowl.

Bowl Removal/Installation Mode: This function is the same as the Open or Close Bowl Adjustment mode, only a second pump is introduced into the circuit to double the flow of oil to the hydraulic

Remote: Light is on when selector switch is turned to Remote and the Power Unit is being automatically controlled from a remote location (Control Room Opera tor).

adjustment motors. This is to speed up bowl removal and installation for maintenance purposes.

High Temperature Warning: Light is on when tank oil temperature is too high.

Calibration: This function allows the operator to establish an accurate Closed Side Setting (CSS)

Bowl Drive Pressure Warning: Light turns on when mantle to bowl liner contact is made during liner calibration, or if

there is some other obstruction or resistance to rotating the bowl assembly in the closed direction. Oil Level Warning: Light is on when tank oil level is low.

Description of Operating the Hydraulic Power Unit from the Local Control Panel Bowl Adjustment Close: 1. Turn selector switch to Local. 2. Turn selector switch to Low Speed 3. Twist selector switch to Close. Note: There is an initial 3 second delay while Clamp Pressure automatically dumps. Bowl Adjustment Open: 1. Turn selector switch to Local. 2. Turn selector switch to Low Speed. 3. Twist selector switch to Open. Note: There is an initial 3 second delay while clamp pressure automatically dumps.

Bowl Removal: 1. Turn selector switch to Local. 2. Open the Clamp Circuit dump valve. 3. Turn selector switch to High Speed. 4. Twist selector switch to Open. 5. Rotate the Bowl Assembly until there is a slight tilt and then stop rotation immediately. 6. De-energize the Hydraulic Power Unit. Note: There is an initial 3 second delay while clamp pressure automatically dumps. Bowl Installation: 1. Turn selector switch to Local. 2. Open the Clamp Circuit dump valve.

3. Turn selector switch to High Speed. 4. Twist selector switch to Close. 5. Close the Clamp Circuit dump valve, upon turning the Bowl Assembly into the desired position. Note: There is an initial 3 second delay while clamp pressure automatically dumps.

Clearing Cycle: 1. Turn selector switch to Local. 2. Open Tramp Release dump valve to dump tramp pressure. 3. Twist the selector switch to Clear. Note: Continue to hold the switch until the hydraulic cylinders fill and raise the Adjustment Ring to the limit of travel.

Operating in Service Mode

Note, continuing to hold the clearing switch after the adjustment ring has lifted will force oil past the system relief valve and rapidly generate heat. If it is necessary to keep the adjustment ring in the raised position, there are safety blocks in the Tool Kit that are to be placed between the adjustment ring and the main frame.

Hydraulic Power Unit Start-Up and Operation

Reset Tramp Pressure: 1. With the Control Panel in Local Mode 2. Close the Tramp Release Circuit dump valve. 3. Turn selector switch to Reset Tramp Pressure. The Tramp Release Circuit will now automatically re-pressurize. 4. Make sure that the Low Tramp Pressure light turns off.

Note, the Tramp Release not pressurize after a Clearing cycle until the Circuit selectorwill switch is momentarily turned to Reset. This Reset mode is to keep the Tramp Release Circuit from accidentally being pressurized while the Safety Blocks are still in place.

The Service Mode Panel switch is located on the service junction box. This small panel is primarily used by service technicians to trouble shoot the Hydraulic Power Unit. It can be used to pressurize the Tramp Release and Clamp Circuits if these functions fail in the Local and Remote Control Modes.

The hydraulic power unit has two modes of operation: Local or Remote. The selector switch for these two modes is located on the remote mounted push button panel. Refer to Figure 12-7 For the Hydraulic Power Unit to operate in either of these modes, the Machine Stop push button must be pulled and Machine Enabled push button pressed to energize the Hydraulic Power Unit control circuits and illuminate the green Machine Enabled push button. With the selector switch in the Remote position, the power unit is controlled by the Control System and all the switches on the remote push button panel are inoperable with the exception of the Machine Stop Push button. The switch should remain in the Remote position during normal crushing operation. (Refer to the Remote Push Button Panel Switch and Button Functions located earlier in this section for a description of the functions available in the Local mode.)

12-9

Power Unit Pressure XL500 Tramp Release

Clamping

If the tramp release and clamping circuits are being pressurized for the first, monitor the oil level sight gauge and add oil as required.

*

Circuit Repressurization Off

1,800 psi 2,800 psi (12,410 kPa) (19,305 kPa)

Circuit Repressurization On

1,600 psi 2,400 psi (11,032 kPa) (16,547 kPa)

Low Circuit Pressure Light On

1,500 psi 2,200 psi (10,342 kPa) (15,168 kPa)

Do not pressurize the tramp release or clamping circuits unless the associated accumulator has been pre-charged with the correct nitrogen pressure. Pressurizing the accumulator without pre-charging will damage the bladder and require replacement of the bladder.

* Clamping circuit pressure drops to 0 psi during setting adjustments. When requested for special applications, the hydraulic power unit can be configured for “adjusting under load.” In this condition, the clamping Bleeding circuit pressure drops to 150 psi (1,034 kPa) during setting adjustments.

Table 12-1

In the Remote mode, the control system monitors the tramp release and clamping circuit pressures and automatically pressurizes as required. Normal closed side setting adjustments can be made from the control system. In either mode the pump motor will be off and only start if any type of HPU operation is performed. Once the operation has been completed the motor will automatically shut off. If while operating the HPU in either the Remote or Local mode either of the red Low Tramp Pressure or red Low Clamp Pressure warning lights illuminates and a check of the related circuit pressure sensor verifies a loss of circuit pressure, there has likely been a malfunction of the hydraulic system. The Crusher should be shut down and the hydraulic problem corrected before the Crusher is restarted if either one or both of these warning lights are activated.

Bleeding and Pressure Testing the Tramp Release and Clamping Systems

the

TTramp o bleed the Release tramp release System system, do the following: 1. Verify that there is adequate hydraulic oil in the reservoir. 2. Turn the Local - Remote selector switch (located on the remote push button panel) to the Local position. 3. Open the door on the front of the Hydraulic Power Unit and turn the Operation - Service selector switch (located on the side of the electrical connection terminal box) to the Service position. Refer to Figure 12-2 and 12-8 for switch locations. 4. Open the tramp release system pressure dump valve (located in the front of the HPU) all the way open. Refer to Figure 12-2 for the release system dump valve location. 5. If the green Machine Enabled light on the remote push button panel is illuminated, go to step 6. If the light is not on, pull the Machine Stop push button and press the Machine Reset push button to turn the HPU on.

During initial Crusher start-up and whenever the tramp release or clamping circuit components have been disconnected, it is necessary to bleed the hydraulic hoses to remove any air that may be trapped.

Warning No attempt should ever be made to bleed any hydraulic circuit when the circuit is fully pressurized. A loose connection may break free allowing high pressure oil to escape causing bodily harm. Always wear suitable eye protection when bleeding any of the circuits.

12-10

Figure 12-8 Power Unit Service Switches

6. During the bleeding of the tramp release circuit, it will be necessary to run the pump for short periods of time to maintain a circuit pressure of 200 psi (14 bars). This pressure is more than adequate to maintain an adequate flow of oil necessary to bleed the system without creating a hazardous high pressure condition. 7. At the service switch box inside the HPU, turn and hold the Tramp Press - Clamp Press selector switch in the Tramp Press position. Adjust the tramp release system dump valve until 200 psi (14 bars) of pressure is maintained as indicated on the tramp release system pressure transducer located on the circuit manifold block. Refer to Figure 12-2 for the tramp release system pressure transducer location. 8. While still holding the switch in the Tramp Press position, loosen the lower hose connection on each tramp release cylinder. Any air in the line will spit out and eventually only oil will leak from the loosened hose connection. At that point, tighten the hose connection. 9. With all the tramp release cylinders bled, release the Tramp Press - Clamp Press selector switch. Completely close the tramp release system dump valve. 10. Turn and hold the Tramp Press - Clamp Press selector switch (located on the service push button box on the side of the electrical terminal box inside the power unit) in the Tramp Press position until the normal operating pressure of 1800 psi (124 bars) is achieved as indicated on the tramp release system pressure transducer. 11. Check all the tramp release system connections to make sure there are no leaks. 12. Turn the Operation - Service selector switch to the Operation position. 13. Turn the Local - Remote selector switch to the Remote position.

Bleeding the Clamping System To bleed the clamping system, do the following: 1. Verify that there is adequate hydraulic oil in the reservoir. 2. Turn the Local - Remote selector switch to the Local position.

3. Open the door on the front of the hydraulic power unit and turn the Operation - Service selector switch to the Service position. Refer to Figure 12-2 and 12-8 for location of the switch. 4. Open the clamping system pressure dump valve all the way open. Refer to Figure 12-2 for the clamping system dump valve location. 5. If the green Machine Enabled light on the remote push button panel is illuminated, go to step 6. If the light is not on, pull the Machine Stop push button and press the Machine Reset push button to turn the power unit on. 6. During the bleeding of the clamping circuit, it will be necessary to run the pump for short periods of time to maintain a circuit pressure of 200 psi (14 bars). This pressure is more than adequate to maintain an adequate flow of oil necessary to bleed the system without creating a hazardous high pressure condition. 7. At the service switch box inside the power unit, turn and hold the Tramp Press - Clamp Press selector switch in the Clamp Press position. Adjust the clamp system dump valve until 200 psi (14 bars) of pressure is maintained as indicated on the clamp system pressure transducer located on the circuit manifold block. Refer to Figure 12-2 for the clamp system pressure transducer location. 8. While still holding the switch in the Clamp Press position, loosen the hose connection at the Adjustment Ring. Any air in the line will spit out and eventually only oil will leak from the loosened hose connection. At that point, tighten the hose connection. NOTE: This can also be done at the bleeder valve above the last clamping cylinder in the chain. 9. With the clamp circuit completely bled, release the Tramp Press - Clamp Press selector switch. Completely close the clamp system dump valve. 10. Turn and hold the Tramp Press - Clamp Press selector switch (located on the service push button box on the side of the electrical terminal box inside the power unit) in the Clamp Press position until the normal operating pressure of 2800 psi (193 bars) is achieved as indicated on the clamp system pressure transducer.

12-11

4. Remove the dirty element from the housing and clean the housing with a mild solvent. 5. Place the new, clean element in the housing, centering it on the element locator. 1. 2. 3. 4.

Hex Canister Base Condition Indicator Button

6. Inspect the canister O-ring and replace if necessary. 7. Install the canister and tighten it to the torque listed on the parts book pages. 8. Unlock the power source and pull out the Machine Stop push button.

Hydraulic Oil Changing

At a minimum, all the oil should be replaced in the entire hydraulic system once a year. The inside of the oil reservoir should also be thoroughly cleaned along with the removal of any contaminates from the suction strainer. Figure 12-9

Power Unit Oil Filter

11. Check all the clamping system connections to make sure there are no leaks. 12. Turn the Operation - Service selector switch to the Operation position. 13. Turn the Local - Remote selector switch to the Remote position.

Changing the Oil Filter Located inside the Hydraulic Power Unit are two high pressure oil filters. Refer to Figure 12-2 for the filter locations. The filter includes a replaceable cartridge. A visual indicator located on the top of the filter will signal when replacement of the cartridge is required. This signal will automatically reset when the cartridge has been changed. To change the filter cartridge, do the following: 1. At the remote push button panel, push the Machine Stop push button to turn the power control circuit off. Also lock out the power source so the system cannot be accidentally started while changing the filter cartridge. 2. As matter ofand safety , dump the systems pressures in both the aclamping tramp release using the dump valves on the front of the HPU. 3. Loosen and remove the filter canister.

12-12

Cleaning the Hydraulic System After the hydraulic system has been in service for a period of time, the following signs are typical indications of the need to clean the hydraulic system: 1. Buildup of contaminates in the reservoir and components within the hydraulic system. 2. Irregular operation of the hydraulic circuits that may include high oil temperatures. 3. Existence of emulsions. 4. Poor condition of the oil that may be indicated by a dark color, cloudy or burnt appearance, rancid smell or an incorrect oil viscosity. To clean the hydraulic system, do the following: 1. At the remote push button panel, push the Machine Stop push button to turn the power control circuit off. Also lock out the power source so the system cannot be accidentally started while changing the filter cartridge. 2. Open both the tramp release and clamping system dump valves so both system pressures are at zero. Close both valves once both systems have been completely depressurized. 3. Drain all the oil from the power unit reservoir. Oil in the release and clamping systems and their lines can be left in place when the reservoir is drained. Refer to Figure 12-2 for the location of the oil drain plug.

4. Remove the round “clean-out” reservoir cover.

6. The inside of the reservoir should be cleaned with a solvent and then dried with lint free rags.

2. Dump the Tramp Release circuit pressure by slowly opening the manual dump valve located in the front of the HPU and then closing the valve. The HPU should automatically pressurize the circuit pressure by firing solenoids #1 and #2 (as indicated by the LED lights on the DIN connectors being illuminated). To verify the actuation of the solenoids, place something metallic with a handle (screwdriver) on the metal end of each coil (hex nut or manual override) to check if the coil on the valve is being energized. When the coil is energized, a magnetic force should pull the screwdriver toward the coil.

7. Reinstall the strainer then the reservoir cover.

3.

Manually pressurize the Tramp Release circuit pressure as follows: Turn the Local - Remote selector switch to the “Local” position. Turn the Operation - Service selector switch to the “Service” position and then hold the Tramp Pressure - Clamp Pressure selector switch to the “Tramp Pressure” position. Again, verify that solenoids #1 and #2 are being actuated.

4.

Verify that the tramp circuit is getting to the correct system pressure by disconnecting the electrical connection to solenoid #2, repeating step 3 and checking the temporary gauge G1 (pump pressure) located on the tramp circuit manifold assembly. If the system pressure is below 3000 PSI during manual pressurization, adjust the system pressure relief valve located in port 2A of the tramp circuit manifold block assembly by loosening the locknut and turning the screw clockwise to see if the pressure increases. If the pressure increases, adjust the valve until the system pressure is 3000 PSI and reconnect solenoid #2. If no pressure is present at G1, remove the coil on solenoid #1 and unscrew the valve to verify that it does not have any debris in it or it is stuck open. Replace if necessary.

5.

Verify that the Tramp circuit dump valve located in front of the HPU is closed and not partially open or leaking. Since the dump valves for the tramp and clamp circuits are the same, the dump valves can be switched to check.

6.

Check the Tramp circuit relief valve located in port 5A of the tramp circuit manifold block assembly. Make sure solenoid #2 is connected. As you hold the selector switch to

5. Remove the suction strainer from the pump inlet inside the reservoir and check for build-up of contamination. Metal particles found on the strainer are an indication of wear in the system. FLSmidth recommends locating and eliminating the cause of the wear before putting the hydraulic power unit back into service.

8. Fill the reservoir with the hydraulic oil defined in Hydraulic Oil Specifications earlier in this section.

Troubleshooting Procedures Note: Copies of the following drawings should be used with these instructions. Hydraulic Power Unit - Electrical Schematic Hydraulic Power Unit - Hydraulic Schematic Hydraulic Power Unit - Tramp Manifold Assembly Hydraulic Power Unit - Clamp Manifold Assembly Hydraulic Power Unit - Remote Push Button Box Assy. Hydraulic Power Unit - Remote Push Button Box Wiring Recommended Tool List: • Combination Wrenches: 9/16”, 11/16”, 3/4”, 7/8”, 1” • Hex Head Allen Wrenches: 5/32”, 3/16”, 1/4” • 1” Deep Socket Wrench • Midsize Adjustable Wrench • Midsize Screwdriver • Small Electrical Screwdriver • Accumulator Gauging Kit • SAE #8 Male Plug or JIC #12 Cap • SAE #8 Cap or SAE #8 Male Plug • • • • • •

Tramp Release Circuit Check

1. With the Local - Remote selector switch in the Remote position and the Operation - Service selector switch on the Service Switch Box Assembly in the “Operation” position, turn the Tramp Pressure Reset - Clear selector switch to “Tramp Pressure Reset” then release allow The the selector position switch toand return to the centertoposition. HPU should automatically pressurize the Tramp Release circuit if the pressure is below 1600 PSI. (Read pressure from sensor PT2, not gauge G1.)

“Tramp Pressure,” tramp circuit pressure displayed on PT2 (also located on the tramp manifold block assembly) sh ould read approx. 2000 P SI. If not, loosen the relief valve locknut and turn the adjustment screw clockwise to increase the tramp circuit pressure. If the pressure does not increase,

12-13

push in the solenoid #2 override pin in the end of the valve while holding the selector switch on “Tramp Pressure.” If you still can’t increase pressure, remove and check the tramp circuit relief valve (“5A”) for any debris or that it is stuck open. Also check the relief valves located on the Tramp Release Cylinders for improper settings. Replace if necessary. 7.

8.

9.

Check the Tramp Clearing circuit by doing the following: Turn the Operation - Service selector switch to “Operation” and the Local - Remote switch to “Remote.” Hold the Tramp Pressure Reset - Clearselector switch on “Clear.” Pressure on sensor PT2 should quickly fall with solenoid #1 and #3 being energized. If pressure does not fall, verify that solenoids #1 and #3 are being energized by checking the LEDs and by placing a screwdriver on the end of each coil. The screwdriver should be “pulled” toward the coil as you are clearing. If not, there is either an electrical problem or the coil is bad. Replace if necessary. Connect Test Gauge to port G1, if Test Gauge reads 3000 PSI and the Crusher does n ot clear, solenoid #1 works, but solenoid #3 may not. While holding the selector switch on “Clear,” push in the solenoid #3 manual override on the end of the valve. If the pressure falls, replace the solenoid #3 coil. If you can’t push in the override, check for debris inside the valve. Replace if necessary. Check the tramp circuit flow control valve located in port 4A along with the pilot-operated check valve located in auxiliary block for any debris or that they are not damaged. The flow control valve should be turned counterclockwise until it stops. Replace if necessary. The only components remaining are the filter, pump and adjoining hose connections. Check the filter for a red “plugged” indicator on the top although the filter should still bypass and provide circuit pressure. To check the pump and hose connections requires thoroughly cleaning the top of the tank area and removing the Pump/Motor. A visual inspection can be made of the hose connections. To verify that the pump is not bad requires either testing by a local qualified hydraulic shop or by replacing.

Clamping Circuit Check

10. Dump the Clamping circuit pressure by slowly opening the manual valve located on the front of the HPU and then close the valve. The Power Unit should automatically pressurize the circuit pressure when PT1 reads less than 2400 PSI by firing sole noid #4 (as indicated by the LED light on the DIN connector being illuminated). To verify the actuation of solenoid #4,

place something metallic with a handle (screwdriver) on the mounting nut of the coil to check if the valve is being energized. When the coil is energized, a magnetic force should pull the screwdriver toward the coil. 11. Manually repressurize the Clamp circuit pressure as follows: Turn the Local - Remote selector switch to the “Local” position. Turn the Operation - Service selector switch to the “Service” position and then hold the Tramp Pressure - Clamp Pressure selector switch to the “Clamp Pressure” position. Again, verify that solenoid #4 is being actuated. 12. Verify that the Clamp circuit dump valve (“on the front of the HPU”) is closed and not partially open or leaking. Since the dump valves for the tramp and clamp circuits are the same, the dump valves can be switched to check. 13. Check the Clamp circuit relief valve located in port 2-2 of the clamp circuit manifold block assembly. While observing the clamp circuit pressure displayed on PT1 (also located on the clamp manifold block assembly), hold the selector switch on “Clamp Pressure.” Turn the relief valve adjustment clockwise to see if the clamp circuit pressure increases. If the pressure increases, adjust the valve until PT1 reads 3000 PSI. If the pressure does not increase, remove and check the clamp circuit relief valve for any debris or tha t it is not stuck in one position. Replace if necessary. 14. If the clamp circuit loses pressure quickly, check the clamp circuit check valve located in port 2-7 along with solenoid #5 (located in port 2-10) and the manual dump valve (located in on the front of the HPU) for any debris or that they are not damaged. Replace if necessary. Also check that the clamp accumulator has a nitrogen precharge pressure of 1000 PSI. Remove pressure from the clamping circuit before verifying the pressure. 15. Repeat step 9 in the Tramp Circuit for the clamping circuit.

Section 13

Operating Instructions Start-Up Check List ......................................................................................................................................... 13-2 Pre Start-Up Procedures ................................................................................................................................13-9 Countershaft Rotation ................................................................................................................................... 13-9 Hydraulic Power Unit Operation .................................................................................................................. 13-9 Initial Start-Up and Break-In Instructions................................................................................................... 13-9 Daily Start-Up Instructions ............................................................................................................................ 13-9 Checking the Setting .................................................................................................................................... 13-10 Daily Shut-Down Instructions .....................................................................................................................13-10 Normal Operating Recommendations ...................................................................................................... 13-10 Setting the Crusher Figure 13-1 ................................................................................................................. 13-10 Setting the Crusher ....................................................................................................................................... 13-10 Adjustment Ring Movement ....................................................................................................................... 13-10 Determining Liner Wear ............................................................................................................................... 13-11 Grease Fittings Figure 13-3 ......................................................................................................................... 13-11 Number of Driver Ring Teeth and Bowl Travel Information Table 13-3 ............................................. 13-11 Position of Adjustment Cap With Worn Liners Figure 13-2 .................................................................. 13-11 Bowl Thread Engagement With Ad justment Ring Figure 13-4 ............................................................ 13-12 Clearing the Crusher ..................................................................................................................................... 13-12 Difficulty Turning the Bowl ......................................................................................................................... 13-12 Thread Lubrication ........................................................................................................................................ 13-12 Safety Blocking Figure 13-5 ........................................................................................................................13-13 Inspection Periods......................................................................................................................................... 13-13 Lubrication Maintenance Chart Table 13-4 ...............................................................................................13-14 Daily Checks and Maintenance ................................................................................................................... 13-15 Monthly Checks and Maintenance ............................................................................................................. 13-16 Weekly Checks and Maintenance ............................................................................................................... 13-16 Annual Checks and Maintenance ............................................................................................................... 13-17 Liner Change Checks and Maintenance .................................................................................................... 13-17

13-1

Start-Up Check List Controls & Interlocks 1. The interlocks of the lube oil pump motor and Crusher drive motor have been verified. (i.e. The Crusher drive motor will not run without the lube pump motor running.) Suggestion: Test with the drive belts off. 2. The interlocks of thelube oil supply oil pressure and Crusher drive motor have beenverified. Suggestion: Manually relievethe oil pressure to the sensor. It is recommended to use a pressure gauge to confirm the minimum set point pressure during this process. 3. The interlock of thelube oil drain oil temperature and theCrusher drive motor has been verified. Suggestion: Apply moderate heat to the temperature sensor probe to cause a “high drain oil temperature” condition. It is recommended to use a temperature monitorto verify the 60°C (140°F) set point temperature during this process. In cases of sensors, a process meter canbe used to simulate the 4 to 20 mA signal to test the various signals. 4. The interlock betweenthe Feed motor and Discharge belthas been verified. 5. The interlock betweenthe Feed motor and Crusher Drivemotor has been verified. 6. The interlock betweenthe Hydraulic PowerUnit and Feed motor has been verified. 7. The interlock of thelube oil drain oil temperature and theFeed motor has been verified. 8. All Crusher mountedsensors, Hydraulic Power Unitjunction box and Lubrication Packagejunction box wiring complete and tested. 9. FLSmidth or customer supplied controlsystem installed andall functions tested. Notes:

13-2

OK

SEE NOTES

Start-Up Check List Lubrication System

OK

SEE NOTES

1. Document specific brandand type of lubrication oil used (ISO – VG 150) _________________________ 2. Pitch of the drain line is a minimum of 25.4mm (1.00”) vertical change for every 304.8mm (12.00”) horizontal change. If a vertical drop of more than 1219.2mm (48”), a trap is installed. 3. All the Lube Package mounted ballvalves are in thecorrect open or closedpositions. 4. The lube oil pump motor has beenjogged to verify clockwise rotation (as viewedfrom the motor end) and the arrow decal on the motor matches the direction of rotation. 5. The Air Cooler fanmotor has been joggedto verify the following direction ofrotation and air flow: Young OCS Air Coolers rotate counter-clockwise(as viewed from the motor end) and the fan “pushes” air out from the motor side of the cooler through the Air Cooler core. 6. All Crusher oil piping has been adequately flushed.(Filter element mayrequire changing.) 7. Flow of oil on the inspection screen from the Crusher mounted relief valve and (when supplied) and Package Lube mounted relief valve has been checked. NOTE: Bypass flow should reduce to nothing as the drain oil temp increases over 38°C (100°F). 8. Piping from Lube Package to Air Cooler (ifused) to the Crusher has been correctly installed and checked for leaks. 9. Lube tank and all fitting connections have beenchecked for leaks. 10. If supplied, the water control valve (on Water Cooled Lube Systems) has been set to provide 43°C (110°F) supply oil temperature. Notes:

13-3

Start-Up Check List Hydraulic System 1. Prior to starting the Hydraulic Power Unit pump motor, the Crusher mounted Tramp Release Circuit Accumulator has been charged to the appropriate pressure. 2. Hydraulic Power Unitmounted 1-gallon Clamping CircuitAccumulator has beencharged to 6.90 ± 0.34 MPa (1000 ± 50 psi). 3. Document brand name and type of oil (ISO-VG 32) _________________________________________ 4. With both the Tramp Release and Clamping Circuit dumpvalves fully opened,the Hydraulic Power Unit pump motor has been jogged to verify clockwise rotation (as viewed from the motor end) and the arrow decal on the motor has been checked that it matches this direction of rotation. 5. All the Crusher to Hydraulic Power Unit hoses havebeen bled. The hoses may be bled by opening the dump valves, so pressure is not being built up. The Clamp and Brake lines may be cracked at the crusher while the Hydraulic Power Unit is attempting to pressurize the circuits. The Tramp and Clear circuits may be bled by cycling both circuits numerous times. 6. The Tramp Release, Clearing and Clamping circuitshave been fully tested (operation andpressurization) and all the fittings have been checked for leaks. The Tramp Release and Clamping circuit pressures hold without frequent pressurization cycles (i.e. not more than eight times an hour after the system stabilizes from the initial commissioning). 7. The Remote Mounted PushButton Panel hasbeen mounted in a location that allows theoperator to observe operation of the Bowl Adjust Mechanism and clearing of the Crusher. All the panel functions have been tested. 8. The hydraulic BowlAdjust Mechanism andbrake have been tested multiple times. Notes:

13-4

OK

SEE NOTES

Start-Up Check List Mechanical

OK

SEE NOTES

1. Shipping Wedges havebeen removed from between the Mantleand Bowl Liner. 2. Backing has been poured in Liners andis cured. Silastic has been installed inFeed Plate. 3. Mantle and Bowl Liner are not in contact with eachother. Record CSS: _____________ 4. Drive Ring centering bolts arepositioned correctly. Drive Ringhas been fully rotated tocheck. 5. Crusher mounting hardware torque checkedand to specification. Grouting (ifused) is properly cured. 6. Crusher Oil Pipingor Blower Breather iscorrectly installed and mounted ina reasonably dust free area. 7. With the Crusher V-belts removed, Crusher drivemotor has been jogged to verify counter-clockwise Crusher rotation as viewed from the front of the Crusher Sheave. 8. Check alignment of Crusher and Motor Sheaves and V-belt tension. 9. Record motor position relative to Crusher Sheave: ________________________________________ 10. Lock out discharge belt before accessing underside of Crusher. Check the discharge area for free fall of material to prevent build up of material. 11. From the underside of the Crusher, make sure the Arm Guards are properly seated on the Main Frame arms and that there is adequate running clearance between the Stationary Guard and the Counterweight. Notes:

13-5

Start-Up Check List Starting and Running the Crusher 1. The lube oil drain line temperature isabove 16°C (60°F). 2. The Crusher has runfor two hours at no-load and has beenchecked for lube oiland hydraulic oil leaks. Head spin speed is within an acceptable range. 3. The Coast down time is: ________ sec after No Load Run. 4. The Crusher Sheave speed is: _________________________ ((Motor Dia.) / (Crusher Dia.)) x Motor RPM = Crusher RPM 5. The full load amps of the Crusher drive motor nameplate is:_______. 6. The no-load amps of the Crusher drive motor is:_______. 7. The Crusher has been run at 65% of FLA for two hours. 8. The Crusher has been run at 80% of FLA for four hours. 9. The Coast down time is: _________sec after 80%Load Run. 10. The Package Lube mounted relief valve stopped by-passing at _______°C / °F drain line temperature. 11. There is adequate feed distribution and the material is hitting the center of the Feed Plate. Notes:

13-6

OK

SEE NOTES

Start-Up Check List After Eight Hours of Operation

OK

SEE NOTES

OK

SEE NOTES

1. The lube oil drain line temperature is_______°C / °FFan ON / OFF 2. The supply oil temperature is _______°C / °FFan ON / OFF 3. The supply oil pressure is_______MPa / psi 4. The closed-side-setting is _______mm/ inches and the Crusher drive motor power draw is _______kW / horsepower. 5. The drive belts have been re-checked and tensioned if required. Notes:

Portable Plants (when applicable) 1. The plant is level. 2. The cribbing is properly installed. 3. All the lube and hydraulic hoses are adequately supported andprotected from rubbing. 4. All the cabling are adequately supported andprotected from rubbing. 5. All the tires are off the ground. 6. All the guards are properly secured. 7. All the ladders are secure. 8. All the safety chains are in place. 9. The plant has proper clearance betweenthe ground and conveyor. 10. The Customer has received the Portable Plant Manual. Notes:

13-7

Start-Up Check List Customer Information

OK

SEE NOTES

1. The customer has been notified ofany recommended installation changes. Noteall specific recommendations and planned schedule of when changes will be made. 2. Customer has received Crusher InstructionManuals and Parts Manuals. Notes:

________________________________

______________

________________________________

Service Technician

Date

Signature

________________________________ Customer

______________ Date

________________________________ Signature

________________________________ Dealer (If Applicable)

______________ Date

________________________________ Signature

13-8

Pre Start-Up Procedures Following proper start up and inspection habits will provide years of successful operation. Regular start up procedures will help eliminate possible expensive down time while increasing Crusher life. Before starting the C rusher, perform the following:

Initial Start-Up and Break-In Instructions

1. Go through the check list at the start of this section, line by line.

Although the Crusher was run no-load at the factory, FLSmidth recommends a field run in as part of initial startup or after new bearings have been installed. Refer to the Start-up Checklist – Starting and Running the Crusher for step-by-step instructions related to power draw. Drain oil temperature should be closely watched during this time. Refer to Oil Temperature in Section 11.

2. Make sure the correct lube oil is being used. Refer to Section 11, Lubricating System.

Daily Start-Up Instructions

3. Check the end float. The Countershaft should be free to move in and out 0.51mm (0.020”) to 0.64mm (0.025”). Refer to Section 5, Countershaft, Countershaft Box and Sheave Assemblies for adjusting the end float. 4. Bump the lube oil pump and hydraulic power unit motors to make sure that they are rotating in the correct direction. Decals on the top of the motors indicate correct direction of rotation. 5. Check both the lube and hydraulic systems for any leaks. 6. Make sure all fasteners are tight. 7. Bump the Crusher drive motor. If the Mantle is hitting the Crusher the Bowl Liner, refer to the Setting instructions as outlined further on in this section.

8. When all the above items have been checked, proceed with starting the Crusher as outlined in the Initial Start-up and Break-In Instructions located further on in this section.

Countershaft Rotation The Crusher is designed to run Counterclockwise as viewed from the front of the Countershaft. Under no circumstances should the Crusher be rotated any differently.

Hydraulic Power Unit Operation

Following the proper break-in period, FLSmidth recommends the following daily start-up procedures: 1. Turn on the lube system to provide adequate lubrication to the Crusher before starting. The start-up tank temperature must be at least 16°C (60°F). The Control System will energize the tank heater automatically to maintain the temperature. In extremely cold conditions, it may be necessary the constantly run the heater to maintain the required pump start-up oil temperature during long periods of down time. 2. Once the lube system is started, the control system begins a timing sequence of two minutes of oil circulation before the Crusher can be started. Access the inspection cover on the lube tank to verify flow of lube oil. The drain oil pipe should be approximately half full. If there’s only a small stream of oil or no flow at all, do not start the Crusher. Insufficient or no oil flow can be a result of an obstruction in the piping, failed oil pump or relief valve, or incorrect relief valve setting. Operating the Crusher in this situation will cause extreme Crusher bearing failure. 3. Start-up the Crusher and run it empty (no-load) for 5 minutes. 4. Slowly start the feed of material to the Crusher and gradually increase the feed rate. Due to design characteristics, the Crusher should never be continuously operated below 50% drive motor full load amps.

Refer to Section 12, Hydraulic Systems for the hydraulic power unit and its related systems operating instructions.

13-9

Daily Shut-Down Instructions 1. Shut the feed off to the Crusher and allow the Crusher to run empty for 5 minutes. 2. Turn the power off to the Crusher drive motor and monitor the time it takes for the Crusher Sheave to coast to a stop. Coast down time should be 60 to 90 seconds. 3. Under normal operating oil temperatures, allow the lube system to run at least 5 minutes before shutting down. In extremely cold conditions refer to Step 1 in Daily Start-Up Instructions above.

Setting the Crusher Size of the crushed product is controlled by the closed side setting. The closed side setting should be slightly less than the maximum product size required. Setting the Crusher is done by turning the Bowl either clockwise (closed) to reduce the closed side setting or counterclockwise (open) to increase the closed side setting.

Checking the Setting One of the methods available to check the closed side setting is called “slugging” the Crusher. This is accomplished by attaching a piece of lead to wire and lowering it all the way down through the parallel zone of the Crusher with the head not spinning. Refer to Figure 13-1 With the Crusher running empty (no-load), the Head will spin in a clockwise direction. As rock is introduced into the crushing cavity, the Head will stop spinning clockwise and start turning slowly in the counter clockwise direction. To accurately check the closed side setting of the Crusher, there must be no rock in the crushing cavity and the Head cannot be spinning. This is best accomplished by slugging the Crusher during start-up or immediately following the completion of feed through the crushing cavity and before spinning of the Head begins.

1. Bowl Liner 2. Adjustment Ring 3.

Bowl

4. Parallel Zone 5. Mantle 6.

Head

Figure 13-1 Setting the Crusher

draw peaks of 110%. Running at a lower average power draw may be necessary to avoid this condition.

Contact FLSmidth customer service to discuss the method best suited for your installation and personnel.

Under no circumstances should the Crusher ever be continuously operated at or below 50% power. Although far less critical, it is suggested to try and minimize starting and stopping of the feed to maximize production. If the Crusher is going to run without feed for more than 30 minutes, it is better to shut the Crusher down and restart when feed becomes available.

Normal Operating Recommendations

Adjustment Ring Movement

Proper operation of the Crusher is critical in maximizing the life of the Crusher. FLSmidth recommends operating as close to full power as possible without exceeding power

Under no circumstances should the Adjustment Ring be allowed to lift during crushing except to pass tramp material.

13-10

1. 2. 3.

Grease Fitting Adjustment Ring Main Frame

Figure 13-3 Grease Fittings

1. 2. 3. 4. 5. 6. 7.

Adjustment Cap Bowl Position of Adjustment Cap with New Liners Dimension “A” Refer to Parts Manual Adjustment Ring Drive Ring Dust Shell

Figure 13-2 Position of Adjustment Cap With Worn Liners

Lifting of the Adjustment Ring (ring bounce) is caused by exceeding the force limit of the Crusher. One or more of the following conditions can cause ring bounce: running the Crusher with too tight of a closed side setting, incorrect Liner configuration, wet feed, segregation of feed and/or inadequate screening.

Determining Liner Wear The following information is intended to help determine when the Liners have worn to the point of needing to be replaced.

3. After several Liner changes, the difference between new and worn Liners should be relatively consistent using the same Liner configuration and closed side setting. Establishing an average vertical travel of the Bowl will enable the customer to determine when the Liners will need to be changed. NOTE: FLSmidth offers Liner wear analysis. With the worn Liners removed, cut vertical slots in both the Mantle and Bowl Liner. Using a piece of cardboard, outline the profiles of the wear surfaces, identify on

the cardboardengineering the Liner part number andThe send them to FLSmidth department. profiles will be converted into CAD, and a profile analysis will be provided to the customer.

Number of Drive Ring Teeth and Bowl Travel Information Crusher Size

1. With a new set of Liners installed set to the desired closed side setting, measure and record the distance from the bottom of the Adjustment Cap to the bottom of the Dust Shell. This measurement should be taken after the installation and setting of each new set of Liners as Liner will vary somewhat from set to set. Referthicknesses to Figure 13-2 2. Take the same measurement at the end of the life of the Liners (when production drops below 10%).

XL500

Number of Drive Ring Teeth Available In One Complete Revolution of Bowl Vertical Travel of Bowl per Drive Ring Tooth Change in Crusher Setting per Drive Ring Tooth in. (mm)*

243 1.969” (50.0mm) 0.008” (0.206mm)

* Contact FLSmidth Engineering with specific liners (STD/SH) for exact “A” dimension.

Table 13-3

13-11

4. Crushing with the Bowl in the same position for extended periods of time without properly lubricating the threads. Whenever the Bowl has been removed from the Crusher, clean the threads and re-coat them with the proper grease. Also check the condition of the Dust Shell Seal and replace it if necessary. If the Bowl will not move using the hydraulic adjust mo tor,contact FLSmidth customer service to discuss doing the following:

1. With the Crusher running and the Bowl unclamped, feed a small amount of rock into the Crusher. 2. Pour penetrating oil or antifreeze around the threads and through the grease fittings. Let the Crusher sit for a few hours to allow the solution to soak in before attempting to turn the Bowl. 1. Adjustment Ring 2. Bowl

3. Crushing Position 4. Released or Turning Position

Figure 13-4 Bowl Thread Engagement With Adjustment Ring

Thread Lubrication

Note: These processes may need to be repeated a few times to free the Bowl.

Clearing the Crusher If the Crusher stops while crushing (under load), no attempt should be made to restart it with the crushing cavity full of material. Trying to restart the Crusher in this condition will severely damage the machine and drive motor.

It is critical that the threads in the Bowl, Adjustment Ring and Clamping Ring are always well lubricated. Evenly distributed grease fittings are located around the perimeter

This condition can occur for a number of reasons. The most common are:

of the Adjustment Ring to provide proper thread lubrication. Refer to Figure 13-3 The relationship of the Bowl threads to the Adjustment Ring and Clamping Ring threads in both the crushing and adjusting positions is illustrated. Refer to Figure 13-4 FLSmidth recommends using lithium based grease like NLGI No. 1 or 2 containing 5-10% molybdenum disulfide by weight. If a high temperature material is being crushed, use high temperature grease with the same 5-10% molybdenum disulfide by weight.

1. The Crusher drive motor stops as a result of a power outage.

Difficulty Turning the Bowl

1. Go to the hydraulic power unit remote push button panel and turn the selector switch labeled Local / Remote to the Local position and turn and hold the Tramp Pressure Reset / Clearselector switch in the Clear position. This will depressurize the tramp release cylinders and pressurize the clearing circuit which will raise the Adjustment Ring and Bowl Assemblies.

Difficulty in turning the Bowl is often the result of galled or damaged threads. Thread galling or damage is usually the result of one or more of the following: 1. Using grease not recommended by FLSmidth. 2. Lack of or improper thread lubrication. 3. A damaged or worn Dust Shell, which allows dust and other contaminants to get into the grease.

13-12

2. The discharge conveyor stops, causing discharge material to backup under the Crusher. 3. Tramp iron becoming stuck in the crushing cavity. To clear the crushing cavity, do the following:

Usually with the Bowl and Adjustment Ring raised and the crushing cavity enlarged, any material in the Crusher will slide out. If the cavity does not clear in Step 1, proceed to Step 5.

2. If the cavity completely clears in Step 1, release the Tramp Pressure Reset / Clear selector switch. The Adjustment Ring and Bowl will lower back onto the frame. 3. Momentarily turn the Tramp Pressure Reset / Clear selector switch to Tramp Pressure Reset position. This will signal the control system to pressurize the tramp release circuit. 4. Turn the Local / Remote selector switch to the Remote position and resume normal operation.

5. Itcavity is possible some the material in the crushing is toothat large to of slide out of the Crusher. If this happens, raise the Adjustment Ring and Bowl as defined in Step 1. With the raised assemblies (holding the Tramp Pressure Reset / Clear selector switch in the Clear position), place safety blocks between the Adjustment Ring and Main Frame at the Main Frame Pin locations. Refer to Figure 13-5 6. Release the Tramp Pressure Reset / Clear selector switch. This will allow the Adjustment Ring and Bowl Assemblies to lower onto the safety blocks. A. Perform shutdown and lockout of the power unit. 7. With the Adjustment Ring and Bowl Assemblies resting securely on the safety blocks, remove any material that was too large to pass through the cavity. 8. With all the material removedfrom the crushing cavity, follow the instructions in Step 1. This will raise the Adjustment Ring and Bowl to the maximum height and allow the safety blocks to be removed. After removing the safety blocks, release theTramp Pressure Reset / Clear selector switch to allow the Adjustment Ring and Bowl to lower back onto the Main Frame.

1. Bowl 2. Adjustment Ring 3. Safety Block (Do not set block on Main Frame Bushing) 4. Main Frame 5. Main Frame Bushing

Figure 13-5 Safety Blocking

Inspection Periods To keep the Crusher in a good operating condition, FLSmidth recommends scheduling daily, weekly, monthly and yearly inspections with a written log of what was done and found. Repairs can be made in advance to avoid major breakdowns.

9. Visually verify that the Adjustment Ring and Bowl have properly seated back onto the Main Frame. If they have not, re-clear and lower. Never pressurize the tramp release cylinders if the Adjustment Ring is not sitting level on the Main Frame. This will damage the tramp release cylinders. 10. With the Adjustment Ring and Bowl Assemblies properly seated on the Main Frame, pressurize the tramp release cylinders as instructed in Step 3 and resume operation per Step 4.

13-13

Lubrication Maintenance Chart Location

Lubrication

Oil

Interval

Method

Crusher Circulating Oil

Change every ISO 150 (630-770 SUS @ 100° F) 2000 hours (With E.P. Additives) (if required)

Circulation

Hydraulic Power Unit (not 2 shown), Tramp Release Cylinders, Clamping Cylinders

Oil: Change every ISO 32 (135-165 SUS @ 100° F) 2000 Hours (if required)

Circulation

1

Bowl and Head Surfaces Only 3 Do Not Oil Mantle or Bowl Liner (contacting the epoxy backing) Bowl, Clamping Ring and 4 Adjustment Ring Threads (unclamp bowl before greasing)

Oil: ISO 150 (630-770 SUS @ 100° F) Grease: Lithium Base NLGI No. 1 with 3% Molybdenum Disulfide (by weight)

Every liner change

Manual, brush

40 hours: Grease fittings every liner Manual, brush change

Grease: 5

Locking Bolt Threads

6

Frame Main and Adjustment Ring Seating Surface

7

Countershaft Box

8

Electric Bowl Adjust

Every liner Lithium Base NLGI No. 1 with 3% Molybdenum Disulfide (by weight)

change

Manual, brush

Grease: Lithium Base NLGI No. 1 with 3% Molybdenum Disulfide (by weight)

2000 hours

Manual, brush

During

Manual, brush

Change every 1000 hours

Pour

1000 hours

Pour

Grease Assembly

Wear Strip

Oil: 220 EP Gear Oil (if required) Oil:

9

Hydraulic Drive Assembly

Change every EP80W90 Gear Oil (if required) Table 13-4

13-14

Daily Checks and Maintenance Check 1 2

Check lube oil tank level Check lube oil pressure at the Crusher

20-40 PSI (1.4-2.8 Bars)

3 Check oil drain temperature at the Lube Tank

100°F to 130°F (38°C to 54°C)

4

Check cavity level and power draw

5

Check closed side setting

6

Check oil piping for leaks

7

Check tramp release circuit pressure

8 9

Normal Condition

Check clamping circuit accumulator pre-charge pressure

Check clamping circuit pressure 10

Check feed distribution in crushing cavity

11

Check the Crushers discharge area to make sure it’s clear and the discharge conveyer is running properly

12

Check the Main Frame arms for buildup of material

13

Check the Counterweight Guard for wear

14

Check Crusher coast down time

15

Check for any loose fasteners

16

Check for any unusual noises

17

Check for cracked, loose or worn Liners

18

Determine remaining Liner life

19

Check the Adjustment Ring for movement

20

Check oil tank strainer basket under the inspection coverin the lube tank for debris and drain line oil flow

21 Check Tramp Release circuit Accumulator pre-charge pressure 22

1800 PSI 1000 PSI 2800 PSI

60 to 90 seconds

1500 PSI

Check Sheaves (Crusher and Motor) for build-up of material

13-15

Weekly Checks and Maintenance

1

Check the condition of the Countershaft Box breather / Blower filter

2

Check the condition of the lube and hydraulic power unit tank breathers

3

Check for wear and tightness of Feed Plate, Bowl Liner and Mantle

4

Normal Condition

Check

Normal Condition

Make sure the Adjustment Ringthreads are lubricated (with the Bowl clamped and unclamped) using the recommended grease

5

Check the V-belts for tightness and alignment

6

Check the Crusher and Motor Sheaves for cracks and tightness of the bushings

7

Check

Check the Main Frame Liners, Arm Guards, Counterweight Guard, Stationary Guard and bottom of Head for wear

Monthly Checks and Maintenance

1

Check the engagement of the adjust motor pinion teeth with the Drive Ring teeth

2

Check and lubricate the adjust motor per the manufacturer’s specifications

3 4

Have the lube and hydraulic oils analyzed and change if required

Check the Countershaft end float 5

If the closed side setting has not changed more than one inch, turn the Bowl in and out a few times

13-16

See Oil Contamination Chart in Section 11 0.51mm (0.020”) – 0.64mm (0.025”)

Annual Checks and Maintenance

1

Completely disassemble the Crusher. Inspect all bearing surfaces along with Gear and Pinion contact for wear

2

Check the Main Frame, Head and Bowl for signs of fatigue cracking

3

Check all piping and fasteners for tightness

4

Check fit of the Main Shaft in the Main Frame bore

Check

Normal Condition

Check

Normal Condition

Liner Change Checks and Maintenance

1

Check and re-condition the Bowl Liner and Mantle seating surfaces on the Bowl and Head if necessary

2

Check the Head Bushings, Head Ball, Socket Liner, Eccentric, Eccentric Bushing, and Dust Shell for wear

3

Check the Head Locking Nut and Feed Plate for wear. Replace if required

4

Check the Main Frame Liners, Arm Guards, Countershaft Box Guard and Counterweight Guard for wear and re-condition or replace if necessary

5

Check for thread galling and wear on the Bowl, Adjustment Ring and Clamping Ring and recondition if necessary

13-17

MECHANICAL WARRANTY

Solely for the benefit of the ORIGINAL USER, SELLER warrants that new equipment and parts manufactured by it and provided to the ORIGINAL USER (collectively, “Products”) shall be free from defects in material and workmanship. The warranty period shall be twelve months from startup of the equipment, not to exceed eighteen months from shipment. If any of SELLER’S Products fail to comply with the foregoing warranty, SELLER shall repair or replace free of charge to ORIGINAL USER, EX WORKS SELLER’S FACTORIES or other location that SELLER designates, any Product or parts thereof returned to SELLER, which examination shall show to have failed under normal use and service operation by the ORIGINAL USER within the Warranty Period; provided, that if it would be impracticable for the Product or part thereof to be returned to SELLER, SELLER will send a representative to the ORIGINAL USER’S job site to inspect the Product. If it is determined after inspection that SELLER is liable under this warranty to repair or replace the Product or part thereof, SELLER shall bear the cost of returning the Product to SELLER for inspection or sending its representative to the job site; however, if it is determined after inspection that SELLER is not liable under this warranty, the ORIGINAL USER shall pay those costs. For SELLER to be liable with respect to this warranty, the ORIGINAL USER must make its claims to SELLER with respect to this warranty in writing no later than thirty (30) days after the date the ORIGINAL USER discovers the basis for its warranty claim and in no event more than 30 days after the expiration of the Warranty Period. In addition to any other limitation or disclaimer with respect to this warranty, SELLER shall have no liability with respect to any of the following: i. failure of the Products, or damages to them, due to ORIGINAL USER’s negligence or willful misconduct, abuse or improper storage, installation, application or maintenance (as specified in any manuals or written instructions that SELLER provides to the purchaser); ii. any Products that have been altered or repaired in any way without SELLER’S prior written authorization; iii. The costs of dismantling and reinstallation of the Products; iv. any Products damaged while in transit or otherwise by accident; v. decomposition of Products by chemical action, erosion or corrosion or wear to Products or due to conditions of temperature, moisture and dirt; or vi.

claims with respect to partsbelts that and are consumable andwhere normally during maintenance filter media, filter drainage the like, except suchreplaced parts are not performing to such as SELLER’S estimate of normal service life, in which case, SELLER shall only be liable for the pro rata cost of replacement of those parts based on SELLER’S estimate of what the remaining service life of those parts should have been; provided, that failure of those parts did not result from any of the matters listed in clauses (i) through (v) above.

With regard to third-party parts, equipment, accessories or components not of SELLER’S design, SELLER’S liability shall be limited solely to the assignment of available third-party warranties.

THE PARTIES AGREE THAT ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE AND MERCHANTABILITY, WHETHER WRITTEN, ORAL OR STATUTORY, ARE EXCLUDED TO THE FULLEST EXTENT PERMISSIBLE BY LAW. ALL WARRANTIES AND OBLIGATIONS OF SELLER SHALL TERMINATE IF BUYER FAILS TO PERFORM ITS OBLIGATIONS UNDER THIS AGREEMENT OR FAILS TO PAY ANY CHARGES DUE SELLER. SELLER’S quoted price for the Products is based upon this warranty. Any increase in warranty obligation may be subject to an increase in price. SELLER shall not be liable for any indirect, special, punitive, exemplary or consequential damages, including damages for lost production, plant shut-down, service interruptions, increased expense of operation, increased costs of power supply, loss of use of capital, lost revenue, lost product, lost profit or lost business opportunities, from any cause whatsoever, including the negligence of any person or entity.

QFORM 0115-02032 Rev E

Rev. April 2008

Index Accumulator Depressurization Figure 4-18 ............ ............ ............ ............. ............ ............ ............. ......... 4-18 Accumulator Mounting Figure 4-19 ............ ............. ............ ............ ............. ............ ............ ............. ......... 4-19 Accumulator Valve Figure 12-5..................................................................................................................... 12-5 Adjusting the Gear Backlash for Wear ............ ............. ............ ............ ............. ............ ............ ............. ......... 6-9 Adjustment Mechanism Installation ............................................................................................................ 10-2 Adjustment Ring Assembly Removal ........................................................................................................... 4-14 Adjustment Ring Movement ....................................................................................................................... 13-11 Adjustment Ring Placement Figure 4-15 ............ ............ ............ ............. ............ ............ ............. ............ . 4-15 Air Cooled ......................................................................................................................................................... 11-5 Air Cooler ............ ............. ............ ............ ............ ............. ............ ............ ............. ............ ............ ............. ..... 11-8 Air Cooler System ............................................................................................................................................ 11-5 Air Oil Cooler Figure 11-3 ........... ............ ............ ............. ............ ............ ............. ............ ............ ............. ..... 11-4 Annual Checks and Maintenance ................................................................................................................ 13-17 Assembling the Gear and Counterweight ............ ............ ............ ............. ............ ............ ............. ............ . 6-10 Backlash and Root Clearance Figure 6-4 ............. ............ ............ ............. ............ ............ ............. ............ ... 6-3 Belt Types Figure 3-1 ............ ............ ............ ............. ............ ............ ............. ............ ............ ............. ............ . 3-3 Bleeding and Pressure Testing the Tramp Release and Clamping Systems ....................................... 12-10 Bleeding the Clamping System ................................................................................................................... 12-11 Bleeding the Tramp Release System .......................................................................................................... 12-10 Bolt Torque Table 3-2 ............ ............ ............ ............. ............ ............ ............. ............ ............ ............. ............ . 3-5 Bowl Bowl Bowl Bowl Bowl Bowl

Adapter Ring Figure 9-8........... ............ ............. ............ ............ ............. ............ ............ ............. ........... 9-7 Assembly Installation .............................................................................................................................. 9-2 Liner Installation ...................................................................................................................................... 9-5 Liner Removal ........................................................................................................................................... 9-4 Removal ..................................................................................................................................................... 9-3 Thread Engagement With Adjustment Ring Figure 13-4 ............ ............ ............ ............. ........... 13-12

Bowl Wedge and Liner Parts Figure 9-3............. ............ ............ ............. ............ ............ ............. ............ ..... 9-3 Bowl, Bowl Liner & Hopper Figure 9-1 ............. ............ ............ ............. ............ ............ ............ ............. ....... 9-2 Bowl, Bowl Liner Seating Surface ................................................................................................................... 9-7 Bushing Lock Removal Figure 6-10 ............ ............. ............ ............ ............. ............ ............ ............. ............ . 6-6 Bushing Removal Plate Figure 5-10 ........... ............. ............ ............ ............. ............ ............ ............. ............ . 5-9 Capscrew Torque and Gear Heating Table 6-2 ............ ............ ............. ............ ............ ............ ............. ..... 6-11 Changing Bowl Hopper Height Figure 9-9 ............ ............ ............ ............. ............ ............ ............. ............ . 9-7 Changing the Bowl Adaptor Ring ................................................................................................................... 9-7 Changing the Oil Filter .................................................................................................................................. 12-12 Charging and Gauging Assembly Figure 12-6 ........... ............ ............ ............. ............ ............ ............. ....... 12-6 Check List for Starting New Crusher (Part 1) ............................................................................................. 13-6 Check List for Starting New Crusher (Part 2) ............................................................................................. 13-8 Checking Backlash and Contact Between the Gear and Pinion ................................................................ 6-3 Checking Bowl Liner Seating Surface Figure 9-7 ........... ............ ............. ............ ............ ............. ............ ... 9-6 Checking for Thread Wear Figure 4-21............... ............ ............ ............. ............ ............ ............. ............ ... 4-20 Checking Socket Contact Figure 7-3 ........... ............. ............ ............ ............. ............ ............ ............. ........... 7-3 Checking the Setting .................................................................................................................................... 13-10 Clamp Cylinder Travel Figure 4-20 ........... ............. ............ ............ ............. ............ ............ ............. ............ . 4-20 Clamp Ring Spacers and Capscrews Figure 4-16............ ............ ............. ............ ............ ............. ............ . 4-16 Clamping Circuit System ................................................................................................................................ 12-7

Index Cleaning the Hydraulic System ................................................................................................................... 12-12 Clearing the Crusher ..................................................................................................................................... 13-12 Cold Weather Oil Specifications .................................................................................................................... 12-5 Contact Patter Corrections Figure 6-6 ............ ............ ............. ............ ............ ............. ............ ............ ....... 6-4 Countershaft and Backlash Tool Figure 6-3 ............ ............. ............ ............ ............. ............ ............ ........... 6-3 Countershaft Box Assembly Figure 5-1 ........... ............ ............. ............ ............ ............. ............ ............ ....... 5-2 Countershaft Assembly Installation (Method-A) Figure 5-3 ........... ............ ............. ............ ............ ......... 5-3 Countershaft Box Assembly Removal ............................................................................................................ 5-4 Countershaft Box Installation ......................................................................................................................... 5-2 Countershaft Box Removal Figure 5-6 ........... ............ ............. ............ ............ ............. ............ ............ ......... 5-5 Countershaft Box Temperature Sensor Installation ................................................................................... 5-4 Countershaft Bushing Figure 5-13 ........... ............ ............. ............ ............ ............. ............ ............ ............. 5-10 Countershaft Bushing Removal by Jacking Figure 5-12 ............ ............ ............. ............ ............ ............. 5-10 Countershaft Bushing Installation ................................................................................................................. 5-9 Countershaft Bushing Removal ...................................................................................................................... 5-8 Countershaft End Float Figure 5-2 ........... ............ ............. ............ ............ ............. ............ ............ ............. .. 5-3 Countershaft Installation ................................................................................................................................. 5-7 Countershaft Removal ...................................................................................................................................... 5-6 Countershaft Rotation .................................................................................................................................... 13-9 Counterweight Assembly Figure 6-1 ........... ............ ............. ............ ............ ............. ............ ............ ........... 6-2 Crusher Air Breather ....................................................................................................................................... 11-6 Crusher Air Breather Figure 11-5 ............ ............ ............ ............. ............ ............ ............. ............ ............ ... 11-6 Crusher and Subassembly Weights ................................................................................................................ 3-3 Crusher Clearance Dimensions ................. ............ ............. ............ ............ ............. ............ ............ ............. .. 3-2 Crusher Grouting Figure 4-2 ............ ............ ............ ............. ............ ............ ............. ............ ............ ............. 4-4 Crusher Installation on a Concrete Foundation .......................................................................................... 4-4 Crusher Installation on a Steel Structure ...................................................................................................... 4-5 Crusher Motor .................................................................................................................................................... 3-4 Crusher Operating Oil Temperature ............................................................................................................. 11-4 Crusher Sheave Assembly Figure 5-7 ........... ............ ............. ............ ............ ............. ............ ............ ........... 5-6 Crusher Sheave Installation ............................................................................................................................. 5-6 Crusher Sheave Removal .................................................................................................................................. 5-5 Crusher to Power Unit Hose Connections ................................................................................................. 12-2 Cutting the Torch Ring Figure 8-4 ............ ............ ............. ............ ............ ............. ............ ............ ............. .. 8-3 Daily Checks and Maintenance .................................................................................................................... 13-15 Daily Shut-Down Instructions............. ............ ............ ............. ............ ............ ............. ............ ............ ....... 13-10 Daily Start-Up Instructions ............................................................................................................................. 13-9 Description of Lights and Switches on the Local Control Panel ........... ............. ............ ............ ............. 12-8 Description of Operating the Hydraulic Power U nit from the Local Control Panel ........... ............ ..... 12-9 Determining Adjustment and Clamping Ring Thread Wear .................................................................... 4-20 Determining Adjustment Ring Wear ............................................................................................................ 4-13 Determining Bowl Thread Wear ...................................................................................................................... 9-7 Determining Liner Wear................................................................................................................................ 13-11 Determining Main Frame Seat Liner Wear................................................................................................... 4-12 Determining Seat Liner Wear Figure 4-12.............. ............ ............ ............. ............ ............ ............. ........... 4-13 Difficulty Turning the Bowl .......................................................................................................................... 13-12

Index Discharge Arrangement ................................................................................................................................... 3-3 Drain Oil Temperature ..................................................................................................................................... 11-4 Drive Assembly ................................................................................................................................................. 10-3 Drive Motor Positioned Below Motor Sheave Figure 5-16 ........... ............. ............ ............ ............. ......... 5-11 Drive Ring Support Figure 10-2 ............ ............. ............ ............ ............. ............ ............ ............ ............. ..... 10-4 Drive Ring Support System ............................................................................................................................ 10-3 Eccentric Assembly Installation ...................................................................................................................... 6-2 Eccentric Assembly Removal ........................................................................................................................... 6-5 Eccentric Bore Inspection ................................................................................................................................ 6-8 Eccentric Bushing .............................................................................................................................................. 6-7 Eccentric Bushing Alignment Figure 6-12............. ............ ............ ............. ............ ............ ............. ............ . 6-8 Eccentric Bushing Alignment Figure 6-13............. ............ ............ ............. ............ ............ ............. ............ . 6-8 Eccentric Bushing Installation......................................................................................................................... 6-9 Eccentric Bushing Removal Figure 6-11 ............ ............ ............ ............. ............ ............ ............. ............ ..... 6-7 Electric Adjustment Mechanism Assembly Figure 10-1A ........... ............. ............ ............ ............. ........... 10-2 Epoxy Grouting Requirements Table 4-1 ............. ............ ............ ............. ............ ............ ............. ............ ... 4-5 Feed Arrangement ............................................................................................................................................ 3-3 Forcing Countershaft Box into Main Frame Figure 5-4............ ............. ............ ............ ............. ............ ... 5-4 Foundation ......................................................................................................................................................... 3-2 Gear Mounting Holes Figure 6-15 ............ ............. ............ ............ ............. ............ ............ ............. ............ . 6-11 Gear Replacement ............................................................................................................................................. 6-9 General Assembly & Disassembly Information ............................................................................................. 3-5 Grease Fittings Figure 13-3 ........... ............ ............. ............ ............ ............. ............ ............ ............. ........... 13-11 Groove Depth Table 6-3............ ............ ............ ............. ............ ............ ............. ............ ............ ............. ......... 6-5 Handling the Head ............................................................................................................................................. 8-7 Handling the Head Figure 8-12 A-E ............ ............. ............ ............ ............. ............ ............ ............. ............ . 8-7 Head Head Head Head

Assembly Installation ............................................................................................................................ 8-11 Ball Replacement ..................................................................................................................................... 8-6 Bushing Installation Figure 8-15 ............. ............ ............ ............. ............ ............ ............ ............. ....... 8-9 Mantle and Feed Plate Assembly Figure 8-1........... ............ ............. ............ ............ ............. ............ . 8-2

Head Removal ..................................................................................................................................................... 8-2 Helix High Point Location Figure 9-5 ........... ............. ............ ............ ............. ............ ............ ............. ........... 9-5 Holding the Countershaft Figure 5-8 ............ ............. ............ ............ ............. ............ ............ ............. ......... 5-7 Hydraulic Adjust Drive Hose Connections Figure 12-4A ........... ............. ............ ............ ............. ............ . 12-4 Hydraulic Adjust Drive Oil Specifications ..................................................................................................... 10-3 Hydraulic Adjustment Mechanism Assembly Figure 10-1B ............ ............. ............ ............ ............. ....... 10-3 Hydraulic Hydraulic Hydraulic Hydraulic Hydraulic Hydraulic

Oil Changing.................................................................................................................................. 12-12 Oil Specifications ............................................................................................................................ 12-4 Power Figure 12-2......................................................................................................................... 12-3 Power Unit Controls............ ............ ............. ............ ............ ............. ............ ............ ............. ....... 12-7 Power Unit Hose Connections Figure 12-3 ........... ............. ............ ............ ............ ............. ..... 12-3 Power Unit Installation ................................................................................................................. 12-2

Hydraulic Hydraulic Hydraulic Hydraulic

Power Unit Operation ................................................................................................................... 13-9 Power Unit Operations and Control Logic ................................................................................ 12-7 Power Unit Start-up and Operation ........................................................................................... 12-9 System Information ........................................................................................................................ 3-4

Index Hydraulic System Pre-Start Tramp Release System .................................................................................. 12-5 Initial Start-Up and Break-In Instructions........... ............ ............. ............ ............ ............. ............ ............ ... 13-9 “Inner” Countershaft Bushing Oil Groove Location Figure 5-14 ............ ............. ............ ............ ........... 5-11 Inspection Periods......................................................................................................................................... 13-14 Installation of Bowl Liner Figure 9-6 ............ ............ ............. ............ ............ ............. ............ ............ ........... 9-5 Installing and Removing Head Assembly Figure 8-2 ............ ............ ............ ............. ............ ............ ......... 8-3 Installing Head Ball Figure 8-11 ............. ............ ............ ............. ............ ............ ............. ............ ............ ....... 8-6 Installing the Adjustment Ring Assembly ................................................................................................... 4-16 Installing the Clamping Ring ......................................................................................................................... 4-19 Installing the Main Frame Seat Liner and Fulcrum Bar ............................................................................. 4-14 Installing the Mantle Figure 8-9 ............ ............ ............ ............. ............ ............ ............. ............ ............ ....... 8-5 Installing the Tramp Release Cylinder ........... ............ ............. ............ ............ ............. ............ ............ ......... 4-17 Lifting Counterweight and Eccentric Figure 6-14 ............ ............ ............ ............. ............ ............ ........... 6-10 Lifting Eccentric Assembly Figure 6-2............ ............ ............. ............ ............ ............. ............ ............ ......... 6-3 Lifting Lug Figure 8-7 ........... ............. ............ ............ ............. ............ ............ ............. ............ ............ ............. 8-5 Lifting of the Crusher Figure 4-3 ............ ............ ............ ............. ............ ............ ............. ............ ............ ..... 4-5 Lifting the Bowl Figure 9-2............. ............ ............ ............. ............ ............ ............. ............ ............ ............. .. 9-3 Liner Change Checks and Maintenance ..................................................................................................... 13-17 Locking Bolt Wrench Figure 8-5 ............ ............ ............ ............. ............ ............ ............. ............ ............ ....... 8-4 Low Oil Level ..................................................................................................................................................... 11-9 Lower Head Bore Inspection ........................................................................................................................... 8-8 Lower Head Bushing Installation .................................................................................................................... 8-8 Lower Support Bracket Figure 10-3............ ............ ............. ............ ............ ............. ............ ............ ........... 10-4 Lower Thrust Bearing and Shims Figure 4-7........... ............. ............ ............ ............. ............ ............ ........... 4-8 Lube System Placement and Installation .................................................................................................... 11-5 Lubricating Oil Specifications ........................................................................................................................ 11-3 Lubrication Maintenance Chart Table 13-4 ................................................................................................ 13-14 Lubrication System (Air Cooled) Figure 11-2 ............ ............. ............ ............ ............. ............ ............ ....... 11-3 Lubrication System (Water Cooled) Figure 11-1 ........... ............. ............ ............ ............. ............ ............ ... 11-2 Main Frame Arm Guard Figure 4-5 ............ ............ ............. ............ ............ ............. ............ ............ ............. .. 4-7 Main Main Main Main Main Main

Frame Assembly Figure 4-1 ............ ............ ............ ............. ............ ............ ............. ............ ............ ..... 4-3 Frame Flange Spacers Figure 4-4 ............ ............ ............. ............ ............ ............. ............ ............ ....... 4-6 Frame Liner Figure 4-6 ............ ............ ............ ............. ............ ............ ............. ............ ............ ............. 4-7 Frame Liners and Arm Guards........... ............ ............. ............ ............ ............. ............ ............ ............. .. 4-6 Frame Pin Bushing Replacement XL300 ............................................................................................. 4-10 Frame Pin Bushing Replacement XL400 ............................................................................................. 4-11

Main Main Main Main Main Main

Frame Pin Replacement XL300............ ............ ............. ............ ............ ............. ............ ............ ............. 4-8 Frame Pin Replacement XL400............ ............ ............. ............ ............ ............. ............ ............ ........... 4-10 Frame Pin XL300 Figure 4-9a .................................................................................................................. 4-9 Frame Pin XL400 Figure 4-9b ................................................................................................................ 4-10 Frame Ring Figure 4-10 ............. ............ ............ ............. ............ ............ ............. ............ ............ ......... 4-11 Frame Seat Liner and Fulcrum Bar........... ............ ............. ............ ............ ............. ............ ............ ..... 4-12

Main Frame Seat Liner and Fulcrum Bar Figure 4-13 ............. ............ ............ ............. ............ ............ ..... 4-14 Main Frame Seat Liner and Fulcrum Bar Frame 4-11............ ............ ............ ............. ............ ............ ....... 4-12 Main Shaft Inspection ....................................................................................................................................... 6-8 Mantle Lifting Figure 8-6 ........... ............. ............ ............ ............. ............ ............ ............. ............ ............ ....... 8-4

Index Mantle Replacement ......................................................................................................................................... 8-3 Mantle Replacement Figure 8-3 ........... ............ ............. ............ ............ ............. ............ ............ ............. ....... 8-3 Maximum Vertical Seat Liner Wear Table 4-2............. ............ ............ ............. ............ ............ ............. ....... 4-13 Measuring Socket Liner Oil Groove Depth Figure 7-4 ........... ............. ............ ............ ............ ............. ....... 7-3 Monthly Checks and Maintenance ............ ............. ............ ............ ............. ............ ............ ............. ........... 13-16 Normal Operating Recommendations........... ............. ............ ............ ............. ............ ............ ............. ..... 13-10 Number of Driver Ring Teeth and Bowl Travel Information Table 13-3........... ............ ............. ........... 13-11 Oil Contamination ............................................................................................................................................ 11-7 Oil Contamination Guidelines Table 11-1 ............. ............ ............ ............. ............ ............ ............. ............ . 11-7 Oil Coolers ......................................................................................................................................................... 11-7 Oil Filtration ..................................................................................................................................................... 11-7 Oil Heater ............ ............. ............ ............ ............ ............. ............ ............ ............. ............ ............ ............. ..... 11-9 Oil Leakage Out of the Drive End of the Countershaft ............................................................................. 5-11 Oil Pressure Sensor.......................................................................................................................................... 11-9 Oil Supply Regulation ...................................................................................................................................... 11-5 Oil Tank Breather .............................................................................................................................................. 11-6 Oil to Water Cooling ........................................................................................................................................ 11-5 Operating in Service Mode ............................................................................................................................. 12-9 Optimal Contact Pattern Figure 6-5 ............ ............. ............ ............ ............. ............ ............ ............. ........... 6-4 “Outer” Countershaft Bushing Oil Groove Positions Figure 5-15 ............ ............ ............ ............. ......... 5-11 Pinion Location Figure 5-9 ............ ............ ............. ............ ............ ............. ............ ............ ............. ............ ... 5-8 Pinion Replacement .......................................................................................................................................... 5-8 Piping Information ............................................................................................................................................ 3-4 Piping Information .......................................................................................................................................... 11-6 Position of Adjustment Cap With Worn Liners Figure 13-2............ ............. ............ ............ ............. ..... 13-11 Positioning Bowl Adjust Pinion Figure 10-4 ............. ............ ............ ............. ............ ............ ............. ....... 10-4 Power Unit Oil Filter Figure 12-9 ............ ............. ............ ............ ............. ............ ............ ............. ............ . 12-12 Power Unit Pressure Table 12-1 ........... ............ ............. ............ ............ ............. ............ ............ ............. ... 12-10 Power Unit Service Switches Figure 12-8 ............ ............ ............ ............. ............ ............ ............. ........... 12-10 Pre Start-Up Procedures ................................................................................................................................ 13-6 Release and Clearing System Hose Connections Figure 12-4............. ............ ............ ............. ............ ... 12-4 Remote Mounted Push Button Control Panel Installation ..................................................................... 12-4 Remote Push Button Panel Figure 12-7 ............ ............ ............ ............. ............ ............ ............. ............ ... 12-7 Removal of the Gear and Counterweight ..................................................................................................... 6-9 Removing Head Ball Figure 8-10 ............ ............. ............ ............ ............. ............ ............ ............. ............ ..... 8-6 Removing the Clamping Ring ............ ............ ............. ............ ............ ............. ............ ............ ............. ......... 4-19 Removing the Countershaft Bushing by Ramming Figure 5-11 ............ ............ ............ ............. ............ . 5-9 Removing the Eccentric Bushing ................................................................................................................... 6-7 Removing the Tramp Release Cylinder ........................................................................................................ 4-16 Replacing the “T” Seal Figure 8-16 ........... ............. ............ ............ ............. ............ ............ ............. ............ . 8-11 Replacing the Accumulator ........................................................................................................................... 4-18 Replacing the Counterweight Guard ............................................................................................................. 6-5 Replacing the Lower Head Bushing ............................................................................................................... 8-7 Replacing the Lower Thrust Bearing and Shims .......................................................................................... 4-7 Replacing the Main Frame Ring .................................................................................................................... 4-11 Replacing the Main Shaft............ ............ ............ ............. ............ ............ ............. ............ ............ ............. ....... 4-6

Index Replacing the Upper Head Bushing ............................................................................................................... 8-9 Reservoir Oil Temperature ............................................................................................................................. 11-4 Safety Blocking Figure 13-5............ ............. ............ ............ ............. ............ ............ ............. ............ .......... 13-13 Sawing Bushing Flange Figure 8-13 ............ ............ ............ ............. ............ ............ ............. ............ ............ 8-8 Sawing Head Bushing Wall Figure 8-14 ............. ............ ............ ............. ............ ............ ............. ............ ...... 8-8 Seating the Mantle Figure 8-8 ........... ............. ............ ............ ............. ............ ............ ............. ............ .......... 8-5 Setting the Crusher ....................................................................................................................................... 13-10 Setting the Crusher Figure 13-1............ ............. ............ ............ ............. ............ ............ ............. ............ .. 13-10 Shim Thickness vs. Backlash Table 6-1 ............. ............ ............ ............. ............ ............ ............. ............ ........ 6-4 Skid Mounted Lube System............................................................................................................................ 11-5 Socket and Socket Liner Installation .............................................................................................................. 7-2 Socket Assembly Figure 7-1 ........... ............. ............ ............ ............. ............ ............ ............. ............ ............ .. 7-2 Socket Installation Figure 7-2 ............ ............. ............ ............ ............. ............ ............ ............. ............ .......... 7-2 Socket Installation Heating Temperature and Socket Capscrew Torque Requirements Table 7-1.... 7-2 Socket Liner Removal Figure 7-6........... ............. ............ ............ ............. ............ ............ ............. ............ ...... 7-4 Socket Liner Installation Figure 7-5 ............. ............ ............ ............. ............ ............ ............. ............ ............ 7-4 Socket Liner Removal and Replacement ....................................................................................................... 7-3 Socket Removal .................................................................................................................................................. 7-4 Socket Removal Figure 7-7.............................................................................................................................. 7-5 Special Tools Furnished with the Raptor Crusher Figure 3-2 ............ ............ ............ ............. ............ ...... 3-6 Supply Oil Temperature .................................................................................................................................. 11-4 “T” and “U” Seal Replacement Figure 6-9 ........... ............ ............ ............. ............ ............ ............. ............ .... 6-6 “T” and “U” Seal Replacement .......................................................................................................................... 6-6 “T” Seal Replacement ...................................................................................................................................... 8-10 Tank Location Figure 11-4........... ............ ............. ............ ............ ............. ............ ............ ............. ............ .... 11-5 Temperature Probe Figure 5-5 ............ ............. ............ ............ ............. ............ ............ ............. ............ ........ 5-5 Thread Lubrication ........................................................................................................................................ Tram p Release and Clamping Cylinders Figure 12-1 ............ ............. ............ ............ ............. ............ ......13-12 12-2 Tramp Release Cylinder Assembly Figure 4-17 ............ ............ ............. ............ ............ ............. ............ .... 4-17 Tramp Release Cylinder Strap Figure 4-14 ........... ............ ............. ............ ............ ............. ............ ............ 4-15 Troubleshooting Procedures ...................................................................................................................... 12-13 “U” Seal Replacement........................................................................................................................................ 4-8 “U” Seal Replacement Figure 4-8 ....... ............. ............ ............ ............. ............ ............ ............. ............ ........ 4-8 Upper Head Bore Inspection ......................................................................................................................... 8-10 Upper Head Bushing Installation .................................................................................................................. 8-10 Upper Thrust Bearing........................................................................................................................................ 6-5 Upper Thrust Bearing Figure 6-8 ............ ............. ............ ............ ............. ............ ............ ............. ............ .... 6-5 Upper Thrust Bearing Wear Figure 6-7 ............. ............ ............ ............. ............ ............ ............. ............ ...... 6-5 V-Belt Drive ......................................................................................................................................................... 3-3 Water Control Valve Troubleshooting ............ ............ ............ ............. ............ ............ ............. ............ ........ 11-8 Water Cooled Lube System Components.................................................................................................... 11-8 Water Cooler .................................................................................................................................................... 11-8 Water Strainer Cleaning .................................................................................................................................. 11-8 Wedge Assembly Figure 9-4 ........... ............. ............ ............ ............. ............ ............ ............. ............ ............ .. 9-4 Weekly Checks and Maintenance ................................................................................................................ 13-16 Weight of Complete Crusher and Assemblies Table 3-1 .............. ............ ............ ............. ............ ............ 3-2 Welding and Weld Repair of Major Castings ............ ............ ............. ............ ............ ............. ............ .......... 3-5