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24215 (10/07)
49999-252-05-05
IMPORTANT INFORMATION
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.
(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.
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
Section 5 - Lubrication
• 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.
General Safety
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.
2
2
04418-955d
3 04418-955d
4b
1 1
4a
6
8
6 9 7
WARNING
1 3
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
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
3
2
04418-955d
3 04418-955d
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
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
Personal Safety
• 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.
• 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.
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General
Inspection Procedures
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).
Inspection Procedures
Operator
Controls
Breather Cap/
Fill Hole
Sight Glass
Reservoir
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.
Inspection Procedures
Clevis/Pin - Typical
Upper (one each side)
Hydraulic Power
Clevis/Pin - Typical Unit
Base (one each side)
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.
Inspection Procedures
Thread
Protector
Caps
Upper Inspection
Door
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.
Inspection Procedures
Adjuster Nut
Tension Spring
Tension
Adj. Nut Lockpin and
Hairpin
Figure 4 - 5 : Breaker Plate Bridge Assembly
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.
Inspection Procedures
Protruding
Rods
Bridge Rests
Against Springs
Lock Pin
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
Inspection Procedures
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.
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.
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.
Seals:
Grease Daily
until 360 Deg.
Extrusion
Seal:
Grease Daily until
360 Deg. Extrusion
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.
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.
Stabilizer Ring
Lock Nut
Outer Seal
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.
Rotor Assembly
Block
Hub Flange
Hub
Figure 6 - 7 Pin Shackle on Shaft
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
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
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.
Bearing Installation
Bearing Installation
Bearing Installation
Bearing Installation
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.
Shear Bars
Equal Distance
Both Sides
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.
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).
Final Touches
Final Touches
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
Hydraulic System
Primary
Bridge Ram (one each side)
Secondary
Bridge Ram
(one each side)
Frame Opener
Cylinder
(one each side)
Hydraulic System
General Precautions
Pre-operation Check
3
NOTICE 2
Hydraulic Controls
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.
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
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
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.
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.
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).
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.
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.
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
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.
Wedge
Assembly
Backer Bars
welded to
rotor disks
Disk
Direction Protector
of Rotation
Impeller Mounting
Grooves (keys)
Insert Bar
Disk Protector
Impeller Bar
Wedge
Backer Bar
Wedge Mounting/
Tightening Bolt Direction of
Rotor Rotation
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.
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.
15. Clear the area, start the crusher and let it run
empty for 5 minutes. Listen for any unusual
WARNING noise or vibration.
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.
1 2.25” 1.63”
100% 91% 1
1 1
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.
Installation
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.
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
Stripper Liner
NOTICE
For Specific dimensions and
mounting instructions for
your machine, refer to the 04418-955d
Installation Specific
Installation Specific
WARNING
Failure to properly guard crusher drive could result in death or serious injury.
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
New belts installed with old. Replace belts with matched set.
Each 1/64" mark equals 1" of belt span Each Mark Equals 1 Pound Pressure
(Centimeters on Opposite Side) (Kilograms on Opposite Side)
Small O-ring
Bottom of
Straightedge or Top of
Adjacent Belt
Span "t"
Large O-ring
Deflection to be 1/64"
Per Inch Span
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.
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
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
Idlers
Driver
Driven Driver
Driven
Idlers
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.