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Operation & Maintenance Manual

Horizontal Shaft Impactor


Models 1313 and 1316

I-130 ENGLISH CEDARAPIDS

24215 (10/07)
49999-252-05-05
IMPORTANT INFORMATION

READ BEFORE USING THIS MANUAL.

The Finlay I-130 Impactor has a Cedarapids 1313 Impactor Crusher in-
corporated. We have therefore included the complete Cedarapids Opera-
tion & Maintenance Instructions for this Crusher.

The Cedarapids Crusher unit operates in a wide variety of Static and Mobile
applications, this universal manual therefore contains a number of topics
that are not relevant to the Unit incorpoated into the Finlay I-130.

I have outlined the main Sections and procedures not relevent to the Finlay
I-130.

(1) In the safety section (2-5) the manual refers to Lockout & Tagout pro-
cedure of the Crusher Unit, this page is not relevant as it is based on a
stand alone unit, the crusher Safety is incorporated into the overall safety
of the I-130, this includes the Safety Interlocks not refered to in this
manual. All other Safety refered to in this manual is very impor-
tant and must be adhered to in conjunction the the safety infor-
mation in the Finlay I-130 Operation Manual.

(2) The complete Installation section (Section 3) is not relevant to the I-


130 as the Crusher Unit is already installed and ready for use.

(3) Some parts of the Hydraulic Section (Section 7) are not relevant as the
Crusher Unit hydraulics are incorporated into the hydraulic system of
the complete I-130 machine. (One examples: This manual refers to
using ISO 32 Hydraulic oil for the hydraulic System , the Finlay hydrau-
lic system uses ISO 46)
To the Owner & Operator:
We have tried to provide information that gives our customers a clear understanding of equipment
construction, function, capabilities and requirements. This information is based on the knowledge and
experience of qualified people at our company and in our field organization. Proper use of this information
rewards users of our equipment with high efficiency, maximum service life and low maintenance costs.
That is why we strongly recommend that anyone using our equipment be familiar with this manual.
Information presented here should not be considered authoritative in every situation. Users will as a matter
of course encounter problems and circumstances that raise questions not anticipated here. Such questions
should be directed to their distributor or the factory.
Anyone who uses this equipment for any purpose other than that for which it was intended assumes sole
responsibility for dangers encountered and injuries sustained as a result of such misuse.

DANGER
Federal, state and local safety regulations aim to protect both people and property from accident,
injury and harmful exposure. When complied with, such regulations are often effective. Hazards
to personnel and property are further reduced when this equipment is used in accordance with all
operation and maintenance instructions. Generally:

(1) Read and heed all danger, warning, caution, and notice decals. Know what guards and protective
devices are included and see that each is installed and in operational condition. Additional guards and
protective devices may be required and must be installed by the user (owner) before operating.
(2) Never attempt to maintain, lubricate or adjust this equipment while it is running. Lock out and tag
out all energy sources before doing maintenance, cleaning, adjusting or repairing this equipment. Make it
impossible for anyone to start this machine while others are working on it or in it.
(3) Wear personal protective equipment such as hard hats, ear plugs, safety glasses and safety shoes
when operating this equipment. Do not wear loose clothing or long hair.
(4) Think safety and act safely. Stay alert at all times. Eliminate or neutralize potential hazards as soon
as you spot them. Never allow anyone to engage in horseplay when near this equipment.

DANGER
Failure to take these precautions will result in death or serious personal injury.

24215 (7/07) HSI 1300


06/06

CEDARAPIDS NEW PRODUCT WARRANTY


Cedarapids Inc, hereafter referred to as Cedarapids, warrants its new products manufactured and sold worldwide, to be free of defects in material or workmanship for a period of one (1) year
after date of start up, provided that Cedarapids receives written start up report within 6 months after the date of shipment (if no start up report is received from the Buyer or the dealer authorized
by Cedarapids to start up the unit within 6 months after the date of shipment, warranty will expire after one (1) year from the date of shipment from the manufacturer), or 2000 hours of use,
whichever occurs first, provided that Cedarapids receives notice of the defect within thirty (30) days of its discovery and Buyer establishes that (1) the equipment has been maintained and
operated within the limits of rated and normal usage, and (2) the defect did not result in any manner from the intentional or negligent action or inaction by Buyer, its agents or employees. If
requested by Cedarapids, Buyer must return the defective equipment to Cedarapids’ manufacturing facility, or other location designated by Cedarapids, for inspection, and if Buyer cannot
establish that conditions (1) and (2) above have been met, then this warranty shall not cover the alleged defect.
Delivery inspection forms are required for warranty validation and processing.
Cedarapids’ obligation and liability under this warranty is expressly limited to, at Cedarapids’ sole option, repairing or replacing, with new or remanufactured parts or components, any part, which
appears to Cedarapids upon inspection to have been defective in material or workmanship. Such parts shall be provided at no cost to the owner, FOB Cedarapids parts facility.
This warranty shall be null and void if parts (including wear parts) other than genuine OEM Cedarapids parts are used in the equipment.
Accessories, assemblies and components included in the Cedarapids equipment, which are not manufactured by Cedarapids, are subject to the warranty of their respective manufacturers.
Normal maintenance, adjustments, or maintenance/wear parts are not covered by this warranty and are the sole maintenance responsibility of Buyer.
Cedarapids makes no other warranty, express or implied, and makes no warranty of merchantability or fitness for any particular purpose.
No employee or representative is authorized to modify this warranty unless such modification is made in writing and signed by an authorized officer of Cedarapids, Inc.
Cedarapids’ obligation under this warranty shall not include duty, taxes, or any other charges whatsoever, or any liability for direct, indirect, incidental, or consequential damage.
Improper maintenance, improper use, abuse, improper storage, operation beyond rated capacity, operation after discovery of defective or worn parts, or alteration or repair of the equipment by
persons not authorized by Cedarapids shall render this warranty null and void. Cedarapids reserves the right to inspect the installation of the product and review maintenance procedures to
determine if the failure was due to improper maintenance, improper use, abuse, improper storage, operation beyond rated capacity, operation after discovery of defective or worn parts, or
alteration or repair of the equipment by persons not authorized by Cedarapids.
Oil Sampling Program: Cedarapids provides kits for an Oil Sampling Program at no charge with certain products. All Warranty claims will be denied if the Buyer does not participate in this Oil
Sampling Program.
Parts Warranty: Cedarapids warrants the parts ordered from the Parts Department to be free of defect in material or workmanship for a period of 6 months after date of shipment from the
factory or 1000 hours of operation, whichever occurs first, provided that the warranty period for any replacement parts supplied pursuant to a Cedarapids equipment warranty shall in no event
exceed the equipment warranty period.
NO TRANSFERABILITY OF WARRANTY: This warranty is limited to the original purchaser or original end-user if sold to a distributor, and is not assignable or otherwise transferable without
written agreement of Cedarapids. Please contact your local Cedarapids Distributor for additional details if needed.
ITEMS NOT COVERED BY CEDARAPIDS WARRANTY

The following items are NOT covered under the Cedarapids Warranty (the following list is not exhaustive):
1. Items sold by any individual, corporation, partnership or any other organization or legal entity that is not an authorized Cedarapids Distributor.
2. Components which are not manufactured by Cedarapids are not covered by Cedarapids warranty. Such components are covered only by the warranty that is provided by the
manufacturer of such components. Such components include, but are not limited to, engines, electric motors, air compressors, air conditioners, batteries, tires etc.
3. Replacement of assemblies: Cedarapids has the option to repair or replace any defective part or assembly. It is Cedarapids’ policy to refuse claims for the replacement of a
complete assembly that is field repairable by the replacement or repair of defective part(s) within the assembly.
4. Normal Operational Maintenance Services and Wear Parts: Maintenance services and wear parts are excluded from warranty claims. Maintenance services not covered
include, but are not limited to, such items as: sheave adjustments and alignment, screen cloth installation and tensioning, wear liner and chute work, wear or adjustment of jaw and toggle plates,
proper tightening of bolts, nuts and pipe fittings, adding or replacing of fluids, filter, breathers, belts, nozzles, screed plates, adjustments of pumps and motors, spark plugs, etc. Wear parts not
covered include, but are not limited to, screen cloth, wear liners, wear of jaw and toggle plates, fluids, filters, breathers, belts, nozzles, screed plates, spark plugs.
5. Transportation damage: Any damage caused by carrier handling is a transportation claim and should be filed immediately with the respective carrier.
6. Deterioration: Repairs, work required or parts exposed as the result of age, storage, weathering, lack of use, demonstration use.
7. Secondary Failures: Should the owner or operator continue to operate a machine after it has been noted that a failure has occurred, Cedarapids will not be responsible under
the warranty for resultant damage to other parts due to that continued operation.
8. Workmanship of Others: Cedarapids does not accept responsibility for improper installation or labor costs of personnel other than authorized Cedarapids Distributor personnel.
9. Stop and Go Warranty: Cedarapids does not recognize “Stop and Go” warranties.
10. Incidental or Consequential Damage: Cedarapids shall not be liable for any Incidental or Consequential Damages of any kind, Including, but not limited to, lost profits, loss of
production, increased overhead, loss of business opportunity, delays in production, costs of replacement components and increased costs of operation that may arise from the breach of this
warranty. Customer’s sole remedy shall be limited to (at Cedarapids sole option) repair or replacement of the defective part.

THIS WARRANTY IS EXPRESSLY IN LIEU OF AND EXCLUDES ALL OTHER WARRANTIES, EXPRESS OR IMPLIED (INCLUDING THE WARRANTIES OF MERCHANTABILITY AND
FITNESS FOR A PARTICULAR PURPOSE) AND ALL OTHER OBLIGATIONS OR LIABILITY ON CEDARAPIDS' PART. THERE ARE NO WARRANTIES THAT EXTEND BEYOND THE
LIMITED WARRANTY CONTAINED HEREIN. Cedarapids neither assumes nor authorizes any other person to assume for Cedarapids any other liability in connection with the sale of
Cedarapids’ equipment. This warranty shall not apply to any of Cedarapids' equipment or any part thereof which has been subject to misuse, alteration, abuse, negligence, accident, acts of God
or sabotage. No action by any party shall operate to extend or revive this limited warranty without the prior written consent of Cedarapids.

IN THE EVENT OF ANY BREACH OF THE WARRANTY BY CEDARAPIDS, CEDARAPIDS' LIABILITY SHALL BE LIMITED EXCLUSIVELY TO THE REMEDIES (AT CEDARAPIDS’ SOLE
OPTION) OF REPAIR OR REPLACEMENT OF ANY DEFECTIVE EQUIPMENT COVERED BY THE WARRANTY. IN NO EVENT SHALL CEDARAPIDS, OR ANY SUBSIDIARY OR
DIVISION THEREOF BE LIABLE FOR INCIDENTAL, INDIRECT, CONSEQUENTIAL OR OTHER DAMAGES OR LOSSES RESULTING FROM A BREACH OF WARRANTY INCLUDING,
WITHOUT LIMITATION, LABOR COSTS, LOSS OF USE OF OTHER EQUIPMENT, THIRD PARTY REPAIRS, PERSONAL INJURY, EMOTIONAL OR MENTAL DISTRESS, IMPROPER
PERFORMANCE OR WORK, PENALTIES OF ANY KIND, LOSS OF SERVICE OF PERSONNEL, OR FAILURE OF EQUIPMENT TO COMPLY WITH ANY FEDERAL, STATE OR LOCAL
LAWS.
Table of Contents

Section 1 - Introduction
About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1
Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1

Section 2 - Safety
General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Safety Alert Symbol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Hazard Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Safety Signs and Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Safety Sign Location (ANSI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Safety Sign Location (ISO Standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Personal Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Work Area Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Equipment and Tools Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Lockout & Tagout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
What is Lockout & Tagout? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
How to Lockout & Tagout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
When is Lockout & Tagout required? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Who must apply a lock & tag? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
When can a lock and tag be removed? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Who can remove a lock and tag? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Section 3 - Installation
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 1
Lifting the Crusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 2
Positioning the Crusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 3
Drive Power and Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 5
Feed Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 7
Conventional VGF Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 7
VGF Interface For Enlarged Feed Opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 7
Chain Curtain and Rubber Curtain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 8
Discharge Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 10
Installation Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 10

Section 4 - Inspection
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Tools & Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Inspection Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Exterior Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Interior Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

24215 (7/07) i HSI 1300


Table of Contents

Closing Crusher and Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 11


Daily Inspection Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 12

Section 5 - Lubrication

Section 6 - Hubs, Shaft & Bearings


Tools & Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 1
Rotor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 2
Bearing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 2
Rotor Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 4
Rotor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 5
Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 7
Drive End and Non-Drive End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 7
Drive End of Shaft Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 9
Non-Drive End of Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 12
Rotor Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 12
Seal Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 14
Final Touches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 14

Section 7 - Operation & Adjustment


Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 1
General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 4
Pre-operation Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 5
Hydraulic Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 5
Opening the Crusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 6
Closing the Crusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 7
Breaker Plate Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 7
Primary Breaker Plate Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 8
Secondary Breaker Plate Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 8
Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 10
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 10
Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 10

Section 8 - Wear Parts Replacement


Tools & Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Frame Liner Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Primary Breaker Plate Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Secondary Breaker Plate Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Liner Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7

24215 (7/07) ii HSI 1300


Table of Contents

Rotor Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 10


General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 10
Rotor Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 10
Impeller Bar Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 12
Disk Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 17
Stripper Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 18
Liner Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 18
Liner Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 18

Appendix A - Component Weights

Appendix B - Drive & Power Options


Typical Crusher Drive Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B - 1
1313 Crusher Drive Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B - 2
1316 Crusher Drive Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B - 4

Appendix C - Belt Drive Care


General Belt Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 1
Maintaining V-Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 2
Check Belt Tension
with Mechanical Tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 4
Belt Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 6
Idlers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 6
Inside Idler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 6
Back-Side Idler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 7
Kiss Idler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 7

Appendix D - Bearing Press Design

24215 (7/07) iii HSI 1300


Table of Contents

This Page Intentionally Left Blank

24215 (7/07) iv HSI 1300


Introduction

About This Manual

Section 1 - Introduction This equipment is precisely engineered, highly


functional and heavy duty designed to provide
About This Manual years of excellent service performing to customer
This book provides operation and routine mainte- specifications. We are proud to manufacture this
nance instructions for the owner and/or operator of equipment for your use and profit. We also take
a Horizontal Shaft Impactor (HSI) manufactured pride in the quality of our service and replacement
by Terex Cedarapids. parts.
We strongly recommend that anyone working with This manual does not supply replacement parts
a Terex HSI become familiar with this manual, information. Only your Cedarapids MVP Parts
whether or not you have experience with other Manual, identified with the serial number of your
Terex Cedarapids equipment. machine, is an authoritative source of part numbers
This manual contains information necessary for and part descriptions for your equipment.
proper installation, safe operation and mainte- Ongoing improvement of product design may
nance practices for this equipment. You can make result in future changes to some parts. Use part
a major contribution to personnel safety if you: numbers, model numbers and serial numbers from
• Comply with OSHA, federal, state and local your parts book to communicate with your
regulations. distributor.

• Read, understand, and follow the instructions If anything in this manual is not clear or if you have
in this and other manuals supplied with this questions, concerns or just want some general
equipment. information about rock processing, please feel free
to contact the Terex Cedarapids Crushing and
• Use good, safe work Practices in a common Screening service department, at 1-800-821-5600.
sense way.
Intended Use
• Only have trained operators, directed by
informed and knowledgeable supervisors, This product and its approved attachments are
operating or servicing this equipment. designed to process aggregates, such as shot rock,
quarry rock, and sand and gravel deposits and for
Experience has shown it is to your advantage to
processing recycled concrete and demolition
keep a copy of this manual where personnel can
material. Use of this product in any other way is
consult it as needed and to have a copy on file in
prohibited and contrary to its intended use.
your office so that shift leaders or supervisors can
conveniently refer to it. Additional copies can be
ordered through your distributor.

The safety alert symbol used in this manual is to alert you to potential
personal injury or hazards. Obey all safety messages that follow this symbol
to avoid possible injury or death.

24215 (7/07) 1-1 HSI 1300


Introduction

This Page Intentionally Left Blank

24215 (7/07) 1-2 HSI 1300


Safety

General Safety

Section 2 - Safety Hazard Levels


General Safety A multi-tier hazard classification system is used to
communicate potential personal injury hazards.
This equipment is designed expressly for The following signal words used with the safety
processing rock and recycling concrete. When our alert symbol indicate a specific level of severity of
equipment is used for purposes other than those for the potential hazard (Figure 2 - 2). Signal words
which it was designed, user assumes sole used without the safety alert symbol relate to
responsibility for any injuries or damage that may property damage and protection only. All are used
result from said misuse. as attention-getting devices throughout this manual
There are many hazards involved in rock as well as on decals and labels fixed to the
processing and in the use of rock-processing machinery to assist in potential hazard recognition
equipment. That is why we emphatically and prevention.
recommend that this equipment be operated only
by personnel who are trained in its use. DANGER indicates a hazardous
DANGER situation which, if not avoided, will
We make no guarantee, either expressly or by result in death or serious injury.
implication, that this equipment meets all local or
federal safety regulations. It is the responsibility of WARNING indicates a hazardous
WARNING situation which, if not avoided,
those individuals who own and/or operate this
could result in death or serious
machine to verify that all safety regulations are injury.
complied with before starting either this unit or any
associated equipment CAUTION CAUTION indicates a hazardous
situation which, if not avoided,
Safety Alert Symbol may result in minor or moderate
injury.
The safety alert symbol (Figure 2 - 1) is used to
alert you to potential personal injury hazards. Obey NOTICE indicates a message
NOTICE related to property damage only.
all safety messages that follow this symbol to avoid
possible injury or death.
Figure 2 - 2 Hazard Classification

Figure 2 - 1 Safety Alert Symbol

24215 (7/07) 2-1 HSI 1300


Safety

Safety Signs and Icons

Safety Signs and Icons


Beneath all safety regulations lies a set of common-
sense rules. Everyone who works with or near
heavy equipment must be aware of those rules. To
foster and maintain such an awareness in our
customers, safety signs are fixed on our equipment.
Icons on our safety signs remind both workers and
supervisors of common hazards and procedures
that, in the course of a busy day, they might
otherwise forget. The language of the icons is
simple and direct (Figure 2 - 3) and (Figure 2 - 4).
Refer to Figure 2 - 5 through Figure 2 - 6 to see
specific safety signs used on this equipment.

Improper operation or maintenance can


result in serious injury or death.

Read and understand operator’s


manual and all safety signs before
using or maintaining machine.
If you do not understand the information
in the manuals, consult your supervisor,
the owner or the manufacturer.

Lockout/ tagout all electrical equipment


prior to performing maintenance or
adjustments.
Stop machine and lockout/tagout
before adjusting or servicing the
machine.

Indicates a lift point or tie-down point.


Refer to manual for instructions.

Figure 2 - 3 Safety Sign Icons

24215 (7/07) 2-2 HSI 1300


Safety

Safety Signs and Icons

This equipment may cause loss or Contact with moving belts can result
degradation of hearing over a period in serious injury or death.
of time.
Wear proper hearing personal
Do not operate this machinery
protection equipment.
without guards in place.

Death, serious injury, or delayed lung


disease may result from breathing Escaping fluid under pressure can
hazardous dusts. Hazardous dusts penetrate skin, causing serious injury.
can be generated during operation Fluid injected into skin must be
of this equipment. surgically removed within a few hours
Use dust suppression or dust or gangrene will result.
collection equipment to minimize the Use cardboard or paper to check for
dust exposure during operation of leaks, not your hand. Relieve pressure
this machine. before disconnecting hydraulic lines
Use approved respiratory protection
to avoid inhalation of dusts, when Grease lubrication required for
required by Federal, State, and Local operation of this equipment. Refer to
safety and health regulations. manual for instructions.

Contact your employer to establish


whether these regulations require
that you use respiratory protection. Hydraulic fluid required for operation
of this equipment. Refer to manual for
Flying material may cause loss or instructions.
degradation of eye sight.
Entanglement hazard. Contact with
Wear proper eye personal protection moving rotor can result in serious injury
equipment. or death. Be sure to lock rotor before
any maintenance is performed. Refer to
manual for instructions..
Falling material can cause death or
serious injury. Falling from this machine can result in
serious injury or death.
Stay clear of falling material during
operation. Use appropriate personal Do not climb on machine. Use personal
protective equipment. lift or appropriate ladder during setup
or maintenance.

Figure 2 - 4 Safety Sign Icons - Continued

24215 (7/07) 2-3 HSI 1300


Safety

Safety Signs and Icons

Safety Sign Location (ANSI)

2
2

04418-955d

3 04418-955d

Made In United States of America

4b
1 1
4a

6
8

6 9 7
WARNING

ENTANGLEMENT HAZARD Stay clear of moving belt. Do


Contact with moving belts not operate this machine
ENTANGLEMENT HAZARD Stay clear of moving rotor. can result in serious injury or without all guards and
Contact with rotor can result Lockout/Tagout before death. covers in place. Stop
in serious injury or death. adjusting or entering the machine and Lockout/Tagout
machine. Lock rotor. before adjusting or servicing
Read Manuals. the machine. 04491-500-17
04490-400-06

1 3

WARNING WARNING WARNING WARNING WARNING WARNING


FALL HAZARD Improper operation or HEARING HAZARD INHALATION HAZARD FALLING MATERIAL FLYING MATERIAL HAZARD
Falling from machine can maintenance can result May cause loss Death, serious injury, or delayed lung disease may HAZARD May cause loss or
result in serious injury or in serious injury or or degradation result from breathing hazardous dusts. Falling material can cause degradation of eye
death. of hearing over death or serious injury sight.
death.
a period of time. Hazardous dusts can be generated during operation
of this equipment.

DO NOT climb on Read and understand Wear proper Use dust suppression or dust collection equipment to STAY CLEAR of falling Wear proper eye
machine. operator’s manualand all hearing minimize the dust exposure during operation of this material during operation. personal protection
safety signs before using personal machine. Use appropriate personal equipment.
Use personnel lift or maintaining machine. protection protective equipment.
or appropriate equipment. Use approved respiratory protection to avoid inhalation
ladder during setup If you do not understand of dusts, when required by Federal, State, and Local
or maintenance. the information in the safety and health regulations.
manuals, consult your
Lockout and tagout. supervisor,the owner or Contact your employer to establish whether these
the manufacturer. regulations require that you use respiratory protection. 04491-500-18

2
04493-500-15

DANGER Injection Hazard


Escaping fluid under pressure
can penetrate skin, causing
51-005-39440 ENTANGLEMENT HAZARD serious injury.
Contact with moving belts can result in
serious injury or death.

4a
Relieve pressure before
DO NOT OPERATE THIS MACHINERY
disconnecting hydraulic lines.
WITHOUT GUARDS IN PLACE.
Keep away from leaks and pin
This machinery IS NOT equipped with a
holes. Use a piece of
guard to prevent accidental contact with
04493-500-15 cardboard or paper to search
the drive mechanism.
for leaks. Do not use hand. 1 2 3
Purchaser is responsible for providing and Fluid injected into skin must be
installing any guards which may be required surgically removed within a few
by Federal, State, or local statutes or hours by a doctor familiar with 3
regulations. 04490-400-07
this type of injury or gangrene 2
04491-500-10 will result.
1
51-005-39440
04493-500-18 04493-500-17

4b 5 Note: Wire tie to 6


sheave for shipping. 7 8 04493-500-19

Figure 2 - 5 ANSI Safety Sign Location

24215 (7/07) 2-4 HSI 1300


Safety

Safety Signs and Icons

Safety Sign Location (ISO Standard)

3
2

04418-955d

3 04418-955d

Made In United States of America

4b
1 1
4a

6
8

6 9 7

04490-400-06-01

1
04491-500-18-01

2
04493-500-15

51-005-39440

4a
Note: Wire tie to
04493-500-15

sheave for shipping.


04491-500-17-01

04490-400-07-01

3 51-005-39440
5
4b

1 2 3

04491-500-10-01 3
2

6
04493-500-18 04493-500-17
04493-500-19

7 8 9

Figure 2 - 6 ISO Standard Safety Sign Location

24215 (7/07) 2-5 HSI 1300


Safety

Personal Safety

Personal Safety • Verify that hydraulic and /or pneumatic


pressure is zero before adjusting, maintaining
Terex Cedarapids equipment is designed with the or attempting any repair on a hydraulic or
safety of all personnel in mind. Do not attempt to pneumatic system.
change, modify, or eliminate accident prevention
devices installed at the factory. Make sure that all • For questions concerning accumulators, which
personnel who work in the area of the equipment are pressure-containment vessels, contact your
are familiar with safety precautions. Terex Cedarapids distributor. Malfunctioning
valves or poor maintenance practices can result
Guards, covers, and shields are installed around in build-up of extremely high hydraulic and/or
moving parts at the factory whenever necessary to pneumatic pressures inside the accumulator.
prevent accidental injury to operators and others
working on or near the equipment. Do not remove • Use adequate hearing protection devices
them. whenever the noise level is above acceptable
limits.
Terex Cedarapids recommends the following basic
safety practices: • Wear an adequate protective breathing mask
whenever dust and fumes are above acceptable
• Read all warning, caution, and instruction limits.
signs.
• Wear adequate eye protection goggles or safety
• Always establish a positive lockout of the glasses with side shields to prevent flying
involved power source before performing particles from entering eyes.
maintenance, cleaning, adjusting, or repair.
Secure the power source lockout to prevent • Hard hats are a good idea in all work sites and
start-up by other persons. required at most. Wear yours.

• Never lubricate the equipment when it is in • Maintain safe work habits by dressing
motion. appropriately for the job. Do not wear loose
sleeves, flowing hair, long coat tails, wrist
• Do not remove any guards, covers, or shields watches or bracelets, or pockets full of tools,
when equipment is running. which could get caught in moving machinery.
• Replace any guards, covers, or shields after Thin-soled shoes without tread could cause
adjustment or maintenance. unexpected falls or foot injury. Wear safe
shoes.
• Block parts as necessary to prevent unexpected
movement while performing adjustments or • Always look around equipment before start-up
repairs. to make sure everyone is clear of the
machinery. Know the whereabouts of your co-
• Do not attempt to remove jammed product or
workers.
other blockage from running equipment. Power
must be shut off and locked out while doing so. • Report defective machinery and unsafe
conditions to your supervisor.

24215 (7/07) 2-6 HSI 1300


Safety

Work Area Safety

• Save your back. If the load is more than 40 lbs., • Check for leaks in tanks or tubing with
get help or use proper lifting procedures. Use flashlights or other proper equipment. Never
your leg muscles, not your back, for lifting. use an open flame to check for leaks.
Keep loads close to your body. Avoid twisting • Know where fire extinguishers and other fire
motions and over-extensions when moving suppression equipment are located. Learn how
loads. to use them.
• Most of all know your equipment. Understand • Be alert and wary around any pressurized
the machine and the conditions under which it system: hydraulic or air. High pressure gases
operates. Don’t limit playing it safe to only and oils can be very dangerous. Know your
these few general rules. Think and act safely for equipment and operate it properly.
your specific work environment and your
particular equipment. • Be alert and watch for pinch points, closing
mechanisms, and falling parts when working
Work Area Safety on or around any machinery. Keep hands and
• Keep the work area as neat and as clean as tools clear
practical. Equipment and Tools Safety
• Keep all warning and caution signs clear and up • Clean and properly labeled tools are safer tools.
to date. Keep your equipment and tools in order.
• Make certain all electrical equipment is • Always use hoisting equipment for heavy
properly grounded. Wet spots near electric loads. Regularly check hooks, cables, shackles
current are dangerous. and chains for stretch and wear. Never overload
• Store hazardous materials in restricted access hoists, cranes or other lifting devices.
areas and mark them clearly. Federal • Keep V-belts and sheaves in good condition.
regulations require special labeling of certain Frayed belts or cracked sheaves can be
materials. dangerous and cause downtime.
• Do not smoke or allow smoking near • Keep your equipment clean and free of dirt and
flammable fuels or solvents. Use non- grease so it can be checked for loose, cracked
flammable solvents for cleaning parts and or broken parts. Replace defective parts as soon
equipment. as they are discovered.
• Make certain enough ventilation is present to • For questions concerning accumulators, which
run engines safely. Do not start an engine in an are pressure-containment vessels, contact your
enclosed space without properly vented Terex Cedarapids distributor. Malfunctioning
exhaust. Exhaust fumes from gasoline or diesel valves or poor maintenance practices can result
engines can kill! in build-up of extremely high hydraulic and/or
• Avoid electrical and static sparks and any open pneumatic pressures inside the accumulator.
flame while handling, storing, moving or
pouring fuels, electrolytes for batteries,
hydraulic fluids or coolants.

24215 (7/07) 2-7 HSI 1300


Safety

Lockout & Tagout

Lockout & Tagout How to Lockout & Tagout

Code of Federal Regulations • Install one or more locks to hold


number 1910.147 requires that !
the master switch lever in the OFF
ate
per
employers establish and follow a Do
No
tO
position.
Lockout & Tagout procedure and • If the switch is keyed, turn the key
train their employees in that to the OFF position and remove
procedure before any employee can operate, the key.
service or maintain any piece of power equipment.
• Disconnect the batteries.
Employers are required to make periodic
inspections to see that their Lockout & Tagout • Regardless of which lockout method is used,
procedures are being followed, and they must place one or more tags on machine control
monitor and update their program on an ongoing panels, access doors and electrical panels.
basis. Employees are responsible for seeing that When is Lockout & Tagout required?
equipment is locked out and tagged out in
accordance with the employer’s policy. • Any time anyone is maintaining, repairing,
lubricating, or, for whatever reason, working
To promote safety in the use of our equipment, on the equipment.
Terex Cedarapids ships a Lockout & Tagout Kit
with every crusher. The kit and its contents are • When the equipment is broken or, for whatever
illustrated in (Figure 2 - 7). reason, unfit or unsafe to operate.

What is Lockout & Tagout? • Whenever the equipment is left unattended.

Lockout & Tagout is a procedure that’s designed to FED


ER
AL
RE
Addi GIS
prevent absolutely the unexpected or accidental tiona
of te l inst
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stea
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ruct
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e in
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of te l inst to read rmat t not in
TER
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xt.
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ruct
io th ion pr this
kit in ease ns ar is tiny ovided block

startup of equipment and to alert all workers stea re


d of fer to
e av

fo
te
aila xt.
tryin the in ble, bu
g to
read rmatio not in
this n pr
t
with

this
tiny ovided block
text
. with
this

this

whenever it is unsafe to operate any piece of


E ER R R R R R R R R
GG E E E E E E E E
NN GGGGGGGG

equipment. When used as intended, Lockout &


AA NNNNNNNN
D D DADADADADADADADA

T & BY
OU & UT Y
TAG OOUCTK&O UT BY
TAGLOUOTCK&OUT B Y
TAG LOOUCTK&O UT BY
TAGLOOUCT K&OUT B Y

Tagout also protects personnel from energy stored


G L
TA OOUCTK&O UT BY
R

TAGLOUOTCK&OUT B Y
TAG LOOUCTK&O UT B Y
TAGGLOOUCTK&O UT B Y
TA LOOUCTKO UT B
TAGL OCKO
D D
A A D D D

in devices such as springs, accumulators, batteries,


N N A A A

T
T HIS
G GN N N

O O B TAG
E E G G G

P NLY ETHRE &


R R E E E

ON ERSO TOBYBT ISMTOAVE LOCK


BAC ONNLLIS EHRE G &D
P Y E
ON ERKS. O BTTYOETDTHMISOTVE LOCK
BAC NONLIS BHEE AGD
R R R

hydraulic systems, etc. PK. LYTE RE &


ON ERSO TBOYD TTHISMOT VE LOCK
BAC ONN LIS BEHE AGD
P K. LY TE RE &
ON ERSO TOBYTDTHISMTOVE LOCK
BAC ONN LISBEHE AG D
P K. LY T RE &
ON ERSO BYETD MOVE LOCK
BAC N LIS HE D
K. TED

Figure 2 - 7 Lockout & Tagout Kit

24215 (7/07) 2-8 HSI 1300


Safety

Lockout & Tagout

Who must apply a lock & tag?


• Any person working on the equipment.
• Foreman or other person responsible for the
work being done.
• If several people are working on a machine at
the same time, each person must apply his or
her own lock and tag.
When can a lock and tag be removed?
After performing these six steps:
1) All safety guards are back in place.
2) All work is complete and tools are put away.
3) All workers are notified that a lock is being
removed.
4) All workers are positioned safely for startup.
5) Controls are positioned for safe startup.
6) The machine is ready for safe operation.
Who can remove a lock and tag?
• Only the person who applied a lock and tag is
permitted to remove them.
Lockout & Tagout rules laid out here are generic.
To get instructions for your particular workplace,
consult your employer’s lockout/tagout procedure.

24215 (7/07) 2-9 HSI 1300


Safety

This Page Intentionally Left Blank

24215 (7/07) 2 - 10 HSI 1300


Inspection

General

Section 4 - Inspection Inspection Procedures


General There are three major procedures entailed in a daily
inspection of your crusher.
Proper care and inspection of the crusher is
something that merits your closest attention. Stay First: Lockout & Tagout and check everything on
away from your crusher while it is running, and the outside of the crusher.
perform inspections every day. Your machine will Second: Open the machine and check all interior
last longer, be safer and more profitable if you do components.
so.
Finally: Review the entire job carefully. When you
Performing daily inspections is the only way to are sure everything is safe and in good order, close
keep your crusher performing safely and the machine, remove your lock and tag, clear the
efficiently. Daily inspections allow you to get the area and start the crusher. Perform the inspection
most profit from your equipment investment. procedures as follows.
Photocopy and use the Daily Inspection Form at Exterior Inspection
the end of this section to establish a maintenance
routine and provide a maintenance record. Doing 1. Lockout & Tagout power to crusher hydraulic
so will help you monitor conditions at your work system, to crusher main drive and all
site and keep your equipment in tip-top shape. equipment associated with crusher.

This section provides detailed instructions for


inspecting the crusher. If you follow these
instructions daily, you will learn to recognize when
WARNING
parts are wearing, and therefore learn to identify Lockout & Tagout all energy sources
and solve most problems before they become before inspecting this equipment. Make it
hazards. impossible for anyone to start this machine
Tools & Equipment or associated equipment while people are in
it or on it. Failure to Lockout & Tagout
To properly inspect the crusher, you will need the equipment could result in death or serious
following tools and equipment: injury.
• grease gun 2. Open belt guards to permit close inspection of
• lithium-base, EP, type 1 Grease, tube belts and sheaves. Repair broken or damaged
guards immediately.
• 1/4-inch flat stock, 3 feet x 1 inch
3. Check belts for cracks, fraying, stretch, signs of
• wrenches slippage, accumulation of grease or grit. Check
• trouble light belt tension. Tighten, clean, replace as needed
(See Appendix C).
• torque wrench (500 foot-pound capacity)
• pressure washer (recommended)

24215 (7/07) 4-1 HSI 1300


Inspection

Inspection Procedures

4. Check drive and driven sheaves for alignment,


wobble, wear and damage, accumulation of oil,
Liner Bolts Visible
grease and grit. Realign, straighten, clean, Around Crusher
replace as needed (See Appendix C).
5. Inspect rotor-shaft pillow blocks. Locate grease
fittings on seals, one at either end of drive-side
pillow block; one at inboard end of non-drive
side pillow block. Seals should have extruded
grease built up at their edges, all around the
shaft. This grease build-up is necessary. Do not
clean it off (See Section 5).

NOTICE
Grease only the seals. The bearings are
greased at defined intervals, but not on a
daily basis. Greasing crusher bearings daily
can cause premature bearing failure.
6. Inspect pillow block seals. If they appear
broken, bent or otherwise distorted, replace Figure 4 - 1 : Liner Bolts
immediately (See Section 6).
7. Using a wrench, check tightness of the liner
NOTICE
bolts visible on the exterior of the crusher
(Figure 4 - 1). Before attempting to tighten a If you find a loose liner bolt that you cannot
loose liner bolt, be sure there is no debris tighten, the threads on the liner plate inside
accumulated behind the liner. The liner may crusher may be stripped out, or the liner
break when tightened against a build up of plate worn through or broken. Replace liner
material. Torque all liner bolts to 200 foot plate and bolt immediately (See Section 8).
pounds (271 N•m).

24215 (7/07) 4-2 HSI 1300


Inspection

Inspection Procedures

Operator
Controls

Breather Cap/
Fill Hole

Sight Glass

Reservoir

Figure 4 - 2 : Hydraulic Power Unit Nomenclature

NOTICE NOTICE
Before you check hydraulic oil, make sure Use only ISO 32 hydraulic oil. Use oils
all hydraulic cylinders are fully retracted. listed on reservoir decal or equivalent.
Filling your reservoir with anything other
8. Check oil level in hydraulic reservoir (Figure 4
than ISO 32 oil voids hydraulic system
- 2). Sight glass should indicate at least 3/4 full.
warranty.
Oil must be clean and clear, not frothy or milky.

24215 (7/07) 4-3 HSI 1300


Inspection

Inspection Procedures

Primary Breaker Plate Rams


Hydraulic Lines
(one each end of bridge)

Secondary Breaker Plate Rams


(one each end of bridge)

Clevis/Pin - Typical
Upper (one each side)

Frame Opener Cylinders


(one each side)

Hydraulic Power
Clevis/Pin - Typical Unit
Base (one each side)

Figure 4 - 3 : Exterior Nomenclature - Hydraulic System

9. Check breather/fill cap on hydraulic reservoir 12. Make sure all hydraulic cylinders (Figure 4 - 3)
to make sure it’s undamaged, fits right, and is are securely mounted and free of visible leaks.
not dirty or plugged (Figure 4 - 2).
13. Clevises at both ends of frame-opening
10. Check hydraulic control lever(s) and valve(s) cylinders (Figure 4 - 3) must be pinned to eyes
for dirt, leaks, damage, sticking and free in crusher. Be sure that pins are retained by
movement (Figure 4 - 2). cotter keys.
11. Check hydraulic lines (Figure 4 - 3) for wear,
cuts, scuffing, and visible leaks. Lines should
be held tightly in place by clamps and
grommets that are in good condition.

24215 (7/07) 4-4 HSI 1300


Inspection

Inspection Procedures

Frame Latch Bolt


(one each side)
Primary Breaker
Plate Bridge

Thread
Protector
Caps

Upper Inspection
Door

Pillow Block Frame Hinge Pin


Bearing Housing and Locking Hole
(one each side)
Secondary Breaker
Plate Bridge
2-3/4”

Side Inspection Door


(one each side)
Safety Switch

Figure 4 - 4 : Exterior Nomenclature - General

14. Check crusher feed intake. Make sure feed 16. Make sure frame hinge ears on lower frame are
chute or feed adapter is in good condition, pinned into yokes on upper frame. Be sure pins
securely fastened to crusher frame. Check are in good condition and secured by cotter
rubber curtain and chains for wear, holes, and keys (Figure 4 - 4).
shredding. Replace as necessary.
17. Check alignment of safety switch. Check that
15. Be sure frame latch bolts on each side of the wiring is in good condition. Clean debris
crusher are tight (Figure 4 - 4). from around switch assembly.

24215 (7/07) 4-5 HSI 1300


Inspection

Inspection Procedures

Lock Pin and


Hairpin Clevis
Retainer Plate Adjuster Rod
Bumper
Primary Bridge
Adjuster Nut

Breaker Plate Bridge

Thread Protector Clevis


Cap
Adjuster Rod
Bumper
Secondary Bridge

Adjuster Nut

Breaker Plate Bridge

Tension Spring
Tension
Adj. Nut Lockpin and
Hairpin
Figure 4 - 5 : Breaker Plate Bridge Assembly

. 20. Check that thread-protector caps are present


and screwed on tight on primary bridge adjuster
DANGER rods. Replace as necessary. (Figure 4 - 4) and
(Figure 4 - 5).
Never open inspection doors while rotor is
turning. Lockout & tagout and wait for all 21. Check plastic breaker plate bumpers for cracks
moving parts to stop before opening and other wear. Examine bridge retainer plates,
inspection doors. Failure to heed this plate lock pins, and hair pins for damage and
warning will result in death or serious completeness. (Figure 4 - 5).
personal injury.
18. Open upper inspection door (Figure 4 - 4).
Using a light, look inside of crusher for rocks
DANGER
and debris accumulation above and in front of Never open inspection doors while rotor is
the breaker plates. Clear as necessary turning. Lockout & tagout and wait for all
19. Check adjuster-rod clevises. Make sure moving parts to stop before opening the
clevises are not cracked or warped where they inspection door. Failure to heed this
attach to the rods. Be sure they are pinned warning will result in death or serious
securely to crusher breaker plates. Repair as personal injury.
necessary.

24215 (7/07) 4-6 HSI 1300


Inspection

Inspection Procedures

22. Use wrench to open inspection doors on side of As crusher opens, watch breaker plate adjuster
unit (Figure 4 - 5). Using 1/4-inch flat stock, rods. Gravity causes breaker plates to swing on
feel space between breaker plates and frame- hinges toward front of machine. Primary rods
liner plates for debris. Clear as necessary. extend through the upper frame and the secondary
bridge presses against the tension springs
23. Check primary and secondary breaker plate
(Figure 4 - 6).
settings (closed side setting) as required for
your application. For proper operation of your If both breaker plates swing forward (primary
crusher, maintain a 2.5 to 1 primary to adjustment rods come out and secondary bridge
secondary adjustment ratio. lifts slightly) proceed with Step 29. If rods do not
come out, it is because an object or condition inside
24. Close all inspection doors and bolt them shut.
crusher prevents them from moving. Following is a
Your check of crusher exterior components is list of four possible causes for the problem:
complete at this point. You are now ready to open
Cause 1) Rock, iron or debris lodged in front of one
crusher and check inside unit.
or both breaker plates prevents them from
Interior Inspection swinging forward.
1. Verify Lockout & Tagout of main crusher drive
Corrective Action: Close the frame to get weight
motor.
of breaker plate off the obstruction. Then clear
2. Remove lock and tag from crusher hydraulic away debris.
system.
Cause 2) Rock, iron or debris in space between
3. Loosen nuts on latch bolts and swing bolts out breaker plate and side of frame wedges in
of the way. place.
4. Start hydraulic power unit
Corrective Action: Close frame to get weight of
. breaker plate off obstruction. Then clear away
WARNING debris.

Failure to stay out from in front of crusher


while frame is open or being opened could NOTICE
result in death or serious injury.
Sometimes you can clear an obstruction by
5. After making sure everyone is clear and no one using crusher hydraulic system to shake the
is standing in front of crusher, operate the breaker plates. Do this by tilting upper
applicable control lever and open crusher. Be frame until its center of gravity is directly
sure cylinders run all the way out, so machine above hinges (you’ll hear hydraulic pump
is fully open. Adjust as necessary to align lock change pitch). Then shake by working
holes in frame. Install lock pins (Figure 4 - 6). control quickly back and forth.

24215 (7/07) 4-7 HSI 1300


Inspection

Inspection Procedures

Protruding
Rods

Bridge Rests
Against Springs
Lock Pin

Figure 4 - 6 : Opened Crusher

tightened, either remove it or cut it with a torch


and let plate fall out of way. Pick up pieces at
DANGER once: You might forget later.
Do not climb between or in front of breaker
plates to clear away debris. As debris is
removed, a breaker plate may suddenly
WARNING
move, resulting in death or serious personal Operating the crusher with an adjuster rod
injury. that has been broken and repaired could
result in death or serious injury, as well as
Cause 3) Frame liner plate is loose, hanging off
system loss or damage.
end of bolt, and has snagged a breaker plate as
it tried to swing past. Cause 4) Adjuster rod is sprung, broken, or loose.
Corrective Action: If broken or sprung, replace. A
Corrective Action: Close crusher far enough to get
bent or broken adjuster rod cannot be repaired. If
weight of breaker plate off loose liner plate,
loose, tighten as necessary.
then tighten liner bolt. If bolt can’t be
6. Lockout & Tagout power to crusher hydraulic
drive unit. Verify crusher main power lockout.

24215 (7/07) 4-8 HSI 1300


Inspection

Inspection Procedures

7. On non-drive side of crusher, install pin but do not retorque. Continuous tightening of
through lock bracket (Figure 4 - 7) and into bolts will make future removal extremely
rotor hub through one of the holes that are difficult (See Figure 4 - 8).
meant to accept it (3 holes on 3-bar rotor; 4
9. Check Disk Guard for damage/cracking
holes on 4-bar rotor). You may have to roll
around pin welds. (Figure 4 - 8)
rotor by hand to line up hole in hub with hole in
bracket.
WARNING
Lock
Bracket Operating the crusher with loose impeller-
Lockpin bar wedges could result in death or serious
Stowage injury.

Impeller Bar
Wedge
1.6” min
Disk Guard

Lockpin
Backer Bar Wedge Bolt

Figure 4 - 7 : Rotor Locked - Non-Drive Side Figure 4 - 8 : Impeller Bar and Disk Guard

10. Inspect impeller bars for looseness and wear


WARNING (Figure 4 - 8). If wear on impeller bars, from
top of any one impeller bar to surface of backer
Failure to lock rotor in place may result in bar, is 1.6 inches or less, all impeller bars must
death or serious personal injury. be turned or replaced (See Section 8).

Look at rotor and adjacent liner plates, on crusher


frame: NOTICE
8. Check Impeller-bar wedge and bolt for
If impeller-bar wear is allowed to exceed
looseness or damage. If wedges are loose,
minimum 1.6” dimension to backer bar,
torque bolts to 150 ft lbs. (203 N•m). If a wedge
serious and expensive damage can result to
is tight, do not retorque bolts. Bolts may loosen the rotor assembly.
over time as the wedge seats tighter against the
impeller bar. It is permitted to tighten bolt snug,

24215 (7/07) 4-9 HSI 1300


Inspection

Inspection Procedures

13. Look for circular wear pattern in liner plates at


both ends of rotor. Some wear is normal, but if
NOTICE grooves are more than 1/2-inch deep, worn
liner plates must be replaced (See Section 8).
Always turn or replace impeller bars as a
set. Replacing bars one or two at a time
makes proper closed side setting
adjustments impossible, and could put rotor
NOTICE
seriously out of balance, causing vibration. Allowing liner plates to wear completely
Operating the crusher with a serious through will result in serious and expensive
vibration could result in death or serious damage to machine.
injury.
11. Two semicircular guards shield Huckbolts in
rotor hubs. Guards must be intact. Damaged or WARNING
missing guards must be replaced at once. Each
guard is anchored by two allen-head bolts. Before pulling lock pin out of rotor, make
Make sure anchor bolts are tight. Torque to 180 sure no one is standing on rotor. Failure to
foot-pounds. Loose or missing Huckbolts must heed this warning could result in death or
be replaced at once. (See Section 8). serious injury.
14. When you’ve cleaned and inspected all you can
see with rotor pinned in place, pull lock pin and
NOTICE roll rotor until next impeller bar is accessible.
Lock rotor and repeat inspection until all bars
A pressure washer is often useful for
have been checked.
cleaning interior of crusher.
If you have a 3-bar rotor, you’ll have to roll the
12. Look at rotor hubs. If material is clogged
rotor a second time and repeat. If you have a 4-bar
between Huckbolts and surrounding guards,
rotor, you’ll have to roll three times and repeat.
leave it alone. It helps protect Huckbolts from
When you’re done, you should be sure that all parts
sandblast wear. Scrape clay and debris off liner
of the rotor are in good order and safe to operate.
plates adjacent to rotor assembly.
15. Check stripper plate liners for wear and cracks.
Replace as necessary.
NOTICE 16. Check clearance between impeller bars and
stripper plate liners. The factory dimension
Operating crusher with unguarded between the impeller bars and the stripper
Huckbolts will result in serious and plate is one (1) inch. Adjust as necessary for
expensive damage to machine. your application. The adjustment is to keep
oversized material from contaminating your
product or fines from becoming trapped in the
rotor wind stream.

24215 (7/07) 4 - 10 HSI 1300


Inspection

Closing Crusher and Startup

17. Make sure rotor is still locked. Then climb into


crusher for a close-up view of the works. At
NOTICE
feed opening, check chain curtain. Replace
broken, missing, or worn chains. Allowing grit, mud and debris to
18. Look at primary breaker plate. Primary breaker accumulate in the crusher will decrease the
plate is cast manganese. Make sure it is at least efficiency of your crusher and can result in
2-inches thick. If less than 2 inches thick, damage and downtime.
replace. Closing Crusher and Startup
19. Look at secondary breaker plate. Check for
cracks and wear of liner castings. Check
tightness of liner bolts. Torque loose liner bolts WARNING
to 495 foot-pounds (671 N•m).
Freeing rotor or closing crusher frame
while personnel are either in or on the
NOTICE crusher or associated equipment could
result in death or serious injury.
Chrome breaker plate liners are extremely
1. Make sure nobody is in harm’s way, either in or
brittle. If debris gets between liner and on the crusher or associated equipment.
breaker plate weldment, liner may break
when tightened. If a liner is loose, it should 2. Remove lock and tag from crusher hydraulic
be removed and thoroughly cleaned before power.
installation. 3. Pull rotor-lock pin and stow it in place provided
near non-drive side bearing..
20. As you move about inside crusher, pay
attention to condition of frame-liner plates. 4. Operate hydraulic controls to close crusher
Where you see cracking and/or excessive wear frame completely. Swing latch bolts shut and
(more than 1/2-inch deep), replace worn liner at tighten nuts securely.
once (See Section 8). 5. Open inspection doors on side of crusher.
Check clearance between breaker plates and
impeller bars. Adjust as necessary.
NOTICE
6. Close inspection doors and bolt them tight.
Never operate a crusher if one or more liner 7. Replace all guards around belts, sheaves and
plates is broken or missing. Serious and other moving parts.
expensive damage will result.
8. Rotate rotor by hand several revolutions and
21. Check for clay and grit build up on frame and listen for any interference.
other surfaces. Scrape it free or use a pressure
9. Remove lock and tag from crusher main power
washer to get rid of it. and from associated equipment.
10. Sound warning horn, get everyone out of
harm’s way.

24215 (7/07) 4 - 11 HSI 1300


Inspection

Daily Inspection Form

11. Start crusher. Let the machine run empty for


five (5) minutes, while you listen for noises and
look for vibration. Anything out of the ordinary
may indicate a defect or hazard.

WARNING
Be sure to sound warning horn before
starting crusher. Not sounding warning
horn could result in death or serious injury.
12. Start discharge conveyor. Start feed device.
While crusher runs under load, check for
correct RPM (if diesel powered) or correct
amperage draw (if electrically driven). Note
abnormalities, correct as necessary.
Daily Inspection Form
The Daily Inspection Checkoff form (See next
page) is a checklist meant to serve the operator as a
memory prompt and the owner as an aid to record-
keeping. The inspection form is not an instruction
set and should not be treated as one. Numbered
items on the inspection form do not correspond to
numbered steps in the rest of this section.
Instructions for carrying out a proper daily
inspection of the crusher are laid out in the
proceeding numbered steps of this section. Study
those instructions until you understand them
completely. Follow them when you perform your
daily inspections. As you learn the instructions,
you will learn to use your crusher more safely and
efficiently.
Feel free to print out the inspection form for your
use.

24215 (7/07) 4 - 12 HSI 1300


Inspection

Daily Inspection Form

Daily Inspection Checkoff Form Use ISO 32 Hydraulic Fluid:


8. Hydraulic System
Date __________ a. Change oil & filter yearly or whenever
Sign when complete_______________________ system is opened
Date last changed __________
Initials __________
Exterior Checks
b. Reservoir -- oil clean; sight glass 3/4 full
1. Lockout & Tagout -- crusher & peripherals with cylinders retracted
❐ OK. Initials __________ ❐ OK. ❐ Not OK. See notes.
2. Under-crusher discharge area -- clear debris Added __________ qts. ISO 32 oil
❐ OK. ❐ Not OK. See notes. Initials __________
3. Belt Guards -- present, good condition c.Breather Cap, Control Levers & Valves --
present, mount secure, no leaks, damage
❐ OK. ❐ Not OK. See notes.
❐ OK. ❐ Not OK. See notes.
4. Belts -- tensioned, clean, good condition
d. Lines -- present, mount secure, no leaks,
❐ OK. ❐ Not OK. See notes. damage
5. Sheaves -- aligned, clean, good condition ❐ OK. ❐ Not OK. See notes.
❐ OK. ❐ Not OK. See notes. e. Cylinders, Clevises -- clevises pinned to
6. Shaft frame; cotter keys hold pins
a. Seals -- good condition ❐ OK. ❐ Not OK. See notes.
❐ OK. ❐ Not OK. See notes. 9. Frame Hinges -- pins through eyes & yokes;
cotter keys hold pins
Use Lithium, EP, Type-1 Grease:
❐ OK. ❐ Not OK. See notes.
b. Grease seals to 360° extrusion daily
10. Intake Area -- chain curtain, feed chute
❐ OK. ❐ Not OK. See notes. present, good condition
c. Grease pillow blocks 1oz. every 72 hrs ❐ OK. ❐ Not OK. See notes.
Last greased at __________ 11. Breaker Plate Pivot Shafts -- end caps present,
Initials __________ tight; pillow blocks tight
d. Pillow Blocks -- all bolts tight ❐ OK. ❐ Not OK. See notes.
❐ OK. ❐ Not OK. See notes. 12. breaker plate Bumpers -- present, good
condition
7. Liner Bolts -- tight
❐ OK. ❐ Not OK. See notes.
❐ OK. ❐ Not OK. See notes.
13. Breaker plate adjuster Rods -- shake to test;
adjust as necessary; thread protectors tight
❐ OK. ❐ Not OK. See notes.

24215 (7/07) 4 - 13 HSI 1300


Inspection

Daily Inspection Form

14. Upper Inspection Doors -- open; breaker plate 24. Fabricated Secondary breaker plates --
adjuster rods & clevises present, good liner bolts tight; liners not cracked, broken
condition; no debris above breaker plates ❐ OK. ❐ Not OK. See notes.
❐ OK. ❐ Not OK. See notes. 25. Interior Walls -- liner plates not cracked,
15. Upper Inspection Doors -- doors closed, bolted broken; no wear more than 3/4-inch deep)
tightly shut ❐ OK. ❐ Not OK. See notes.
❐ OK. ❐ Not OK. See notes. 26. General Cleanliness -- use pressure washer to
16. Lower Inspection Doors -- open; check for hose mud & grit out of crusher
debris between breaker plates & frame; clear ❐ OK. ❐ Not OK. See notes.
debris
❐ OK. ❐ Not OK. See notes.
Closure & Start Up
27. Pull rotor-lock; close crusher; swing latch
Interior Checks bolts into yokes; tighten securely with wrench
17. Verify Lockout & Tagout, crusher main power ❐ OK. ❐ Not OK. See notes.
❐ OK. Initials __________ 28. Lower Inspection Doors -- check clearance
18. Open Crusher -- breaker plate adjuster rods between impeller bars & both breaker plates
thrust ❐ OK. ❐ Not OK. See notes.
farther through top of crusher as frame opens 29. Lower Inspection Doors -- close doors & bolt
(If not, stop here & troubleshoot. See O&M them tightly
Section 4, Step 28, for procedures) ❐ OK. ❐ Not OK. See notes.
❐ OK. ❐ Not OK. See notes. 30. Guards -- replace guards around belts
19. Rotor Hubs -- clear away debris; no adjacent & sheaves
liners worn deeper than 3/4 inch ❐ OK. ❐ Not OK. See notes.
❐ OK. ❐ Not OK. See notes. 31. Rotate rotor by hand - listen for interference
20. Rotor Assembly -- no debris; wedge bolts ❐ OK. ❐ Not OK. See notes.
tight; bar wear acceptable, no breakage; 1/8- 32. Crusher Running Empty -- check for abnormal
inch hard-facing present on rotor discs noise & vibration
❐ OK. ❐ Not OK. See notes. ❐ OK. ❐ Not OK. See notes.
21. Stripper Liners-- check liner plates for wear & 33. Crusher at Work
breakage; check stripper-liner-to-rotor Diesel -- RPM set at __________
clearance Electric -- amp draw is __________
❐ OK. ❐ Not OK. See notes. Total crushing hours this date __________
22. Feed Opening -- check rubber curtain, all bolts Downtime this date __________
& attachments NOTES:______________________________
❐ OK. ❐ Not OK. See notes. _______________________________________
23. Cast Primary breaker plate -- lift eye & pivot
_______________________________________
intact;
casting at least 2 inches thick
❐ OK. ❐ Not OK. See notes.

24215 (7/07) 4 - 14 HSI 1300


Lubrication

Section 5 - Lubrication
The impeller shaft of the crusher rides on spherical
roller bearings, contained in pillow blocks. One
pillow block assembly is mounted on each side of
the crusher. The outboard end of the non-drive side
pillow block has a protective end cap
The bearings are protected from moisture and grit
by three seals, one at either end of the drive side
and one at the inboard end of the non-drive side.
Refer to Figure 5 - 1 for an overview of grease
points.
• Only use lithium-base, EP, type-1 grease
• Check grease seals every day before startup.
Pump grease into each seal until an extrusion of
fresh grease is present all around shaft. Grease
must extrude from seals at all times to produce
an effective dust and moisture seal.
• Pump one ounce of grease into both the
non-drive side and drive side bearings every
72 hours of operation.

24215 (7/07) 5-1 HSI 1300


Lubrication

Bearings: Add One


Ounce of Grease
Every 72 Hours.

Seals:
Grease Daily
until 360 Deg.
Extrusion
Seal:
Grease Daily until
360 Deg. Extrusion

Non-Drive Side of Pillow Block


(Cutaway View)

Drive-Side Pillow Block


(Cutaway View)

Lithium-Base, EP, Type 1

Figure 5 - 1 Pillow Block and Seal Lubrication Points

24215 (7/07) 5-2 HSI 1300


Hubs, Shaft & Bearings

Tools & Equipment

Section 6 - Hubs, Shaft & Bearings • 1/4-inch drill bit


This section tells how to remove the rotor assembly • 3/4-inch drive ratchet
from the crusher; how to pull bearings off the rotor; • 1/2-inch drive ratchet
how to pull the rotor and stub shafts apart; how to
put the rotor assembly back together. • 1/4-inch screwdriver

Tools & Equipment • hammer

Prior to hub, shaft, and bearing assembly or • 3/8-inch pin punch


disassembly, be sure you have the following tools,
parts, and consumables on hand.
Parts
Tools
• 8 1-1/2” nuts (1” dia. coarse) & flat washers
• ruler
• 8 special bolts (See Appendix D.)
• soft-lead pencil
• 4 1-1/2-inch hex head, 1-inch dia. x 4-inch
• multi-depth feeler gage long. coarse bolts
• 2 chains, straps or slings capable of lifting rotor • 6-foot length of 1-inch all-thread
assembly safely (see Appendix A)
• spare lock nut to build bearing press
• Porto-Power & hose
• eyebolt, 3/8-16 NC
• oxy-acetylene torch with cutting tip
• grease gun
Consumables
• 24 Huckbolts & Huckcollars
• tube of Loctite 262
• Huck gun
• 6 tubes of lithium-base, EP, type-1 grease
• inch-pound torque wrench
• Anti-seize compound
• torque wrench (500 foot-pound capacity)
• lint-free rags
• adjustable-hook spanner, 4-to-12-inch
• cleaning solvent (for grease & dirt)
• 5/32-inch Allen wrench
• spray paint can, or other marker
• 3/4-inch Allen wrench
• Assorted metal and wood blocks, wedges, and
• 1-1/2-inch socket wrench thicknesses (read through instructions that
• bearing press bolt head wrench follow to learn kinds and sizes).

• 1-inch impact wrench (& power source) or


breaker bar
• 3/8 or 1/2-inch drill

24215 (7/07) 6-1 HSI 1300


Hubs, Shaft & Bearings

Rotor Removal

Rotor Removal
Threaded Housing
1. Lockout & Tagout power to peripherals and to Lifting Hole
Nuts &
crusher main drive. (3/8”-16NC)
Lockwashers

WARNING
Failure to Lockout & Tagout crusher drive
power could result in death or serious
injury.
2. Remove belt guard(s), belts and drive sheave
from crusher.
3. Loosen latch bolts and swing them aside.
4. Open crusher frame. Install frame lock pin.
Pillow Block
5. Wrap a pair of choker slings around rotor Mounting
assembly, using chains, straps or slings with Bolts
sufficient rated capacity. Hook slings to crane Figure 6 - 1 Pillow Block
or other lifting device, of sufficient capacity,
and take up slack in slings.
Bearing Removal
6. At both ends of rotor assembly, remove four
The following procedure applies to removal of the
each mounting bolts, nuts, lockwashers, and
bearing from either end of the rotor, except as
eight each flat washers from each pillow-block
indicated.
assembly (Figure 6 - 1). Set aside in a clean
area for later assembly. 1. Crib lumber under pillow-block assembly (If
you plan to remove both stub shafts, crib under
both pillow blocks)
WARNING 2. Use spray paint or marker to stripe across seam
in pillow block. Stripe each pillow block
Stay away from the rotor assembly while it differently from the other (e.g. one with a wavy
hangs from lifting device. Failure to do so line and the other with a straight line). This
could result in death or serious injury. identifies top and bottom halves as a set.

7. Lift assembly up and out of crusher, swing it


clear of the crusher frame and set it down on NOTICE
hardwood blocks.
If during reassembly you get upper and
lower halves of two different pillow blocks
mixed up, premature bearing failure may
result.

24215 (7/07) 6-2 HSI 1300


Hubs, Shaft & Bearings

Bearing Removal

WARNING
Stay out from under pillow block while it
hangs from lifting device. Failure to do so
could result in death or serious injury.
3. Remove four nuts and lockwashers that hold
top half of pillow block to bottom (Figure 6 - 1)
and set aside in clean area for reassembly.
Thread an eyebolt (3/8”-16 NC) into bolt hole
in top half of pillow block (Figure 6 - 2). Use
lifting device to remove pillow block top half
and set it aside.

Figure 6 - 3 Lower Pillow Block Lift Method

Stabilizer Ring

Lockwasher with Tabs

Lock Nut

Outer Seal

Figure 6 - 2 Upper Pillow Block Lift Method

4. On held side only (usually drive side), remove


stabilizing ring from bearing housing.
5. Attach lifting device to bottom half of pillow
block (Figure 6 - 3). Be sure to screw the nuts
all the way to the end of the threads on each
stud, to protect the threads. Put tension on lift;
remove cribbing under pillow block and let
block down off the bearing. Set it aside.
6. Use 5/32-inch Allen wrench to loosen set Pipe Plug
screws in outer seal (Figure 6 - 4). Remove seal
from shaft. Figure 6 - 4 Loosen Set Screws on Outer Seal

24215 (7/07) 6-3 HSI 1300


Hubs, Shaft & Bearings

Rotor Disassembly

7. Use screwdriver to straighten tab on bearing several times by hand, but it must be vented. If not,
lock washer. Break off the tab you just then atmospheric pressure will make removal of
straightened, so that it cannot be used again. stub shaft difficult.

CAUTION Breather Vent Hole

Loosen, but do not remove, the AN nut 6”


before the bearing has been disengaged
from the tapered seat. When oil pressure is
applied to the shaft, the AN nut will keep
the bearing from completely sliding from
shaft, causing possible injury.
8. Loosen, but do not remove, the lock nut, lock
washer and stabilizer ring on shaft. Be sure lock
nut is still engaged in the shaft threads.
9. Remove 3/8-inch pipe plug from end of shaft.
Thread Porta-Power hose into hole.
10. Use a Porta-Power device to inject high- Vent may be located anywhere
along this circumference.
pressure oil into end of shaft. Oil pressure
forces bearing inner race off its tapered seat, Figure 6 - 5 Rotor Breather Vent Location
allowing removal of bearing from shaft. When 2. Use 3/4-inch Allen-head socket to remove
bearing is loose, remove Porta-Power and hose; semicircular Huckbolt guards from hub. Retain
replace plug. guards and guard bolts.
11. Remove the lock nut, lock washer and 3. Using oxy-acetylene torch, cut collars off
stabilizer ring from shaft. Huckbolts and knock bolts out of hub with
12. Loosen set screws of inboard seal. Remove seal hammer and punch. Discard used Huckbolts.
from shaft.
Rotor Disassembly NOTICE
The following procedure applies to removing the
rotor shaft at either end of the rotor. Be careful not to mar the hub when cutting
collars off Huckbolts
1. Find breather vent in body of rotor. Vent is Pay attention to four 1-inch holes that held
plugged with silicone. Using a drill or other Huckbolt-guard retaining bolts. Notice that guard-
tool, remove the plug, clearing the vent bolt holes are threaded and have metal behind
(Figure 6 - 5).
them, whereas holes that held Huckbolts
The vent may not be easy to find. It’s only 1/4 inch themselves are not threaded and open at both ends.
in diameter. To find the vent, you might have to
clear away some dust and debris and turn the rotor

24215 (7/07) 6-4 HSI 1300


Hubs, Shaft & Bearings

Rotor Assembly

4. Thread four 1-inch bolts, 4 inches long,


threaded National coarse, into guard bolt holes
(Figure 6 - 6) until they bottom against rotor.

Block
Hub Flange

Hub
Figure 6 - 7 Pin Shackle on Shaft

8. Repeat steps 5 and 6 until inboard end of shaft


is clear of rotor and hangs from lifting tackle.
Then lower shaft to deck, unpin shackle and
roll old shaft out of the way.

Figure 6 - 6 Blocks Between Jackscrews & Rotor


Rotor Assembly
The following procedure applies to installing a
5. Using an impact wrench or a big ratchet, work rotor shaft at either end of the rotor body.
those four bolts as jackscrews to push stub shaft
out of rotor. Shaft should move about 1 inch 1. Use lint-free rags and degreasing solvent to
before jackscrews run out of thread. clean grease and grit from rotor tube and hub
flange. Dry surfaces. Check contact points
6. Back jackscrews off until you can get steel from jack screws used to remove shaft and
blocks between jackscrews and rotor grind flat if necessary.
(Figure 6 - 6). Then tighten jackscrews again.
7. Repeat steps 5 and 6 until you have enough
room between hub and rotor to pin a 3/4-inch NOTICE
shackle to topmost hole in hub (Figure 6 - 7).
Hook shackle to suitable lifting device and lift Cleanliness is critical here. Clearance
slack out of tackle. between new shaft stub and rotor tube is
more than 0.001 inch (0.025 mm) but less
than 0.005 inch (0.127 mm). A single grain
WARNING of sand will change that to an interference
fit.
Stay out from under stub shaft while it 2. Cut four 18-inch lengths of 1-inch all-thread
hangs from lifting device. Failure to do so rods. Get eight nuts and flat washers that will fit
could result in death or serious injury. the all-thread rods.

24215 (7/07) 6-5 HSI 1300


Hubs, Shaft & Bearings

Rotor Assembly

WARNING
Stay out from under stub shaft while it
hangs from lifting device. Failure to do so
could result in death or serious injury.
3. Pin shackle to new shaft and lift it into position. 90o

Before sliding inboard end of shaft into rotor


hole, make sure holes in hub line up with
counterpart holes in rotor. If holes don’t match,
set shaft back on deck and move shackle. Then
lift shaft into position and check hole match
again.
Figure 6 - 8 Pull Shaft Evenly into Rotor

NOTICE
NOTICE
If working on non-drive shaft, you must
also make certain that lock-pin holes in hub When assembly is pulled together,
(1-9/16 inches in diameter) match lock-pin Huckbolt holes in rotor tube must match
holes in rotor. Huckbolt holes in shaft and four threaded
holes in shaft (Huckbolt guard retainer-bolt
4. When all holes match, leave shaft hanging from
shackle while you use lint-free rags and solvent holes) will have metal behind them.
to clean all dirt off hub flange and stub end of 8. Remove shackle from shaft before it butts
shaft. Be sure to completely dry all surfaces. against flange of rotor. Then pull shaft
5. Apply a coat of FEL-PRO C5-A Anti-Seize completely in, so flange of shaft is flush against
lubricant (or equivalent) on surfaces of inboard end of rotor.
side of shaft and inside of rotor tube. 9. Remove all-thread rods and set them aside.
6. At 90-degree intervals, slip all-thread rod
through each of four huckbolt holes in shaft
hub and through four matching holes in rotor NOTICE
(Figure 6 - 8). Slip washer over both ends of
each rod, then start nuts on both ends. Check to make sure that all holes line up
7. Start stub end of shaft into rotor tube. Tighten correctly.
both nuts alternately on each all-thread. Ensure 10. Install 12 Huckbolts from the inside of the
that shaft is being drawn evenly into rotor tube rotor, so the end extends outside the hub flange.
(Figure 6 - 8) without binding. Huckbolt holes Slip Huckcollars over (shaft flange side) end of
come into alignment as you turn nuts down. Huckbolts. Use Huck gun to run collars down

24215 (7/07) 6-6 HSI 1300


Hubs, Shaft & Bearings

Bearing Installation

tight. Tighten the first four collars using a cross 2. Slide inner seal assembly onto shaft until it’s an
pattern to be sure shaft stays aligned properly inch or two past tapered section. Be careful not
(Figure 6 - 9). to cut the O-ring. Orient seal so grease fittings
11. Put the semicircular Huckbolt guards in place are at top of shaft. Leave it for now.
and bolt them to hub using hardware retained in 3. Stand bearing on bench and measure
rotor disassembly. unmounted clearance at top of bearing,
If you’re replacing both stub shafts, repeat this between rollers and outer race (Figure 6 - 10).
procedure at other end of the rotor. If not, you’re Record measurement taken for later use.
ready to mount a bearing. With both shafts installed
on the rotor, plug vent hole in body of rotor, using
silicone sealant.

Figure 6 - 9 Attaching Shaft to Rotor Figure 6 - 10 Measure Unmounted Clearance

Bearing Installation 4. Slip tapered bore of bearing onto shaft, large


end first. Slide it on as far as you can without
using force.
NOTICE 5. With bolt heads outboard, thread bearing press
onto shaft, chamfered side first (Figure 6 - 11).
The following procedure requires a bearing Refer to Appendix D - Bearing Press Design
press, which you must build from a spare for instructions
N-44 size lock nut and some bolts.
6. Tighten press until chamfered side touches
Drive End and Non-Drive End bearing. With your fingers, tighten bolts until
1. With your hands, squeeze and press two halves ends touch against bearing race.
of inner seal assembly together.

24215 (7/07) 6-7 HSI 1300


Hubs, Shaft & Bearings

Bearing Installation

7. Now, using wrench in circular pattern, tighten


bolts one quarter-turn at a time, pressing inner
bearing race farther onto tapered portion of
shaft (Figure 6 - 11).

Figure 6 - 12 Checking Mounted Clearance

10. When correct clearance is reached, remove


bearing press. Locate lockwasher and make
sure all previously used tabs have been
removed. (If all tabs have been used and
removed, a new lockwasher is required.) With
Inner tabs pointing toward bearing, slide
Figure 6 - 11 Using Bearing Press
lockwasher onto shaft.
11. With chamfered side facing inboard, thread
8. After each full pass around circle, check lock nut onto shaft. Tighten lock nut until it
mounted bearing clearance on underside of presses lock washer firmly against bearing.
shaft, between rollers and inner race (Figure 6 -
If clearance is now different from 50-60
12). percent of measurement recorded in step 3,
9. Continue tightening procedure until mounted repeat installation procedure until correct
clearance reading is 50-to-60 percent of results are obtained.
unmounted clearance (previously recorded in 12. Find lock washer tab nearest to a slot in the lock
step 3). nut. If no slot lines up with a tab, use
adjustable-hook spanner to tighten nut so
Example: If unmounted clearance was 0.010
nearest slot and tab come together. Do not
inch (0.254 mm), mounted clearance should be loosen the nut to align a tab.
from 50 to 60 percent of that, or 0.005 to 0.006
inch (0.127 to 0.152 mm). 13. Check mounted clearance again as in Step 11.
Be certain it’s still within specification. If it is,
bend lock tab into slot (Figure 6 - 13).
14. Pump bearing full of EP type-1 grease. Pump
grease between all rollers on both sides of
bearing. This assures adequate lubrication at
startup.

24215 (7/07) 6-8 HSI 1300


Hubs, Shaft & Bearings

Bearing Installation

Figure 6 - 13 Bend Lock washer Tab into Lock Slot

Drive End of Shaft Only


1. Press halves of outer seal assembly together. WARNING
2. Slide outer seal assembly onto shaft until
O-ring edge is an inch or so from the lock nut. Stay out from under pillow block while it
Be careful not to cut the O-ring. Orient seal so hangs from lifting device. Failure to do so
grease fittings are at top of shaft. Leave it for could result in death or serious injury.
now. 4. Use appropriate lifting device to lift lower half
3. Using lint-free rags and degreaser solvent, of pillow block up to bearing. Raise/lower it
clean pillow block carefully. Make sure mating carefully, so that bearing O-ring seals are
surfaces, bearing seats and O-ring grooves in correctly fitted into lower-half, pillow block
both halves are totally free of old grease grooves and bearing sits squarely in lower-half,
residue, grit, paint, etc. Run small wire through pillow-block seat (Figure 6 - 14). Be careful not
grease ports. Make sure they are unclogged. to cut the O-ring.

24215 (7/07) 6-9 HSI 1300


Hubs, Shaft & Bearings

Bearing Installation

5. Slide pillow block so that stabilizer ring can be


inserted between locknut side of outer race and
shoulder of bearing housing (Figure 6 - 14). NOTICE
6. Crib lumber under lower half of pillow block to Before torquing bolts, check seal
hold it in position. Remove hoist and tackle. orientation. Make sure grease fittings are
up.
7. With grease gun, pump lower half of pillow
block 1/3 to 1/2 full of EP, type 1 grease. 9. Replace four lockwashers and nuts (retained in
Bearing Removal, step 13) on the four studs
protruding through upper half of pillow block.
WARNING Thread nuts down tight. Alternately torque
each nut, in 100-foot pound increments, to 500
Stay out from under pillow block while it foot-pounds each.
hangs from lifting device. Failure to do so
10. If pillow block is new, install grease fitting in
could result in death or serious injury.
lube port of pillow block.
11. If bearing only (and not rotor) was replaced,
NOTICE using hardware retained during disassembly.
Place a flat washer over each pillow block
During assembly, be sure that top and mounting hole; insert a bolt through each hole;
bottom halves of pillow blocks are and add flat washer, lockwasher, and nut to end
matching as marked in disassembly. of each bolt. Thread nuts down tight.
Alternately torque each nut, in 100-foot pound
increments, to 1,500 foot-pounds each.
8. Using appropriate lifting device lift upper half
of pillow block, place each upper half fastening
hole over lower half studs, and set it carefully
upon lower half, making sure aligning pins are
inserted into aligning holes. Be sure bearing O-
ring seals fit properly into upper-half, pillow-
block grooves, and bearing is seated squarely in
upper-half, pillow-block seat. Be careful not to
cut the O-ring. Mating surfaces will come flush
together without use of force.

24215 (7/07) 6 - 10 HSI 1300


Hubs, Shaft & Bearings

Bearing Installation

1. Pillow Block (upper half) 6. Stabilizing Ring


2. Pillow Block (lower half) 7. Lock Washer
3. Inner Seal Assembly 8. Lock Nut
4. Grease Fitting 9. Outer Seal Assembly
5. Spherical Bearing 10. Set Screw

4
5 6 8
7 4
1
10

10

3 9
2
The only differences between drive-side
and driven-side assemblies are these:
1) The non-drive side assembly has no
outer seal. Instead, a neoprene end cap
protects the assembly from contaminants.
2) The non-drive side assembly uses no
stabilizing ring. Instead, the bearing is
allowed to “float” inside its pillow.

Figure 6 - 14 Drive-Side Bearing Assembly Nomenclature

24215 (7/07) 6 - 11 HSI 1300


Hubs, Shaft & Bearings

Rotor Assembly Installation

Non-Drive End of Shaft 2. Using chains, straps or slings with sufficient


rated capacity (See Appendix A), wrap a pair of
The non-drive side of the crusher rotor shaft carries
choker slings around rotor assembly.
no outer seal. In place of an outer seal, a neoprene
end cap is inserted in the O-ring groove of the
bearing housing.
WARNING
Do not use a stabilizer ring against the bearing on
the non-drive side. Just make sure that mounted Stay out from under rotor assembly while it
clearance is correct and that the bearing sits square
hangs from lifting device. Failure to do so
within its housing. This side must be free to float
could result in death or serious personal
axially within the housing during operation.
injury.
With those exceptions, assembly of the non-drive
side is the same as assembly of the drive side. 3. Hook slings to suitable lifting device. Lift
Follow drive-side procedure, steps 26 through 36 assembly and move it into position over
(allowing for exceptions stated here), to assemble crusher.
the non-drive side. 4. Set assembly down on crusher frame so that
pillow blocks fit between shear bars and sit flat
Rotor Assembly Installation
upon their seats (Figure 6 - 15).
1. Using lint-free rags and appropriate degreasing
solvent, clean all grit away from shear bars and
pillow-block seats on crusher frame.

Shear Bars

Figure 6 - 15 Bearing Shear Bars

24215 (7/07) 6 - 12 HSI 1300


Hubs, Shaft & Bearings

Rotor Assembly Installation

Equal Distance
Both Sides

Figure 6 - 16 Opposite Ends of Rotor Equidistant from Crusher Frame.

5. Use ruler to position assembly so that opposite Adjust the pillow block so that the bearing is
ends of rotor are equidistant from crusher frame approximately centered in its housing. Then let
(Figure 6 - 16). go the hoist, remove your lifting tackle. Using
4 each bolts, lockwashers, and nuts, and 8 each
6. Check clearance between interior walls and
flat washers per pillow block, bolt both pillow
ends of rotor one more time. If clearance is
blocks to the frame. Alternately torque each
equal, remove lifting tackle from drive side of
bolt and nut, in 100-foot pound increments, to
rotor assembly.
1,500 foot-pounds each.
7. On the non-drive side, you’ll be able to move
8. Make sure that vent hole in rotor is filled-
the pillow block back and forth about 3/8 of an
plugged with appropriate silicon sealer.
inch (10 mm) along the shaft because you
didn’t put a stabilizer ring in the bearing
housing.

24215 (7/07) 6 - 13 HSI 1300


Hubs, Shaft & Bearings

Seal Positioning

Seal Positioning
1. At the sheave end of the drive shaft, use your
fingers to push the outboard seal into the pillow
block as far as you can.
2. Using the outer edge of the outboard seal as a
guide, take a lead pencil and draw a ring around
the shaft (Figure 6 - 17).

Figure 6 - 18 Pull Seal Just Enough to Cover Ring

5. Lock the seal to the shaft by tightening both


setscrews. Torque them to 156 inch-pounds
(17.6 N•m).
6. Now perform steps 1 through 5 on inboard
seals at both ends of rotor.
7. Apply grease to all seals until grease extrudes
from seals for fully 360 degrees.
Final Touches
1. Remove all tools, extra parts and equipment
from inside crusher. Check the area twice.
2. Remove frame lock pin and rotor lock pin, and
store.
Figure 6 - 17 Draw Ring Around Shaft
3. Clear personnel away from machine.
3. Now pull the seal out of the pillow block, just 3. Remove lock & tag from crusher hydraulic
far enough so that you can no longer see the power source and close crusher frame. Engage
pencil ring (Figure 6 - 18). This provides 1/16- each side latch bolt tighten.
to 1/8-inch axial clearance, which is required
for proper operation of the seal. 4. Lockout & Tagout power to crusher hydraulic
system. Verify main power lock and tag.
4. Using a 5/32-inch Allen wrench, turn the 2
5. Open inspection doors at both sides of crusher.
setscrews out of the seal, coat them with Loctite
262 and thread them back in. 6. Refer to Section 7, Operation and Adjustment
to adjust breaker plates and set the closed side
setting.
7. After any adjustments, roll rotor by hand at
least one full turn, to be sure that no part of
rotor contacts breaker plates or stripper liner.

24215 (7/07) 6 - 14 HSI 1300


Hubs, Shaft & Bearings

Final Touches

8. Close and bolt both side inspection doors.


9. Install drive components and all guards. Make
sure everything is properly aligned.
10. Pick up and inventory all tools and equipment
to make sure you’ve left nothing inside the
machine.
11. Clear personnel away from machine.
12. Remove lock and tag from crusher drive power
source.
13. Start machine and let it run empty while you
listen for unusual noise or vibration.
If no noise or vibration is present, machine is ready
for operation.

24215 (7/07) 6 - 15 HSI 1300


Hubs, Shaft & Bearings

Final Touches

This Page Intentionally Left Blank

24215 (7/07) 6 - 16 HSI 1300


Operation & Adjustment

Hydraulic System

Section 7 - Operation & Adjustment Operator controls are labeled for easy
identification. A sight glass mounted on the
Hydraulic System reservoir provides a quick way to check the
The hydraulic system provides a way to open the hydraulic fluid level.
crusher for service and to release pressure on the
One control valve is used to open and close the
primary and secondary bridge for performing
frame of the crusher, one to lift the upper breaker
breaker plate adjustments. The system consists of
plate and one to lift the lower breaker plate. When
an electric motor and pump, a 5-gallon (18.9 L)
the bridges are lowered, locking plates maintain the
reservoir tank, and control valve assembly. Refer to
operator setting.
Figure 7 - 1 and Figure 7 - 2 for aid in locating
components of the hydraulic system. Refer to A test fitting at the rear of the pump allows
Figure 7 - 3 for a schematic diagram of the system. connection of a pressure gauge to check and adjust
the 2,000 psi (140.6 kg/cm2) system pressure.

Pressure Gauge
Attachment

Motor/Pump
Assembly

REAR VIEW

Operator
Controls
Sight Glass

Breather Cap/
Fill Hole

Reservoir

Drain Plug

Figure 7 - 1 Hydraulic Power Unit

24215 (7/07) 7-1 HSI 1300


Operation & Adjustment

Hydraulic System

Primary
Bridge Ram (one each side)

Secondary
Bridge Ram
(one each side)

Frame Opener
Cylinder
(one each side)

Hydraulic Power Unit


(mounted on non-drive side)

Figure 7 - 2 Hydraulic System

24215 (7/07) 7-2 HSI 1300


Operation & Adjustment

Hydraulic System

Figure 7 - 3 Hydraulic System Schematic

24215 (7/07) 7-3 HSI 1300


Operation & Adjustment

General Precautions

General Precautions • Lockout & Tagout power to crusher hydraulic


system before allowing anyone to climb onto
When operating the hydraulic system, take the or into machine.
following precautions:
• Lockout & Tagout power to the crusher drive
motor, and wait for rotor to stop turning before WARNING
opening any access doors or attempting to
Lockout & Tagout power to crusher
open the crusher. The spinning rotor contains hydraulic system before climbing onto or
enough momentum to cause death or serious into this machine. Failure to heed this
injury from either direct contact or from flying warning could result in death or serious
material. injury.
• Never climb inside crusher unless rotor is
locked, frame is fully open and secured in that
DANGER position. Minimize the possibility that anyone
could close frame while people are in or on
Lockout & Tagout power and wait for all
machine.
moving parts to stop before opening
crusher. Failure to heed this warning will • When operating crusher hydraulic system,
result in death or serious injury. watch for and stay away from high-pressure
fluid leaks.
• Lockout & Tagout power to crusher drive
motor before operating the hydraulic system.
WARNING
NOTICE High-pressure fluids are dangerous. Use
cardboard or paper to check for leaks, not
Be sure rotor is not turning before your hand. Relieve pressure before
attempting to adjust breaker plates. If a disconnecting hydraulic lines. Failure to
breaker plate contacts a turning rotor, heed this warning could result in death or
serious damage will result. serious injury.
• Keep away from front of crusher whenever • When using hydraulic assistance for breaker
frame is open or being opened. Weight of plate adjustments, always follow procedures
breaker plates inside crusher can shift listed in this section.
suddenly and push primary adjuster rods
• When making breaker plate adjustments, use
through frame with great force. crusher hydraulic system only to raise or lower
breaker plates. Always use adjuster nuts to
secure breaker plates in desired position.
WARNING Never attempt to operate crusher when weight
of breaker plates is supported by the hydraulic
Keep away from front of crusher when rams.
frame is open or being opened. Failure to
heed this warning could result in death or • Make sure all hydraulic cylinders are fully
serious injury. retracted before starting crusher.

24215 (7/07) 7-4 HSI 1300


Operation & Adjustment

Pre-operation Check

Pre-operation Check Hydraulic Controls


It’s a good idea to do a short inspection before The procedures that follow show the location and
using the hydraulic system of your crusher. Before function of the hydraulic controls on the crusher.
you start the pump, always do as follows: Hydraulic controls for stationary units are mounted
on the side of the crusher opposite the sheave.
1. Walk slowly around crusher and look for oil Hydraulic controls for units mounted on portable
leaks. As you do so, check oil lines for cracks plants are usually located on the side of the truck
and wear. Make sure lines are mounted frame, accessible from ground level.
securely and all fittings are tight. This keeps The function of each control lever is shown by a
oil inside system while it keeps air and dirt out. decal affixed to the unit near the control levers
(Figure 7 - 4).
2. Make sure reservoir’s breather/filler cap is
present, clean, and securely in place.Make sure
oil in reservoir is clean -- not foamy or milky -
- and sight glass shows at least 3/4 full.
Label on
hydraulic unit
NOTICE shows control
function.

Be sure all cylinders are fully retracted


before checking oil level.
1 2 3

3
NOTICE 2

Never operate hydraulic system when oil


level is low or when oil is contaminated 04493-500-19

with air, dirt, or alien fluids. Failure to heed


this notice will cause damage to machine.

3. Check system control levers and valves:


Valves are 3-position (forward, back and
neutral), and normally rest in center (neutral)
position. You should be able to grasp levers
and move them freely, forward and back.
There should be no leaks anywhere.
If inspection does not reveal a problem, the
hydraulic system is ready to use.

Figure 7 - 4 Hydraulic Unit Control Functions

24215 (7/07) 7-5 HSI 1300


Operation & Adjustment

Hydraulic Controls

Opening the Crusher 5. Lockout & Tagout power to crusher hydraulic


Run the crusher until the crushing chamber is system. Verify main power lockout.
completely empty. Stop the crusher drive system
and Lockout & Tagout the power source. Be sure
rotor is completely stopped before opening the WARNING
crusher.
Be sure to install lock pins in both the rotor
and frame hinge, whenever the crusher is
WARNING open. Do not enter machine until the lock
pins are installed. If the frame closes or the
Always lock out power source before rotor suddenly turns, death or serious injury
cleaning, adjusting or performing any could result.
maintenance or repairs. Make it impossible 6. Locate stored locking pins. Use one pin to lock
for anyone to start the machine while others the frame into an open position. Use one pin to lock
work in or on it. Failure to do so could the rotor. If necessary, roll rotor by hand to align
result in death or serious injury. holes. Install pin through aligned holes. The rotor
and frame lock access holes are located on either
1. Lockout & Tagout power to crusher main drive,
side of the crusher (Figure 7 - 5)
and associated equipment.
2. Loosen nuts on frame latch bolts and swing
bolts aside, out of latches.
3. Warn everyone away from the crusher. Make
sure all hands are clear.

WARNING
Keep away from front of crusher when
frame is open or being opened. Breaker
plates inside the machine can swing
causing the adjuster rods to move suddenly.
Failure to stay clear of rods could result in
death or serious injury.
4. Start crusher hydraulic pump. Pull the
applicable control valve to raise the upper
portion of the frame. As frame opens, the Rotor Lock Hole
weight of the breaker plates, will push the
Frame Lock Hole
adjuster rods partially out through frame.
Operate the valve as necessary to allow
Figure 7 - 5 Typical Locking Hole Locations
installation of frame lock pin. Lifting cylinders
will automatically stop when fully extended.

24215 (7/07) 7-6 HSI 1300


Operation & Adjustment

Breaker Plate Adjustment

Closing the Crusher • The primary breaker plate is factory set to


1. Pick up and stow all tools and equipment. Make within about 5 inches of the rotor
sure nothing is left inside crusher chamber. circumference (shown as dimension A).

2. Remove and store locking pins from frame and • The secondary breaker plate is factory set to
rotor. within about 2 inches of the rotor
circumference (shown as dimension B).
3. Remove lock & tag from crusher hydraulic
power unit. • Turn the adjustment nuts on each end of the
4 Start crusher hydraulic pump. Push right-hand applicable bridge the same amount. When
control lever forward, away from your body. adjustment is completed, always look inside
Cylinders will retract and bring frame closed. the machine to verify the breaker plates to
rotor clearance (closed side setting (CSS)).
5. On each side of crusher, engage latch bolts into
Make sure the breaker plate is parallel to the
notches and tighten nuts fully.
rotor.
6. Remove Lock & Tag from crusher drive power
source. • Tension Rod Adjustment Ratio:
Primary breaker plate - one inch of adjustment
Breaker Plate Adjustment of the tension rod equals about 1.4 inches of
Run the crusher until the crushing chamber is movement at the tip of the breaker plate
completely empty. Stop the crusher drive system nearest the rotor.
and Lockout & Tagout the power source. Be sure Secondary breaker plate - one inch of
rotor is completely stopped before working on adjustment of the tension rod equals about 1.6
crusher. After adjustment of either breaker plate, be inches of movement at the tip of the breaker
sure to visually check clearance of the breaker plate plate nearest the rotor.
to the rotor (Figure 7 - 6).

A
WARNING
Always lock out power source before
cleaning, adjusting or performing any
maintenance or repairs. Make it impossible
for anyone to start the machine while others
work in or on it. Failure to do so could
result in death or serious injury.
As a general guideline:
• The primary breaker plate should always be set
to within about 2 to 3 times the distance of the
secondary breaker plate.
B

Figure 7 - 6 Closed Side Setting Reference

24215 (7/07) 7-7 HSI 1300


Operation & Adjustment

Breaker Plate Adjustment

Primary Breaker Plate Adjustment Secondary Breaker Plate Adjustment


The following procedure applies to the adjustment The following procedure applies to the adjustment
of the primary breaker plate (Figure 7 - 7). of the secondary breaker plate (Figure 7 - 7).
1. Remove the two pins holding each locking 1. Fully extend hydraulic rams, to raise secondary
plate in place. bridge. Raising the bridge frees the adjustment
nut from the bridge assembly retainer, and
2. Remove locking plates from each tension rod.
takes pressure off the rod threads.
Locking plate should slide freely over the
tension rod cover. 2. Turn the adjustment nut clockwise to increase
breaker plate setting (css). Turn counter
3. Loosen each tension rod cover about 1 inch
clockwise to decrease breaker plate setting.
above the bridge.
4. Fully extend hydraulic rams, to raise primary
bridge. Raising the bridge frees the adjustment
nut from the bridge assembly retainer, and NOTICE
takes pressure off the rod threads.
5. Turn the adjustment nut clockwise to increase To be sure of proper operation, turn both
breaker plate setting (CSS). Turn counter adjustment nuts an equal amount. One (1)
clockwise to decrease breaker plate setting. inch of rod movement produces about 1.4
inches of breaker plate movement.
3. Retract hydraulic rams. Be sure bridge sets
over the adjustment nut. Nut may have to be
NOTICE turned slightly to align with the bridge retainer
socket.
To be sure of proper operation, turn both
4. Verify the each tension spring upper seat is
adjustment nuts an equal amount. One (1)
flush with the bottom of the access hole in the
inch of rod movement produces about 1.4
spring guard. Adjust the spring as necessary by
inches of breaker plate movement.
removing the clip pin and turning the adjusting
6. Retract hydraulic rams. Be sure bridge sets nut. Turn the nut clockwise to decrease spring
over the adjustment nut. Nut may have to be tension or counter clockwise to increase spring
turned slightly to align with the bridge retainer tension. When finished, install the clip pins in
socket. each adjusting nut/spring guard.
7. Tighten both tension rod covers.
8. Install both locking plates and retaining pins.

24215 (7/07) 7-8 HSI 1300


Operation & Adjustment

Breaker Plate Adjustment

3
5

1. Primary Bridge
2. Retaining Pins
3. Locking Plate
9 6 4.Tension Rod Cover
7
5. Breaker Plate adjusting Nut
6. Secondary Bridge
7. Tension Spring Upper Seat
8. Tension Adjusting Nut
9. Clip Pin

Figure 7 - 7 Breaker Plate Adjustment

24215 (7/07) 7-9 HSI 1300


Operation & Adjustment

Periodic Maintenance

Periodic Maintenance .
General NOTICE
Perform regular maintenance to keep the hydraulic
Use only ISO 32 hydraulic oil. Filling
system in operating condition.
reservoir with anything other than ISO 32
• Perform a preoperation check every day. oil voids warranty on hydraulic system.
• Repair defects or leaks as soon as they appear. 6. Replace breather cap.
• Change hydraulic oil, at minimum, once a 7. Start hydraulic pump and check system for
year. leaks. Then shut pump off.
• Change hydraulic oil every time the system is 8. Check oil level. Sight glass must be 3/4 full;
opened for any reason. add oil as necessary.
Oil Change
1.Make sure all cylinders are fully retracted. NOTICE
2. Use a rag to clean grit off reservoir filler neck
and breather cap. Then take breather cap off Failure to dispose of used oil properly could
reservoir and clean it with solvent. result in serious environmental damage.

NOTICE
Crusher hydraulic system has no oil filter.
Wire suction strainer inside reservoir
prevents debris from the oil-pump intake,
but that screen doesn’t stop fine particles
like those that build up on and around the
breather cap during operations. Keep the
breather clean.
3. Remove drain plug from reservoir and let used
oil drain into a bucket.
4. Clean drain plug, then replace and tighten it.
5. Fill reservoir with fresh ISO 32 hydraulic oil
until sight glass is at least 3/4 full.

24215 (7/07) 7 - 10 HSI 1300


Wear Parts Replacement

Tools & Equipment

Section 8 - Wear Parts Replacement


This section contains procedures to replace wear WARNING
parts inside the crusher. Steps listed in these
procedures for opening the crusher, closing the Failure to lock rotor before working inside
crusher or adjusting breaker plates (closed side the crusher could result in death or serious
setting) are for reference only. injury.
For proper safety requirements and operating
procedures to open and close the crusher, and make
Tools & Equipment
adjustments, refer to the applicable paragraph • impeller-bar hooks (ship with crusher)
contained in Section 7, Operation and Adjustment. • whisk broom or brush
• steel wire brush
WARNING • assorted wrenches
• cutting torch
For proper procedures to open the crusher,
close the crusher and make adjustments to • hardwood blocks
the breaker plates, refer to Section 7, Frame Liner Replacement
Operation and Adjustment. Failure to
follow these procedures could result in One inch thick steel liners protect the crusher’s
death or serious injury. frame from damage. The liners are held in place by
3/4 inch, Grade 5 bolts. The eight liners that cover
the frame directly around the shaft openings are
1/4-inch thick and are plug welded in place. Frame
WARNING
liners should be replaced when they are worn to a
Lockout & Tagout all energy sources thickness of 1/2-inch. Since the liners around the
before performing any maintenance on this shaft openings are relatively thin, they should be
equipment. Make it impossible for anyone regularly inspected for damage and replaced using
to start this machine or associated judgement as to how quickly they are wearing. Any
equipment while people are in it or on it. liner that is cracked or broken must be replaced
Failure to Lockout & Tagout could result in immediately, regardles of wear. (Figure 8 - 1).
death or serious injury.

NOTICE
WARNING
Some machines are designed with frame
Failure to stay out from in front of crusher liners that require the mounting bolts to be
while frame is being opened could result in installed from inside the crusher, and
death or serious injury. secured on the outside of the frame using a
hardened flat washer and lock nut. These
liners have a recessed hole to secure the
mounting bolt head, but are not tapped.

24215 (7/07) 8-1 HSI 1300


Wear Parts Replacement

Frame Liner Replacement

NOTICE
Always replace liner bolts when you turn or
replace a liner.
6. Coat threads of each bolt with Loctite 271.
7. Start bolts from outside, through frame and
screw into liner. Torque bolts to 200 foot-
pounds (271 N•m).
OR - on some crusher models,
Install bolts from inside, through frame,
aligning bolt head in liner plate. Install
hardened flat washer and lock nut on bolt.
Torque lock nut to 200 foot pounds (271 N•m).

Figure 8 - 1 Typical Frame Liner Arrangement


WARNING
Failure to follow procedures listed in
WARNING Section 7 - Operation and Adjustment
could result in death or serious injury.
Failure to follow procedures listed in
Section 7 - Operation and Adjustment 8. Close the crusher. Follow procedures in
could result in death or serious injury. Section 7 - Operation and Adjustment, Closing
the Crusher.
1. Open the crusher. Follow procedures in Section
7 - Operation and Adjustment, Opening the 9. Clear the area, start the crusher and let it run
Crusher. empty for 5 minutes. Listen for any unusual
noise or vibration.
2. Identify the liner(s) to be replaced.
If no noise or vibration is present, you are finished
3. Loosen and remove bolts from worn liner or, if with this procedure and the crusher can be returned
bolts won’t come loose, burn the heads off. to service.
4. Remove old liner and clean all grit and debris
from out of its location.
5. Clean mounting surface of new liner and set
liner in place.

24215 (7/07) 8-2 HSI 1300


Wear Parts Replacement

Primary Breaker Plate Maintenance

Primary Breaker Plate Maintenance


The primary breaker plate must be turned or NOTICE
replaced when it has less than 2 inches of thickness
in any circumferential direction from pivot shaft Tackle and lifting device must be capable
center to breaker plate surface (Figure 8 - 2). The of lifting weight of breaker plate. Refer to
following procedures will describe steps necessary Appendix A.
to either turn or replace the primary breaker plate. 3. Remove breaker plate pivot shaft retainer,
capscrews, and lockwashers. Retain parts for
reuse, unless damaged, then replace.
WARNING
4. At front of crusher, remove lock pins, retainer
Failure to follow procedures listed in plates, and thread-protector caps from primary
Section 7 - Operation and Adjustment breaker plate adjuster rods. Then, remove
could result in death or serious injury. bridge, primary breaker plate adjusting nuts
and breaker plate bumpers, from under the
1. Open the crusher. Follow procedures in Section
bridge. Retain parts for reuse, unless damaged,
7 - Operation and Adjustment, Opening the
then replace.
Crusher.
2. Connect appropriate lifting tackle to lifting
WARNING
eyes cast in the primary breaker plate (Figure 8-
2). Hook tackle to appropriate lifting device Failure to use safe lifting practices while
and take out all slack. performing procedures detailed in this
manual may result in death or serious
injury.
Lifting Eye (one each end)
5. Working carefully, making sure that breaker
plate adjuster rods don’t bind while sliding
through guides, lift breaker plate up until it is
clear of the frame.
6. Lay breaker plate on deck, impact-side down.
Remove tackle from lifting eyes.
7. Pull breaker plate shaft out of breaker plate-
hinge bore and inspect for wear, damage.
Replace if necessary.
2"
8. Slip shaft into hinge bore of new breaker plate.
OR
If you’re turning the old breaker plate, slip shaft
into hinge bore at opposite end of breaker plate.
Figure 8 - 2 Primary Breaker Plate Wear Measurements

24215 (7/07) 8-3 HSI 1300


Wear Parts Replacement

Primary Breaker Plate Maintenance

9. If changing breaker plate, remove adjuster rods 12. Install keeper and hardware removed in step 3
from old breaker plate and bolt them onto new of this procedure. Replace any damaged
breaker plate in eyes located opposite breaker hardware. Torque bolts to 200 foot pounds (271
plate shaft. N•m).
OR
13. Remove lifting tackle from breaker plate.
If you are turning a worn breaker plate, unbolt
adjuster rods from eyes in which they’re 14. At front of crusher, install hardware removed in
located and bolt them into corresponding eyes step 4 of this procedure, back onto adjuster
at opposite end of breaker plate. rods, in the reverse order in which it was
removed. Replace any damaged hardware that
10. Attach tackle to upper lifting eye of primary
was previously removed.
breaker plate.

WARNING WARNING
Failure to use safe lifting practices while Failure to follow procedures listed in
performing procedures detailed in this Section 7 - Operation and Adjustment
manual may result in death or serious could result in death or serious injury.
injury.
15. Close the crusher. Follow procedures in
Section 7 - Operation and Adjustment, Closing
the Crusher.
WARNING
16. Lockout & Tagout power to crusher hydraulic
Do not climb in front of, under, or between system. Verify main power lockout.
breaker plates when trying to manipulate
17. Open side inspection door.
adjuster rods. Failure to heed this warning
may result in death or serious injury. 18. Rotate rotor by hand until an impeller bar is as
11. Lift breaker plate assembly in place over frame, close to primary breaker plate as possible.
and slowly lower it, until ends of adjuster rods 19. Use a measuring device to gauge distance
are level with frame and bumper holes. Feed between impeller bar (rotor circle) and primary
hooks made of stiff wire through front side of breaker plate. Turn adjuster nuts to achieve
bumpers to steer adjuster rods through upper desired clearance. Make sure both adjuster rods
frame of crusher and into nylon guides on carry equal weight. Refer to Figure 8 - 3,
frame. Continue lowering, making sure that dimension A.
adjuster rods do not bind while sliding through
guides, until breaker plate shaft is fully seated
in notches on crusher frame.

24215 (7/07) 8-4 HSI 1300


Wear Parts Replacement

Secondary Breaker Plate


Maintenance

Secondary Breaker Plate Maintenance


NOTICE The following procedures describes steps
necessary to replace the primary breaker plate.
Detailed instructions for performing breaker
plate adjustments are given in Section 7. The Removal
primary breaker plate is factory set to within
about 5 inches of the rotor circumference 1. Remove primary breaker plate. Follow Primary
(shown as dimension A). Breaker Plate Maintenance procedure, steps 1
through 6, previously contained in this section.
2. Verify lockout & tagout of crusher main drive,
A hydraulic system and crusher peripherals.
3. The secondary breaker plate consists of steel
ribs connected at equal intervals 90 degrees to
the breaker plate shaft tube.
Connect appropriate lifting tackle to the
secondary breaker plate, using chain slings
around the shaft on the outside of the two
outermost ribs.
4. Hook tackle to appropriate lifting device and
take out all slack.
.

B NOTICE
Figure 8 - 3 Adjust breaker plate-to-Rotor Clearances
Tackle and lifting device must be capable
20. Close the side inspection door and bolt it shut. of lifting weight of breaker plate and any
attached liners. Refer to Appendix A.
21. Whenever adjusting crusher breaker plates, be
sure to roll rotor over by hand a few revolutions 5. Remove breaker plate pivot shaft retainer,
and listen for any interference, before applying capscrews, and lockwashers. Retain parts for
power. reuse, unless damaged, then replace.
22. Remove lock & tag from crusher main power 6. At front of crusher, remove lock pins, tension
and crusher hydraulic system. adjusting nuts, upper spring seat and tension
23. Clear the area, start the crusher and let it run springs from secondary breaker plate adjuster
empty for 5 minutes. Listen for any unusual rods. Then, remove bridge, secondary breaker
noise or vibration. plate adjusting nuts and breaker plate bumpers,
If no noise or vibration is present, you are finished from under the bridge. Retain parts for reuse,
with this procedure and the crusher can be returned unless damaged, then replace.
to service.

24215 (7/07) 8-5 HSI 1300


Wear Parts Replacement

Secondary Breaker Plate


Maintenance

2. Lift breaker plate assembly in place over frame,


and slowly lower it, until ends of adjuster rods
WARNING are level with frame and bumper holes. Feed
Failure to use safe lifting practices while hooks made of stiff wire through front side of
performing procedures detailed in this bumpers to steer adjuster rods through upper
manual could result in death or serious frame of crusher and into nylon guides on
injury. frame. Continue lowering, making sure that
adjuster rods do not bind while sliding through
7. Working carefully, making sure that breaker guides, until breaker plate shaft is fully seated
plate adjuster rods don’t bind while sliding in notches on crusher frame.
through guides, lift breaker plate up until it is
3. Install keeper and hardware removed in step 5
clear of the frame.
of removal procedure. Replace any damaged
8. Lay breaker plate on deck, with impact side up. hardware. Torque bolts to 200 foot-pounds
Remove lifting tackle. (271 N•m).
9. Transfer any usable liners to the replacement 4. Remove lifting tackle from breaker plate.
breaker plate.
5. At front of crusher, install hardware removed in
step 6 of removal procedure, back onto adjuster
Installation
rods, in the reverse order in which it was
1. Attach tackle, as before, to replacement breaker removed. Replace any damaged hardware that
plate. was previously removed.
6. Install primary breaker plate. Follow Primary
Breaker Plate Maintenance procedure, steps 10
WARNING through 19, previously contained in this section.
7. Rotate rotor by hand until an impeller bar is as
Failure to use safe lifting practices while close to secondary breaker plate as possible.
performing procedures detailed in this
manual may result in death or serious 8. Use a measuring device to gauge distance
personal injury. between impeller bar (rotor circle) and
secondary breaker plate. Turn adjuster nuts to
achieve desired clearance. Make sure both
WARNING adjuster rods carry equal weight. Refer to
Figure 8 - 3, dimension B.
Do not climb in front of, under, or between
breaker plates when trying to manipulate
adjuster rods. Failure to heed this warning
NOTICE
may result in death or serious personal Detailed instructions for performing
injury. breaker plate adjustments are given in
Section 7.
16. Close the side inspection door and bolt it shut.

24215 (7/07) 8-6 HSI 1300


Wear Parts Replacement

Secondary Breaker Plate


Maintenance

17. Whenever adjusting crusher breaker plates, be coming out of inspection door using free end of
sure to roll rotor over by hand a few revolutions rope, such that block’s position between
and listen for any interference, before applying breaker plate and front wall will be maintained.
power.
18. Remove lock & tag from crusher main power
and crusher hydraulic system. WARNING
19. Clear the area, start the crusher and let it run
empty for 5 minutes. Listen for any unusual Failure to follow procedures listed in
noise or vibration. Section 7 - Operation and Adjustment
could result in death or serious injury.
If no noise or vibration is present, you are finished
with this procedure and the crusher can be returned 5. Open the crusher. Follow procedures in Section
to service. 7 - Operation and Adjustment, Opening the
Crusher.
Liner Replacement
The following procedures describes steps WARNING
necessary to turn, or replace, liners on the
secondary breaker plate. It is not necessary to Only when the secondary breaker plate
remove either the primary or secondary breaker rests safely on hardwood block will it be
plates in order to replace liners on the secondary safe to work under the breaker plate. You
breaker plate. must reach under the breaker plate to
remove hardware that attaches the breaker
1. Lockout & Tagout power to crusher main drive plate liners. Failure to correctly support the
and all crusher peripherals. secondary breaker plate may result in death
or serious personal injury.
2. Open the rear inspection door.
3. Get a hardwood block of sufficient thickness
(about 12 x 12) and 18 inches long to fit WARNING
between frame of crusher and center rib of
secondary breaker plate. Bore a hole through The primary breaker plate will not swing
one end of block, and pass a light rope (or wire) against the secondary breaker plate when
through hole. Rope should be of sufficient the frame is fully opened. However, make
length (at least 20 feet) to lower block in place, sure the primary breaker plate swings freely
before working around it. If the primary
pass through the crusher’s front lifting eyes,
breaker plate suddenly moves, death or
and be tied off between the eyes.
serious could result.
4. Run free end of rope through both front lifting 6. Being careful to keep clear of adjuster rods,
eyes of crusher, and bring free end back to look through rear inspection door to be sure
center of inspection opening. Use other end of that center rib of secondary breaker plate rests
rope to lower hardwood block through securely on the hardwood block. If breaker
inspection door and down into crusher. Position plate does not rest properly on block, you must
block between center rib of secondary breaker close the crusher, relocate the block and try the
plate and front wall of crusher. Tie off rope

24215 (7/07) 8-7 HSI 1300


Wear Parts Replacement

Secondary Breaker Plate


Maintenance

procedure again. Do not work under the


breaker plate with weight supported only by
springs.

NOTICE
It may be necessary to loosen spring tension
in order for the breaker plate to rest on the
block.
Breaker plate liners are arranged on the secondary
breaker plate frame as shown in Figure 8 - 4. Under
normal conditions most wear occurs close to rotor,
at lower edge of bottom row of liners. The edges Figure 8 - 4 Liner Arrangement - 1316 Shown
nearest the rotor wear away first (Figure 8 - 5).
When distance between the breaker plate frame and
liner wear is less than 1/2 inch (12 mm), as at point
A, liner must be turned or replaced. Where distance Liner
between worn surface and head of liner bolt is less
than 1/4 inch (6 mm), as at point B & C, liner must
be turned or replaced. Liners that are cracked or
broken must be replaced immediately regardless of Liner Bolts
other wear.

NOTICE
If broken liners are not replaced
immediately or if liner wear is allowed to
progresses past limits given here, serious
damage to the breaker plate frame will
result. Frame B

WARNING
Liners weigh about 100 lbs each. If one A
C
were to suddenly break free and fall,
Dim. A must not be less than 1/2” Worn
serious injury could result. Dim. B and C must not be less than 1/4” Area
7. Remove liner bolts from any liners to be
replace/ exchanged. If bolts won’t come loose, Figure 8 - 5 Mounted Liners Profile
burn nuts off. Be careful not to mar breaker
plate frame.

24215 (7/07) 8-8 HSI 1300


Wear Parts Replacement

Secondary Breaker Plate


Maintenance

The useful life from a set of liners depends on your


specific application. Experience will teach you
NOTICE whether and when it is cost-effective to turn a set of
worn liners or replace them.
Whether you’re installing new liners or
turning worn liners, always replace old
mounting hardware with new. WARNING
8. Using proper lifting procedures, lift worn liners
Failure to follow procedures listed in
off their seats and set them aside.
Section 7 - Operation and Adjustment
could result in death or serious injury.
WARNING 12. Close the crusher. Follow procedures in
Failure to use safe lifting practices while Section 7 - Operation and Adjustment, Closing
performing procedures detailed in this the Crusher.
manual could result in death or serious 13. Lockout & Tagout power to crusher hydraulic
injury.
system. Verify main power lockout.
9. Clean seating surface of breaker plate and
backs of all liners. 14. Open side inspection door.
15. Rotate rotor by hand until an impeller bar is as
NOTICE close to primary breaker plate as possible.
16. Use a measuring device to gauge distance
Secondary breaker plate liners are brittle. between impeller bar (rotor circle) and
Even new liners can break when tightened secondary breaker plate. Turn adjuster nuts to
down on a piece of debris. Be sure seating achieve desired clearance. Make sure both
surface and liner are clean before mounting. adjuster rods carry equal weight. The
secondary breaker plate is factory set to within
10. Set new or reusable liners in place. If used about 2 inches of the rotor circle (Figure 8 - 3,
liners are installed, position them with worn dimension B).
surfaces facing top of breaker plate.
11. Install bolt through liner and breaker plate
frame. Install hardened flat washer and lock nut NOTICE
on each bolt. Torque each pair of bolts evenly
to 695 foot pounds (942 N•m). Detailed instructions for performing
breaker plate adjustments are given in
Because liners at the top of the breaker plate take Section 7.
less wear than others, it makes sense to swap good
upper liners with worn liners from bottom tier. You
may also be able to turn the bottom tier of liners to
get more life.

24215 (7/07) 8-9 HSI 1300


Wear Parts Replacement

Rotor Assembly Maintenance

17. Close the side inspection door and bolt it shut.


18. Whenever changing liners and adjusting NOTICE
crusher breaker plate, be sure to roll rotor over
by hand a few revolutions and listen for any The useful life of impeller bars in any given
interference, before applying power. machine is dependant on specific
19. Remove lock & tag from crusher main power application. Terex Cedarapids makes no
and crusher hydraulic system. guarantee to the extent of useful life of any
impeller bars.
20. Clear the area, start the crusher and let it run
empty for 5 minutes. Listen for any unusual Wedges, located on each rotor disk, pin the
noise or vibration. impeller bar tight against the backer bar.
If no noise or vibration is present, you are finished Tightening the mounting bolt of the wedge, forces
with this procedure and the crusher can be returned it against the impeller bar. This force in tandem
to service. with the insert bar, provide friction to the hold the
impeller bar in place.
Rotor Assembly Maintenance
Hardened plates, known as disk protectors, are
General Description bolted on the leading edge of each rotor disk to
Rotor disks are welded on the circumference of the protect the surface from excessive wear caused by
rotor tube. Across the rotor disks, parallel to the material impact.
rotor shaft, three backer bars are welded into place. A 3-bar rotor with no mounted impeller bars is
Machined into the forward surface of each backer- shown in Figure 8 - 6. Figure 8 - 7 shows a detailed
bar, a rectangular channel accepts the impeller bar. cross section of an impeller bar mounted into the
The rounded surface of the insert bar fits into a rotor.
groove (key) in the face of the impeller bar. Rotor Balance
Impeller bars strike the feed material and throw it
against the breaker plates. During crushing The rotor is static-balanced during assembly.
operation, the impact surface of each bar is rounded However, because of the centrifugal forces caused
off as it wears away. by the turning rotor, balance of the rotor assembly
is critical to reduce vibrations to an acceptable
Each impeller bar can be turned top-to-bottom and level. Terex Cedarapids recommends impeller bars
end-to-end as it wears to present up to four (4) be installed in weight-matched sets. Weights are
impact surfaces. In this way, the useful life of an cast or otherwise marked on the bar. A weight-
impeller bar is greatly extended. A special lifting matched set of impeller bars are specified to weigh
hook fits into an integral hole cast in the impeller within three (3) pounds of each other.
bar to aid in removal, rotation and installation of
the bar into the rotor. • For a 3-Bar Rotor, the weight of each bar must
be within the 3-pound tolerance.
• For a 4-bar rotor, the weight of the two
opposing bars must be within the 3-pound
weight tolerance

24215 (7/07) 8 - 10 HSI 1300


Wear Parts Replacement

Rotor Assembly Maintenance

Wedge
Assembly

Backer Bars
welded to
rotor disks

Disk
Direction Protector
of Rotation

Insert Bar fits into


channel on leading
edge of each backer bar

Figure 8 - 6 Rotor Without Impeller Bars

Impeller Mounting
Grooves (keys)
Insert Bar
Disk Protector
Impeller Bar

Wedge

Backer Bar
Wedge Mounting/
Tightening Bolt Direction of
Rotor Rotation

Figure 8 - 7 End View of Mounted Impeller Bar

24215 (7/07) 8 - 11 HSI 1300


Wear Parts Replacement

Rotor Assembly Maintenance

Impeller Bar Replacement (see Appendix A for bar weights) and put the
hook end through the lifting hole of the first
Impeller bars should be turned or replaced when
impeller bar you intend to remove.
the crushing surface is worn to 1.63 inches in
height above the surface of the respective backer 3. The end of the hook is drilled and tapped to
bar (Figure 8 - 8). Allowing this height to be less accept a bolt and washer that will keep the
could serious rotor damage. impeller bar from falling off the hook while it
hangs from the lift. Always install this retaining
bolt when lifting a bar.

Impact surface 1.63”


Wedge Driver
wears away
Impeller Bar

Impeller Bar Hook


One hook required to lift
48” impeller bars. Two
hooks required for 64”
impeller bars.
Direction of Figure 8 - 9 Impeller-Bar Hook and Wedge Driver
Rotor Rotation
4. Remove nut and washer from wedge retaining
Figure 8 - 8 Wear Limit
bolt. Depending on model of your crusher,
Removal there are 3 or 4 wedges, with associated
hardware, for each impeller bar.
5. Remove wedge retaining bolt and washer.
WARNING Insert wedge driver into bolt hole and strike to
drive wedge down, to loosen (Figure 8 - 10).
Failure to follow procedures listed in
Section 7 - Operation and Adjustment
could result in death or serious injury. WARNING
1. Open the crusher. Follow procedures in Section Failure to use safe lifting practices while
7 - Operation and Adjustment, Opening the performing procedures detailed in this
Crusher. manual could result in death or serious
2. Find the impeller-bar hook and wedge driver injury.
that shipped with your crusher (Figure 8 - 9).
6. Use lifting hook to remove impeller clear of the
Hang the hook from a suitable lifting device
rotor and crusher. Set the bar on the deck.

24215 (7/07) 8 - 12 HSI 1300


Wear Parts Replacement

Rotor Assembly Maintenance

backer bar. Make sure the impeller bar lays flat


against the backer bar along its entire length.
(Figure 8 - 7).
3. Slide one of the impeller bar wedges as far as it
Wedge Driver will go, up into the gap between the face of the
impeller bar and the rotor disk Make sure the
two half holes of the wedge and disc line up.
Wedge

NOTICE
Do not reuse hardware to install wedges.
Use only Cedarapids approved capsrews,
flat washers and nyloc locking nuts.
Unapproved hardware may allow the
Figure 8 - 10 Wedge Removal impeller bars to become loose during
operation causing equipment damage.
4. Insert a hardened flat washer on a bolt. Insert
NOTICE bolt into top of rotor disc and wedge hole.
Install hardened flat washer and locknut on bolt
If you are turning an impeller bar, refer to
end. Torque wedge retaining bolts to 150 ft lbs.
Turning Impeller Bars, later in this section
(203 N•m).
for detailed information.
Installation
NOTICE
1. Clean seating surfaces of the rotor assembly
free of grit. Clean corresponding surfaces of Do not over tighten wedge bolts. If bolts are
impeller bar. over tightened, wedge will be very difficult
to remove at the next service interval.

WARNING 5. Repeat steps 1 through 4 for each wedge


assembly along an impeller bar, and for each
Failure to use safe lifting practices while impeller bar.
performing procedures detailed in this
manual could result in death or serious
injury.
2. Attach the bar to the lifting hook. Lower it
slowly into position on the rotor seat. Always
position a new impeller bar so the upper groove
(key) in the back of the bar is seated against the

24215 (7/07) 8 - 13 HSI 1300


Wear Parts Replacement

Rotor Assembly Maintenance

15. Clear the area, start the crusher and let it run
empty for 5 minutes. Listen for any unusual
WARNING noise or vibration.

Failure to follow procedures listed in


Section 7 - Operation and Adjustment
WARNING
could result in death or serious injury.
6. Close the crusher. Follow procedures in Failure to follow procedures listed in
Section 7 - Operation and Adjustment, Closing Section 7 - Operation and Adjustment
the Crusher. could result in death or serious injury.

7. Lockout & Tagout power to crusher hydraulic 16. Open the crusher. Follow procedures in Section
system. Verify main power lockout. 7 - Operation and Adjustment, Opening the
Crusher.
8. Open side inspection door.
17. Check and retorque all wedge bolts.
9. Rotate rotor by hand until an impeller bar is as
close to primary breaker plate as possible.
10. Use a measuring device to gauge distance WARNING
between impeller bar (rotor circle) and primary
breaker plate. Turn adjuster nuts to achieve Failure to follow procedures listed in
desired clearance. Make sure both adjuster rods Section 7 - Operation and Adjustment
carry equal weight. Refer to Figure 8 - 3, could result in death or serious injury.
dimension A. 18. Close the crusher. Follow procedures in
Section 7 - Operation and Adjustment, Closing
the Crusher.
NOTICE
Operate the crusher normally for eight (8) hours.
Detailed instructions for performing Check and re-torque all wedge bolts. Following the
breaker plate adjustments are given in initial 8-hour check, wedges should be periodically
Section 7. checked during standard operation. Do not retorque
11. Repeat step 10 for secondary breaker plate. bolts unless wedges are loose, after the initial 8
Make sure both adjuster rods carry equal hours of operation.
weight. Refer to Figure 8 - 3, dimension B.
12. Check clearance to stripper liner. Adjust
stripper liner as necessary. Refer to Stripper WARNING
Liner paragraph at the end of this section.
Operating the crusher with loose impeller-
13. Close the side inspection door and bolt it shut. bar wedges could result in death or serious
14. Remove lock & tag from crusher main power injury.
and crusher hydraulic system.

24215 (7/07) 8 - 14 HSI 1300


Wear Parts Replacement

Rotor Assembly Maintenance

Turning Impeller Bars Second Rotation Notes


The procedure for turning impeller bars is almost 1. Remove impeller bar per previous removal
the same as procedure for removing and replacing procedure.
impeller bars. The difference is that, instead of
2. Clean mating surfaces of bar and rotor.
replacing a set of worn bars, you turn old bars and
remount them to create a set of new impact surfaces 3. Turn the bar (swivel) 180 degrees, horizontally,
on the rotor assembly. swapping end-for-end. Remove lifting hook
and install it in the “wedge” side of bar.
Even though the impeller bars are designed for
three rotations (four wear edges), your application 4. Remount the impeller bar per previous
may not make it feasible to use all four edges. installation procedure.
Consult Cedarapids if you plan to use all four wear This procedure presents the third impeller bar wear
edges of the impeller bars (three rotations). surface to the incoming rock. Height of the new
Impeller bars should be turned when the height of impeller bar crushing surface, after rotation, should
the current crushing surface of impeller bars wear be about 2-1/4” inches above surface of the
to no less than 1.63 inches above surface of its corresponding backer bar. When the third surface is
corresponding backer bar. Figure 8 - 11 shows the used up, replace the impeller bar.
necessary amount that should be left if using three
wear edges (two rotations). Wear edges are
indicated by numbers 1 through 3 on the
illustration.
Refer to Figure 8 - 11 for the sequence of rotating
impeller bars.
First Rotation Notes
1. Remove impeller bar per previous removal
procedure.
2. Clean mating surfaces of bar and rotor.
3. Rotate bar 180 degrees top to bottom.
4. Remount the impeller bar per previous
installation procedure.
This procedure presents the second impeller bar
wear surface to the incoming rock. Height of the
new impeller bar crushing surface, after rotation,
should be about 2-1/4 inches above surface of the
corresponding backer bar. When the second surface
is used up, you’ll have to turn the bar again to bring
the third wear surface into play.

24215 (7/07) 8 - 15 HSI 1300


Wear Parts Replacement

Rotor Assembly Maintenance

1. New Bar 1a. Wear to 1.63”

1 2.25” 1.63”
100% 91% 1

2. Flip Bar Top-to-Bottom


(1st Rotation) 2a. Wear to 1.63”

Rotated Top to Bottom 2 2.25” 1.63”


91% 82% 2

1 1

3. Flip Bar Front-To-Back


3a. Wear to 1.63”
(2nd Rotation)
3 1 2.25” 1 1.63”
3
82% 68%
Swivel, Then Reset
Hook to Wedge Side
2 2

Note: Bar End Retainer Not Shown.

Figure 8 - 11 Sequence of Impeller Bar Rotation

24215 (7/07) 8 - 16 HSI 1300


Wear Parts Replacement

Rotor Assembly Maintenance

Disk Guards they are tightened. This ensures the guards will
not rattle during operations. Torque lock nuts
Because of concern to maintain rotor balance, disk
to 200 foot pounds (271 N•m)
guards should all be either turned or replaced at the
same time. Do not replace some guards while
turning the rest. Disk guard life can be extended by
hard-facing them. Disk guards should be turned WARNING
when the leading edge wears to no less than 1/4
Failure to follow procedures listed in
inch above the rotor disk (Figure 8 - 12).
Section 7 - Operation and Adjustment
Use the following procedure to replace rotor disk could result in death or serious injury.
guards .
4. Close the crusher. Follow procedures in
Removal Section 7 - Operation and Adjustment, Closing
the Crusher.
5. Clear the area, start the crusher and let it run
WARNING empty for 5 minutes. Listen for any unusual
noise or vibration.
Failure to follow procedures listed in
Section 7 - Operation and Adjustment If no noise or vibration is present, you are finished
could result in death or serious injury. with this procedure and the crusher can be returned
to service.
1. Open the crusher. Follow procedures in Section
7 - Operation and Adjustment, Opening the
Crusher. Wear Surface
1/4"
2. Remove nuts, washers and bolts securing
guard to the rotor disk.

3. Remove guard from rotor disk (retain guard if Mounting


it’s to be turned). If turning guards, turn each Bolts
end to end . Direction of Rotation

Installation

1. Position new (or turned) guard on rotor disc,


lining up mounting holes in both guard and
disc.
Disk Guard Turned
2. From drive end of rotor, insert bolts into both End for End
holes. Install hardened flat washers and
locking nuts on bolts. Pull bolts up toward Figure 8 - 12 Disk Guard Rotation
wear surface of guards, to remove any play, as

24215 (7/07) 8 - 17 HSI 1300


Wear Parts Replacement

Stripper Liner

Stripper Liner
The 1300 series HSI has an adjustable stripper NOTICE
liner. The stripper liner protects the edge of the
adjacent lower feed opening liners from damage, Always replace mounting bolts when you
due to material caught in the rotor stream. As the replace a liner.
stripper liner wears, it must be adjusted, and 4. Coat threads of each bolt with Loctite 271.
eventually replaced, to maintain coverage of the
lower feed opening liner. Be sure not to extend the 5. Start bolts from outside, through frame and
liner so far that it will contact an impeller bar. After screw into liner. Snug bolts, but do not fully
adjusting the stripper liner, rotate the rotor by hand tighten.
to check clearance (Figure 8 - 13).

NOTICE WARNING
Failure to follow procedures listed in
After installing or adjusting the stripper
Section 7 - Operation and Adjustment
liner, be sure to check clearance between
could result in death or serious injury.
the stripper liner and the rotor turning
circle. Serious damage will result if the 6. Close the crusher. Follow procedures in
breaker bars contact the stripper liner Section 7 - Operation and Adjustment, Closing
during operation. the Crusher.

Liner Replacement 7. Procede to the following Liner Adjustment


procedure
Liner Adjustment
WARNING
1. Lockout & Tagout power to crusher hydraulic
Failure to follow procedures listed in system. Verify main power lockout.
Section 7 - Operation and Adjustment 2. Open side inspection door.
could result in death or serious injury.
3. Loosen stripper liner bolts, as necessary, to
1. Open the crusher. Follow procedures in Section slide liner. Adjust (slide) liner so that it covers
7 - Operation and Adjustment, Opening the the end of the lower feed opening liner.
Crusher.
4. Tighten mounting bolts as you verify stripper
2. Loosen and remove bolts from stripper liner. liner adjustment. Torque mounting bolts to 200
Remove old liner(s) and clean all grit and foot-pounds (271 N•m).
debris from its location. 5. Rotate rotor by hand to check clearance of
impeller bars to stripper liner.
3. Clean mounting surface of new liner and
position liner in place. 6. Close the inspection door and bolt it shut.
7. Remove lock & tag from crusher main power
and crusher hydraulic system.
24215 (7/07) 8 - 18 HSI 1300
Wear Parts Replacement

Stripper Liner

8. Clear the area, start the crusher and let it run If no noise or vibration is present, you are finished
empty for 5 minutes. Listen for any unusual with this procedure and the crusher can be returned
noise or vibration. to service.
.

n
tio
ta
ro

Stripper Liner
Mounting Bolts
(hidden)
Breaker Bar

Lower Feed
Opening Liner Stripper Liner
Adjust Stripper Liner to protect
end of adjacent liner from damage.
Figure 8 - 13 Stripper Liner Adjustment

24215 (7/07) 8 - 19 HSI 1300


Wear Parts Replacement

Stripper Liner

This Page Intentionally Left Blank

22660 (10/07) 8 - 20 Andreas-Type Primary Crusher


Component Weights

Appendix A - Component Weights


Following are charts containing the weight of
various HSI components. Slight difference in
weights listed can occur due to casting variations.
Before attempting any lifting procedure, be sure
your equipment is capable of lifting, at minimum,
the specified weight. Table A-1 lists crusher
component weights in standard pounds (lbs). Table
A-2 lists crusher component metric weights (kg).

24215 (7/07) A-1 HSI 1300


Component Weights

Table A-1 Standard HSI Component Weights (lbs.)


Frame Components 1316 1313 Rotor Assemblies 1316 1313
upper frame & liners 6,871 6,710 3-row, 5” bar 13860 10,350
lower frame & liners 5,444 4,858 4-row, 5” bar -- 11,670
Frame Liners All Models Impeller Bars 1316 1313
08610-610-37 49 5” x 48” Manganese -- 832
08610-610-38 35 5” x 48” Tool Steel -- 793
08610-610-39 42 5” x 64” Manganese 1109 --
08610-610-40 71 5” x 64” Tool Steel 1109 --
08610-610-44 26 Feed Options 1316 1313
08610-610-45 44 VGF adapter 552 474
08610-610-46 (used on 1316 1313
98 Sheaves
model 1316 only) (10 groove) (8 groove)
08610-610-47 107 40” 910 750
breaker plates (breaker
1316 1313 44.5” 950 880
plates)
cast primary 6,470 4,590 53” 1,210 1,070
secondary w/liners 4,430 3,460 Hydraulic Power Unit All Models
breaker plate shaft 142 111 125
3” x 8” x 16” breaker 101
plate liner

Total Weight - Assembled


1313 — 31,330 lbs.
1316 — 45,290 lbs.

24215 (7/07) A-2 HSI 1300


Component Weights

Table A-2 Metric HSI Component Weights (kg.)


Frame Components 1316 1313 Rotor Assemblies 1316 1313
upper frame & liners 3,117 3,044 3-row, 5” bar 6,287 4,694
lower frame & liners 2,469 2,204 4-row, 5” bar -- 5,293
Frame Liners All Models Impeller Bars 1316 1313
08610-610-37 22 5” x 48” Manganese -- 378
08610-610-38 16 5” x 48” Tool Steel -- 360
08610-610-39 19 5” x 64” Manganese 503 --
08610-610-40 32 5” x 64” Tool Steel 503 --
08610-610-44 12 Feed Options 1316 1313
08610-610-45 20 VGF adapter 250 215
08610-610-46 (used on 1316 1313
44 Sheaves
model 1316 only) (10 groove) (8 groove)
08610-610-47 49 40” 413 340
breaker plates (breaker
1316 1313 44.5” 431 399
plates)
cast primary 2,935 2,082 53” 549 485
secondary w/liners 2,009 1,569 Hydraulic Power Unit All Models
breaker plate shaft 64 50 57
3” x 8” x 16” breaker 46
plate liner

Total Weight - Assembled


1313 — 14,211 lbs.
1316 — 20,543 lbs.

24215 (7/07) A-3 HSI 1300


Component Weights

This page intentionally left blank

24215 (7/07) A-4 HSI 1300


Drive & Power Options

Typical Crusher Drive Setup

Appendix B - Drive & Power Options


Typical Crusher Drive Setup

NOTICE
For Specific dimensions and
mounting instructions for
your machine, refer to the 04418-955d

Installation and Setup section


of this manual.

Installation Specific

Installation Specific

WARNING
Failure to properly guard crusher drive could result in death or serious injury.

• Power options and sheave combinations detailed in tables on following pages


• Drives ship without guards. Customer is responsible for providing any and all guards
required by local, state or federal laws.
• When mounting drive motor, be sure to allow enough space for opening or otherwise
maintaining the crusher.

24215 (7/07) B-1 HSI 1300


Drive & Power Options

1313 Crusher Drive Options

1313 Crusher Drive Options

Crusher Drives for 1000 RPM Electric Motor


(Approximately 985 RPM at Full Load)
Crusher Sheave Motor Sheave Motor Bushing Motor Sheave V-Belts
Dia RPM Dia RPM Size Max Bore Max HP Cent Dist Qty Size
40 304 12.5 985 “J” 4.50 234 135.6 8 8V3550
40 322 13.2 985 “J” 4.50 257 135.1 8 8V3550
40 341 14.0 985 “J” 4.50 283 134.5 8 8V3550
40 366 15.0 985 “J” 4.50 300 133.7 8 8V3550
40 391 16.0 985 “J” 4.50 300 133.0 8 8V3550
40 416 17.0 985 “M” 5.50 300 132.3 8 8V3550
40 441 18.0 985 “M” 5.50 300 131.5 8 8V3550
40 465 19.0 985 “M” 5.50 300 130.8 8 8V3550
40 490 20.0 985 “M” 5.50 300 130.0 8 8V3550
40 520 21.2 985 “M” 5.50 300 129.1 8 8V3550
40 549 22.4 985 “M” 5.50 300 128.2 8 8V3550
Table B - 1

Crusher Drives for 1200 RPM Electric Motor


(Approximately 1160 RPM at Full Load)
Crusher Sheave Motor Sheave Motor Bushing Motor Sheave V-Belts
Dia RPM Dia RPM Size Max Bore Max HP Cent Dist Qty Size
40 358 12.5 1160 “J” 4.50 260 135.6 8 8V3550
40 379 13.2 1160 “J” 4.50 285 135.1 8 8V3550
40 403 14.0 1160 “J” 4.50 300 134.5 8 8V3550
40 431 15.0 1160 “J” 4.50 300 133.7 8 8V3550
40 460 16.0 1160 “J” 4.50 300 133.0 8 8V3550
40 490 17.0 1160 “M” 5.50 300 132.3 8 8V3550
40 519 18.0 1160 “M” 5.50 300 131.5 8 8V3550
40 548 19.0 1160 “M” 5.50 300 130.8 8 8V3550
40 577 20.0 1160 “M” 5.50 300 130.0 8 8V3550
Table B - 2

24215 (7/07) B-2 HSI 1300


Drive & Power Options

1313 Crusher Drive Options

Crusher Drives for 1500 RPM Electric Motor


(Approximately 1425 RPM at Full Load)
Crusher Sheave Motor Sheave Motor Bushing Motor Sheave V-Belts
Dia RPM Dia RPM Size Max Bore Max HP Cent Dist Qty Size
53.0 332 12.5 1425 “J” 4.50 300 124.4 8 8V3550
53.0 351 13.2 1425 “J” 4.50 300 123.9 8 8V3550
53.0 372 14.0 1425 “J” 4.50 300 123.4 8 8V3550
53.0 399 15.0 1425 “J” 4.50 300 122.6 8 8V3550
53.0 426 16.0 1425 “J” 4.50 300 121.9 8 8V3550
53.0 453 17.0 1425 “M” 5.50 300 121.2 8 8V3550
44.5 476 15.0 1425 “J” 4.50 300 129.9 8 8V3550
44.5 508 16.0 1425 “J” 4.50 300 129.2 8 8V3550
44.5 540 17.0 1425 “M” 5.50 300 128.5 8 8V3550
44.5 573 18.0 1425 “M” 5.50 300 127.7 8 8V3550
Table B - 3

Crusher Drives for 1800 RPM Diesel Engine


Crusher Sheave Motor Sheave Motor Bushing Max Sheave V-Belts
Dia RPM Dia RPM Size Max Bore Cont HP Cent Dist Qty Size
53.0 419 12.5 1800 “J” 4.50 300 124.4 8 8V3550
53.0 443 13.2 1800 “J” 4.50 300 123.9 8 8V3550
53.0 470 14.0 1800 “J” 4.50 300 123.4 8 8V3550
44.5 500 12.5 1800 “J” 4.50 300 131.8 8 8V3550
44.5 528 13.2 1800 “J” 4.50 300 131.3 8 8V3550
44.5 561 14.0 1800 “J” 4.50 300 130.7 8 8V3550
Table B - 4

24215 (7/07) B-3 HSI 1300


Drive & Power Options

1316 Crusher Drive Options

1316 Crusher Drive Options

Crusher Drives for 1000 RPM Electric Motor


(Approximately 985 RPM at Full Load)
Crusher Sheave Motor Sheave Motor Bushing Motor Sheave V-Belts
Dia RPM Dia RPM Size Max Bore Max HP Cent Dist Qty Size
40.0 304 12.5 985 “J” 4.50 293 135.6 10 8V3550
40.0 322 13.2 985 “J” 4.50 321 135.1 10 8V3550
40.0 341 14.0 985 “J” 4.50 353 134.5 10 8V3550
40.0 366 15.0 985 “M” 5.50 392 133.7 10 8V3550
40.0 391 16.0 985 “M” 5.50 400 133.0 10 8V3550
40.0 416 17.0 985 “M” 5.50 400 132.3 10 8V3550
40.0 441 18.0 985 “M” 5.50 400 131.5 10 8V3550
40.0 465 19.0 985 “M” 5.50 400 130.8 10 8V3550
40.0 490 20.0 985 “M” 5.50 400 130.0 10 8V3550
40.0 520 21.2 985 “M” 5.50 400 129.1 10 8V3550
40.0 549 22.4 985 “M” 5.50 400 128.2 10 8V3550
Table B - 5

Crusher Drives for 1200 RPM Electric Motor


(Approximately 1160 RPM at Full Load)
Crusher Sheave Motor Sheave Motor Bushing Motor Sheave V-Belts
Dia RPM Dia RPM Size Max Bore Max HP Cent Dist Qty Size
40.0 358 12.5 1160 “J” 4.50 325 135.6 10 8V3550
40.0 379 13.2 1160 “J” 4.50 356 135.1 10 8V3550
40.0 403 14.0 1160 “J” 4.50 391 134.5 10 8V3550
40.0 431 15.0 1160 “M” 5.50 400 133.7 10 8V3550
40.0 460 16.0 1160 “M” 5.50 400 133.0 10 8V3550
40.0 490 17.0 1160 “M” 5.50 400 132.3 10 8V3550
40.0 519 18.0 1160 “M” 5.50 400 131.5 10 8V3550
40.0 548 19.0 1160 “M” 5.50 400 130.8 10 8V3550
40.0 577 20.0 1160 “M” 5.50 400 130.0 10 8V3550
Table B - 6

24215 (7/07) B-4 HSI 1300


Drive & Power Options

1316 Crusher Drive Options

Crusher Drives for 1500 RPM Electric Motor


(Approximately 1425 RPM at Full Load)
Crusher Sheave Motor Sheave Motor Bushing Motor Sheave V-Belts
Dia RPM Dia RPM Size Max Bore Max HP Cent Dist Qty Size
53.0 332 12.5 1425 “J” 4.50 373 124.4 10 8V3550
53.0 351 13.2 1425 “J” 4.50 400 123.9 10 8V3550
53.0 372 14.0 1425 “J” 4.50 400 123.4 10 8V3550
53.0 399 15.0 1425 “M” 5.50 400 122.6 10 8V3550
53.0 426 16.0 1425 “M” 5.50 400 121.9 10 8V3550
53.0 453 17.0 1425 “M” 5.50 400 121.2 10 8V3550
44.5 476 15.0 1425 “M” 5.50 400 129.9 10 8V3550
44.5 508 16.0 1425 “M” 5.50 400 129.2 10 8V3550
44.5 540 17.0 1425 “M” 5.50 400 128.5 10 8V3550
44.5 573 18.0 1425 “M” 5.50 400 127.7 10 8V3550
Table B - 7

Crusher Drives for 1800 RPM Diesel Engine


Crusher Sheave Motor Sheave Motor Bushing Motor Sheave V-Belts
Dia RPM Dia RPM Size Max Bore Max HP Cent Dist Qty Size
53.0 419 12.5 1800 “J” 4.50 400 124.4 10 8V3550
53.0 443 13.2 1800 “J” 4.50 400 123.9 10 8V3550
53.0 476 14.0 1800 “J” 4.50 400 123.4 10 8V3550
44.5 500 12.5 1800 “J” 4.50 400 131.8 10 8V3550
44.5 528 13.2 1800 “J” 4.50 400 131.3 10 8V3550
44.5 561 14.0 1800 “J” 4.50 400 130.7 10 8V3550
Table B - 8

24215 (7/07) B-5 HSI 1300


Drive & Power Options

This Page Intentionally Left Blank

24215 (7/07) B-6 HSI 1300


Belt Drive Care

General Belt Information

Appendix C - Belt Drive Care 5) Periodically inspect for proper sheave


alignment (Figure C - 1) and for wear of the
General Belt Information sheave grooves or belt (Figure C - 2) and
You get more service from V-belts if you keep them (Figure C - 3).
clean and dry. Rock dust and rust from metals are 6) Do not overtighten belts.
abrasive. Oils and acids deteriorate belt material.
Dust buildup in sheaves causes harmful vibration. Overtightening shortens useful life of belts and
On belts, dust or water causes slippage. sheaves and also places undue strain on shafts
which, in turn, causes premature bearing failure.
For maintenance purposes, so-called belt dressing Ideal belt tension is lowest at which belts won't slip
compounds are worse than worthless. Most belt under peak load.
dressings actually shorten belt life. Clean, well
cared for belts are the best answer to problems that
belt dressings are meant for but do not solve. Daily
cleaning of belts and sheaves by blowing them off
with compressed air increases their useful life and
saves you money.
1) Keep belts and sheaves clean.
2) Avoid belt or sheave rubbing. Don't let belts or OK
sheaves rub against the guard (or anything else)
while they’re running.
3) Drive your belts with motors mounted on
adjustable bases.
Mount drive motors on a slotted base, so you can OK
shorten the distance from motor to driven sheave
when you need to do so. This allows convenient
and proper installation of belts. Prying on belts Figure C - 1: Align Sheaves
with tools cracks and prematurely breaks them.
7) Keep belts straight (Figure C - 1).
With belts already lightly seated in their grooves,
you can tighten the belts correctly by moving the Don't allow V-belts to run out of alignment. To run
motor and rolling the sheaves at the same time. properly, sheaves must be parallel and grooves
must be in line.
4) Keep belts tight.
8) Use only matched belts. A matched set of belts
Most belt stretch occurs in the first 30-40 hours of
lasts longer because loading is evenly divided
operation after new belts are installed. Check belt
among all the belts.
tension frequently during this period. Slack belts
cause slipping and excessive wear. They cost you
money by delivering less power and causing more
frequent replacement.

24215 (7/07) C-1 HSI 1300


Belt Drive Care

Maintaining V-Belt Tension

Belts often wear at the sides, so their cross- 4) If sheaves are worn excessively, replace them.
sectional area decreases. They stretch with use and
5) If belts are not tight enough, loosen drive motor
age. New belts ride higher in sheave grooves. They
mount bolts and adjust take-up bolts to tighten
travel faster and take higher tension than worn
belts. Retighten motor mount bolts to hold
belts. If its center cord breaks, a belt stretches and
tension.
won't carry its load. Putting one or two new belts on
a partially used set very soon wears and stretches
Worn Sheave Worn Belt Just Right
the new ones until they are in poor condition. Their or Sheave
cost is wasted.
Belts from different manufacturers should not be
mixed in a set because of slight material and quality
differences that could reduce the life of all the belts.
Always replace belts in full sets.
9) Don't overload.
If the sheave has 10 grooves, use 10 belts. Using
less than the designed number of drive belts puts
too much strain on remaining ones. They will break
down quickly and cause you downtime. Figure C - 2: Belt & Sheave Wear

10) Replace worn sheaves.


Worn sheaves reduce belt life. If the sheave is worn
enough that belts touch bottom in the grooves, belts
soon start to slip and burn.
If your maintenance program takes all of those
things into account, your troubles with belts and
sheaves will be minimal. Still, you’re bound to
experience some problem, sooner or later. When
you do, use Table B - 1 as a diagnostic tool.
Maintaining V-Belt Tension
1) Check drive belt tension daily. Check condition
of belts and sheaves (Figure C - 2).
Figure C - 3: Sheave Gauge Shows Wear
2) If belts are worn, replace with a matched set.
3) Use a sheave gauge (Figure C - 3) to look for
steps worn in sheave grooves. Steps are a
measure of sheave wear. Belts must not bottom
out in grooves.

24215 (7/07) C-2 HSI 1300


Belt Drive Care

Maintaining V-Belt Tension

Trouble Cause Correction


Belts slip (sidewalls glazed) Insufficient tension Replace belts; increase tension

Overloaded drive. Find cause and correct.


Drive squeals. Arc of contact too short. Increase distance between hubs.
Heavy starting load. Increase tension.

Rock gets into drive.


Replace belt correctly.
Broken cord caused by prying.
Redesign drive.
Overloaded drive.
Apply proper tension.
Impulse Loads.
Realign drive.
Belt rolls over. Misalignment.
Replace sheave.
Worn sheave grooves.
Align and reposition.
Flat idler sheave.
Check drive design, mounting.
Excessive vibration.
Consider banded belts.

New belts installed with old. Replace belts with matched set.

Sheave grooves worn unevenly. Replace sheaves.


Mismatched belts
Improper groove angle.

Shafts not parallel. Align drive.


Shock loads. Apply proper tension.

Heavy starting load. Apply proper tension.


Use compensator starting.
Belt breaks
Belt pried over sheaves. Replace belt correctly.
Foreign object in drive. Determine source of object, design
guard to correct problem.
Sheave grooves worn. Replace sheaves.
Sheave diameter too small. Redesign drive.
Mismatched belts. Replace with matched set.
Drive overloaded. Redesign drive.
Belt wears prematurely.
Belt slips. Increase tension.
Sheaves misaligned. Align sheaves.
Oil present. Eliminate oil.
Excess heat present. Ventilate drive.
Table C - 1: Belt-Drive Diagnostics

24215 (7/07) C-3 HSI 1300


Belt Drive Care

Check Belt Tension with


Mechanical Tester

Each 1/64" mark equals 1" of belt span Each Mark Equals 1 Pound Pressure
(Centimeters on Opposite Side) (Kilograms on Opposite Side)

Large O-ring Small O-ring

Figure C - 4: Belt Tension Tester (Cedarapids P/N 45500-036-08)

Small O-ring
Bottom of
Straightedge or Top of
Adjacent Belt

Span "t"

Large O-ring
Deflection to be 1/64"
Per Inch Span

Figure C - 5: Using the Belt Tension Tester

Check Belt Tension 4) Remove tester and read belt deflection force, in
with Mechanical Tester pounds, at small O-ring. Compare this figure
with values given in tables that follow. If
1) Measure span length "T" (Figure C - 5). required force is within limits shown in table
2) Position large O-ring on tester at 1/64 inch for that particular belt, drive tension should be
(0.397 mm) for each inch of belt span. Set small satisfactory. If required force is outside these
O-ring at zero (Figure C - 5). Example: For belt limits, drive should be retensioned.
span of 48 inches (1.219 m), setting would be 5) When installing new belts, tension may relieve
48/64 inch (3/4 inch, or 19.05 mm). during run-in. After drive is operated for
3) At center of belt span, push yellow tipped several days, tension should be checked and
plunger until bottom of large O-ring is level adjusted to recommended tension values.
with top of adjacent belt (Figure C - 5). If there
is no adjacent belt, lay straight edge between
sheaves for reference.

24215 (7/07) C-4 HSI 1300


24215 (7/07)
Belt Drive Care

Belt Deflection Force


(Pounds) Belt Deflection Force
Uncogged Cogged (Pounds)
Smallest
Hy-T Belts Torque-Flex Cogged Hy-T
Cross Sheave RPM Uncogged Hy-
& Uncogged & Machined Wedge Belts
Section Diameter Range Smallest T
Hy-T Torque Edge Torque & Hy-T
Range Cross Sheave RPM Wedge Belts
Team Belts Team Belts Wedge
Section Diameter Range & Uncogged
Used New Used New Machine
Range Hy-T Wedge
Belt Belt Belt Belt Edge
Torque Team
Torque Team
1000 - 2500 3.7 5.5 4.1 6.1
3.0 - 3.6 Used New Used New
2501 - 4000 2.8 4.2 3.4 5.0
Belt Belt Belt Belt
1000 - 2500 4.5 6.8 5.0 7.4
A, AX 3.8 - 4.8 1000 - 2500 3.3 4.9
2501 - 4000 3.8 5.7 4.3 6.4 2.2 - 2.4
2501 - 4000 2.9 4.3
1000 - 2500 5.4 8.0 5.7 9.4
5.0 - 7.0 1000 - 2500 3.6 5.1 4.2 6.2
2501 - 4000 4.7 7.0 5.1 7.6 3V, 3VX 2.65 - 3.65
2501 - 4000 3.0 4.4 3.8 5.6
860 - 2500 4.9 7.2
3.4 - 4.2 1000 - 2500 4.9 7.3 5.3 7.9

C-5
2501 - 4000 4.2 6.2 4.12 - 6.90
2501 - 4000 4.4 6.6 4.9 7.3
860 - 2500 5.3 7.9 7.1 10.5
B, BX 4.4 - 5.6 500 - 1749 10.2 15.2
2501 - 4000 4.5 6.7 7.1 9.1
4.4 - 6.7 1750 - 3000 8.8 13.2
860 - 2500 6.3 9.4 8.5 12.6 3001 - 4000 5.6 8.5
5.8 - 8.6
2501 - 4000 6.0 8.9 7.3 10.9
Check

5V, 5VX 500 - 1740 12.7 18.9 14.8 22.1


500 - 1740 11.5 17.0 14.7 21.8 7.1 - 10.9
7.0 - 9.0 1741 - 3000 11.2 16.7 13.7 20.1
1741 - 3000 9.4 13.8 11.9 21.6
CX 500 - 1740 15.5 23.4 17.1 25.5
500 - 1740 14.1 21.0 15.9 23.52 11.8 - 16.0
9.5 - 16.0 1741 - 3000 14.6 21.8 16.8 25.0
1741 - 3000 12.5 18.5 14.6 1.6
200 - 850 33.0 49.3
Belt

200 - 850 24.9 37.0 12.5 - 17.0


12.0 - 16.0 851 - 1500 26.8 39.9
851 - 1500 21.2 31.3 8V
D 200 - 850 39.6 59.2
Mechanical Tester

200 - 850 30.4 45.2 18.0 - 22.4


18.0 - 20.0 851 - 1500 35.3 52.7
851 - 1500 25.6 38.0
Table C - 2: Belt Deflection Force
Table C - 3: Belt Deflection Force
withTension

HSI 1300
Belt Drive Care

Belt Guards

Belt Guards
V-belt drive guards promote both cleanliness and
.38” .62” 1.0” safety. Screened, meshed or grilled guards are best
because they allow air to circulate and heat to
3V .31” escape.
5V .54”
8V
.88” Idlers
A properly designed V-belt drive does not require
an idler to deliver full rated horsepower if proper
.50” belt tension can be maintained. Idlers should be
A .31” avoided if possible because an idler puts an
additional bending stress point on the belt. This
.66” reduces the belt’s horsepower rating and its life
expectancy. The smaller the idler, the greater the
B .41” stress and the more belt life is reduced.
Inside Idler
.88”
A V-grooved idler located on the inside of the belts
C .53” on the slack side of the drive is recommended over
a back-side idler. The idler should be located near
the large sheave to minimize reduction of the arc of
1.25”
contact across the small sheave. The diameter of
the V-idler pulley should be equal to or larger than
D .75”
that of the small sheave.

1.5”

E .91”
Driver

Driven
Figure C - 6: Belt Types in Cross-Section

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Belt Drive Care

Idlers

Back-Side Idler Kiss Idler


A back-side idler increases the arc of contact on A kiss idler differs from the back-side idler because
both sheaves. However, it forces a backward bend the kiss idler does not penetrate the belt span and
in the V-belt that contributes to premature belt create a back-bend on the belt. Consequently, the
failure. The idler puts additional stress on the kiss idler does not contribute to premature belt
bottom portion of the belt which will result in failure.
bottom cracking. If a back-side idler must be used,
Use of a kiss idler can help control belt vibration
the diameter of the flat idler pulley should be at
and whip on drives subject to shock and pulsating
least 1-1/2 times (1.5x) the diameter of the small
loads. Kiss idlers can be used in single-belt drives
sheave. A back-side idler should be located as close
where joined belts are not applicable.
as possible to the small sheave.
If a kiss idler is used, diameter of the flat pulley
should be at least 1-1/2 times (1.5x) greater than
the diameter of the small sheave.

Driver

Driven Driver

Driven

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Belt Drive Care

Idlers

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24215 (7/07) C-8 HSI 1300


Bearing Press Design

Appendix D - Bearing Press Design

Bolt Hole Circle


Bearing Shaft Nut Type/Size Bolt Size
Diameter
90mm 3-3/16” AN-18 4” .25” x 1.5”
100 mm 3-7/16” AN-20 4.375” .25” x 1.5”
110 mm 3-15/16” AN-22 4.8125” .25” x 1.5”
120 mm 4-3/16” AN-24 5.25” .3125” x 1/75”
130 mm 4-7/16” AN-26 5.625” .3125 x 1.75”
140 mm 4-15/16” AN-28 6.0625” .3125” x 1.75”
150 mm 5-3/16” AN-30 6.625” .375” x 1.75”
160 mm 5-7/16” AN-32 7” .375” x 1.75”
170 mm 5-15/16” AN-34 7.375” .375” x 1.75”
180 mm 6-7/16” AN-36 7.785” .375” x 1.75”
190 mm 6-15/16” AN-38 8.125” .375” x 1.75”
200 mm 7-3/8” AN-40 8.5” .375” x 1.75”
220 mm 7-15/16” AN-44 9.675” .625 x 2.375”
Table D - 1 Bearing and Hardware Sizes

This section contains information to build a bearing


press for your machine.
1) From your Cedarapids distributor, get a lock
nut and eight grade 8 bolts of size appropriate
to your bearings (Table D - 1). Diameter

2) Drill and tap eight holes through the lock nut


(Table D - 1) (Figure D - 1).
3) Use a grinder to remove threads from ends of
Install Bolt Until
bolts and then flatten the ends (Figure D - 2). End is Flush

4) Install all eight bolts into holes from flat side of Figure D - 1Lock Nut Bolt Hole Diameter
the lock nut (Figure D - 1). Install so the
flattened end of the bolt is flush with the back
side of the nut.
Your bearing press is now complete and ready to
use.

Figure D - 2Remove Threads from Bolt Ends

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Bearing Press Design

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24215 (7/07) D-2 HSI 1300

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