Technical Reference Manual
Technical Technical Reference Manual
42-65 SUPERIOR® MK II® Gyratory Crusher
Installation, Operation and Maintenance Instructions
42-65 SUPERIOR MK-II Gyratory Crushers
TABLE OF OF CONTENTS
1.
Safe Safe Equipme Equipment nt Operati Operation on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
2.
Safe Safe Ha Handl ndling ing of Hea Heavy vy Equip Equipme ment nt and and Mac Machin hinery ery . . . . . . . . . . . . .
2
3.
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
4.
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
5.
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
6.
HYDROSET HYDR OSET Control Control System System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
7.
Bottom Bottom Shell Shell As Assemb sembly ly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
8.
Eccentric Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
9.
Pinionshaft Pinionshaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
10. Mainshaft Mainshaft Assembly Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
11. Top Shell Assembly Assem bly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
12. Spider Assembly Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
13. Lubrication Lubrication Recommendati Recommendations ons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
14. Operation Operatio n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
15. Low Temperatu Temperature re Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
17X0115-05.0003
Section 1 — Index
General Information
1. Safe Equipment Operation
P age 1-2 1-2 1-2 1-2 1-2 1-2 1-3 1-3 1-3 1-4 1-4 1-5 1-5 1-5 1-6 1-6 1-7
Description Introduction Safety Program Safety Responsibility Safety Awareness Caution Signs And Warning Tags Advisory An And Ca Cautionary St Statements General Safety Precautions Personnel Safety Work Area Safety Equipment Safety Electrical Safety Flammable And Hazardous Ma Materials Safety Pressurized Systems Safety Welding Safety Crusher Safety Precautions Personnel Safety Ten Commandments Of Safety
17X0115-05.0003
1-1
Section 1 — Safe Equipment Operation INTRODUCTION We welcome you as a user of Svedala Industries equipment. Every effort has been made to provide information that is representative of the equipment we have furnished. However, equipment and control variations may exist because of owner’s special requirement or recent design changes. Contact your Svedala Industries, Inc. sales representative or Svedala Industries, Inc., Crushing and Screening, Appleton, Wisconsin, for specific information that is not covered in the operator’s manual. The operator’s manual will acquaint you with the easiest and most practical way to install, operate and maintain your equipment. Do not attempt to operate the equipment without proper training or supervision.
NOTE All personnel should read and completely understand all instructions that apply to the equipment before performing operation and maintenance procedures. SAFETY PROGRAM The owners and operators of this equipment are responsible for establishing an effective safety program that is consistent with good management practices and any laws, regulations or ordinances that may apply. Specified requirements, precautions and hazards associated with equipment operation and the general work area must be effectively communicated to plant personnel. A common understanding of these factors must be reached by all involved personnel to assure safe performance in operating and maintaining the equipment. SAFETY RESPONSIBILITY According to the OSHA Act of 1970, employers are required to provide a place of employment free of hazards which may cause illness, injury or death to employees. The employer is also required to comply with standards, rules and regulations proclaimed by the Secretary of Labor and to post notices which inform the employees of their rights and duties as outlined by the law. The employer is expected to take necessary action, including the establishment and enforcement of rules, to ensure compliance. If a citation is levied against the employer, a copy of that citation must be posted where the violation occurred or at other specified locations. Additionally, employers and employees must also be aware of the federal, state and local governmental agencies that are responsible for enforcement of applicable rules and regulations concerning their operation. SAFETY AWARENESS A careful equipment operator is the key to safe job performance and the best insurance against having or 1-2
General Information
contributing to an accident. Operator safety and the safety of others depends upon reasonable care and judgment in equipment operation. Most accidents are caused by failure to observe simple safety rules and precautions. Be aware of what is going on around the work area. Learn to recognize hazards before they become accidents and to avoid setting up dangerous situations.
CAUTION SIGNS Every effort has been made to design and build this equipment so that it can be operated and maintained in a safe and efficient manner. Caution and advisory signs are noticeably posted, securely attached and legible when shipped from the manufacturer. Should any of the caution and advisory signs on the equipment become damaged, destroyed, lost or illegible, replacements are available from the Crushing and Screening Division, Customer Service Department, at no charge. When requesting additional tags and signs, please specify the serial number and the model of the equipment along with the wording and location of the signs, if known. Quantity will be limited to the number of signs originally on the equipment. Additional signs may be purchased for a nominal fee. LOCKOUT DANGER TAGS Lockout “DANGER” tags are required for tagging electrical/mechanical controls during equipment shutdown. The purpose of these tags is to notify all personnel that equipment components associated with the controls are being worked on and that the controls must not be started or engaged.
IMPORTANT Lockout “DANGER” tags must be used in conjunction with approved lockout devices. Lockout “DANGER” tags are never to be used as the only means of safety.
ADVISORY AND CAUTIONARY STATEMENTS Five levels of advisory and cautionary statements are used throughout the operator’s manual to call attention to special information, operating procedures and safety precautions. Each is set off in a distinctive box and labeled to identify the level of significance which it covers. Advisory statements consist of two levels: NOTE and IMPORTANT. These are intended to alert personnel to conditions affecting equipment operation, maintenance and servicing practices. NOTE . . . a general advisory statement relating to equipment operation and maintenance procedures. Example:
NOTE Replace all drain plugs after draining lubricant. 17X0115-05.0003
General Information
IMPORTANT . . . a specific advisory statement or procedure intended to prevent damage to the equipment or associated components. Example:
IMPORTANT Do not operate the equipment if any component or parts are damaged, malfunctioning or out of operating specifications. Cautionary statements consist of three levels: CAUTION, WARNING, AND DANGER. These are intended to alert personnel of dangerous situations and hazards that exist around the equipment and work area. The safety alert symbol will be used in conjunction with all cautionary statements. THE SAFETY ALERT SYMBOL MEANS ATTENTION! BECOME ALERT! PERSONAL SAFETY IS INVOLVED! WHEN THIS SYMBOL APPEARS, CAREFULLY READ THE MESSAGE THAT FOLLOWS AND BE ALERT TO THE POSSIBILITY OF PERSONAL INJURY OR DEATH. CAUTION . . . a safe operating procedure that can only be ignored at the risk of personal injury. Example:
CAUTION Ensure that all guards and safety devices are installed before starting equipment. WARNING . . . a statement of a serious safety hazard. Failure to follow the instructions presents serious risk of personal injury or death. Example:
WARNING Do not disconnect any cylinders, hoses or fittings on a pressurized system until ALL pressure in the system is relieved. DANGER . . . a statement designating the most serious safety hazards. Failure to follow the instructions or heed the warning will most likely result in serious personal injury or death. Example:
TO PREVENT ELECTROCUTION OR SERIOUS BODILY INJURY, DISCONNECT, TAG AND LOCKOUT ALL POWER BEFORE WORKING ON ANY ELECTRICAL COMPONENTS OR CONTROLS. 17X0115-05.0003
Section 1 — Safe Equipment Operation GENERAL SAFETY PRECAUTIONS The following list of general safety precautions should be considered as a guide only. There may be other conditions and variations in the operation of this equipment that are not covered in these general safety precautions. The purpose of the general safety precautions is to make all personnel aware of the general hazards and dangerous situations that exist around the equipment and the work area. Personnel Safety 1. Read and understand each of the warnings, cautions and instructions in the operator’s manual and on signs fixed to the equipment. 2. Report all accidents immediately to your supervisor. Consult a doctor or medical facility as soon as possible if personal injury is involved. 3. Keep a list of emergency telephone numbers close to the telephone and instruct all work area personnel as to the locations of the list. 4. Do not operate or work around equipment while under the influence of alcohol, medicines, tranquilizers or other drugs that can make you less alert or affect your judgment. 5. Use hand grips, ladders, guard rails and other safety devices when getting on or off equipment and when moving around while on the equipment. Use a safety belt when necessary. 6. Take precautions to keep hair, ties, scarves, sleeves, trouser legs and other loose fitting clothing from being caught on moving parts or controls. 7. Wear safety glasses whenever there is any danger of flying debris, chips, objects or dust that could enter the eyes, and when required by operating regulations. Be extra safe — always wear eye protection. 8. Wear gloves whenever possible to protect hands and fingers from cuts, scrapes, burns and solvents. 9. Always wear a hard hat and safety shoes when working under equipment, when work is being done above you, and when required for the area in which you are working. 10. Remove rings, watches and bracelets before handling, lifting or working on any parts and equipment. 11. In area where loud noise is a problem, wear hearing protection devices. 12. Wear a breathing apparatus or respirator whenever painting or working with chemicals, solvents and other substances that may be hazardous to your health. 13. Do not take chances with your back. Use lifting and moving devices to help you with your work. Always lift with your legs, not with your back. Work Area Safety 1. Keep the general work area clean and free of debris. Avoid stone or other material build-ups on walkways, platforms and ladders. Always keep the walking 1-3
Section 1 — Safe Equipment Operation
2.
3. 4.
5. 6. 7.
8.
9.
10. 11.
surfaces or platforms under conveyor transfer points free of debris or material build-up. Do not allow unauthorized personnel in or around the work area. Know who is in your work area at all times. Use a head count when necessary. Keep equipment surfaces that will be touched by hands and feet clean, dry and free of oil or grease. Keep controls, push buttons, levers and switches dry and free of oil or grease. Avoid operating controls, push buttons, levers or switches with wet or oily hands. Keep hand grips, guard rails, ladders and platforms clean, dry and free of oil or grease. Store parts and tools in a designated place when not in use. Keep safety equipment in a designated place and ensure that work area personnel know the location and the proper use of the safety equipment. Make a daily check of starting alarms and warning devices in the work area, and ensure that each device is properly working before starting or operating the equipment. Do not stand under or allow anyone else to stand under equipment that is being hoisted or suspended. Use a safety hook or hook with a safety latch when hoisting equipment and use spreader bars when necessary. Always use a signalman when hoisting or moving equipment. Learn the weight limitations and clearances in and around your work area and for the equipment in use. Be alert to conditions such as dust, smoke, fog, machinery and the general surroundings that may obscure the vision around your work area.
Equipment Safety 1. Do not alter, deface or remove factory installed informations signs affixed to the equipment. See ”CAUTION SIGNS AND WARNING TAGS.” (See Page 1-2) 2. Before setting up portable equipment, be sure that the ground surface is firm and level. Make sure that all supporting devices and blocking are securely in place. Follow manufacturer’s recommended procedures for blocking and setting up equipment when applicable. 3. Before moving portable equipment with a tractor, check air brakes and running lights for proper operation. Ensure that the fifth wheel is locked into position and that jack legs and landing gear are raised high enough off the ground to provide sufficient clearance for transporting. 4. Never climb aboard equipment while it is in transit or being hoisted, or allow anyone else to do so. 5. Inspect all equipment components before each operating shift to ensure that no parts are damaged or suspected of being damaged. Repair or replace damaged parts before starting or operating the equipment. 1-4
General Information
6. Before starting or operating equipment, walk around the work area and the equipment to check that no personnel, animals, tools, parts or other foreign objects are in, on, under or around the equipment. Make sure that all guards and safety devices are properly installed and in good working condition. Check for warning tags on equipment components and controls before starting or operating the equipment. 7. Before starting equipment, make sure that all work area personnel and visitors know that the equipment is going to be started. Use appropriate warning devices such as horns, alarms or flashing lights to warn personnel and visitors that equipment is going to be started. Use a head count to make sure that you know where all work area personnel and visitors are located. 8. When starting equipment, follow the manufacturer’s recommended starting sequence. 9. Do not allow unskilled persons to start or operate any equipment without the proper supervision of a skilled operator. 10. Never leave equipment controls unattended. Always have a qualified operator relieve you if you must leave. 11. During start-up and while equipment is operating, be alert for improper readings, visual defects, odors or unusual sounds that could be a warning of a potential hazard. Shut down equipment immediately, following established shutdown procedures, if any unsafe condition should arise. 12. Do not work on equipment while it is in operation. Perform all required inspection, maintenance, lubrication or adjustments before starting or operating the equipment, or after the equipment is shut down. Use extreme caution whenever any equipment is required to be operating during an inspection, maintenance, lubrication or adjustment procedure. 13. Perform all inspection, maintenance, lubrication and adjustment procedures with caution and in accordance with manufacturer’s recommended procedures. Electrical Safety 1. Permit only licensed electricians to work on electrically live parts of any plant or equipment. 2. Always assume that an electrical circuit is live until it is proven dead by proper testing procedures. 3. Lockout and tag electrical/mechanical controls before performing any inspection, maintenance, lubrication or adjustment procedures. 4. Repair or replace electrical wires, cables and connectors that are frayed, cut, broken or damaged in any way. 5. Check that electrical ground wires, motor plugs and power cable connections are properly and securely connected before starting any equipment.
17X0115-05.0003
General Information
6. Know the location of all power lines and underground cables. Use extreme caution when working around these areas. Know the location of all main electrical shut-off boxes. 7. Never work on electrical equipment while it is raining or while standing in water or on wet surfaces unless you know that the power is disconnected. 8. Be alert when working around or with electricity. Report any electrical hazard immediately to your supervisor. Flammable and Hazardous Materials Safety 1. Store flammable, combustible or hazardous materials in a safe place and in containers specifically designed and clearly marked for that purpose. 2. Store used cleaning and oily rags in the properly designed container as required by federal, state and local rules and regulations, and away from flammable and combustible materials. 3. Do not store flammable or combustible materials in, on or around the equipment 4. Do not permit smoking or open fires around fuel tanks or other combustible materials storage facilities. 5. Keep several fully charged fire extinguishers located throughout the work area. Know their locations and how to operate them. Have them readily available during fueling operations or when other fire hazards are present. Check the charge on each fire extinguisher at least once a month or when otherwise specified. 6. Shut down all engines and motors (with the exception of material transfer systems) when fueling or transferring flammable, combustible or hazardous materials. Follow the recommended fueling and transfer procedures for the substance or material being worked with. 7. Fill fuel storage tanks and other combustible materials storage facilities in a well ventilated area, away from smoking materials, open flames, heaters or other heat sources that could cause ignition of the material. 8. When refueling or transferring flammable or combustible materials, ground the nozzle or spout against the storage facility filler neck to prevent static electrical sparks. 9. Never start a diesel or gasoline engine in an enclosed area unless their is adequate ventilation. Exhaust fumes can kill. 10. Do not use flammable or combustible substances such as gasoline, kerosene or diesel fuel for cleaning parts. Always use a nonflammable solvent for cleaning. 11. When using epoxy resin based materials, follow the manufacturer’s recommended procedures and precautions. Mix and pour epoxy materials in an open or well ventilated area. Do not burn cured resin without
17X0115-05.0003
Section 1 — Safe Equipment Operation adequate ventilation. Avoid skin contact with uncured epoxy resin materials. 12. Always inspect and change batteries in an open or well ventilated area. Do not permit smoking materials or open flames near batteries. 13. Properly dispose of waste, drain fluids and hazardous materials with due regard and in full accordance with all federal, state and local environmental, safety, transportation and other regulatory agency’s rules, regulations and ordinances. 14. Think before you act when working with flammable, combustible or hazardous materials. Wear the appropriate clothing and protection devices, and follow the recommended procedures when working with these materials. Pressurized Systems Safety (Air & Hydraulic) 1. Do not perform maintenance on pressurized system components without first relieving ALL pressure to the system. 2. Do not make internal checks on pressurized oil or fluid system reservoirs or levels until ALL pressure to the system is relieved. Pressurized oils and fluids are dangerous if released incorrectly. Oils and fluids under pressure can get very hot; use extreme caution and allow the system to cool before working on it. 3. Do not attempt to remove an air or hydraulic cylinder clevis from its connection unless ALL pressure to the system is relieved. 4. Do not operate pressurized systems with worn or damaged hoses, valves or fittings. Replace defective components before pressurizing the system. 5. Do not attempt to disassemble air or hydraulic cylinders unless trained and authorized, and you have the correct equipment for such maintenance. Some air and hydraulic cylinders contain a heavy spring which, it improperly released, could result in severe injury or death to anyone in its path. 6. Never adjust pressure relief valves beyond recommended values to get higher operating pressures. The manufacturer’s recommended pressures give the safest performance with the longest life. 7. Follow the manufacturer’s recommended inspection and maintenance procedures for pressurized systems to ensure that safe operating conditions exist at all times. Welding Safety Starts with Safety Glasses 1. Any welding or cutting operations should only be performed by experienced welders who are familiar with the welding equipment and the materials to be welded. 2. Take all necessary precautions to avoid dropping sparks or welding splatter on belts, hoses, tanks, other parts of equipment and work area personnel.
1-5
General Information
Section 1 — Safe Equipment Operation Have several fully charged fire extinguishers close by whenever any welding or cutting operation is being performed. 3. Attach the welding ground cable to the piece being welded to avoid damage to the equipment and potential injury to personnel. 4. Always consult with the manufacturers of the equipment to be welded on before performing any welding operation.
5.
CRUSHER SAFETY PRECAUTIONS All personnel operating and maintaining a SUPERIOR crusher should be aware of the following safety precautions. Personnel Safety 1. Noise levels at one meter distance from the crusher when crushing rock range from 90 to 110 DBA. Ear protection should be used when working near and around the crusher when it is in operation. Signs should be posted to advise personnel to wear ear protection. 2. Dumping material into the crusher and crushing material results in dust. The amount of dust produced, as well as the danger from breathing it into your lungs, is dependent on the type of material being processed. It is the responsibility of the purchaser to post signs advising of any dangerous dust conditions and to provide a means of dust suppression such as water sprays or ventilation fans with collectors or provide respirators for personnel working near the crusher, as required. 3. The dump pocket around the top opening of the crusher is dangerous. Personnel should not be in the dump pocket when the crusher is in operation. Being struck by falling material from trucks when dumping, or personnel falling into the crushing chamber could be fatal. It is the responsibility of the buyer to provide visual warnings of dump pocket dangers, visual / acoustic warnings of trucks dumping material, and acoustic warning of crusher start up. 4. All maintenance should be performed when the crusher is shut down. Personnel performing maintenance in the crushing chamber or underneath the crusher are susceptible to falling material or
1-6
6.
7.
8.
9.
10.
objects from the dump pocket. It is the operator’s responsibility to ensure the dump pocket has no loose material that could slide into the crushing chamber and injure personnel in the chamber or underneath the crusher. Use a temporary ring around the crusher feed opening or completely empty the dump pocket before performing maintenance in the crushing chamber or underneath the crusher. Several liners on the crusher are manganese steel. In particular the spider rim and arm liners and crusher mainshaft liner (mantle). Torch cutting, welding, and grinding on manganese steel produces toxic fumes and dust. Approved respirators should be worn for personnel protection. A plastic backing is used between the mainshaft and its liner (mantle) also between the top shell liners (concaves) and the top shell. See “Precautions When Using Plastic Pack” in the Appendix to Section 4 under Plastic Pack Directions For Use Controls: Since some of the control wiring is by the customer, it is their responsibility to ensure the following conditions are met. It must be possible to start the crusher by voluntary actuation of a control provided for that purpose. Any stoppage of the crusher caused by power fluctuations or a significant change in operating conditions (pressure, temperature, speed, power, etc.) should not result in an automatic restart of the crusher. The crusher main drive must be guarded to prevent serious injury. If the guard is supplied by the customer, it is their responsibility to design it to meet all EC and OSHA standards. Controls: All controls furnished by the customer must be designed, constructed, and equipped so that all electrical hazards are or can be prevented. Machinery Maintenance: Several areas of the crusher require access for maintenance. Access to areas such as the main drive assembly, spider bearing assembly, HYDROSET cylinder assembly (underneath the crusher), and the lubrication system is not provided by the manufacturer. It is the customers’ responsibility to provide a safe means for servicing these areas. The design and building of access for maintenance are customers’ responsibility.
17X0115-05.0003
General Information
Section 1 — Safe Equipment Operation
TEN COMMANDMENTS OF SAFETY I.
Support efforts to make your workplace safe and healthful. Do your part; observe safety regulations and established work practices.
II. Act responsibly and with concern for the safety of others, as well as your own. III. Check all tools and protective equipment frequently, to make sure they are in safe working order. IV. Educate yourself and others in the hazards associated with your job and safe ways to perform familiar tasks V. Ask others how to perform tasks with which you are unfamiliar. “Playing it by ear” can lead to costly accidents.
17X0115-05.0003
VI. Think over accident and injury possibilities before starting on any project. Take appropriate precautions to protect yourself and others. VII. Warn others of the possibility of accidents and injuries if you see them working unsafely or creating potential hazards. VIII.Stay alert for changes in work conditions and the work process. IX. Report unsafe acts and conditions immediately to your supervisor. Don’t assume that someone else will do it. X. Keep your work area clean. Keep tools and materials picked up and properly stored.
1-7
Section 2 — Index
General Information
2.
Page 2-2 2-2 2-3 2-4 2-4 2-4 2-5 2-5 2-5 2-5 2-6 2-6 2-6 2-6 2-7 2-7 2-7 2-8 2-8 2-9 2-9 2-10 2-10 2-11 2-12 2-12 2-13 2-14
Safe Handling of Heavy Equipment and Machinery
Description Introduction Making a safe Hitch Factors Affecting the Use of Slings Sling and Load protection Blocking Loads Hooks Eyebolts Inspection Application Cautions Definition of Rated Capacity Capacity Table for Type 1 Eyebolt Capacity Table for Type 2 Eyebolt Shackles Safe Rigging Practices Safe Loading Table for Standard Shackles Wire Rope Slings Safe Rigging Practices Wire Rope Clip Installation Clips Required for Fastening Wire Rope Ends Safe Loading Table for FC or IWRC Wire Rope Slings Braided Wire Rope Slings Safe Rigging Practices Safe Loading Table for 8-Part Braided Rope Slings Alloy Steel Chain Slings Safe Rigging Practices Safe Loading Table for Alloy Steel Chain Slings Hand Signals for Cranes and other Lifting Devices
17x11155–01.9306
2
2–1
Section 2 — Safe Handling of Heavy Equipment and Machinery INTRODUCTION Hoisting devices are the most frequently used type of equipment for handling heavy machinery. Slings and related equipment provide the critical link between the load and the lifting device. They often determine the difference between a safe effective lift and a disaster. The following information is provided to assist personnel responsible for the unloading, handling and installation of heavy machinery. The primary consideration in providing this information is the safety of personnel working with or near the machinery while it is being handled. The secondary concern is the avoidance of damage to the machinery itself.
WARNING
General Information Protect finished surfaces of the load from possible damage by the hitching equipment. Secure protecting material to the load or sling to prevent them from falling when the sling becomes slack. 7. When it is necessary to climb on the machinery to place hitching equipment, observe the following rules: a. Use ladders of the approved type whenever possible and ensure that they are held securely in place. b. Keep both hands free for climbing. Hitching equipment should be pulled up with a crane. 8. When the hitching equipment is in position, give the signal to take out the slack. Give particular attention to the position of the fingers to prevent them from getting pinched. See figures 2-1 and 2-2.
Check the weight of all loads before lifting. Make sure the lifting device and other components that will support the weight of the load, are in good condition and are rated for the weight of the load. MAKING A SAFE HITCH 1. Before lifting and transporting a load, check its physical characteristics, weight, size and shape. a. The weights of major assemblies and complete machines are usually listed on installation drawings and in the respective equipment instruction manuals. Larger assemblies may have the weight marked on them. If no weight is found consult your supervisor or weigh the load. b. The size and shape of loads will indicate the type of hitch to be used — choker, basket or a hitch with special attachments. It may also indicate the type of hitching equipment to be used — wire rope, alloy chain, eyebolts, shackles, etc. 2. When the weight of the load, load angle, type of hitch and hitching equipment to be used has been determined, select the proper size hitching equipment of that type from the Safe Loading Tables in this section. 3. If the load to be lifted exceeds the safe load rating of a particular size sling or related hitching components, go to the next larger size that will carry the load safely. The safe load rating of the hitching equipment must not be exceeded. 4. If there is any doubt as to the correct type of hitch, or size and type of hitching equipment to use, contact your supervisor. 5. Hitching equipment must be carefully checked when it is removed from the storage rack. Defective equipment must be removed from service and notice given to your supervisor. 6. To assure longer life of hitching equipment and greater safety in its use, the equipment must not be overloaded and must be protected from the sharp corner of the load by using bagging, corner irons, lagging, etc. 2–2
FIG. 2-1 — Position of hand when taking slack out of sling.
FIG. 2-2 — Position of hand when guiding hook.
9. Give standard crane signals clearly and in sight of the crane operator so he can move the load as desired. See ”Hand Signals” at the end of this section. 10. Before giving the signal to lift the load, the person making the hitch must check the following: a. Make sure no loose materials, tools, dirt, bolts, etc. are on the load. b. Make sure unused sling legs are secured by hooking them back into the master ring or by shackling them together. Unused legs must not be allowed to dangle loose. 17x11155–01.9306
Section 2 — Safe Handling of Heavy Equipment and Machinery
General Information
11.
12. 13.
14. 15.
Stand in the clear and be sure others in the immediate area are also in the clear before proceeding with the lift. Check the hitch at all points, when the slack has been taken out to see that it is safe, secure and in balance. Check the hitching equipment to see that ii is still protected from the load and that finished surfaces are protected from the hitching equipment. When the load has been raised several inches off the ground and is completely supported by the lifting device, check the load brake and recheck the hitch at all positions. Whenever possible, transport loads over areas where no one is working. Give sufficient warning when loads will be moved over personnel occupied areas. A clear area with adequate blocking should be prepared when selecting a place for the load, avoid placing loads in aisles, roadways, tracks or heavy occupied areas. When the load is being lowered to its approximate position, keep all personnel clear of the area. Stop the load just before contact with the ground and adjust the blocking to the loads final position.
CAUTION
c.
CAUTION Keep hands and feet away from the pinch point areas between the blocking and the load. See figure 2-7. 16. Properly place blocking to assure that the load will be level and stable when lowered to the ground. Consider the following guidelines when placing blocking: a. Weight of the load — blocking must provide a stable resting surf ace capable of supporting the complete weight of the load. b. Finish of the load — protect finished surfaces by padding the blocking and hitching equipment with bagging, pressed cardboard, belting, etc. See figure 2-4. c. Size and shape of the load — wedge and block round shafts, forging and rings. See figure 2-6. Use blocking of equal dimensions to ensure that the load will rest level. Be sure adequate blocking is used when off-balance loads are encountered. d. Working surfaces — compensate for flaws in floor and yard surfaces when using blocking. Use extra care when blocking on frozen ground to assure the load will not shift when the ground thaws. e. Condition of blocking — use blocking that is in good condition and of uniform size. Do not use defective blocking that is rounded, rotted, broken, containing large knots, etc. See figure 2-5. 17. Slowly lower the load until its full weight is supported by the ground or blocking. 17x11155–01.9306
Hitching equipment protection such as corner irons, belting and lagging may fall when sling is slack. Keep personnel away from area until hitching equipment protection is removed. 18. When the hitch has been completed, remove and check the hitching equipment for damage. If no longer needed, place the hitching equipment back on the storage rack. FACTORS AFFECTING THE USE OF SLINGS The Safe Load Tables in this section give the maximum safe load for each size of hitching equipment when used as shown in the illustrations above each table. The illustrations cover most of the common applications of hitching equipment. See your supervisor for applications not covered in the Safe Load Tables. The Safe Load Tables take into account the following factors: NUMBER OF LEGS — the number of sling legs connecting the crane hook with the load. LOAD ANGLE — the angle between the load (horizontal surface) and the sling. The smaller the load angle the smaller is the safe load capacity or efficiency of the hitching equipment as shown in the table below and in figure 2-3. ANGLE EFFICIENCY TABLE Safe Working Load Angle Lifting Load for One Leg Degrees Efficiency Based on 500 Lb. Percent (227 kg) Load o 30 50.0% 250 lbs. (113 kg) o 45 70.7% 354 lbs. (161 kg) 60o 86.6% 433 lbs. (196 kg) o 90 100.0%. 500 lbs. (227 kg)
FIG. 2–3 – Sling angle
2–3
Section 2 — Safe Handling of Heavy Equipment and Machinery
General Information
SPLICE EFFICIENCY — the reduction in strength of wire rope due to eye splices or endless splice. CORNER CORNE R EFFICIENCY — the reduction in strength of slings when bent around reasonable corners. The Safe Load Tables Tables are not set up for sharp corners. CHOKER CHOKE R EFFICIENCY — the reduction in strength strength of slings when used for choker hitches. LOADING — the reduction in strength of hitching equipment due to shock or impact loading and acceleration loading by the crane or hoist. WEAR — the reduction in strength of hitching equipment due to normal wear. The Safe Load Tables do not take into account such unusual factors as high temperatures, sub-zero temperatures, excessive vibration and corrosive or solvent exposures.
Blocking should be approximately square in cross section sect ion and in good condition. Wedge and block loads that may roll or move. See figure 2-6. When blocking blocking loads on frozen ground, make allowances for the possibility of thawing which can cause loads to sink si nk or shift.
SLING AND LOAD PROTECTION Protect slings with materials designed to increase the radius of corners, such as burlap bagging, sheet metal lagging ,corner irons, belting or wood blocking. See figure 2-4.
FIG. 2-6 — Wedging and blocking a round load.
Correct
Wrong
FIG. 2-4 — Increasing radius of sharp corner with sling protection.
Protect finished surfaces of loads from slings and hitching equipment by using soft sling protection materials. BLOCKING LOADS Always use good hardwood timber whenever blocking is required. Place blocking under loads so that they will be stable and level. This will also allow space under the load to get stings on and off off easily. easily. See figure 2-5.
Correct FIG. 2-5 — 2-5 — Use of blocking.
2–4
Wrong
Figure 2-7 shows the proper position for the hand when moving blocking so the hand will not be pinched if the load should shift.
FIG. 2-7 — Position of hand when placing blocking.
HOOKS Hooks that are permanently fastened to the ends of wire rope or chain slings must not be point loaded or wedged on a load. The load rating for hooks is usually stamped somewhere somewhe re on the hook. hook. Check with your your supervisor if no load rating is given for the hooks. Secure each leg of a wire rope sling at the hook to prevent reeving of the sling sling on the hook. Figure 2-8 shows shows the correct method of rigging wire rope slings to a hoist hook. Do not use single leg wire rope slings alone because of the possibility of load rotation unlaying the rope.
Correct
Wrong
FIG. 2-8 — Rigging wire rope to the hook. 17x11155–01.9306
Section 2 — Safe Handling of Heavy Equipment and Machinery
General Information
Use spring latch hooks for the hoist hook whenever possible. If spring latch hooks are not available, mouse the hook as shown in figure 2-9.
Load
Load
FIG. 2-9 — Mouse hook if load is liable to slip off. Correct (Front View)
EYEBOLTS EYEBOLTS (ANSI/ASME B18.15–1985) Type 1, plain pattern (straight shank) and Type 2, shoulder pattern eyebolts are furnished by Svedala Industries for use on specific parts or assemblies. The material and mechanical property requirements for these general purpose forged carbon steel eyebolts are covered by ASTM A489. INSPECTION Eyebolts Eyebol ts shall be free from visible defects that might affect affect serviceability. Eyebolts should be routinely visually inspected for such defects as: a. Bent Bent or or dist distor orte ted d eye eye or sha shank nk.. b. Nick Nicks s and and goug gouges es.. c. Obvi Obviou ous s we wear ar.. d. Worn Worn and and/or /or distort distorted ed thread threads. s. e. Cracks. If any of these defects are visible, the eyebolt should be removed from service and destroyed. APPLICATION 1. Cap Capaci acitie ties s shown shown in the the followi following ng table tables s are for for carbon steel ASTM A489 eyebolts, at temperatures between 30o F (–1o C) and 275o F (135o C). Carbon steel is subject to failure from shock loading at temperatures temperatures below 30o F (–1o C) and loses strength at temperatures above 275 o F (135 o C). 2. Ref Refer er to table tables s for redu reduced ced loads loads on on angular angular lift lift capacities. 3. Loads must must always always be applied applied to eyebol eyebolts ts in the the plane plane of the eye, not at some angle to this plane. See figure 2-10.
17x11155–01.9306
Wrong (End View)
FIG. 2-10 — Load applied in the plane of the eye, not at some angle to the plane.
4. Type 1 plain plain eyebo eyebolts lts must must b be e engage engaged d to within within one-half one-ha lf turn from the eye end of the threads to obtain rated capacities. 5. Type Type 2 shoulder shoulder eyebolts eyebolts should bear firmly against against the mating part; otherwise the rated capacity must be reduced reduce d to those indicated for Type 1 eyebolts. A steel washer or spacer, not to exceed one thread pitch, may be required to put the plane of the eye in the direction of the load when the shoulder is seated.
CAUTIONS 1. Eyebolts Eyebolts should never be ground ground,, notched notched,, undercu undercutt or welded. Such alterations will weaken the eyebolt. Eyebolts showing signs of having been so altered should be immediately destroyed. 2. Eyebolts Eyebolts that are being being remov removed ed from from servic service e should should be rendered unusable. Crushing or cutting clear across the eye is recommended. 3. Never Never stand, stand, work work or or crawl crawl under under the the load. load. IfIf the load could swing, or if pieces could scatter in the event of a drop, allow for this possibility by establishing a safe distance from the load. 4. Any visib visible le rendin rending g or elonga elongatio tion n of the eyeb eyebolt olt is a danger signal and indicates that it has been stressed beyond rated capacity. The bolt should be removed and destroyed, and the application investigated.
2–5
Section 2 — Safe Handling of Heavy Equipment and Machinery
General Information
DEFINITION OF RATED CAPACITY CAPACITY Rated capacity is the maximum recommended load that should be exerted on the item. All rated capacities are for in-line pull with respect to the centerline of the item. RATED RA TED CAPACITY OF TYPE 1, PLAIN PATTERN PATTERN (STRAIGHT SHANK) EYEBOLTS 0 deg.
30 deg. 60 deg. 90 deg.
SHANK Dia.
0 Degree Per Bolt Pounds Kg 40 0 18 1
30 Degree Per Bolt Pounds Kg 70 31
60 Degree Per Bolt Pounds Kg NR –– –
90 Degree Per Bolt Pounds Kg NR –––
Inches 1/4
MM 6.4
1/2 3/4 1 1-1/4 1-1/2
12.7 19.3 25.4 31.8 38.1
1,840 4,340 7,880 12,600 18,260
83 4 1,968 3,574 5,715 8,282
8 05 2,115 3,670 5,896 8,575
365 9 59 1,664 2,674 3,889
47 0 1,190 2,390 3,752 5,495
2 13 5 39 1,084 1,701 2,492
39 5 1,040 2,110 3,350 4,960
17 9 471 9 57 1,519 2,249
2 2-1/2
50.8 63.5
32,500 52,000
14,741 23,586
15,210 24,500
6,899 11,113
9,915 16,800
4,497 7,620
8,880 14,000
4,027 6,350
RATED CAPACITY OF TYPE 2, SHOULDER PATTERN EYEBOLTS 0 deg.
30 deg. 60 deg. 90 deg.
SHANK Dia. Inches 1/4 1/2
MM 6.4 12.7
3/4 1 1-1/4 1-1/2 2
19.3 25.4 31.8 38.1 50.8
0 Degree Per Bolt Pounds Kg 400 18 1 1,840 8 34 4,340 7,880 12,600 18,260 32,500
1,968 3,574 5,715 8,282 14,741
30 Degree Per Bolt Pounds Kg 75 34 850 385 2,230 3,850 6,200 9,010 15,970
SHACKLES Shackles are made of drop forged steel and bent into shape. Shakles are strong, closed attachments which won’t come unhooked and are recommended for hitching. 2–6
1,011 1,746 2,812 4,086 7,243
60 Degree Per Bolt Pounds Kg NR –– – 520 23 5 1,310 2,630 4,125 6,040 10,910
59 4 1,192 1,871 2,739 4,948
90 Degree Per Bolt Pounds Kg NR ––– 44 0 199 1,140 2,320 3,690 5,460 9,740
517 1,052 1,673 2,476 4,418
The size is determined by the diameter of the body — not the pin. See figure 2-11.
17x11155–01.9306
Section 2 — Safe Handling of Heavy Equipment and Machinery
General Information
Safe Rigging Practices 1. Side pull on the shackle body may cause bending and should be avoided. 2. Shackle pins should fit free without binding. 3. Safe loads on larger size shackles are stamped on the shackle body. The safe load of anchor or chain shackles, screw pin or slip pin, are the same. 4. Never substitute a bolt for the shackle pin. Common bolts are weaker than shackle pins. 5. When shackles are used at load angles other than 90o reduce safe load rating according to Angle Efficiency Table, in the section on “Factors Affecting The Use Of Slings”, page no. 2-3.
Diameter Size
Anchor Shackle Screw Pin
Chain Shackle Screw Pin
FIG. 2–11 — Shackles
SAFE LOADING TABLE FOR STANDARD SHACKLES
Diameter Inches 1/4 5/16 3/8 7/16 1/2 5/8 3/4 7/8 1 1-1/8 1-1/4 1-3/8 1-1/2 1-3/4 2 2-1/4 2-1/2 2-3/4 3 4
MM 6.4 7.9 9.5 11.1 12.7 15.9 19.3 22.2 25.4 28.6 31.8 34.9 38.1 44.5 50.8 57.2 63.5 70.1 76.2 101.6
One Shackle Vertical Short Metric Tons Tons 1/3 .3 1/2 .5 3/4 .7 1 .9 1-1/2 1.4 2 1.8 3 2.7 4 3.6 5-1/2 5 6-1/2 5.9 8 7.2 10 9 12 10.8 16 14.5 21 19 27 24.5 34 31 40 36.2 80 45.3 100 90.7
2 Shackles 60o Short Metric Tons Tons 3/4 .7 1 .9 1-1/4 1.1 1-3/4 1.6 2-1/2 2.3 3-3/4 3.4 5-1/2 5 7 6.3 10 9 11-1/2 10.5 14 12.7 17 15.4 20 18.1 28 25.4 36 32.6 46 41.7 58 52.6 69 62.9 87 78.8 173 156.9
WIRE ROPE SLINGS Wire rope slings are made from the best quality tempered steel wire. Wires are laid into strands. Six strands are laid around a fiber core (FC) or an independent wire rope core (IWRC) to form the complete rope. The fiber core acts as a cushion and oil reservoir, while the independent wire 17x11155–01.9306
2 Shackles 45o Short Metric Tons Tons 1/2 5 3/4 .7 1 .9 1-1/2 1.4 2 1.8 3 2.7 4-1/2 4.1 6 5.4 8 7.2 9-1/2 8.5 12 10.8 14 12.7 17 15.4 23 20.9 30 27.1 38 34.5 48 44 57 51.9 71 64.4 142 128.7
2 Shackles 30o Short Metric Tons Tons 1/3 .3 1/2 .5 3/4 .7 1 .9 1-1/2 1.4 2 1.8 3 2.7 4 3.6 5-1/2 5 6-1/2 5.9 8 7.2 10 9 12 10.8 16 14.5 21 19 27 24.5 34 31 40 36.2 50 45.3 100 90.7
rope core gives greater resistance to crushing and heat. Use the Safe Load Table For Wire Rope slings for both types of cores. Wire rope slings are very strong for their weight, are lighter than chain, but are inclined to be stiff to handle. Wire rope slings are best used in straight hitches 2–7
Section 2 — Safe Handling of Heavy Equipment and Machinery
General Information
or around large radius corners. Wire rope is made up into slings by hand splicing or by swaged fittings. Size of the wire rope is obtained by measuring its overall diameter. See figure 2-12. Diameter Size
d. Broken seizing wire. e. Damage to swaged fittings. f. Other signs of damage or abuse.
Core
Strand Wire
Correct FIG. 2-12 — Wire rope.
Safe Rigging Practices 1. Protect wire rope slings against weather, solvents, high temperatures, and chemicals. 2. Do not exceed the following temperatures when using wire rope slings: Fibre core – 212 o F (100o C). Higher temperatures damage the core. Independent wire rope core – 400 o F (210o C). Higher temperatures damage the steel. 3. Knots permanently damage wire rope slings and must not be used. 4. Protect rope slings from sharp corners by increasing the corner radius with corner irons or blocks. See figure 2-13. Bagging and lagging in sufficient amounts may also be used.
FIG. 2-13 — Corner iron protection for wire rope sling.
5. Figure 2-14 shows proper methods of rigging wire rope slings to the hook. a. Secure each leg of a wire rope sling at the hook to prevent reeving of the sling on the hook. b. Do not use single leg wire rope slings alone because the load might spin, unlaying the wire rope and allowing the splice to pull out. 6. Do not make a complete turn of wire rope around a crane hook. The sharp radius will damage the sling. 7. Check wire rope slings for: a. Broken or cut wires or strands. b. Rust and corrosion. c. Kinks and doglegs. 2–8
Wrong
FIG. 2-14 — Rigging wire rope to the hook.
8. Protect finished surfaces from wire rope slings with bagging and lagging. 9. Avoid bending the eye sections of wire rope slings around corners because the splice or swaging may be weakened.
FIG. 2-15 — Use shackles for wire rope choker hitches.
10. Use a shackle when making choker hitches with wire rope slings. See figure 2-15. 11. Use the larger end of pear shaped master links on the crane hook so as to prevent the master links from binding. The smaller end is used for the wire rope sling. Wire Rope Clip Installation There is only one correct method of attaching wire rope clips. Attach clips to the rope ends as shown in figure 2-16. The base of each clip must bear against the live end of the rope and the U–bolt of the clip must bear against the dead end. The proper number of clips and the spacing between clips to use with various sizes of wire rope are listed in the table below. Tighten clip nuts to the recommended torque. Wire rope Clip U-Bolt thimble
Dead End
Spacing between clips
Clip base or saddle
Live End
FIG. 2–16 — Proper wire rope clip installation.
After the rope has been placed in service and is under tension, tighten the clip nuts again to compensate for any 17x11155–01.9306
Section 2 — Safe Handling of Heavy Equipment and Machinery
General Information
decrease in rope diameter caused by the load. Check the clip nuts and tighten periodically to compensate for rope
stretch and diameter shrinkage.
CLIPS REQUIRED FOR FASTENING WIRE ROPE ENDS Rope Diameter U-Bolt Diameter Clip Spacing Minimum Number Inches MM Inches MM Inches MM of Clips Required 3/16 4.76 11/32 8.73 3 76 2 1/4 6.35 7/16 11.11 3-1/4 83 2 5/16 7.94 1/2 12.70 3-1/4 83 2 3/8 9.53 9/16 14.29 4 102 2 7/16 11.11 5/8 15.88 4-1/2 114 2 1/2 12.70 11/16 17.46 5 127 3 5/8 15.88 3/4 19.05 5-3/4 146 3 3/4 19.05 7/8 22.23 6-3/4 172 4 7/8 22.23 1 25.40 8 203 4 1 25.40 1-1/8 28.58 8-3/4 222 4 1-1/8 28.58 1-1/4 31.75 9-3/4 248 5 1-1/4 31.75 1-7/16 36.51 10-3/4 273 5 1-3/8 34.93 1-1/2 38.10 11-1/2 292 6 1-1/2 38.10 1-23/32 43.66 12-1/2 318 6 1-5/8 41.28 1-3/4 44.45 13-1/4 337 6 1-3/4 44.45 1-15/16 49.21 14-1/2 368 7 2 50.80 2-1/8 53.98 16-1/2 419 8 2-1/4 57.15 2-5/8 66.68 16-1/2 419 8 2-1/2 63.50 2-7/8 69.85 17-3/4 451 8 SAFE LOADING TABLE FOR FC OR IWRC WIRE ROPE SLINGS
Wire Rope Diameter
Straight 1 Leg Short Metric Tons Tons 1/2 .5 1 .9 2 1.8 3 2.7
Choker 1 Leg Short Metric Tons Tons 1/3 .3 3/4 .7 1-1/2 1.4 2 1.8
60o Choker 2 Leg Short Metric Tons Tons 2/3 .6 1-1/4 1.1 2-1/2 2.3 4 3.6
45o Choker 2 Leg Short Metric Tons Tons 1/2 .5 1 .9 2 1.8 3 2.7
30o Choker 2 Leg Short Metric Tons Tons 1/3 .3 3/4 .7 1-1/2 1.4 2 1.8
Inches 1/4 3/8 1/2 5/8
MM 6.4 9.5 12.7 15.9
3/4 1 1-1/4 1-1/2 2
19.3 25.4 31.8 38.1 50.8
4 7 10 13 21
3.6 6.3 9 11.8 1.9
3 5 7 9 15
2.7 4.5 6.3 8.2 13.6
5 8 12 16 27
4.5 7.2 10.8 14.5 24.5
4 7 9 13 22
3.6 6.3 8.2 11.8 20
3 5 7 9 15
2.7 4.5 6.3 8.2 13.6
2-1/2 3 3-1/2
63.5 76.2 88.9
28 38 40
25.4 32.6 36.2
22 28 34
20 25.4 31
38 49 59
34.5 44.5 53.5
31 40 48
28 36.2 43.5
22 28 34
20 25.4 31
17x11155–01.9306
2–9
Section 2 — Safe Handling of Heavy Equipment and Machinery
Wire Rope Diameter Inches
MM
General Information
60o Basket 2 Leg Short Tons
Metric Tons
45o Basket 2 Leg Short Tons
30o Basket 2 Leg
Metric Tons
Short Tons
Metric Tons
60o Basket 4 Leg Short Tons
Metric Tons
45o Basket 4 Leg Short Tons
30o Basket 4 Leg
Metric Tons
Short Tons
Metric Tons
3/4 3/8 1/2
6.4 9.5 12.7
2/3 1-1/2 2-1/2
.6 1.4 2.3
1/2 1 2
.5 .9 1.8
1/3 3/4 1-1/2
.3 .7 1.4
1 3 5
.9 2.7 4.5
1 2 4
.9 1.8 3.6
3/4 1-1/2 3
.7 1.4 2.7
5/8 3/4 1 1-1/4 1-1/2
15.9 19.3 25.4 31.8 38.1
4 5 9 13 17
3.6 4.5 8.2 11.8 15.4
3 4 7 11 14
2.7 3.6 6.3 1.0 12.7
2 3 5 7 10
1.8 2.7 4.5 6.3 9
7 11 18 26 35
6.3 1.0 16.3 23.6 31.7
6 9 15 21 28
5.4 8.2 13.6 1.9 25.4
4 6 10 15 20
3.6 5.4 9 13.6 18.1
2 2-1/2 3 3-1/2
50.8 63.5 76.2 88.9
27 38 49 59
24.5 34.5 44.5 53.5
22 31 40 49
20 28 36.2 44.5
15 22 29 34
13.6 20 26.3 31
53 75 97 118
48 68 88 107
44 61 80 97
40 .3 72.5 88
31 43 56 68
28 39 51 62
BRAIDED WIRE ROPE SLINGS Braided slings are made by braiding wire ropes together. An 8-part braided sling has a cross section of 8 wire ropes. The size of a braided sling is determined by the diameter of one wire rope or part, together with the number of parts in the cross section of the sling. See figure 2-17. Example: 1/4” x 8 part braided sling. Braided slings have greater flexibility than wire rope slings, which makes for easier handling in the larger sizes. They also have a better grip on the job than wire rope slings.
3. Knots must not be used – they will permanently damage braided slings. 4. Rig braided slings to a hook similar to methods used for wire rope. 5. Check braided slings for: a. Broken or cut wires, strands or parts. b. Rust and corrosion. c. Kinks and doglegs. d. Excessive slack in any of the parts. e. Broken seizing wire. f. Other signs of damage or abuse. 6. Protect braided slings from sharp corners by increasing the radius of the corner with bagging, lagging, and corner irons. See figure 2-18.
Size: Diameter of one part and number of parts.
FIG. 2-17 — Braided wire rope sling.
Safe Rigging Practices 1. Protect braided slings from weather, solvents, high temperatures, and chemicals. 2. Do not use braided slings at temperatures above 212o F (100o C) if made with a fiber core or above 400 o F (210o C) if made with an independent wire rope core. 2–10
FIG. 2-18 — Lagging protection for braided sling.
7. Protect finished surfaces from braided slings by bagging and lagging. 17x11155–01.9306
Section 2 — Safe Handling of Heavy Equipment and Machinery
General Information
8. Avoid bending the eye sections of braided slings. It 9. When making choker hitches with braided slings, use shackles similar to wire rope. See figure 2-15. may cause the seizing wire to break and damage splices. SAFE LOADING TABLE FOR 8–PART BRAIDED ROPE SLINGS
Diameter of One Part Inches 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1-1/4
MM 6.4 7.9 9.5 11.1 12.7 14.3 15.9 19.3 22.2 25.4 31.8
Diameter of One Part Inches
1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1-1/4
MM
6.4 7.9 9.5 11.1 12.7 14.3 15.9 19.3 22.2 25.4 31.8
17x11155–01.9306
Straight 1 Leg Short Metric Tons Tons 3 2.7 5 4.5 7 6.3 9 8.2 12 10.8 15 13.6 19 17.2 27 24.5 36 32.6 47 42.6 74 67.1
60o Basket 2 Leg Short Tons
5-1/2 8 12 16 21 26 32 46 63 81 128
Metric Tons
5 7.2 10.8 14.5 1.9 23.6 29 41.7 57.1 73.5 116
Choker 1 Leg Short Metric Tons Tons 2-1/2 2.3 3-1/2 3.2 5 4.5 7 6.3 9 8.2 11 10 14 12.7 20 18.1 27 24.5 35 31.7 55 50
45o Basket 2 Leg Short Tons
4-1/2 7 10 12 17 21 26 38 52 66 104
Metric Tons
4 6.3 9 11.8 15.4 1.9 23.6 34.5 47.1 60 94.3
60o Choker 2 Leg Short Metric Tons Tons 4 3.6 6 5.4 9 8.2 12 10.8 16 14.5 20 18.1 24 21.7 35 31.7 47 42.6 61 55.3 95 86.2
30o Basket 2 Leg Short Tons
3 5 7 9 12 15 19 27 36 47 74
Metric Tons
2.7 4.5 6.3 8.2 10.8 13.6 17.2 24.5 32.6 42.6 67.1
45o Choker 2 Leg Short Metric Tons Tons 3-1/4 2.9 5 4.5 7 6.3 10 9 13 11.8 16 14.5 20 18.1 28 25.4 39 35.4 50 45.3 77 69.8
60o Basket 4 Leg Short Tons
11 16 24 32 42 52 64 92 126 162 256
Metric Tons
10 14.5 21.7 29 38 47.1 58 83.4 114 147 232
45o Basket 4 Leg Short Tons
9 14 20 26 34 42 52 76 104 132 208
30o Choker 2 Leg Short Metric Tons Tons 2-1/2 2.3 3-1/2 3.2 5 4.5 7 6.3 9 8.2 11 10 14 12.7 20 18.1 27 24.5 35 31.7 55 50
30o Basket 4 Leg
Metric Tons
Short Tons
Metric Tons
8.2 12.7 18.1 23.6 31 38 47.1 69 94.3 120 189
6 10 14 18 24 30 38 54 72 94 148
5.4 9 12.7 16.3 21.7 27.2 34.5 49 65.3 85.2 134
2–11
Section 2 — Safe Handling of Heavy Equipment and Machinery
General Information
ALLOY STEEL CHAIN SLINGS Alloy chain slings are made by bending, electric welding and heat–treating alloy steel rods into chain links. Alloy chain slings are more rugged and flexible, but less shock resistant than wire rope or braided slings. The size is measured by the diameter of the link stock. See figure 2-19.
See figure 2-20. Never shorten a chain by twisting, knotting or by use of bolts. 5. Protect alloy chain slings from sharp corners which can bend the links. Use lagging, corner irons, etc. for this purpose. See figure 2-21.
Diameter Size
FIG. 2-19 — Alloy steel chain sling.
Safe Rigging Practices 1. Protect alloy chain slings against chemicals, rust and corrosion. Extremely low temperatures (below 0 o F) will cause brittle fractures and it is advisable to reduce the safe load rating under those conditions by 50%. 2. Reduce safe loads of alloy chain slings by the following percentages when the chain is heated. Temperatures Up To
Reduce % Of Load
500o F (250 o C) . . . . . . . . . . . . . . . . .
None
600o F (315 o C) . . . . . . . . . . . . . . . . .
10%
700o F (368 o C) . . . . . . . . . . . . . . . . .
20%
800o F (425 o C) . . . . . . . . . . . . . . . . .
30%
Above 800o F (425 o C) – red heat visible in the dark – there is a permanent reduction in strength when the chain cools to room temperature. After such exposure, take alloy chain slings out of service and notify your supervisor. 3. Knots must not be used. They weaken alloy chain slings and may cause chain links to bend or otherwise fail.
Correct
Wrong
FIG. 2-21 — Corner iron protection for alloy chain sling.
6. When making choker hitches with alloy chain slings always face the hook opening out and away from the pull of the sling so the hooks will not slip out when slack is taken out of the sling. See figure 2-22. 7. Check alloy chain slings for: a. Nicks, cracks, gouges and wear. b. Bent links, lifted weld fins, bent or opened hooks, and stretch. c. Rust and corrosion. d. Uneven lengths when sling legs are hanging free. 8. If all the legs of an alloy steel chain sling are hooked back into the master link, the safe load capacity of the whole sling may be increased 50%. 9. Finished surfaces must be protected from alloy chain slings by bagging, lagging, etc. 10. Sling hooks should not be point loaded. 11. Use the larger end of pear shaped master links on the crane hook so as to prevent the master links from binding. The smaller end is used for the alloy sling chain.
Correct
Wrong
FIG. 2-20 — Shortening alloy chain sling
4. Alloy chain slings may be shortened by hooking back into the chain, into the master link, or with grab hooks. 2–12
FIG. 2-22 — Face hooks out from pull of sling. 17x11155–01.9306
Section 2 — Safe Handling of Heavy Equipment and Machinery
General Information
SAFE LOADING TABLE FOR ALLOY STEEL CHAIN SLINGS
Alloy Chain Diameter Inches MM
Straight 1 Leg Short Metric Tons Tons 1 .9
Choker 1 Leg Short Metric Tons Tons 3/4 .7
60o Choker 2 Leg Short Metric Tons Tons 1-1/2 1.4
45o Choker 2 Leg Short Metric Tons Tons 1-1/4 1.1
30o Choker 2 Leg Short Metric Tons Tons 3/4 .7
1/4
6.4
3/8 1/2 5/8 3/4 7/8
9.5 12.7 15.9 19.3 22.2
2 3-1/2 5-1/2 8 10
1.8 3.2 5 7.2 9
1-1/2 3 4 6 8
1.4 2.7 3.6 5.4 7.2
3 5 7-1/2 11 14
2.7 4.5 6.8 1.0 12.7
2-1/2 4 6 9 12
2.3 3.6 5.4 8.2 10.8
1–1/2 3 4 6 8
1.4 2.7 3.6 5.4 7.2
1 1-1/8 1-1/4 1-1/2 1-3/4
25.4 28.6 31.8 38.1 44.5
14 16 21 27 36
12.7 14.5 1.9 24.5 32.6
11 13 16 21 30
1.0 11.8 14.5 19 27.2
19 22 28 7 50
17.2 20 25.4 33.5 45.3
15 18 23 30 41
13.6 16.3 20.8 27.2 37.2
11 13 16 21 30
1.0 11.8 14.5 19 27.2
Alloy Chain Diameter Inches
MM
60o Basket 2 Leg Short Tons
Metric Tons
45o Basket 2 Leg Short Tons
Metric Tons
30o Basket 2 Leg Short Tons
60o Basket 4 Leg
Metric Tons
Short Tons
Metric Tons
45o Basket 4 Leg Short Tons
Metric Tons
30o Basket 4 Leg Short Tons
Metric Tons
1/4 3/8 1/2
6.4 9.5 12.7
1-1/2 3 5
1.4 2.7 4.5
1-1/4 2-1/2 4
1.1 2.3 3.6
3/4 1-1/2 3
.7 1.4 2.7
3 6 10
2.7 5.4 9
2-1/2 5 8
2.3 4.5 7.2
1-1/2 3 6
1.4 2.7 5.4
5/8 3/4 7/8 1 1-1/8
15.9 19.3 22.2 25.4 28.6
7-1/2 11 14 19 22
6.8 1.0 12.7 17.2 20
6 9 12 15 18
5.4 8.2 10.8 13.6 16.3
4 6 8 11 13
3.6 5.4 7.2 10 11.8
15 22 28 38 44
13.6 20 25.4 34.5 40
12 18 24 30 36
10.8 16.3 21.7 27.2 32.6
8 12 16 22 26
7.2 10.8 14.5 20 23.6
1-1/4 1-1/2 1-3/4
31.8 38.1 44.5
28 37 50
25.4 33.5 45.3
23 30 41
20.8 27.2 37.2
16 21 30
14.5 19 27.2
56 74 100
50.8 67.1 90.7
46 60 82
41.7 54 74.4
32 42 60
29 38 54
17x11155–01.9306
2–13
Section 2 — Safe Handling of Heavy Equipment and Machinery
2–14
General Information
HOIST. With forearm vertical, forefinger pointing up, move hand in small horizontal circle.
LOWER. With arm extended downward, forefinger pointing down, move hand in small horizontal circles.
USE MAIN HOIST. Tap fist on head; then use regular signals.
USE WHIPLINE (Auxiliary Hoist). Tap elbow with one hand; then use regular signals.
17x11155–01.9306
General Information
17x11155–01.9306
Section 2 — Safe Handling of Heavy Equipment and Machinery
RAISE BOOM. Arm extended, fingers closed, thumb pointing upward.
LOWER BOOM. Arm extended, fingers closed, thumb pointing downward.
MOVE SLOWLY. Use one hand to give any motion signal and place other hand motionless in front of hand giving the motion signal. (Hoist slowly shown as example).
RAISE THE BOOM AND LOWER THE LOAD. With arm extended, thumb pointing up, flex fingers in and out as long as load movement is desired.
2–15
Section 2 — Safe Handling of Heavy Equipment and Machinery
General Information
LOWER THE BOOM AND RAISE THE LOAD. With thumb extended, thumb pointing down, flex fingers in and out as long as load movement is desired.
STOP. Arm extended, palm down, hold position rigidly.
2–16
SWING. Arm extended point with finger in direction of swing of boom.
EMERGENCY STOP. Arm extended, palm down, move hand rapidly right and left.
17x11155–01.9306
General Information
TRAVEL. Arm extended forward, hand open and slightly raised, make pushing motion in direction of travel.
TRAVEL (Both Tracks). Use both fists in front of body, making a circular motion about each other, indicating direction of travel; forward or backward. (For crawler cranes only.)
17x11155–01.9306
Section 2 — Safe Handling of Heavy Equipment and Machinery
DOG EVERYTHING. Clasp hands in front of body.
TRAVEL (One Track). Lock the track on side indicated by raised fist. Travel opposite track in direction indicated by circular motion of other fist, rotated vertically in front of body. (For crawler cranes only.)
2–17
Section 2 — Safe Handling of Heavy Equipment and Machinery
EXTENDED BOOM. (Telescoping Booms). Both fists in front of body with thumbs pointing outward.
EXTEND BOOM (Telescoping Boom). One hand signal. One fist in front of chest with thumb tapping chest.
General Information
RETRACT BOOM. (Telescoping Booms). Both fists in front of body with thumbs pointing toward each other.
RETRACT BOOM (Telescoping Boom). One Hand Signal. One fist in front of chest, thumb pointing outward and heel of fist tapping chest.
REPRINTED BY PERMISSION OF THE AMERICAN SOCIETY OF MECHANICAL ENGINEERS, B30 COMMITTEE.
2–18
17x11155–01.9306
42-65 SUPERIOR MK-II
Section 3 — Index
Gyratory Crushers
3. General information
Page 3-1 3-2 3-2 3-2 3-2 3-2 3-2 3-2 3-3 3-3 3-3 3-3 3-4 3-4 3-4 Appendix
Description Index Introduction Shipping Check For Loss Or Damage In Shipment Types Of Damage To Watch For If Damage Occurs From Shipment Or Handling Use Of Drawings And Parts Manual Service Parts Recommended Spare Parts SUPERIOR Crusher Size Designation Recommended Feed Size Recommendations For Handling Parts Protecting Crusher Parts In Storage Removal From Storage Storing Completely Assembled Crushers General Specifications – 17X0120-02.9709
17X0115-02.9709
3
3-1
Section 3 — General Information INTRODUCTION We welcome you as a user of a Svedala Industries product. With reasonable care and attention, it will give long and trouble free service. A combination of high quality materials and engineering skills make this a simple machine to install and operate. Parts arrangements facilitate care and inspection, so that any good mechanic can operate and maintain the crusher, once he is familiar with i t. This instruction book will acquaint you with the easiest and most practical way to install, operate and maintain your crusher. Read it carefully before installing or operating the crusher and keep it on hand for future reference. For assistance in any processing problem, please contact your area Svedala Industries aggregates equipment distributor or company representative, or call or write direct to Svedala Industries, Inc., Crushing & Screening Division, Appleton, Wisconsin. SHIPPING 42-65 SUPERIOR gyratory crushers are shipped in sub-assemblies, plus separately packaged parts which cannot be secured to a sub-assembly during shipment. The degree of assembly depends on shipping restrictions and equipment available for handling at the job site. The usual breakdown of assemblies includes the spider, top shell, concaves, mainshaft, bottom shell, eccentric, bevel gear and eccentric sleeve, pinionshaft and external lubrication system. CHECK FOR DAMAGE OR LOSS IN SHIPMENT The crusher was thoroughly inspected and carefully prepared for shipment before it was turned over to the carrier. However, it is possible for machinery to be damaged or lost in shipment. Check each item carefully with the shipping manifest, freight bill or bill of lading. Call any damage or shortage to the carrier’s immediate attention. Be sure that he makes a full statement of the problem on the appropriate shipping document. This will help avoid controversy where a claim is made and facilitate prompt and satisfactory adjustment. TYPES OF DAMAGE TO WATCH FOR 1. Bearing surfaces damaged by chains or slings on upper or lower mainshaft journals. 2. Bruises in critical fits or bearing surface damage from dropping the part or dropping an object on the part. 3. Railroad damage from bumping cars or trucking damage from improper or inadequate tie-downs.
3-2
42-65 SUPERIOR MK-II Gyratory Crushers
4. Removal of or damage to protective covering, allowing rust to attack the bare metal in critical bearing or fit areas. IF DAMAGE OCCURS FROM SHIPMENT OR HANDLING 1. For damages in shipment, the settlement is between the shipper and the distributor or customer. 2. It handling damage occurs, notify the Svedala Industries, Inc. distributor or sales office to determine if a repair or a new part is required. USE OF DRAWINGS AND PARTS MANUAL Number references, associated with part names in copy and illustrations throughout this instruction book, are termed “catalog numbers.” A parts list, with catalog numbers and reference drawings, is included in Section 4 of this book. In addition, a parts manual is supplied with each crusher. The parts manual is forwarded separately, after the crusher has been shipped. It is broken down by assemblies and subassemblies and lists the quantities and specific “part numbers” of each item used in the crusher assembly. Catalog and part numbers, reference drawings, parts lists and the parts manual are provided for your use when ordering spare or replacement parts. SERVICE PARTS Wearing and replacement parts for SUPERIOR gyratory crushers are carried in stock by Svedala Industries, Inc., C&SD, Appleton, Wisconsin. In addition, local stocking distributors associated with the Crushing & Screening Division carry major parts in stock. Order replacement parts through your local Svedala Industries, Crushing & Screening Division aggregates distributor, or direct from Svedala Industries, Inc., C&S Division, Appleton, WI. When ordering service parts, include the following information: 1. crusher size; 2. crusher serial number — look for the serial number plate affixed on the crusher bottom shell near the pinionshaft — the serial number is also listed on the parts manual cover sheet; 3. parts description by name, along with catalog and part numbers; 4. quantity of each part required; and 5. complete shipping instructions, including whether shipment should be via mail, express, surface or air freight.
17X0115-02.9709
42-65 SUPERIOR MK-II
Section 3 — General Information
Gyratory Crushers
RECOMMENDED SPARE PARTS Wearing parts for crushers are carried in stock at Svedala Industries, Inc., Appleton, Wisconsin. However, we suggest that you carry the following parts in your own stock to eliminate down-time in an emergency. Spider Bushing . . . . . . . . . . . . . . . . . . . . . . . . Spider Bearing Oil Seal . . . . . . . . . . . . . . . . Mainshaft Sleeve . . . . . . . . . . . . . . . . . . . . . . Head Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mantle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dust Seal Ring . . . . . . . . . . . . . . . . . . . . . . . . Bottom Shell Bushing . . . . . . . . . . . . . . . . . . Eccentric Bushing . . . . . . . . . . . . . . . . . . . . . Concaves (Bottom Tier) . . . . . . . . . . . . . . . . (Second Tier) . . . . . . . . . . . . . . . . . . . . . . . . . (Third Tier) . . . . . . . . . . . . . . . . . . . . . . . . . . . (Top Tier) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mainshaft Step Bearing . . . . . . . . . . . . . . . . Step Washer . . . . . . . . . . . . . . . . . . . . . . . . . . Piston Wearing Plate . . . . . . . . . . . . . . . . . . . HYDROSET Cylinder Bushing . . . . . . . . . . HYDROSET Oil Seal . . . . . . . . . . . . . . . . . . Pinionshaft Oil Seal — Pinion End . . . . . . . Sheave End . . . . . . . . . . . . . . . . . . . . . . . . . Gasket Stock for all Gaskets Filter Cartridges (Nelson)
5675-0 5705-0 4025-0 4205-0 4175-0 4305-0 1200-0 1810-0 6305-0 & -1 6325-0 & -1 6345-0 & -1 6395-0 & -1 4075-0 2280-0 2260-0 2050-0 2305-0 3170-1 3170-2
NOTE Spare parts are not included as standard equipment on regular machine purchases, but ordered separately.
42” 107 cm
65” 165 cm
FIG. 3-1 — Method of designating crusher size. 17X0115-02.9709
SUPERIOR CRUSHER SIZE DESIGNATION The size and model number of a SUPERIOR crusher is designated in terms of the feed opening at its widest point and the mantle diameter at its largest point, in inches. For example, on a model 42-65 SUPERIOR crusher, the distance from the top of the mantle to the top of the concave assembly is nominally 42 inches (107 cm). The crushing head diameter is nominally 65 inches (165 cm) at the bottom of the mantle. See Fig. 3-1. If the approximate feed opening were 60 inches (152 cm), the crushing head measured 89 inches (226 cm) at the largest diameter, the crusher would be designated as a 60-89. RECOMMENDED FEED SIZE Vertical adjustment of the crushing head allows compensation for wear at the discharge point. We recommend that 80% of the feed to a SUPERIOR gyratory crusher be less than two-thirds of the feed opening in size. This applies to both secondary and primary SUPERIOR gyratory crushers. This size distribution helps to prevent blockage of the spider openings and permits a well-filled crushing chamber that evenly distributes bearing pressures between the spider and eccentric bearing surfaces. Scalping of the feed ahead of a primary crusher can be advantageous when there is an excessive quantity of fines in the feed, or if the material is extremely abrasive and could wear the manganese excessively. RECOMMENDATIONS FOR HANDLING PARTS When handling crusher parts, observe these precautions: General When lifting or removing parts, use equipment of suffi• cient size to make the parts handling easy. Assembly weights are tabulated in “General Specifi• cations,” in the Appendix to this section, for use in selecting hoists, jacks, etc. Handle bronze parts carefully. Driving or hammering • on soft bronze may cause it to flow and destroy the fit with mating parts. Clean and lubricate parts carefully, and check for any • damage or imperfections that should be removed before assembling. Machined and Bearing Surfaces Take special care to prevent damaging parts with ma• chined or bearing surfaces. Protect machined and bearing surfaces with oil or rust • preventive if the part is to be exposed to atmosphere for any extended time period. Place machined surfaces on timbers or padded sup• ports NOT on the ground. Never assemble a bearing surface without first elimi• nating any imperfections and applying lubricant. 3-3
Section 3 — General Information PROTECTING CRUSHER PARTS IN STORAGE Special protective measures are required to prevent deterioration of crusher parts stored for extended time periods. Here are general recommendations on parts storage. 1. Large castings (bottom shell, top shell, spider, dust seal retaining rings, dust collar) — items of this type may be stored out of doors if properly protected. Do not place parts directly on the ground; set them on timbers or some type of support. Coat all machined surfaces with a rust preventive, such as Rust Veto 344 (E.F. Houghton & Co.). For added protection, fill the spider and bottom shell hubs, and the bottom shell pinionshaft arm, with crumpled VPI treated wrapping paper such as Nox Rust Vapor Wrapper VW35D (Daubert Coated Products, Inc.) and cover openings with plywood. Plug all pipe tapped holes to prevent entry of dirt and moisture. Then cover the entire piece with a tarpaulin, properly positioned and securely fastened to protect the parts from weather and ultraviolet exposure. 2. Small castings (spider bushing, step bearings, eccentric assembly) — items of this type are best stored indoors, with machined surfaces coated with rust preventive. If possible, store parts in boxes filled with crumpled VPI treated paper. It is extremely important to protect polished bearing surfaces against corrosion and physical damage. 3. Mainshaft assembly — Coat machined surfaces with a rust preventive such as Rust Veto 344. If the shaft is to be stored in shipping saddles, use a double saddle arrangement and place felt, saturated with rust preventive, between the shaft and the saddles. If stored out of doors, cover the entire assembly with a tarpaulin. 4. Pinionshaft and HYDROSET cylinder assembly — Store these assemblies indoors at all times. Fill the pinionshaft assembly to the proper level with a rust preventive oil such as Nox Rust VPI 10 (Daubert Chemical Co.). Coat all external machined surfaces with rust preventive. To assure that bearings are always coated with oil, rotate the shaft one complete revolution at least once a month. Avoid damage to the small breather which should remain generally on the “up” side. Remove the oil seal from the cylinder assembly before storing. After plugging all open holes in the cylinder assembly, pour about two gallons of rust preventive oil such as Nox Rust VPI 10 into the cylinder. Cover the open end of the cylinder with plywood and coat all exposed machined surfaces with a rust preventive. Once a year, pour a quart of oil around the edges of the piston so it flows down all the sides. 5. HYDROSET control and lubrication system piping — Pour several gallons of rust preventive oil such as Nox Rust VPI 10 into the HYDROSET control and oil tank. Fill the oil piping with the same rust preventive oil, breaking lines open at convenient locations such
3-4
42-65 SUPERIOR MK-II Gyratory Crushers
as the pressure gauges. Make sure a small quantity of oil enters the oil pumps in order to prevent internal pump corrosion. Plug all open oil pipes and securely fasten cover to prevent entrance of air and moisture into the system. If the lubrication pump is equipped with a gear reducer, fill it with Nox Rust VPI 10 or other rust preventive oil. If the lubrication system is stored outside, cover it with a tarpaulin. Tightly cover the ends of the HYDROSET oil piping after pouring several gallons of rust preventive oil into it. Do not store anything with seals near a high voltage source like a welder or transmitter. 6. Seals and gaskets — Seals and gaskets may harden and lose their sealing efficiency if they were not fully protected against heat and oxidation. We recommend replacement of such parts after eight months. If seals and gaskets are to be stored, coat them with a preservative oil and keep them in a cool, dry area. 7. Round and cylindrical shapes — Avoid distorting critical dimensions of round and cylindrical component shapes. Always use spreaders when lifting bronze cylinders (unless on a skid). Store dust seals and collars flat — across the larger dimension and not on edge. Store cylindrical shapes such as bottom shell bushings or eccentric sleeves on end. For protection, store components in the shipping container indoors. Be extremely careful to prevent physical damage to parts during handling and storage. Because climatic conditions vary, it is best to contact a local supplier of protective coatings for recommendations of products best suited for the conditions which will be encountered. Periodically inspect stored parts to insure that protective measures are intact and that parts are undamaged. Svedala Industries, Inc. assumes no responsibility for the success of protective measures during storage. REMOVAL FROM STORAGE Before reassembling the crusher, remove the rust preventive from all surfaces using a suitable solvent. Completely drain preservative oil from all components which had been previously filled. Complete flushing should not be required. Nox Rust VPI 10 is generally compatible with the type of lubricating oil used in crushers. Thoroughly inspect all components for corrosion or damage which could be detrimental to machine operation. Correct any such conditions discovered. STORING COMPLETELY ASSEMBLED CRUSHERS If the crusher assembly is complete but anticipated start-up is delayed in excess of thirty (30) days, use the following procedure: 1. Fill the bottom shell cavity with the recommended lubrication oil until it slightly overflows the dust collar, using the lubrication pump. Valve or blank off the drain line to retain the oil in the bottom shell. Close the valve
17X0115-02.9709
42-65 SUPERIOR MK-II Gyratory Crushers
from the tank to the pump to prevent oil flow back to the tank through pump clearances, etc. 2. Fill the spider bearing cavity with oil to prevent condensation in the bearing area. 3. Turn the pinionshaft drive sheave by hand at least four (4) complete revolutions every two (2) weeks. The pinionshaft assembly is shipped with rust inhibiting Nox
17X0115-02.9709
Section 3 — General Information Rust VPI 10. 4. Coat the mainshaft sleeve on the upper journal with grease in the exposed area between the spider hub and mainshaft head nut. 5. If the lubrication and HYDROSET pumps are exposed to the weather, cover them with a waterproof cover or shield.
3-5
General Specifications
42-65 SUPERIOR MK-II Gyratory Crushers
SUPERIOR GYRATORY CRUSHER — GENERAL SPECIFICATIONS Approximate Weight – Pounds (Kilograms) Crusher Size
Total Crusher
Spider Cap
Spider Assembly
Top Shell Assembly
Mainshaft Assembly
Bottom Shell Assembly
Hydroset Assembly
Eccentric Assembly
Pinionshaft Assembly
External Lube Assembly
Balance Cylinder & Piping
42-65
263,300 (119,430)
2,800 (1,270)
42,500 (19,280)
80,100 (36,330)
50,600 (22,950)
60,900 (27,625)
8,900 (4,040)
6,800 (3,085)
2,400 (1,090)
2,400 (1,090)
1,000 (455)
Pinionshaft Standard Eccentric Throws Inches (mm)
Crusher Size
42-65
Max. Horsepower
Gyrations Per Minute
Wk2 at Pinionshaft Lb.-Ft.2 (Kg-m2)
500
178
1414 (59.6)
1, 1-1/4, 1-1/2 (25, 32, 38)
Speed (RPM)
600
Diameter at Drive End Inches (mm)
Keyway WxD Inches (mm)
Shaft Ext. For Drive Inches (mm)
Pitch Line Backlash Inches (mm)
Pinion Gear Pitch Dia. Inches (mm)
Approx. Oil Required Quarts (Liters)
10.50 (266.7)
0.051 – 0.061 (1.30 – 1.55)
15.3 (388.6)
6 (7.6)
1.250 x 0.625 (31.75 x 15.88)
4.998 (126.95)
Mainshaft Step Bearings-Inches (mm)
HYDROSET Gear Pump Crusher Size
Approx. Feed Opening Inches (Meters)
Largest Open Side Setting Inches (mm)
For Wear Mainshaft Travel Inches (mm)
Mainshaft Travel Rate* In./Min. (mm/Min.) 50HZ 60HZ
42-65
42 x 108 (1.07 x 2.74)
7.0 (178)
6.9 (175)
1.54 (39.1) 1.84 (46.7)
Setting Change for 1” (25mm) Mainshaft Travel Inches (mm)
Min. Oil Under Piston (nches (mm)
0.400 (10.16)
1.0 (25)
Capacity GPM (LPM) 50HZ
Motor HP
Motor RPM
50HZ
50HZ
60HZ
60HZ
60HZ
3.0 (11.4)
2890
3.0
3.6 (13.6)
3.5
Pinionshaft Housing
Pinion & Gear
Hydroset Relief Valve Setting PSIG (MPa)
Thickness at O.D. New
Allowable M.S. Step Wear
750 (51.7)
1.75 (44.5)
0.75 (19)
Step Bearings Thickness New
Step Bearings Total Wear
6.50
1.50 (38.1)
(165.1)
(1)
3470
NOTE: (1)Maximum allowable wear on mainshaft step, washer, and piston wearing plate. Lubrication Gear Pump
Tank Capacity Gallons (Liters)
Water Cooler
Crusher Size
Lube Oil
Hydroset Oil
Immersion Heater (KW)
Capacity GPM (LPM)
Motor HP (3ph,60HZ, 230-460V)
Motor RPM
Oil Filter Retention Size (Microns)
Water Required GPM (LPM)
Water Pipe Fitting
42-65
164 (620)
105 (397)
6
30 (114)
5
1800
20
30 (114)
1.5” NPT
Air Radiator Dia. x Length Inches (mm)
6.25 x 53 (158.8 x (134.6)
Air Flow SCFM (CMM)
Fan Motor HP (3ph,60HZ)
22500 (637)
10
Fan RPM 50HZ 60HZ
1000
1200
Width x Height x Depth Inches (mm)
64.75 x 58.75 x 35.5 (1645x 1492x 902)
NOTE: (1) 100oF ambient air at 1500 foot elevation application. Spider Bushing Clearance(1)
Balance Cylinder
Backing Material
Inches (mm)
Concaves
Mantle
Crusher Size
Bore x Stroke Inches (mm)
Oil Capacity Gallons (liters)
Standard Charging PSIG (MPa)
New
Maximum
Zinc Lbs. (Kg)
Plastic Pack 22 lb. Kits (10 Kg Kits)
Zinc Lbs. (Kg)
Plastic Pack 22 lb. Kits (10 Kg Kits)
42-65
8 x 20 (203 x 508)
4.5 (17)
90 (0.62)
0.01220.044 (0.561.12)
0.130 (3.30)
6,100 (2,770)
61
2000 (910)
20
NOTE: (1)Clearance at fulcrum 17X0120-02.9709
1
42-65 SUPERIOR MK-II
Section 4 — Index
Gyratory Crushers
4. Installation
Page 4-1 4-2 4-2 4-2 4-2 4-3 4-3 4-3 4-3 4-3 4-4 4-4 4-5 4-7 4-8 4-8 4-9 4-9 4-11 4-12 4-12 4-13 4-13 Appendix
Description Index Preliminary Considerations Foundation Requirements Feed Arrangements To Crushers Arrangements For Proper Feeding Effect Of Change To Larger Haul Trucks Discharge Arrangement For Crusher Pressurized Air Provision Crusher Drives Erecting The Crusher — Bottom Shell Placement — Eccentric Assembly — HYDROSET Cylinder Assembly — Pinionshaft Assembly — Dust Collar — Mainshaft Assembly — Top Shell Assembly — Installing Concaves — Spider Assembly — Drive — Lubrication And HYDROSET Control Piping — Bottom Shell Vent System — Over Pressure Dust Sealing Unit Approximate Weights And Dimensions – 17X0124-01.9612 Special Tools For SUPERIOR Gyratory Crusher – 17X0122-02.9709 Parts Drawings And Parts Lists – 17X0123-05.0003 PLASTIC PACK Directions For Use – 17X0085-03.9708 Mainshaft Lifting Eye Dimensions – 17X10715-02.9706 Procedure For Tightening Bolts – 26X1451-08.9406 42-65 SUPERIOR Crusher Bolt Torques – 17X0121.9403
17X0115-04.9911
4
4-1
Section 4 — Installation
PRELIMINARY CONSIDERATIONS FOUNDATION REQUIREMENTS An installation drawing showing clearances and approximate weights of main parts and assemblies is furnished with each crusher. In addition, approximate weights and dimensions are tabulated in the Appendix to this section. Locate the crusher where it can be serviced with a crane or trolley and hoist to save erection time and speed parts replacement. In building the foundation, allow ample clearance for removing the HYDROSET cylinder, eccentric and pinionshaft assemblies. Foundation requirements are usually designed by the customer, contractor or Svedala Industries, Inc. distributor, who are usually familiar with soil conditions for footings. Svedala Industries, Inc. is responsible for crusher design and function only, but is available for comments on overall layout and clearances required for maintenance, method of feeding the crusher, etc. An installation outline drawing is furnished by Svedala Industries, Inc. for suggested minimum clearances and general arrangements. Generally, these criteria have been followed with success: For solid mounted crushers: 1. Footing on bedrock or footing of appropriate area to suit soil conditions. 2. Concrete mass ratio to crusher weight of four to one. 3. The footing doweled into bedrock whenever possible to prevent slippage from vibration. 4. The mounting piers for the crusher tied into the footing steel with reinforcing steel so that piers and footing are integral. The concrete of the piers and footing should be a monolithic pour so that if settlement does occur it will be as a unit and prevent crusher mounting misalignment. Fully portable: Allow for proper cribbing under the frame in at least each corner of the frame. FEED ARRANGEMENT TO CRUSHER The need for an effective means of feeding into the crushing chamber cannot be over-stressed. Long service life of mechanical components as well as optimized crusher capacity are dependent upon an even, well-distributed feed, entering the chamber with a minimum of impact on the spider cap, mantle and concaves. Uneven feed may be defined as a greater quantity of feed in one portion of the crushing chamber than in the balance of the 360 o of the crushing chamber, and/or coarse and fine feed segregation into separate portions of the chamber. Either of the above conditions may cause: 1. High hydraulic surges in the HYDROSET control with subsequent high impact bearing pressures, excessive wear, and even failure of components.
4-2
42-65 SUPERIOR MK-II Gyratory Crushers
2. Uneven and accelerated concave wear in localized areas resulting in uneven product sizing and shortened crushing surface life. 3. Lower crusher throughput due to the crushing chamber not crushing to capacity in the full 360 o of the chamber. It is important that feed be evenly distributed to maintain a round crushing chamber with a minimum of shock loading. It is equally important that trucks dump from two sides of the stone box around the spider, over the spider arms. Arrangements for Proper Feeding Spider arms must be positioned to be in line with the truck discharge, with trucks dumping at both sides. See Fig. 4-1. The heavy arm will split material flow into the crusher chamber for more even feed distribution to each quadrant of the chamber. The stone box around the spider must permit material discharge from the truck dump to fall on a dead bed of stone and fines, and roll - not fall - into the chamber. Dumped material must not be allowed to impact directly on the spider cap or mainshaft assembly. High impact loading of crusher components results when large pieces of stone are dropped directly into the crushing chamber. The mainshaft assembly usually is the component that suffers from bad dump pit design or improper barricade locations for stopping the truck when backing up to the pit for the load discharge.
FIG. 4-1 — Proper feed arrangement for SUPERIOR crushers. Spider arms are in line with truck dump. Dumped material falls on dead bed — not directly on crusher.
17X0115-04.9911
42-65 SUPERIOR MK-II Gyratory Crushers
Increased crushing chamber wear life and bearing life are other benefits of correct feeding. Truck dumping from only one side of the crusher can cause excessive concave wear in a localized area. It can also accelerate bearing deterioration, especially in the spider bushing, which may wear elliptically due to the absorption of impact from one side only. When designing a dump pit for a primary crusher, it is imperative that it be designed for the largest truck that will be used in the hauling fleet. This will allow for the stone to impinge on the pit dead bed on the free fall and then slide or roll into the crushing chamber. This holds the impact on the crusher to a minimum. Effect of Change to Larger Haul Trucks A scale-up in truck size and capacity in an existing crushing plant operation can significantly alter the material discharge angle and the relationship between the truck dump point and the impact point of heavy pieces. In recent years, pit economies have resulted in larger trucks being procured to replace smaller and less efficient units. This has, in some instances, resulted in component failures and excessive down-time, sometimes serious in consequences. Ways to avoid the problem include: 1. Move the truck stop location on both sides of the crusher far enough to keep the dump impact away from the crusher feed opening. This is especially true if the entire truck fleet has been changed to larger units. 2. If the fleet contains both smaller and larger trucks, set up dumping cycles so that the smaller trucks dump at one side, with the stop located accordingly, and larger trucks at the other side, with the stop farther from the crusher. The effectiveness of any change can be readily observed when new trucks go into service. DISCHARGE ARRANGEMENT FOR CRUSHER Provide a discharge storage chamber beneath the crusher that is spacious enough to contain at least two truck or quarry car dump loads. This would permit emptying the crushing chamber in the event that the under-crusher discharge conveying system shuts down during operations. Using a feeder between the discharge storage chamber and discharge conveyor will regulate the discharge rate and eliminate surging. PRESSURIZED AIR PROVISION Crushers are equipped with an air inlet connector (1675-0) for connecting a source of pressurized air to the lubrication oil chamber when dusty conditions prevail. The connector is located in the bottom shell at one of the arms.
17X0115-04.9911
Section 4 — Installation
Positive air pressure in the chamber helps to exclude dust-laden air and prevent oil contamination. The pressurized air source can be from either the air blower supplied with the crusher or from compressed air, if available. See “Over Pressure Dust Sealing Unit” in this section. CRUSHER DRIVES SUPERIOR gyratory crushers are driven by a spiral-toothed bevel gear and pinion through a pinionshaft mounted in a housing extending through the side of the bottom shell. The driving force is usually provided by an electric motor. See “General Specifications,”, in the Appendix to Section 3 for pinionshaft rpm, as well as maximum recommended horsepower. Crushers with drives under 300 HP are generally V-belt driven, with the motor at either side. Larger horsepower drives are generally direct-connected to an electric motor. This reduces the load on the pinionshaft and motor bearings and eliminates time-consuming adjustment of multiple V-belts. Direct drives should include a jackshaft between the motor and pinionshaft to permit removal of the pinionshaft assembly without moving the motor. Larger crushers are frequently installed with a controlled torque coupling with a zero speed switch to protect the motor from severe surge loading such as that which could result from large pieces of tramp iron in the crushing chamber. Motors should have 180% starting and 250% breakdown torque. When calculated horsepower requirements indicate that power draw is close to rated horsepower, specify a 1.15 service factor. Wound rotor induction motors are recommended because of their inherently high starting torque characteristics. Squirrel cage induction motors may be specified when the power system can supply high starting currents. ERECTING THE CRUSHER Crusher parts are subjected to severe strains in operation with high unit pressure on bearings. Take care during assembly to assure proper alignment and an ample supply of clean, uncontaminated lubricant to wearing parts. Bearing surfaces are provided with means for excluding dirt and dust when the machine is properly assembled and cared for during operation. Thoroughly clean all joints and fittings before closing. Carefully examine all oil passages and remove any rust or dirt before installation. Clean bright or finished parts, covered with protective coating, with solvent. Slight damage to finished parts should be smoothed and trued to insure proper fits when assembled.
4-3
42-65 SUPERIOR MK-II
Section 4 — Installation
Gyratory Crushers
BOTTOM SHELL PLACEMENT Before placing the bottom shell on the foundation, foundation bolts must be set into the concrete piers and other preparatory steps taken. Svedala Industries, Inc. will furnish foundation bolts when specifically requested, as an added cost option. Consult available drawings to determine the area where heavy or concentrated loads will be placed. Use two steel plates, as thick and large as practical, to make that section of the foundation level and smooth. Embed the plates in a batch of two parts sand and one part cement mortar, with low water content. Level both ways and allow to set. Place similar plates adjacent to all foundation bolts to prevent base or frame distortion when nuts are tightened. Thoroughly clean the bottom shell mounting surface and put the shell on the foundation, supporting it at grade, two inches (5.08 cm) above the foundation surface with blocks or shims. Grout the space between the foundation and bottom shell. Tighten foundation bolts after the grout has set. Fig. 4-2 shows a typical bottom shell assembly, being placed on a massive concrete foundation. FIG. 4-2 — Placing bottom shell on foundation
UPPER COUNTERWEIGHT 1811-0
LOWER COUNTERWEIGHT 1812-0
ECCENTRIC GEAR KEY 1855-0
PIPE
LOWERING ROD 8955-0
O-RING 1920-0
SK021392-JJB-3
ECCENTRIC SUPPORT PLATE 1905-0
1910-0 1910-4 ECCENTRIC GEAR 1850-0 ECCENTRIC BUSHING 1810-0 ECCENTRIC 1805-0 ECCENTRIC WEARING PLATE 1880-0
FIG. 4-3 — Eccentric assembly, showing location in bottom shell, with support and wearing plates.
ECCENTRIC ASSEMBLY The eccentric assembly consists of the eccentric (1805-0), the eccentric bushing (1810-0), the eccentric gear (1850-0), the lower counterweight (1812-0), the upper counterweight assembly (1811-0) and keys (1820-0 4-4
and 1855-0). The assembly rests on the eccentric wearing plate (1880-0) and is held in place by the eccentric support plate (1905-0). An O-ring (1920-0) is used to seat the joint between the bottom shell and the eccentric support plate. See Fig. 4-3 for details. 17X0115-04.9911
42-65 SUPERIOR MK-II
Section 4 — Installation
Gyratory Crushers
Proceed with installation as follows: 1. Position the eccentric support plate (1905-0) on a skid or eccentric cart so that the oil drain hole lines up with the hole in the HYDROSET cylinder flange. Place the wearing plate (1880-0) and support plate O-ring (1920-0) on the support plate. Place the eccentric (1805-0) on the wearing plate. 2. Move the skid or cart with the assembly under the bottom shell. 3. Use the eccentric lowering rods (8955-0) to raise the eccentric into place.
2205-1 2205-2 (NOT SHOWN)
2140-0
4. Secure the support plate to the bottom shell with the support plate bolts (1910-0) and lock washers (1910-4). HYDROSET CYLINDER ASSEMBLY The HYDROSET cylinder assembly Includes the HYDROSET cylinder (2005-0), piston (2205-0), packing clamp plate (2325-0), oil seal packing (2305-0), piston wearing plate (2260-0), mainshaft step washer (2280-0), cylinder bushings (2050-1 and 2050-2) and the cylinder cover plate (2505-0). See Fig. 4-4 for details.
2276-0
2275-0 2280-0
2260-0 2060-0
2225-0
2005-0
2120-0
2050-2
2217-0
2050-1
2340-1 2340-8
2205-0
2325-0
2305-0
2090-0
2515-0 2515-1 2515-3
2505-0
2055-0
2325-1
2506-0
2530-0
2606-1 2606-2
2606-0 SK021392-JJB-6
2650-8 2650-9 2651-0
2606-6
2325-2 2325-4
FIG. 4-4 — HYDROSET cylinder assembly 17X0115-04.9911
4-5
42-65 SUPERIOR MK-II
Section 4 — Installation
Gyratory Crushers
Catalog Number
Description
Catalog Number
Description
2005-0 2050-1 2050-2 2055-0 2060-0 2090-0 2120-0 2140-0 2205-0 2205-1 2205-2 2225-0 2260-0 2275-0 2276-0 2280-0 2305-0 2325-0
HYDROSET cylinder HYDROSET cylinder bushing (lower) HYDROSET cylinder bushing (upper) Lower bushing bolt Upper bushing bolt HYDROSET cylinder dowel Bottom plate drain plug HYDROSET cylinder O-ring Piston Piston plug Piston plug capscrew Piston dowel Piston wearing plate Stepwasher retainer Stepwasher retaining ring Stepwasher Oil seal Clamp plate
2325-1 2325-2 2325-4 2340-1 2340-8 2505-0 2506-0 2515-0 2515-1 2515-3 2530-0 2606-0 2606-1 2606-2 2606-6 2650-8 2650-9 2651-0
Clamp plate retaining ring Bolt Washer Clamp plate plug Gasket HYDROSET cylinder cover HYDROSET cylinder cover O-ring Cylinder cover bolt Cylinder cover nut Cylinder cover locknut Cylinder drain plug Cover plate guard Capscrew Washer Plug O-ring Cover plate closure plug Capscrew
Proceed with Installation as follows. 1. Place the HYDROSET cylinder assembly on the skid and move It into place beneath the bottom shell. Be sure that the holes line up for the bottom shell drain plug (2120-0). Make sure that the HYDROSET cylinder O-ring (2140-0), piston wearing plate (2260-0) and the step washer (2280-0) are in place. 2. Use the eccentric lowering rods to raise the assembly into position. Raising or lowering the HYDROSET cylinder assembly as well as the eccentric assembly can be simplified by using a hydraulic jack in combination with the lowering rods (see Fig. 4-5). Lowering rod
3. Put the nuts (2020-1) on the studs (2020-0) and draw them up tightly to prevent oil leakage.
Hydraulic jack
Block
FIG. 4-5 - HYDROSET cylinder removal and installation
4-6
17X0115-04.9911
42-65 SUPERIOR MK-II
Section 4 — Installation
Gyratory Crushers
PINIONSHAFT ASSEMBLY See Fig. 4-6 for details of the pinionshaft assembly. Clean up the housing before assembly. For method of assembly refer to Section 9, Pinionshaft Assembly under the heading “Replacement in Crusher”.
1.0”–8UNC LIFT HOLES 3005-0
NOTE On a new machine, backlash and tooth contact must be set and checked. See “Bevel Gear Installation and Maintenance” in Appendix Section 8 and “Gear and Pinion Backlash Adjustment” in Section 9. 3030-0
3305-0
1.0”–8UNC LIFT HOLE 3231-0 3240-2 3231-1 3190-2 3170-2 3090-2
3650-0
101.6MM (4.00”) OPERATING OIL LEVEL
3515-0 3050–0
3090-1
3170-1 3190-1 3210-0 3210-4 TORQUE TO 157-166Nm (116–123 FT–LBS)
3555-0 3210-4 3505-0 3220-0 TORQUE TO 157-166Nm (116–123 FT–LBS) 3540-0
3070-2
3160-0
3575-0 TO PINIONSHAFT OIL LEVEL SIGHT GAUGE (DRAIN PORT) 3150-0
3240-1
SK063099–JJB–1
FIG. 4-6 — Pinionshaft assembly Catalog Number
Description
Catalog Number
Description
3005-0 3030-0 3050-0 3070-1 3070-2 3090-1 3090-2 3150-0 3160-0 3170-1 3170-2 3190-1 3190-2
Housing — Pinionshaft Gasket — Pinionshaft housing Pinion Bearing — Pinionshaft (Pinion end) Bearing — Pinionshaft (Sheave end) Spacer — Pinion end Spacer — Sheave end Lockwasher — Sheave end Lockwasher — Pinion end Seal — Pinionshaft oil (Pinion end) Seal — Pinionshaft oil (Sheave end) Plate — Pinion end seal Plate — Sheave end seal
3210-0 3210-4 3220-0 3231-0 3240-1 3240-2 3305-0 3505-0 3515-0 3540-0 3555-0 3575-0 3650-0
Bolt — Pinion end seal plate Lockwasher Bolt — Sheave end seal plate Fitting — Lube Gasket — Pinion end seal plate Gasket — Sheave end seal plate Cup — Pressure relief pinionshaft housing Shaft — Pinion Key — Pinion Bolt — Pini onshaf t housing j ack Key — Crusher sheave Plug Retainer — Pinion
SK021392-JJB-4 FIG. 4-7 — Inserting pinionshaft assembly in bottom shell. 17X0115-04.9911
FIG. 4-8 — Pinionshaft and housing assembly with bottom shell.
4-7
42-65 SUPERIOR MK-II
Section 4 — Installation
Gyratory Crushers
EYEBOLT 4050-0
4027-0 4027-2
CLAMPING RING 4026-0 MAINSHAFT SLEEVE 4025-0 HEAD NUT 4205-0 DOWEL 4220-0
MAINSHAFT 4005-0
BACKING MANTLE 4175-0
4435-0 4435-1 UPPER DUST SEAL RETAINER 4325-0 4330-0 4330-4 CLAMP 4425-0 SPLASH CURTAIN 4405-0
4365-0 LOWER DUST SEAL RETAINING RING 4350-0
MAINSHAFT DOWEL 4035-0
DUST SEAL 4305-0 MAINSHAFT STEP 4075-0 MAINSHAFT STEP RETAINER 4135-0
SK021792-JJB-4 FIG. 4-9 — Mainshaft assembly.
DUST COLLAR If the dust collar (1400-0) was not already assembled with the bottom shell, place the dust collar gasket (1430-0) and collar and secure it on the studs provided. Be sure that 4-8
overflow oil passages are open. Install the upper counterweight splash ring (1420-0, Fig. 7-1) to the dust collar lifting eyebolt holes (3) with bolts (1421-0). 17X0115-04.9911
42-65 SUPERIOR MK-II
Section 4 — Installation
Gyratory Crushers
MAINSHAFT ASSEMBLY Major components of the mainshaft assembly include the mainshaft (4005-0), mainshaft sleeve (4025-0), mantle (4175-0), head nut (4205-0), mainshaft step (4075-0), step retainer (4135-0), dust seal (4305-0), dust seal retainer (4350-0), and the lifting eyebolt (4050-0). See Fig. 4-9 for detail. Before installing the mainshaft assembly, remove the dust seal assembly. Carefully inspect and clean the dust seal and its retainer. Make sure that the dust seal ring moves freely in the retainer after reassembly. The lifting eyebolt is installed at the Factory and should not be removed in the field. Check to make sure that the eyebolt is fully shouldered before lifting. On the 42-65 crusher, a shackle is required between the shaft eyebolt and crane hook. See Appendix, item 17X10715 for eyebolt dimensions of the various crusher sizes. The mainshaft assembly, except for small settings, can be installed in the crusher either before or after installing the concaves. TOP SHELL ASSEMBLY (FIG. 4-10) Inspect the taper fits of both the top shell (5005-0) and bottom shell (1005-0). See Fig. 4-11. Remove any burrs, bruises or interfering accumulation of rust or dirt. Coat
both taper fits with oil or anti-seize compound. Do not use white lead; it will harden and make it difficult to remove the top shell. Make sure that the concave support ring (6050-0) is in place on the bottom shell. Make a level hitch on the top shell assembly and lower it into the matching taper fits. Position it as level as possible so that the bolting flanges are as close to parallel as possible. The joint has a slight interference fit, and will remain open about 1/8 inch (3 mm) until it is drawn tight. Tighten down two bolts, 180 o apart, making sure that the gap between top and bottom shells is equal. Then install two bolts 90o from the first two, again making sure the gap is equal. Install the balance of the bolts at approximately the same tightness as the first four. Continue to tighten bolts in the same sequence, approximately the same number of turns, until a 0.004 inch feeler gauge cannot be inserted between the bolting flanges at any point on the circumference. If there is any clearance between top and bottom shells after tightening, it is an indication that the joint has not been pulled up tightly enough or that something in the joint is holding it open. KEEP THIS JOINT TIGHT TO PREVENT JOINT BOLT BREAKAGE.
Spider Assembly
Top tier concaves
Third tier concaves
Top shell
Second tier concaves
Bottom tier concaves
Bottom shell assembly
Concave support ring
FIG. 4-10 — Top shell assembly. 17X0115-04.9911
4-9
42-65 SUPERIOR MK-II
Section 4 — Installation
Gyratory Crushers
INSTALLING CONCAVES Lower tier concaves are generally supplied paneled out in back. To save on zinc or plastic backing, fill the backs of lower row concaves with a grout of three parts sand to one part cement. Weld reinforcing rod hairpins to the backs and pockets of the concaves to retain the grout. If using zinc backing, allow grout to cure in a dry atmosphere to eliminate moisture.
CAUTION Molten zinc coming in contact with moisture can cause explosions and endanger person- nel. Molten zinc is poured at 1000 o to 1100 o F. (540 o to 590 o C.) Thoroughly clean the inside of the top shell and backs of concaves, and make sure they are dry.
coating thickness, and this could result in looseness and movement of concaves during crushing. Set the bottom row of concaves with 3/8 inch (9.5 mm) vertical spacing between concaves. Place wooden strips in each joint to about half the depth of the joint. If 3/8 inch (9.5 mm) is not sufficient to space out the full row of concaves, alternately increase spacing, but do not exceed 5/8 inch (16 mm) between concaves. See Fig. 4-12. One method of holding concaves in place before pouring backing material is to install a ring, behind which wedges can be driven, as shown in Fig. 4-13. Another is to block the row in place with wooden props or dry sand. Next, stop off the joints between and below the concaves to prevent the escape of hot zinc or plastic backing when poured in at the top. If zinc is to be used, seal the wood strips and bottom area of the concaves against the concave support ring with Babbitrite or equivalent oil-based putty.
Concaves
Wood Slat
A
B
Zinc
C 07–146–350
FIG. 4-12 — Precautionary steps when placing manganese concaves.
CAUTION Do not use water-based putty, where zinc is used. FIG 4-11 — Top shell to bottom shell installation. Note interference taper fit machined in bottom face of top shell. Size 42-65 crusher shown.
NOTE Coat top shell surfaces with oil, when using zinc backing. It will help prevent explosions. Do not use petroleum based products when backing with PLAS- TIC PACK. When plastic backing (PLASTIC PACK) is to be used, do not coat the backs of concaves or inside of the top shell with a parting agent of any type. It is impossible to control 4-10
If PLASTIC PACK backing is used, plaster of paris can be substituted — do not use oil-based putty. It is best to set and back up one row of concaves at a time. Pour the backing up about three-fourths of the height of the row. This will prevent having a coinciding joint at the same place for a compound separation. This is especially true when using zinc, which will not bond to a previous joint. Pour zinc backing as quickly as facilities will permit, proceeding all the way around. Avoid the possibility of voids being left due to cooling of the zinc. Continue setting concaves and pouring backing in the same manner until all succeeding rows are set and backed. 17X0115-04.9911
42-65 SUPERIOR MK-II
Section 4 — Installation
Gyratory Crushers
Particular precautions must be taken in the setting and maintenance of the manganese concaves when the crusher is to be used to reduce hard non-abrasive material. A hard material which is not abrasive will peen the manganese faster than it will wear it off, thus causing the metal to flow. See A, Fig. 4-12. IF ALLOWED TO CONTINUE, THE FLOWING OF METAL WILL TIGHTEN THE ROW OF CONCAVES TO SUCH AN EXTENT THAT THE TOP SHELL CAN CRACK. In order to help combat these conditions, the width of the vertical joint between the concaves can be increased to 5/8 inch (16 mm). Cut 5/8 inch (16 mm) thick wooden slats of a length equal to the height of the concave and width equal to about half of the thickness of the concave and place them in the vertical joints when setting the next set of concaves. See B of Fig. 4-12. 5/8 inch (16 mm) is generally the maximum practical spacing between concaves because of their tendency to loosen and fall out. When increasing the space width it may become necessary to trim the sides of the key concave to fit the available space. When starting a new operation, if the operator suspects the material being crushed is of the type to cause manganese flow, we recommend that he check the concave joints daily for manganese flow. Most of the peening occurs on the face of the concaves and closes the joint between, as shown in A. This may be
COVER SEALANT 5755-2
remedied sufficiently by cutting back the edges of the vertical and horizontal joint with an acetylene torch periodically, as shown in C. In this way the top shell is relieved from the stress caused by the peening. Use care in determining this period, as under adverse conditions top shells have been known to burst from peening within one month of operation.
FIG. 4-13 — Method of zincing manganese steel concave in top shell.
5755-1
5760-0 5760-4
SK021892JJB-7 5750-0 SPIDER CAP 5650-0
SPIDER 5605-0
SPIDER BUSHING 5675-0 5685-0 5685-4
ARM SHIELD 5150-0 5160-0 5160-1 5160-2 5160-3 5160-5
OIL SEAL 5705-0 SCRAPER 5706-0
LUBE HOSE 5240-0 SPIDER JOINT BOLT 5311-0
SPIDER JOINT STUD 5310-0
FIG. 4-14 — Spider Assembly
SPIDER ASSEMBLY The spider must be installed after the top shell and mainshaft are in place. Main components include the spider (5605-0), spider bushing (5675-0), spider bearing oil seal 17X0115-04.9911
(5705-0), spider cap (5650-0), arm shields (5150-0) and rim liners. See Fig. 4-14 and 4-15 for detail.
4-11
42-65 SUPERIOR MK-II
Section 4 — Installation
Gyratory Crushers
Thoroughly clean the mainshaft sleeve and top end of the mainshaft, as well as the bore of the spider hub. Inspect the taper fits of both the spider and top shell. Remove burrs, bruises and any interfering accumulation of rust and dirt. Coat both taper fits with oil or anti-seize compound. Do not use white lead — it will harden and make removal of the spider assembly difficult.
NOTE Install the spider – top shell jackscrew separator col- lars (5007-2) or optional spider – top shell hydraulic separator collars (5008-2) into the counterbored holes in the top flange of the top shell before installing the spider assembly. See Section 12 for details Make a level hitch on the spider assembly and lower over the mainshaft into the matching taper fits of the spider and top shell. Position the top shell so that the bolting flanges are as close to parallel as possible.
Tighten down two bolts, 180 o apart, making sure that the gap between the spider and top shell is equal. Then install two bolts 90o from the first two, again making sure of an equal gap between the two shells. Install the balance of the bolts at approximately the same tightness as the first four. Continue to tighten the bolts in sequence approximately the same number of turns until a .004 inch feeler gauge cannot be inserted between the bolting flanges at any point in the circumference. Check the spider bearing oil seals (5705-0) which are pressed into a counterbore in the bottom of the spider bushing (Fig. 4-15). Note that the shaft scraper (5606-0) must be installed in the spider (5605-0) before the spider bushing (5675-0). Install the spider bushing When the bushing is placed in the spider hub, there will be a gap of approximately 1/16” (1.6 mm) between the bottom of the bushing flange and the top face of the spider. The flange must be pulled down tightly on the spider with the spider bushing bolts. Tighten bolts evenly to prevent the bushing from becoming cocked in the spider hub. SK021892JJB7A
SPIDER BUSHING 5675-0
DUAL OIL SEALS 5705-0 LIP UPWARDS
FIG. 4-15 — Spider bearing oil s eal arrangement
DRIVE Align the motor and put the V-belts or jackshaft in place.
NOTE Set gear – pinion alignment and backlash prior to set- ting the drive. Refer to ”Curved Tooth Spiral Bevel Gear Installation and Maintenance” in Section 8 and “Gear and Pinion Backlash Adjustment” in Section 9.
NOTE Drive must be arranged so that the pinionshaft re- volves clockwise, viewed from the outboard end, making the crusher’s direction of gyration such that the self-tightening head nut functions properly. 4-12
LUBRICATION AND HYDROSET CONTROL PIPING The external lubrication package includes the tank, pumps, motors, piping, etc., for both the HYDROSET control and crusher lubricating systems. Locate the package as close to the crusher as practical, to keep piping to a minimum. You will have to supply pipes and fittings for carrying oil between the crusher and tank. See Fig. 4-16 for piping lubrication systems with the oil-to-water heat exchanger. See Fig. 4-17 for piping arrangement where optional oil-to-air heat exchanger is used. Two pipes carry the lubricating oil to connections on the crushers; another larger pipe carries return oil to the tank. A separate pipe connects the crusher with the pump for the HYDROSET control. Be sure all piping is properly sup17X0115-04.9911
42-65 SUPERIOR MK-II
Section 4 — Installation
Gyratory Crushers
ported and braced to prevent “springing” of joints and possible leakage. Two sediment separators are supplied with each crusher for installation, one each, in the two oil lines to the crusher. Install each separator as close to the crusher as is practical, with the open end of the “Y” toward the crusher. Separators are provided to reduce the possibility of particles in the oil stream getting into bearing areas. See Section 5 under “Sediment Separators” for details.
check valve (8525-0) and piping (8085-0, 8555-0 and 8558-0) are provided for mounting to the crusher. See Fig. 4-18 See Sections 5, “Lubrication System,” and 6, “HYDROSET Control System,” of this manual for details, including wiring of pumps, flow monitors, etc. Details on the balance cylinder (8075-0) supplied with primary gyratory crushers are also included in Section 6, “HYDROSET Control System.”
IMPORTANT
BOTTOM SHELL VENT SYSTEM An air inlet connector (1675-0) is located in the bottom shell at one of the arms. This connector has a 1” NPT port to be connected, by means of a 1” minimum diameter line, to the lube oil reservoir in order to provide a closed vent system for the bottom shell. A low pressure air or exhaust hose is adequate for this line. The connection to the lube tank is to be made at the tee located beneath the pressure relief/breather on top of the tank. See Fig. 4-16.
Before assembling the piping, be sure it is free of such foreign matter as chips, dirt, slag and scale that can be picked up in the lubricating oil and damage bearing surfaces. Remove burrs from inside and out- side of tubes or pipes and make all joints oil tight. Lubrication System Either pipe, tubing or hose may be used for connections between the crusher and lubrication system. Keep the number of bends at a minimum to avoid unnecessary line resistance. Install adequate supports and protection to guard pipe or tubing against mechanical loading and wear.
CAUTION Fittings suitable for 150 psi (10.54 kg per sq. cm) oil pressure and higher must be used . Higher than normal operating pressures occur when the crusher and oil are cold. Use as large a diameter, no smaller than return port on bottom shell, and as steep a slope as possible for the return oil line to insure free gravity oil flow from the crusher to the oil tank. The minimum recommended slope is one inch (2.54 cm) per foot (30.48 cm) of pipe. Keep bends and elbows to a minimum. There is no 3pressure involved. HYDROSET System A separate pipe connects the crusher with the HYDROSET control valve assembly.
CAUTION Use high pressure pipe, suitable for 3,000 psi (210.0 kg per sq cm) for all piping between the pump in the HYDROSET control and the crush- er. This type of pipe is usually designated by the term “Schedule No. 80.” Most components used with HYDROSET control are mounted on the lubrication system base. See “Lubrication System Components” in the appendix to this section. These include the HYDROSET oil tank, pump assembly (8104-0), control valve assembly (8608-0) and filter(s) (8609-1). These components are pre-piped. In addition, two relief valves (8645-0), a balance cylinder (8075-0), 17X0115-04.9911
IMPORTANT This closed vent system must be installed in order to provide proper breathing of the bottom shell and pre- vent dust ingression and lube oil contamination.
NOTE A sight gauge and drain plug are located at the bot- tom of the air inlet connector (1675-0, Fig. 4-16). When oil or water appears in the sight gauge it should be drained to prevent it from entering the crusher or plugging the closed vent system or the over pressure dust sealing line. OVER PRESSURE DUST SEALING UNIT (8896-0) In addition to the closed vent system, pressurized air should be supplied into the bottom shell via the air inlet connector (1675-0, Fig. 4-16) to maintain a positive pressure inside the crusher and prevent dust ingression. Pressurized air can be supplied from either the air blower (8896-0, Fig. 4-16), which is supplied with the crusher, or from a compressed air source. If the blower that was supplied with the crusher is used, it should be installed in a dust free area, at least 8 inches (200 mm) above the inlet to the crusher. Piping between the blower, which has a 1.0” NPT male pipe thread outlet, and the air inlet connector (1675-0) located on the bottom shell at one of the arms, should be 1.0” SCH 40 pipe or equivalent hose (not furnished). When connecting the blower motor, check that the direction of rotation corresponds to the arrow on the blower housing and that it starts and stops with the crusher drive motor. If compressed air is to be used, piping should be 1.0” SCH 40 pipe or equivalent hose, valved to admit approximately 6 CFM to the crusher. The compressed air should be filtered and dry. 4-13
42-65 SUPERIOR MK-II
Section 4 — Installation
Gyratory Crushers
1.0” NPT MALE OUTLET
FILTER ELEMENT (8896-3)
1.0” SCH. 40 PIPE OR EQUIVALENT HOSE
AIR BLOWER (8896-0)
BALANCE CYLINDER
SEDIMENT SEPARATOR
CHECK VALVE AIR INLET CONNECTOR (1675-0)
1.0” SCH. 40 PIPE OR EQUIVALENT HOSE TO BOTTOM SHELL 15 GPM
3.0” SCH. 40 PIPE OR EQUIVALENT HOSE OIL RETURN LINE
SEDIMENT SEPARATOR 1.0” SCH. 80 PIPE OR EQUIVALENT HOSE HYDROSET PIPING 1.0” SCH. 40 PIPE OR EQUIVALENT HOSE FOR BOTTOM SHELL VENTING
LUBRICATION SYSTEM
1.0” SCH. 40 PIPE OR EQUIVALENT HOSE TO HYDROSET CYLINDER 15 GPM
PRESSURE BREATHER
“A”
VIEW “A” SK111194-JJB-3
FIG. 4-16 — General arrangement of lubrication and HYDROSET s ystems
4-14
17X0115-04.9911
42-65 SUPERIOR MK-II
Section 4 — Installation
Gyratory Crushers
3.0” NPT OIL RETURN
1.0” SCH 40 PIPE OR EQUIVALENT HOSE TO BOTTOM SHELL 15 GPM
7850–2
7875–0
2.0” SCH. 40 PIPE OR EQUIVALENT HOSE TO AIR–OIL COOLER 30 GPM
1.0” SCH 40 PIPE OR EQUIVALENT HOSE TO HYDROSET CYLINDER 15 GPM
7805–0
7850–1
COOLER RELIEF VALVE 7725– 0 COOLER BYPASS 1.5” SCH 40 PIPE OR EQUIVALENT HOSE
AIR-OIL HEAT EXCHANGER 7705-0
SK071698–JJB–1
FIG. 4-17 — Typical piping arrangement for lubrication system with oil-to-air cooler. 17X0115-04.9911
4-15
42-65 SUPERIOR MK-II
Section 4 — Installation
Gyratory Crushers
8075-3 PRESSURE GAUGE 8075-4
8076-0 8076-1 8076-4
8075-0
8026-0
(INCH) 0.25” NPT1 (FEMALE) BLEEDER PORT 8565-0 8565-4
8085-0 8556-0 8540-0 8540-1 8521-0 8525-0 8530-0 8028-0 8755-8
(INCH) 1.0” NPT1 (FEMALE) HYDROSET OIL INLET PORT 8425-0 8645-0 8645-1
8555-0
8556-0 8556-1 8565-0 8565-4
8558-0
SK080897-JJB-2
FIG. 4-18 — Balance cylinder and HYDROSET piping.
4-16
17X0115-04.9911
Weights and Dimensions
42-65 SUPERIOR MK-II Gyratory Crushers
A C D B D C ’N’ for mainshaft
N assembly removal F
L
G J
t f a h s f o d n E
y r y a l d n n o o s c r e e M s h r s o u f ’ r c M ’
M
P O
H Minimum for
removing eccentric
Recommended discharge chamber size – minimum two truckloads live storage
Eccentric lowered on skid
APPROXIMATE DIMENSIONS — FT. IN. (CM) A
B
C
D
E
F
G
H
ft. in.
11-2
9-0
2-6
5-5 1 / 2
5-0
12-11
22-87 / 8
6-115 / 8
cm
340.4
274.3
76.2
166.4
152.4
388.6
693.1
212.4
J
K
L
M
N
O
P
ft. in.
11-11 / 4
4-8
7-23 / 8
6
15-33 / 4
4-11 / 4
9-101 / 2
cm
338.5
142.2
219.4
15.2
466.7
125.1
301.0
APPROXIMATE WEIGHT OF MAJOR PARTS . . . pounds and (kilograms) Total Weight
263,300 (119,431)
Spider
42,500 (19,300)
Mainshaft Assembly
51,000 (23,150)
Eccentric Assembly
6,800 (3,090)
Top Shell and Concaves
80,100 (36,333)
HYDROSET Cylinder Assembly
8,900 (4,037)
Bottom Shell
65,200 (29,574)
17X0124-01.9612
1
Tool List
42-65 SUPERIOR MK-II Gyratory Crushers
Quantity
Description
Part Number
1
4.625” Sledging wrench for top and bottom shell joint, and top shell to spider joint
17-103-757-005
1
3.75” Sledging wrench for spider jack bolts
17-103-757-011
1
2.75” Sledging wrench for HYDROSET cylinder and bottom shell joint, and HYDROSET cylinder cover nut
17-103-757-006
1
3.125” Socket for 1.50” drive for arm liners to spider
00-935-147-250
1
2.625” Sledging wrench for HYDROSET cylinder cover
17-103-757-017
1
1.875” Sledging wrench for bottom shell side liners
17-103-757-013
1
.625” Hex head wrench for HYDROSET cylinder upper and lower bushing bolts, and upper 17-106-407-010 and lower counterweight bolts
1
.75” Hex head wrench for eccentric support plate bolts and spider bushing bolts
17-106-407-009
1
6mm Hex head wrench for HYDROSET cylinder
65-936-009-010
1
1.0” Hex head wrench for mainshaft sleeve clamp bolts
17-106-407-008
1
Spanner wrench for pinionshaft drive and sheave end spacers
07-144-803-501
1
Snap ring pliers for pinionshaft snap ring
00-673-247-150
1
Snap ring pliers for piston snap ring
00-673-247-160
1
Snap ring pliers for mainshaft snap ring
00-673-247-087
1
.75” Lowering rod assembly for mainshaft step
17-202-513-801
3
1.0” Lowering rod assembly for piston assembly and cover plate
17-105-881-504
3
1.75” Lowering rod assembly for eccentric and HYDROSET cylinder assembly
17-105-881-512
2
.38” Eyebolt for lifting piston wear plate
00-691-525-095
3
.50” Eyebolt for lifting bottom shell bushing, dust collar, eccentric bushing, mainshaft step and mainshaft sleeve
00-691-531-184
2
.625” Eyebolt for lifting lower dust seal retaining ring
00-691-531-242
4
.75” Eyebolt for lifting eccentric, eccentric wearing ring, HYDROSET clamp plate, gear and pinion, upper and lower HYDROSET bushings, mainshaft step washer, and mainshaft upper dust seal retaining ring.
00-691-531-302
4
1.0” Eyebolt for lifting upper and lower eccentric counterweights, pinionshaft housing, spider bushing
00-691-531-412
1
1.25” Eyebolt for lifting piston
00-691-531-517
1
Piston stop plate
07-247-368-501
2
1.0” Hex capscrew, 5.5” long, for piston stop plate
00-611-271-736
2
1.0” Hex nut for piston stop plate
00-631-001-116
4
Shell splitting wedge
17-201-978-001
1
Adjustable wrench set, 2 pieces, 8” and 12”
17-107-059-002
1
Hex key wrench set, 15 pieces, 5/64” to 3/4”
17-107-059-003
1
Charging and gauging assembly for balance cylinder
07-149-510-002
17X0122-02.9709
1
42-65 SUPERIOR MK-II
Crusher Parts List
Gyratory Crusher
INSTRUCTIONS FOR ORDERING PARTS When ordering parts, furnish the following information to nearest Svedala Industries crushing and screening distributor or sales office. Serial number of machine. Catalog number of part. Description of part. Quantity required. Definite shipping instructions Strict compliance with instructions will expedite delivery of your order. HYDROSET MECHANISM BALANCE CYLINDER 17-202-619-002 Catalog Number
Description
Catalog Number
Description
8025-0 8027-0 8027-1 8028-0 8075-0 8075-3 8075-4 8076-0 8076-1 8076-4 8085-0 8425-0 8521-0
Balance Cylinder Support Bracket Gusset – Upper (not shown) Gusset – Lower (not shown) Bracket – Pipe Balance Cylinder Balance Cylinder Gauge Balance Cylinder Gauge Bushing Bolt Nut Lockwasher HYDROSET Pipe Assembly Relief Valve Discharge Cup Check Valve Welding Flange
8525-0 8530-0 8540-0 8540-1 8555-0 8556-0 8556-1 8558-0 8565-0 8565-4 8645-0 8645-1 8755-8
HYDROSET Check Valve Check Valve Gasket Bolt Nut HYD. Pipe Asm–Flange to Check Valve O-ring Square Flange W/O-ring Groove HYDROSET Pipe Asm.– Cover to Flange Bolt Lockwasher Pressure Relief Valve Nipple HYD. Return Bend Clamp (Pipe Support)
8076-0 8076-1 8076-4
8075-3 PRESSURE GAUGE 8075-4
8075-0
8026-0
0.25” NPT1 (FEMALE) BLEEDER PORT 8565-0 8565-4
8085-0 8556-0 8540-0 8540-1 8521-0 8525-0 8530-0 8028-0 8755-8 1.0” NPT1 (FEMALE) HYDROSET OIL INLET PORT 8425-0 8645-0 8645-1
8555-0 8556-0 8556-1 8565-0 8565-4
17X0123-05.0003
8558-0 SK080897-JJB-2
1
2
L P C i a r s r u t t s s h e r
TEFLON BACKUP 8
AIR VALVE 14 15
2
PIPE PLUG INSPECTION HOLE 11 BUNA O–RING 12 PISTON GUIDE 6
BUNA O–RING 7 PISTON U-CUP TYPE 4
SET SCREW 13
1
PISTON ROD 5
B a l a n c e C y l i n d e r
3
1 7 X 0 1 2 3 0 5 . 0 0 0 3
U-CUP BUNA 10 TEFLON BACKUP 9
PARTS LIST NITROGEN–OIL BALANCE CYLINDER PART NO. PART NAME QUANTITY 1 ROD END COVER 1 2 BLIND END COVER 1 3 BALANCE TUBE BODY 1 4 PISTON U–CUP TYPE 1 5 PISTON ROD 1 6 PISTON GUIDE 1 7 O–RING (BUNA) 2 8 BACKUP (TEFLON) 2 9 BACKUP (TEFLON) 2
18 17
PART NO. 10 11 12 13 14 15 16 17 18
PART NAME QUANTITY U–CUP (BUNA) 2 PIPE PLUGS (.25” NPT) 3 O–RING (BUNA) 1 SET SCREW (0.25”–20) 2 VALVE (0.25” NPT) 1 HEX NUT JAM (1.0”–14) 1 HEX NUT (0.75”–10) 24 TIE ROD (LONG) 8 TIE ROD (SHORT) 4
16 TORQUE 135 TO 145 FT.–LBS. (183 TO 197 Nm) CATALOG DESCRIPTION NUMBER 8075–4 SEALS REPAIR KIT 8075–8 PISTON REPAIR KIT
SK082598–JJB–1
4 2 - G 6 5 y r S a U t o P r y E C R r I u O s h R e r M K - I I
42-65 SUPERIOR MK-II
Crusher Parts List
Gyratory Crusher
TERMINAL JUNCTION BOX 8608–0 8225–0 7170–0 8104–0
HYDROSET PIPE CENTERLINE
8609–9 7177–0 OPTIONAL
VENT PIPE CENTERLINE
8005–3 OPTIONAL 8005–5
[INCH] 3.00” NPTI (FEMALE) OIL RETURN
7005–8 7005–5
7181–0 OPTIONAL
7005–3 OPTIONAL
8825–0 7005–8 7405–0
8850–0
7205–0
7405–0
7205–0
7705–0 7175–0 7576–0 7510–0 7005–0 7505–0
VENT PIPE CENTERLINE
[INCH] 1.00” NPTI (FEMALE) PRESSURE BREATHER PORT 7505–0 7120–0
OIL RETURN 7150–0 7005–8 7405–0 7875–0 7850–2 1.0” NPT (FEMALE) OIL OUTLET PORT 7850–1 7805–0 [INCH] 2.00” NPTI OIL (FEMALE) DRAINS OIL DRAINS SK071698–JJB–2
WATER PORTS 1.5” NPT (FEMALE) 7005–0 7705–0
External oil conditioning system (water cooler) Catalog Number
Description
7005-0 7005-3 7005-5 7005-8 7120-0 7150-0 7170-0 7175-0 7177-0 7179-0 7181-0 7205-0 7405-0 7505-0 7510-0
Base and tank assembly Lube oil level sensor (optional) Inspection cover Sight gauge Pressure breather Sieve High temperature shut-down switch (TS-3) Thermometer Oil return temp. probe (optional) Temperature switch (cooler) (TS-1) Lube tank oil temp. sensor asm (optional) Lube pumping unit Ball valve Filter Pressure gauge 0 - 200 PSI (18.8 KPa)
17X0123-05.0003
Catalog Number
Description
7576-0
Differential pressure gauge (switch optional)
7705-0 7720-0 7805-0 7850-1 7850-2 7875-0 8005-3 8104-0 8225-0 8608-0 8609-9 8825-0 8850-0
Cooler Check valve Flow regulator Flow switch (FS-1) lower Flow switch (FS-2) upper Relief valve HYDROSET oil level sensor (optional) HYDROSET pumping unit Ball valve Control valve assembly HYDROSET filter cartridge Immersion heater Heater control switch (TS-2)
3
42-65 SUPERIOR MK-II
Crusher Parts List
Gyratory Crusher
TERMINAL JUNCTION BOX 8608–0
8225–0 7170–0
HYDROSET PIPE CENTERLINE VENT PIPE CENTERLINE
8104–0 8609–9
7179–0 7177–0 OPTIONAL
8005–3 OPTIONAL [INCH] 3.00” NPTI (FEMALE) OIL RETURN
8005–5
7005–8 7005–5
7005–3 OPTIONAL
7181–0 OPTIONAL 8825–0 7005–8 7405–0 8850–0 7205–0
7405–0 LUBE SYSTEM OUTPUT CONNECTION 7205–0
7175–0 7576–0 7510–0
VENT PIPE CENTERLINE
7005–0 7505–0
[INCH] 1.00” NPTI (FEMALE) PRESSURE BREATHER PORT 7505–0 7120–0
OIL RETURN
7150–0
7405–0 7005–8 7720–0
7720–0 7205–0
[INCH] 2.00” NPTI (FEMALE) OIL OIL DRAINS DRAINS 7005–0
External oil conditioning system (air cooler)
4
17X0123-05.0003
TOPVIEWOF SPIDER LINERS
SHELL SEPARATOR
VIEW”A”
VIEW”B”
VIEW”C”
ENDVIEWOF PINIONSHAFT ASM
SEE VIEW ”B”
SEE VIEW”C” HYDROSET CYLINDER DETAIL
5
17X0123-05.0003
CAT.NO.
DESCRIPTION
17X0123-05.0003
CAT. NO.
DESCRIPTION
CAT.NO.
DESCRIPTION
6
Plastic Pack
Directions for Use
Crusher Wear Surface Backing Material PLASTIC PACK is an epoxy resin for backing crusher wearing parts and other applications where zinc or cement might otherwise be used for filling cavities between mating parts. It is also an economical bonding agent. PLASTIC PACK will flow into spaces where zinc or concrete grout will not, providing a more solid structure. PLASTIC PACK is designed for impact resistance, compressive strength, chemical resistance and economy of installation in its completely cured form. Compressive and tensile strengths are approximately three and five times respectively stronger than concrete. In its cured form, PLASTIC PACK also resists most solvents, greases, oils, acids and alkalies that are found around construction machinery. APPLICATIONS As a backing for crusher wearing parts, PLASTIC PACK has a relatively high impact strength when tested on our “Bond Impact Tester”. A compressive strength of 17,700 psi is more than adequate for the toughest service. Shrinkage is only .0003”/1.0” (.008/25.4mm). The 22-pound (10 Kg) kit provides 340 cubic inches (5572 cm3) of backing. PLASTIC PACK is not recommended for use where cured resin will be subjected to temperatures in excess of 130oF.
IMPORTANT In order to obtain these fully cured properties the whole process of mixing, pouring, and maintaining the correct temperatures of the PLASTIC PACK and the adjacent machinery parts must be strictly con- trolled.
PRECAUTIONS WHEN USING PLASTIC PACK Although PLASTIC PACK has a low volatility, it is good practice to mix and pour in a well-ventilated area. Do not burn cured resin without adequate ventilation and respiration equipment. PLASTIC PACK should be washed immediately from skin with soap and water. Should PLASTIC PACK get into the eyes, flush immediately with running water for at least 15 minutes. Launder soiled clothes before reuse. THE USER NEEDS TO STRICTLY CONTROL THE COMPLETE PROCESS OF STORAGE, MIXING, POURING, AND MAINTAINING CORRECT TEMPERATURES OF THE PLASTIC PACK AND MACHINERY PARTS AS CALLED FOR IN THESE DIRECTIONS. Svedala Industries, Inc. MAKES NO WARRANTY WHETHER EXPRESSED OR IMPLIED INCLUDING THE IMPLIED WARRANTY OF MERCHANTABILITY AND USER ASSUMES ALL RISK WITH RESPECT TO THE FITNESS OF THIS PRODUCT FOR HIS USE. 17X0085-03.9708
STORING PLASTIC PACK Unopened and undamaged kits of PLASTIC PACK have a limited shelf life of two years. Do not store where temperatures exceed 90o F. (32.2o C) or below 32o F (0o C). Rotate any stock on hand to avoid exceeding storage limits. The batch number stamped on the label on each can shows the date when packaged. Do not attempt to mix partial cans of PLASTIC PACK. TEMPERATURE AFFECTS CURE When curing, the hardener and resin portions react and generate heat. Epoxies are good insulators and, in large masses, the internal heat build-up will shorten the pot life. See comparative curves on Page 2 for pot hardening times. When poured in thin sections, along with natural heat loss to surrounding materials, cure takes longer. The optimum temperature range for mixing and pouring PLASTIC PACK is 70-80 o F. (21-26.6 o C). When air temperature is below 60 o F. (15.6 o C), warm unmixed ingredients to the 70-80 o F. (21-26.6 o C) range. If air temperature is above 90 o F. (32.2o C), cool ingredients by immersion in cool water or store in air conditioned room, to optimum temperature range of 70 o F. - 80o F. (avoid getting water into contents of cans).
IMPORTANT The time required for a complete cure for PLASTIC PACK used for backing crusher wear parts depends on environmental temperature. It will range from 24 hours at 70 o F and higher to 72 hours at 60 o F. PLASTIC PACK retains its temperature (hot or cold) for long periods of time. During cold weather, it should be maintained at 60oF. (15.6oC) or above for at least 12 hours before use. Before mixing cold PLASTIC PACK in metal containers, it can be warmed in the following manner: 1. Carefully brush the flame of a propane or acetylene torch against one side of opened resin container (metal containers only) while pre-mixing, keeping pail handle on opposite side. Keep stirring rod on side being heated until resin appears quite fluid. Use thermometer and bring resin temperature to 80 o F. (26.6 oC) to compensate for colder temperature of hardener you will add during mixing. 2. Remove torch. 3. Add hardener, mix and pour.
IMPORTANT Pouring into or against cold machinery will adversely affect curing. Parts to be filled must be warmed to 70 - 80 o F (21 - 26.6 o C). 1
Directions for Use
Plastic Pack
Crusher Wear Surface Backing Material
. P M 100 E T T 90 O P G 80 K N C I T F A S S P A E 70 C I C E T D R S N G A A E60 L D P N I S E R 50 D E 40 X I 0 10 M
PLASTIC PACK POT LIFE TIME
32 27 POT LIFE 200 GRAMS
POT LIFE – 22 POUNDS (10 Kg.)
C S 21 E E R G 16 E D
10
4 20 30 40 50 60 70 80 90 100 110 MINUTES TO HARDEN (APPROXIMATE)
EFFECT OF MOISTURE PLASTIC PACK can be poured into damp areas, although it will not adhere to damp surfaces. Small amounts (several grams) of water accidentally entrained into the material during mixing will cause it to cure slower and to be slightly softer. If greater amounts of water become entrained in the material during mixing, it will lose its strength characteristics and become unusable. PREPARATION OF MACHINE PARTS Backing Crusher Parts 1. Prepare all parts by removing all oil, grease, scale, rust, dirt, etc. from surfaces to be bonded. PLASTIC PACK is normally bonded to wearing parts only and this especially applies to self tightening crusher mantles. However, in the case of Superior crusher concaves only PLASTIC PACK should be bonded to both wearing and mating surfaces for extra stability. Therefore, both surfaces must be cleaned, preferably by sandblast. 2. Where necessary, coat surfaces not to be bonded with silicone spray or another release agent to prevent bonding. DO NOT USE PRODUCTS CONTAINING PETROLEUM FOR THIS PURPOSE. 3. Assemble the mating parts. 4. Protect threaded parts with clay or putty dams to direct flow away from threads. 5. To provide for proper flowing and curing of PLASTIC PACK at temperatures lower than 60 o F. (15.5 o C), warm parts to be bonded, and unmixed PLASTIC PACK, to 70 - 80 o F (21 - 26.6 o C).
CAUTION Adequately vent working area when heating crusher parts and do not create fire hazards.
2
PREFERRED TEMPERATURE RANGE FOR APPLICATION SHOWN IN SHADED AREA
38
MIXING PLASTIC PACK PLASTIC PACK resin must be mixed thoroughly and uniformly with hardener before using. Otherwise it will not flow and cure properly. When mixing an entire kit (11 or 22 pounds (5 or 10Kg) of resin with hardener supplied), follow these instructions: 1. When air temperature is lower than 60o F. (15.6 o C), warm unmixed PLASTIC PACK to 70-80 o F. (21-26.6o C). 2. When air temperature is above 90 o F. (32.2o C) cool unmixed PLASTIC PACK to 70o - 80o F (21o - 26.6o C) by immersion of closed and sealed can in cool water. 3. Pre-mix resin thoroughly with power drill and stirring rod, scraping bottom and sides of can. Mix for one to two minutes. 4. Add entire contents of hardener container and continue power mixing until mixture is completely uniform in color (streaks of color in mixture or around edge indicate further mixing is required). 5. Use of less than full kits of PLASTIC PACK for crusher wear surface backing is not recommended.
CAUTION Mix and pour PLASTIC PACK only in quantities that allow complete usage before pot life is ex- ceeded. See pot life guide diagram. POURING PLASTIC PACK Pour mixed PLASTIC PACK immediately. Hardening begins when hardener is added to resin. Mixed PLASTIC PACK (at 70o F or 21o C) will harden into a solid mass in approximately 20 minutes if left in the can. This hardening time is extended to 30-40 minutes if pouring is started immediately after mixing. This extended hardening time occurs when PLASTIC PACK is in thin sections or between cooler surfaces.
17X0085-03.9708
Plastic Pack
Directions for Use
Crusher Wear Surface Backing Material Backing Crusher Parts 1. For uniform distribution, pour mixture at several points around the cavity. 2. Additional batches of PLASTIC PACK can be poured with positive bonding results.
QUANTITY REQUIREMENTS For estimating quantity requirements, use a ratio of one part PLASTIC PACK to four and one-half parts of zinc by weight. A 22-pound (10Kg) kit of PLASTIC PACK provides 340 cubic inches (5572cm3) of poured and set material.
IMPORTANT
NOTE
When pouring PLASTIC PACK behind gyratory crusher concaves, PLASTIC PACK flow difficulties can be avoided if poured in quantities to fill no more than one tier of concaves at a time.
If concaves are supplied with the backs paneled out, fill the panels with grout, or more plastic backing ma- terial will be required than was supplied with your crusher. Also note that thicker sections of PLASTIC PACK allow more shrinkage
17X0085-01.9405
3
Directions for Use
Plastic Pack
Crusher Wear Surface Backing Material BACKING REQUIREMENTS — SUPERIOR CRUSHERS SUPERIOR GYRATORY WITH MANGANESE CONCAVES Backing Requirements — SUPERIOR Crushers Manganese Concaves SUPERIOR Crushers Model
Plastic Kits*
42-65
Zinc Pounds Kilograms
61
6100
2765
Mantles Plastic Kits*
Zinc Pounds Kilograms
20
2000
905
SUPERIOR GYRATORY WITH ALLOY STEEL CONCAVES Machine Size 42-65
Lower Row Kits 17
Lower Middle Kits 18
Upper Middle Kits 22
Upper Row Kits 16
Total (One Kit = 22 lbs.) 73
(*) PLASTIC PACK backing materials is sold in 22 pound (10Kg) Kits, each providing approximately 340 cubic inches (5572 cm 3) of poured and set material
4
17X0085-03.9708
SUPERIOR MK-II
Mainshaft Lifting Eye Dimensions
Gyratory Crushers
The lifting eye on mainshafts for all crushers except the sizes 13-36 and 16-50 is permanently installed. A shackle is required between the eye and lifting hook on all except the size 13-36 crusher. Use the largest standard shackle fitting the “C” dimension. All dimensions are in inches.
B
C Dia.
A
Mainshaft Assembly Wgt.-Lbs (Kg)
Inches (mm) A
Inches (mm) B
Inches (mm) C
50”
17,100 (7,755)
2.3 (58.4)
1.75 (44.5)
1.375 (34.9)
55”
31.200 (14,150)
3.5 (88.9)
3.125 (79.4)
2.375 (60.3)
(42) 65”
51,000 (23,135)
3.5 (88.9)
3.125 (79.4)
2.375 (60.3)
(50) 65”
60,000 (28,125)
3.5 (88.9)
3.125 (79.4)
2.375 (60.3)
70”
49,100 (22,270)
3.5 (88.9)
3.125 (79.4)
2.375 (60.3)
75”
85,000 (38,560)
4.4 (112)
3.88 (98.6)
2.875 (73.0)
89”
143,500 (65,090)
4.9 (125.4)
4.75 (120.7)
3.30 (83.8)
Crusher Size
10.0
10.0
14.0
110” SUPERIOR Mainshaft Assembly Weight = 218,500 Lbs.
17X10715-03.9811
1
Procedure For Tightening Bolts
Maintenance Instructions
and grade of bolt in “foot pounds” and “kilogram metres” (in parentheses).
GENERAL Successful operation of a machine depends upon good maintenance. MACHINERY MUST BE INSPECTED FREQUENTLY TO INSURE THAT ALL BOLTS ARE TIGHT. Check the tightness of all bolts after the first few hours of initial operation of the machine. During the first week of operation, check the bolts for tightness daily and then periodically thereafter. This procedure also applies to parts and components that have been disassembled and reassembled during normal maintenance periods. PROCEDURE FOR TIGHTENING BOLTS 1. Deburr all bolt holes before assembly to ensure a tight fit between parts being fastened together. 2. Contact surface of the parts attached with bolts must be free of dirt, oil, rust, loose scale, etc. 3. Use two hardened washers per bolt; one under the bolt head and one under the nut. See Figure 1. 4. Use the proper size and grade of bolt required for the job. The “Bolt Torque Value” chart lists the size, grade and head marking of the bolt, and provides a minimum and maximum torque value for each size
5.
Tighten bolts to the recommended torque value with a torque wrench.
IF A TORQUE WRENCH IS NOT AVAILABLE 1. Install sufficient fitting-up bolts and tighten as required to bring the parts together. 2. Install bolts in the balance of the holes.Tighten the nuts by the “turn-of-nut” method. This requires that bolts be brought to a “snug-tight” condition to insure that the joint material is properly compacted before the nut is rotated through the specified turn. ”Snug-tight” is defined as “The tightness attained by a few impacts of an impact wrench or the full effort of a man using an ordinary spud wrench”. When using an impact wrench, snug condition is readily noticeable as that point at which the wrench starts impacting solidly. 3. Give nuts an additional 1/2 to 2/3 turn. 4.
Tighten nuts on fitting-up bolts to “snug-tight” condition and then give these nuts an additional 1/2 to 2/3 turn.
Bolt
Hardened Washers
Holes Must Not Be More Than 1/16” (2 mm) Larger Than Bolt Diameter
Nut
Figure 1
26X1451-08.9406
1
Maintenance Instructions
Procedure For Tightening Bolts
MINIMUM AND MAXIMUM BOLT TORQUE VALUES — FOOT POUNDS (KILOGRAM METRES) A325
BC
BOLT GRADE BOLT SIZE .25 .3125 .375 .4375 .50 .5625 .625 .75 .875 1.0 1.125 1.25 1.375 1.50 1.75 2.0 2.25 2.50 2.75 3.0 3.25 3.50 3.75 4.0
26X1451-08.9406
SAE GRADE 2
ASTM A449
SAE GRADE 5
6.6 (.9) 6.9 (1.0) 13.5 (1.9) 14 (2.0) 24 (3.3) 25 (3.5) 38 (5.3) 40 (5.5) 58 (8.0) 62 (8.6) 84 (11.6) 89 (12.3) 116 (16.0) 123 (17.0) 207 (28.6) 218 (30.1) 200 (27.6) 211 (29.1) 300 (41.5) 317 (43.8) 425 (58.7) 448 (61.9) 600 (83.0) 633 (87.5) 786 (108.7) 830 (114.8) 1043 (144.2) 1101 (152.3)
10 (1.4) 11 (1.5) 21 (2.9) 22 (3.0) 37 (5.1) 39 (5.4) 59 (8.2) 63 (8.7) 90 (12.4) 95 (13.1) 130 (18.0) 138 (19.0) 180 (24.9) 190 (26.3) 319 (44.1) 337 (46.6) 515 (71.2) 544 (75.2) 773 (107.0) 816 (112.8) 953 (131.8) 1006 (139.1) 1344 (185.9) 1419 (196.2) 1763 (243.8) 1861 (257.4) 2339 (323.5) 2469 (341.5) 2743 (379.3) 2895 (400.4) 4125 (570.5) 4354 (602.2) 6033 (834.4) 6368 (880.7) 8250 (1141.0) 8708 (1204.3) 11185 (1546.9) 11806 (1632.8) 14776 (2043.5) 15597 (2157.1)
10 (1.4) 11 (1.5) 21 (2.9) 22 (3.0) 37 (5.1) 39 (5.4) 59 (8.2) 63 (8.7) 90 (12.4) 95 (13.1) 130 (18.0) 138 (19.0) 180 (24.9) 190 (26.3) 319 (44.1) 337 (46.6) 515 (71.2) 544 (75.2) 773 (107.0) 816 (112.8) 953 (131.8) 1006 (139.1) 1344 (185.9) 1419 (196.2) 1763 (243.8) 1861 (257.4) 2339 (323.5) 2469 (341.5)
ASTM A325
90 (12.4) 95 (13.1) 130 (18.0) 138 (19.0) 180 (24.9) 190 (26.3) 319 (44.1) 337 (46.6) 515 (71.2) 544 (75.2) 773 (107.0) 816 (112.8) 953 (131.8) 1006 (139.1) 1344 (185.9) 1419 (196.2) 1763 (243.8) 1861 (257.4) 2339 (323.5) 2469 (341.5)
ASTM-A354 GRADE BC 12.5 (1.7) 13.2 (1.8) 26 (3.6) 27 (3.7) 46 (6.4) 48 (6.6) 73 (10.1) 77 (10.6) 112 (15.5) 118 (16.3) 161 (22.3) 170 (23.5) 222 (30.7) 235 (32.5) 394 (54.5) 416 (57.5) 637 (88.1) 672 (92.9) 954 (132.0) 1007 (139.3) 1352 (187.0) 1427 (192.4) 1908 (263.9) 2014 (278.5) 2501 (345.9) 2640 (365.1) 3319 (459.0) 3504 (484.6) 5237 (724.3) 5528 (764.5) 7875 (1089.1) 8313 (1149.7) 11517 (1592.8) 12157 (1681.3) 15750 (2178.2) 16625 (2299.2) 19319 (2617.8) 20393 (2820.4) 25522 (3529.7) 26940 (3725.8) 32882 (4547.6) 34709 (4800.3) 41546 (5745.8) 43854 (6065.0) 51621 (7139.2) 54488 (7535.7) 63156 (8734.5) 66665 (9219.8)
A490
SAE GRADE 8 ASTM-A354 GRADE BD 14.3 (2.0) 15.1 (2.1) 29 (4.0) 31 (4.3) 52 (7.2) 55 (7.6) 84 (11.6) 88 (12.2) 128 (17.7) 135 (18.7) 184 (25.4) 194 (26.8) 254 (35.1) 268 (37.0) 451 (62.4) 476 (65.8) 728 (100.7) 768 (106.2) 1091 (150.9) 1151 (159.2) 1545 (213.7) 1631 (225.6) 2180 (301.5) 2301 (318.2) 2859 (395.4) 3017 (417.3) 3793 (324.6) 4004 (553.8)
ASTM A490
128 (17.7) 135 (18.7) 184 (25.4) 194 (26.8) 254 (35.1) 268 (37.0) 451 (62.4) 476 (65.8) 728 (100.7) 768 (106.2) 1091 (150.9) 1151 (159.2) 1545 (213.7) 1631 (225.6) 2180 (301.5) 2301 (318.2) 2859 (395.4) 3017 (417.3) 3793 (324.6) 4004 (553.8) 5985 (827.7) 6317 (873.6) 9000 (1244.7) 9500 (1313.9) 13162 (1820.3) 13894 (1921.5) 18000 (2489.4) 19000 (2627.7) 21353 (2953.1) 22539 (3117.1) 28208 (3901.2) 29775 (4117.9) 36343 (5026.2) 38362 (5305.5) 45919 (6350.6) 48470 (6703.4) 57054 (7890.0) 60224 (8329.0) 69804 (9653.9) 73682 (10190.2)
2
Bolt Torques
42-65 SUPERIOR MK-II Gyratory Crushers
Catalog Number
17X0121.9403
Description
1365-0
Side Liner Bolt 1.25”-7
1405-0
Dust Collar Bolt 1.0”-8
1505-0 1540-0
Bottom Shell to Pinionshaft Housing Stud 1.0”-8 Bottom Shell to Top Shell Joint Bolt 3.0”-4
1811-1
Upper Counterweight Bolt 0.75”-10
1811-6
Upper Counterweight Bolt 0.50”-13
1812-1 1851-0
Lower Counterweight Bolt 0.75”-10 Eccentric Gear Key Bolt 0.625”-11
1910-0
Eccentric Support Plate Bolt 1.0”-8
2020-0
HYDROSET Cylinder Stud 1.75”-5
2055-0
Lower Bushing Bolt 0.75”-10
2060-0
Upper Bushing Bolt 0.75”-10
2325-2
Clamp Plate Retaining Ring Bolt 0.375”-16
2515-0
Cylinder Cover Bolt 1.75”-5
2606-1
Cover Plate Bolt 0.50”-13
2651-0
Cover Plate Closure Plug Bolt 8x25 (metric)
3210-0
Pinion Seal Plate Bolt 0.625”-11
3220-0
Sheave End Seal Plate Bolt 0.625”-11
4027-0
Mainshaft Sleeve Clamp Bolt Hex Socket 1.5”-6
4330-0 4365-0
Upper Dust Seal Retainer Ring Bolt 0.75”-10 Dust Seal Retaining Ring Bolt 0.625”-11
4435-0
Splash Curtain Bolt 0.50”-13
5007-1
Spider Jack Bolt 2.5”-8
5125-0
Spider Rim Liner Bolt 0.875”-9
5160-0
Spider Arm Shield Bolt 2.0”-4.5
5285-0
Lube Hose Bracket Bolt 0.625”-11
5310-0 5311-0 5685-0
Spider to Top Shell Joint Stud 3.0”-4 Spider to Top Shell Joint Bolt 3.0”-4 Spider Bushing Bolt 1.0”-8
5760-0
Spider Vent Cover Bolt 0.50”-13
Torque ft.-lbs N-m 600 633 300 317 300 317 7500
813 858 406 430 406 430 10,168
319 337 90 95 395 116 123 300 317 1400
432 457 122 129 535 157 167 406 430 1898
207 218 207 218 24
280 295 280 295 33
1400
1898
90 95 18
122 129 24
116 123 116 123 1800 2000 319 337 116 123 58 62 8240
157 167 157 167 2440 2710 432 457 157 167 79 84 11,172
200 271 211 286 To get 0.75” spring compression 116 157 123 167 7500 10,168 7500 10,168 773 1048 816 1106 58 79 62 84
1
Section 5 — Index
42-65 SUPERIOR MK-II Gyratory Crushers
5. Lubrication
Page 5-1 5-2 5-2 5-2 5-2 5-2 5-2 5-3 5-3 5-3 5-4 5-4 5-4 5-4 5-8 5-8 Appendix
Description Index General Information Immersion Oil Heater Oil Storage Tank Return Oil Sieve Lubrication Oil Pump Oil Filter Lubrication Oil Coolers — Air-To-Oil Coolers — Water-To-Oil Coolers Oil Flow Divider Circuit Flow Monitors Temperature Switch Temperature Gauge Sediment Separators Suggested Control Systems Lubrication Pumps For Crusher Lubrication Systems – 17X11113-03.0003 Nelson Liquid Filters – 17X0098-01.0003 — Pre-Operational Fluid Test — Element Replacement Basco Heat Exchanger – 17X10647 Waterman Flow Regulator – 17X11105 Universal Flow Monitors – 17X0099-01.0003
17X0115-05.0003
5
5-1
42-65 SUPERIOR MK-II
Section 5 — Lubrication
Gyratory Crushers
GENERAL INFORMATION The SUPERIOR gyratory crusher is equipped with an external, skid mounted, split-flow lubrication system (Fig. 5-1). Oil is pumped from a storage tank, filtered, cooled and piped to the crusher through two separate feed lines and is returned to the storage tank by gravity flow. One of the oil lines enters the crusher through the HYDROSET cylinder (2005-0), passes through the piston (2205-0), the step bearing (2260-0, 2280-0, 4075-0), and eccentric bushing (1810-0), and lubricates these surfaces. The oil is forced outward through holes at the top of the eccentric bushing by centrifugal force and flows down between the eccentric (1805-0) and bottom shell bushing (1200-0) where it joins the second oil flow to lubricate the bushing and gears. Finally, the combined flow enters the sump below the pinionshaft housing and flows back to the storage tank by gravity. For illustration, see Section 4, Fig. 4-16.
NOTE Never run the crusher unless the lubrication system is operating and oil is returning to the storage tank. Warm oil temperature, with the crusher operating, should be the same in winter as in summer — 100 oF to 130oF (39oC to 54oC) for return oil from the crusher. (Depending on the viscosity of oil used). A properly functioning cooling system will keep the oil temperature within safe operating limits. Maintain oil temperature between 100 oF (39oC) and 115oF (46oC) when using an ISO Grade 68 oil (300 SSU viscosity at 100oF) and between 100oF (39oC) and130oF (54oC) when using an ISO Grade 150 oil (750 SSU viscosity at 100oF).
NOTE The proper type and viscosity of oil must be used for good crusher operation. Refer to lubricant recom- mendations (Section 13) for oil specifications.
IMMERSION OIL HEATER Oil temperature and viscosity are important when starting up the crusher. Oil returns to the bottom of the crusher and to the storage tank by gravity, and if viscosity is too high the oil return holes in the bottom shell may not be able to pass all the oil and it will overflow the dust collar. The result will be detrimental to some crushing operations. Immersion oil heaters keep the oil warm at all times, permitting use of the same oil grade in all seasons. Heater operation is controlled by a temperature switch (8850-0) mounted on the side of the storage tank. The switch is set to maintain oil temperature in the tank at approximately 90oF (32oC). See schematic control diagram, Fig. 5-2. 5-2
OIL STORAGE TANK The oil outlet is located above the tank (7005-0) bottom to provide a reservoir for sludge. To keep sludge from building up above the outlet level, clean the tank periodically — once a month, or more frequently if sludge accumulates rapidly. To clean the tank, disconnect the pump discharge line (7250-0) at the oil filter and pump the oil into drums. Drain off the remaining oil and sludge mixture through the oil drain plug (7270-0) and throw the mixture away. If the bulk of the oil pumped out of the tank is in good condition, it can be filtered and reused. Be sure to clean the tank thoroughly before replacing the oil. RETURN OIL SIEVE A return oil sieve (7150-0) is located under the inspection cover in the top of the storage tank. This wire mesh strainer will remove any large particles from oil returning to the tank. Check the sieve regularly for any unusual amount of metallic particles. LUBRICATING OIL PUMP (7205-0) Two complete oil pump assemblies, one primary and one back-up, are provided (Fig. 5-1) pre-piped with separate isolation valves and suction lines for each. Each assembly has an electric motor-driven, positive displacement gear pump for circulating oil to the crusher.
IMPORTANT Keep pump and motor properly aligned to assure sat- isfactory operation. When starting the lubrication system, be sure to check the pump for correct direction of rotation. With the pump operating correctly, flow monitors in the oil piping arrangement will indicate flow within five seconds after start-up. For additional information on pump operation and maintenance, refer to pump manufacturer’s instructions included in Appendix to this section. OIL FILTER The oil filter (7505-0) supplied with the external lubrication system is of the replaceable cartridge type. The filter elements will retain particles approximately 20 micron size and larger. Dual filters are provided so filter maintenance can be accomplished while the lube system and crusher are in operation. Each filter canister on the lube system contains one replaceable filter cartridge. With the valve arrangement, either of the filter canisters can be used in conjunction with either of the two lube oil pumps. The filter is supplied with an internal bypass. Pressure drop across the filters can be checked by the differential pressure gauge (7576-0). When pressure drop through the filter exceeds 25 psi (1.76 kg/cm 2), the bypass relief valve (7535-0) inside the filter housing will open, allowing 17X0115-05.0003
42-65 SUPERIOR MK-II
Section 5 — Lubrication
Gyratory Crushers
oil to flow through the bypass line. If this occurs when the lube oil is up to operating temperature, it indicates that the filter element is plugged with dirt and should be replaced. Some bypassing may occur if the lube system is started when the oil is cold and stifF This may be because of the increased viscosity of the oil and does not necessarily mean that the filter elements need to be replaced. However, if bypassing continues after the oil has reached normal operating temperature, the filter elements should be replaced. A differential pressure gauge (7576-0) provides an indication of the condition of the filter. When differential pressure exceeds 20 psi with the oil at normal operating temperature, the filter element should be replaced. The face of the gauge is marked “change filter” to indicate this condition. An optional differential pressure switch can be wired to sound an alarm or to activate a warning light when filter replacement is required. Filter maintenance is simple. If the disposable cartridge-type element becomes clogged with dirt, remove it and replace with a new element. With the dual filter arrangement, it is not necessary to shut the lube system and crusher down, since the alternate filter can be in operation when filter maintenance is being performed. To change the filter element, close the isolation valve (7405-0) on the inlet line to the filter. A check valve (7720-0) in the filter discharge line will prevent oil back-up into the filter. Drain the oil from the filter, using the drain plug at the side of the shell. Remove the filter cover and lift out the dirt filled element. Remove the bypass valve from the dirty element. Flush dirt out through the filter drain. Install a clean element, making sure that it is properly seated in the filter shell. Install the bypass valve assembly and fasten the cover securely in place. Be careful not to damage the seal. Refer to appendix, this section, Fig. 1 for illustration of filter. filter. Use the following procedure to place the filter unit in service. 1. Che Check ck and make make sure sure that that the the valve valve (7405 (7405-0) -0) on on the inlet side of the filter is completely closed. 2. Operate Operate eithe eitherr of the the lube lube oil pump pumps, s, making making sure sure the the isolation valves on both the suction and discharge lines are fully open. 3. Loosen the vent vent in the filter filter cover to permit permit any any en en-trapped air to bleed out of the filter enclosure as it is being filled with oil. 4. Partially Partially open the the va valve lve (7405-0 (7405-0)) on the inlet side of the filter, allowing a flow of oil to slowly and completely fill the filter.
IMPORTANT Be careful to prevent hydraulic hammer in the lubrica- tion system piping whenever opening or closing valves controlling oil flow through the filters. Ham- mering can severely damage filter elements and main body connections. 17X0115-05.0003
5. Allow the vent plug to remai remain n open open long long enough enough to to perpermit entrapped air to escape from the vented unit. As soon as a small amount of oil is seen to flow from the loosened vent plug, close the plug securely. securely. 6. Open the valve (7405-0) (7405-0) in the the filter filter inlet line completely to allow full flow of oil through the filter. LUBRICATION OIL COOLERS SUPERIOR gyratory crusher lubrication systems can be supplied with either an air-to-oil or a water-to-oil heat exchanger to maintain the oil at the proper operating temperature. Air-To-Oil Air-To-Oil Coolers SUPERIOR gyratory crushers are generally supplied with an air-to-oil type cooler. This unit consists of a radiator core through which the oil is circulated, and an electric momotor driven fan. The only maintenance required is to keep radiator surfaces free of dust accumulations by blowing them clean with compressed air. For piping arrangement see Section 4, Fig. 4-17. Install fans and radiators in an open area where the normal air temperature can adequately cool the circulating oil. Do not restrict air flow to the fans.
NOTE It is necessary to protect the cooler from high oil line pressure when the oil is cold. A lubrication oil bypass line is provided for this purpose, along with wi th a 40 psi (2.8 bar) relief valve. Be sure the bypass line has been installed per the drawing furnished with it.
NOTE Drain preservative oil from the cooler before starting the lubricating system. Air-to-oil cooler operation is controlled by a temperature switch (7179-0) in the return oil line. This switch will turn on the cooler fan when return oil temperature reaches 110oF (44oC). Fan will be turned off when the return oil temperature drops to 100 oF (38oC). See schematic diagram, Fig. 5-3. Water-To-Oil Coolers SUPERIOR gyratory crusher lubrication systems are supplied with a condenser-type cooler as standard equipment. The cooler reduces oil temperature by passing it around water-cooled bronze tubes. The cooler has two connections for cooling water on one end. Under normal conditions the crusher will require from 10 to 80 gallons (38 to 300 liters) per minute of cooling water. The amount of water depends on water temperature, crusher setting and stone hardness. Maintain oil temperature between 100 oF (39oC) and 115oF (46oC) when using an ISO Grade 68 oil (300 SSU viscosity @ 100oF) and between 100 oF (39oC) and 130oF (54oC) when using an ISO Grade 150 oil (750 SSU viscos5-3
42-65 SUPERIOR MK-II
Section 5 — Lubrication
Gyratory Crushers
ity @ 100oF). If it levels off somewhere between these readings, the cooler is getting an adequate supply of cooling water. When cooling water is scarce, use a storage tank and re-circulate the water by pumping.
NOTE Drain water from the cooler in winter, when not oper- ating. Water Water freezing in the cooler will cause serious damage. Refer to heat exchanger instructions included in Appendix to this section for further information. OIL FLOW DIVIDER CIRCUIT The oil flow from the external lubrication system is divided to supply oil to the two lubrication oil inlets on the crusher. This is accomplished by means of a flow regulator (7805-0) and a relief valve (7875-0) located near the discharge end of the oil cooler. cooler. The flow regulator allows approximately one-half the output gallonage of the lubricating oil pump to pass through to the inlet on the HYDROSET control cylinder. Any excess will open the relief valve and pass through to the inlet on the bottom shell bushing. It is important to understand two points about circuit operation: 1. Oil must must first first pass pass th through rough the flow regulator regulator before before any oil will pass through the relief valve. 2. The flow regul regulator ator holds the rate rate of flow flow at its set set gallogallonage regardless of variations in applied pressure. However, the relief valve operates on a set applied pressure which must be exceeded before any oil will pass through. FLOW MONITORS Oil flow monitors (7850-1 and and -2) are installed in the two feed lines to the crusher. Their operation depends upon the pressure exerted by the oil flow, which forces a vane open against a holding spring. Vane movement is transmitted through a lever system to a micro-switch. See Appendix for adjustment information and parts list.
5-4
Interlocking the flow monitors to the crusher drive motor provides the means for shutting down the crusher should there be a loss or a set reduction of oil flow in either of the two feed lines. See “Suggested Control Systems” and associated schematics on page 5-8. Each flow switch should be set to actuate if flow falls below 11 GPM (42 LPM). Normal flows is15 GPM (57 LPM) respectively. See section in appendix “Setting the Switch Point” on the flow monitors. TEMPERATURE TEMPERATURE SWITCH A high temperature limit switch (7170-0) is supplied in the return oil line from the crusher to the oil storage tank. See “Suggested Control Systems” and associated control schematics, below. This switch should be set to open at 125oF (52oC) when using an ISO Grade 68 oil (300 SSU viscosity oil @ 100 oF) and 135oF (57oC) when using an ISO Grade 150 oil (750 SSU viscosity oil @ 100 oF). The normal factory setting is 125 oF (52oC). When interlocked to the crusher drive motor it provides the means for shutting down the crusher should the oil become too hot. The temperature switch setting is adjustable. If normal operating oil temperature as read on the dial thermometer (see below) is below 115 oF (46oC), we suggest that the setting be left at approximately 125oF (52oC). This will provide a warning if any unusual temperature rise occurs.
NOTE Never disconnect warning devices such as flow switches and high temperature switches. They are intended to indicate trouble which should be identified and remedied. Keep devices clean, closed and dust-tight when the crusher is operating. TEMPERATURE TEMPERATURE GAUGE A dial thermometer (7175-0) is provided in the return oil line. Read this thermometer at regular intervals during crusher operation. Investigate any unusual rise over normal operating temperature.
17X0115-05.0003
42-65 SUPERIOR MK-II
Section 5 — Lubrication
Gyratory Crushers
TERMINAL JUNCTION BOX 8608–0 8225–0 7170–0 8104–0
HYDROSET PIPE CENTERLINE
8609–9 7177–0 OPTIONAL
VENT PIPE CENTERLINE
8005–3 OPTIONAL 8005–5
[INCH] 3.00” NPTI (FEMALE) OIL RETURN
7005–8
7005–3 OPTIONAL
7005–5
7181–0 OPTIONAL 8825–0 7005–8
7405–0
8850–0
7205–0
7405–0
7205–0
7705–0 7175–0 7576–0 7510–0 7005–0 7505–0
VENT PIPE CENTERLINE
[INCH] 1.00” NPTI (FEMALE) PRESSURE BREATHER PORT 7505–0 7120–0
OIL RETURN 7150–0 7005–8 7405–0 7875–0 7850–2 1.0” NPT (FEMALE) OIL OUTLET PORT 7850–1 7805–0 [INCH] 2.00” NPTI OIL (FEMALE) DRAINS OIL DRAINS
WATER PORTS 1.5” NPT (FEMALE) 7005–0
SK071698–JJB–2
7705–0
FIG. 5-1a — External oil conditioning system (water cooler) Catalog Number
Description
7005-0 7005-3 7005-5 7005-8 7120-0 7150-0 7170170-0 0 7175-0 7177-0 7179-0 7181 7181-0 -0 7205-0 7405-0 7505-0 7510- 0
Base and ta t ank assembly Lube oil level sensor (optional) Inspection co cover Sight gauge Pressure breather Sieve High temp temper erat atur ure e sh shut-d ut-dow own n sw switch tch (TS (TS-3 -3)) Thermometer Oil return temp. probe (optional) Temperature sw switch (c (cooler) (T (TS-1) Lube Lube tank tank oil oil tem temp. p. sens sensor or asm asm (op (opti tion onal al – not not show shown) n) Lube pumping unit Ball valve Filter Pressure gauge 0 - 200 PSI (1 (18.8 KPa)
17X0115-05.0003
Catalog Number
Description
7576 7576-0 -0
Diff Differ eren enti tial al pres pressu sure re gaug gauge e (swi (switc tch h opti option onal al))
7705-0 7720-0 7805-0 7850-1 7850-2 7875-0 8005005-3 3 8104-0 8225-0 8608-0 8609-9 8825-0 8850-0
Cooler Check valve Flow regulator Flow switch (FS-1) lower Flow switch (FS-2) upper Relief valve HYDROSE OSET oil oil level evel sens sensor or (op (optio tional) nal) HYDROSET pumping unit Ball valve Control valve assembly HYDROSET filter cartridge Immersion he heater Heater control switch (TS-2)
5-5
42-65 SUPERIOR MK-II
Section 5 — Lubrication
Gyratory Crushers
TERMINAL JUNCTION BOX 8608–0
8225–0 7170–0
HYDROSET PIPE CENTERLINE
8104–0 8609–9
7179–0 7177–0 OPTIONAL
VENT PIPE CENTERLINE
8005–3 OPTIONAL [INCH] 3.00” NPTI (FEMALE) OIL RETURN
8005–5
7005–8 7005–5
7005–3 OPTIONAL
7181–0 OPTIONAL 8825–0 7005–8 7405–0 8850–0 7205–0
7405–0 LUBE SYSTEM OUTPUT CONNECTION 7205–0
7175–0 7576–0 7510–0
VENT PIPE CENTERLINE
7005–0 7505–0
[INCH] 1.00” NPTI (FEMALE) PRESSURE BREATHER PORT 7505–0 7120–0
OIL RETURN
7150–0
7405–0 7005–8 7720–0
7720–0 7205–0
[INCH] 2.00” NPTI (FEMALE) OIL OIL DRAINS DRAINS 7005–0
FIG. 5-1b — External oil conditioning system (air cooler)
5-6
17X0115-05.0003
42-65 SUPERIOR MK-II
Section 5 — Lubrication
Gyratory Crushers
Control transformer furnished by customer
Temperature switch (8850-0)
OPEN @ 90o F CLOSE @ 86o F
Magnetic contactor furnished by customer
Immersion heater (8825-0) Magnetic contactor
Immersion heater (8825-0)
623153-85 FIG. 5-2 — Schematic diagram for immersion heater connections. Indicator light furnished by customer
Oil-to-air heat exchangers temperature switch (7179-0) CLOSES @ 110o F
Heat exchangers running
OPENS @ 100o F
Oil-to-air heat exchangers motor starter furnished by customer
17-103-940-401 FIG. 5-3 — Schematic diagram for oil-to-heat exchanger connections 17X0115-05.0003
5-7
42-65 SUPERIOR MK-II
Section 5 — Lubrication
Gyratory Crushers
SEDIMENT SEPARATORS Two Y-pattern sediment separators are furnished along with the external lubrication package for every SUPERIOR gyratory crusher. Separators are provided as a means for collecting rust, scale, pipe sealant and other foreign particles from the lubricating oil to reduce the possibility of bearing damage from oil-borne contaminants. Mount the separator as shown in Fig. 4-16 and 5-4 to assure proper flow of the oil through the screening device, locating one in each of the two oil inlet lines, as close to the crusher as possible. Clean the separators after each eight hours of operation during break-in and the first week of full operation, and once a week thereafter. A flow indicator is mounted in each of the two supply connections from the oil flow divider circuit. Plugging of the separator in either oil line will be indicated by the associated flow meter. In extreme cases, the lube oil pump motor overload relays may stop the pump and shut down the crusher. Toward crusher
FIG. 5-4 — Sediment separators are furnished for customer installation in lube lines to crusher.
In either event, with the crusher shut down, disassemble the separators and thoroughly clean the screen with a non-toxic solvent. For disassembly, simply unscrew the bronze cap from the separator housing and slide the screen out. After cleaning, re-insert the screen and replace the cap on both separators, and resume normal operation. SUGGESTED CONTROL SYSTEMS Numerous control system possibilities can be used to protect the crusher during operation. Two typical control systems are described here, along with associated electrical schematic drawings. These two systems require a mini5-8
mum amount of additional electrical equipment. Further interlocking is possible with additional switches, control relays, time delay relays, etc. Control Arrangement No. 1 (Fig. 5-5) This basic control arrangement shows the minimum recommended interlocking between the lubrication system and the crusher. With this arrangement, the crusher drive motor cannot be started unless a sufficient amount of lube oil is flowing through each of the feed line flow switches, and the lube oil temperature is below the maximum safe operating temperature. If oil flow through either of the two feed line flow switches drops below the safe minimum value during operation, a “low oil flow” warning signal will be actuated and the crusher drive motor will be shut down. Likewise, if return oil temperature rises above the safe operating limit, a “high oil temperature” warning signal will be actuated and the crusher drive motor will be shut down. The optional filter differential pressure switch, if provided, should be connected to an indicator or alarm which will warn the operator that the lube oil is bypassing the filter. Control Arrangement No. 2 (Fig. 5-6) This arrangement gives the same basic protection as control arrangement No. 1, but with two added features. It adds an interlock between the crusher discharge conveyor and the crusher, and between the crusher drive motor and the feeder. With this arrangement, the crusher drive motor cannot be started unless a sufficient amount of lube oil is flowing through each of the feed line flow switches, the lube oil is below the maximum safe operating temperature, and the crusher discharge conveyor is operating. In addition, the feeder to the crusher cannot be started unless the crusher is running. This control scheme provides the following crusher protection. Should oil flow through either of the two feed line flow switches drop below the safe minimum value, a “low oil flow” warning signal will be activated and the crusher drive motor will be shut down. If return oil temperature rises above the safe operating limit, a “high oil temperature” warning signal will be activated and the crusher drive motor will be shut down. A zero speed switch on the crusher discharge conveyor will also shut down the crusher, if the discharge conveyor stops. This will prevent crushed material from backing up underneath the crusher and causing damage. In all instances, shutting down the crusher drive motor will cause feed to the crusher to be stopped, due to electrical interlocking between the crusher drive motor and the feeder drive. This will prevent feed spill overs when the crusher is shutdown. The optional filter differential pressure switch (if provided) should be connected to an indicator or alarm which will warn the operator that lube oil is bypassing the filter. 17X0115-05.0003
42-65 SUPERIOR MK-II
Section 5 — Lubrication
Gyratory Crushers
LIGHT OR OTHER SUITABLE WARNING DEVICE FURNISHED BY CUSTOMER LUBE OIL FLOW SWITCH IN HYDROSET CYLINDER LINE - 1 NO & 1 NC CONTACT
LUBE OIL FLOW SWITCH IN BOTTOM SHELL BUSHING LINE - 1 NO & 1 NC CONTACT
HIGH OIL TEMPERATURE START
STOP
HIGH OIL TEMPERATURE ALARM SWITCH IN RETURN LINE - 1 NO & 1 NC CONTACT
CRUSHER DRIVE MOTOR STARTER FURNISHED BY CUSTOMER LOW OIL FLOW
STOP
DIFFERENTIAL PRESSURE SWITCH IN FILTER BY-PASS (OPTIONAL)
LIGHT OR OTHER SUITABLE WARNING DEVICE FURNISHED BY CUSTOMER
START
LUBE PUMP MOTOR STARTER FURNISHED BY CUSTOMER LUBE PUMP MOTOR STARTER FURNISHED BY CUSTOMER
FILTER BY-PASSING
LIGHT OR OTHER SUITABLE WARNING DEVICE FURNISHED BY CUSTOMER
17-201-136-401
FIG. 5-5 — Control Arrangement No. 1 ZERO SPEED SWITCH ON CRUSHER DISCHARGE CONVEYOR FURNISHED BY CUSTOMER
LIGHT OR OTHER SUITABLE WARNING DEVICE FURNISHED BY CUSTOMER LUBE OIL FLOW SWITCH IN HYDROSET CYLINDER LINE - 1 NO & 1 NC CONTACT
LUBE OIL FLOW SWITCH IN BOTTOM SHELL BUSHING LINE - 1 NO & 1 NC CONTACT
HIGH OIL TEMPERATURE START
STOP
HIGH OIL TEMPERATURE ALARM SWITCH IN RETURN LINE 1 NO & 1 NC CONTACT
CRUSHER DRIVE MOTOR STARTER FURNISHED BY CUSTOMER LOW OIL FLOW
STOP
START
LIGHT OR OTHER SUITABLE WARNING DEVICE FURNISHED BY CUSTOMER
LUBE PUMP MOTOR STARTER FURNISHED BY CUSTOMER
STOP
LUBE PUMP MOTOR STARTER FURNISHED BY CUSTOMER START
DIFFERENTIAL PRESSURE SWITCH IN FILTER BY-PASS (OPTIONAL)
CONTACT IN CRUSHER MOTOR STARTER
FEEDER MOTOR STARTER FURNISHED BY CUSTOMER FEEDER MOTOR STARTER FURNISHED BY CUSTOMER
LIGHT OR OTHER SUITABLE WARNING DEVICE FURNISHED BY CUSTOMER
FILTER BY-PASSING
17-201-137-401
FIG. 5-6 — Control Arrangement No. 2 17X0115-05.0003
5-9
Lubrication Pumps
MAINTENANCE AND REPAIR
for Crusher Circulating Oil Lubrication Systems
March 2000 Supersedes November 1998
CIRCULATING OIL LUBRICATION PUMP An electric motor-driven, positive displacement gear pump circulates lubricating oil to the crusher’s eccentric gearing, thrust bearing and critical bearing surfaces in the eccentric bearing assembly. The pump is mounted on the base of the circulating oil lubrication system, immediately next to the oil reservoir, and connected to the reservoir by piping. A gate valve in the suction line makes it possible to shut off the oil supply when working on the pump and other components of the circulating oil lubrication system. An internal safety relief valve, mounted on the head of the pump, will relieve excessive oil pressure in the pump, and serve as a protective device for other components in this system. Figure 1 illustrates how the pump works. As the pumping elements (gears) come out of mesh, point A, oil is drawn in to the suction port from the piping. The oil travels three-quarters of the circumference of the pump casing (270o), from the suction port to the discharge port. As the pumping elements (gears) come out of mesh, point B, oil is forced out the discharge port and into the piping. The pumping elements (gears) return to point A to repeat the cycle. In order for the pump to work properly, the oil must travel the longest circumferential distance between ports.
DISCHARGE PORT
“A”
B”
PUMP CASING
SUCTION
DISCHARGE
SUCTION
DISCHARGE
LEFT HAND PUMPS SUCTION
DISCHARGE
DISCHARGE
SUCTION
RIGHT HAND PUMPS
FIG. 2 – Determining port functions from direction of shaft rotation.
COUPLING ALIGNMENT The pump, reducer (if used) and motor were properly aligned at the time they were assembled. However, the alignment of the couplings may have been disturbed during shipping and mounting. CHECK THE ALIGNMENT BEFORE OPERATING THE PUMP.
CAUTION SUCTION PORT
Shut OFF, lockout and tag all power to the circulating oil lubrication system before performing any inspection, maintenance, adjustment or lubrication on the pumping unit.
IDLER PIN ON PUMP HEAD
ROTOR
ROTOR GEARS DIRECTION OF PUMP ROTATION OIL TRAVELS BETWEEN GEAR TEETH AND CASING AROUND THE LONGEST CIRCUMFERENTIAL DISTANCE BETWEEN PORTS
FIG. 1 – Cutaway view of the lubricating pump from the head end.
To determine which port is suction and which is discharge, always look at the direction of rotation of the pump shaft when viewing the shaft end of the pump. The oil must travel the longest circumferential distance between ports. 17x11113–03.0003
Use the following procedures to check or align couplings. 1. With the pumping unit on its operating foundation, level the unit by using shims or wedges at the foundation bolts. Additional shims or wedges may be needed for the long sides of the longer bases. 2. When the pumping unit base is level and properly shimmed, snug down all foundation bolts. 3. If the piping is already in place, check the pump parts to be sure that they are in alignment with the piping. Shim and align the pump as required. Tighten pump mounting bolts. All alignment from this point on should be done without moving the pump. 4. Remove any coupling guards or covers. 1
Lubrication Pumps
MAINTENANCE AND REPAIR
for Crusher Circulating Oil Lubrication Systems
March 2000 Supersedes November 1998 B STRAIGHT EDGE ±.005
in (0.13 cm.)
8. A final alignment check should be made after any piping is connected to the pumping unit to be certain that there are no piping strains on the pump casing.
A COUPLING HALF ±.008
in (0.20 cm.)
COUPLING INSERT
DO NOT ROTATE COUPLING DURING ALIGNMENT PROCESS
±.005
in (0.13 cm.)
C
PARALLEL ALIGNMENT (A)
The pumping unit jaw couplings have a built–in spacing feature. Raised dots on each side of t he coupling insert give the correct premeasured gap between the coupling jaw and the insert body. Align the coupling so that a straightedge rests squarely or within .008 in (0.20 cm.) on the coupling hubs. The clearance at dimension A must not exceed the offset limit of .008 in (0.20 cm.). Repeat this procedure at 90–degree intervals. ANGULAR ALIGNMENT (B)
To check the angular alignment, measure the gap at dimension B. Next, measure the gap 180 degrees from B, at dimension C. The dimension at C should be the same as the dimension at B, or within plus or minus .005 in (0.13 cm.). Repeat this procedure at 90–degree intervals. If this procedure is done correctly, it will limit the angular misalignment to within one degree. After checking the angular alignment, recheck the parallel alignment.
FIG. 3 – Alignment procedure for pumping unit jaw couplings.
5. If the pump is driven through a reducer, check the alignment of the coupling between the reducer and the pump. See Figure 3. If any realignment is needed, move and/or shim the reducer. Tighten the reducer mounting bolts when alignment is correct. 6. Check the alignment of the coupling between the reducer and the motor. See Figure 3. If any realignment is needed, move and/or shim the motor. Tighten the motor mounting bolts. Recheck the coupling between the reducer and the pump to be sure that this alignment did not change. 7. If the pump is connected direct to the motor (no reducer), check the alignment of the coupling
2
between the motor and the pump. Follow steps 1–4 and refer to Figure 3. If any realignment is needed, move and/or shim the motor.
9. Replace coupling covers and guards. 10. Remove any warning tags and lockout devices before turning ON power to the circulating oil lubrication system. PUMP MAINTENANCE Performing these preventive maintenance procedures will help to extend the life of the pump. Lubrication – Grease all lubrication fittings on the pump every 500 hours of operation or every sixty (60) days, whichever occurs first. If service is severe, grease more often. Do not over grease the bearing. Use a hand-type grease gun. Pressurized grease guns can damage bearing seals. Use an NLGI #2 grease for normal applications. Consult a grease lubricant manufacturer to determine the appropriate grease for extreme hot or cold applications. Examine Internal Parts – Periodically remove the pump head and examine the idler, idler bushing, idler pin and the pump head. Replacing a relatively inexpensive idler bushing and idler pin after only moderate wear may eliminate the need to replace more expensive parts at a later date. See “Pump Disassembly” for instructions in removing the pump head and replacing parts. Clean the Pump – Keep the pump exterior as clean as possible. This will result in easier inspection, adjustment, lubrication and repair work. A clean pump will also run cooler. End Clearance Adjustment After long term operation, it is sometimes possible to improve pump performance without major repair, through adjustment of the end clearance. See instructions on ”Thrust Bearing Adjustment” in this section. Storage – If a pump is to be out of service or stored for more than six (6) months, drain it and protect it from rust and corrosion. Apply a light coat of lubricating and preservative oil to the internal parts and the exterior housing. Grease all lubrication fittings.
17x11113–03.0003
Lubrication Pumps
MAINTENANCE AND REPAIR
for Crusher Circulating Oil Lubrication Systems
March 2000 Supersedes November 1998
1 2 3 4
10 11 12 13
19 20 21 22
28 29 30 31
5
14
23
32
6 7 8 9
15 16 17 18
24 25 26 27
33
FIG. 4 – Exploded view of circulating oil lubrication pump (Model KK125) with packing gland.
CAUTION
Pump Disassembly – Model KK125 (Packing Gland) (FIG. 4) (Units sold prior to January 1998)
One of three conditions will occur when the pump head (27) is separated from the pump casing (20). 1. The idler (23) may be in the rotor (22) when the head (27) is removed. 2. The idler (23) may be on the idler pin (26) and be removed with the head (27). 3. The idle, (23) may drop out between the head (27) and the casing (20), when the head is separated from the casing, and can cause personal injury.
CAUTION Shut OFF, lockout and tag all power to the circulating oil lubrication system before performing any inspection, maintenance, adjustment or lubrication on the pumping unit. Vent any pressure from the pump casing before disassembly.
1. Remove the pump from the pumping unit foundation and place it on a clean, sturdy working surface.
4. Slowly remove the head (27) from the casing (20).Tilt the top of the head back as it is being removed from the casing to avoid dropping the idler. 5. Remove the idler and bushing assembly (23).
2. Mark the head and casing of the pump before disassembly to make sure the parts are reassembled properly. This is done to ensure that the idler pin, which is offset in the pump head, is positioned toward and between the port connections to allow for proper flow of liquid through the pump. 3. Loosen and remove the capscrews (30) from the pump head (27). Slowly remove the head from the pump casing (20), being careful not to damage the head gasket (25). 17x11113–03.0003
NOTE The safety relief valve (33) does not have to be disassembled or removed from the pump head (27) at this time. See instructions under “Pump Safety Relief Valve” in this section. 6.
Insert a piece of hardwood or brass rod in to one of the casing ports and between the teeth of the rotor to prevent the rotor and shaft assembly from turning during loosening. 3
Lubrication Pumps
MAINTENANCE AND REPAIR
for Crusher Circulating Oil Lubrication Systems
March 2000 Supersedes November 1998
7. Bend up a tang on the lockwasher (2) and with a spanner wrench remove the locknut (1) and lockwasher (2) from the rotor shaft (22). Remove the piece of hard wood or brass rod from the rotor. 8. Remove the packing gland nuts (11). 9. Tap the rotor shaft assembly (22) forward approximately 1/2 in (13 mm) and check for a pair of half circle, round wire rings (8) under the inner bearing spacer collar (7).These rings must be removed before the rotor and shaft assembly can be removed from the pump. Remove the pair of rings (8). (The half circle, round wire rings are not used on HL size pumps.) See Figure 5.
NYLON INSERT
SET SCREWS OUTER END CAP (3)
INNER END CAP (9)
LOCKWASHER (2)
HALF ROUND RINGS (8)
LOCKNUT (1)
ROTOR SHAFT (22)
INNER SPACER COLLAR (7) INNER LIP SEAL (4) BALL BEARING (6)
OUTER SPACER COLLAR (5) OUTER LIP SEAL (4)
BRACKET (17)
FIG. 5 –Cutaway view of pump bearing assembly on the bracket.
10. Carefully remove the rotor and shaft assembly (22) to avoid damaging the bracket bushing (15). 11. Remove the packing gland (10) from the side of the bracket (17). 12. Loosen the four set screws (two on HL size pumps) in the bearing housing area of the bracket (17). Use a spanner wrench to remove both end caps (3 and 9), both lip seals(4), both bearing spacer collars (5 and 7) and the bearing (6). The inner end cap (9) can be removed through the side opening of the bracket. See Figure 5. 13. Remove the packing (13) and the packing retainer washer (14). 14. Clean all parts thoroughly and examine for wear and damage. Check lip seals, ball bearing, bushings and idler pin, and replace if necessary. Check all other parts for nicks, burrs, excessive wear or damage, and replace if necessary. Scratches on the shaft in the packing area may cause leakage paths under the packing. The pump casing can be checked for wear or damage while still mounted on the bracket. 4
Pump Assembly – Model KK125 (Packing Gland) (FIG. 4) 1. Install the bracket bushing (15) in the bracket (17). 2. Install the rotor and shaft assembly (22) in the bracket (17). Start the end of the shaft in the bracket bushing (15) and turn the rotor slowly in a counterclockwise direction while pushing it into the pump casing (20). 3. Place the packing retainer washer (14) in the bottom chamber on the pump bracket and pack the pump using new packing (13). Packing should be suitable for the oil being pumped and the conditions of operation. Install and seat each ring of packing (13) one at a time, staggering the ring joints from one side of the rotor shaft to the other. Lubricate the packing rings with oil, grease or graphite to aid assembly. A length of pipe or tubing will help to install and seat each packing ring. 4. Install the packing gland (10), capscrews (12) and nuts (11). Back the rotor and shaft assembly out of the casing just far enough to insert the packing gland through the side opening of the bracket and over the end of the rotor shaft. The packing gland cannot be installed with the rotor and shaft assembly in place. Make sure the packing gland is installed evenly and the nuts are tightened evenly. Tighten the nuts wrench-tight and then back off until the packing gland is slightly loose. 5. Coat the idler pin (26) with a light oil and place the idler bushing (24) and idler (23) on the idler pin in the head (27). 6. Put a .010 in (.025 cm) to .015 in (.038 mm) head gasket (25) on the pump head and install the head (27) and idler (23) assemblies on the pump casing (20). Tighten all the head capscrews (30). If the safety relief valve (33) was disassembled from the head, it can be installed now or installed after the pump is completely assembled. See instructions on ”Pump Safety Relief Valve” in this section. 7. Slide the inner bearing spacer collar (7) over the rotor shaft with the recessed end of the spacer collar toward the rotor. (Spacer collars on HL size pumps are not recessed.) See Figure 5. 8. Place the pair of half circle, round wire rings (8) in the shaft groove and slide the inner bearing spacer collar over them. (The half circle, round wire rings are not used on HL size pumps.) 9. Press the inner lip seal (4), with the lip toward the shaft end, into the inner end cap (9). Insert the inner end cap through the shaft end of the bracket (17).Turn the inner end cap clockwise (when looking from the shaft end) until it engages the threads. The spanner wrench holes in the end cap must be facing the rotor. Turn the end cap with a spanner wrench until it projects slightly into the opening on the side of the bracket. See Figure 5. 17x11113–03.0003
Lubrication Pumps
MAINTENANCE AND REPAIR
for Crusher Circulating Oil Lubrication Systems
March 2000 Supersedes November 1998
NOTE
13. Install the lockwasher (2) and locknut (1) on the shaft and tighten. Bend one tang of the lockwasher into the slot on the locknut. Remove the piece of hardwood or brass rod from the pump casing.
The inner end cap (9) must not be turned so far that the lip of the lip seal (4) drops off the end of the spacer collar on the shaft or that the end cap disengages the bracket threads.
14. Adjust the pump end clearance. See instructions on “Thrust Bearing Adjustment” in this section.
10. Pack the ball bearing (6) with an NLGI #2 grease. Place the bearing on the shaft and push or gently tap it into position in the bracket.
15. If removed during disassembly, install the safety relief valve (33) so the valve cap is pointing toward the suction port. See instructions on “Pump Safety Relief Valve” in this section.
11. Install the outer lip seal (4), with the lip toward the shaft end, and the outer bearing spacer collar in the outer end cap (3). Turn the end cap into the bracket until it is tight against the bearing.
16. Install the pump on the pumping unit base. Refer to the instructions on “Coupling Alignment” in this section, to insure that the pump is properly installed and aligned before operating.
12. Insert a piece of hardwood or brass rod into one of the casing ports and between the teeth of the rotor to prevent the rotor shaft from turning during tightening.
17. Install all guards. Remove any warning tags or lockout devices before turning ON power to the circulating oil lubrication system.
PUMP DISASSEMBLY (FIG. 6) MECHANICAL SEALS (TEFLON FITTED TYPE) MODEL KK4125 Superseded Model KK125 in January 1998.
1 2 3 4
9 10 11 12
17 18 19 20
25 26 27 28
5 6 7 8
13 14 15 16
21 22 23 24
29 30 31
Fig. 6 — Exploded view of circulating oil lubrication pump (KK4125) with mechnical seals
Pump Disassembly (Mechanical Seals) (Fig. 6) (Units sold after January 1998.
CAUTION Shut OFF, lockout and tag all power to the circulating oil lubrication system before performing any inspection, maintenance, adjustment or lubrication on the pumping unit. Vent any pressure from the pump casing before disassembly.. 17x11113–03.0003
1. Remove the pump from the pumping unit foundation and place it on a clean, sturdy working surface. 2. Mark the head and casing of the pump before disassembly to make sure the parts are reassembled properly. This is done to ensure that the idler pin, which is offset in the pump head, is positioned toward and between the port connections to allow for proper flow of liquid through the pump. 3. Loosen and remove the capscrews (28) from the pump head (25). Slowly remove the head from the 5
Lubrication Pumps
MAINTENANCE AND REPAIR
for Crusher Circulating Oil Lubrication Systems
March 2000 Supersedes November 1998
pump casing (18), being careful not to damage the head gasket (23).
CAUTION One of three conditions will occur when the pump head (25) is separated from the pump casing (18). 1. The idler (21) may be in the rotor (20) when the head (25) is removed. 2. The idler (21) may be on the idler pin (24) and be removed with the head (25). 3. The idler (21) may drop out between the head (25) and the casing (18), when the head is separated from the casing, and can cause personal injury. 4. Slowly remove the head (25) from the casing (18).Tilt the top of the head back as it is being removed from the casing to avoid dropping the idler. 5. Remove the idler and bushing assembly (21).
12. Examine seal chamber lip seal (10) and remove if it shows wear or damage. Lip seal must be removed if bracket bushing (15) needs to be replaced. 13. Clean all parts thoroughly and examine for wear and damage. Check lip seals, ball bearing, bushings and idler pin, and replace if necessary. Check all other parts for nicks, burrs, excessive wear or damage, and replace if necessary. The pump casing can be checked for wear or damage while still mounted on the bracket. Pump Assembly (Mechanical Seals) (Fig. 6) 1. Install bracket bushing (15) in bracket (13). When installing carbon graphite bushing, extreme care must be taken to prevent breaking. Carbon graphite is a brittle material and easily cracked. If cracked, the bushine will quickly disintegrate. Using a lubricant and adding a chamfer on the bushing and the mating part will help in installation. The additional precautions listed below must be followed for proper installation: a. A press must be used for installation. b. Be certain bushing is started straight.
NOTE The safety relief valve (31) does not have to be disassembled or removed from the pump head (25) at this time. See instructions under “Pump Safety Relief Valve” in this section. 6. Insert a piece of hardwood or brass rod in to one of the casing ports and between the teeth of the rotor to prevent the rotor and shaft assembly from turning during loosening. 7. Bend up a tang on the lockwasher (2) and with a spanner wrench remove the locknut (1) and lockwasher (2) from the rotor shaft (20). Remove the piece of hard wood or brass rod from the rotor.
c.
Do not stop pressing operation until bushing is in proper position. Starting and stopping will result in a cracked bushing.
d. Check bushing for cracks after installation. 2. Install lip seal (10) in bracket (13). 3. Clean the rotor hub Fig. 9 and bracket seal housing bore (13), Fig. 6. Make sure both are free from dirt and grit. Coat outer diameter of seal seat gasket and inner diameter of seal housing bore (13) with non-detergent SAE30 weight oil. INSTALLATION TOOL
ANTI-ROTATION PINS ALIGNED WITH SLOTS IN BUSHING
8. Tap the rotor shaft assembly (20) forward approximately 1/2 in (13 mm) and check for a pair of half circle, round wire rings (8) under the inner bearing spacer collar (7).These rings must be removed before the rotor and shaft assembly can be removed from the pump. Remove the pair of rings (8). (The half circle, round wire rings are not used on HL size pumps.) See Figure 5. 9. Carefully remove the rotor and shaft assembly (20) to avoid damaging the bracket bushing (15). 10. Remove rotary member of seal (16) from shaft and stationary seal seat (16) from bracket (13). 11. Loosen the four set screws (two on HL size pumps) in the bearing housing area of the bracket (13). Use a spanner wrench to remove both end caps (3 and 9), both lip seals(4), both bearing spacer collars (5 and 7) and the bearing (6). The inner end cap (9) can be removed through the side opening of the bracket. See Figure 5. 6
COAT WITH LIGHT OIL BEFORE ASSEMBLY BRACKET SEAL HOUSING BORE WITH SEAL SEAT INSTALLED. NOTE SPECIAL INSTALLATION TOOL USED FOR FACTORY ASSEMBLY
17x11113–03.0003
Lubrication Pumps
MAINTENANCE AND REPAIR
for Crusher Circulating Oil Lubrication Systems
March 2000 Supersedes November 1998 FIG. 7 — Bracket seal housing bore with seal seat installed.
4. Start seal seat in seal housing bore. Make sure seat anti-rotation pins (if provided) are aligned to engage slots in end of bracket bushing. Refer to Figure 7. 5. Using a cardboard disc to protect lapped face of seal seat, press seal seat assembly to bottom of seal housing bore using a piece of wood. An arbor press can also be used to install the seal seat. Seal seat must be started square and carefully pressed to bottom of seal housing bore. TAPERED INSTALLATION SLEEVE
MECHANICAL SEAL ROTARY MEMBER
SHAFT
FIGURE 8
6. Place tapered installation sleeve (furnished with H, HL, K, KK, L, LQ and LL size replacement mechanical seals) on shaft. Refer to Figure 8. Coat inner diameter of seal rotary member, tapered installation sleeve and the shaft with a generous quantity of non-detergent SAE30 weight oil. Place rotary member on shaft over sleeve and against hub of rotor. Refer to Figure 9.
clips to release springs after seal is installed on shaft. Tighten all drive setscrews securely to shaft. 7. Coat the rotor shaft (20) with non-detergent SAE30 weight oil. Start the end of the shaft in the bracket bushing (15) and turn the rotor slowely in a counterclockwise direction while pushing it into the pump casing (18) until the end of the rotor teeth are just below the face of the casing. 8. Using a .010 to .015 inch head gasket (23), install head (25) and idler assembly (21) on pump. Pump head and casing were marked before disassembly to ensure reassembly. If the internal relief valve (31) was disassembled from the head, it can be installed now or installed after the pump is completely assembled. See instructions on “Pump Safety Relief valve” in this section. Tighten all head capscrews (28) evenly. 9. Remove tapered installation sleeve (Fig. 8) from the shaft. 10. Slide the inner bearing spacer collar (7) over the rotor shaft with the recessed end of the spacer collar toward the rotor. (Spacer collars on HL size pumps are not recessed.) See Figure 5. 11. Place the pair of half circle, round wire rings (8) in the shaft groove and slide the inner bearing spacer collar over them. (The half circle, round wire rings are not used on HL size pumps.) 12. Press the inner lip seal (4), with the lip toward the shaft end, into the inner end cap (9). Insert the inner end cap through the shaft end of the bracket (13).Turn the inner end cap clockwise (when looking from the shaft end) until it engages the threads. The spanner wrench holes in the end cap must be facing the rotor. Turn the end cap with a spanner wrench until it projects slightly into the opening on the side of the bracket. See Figure 5.
NOTE ROTOR HUB MECHANICAL SEAL ROTARY MEMBER
SHAFT
1/4 Inch thick spacer collar used here on”K” size pump.
FIGURE 9
Some Teflon seals are equipped with holding clips which compress the seal springs. Remove holding 17x11113–03.0003
The inner end cap (9) must not be turned so far that the lip of the lip seal (4) drops off the end of the spacer collar on the shaft or that the end cap disengages the bracket threads. 13. Pack the ball bearing (6) with an NLGI #2 grease. Place the bearing on the shaft and push or gently tap it into position in the bracket. 14. Install the outer lip seal (4), with the lip toward the shaft end, and the outer bearing spacer collar in the outer end cap (3). Turn the end cap into the bracket until it is tight against the bearing. 15. Insert a piece of hardwood or brass rod into one of the casing ports and between the teeth of the rotor to prevent the rotor shaft from turning during tightening. 16. Install the lockwasher (2) and locknut (1) on the shaft and tighten. Bend one tang of the lockwasher into the slot on the locknut. Remove the piece of hardwood or brass rod from the pump casing. 7
Lubrication Pumps
MAINTENANCE AND REPAIR
for Crusher Circulating Oil Lubrication Systems
March 2000 Supersedes November 1998
17. Adjust the pump end clearance. See instructions on ”Thrust Bearing Adjustment” in this section. 18. If removed during disassembly, install the safety relief valve (31) so the valve cap is pointing toward the suction port. See instructions on ”Pump Safety Relief Valve” in this section. 19. Install the pump on the pumping unit base. Refer to the instructions on ”Coupling Alignment” in this section, to insure that the pump is properly installed and aligned before operating. 20. Install all guards. Remove any warning tags or lockout devices before turning ON power to the circulating oil lubrication system. THRUST BEARING ADJUSTMENT (FIG. 5) The thrust bearing adjustment determines the end clearance of the rotor and the pump head. Proper end clearance will improve pump performance and efficiency. High viscosity liquids will require additionalend clearances. Consult the pump manufacturer for specific recommendations when high viscosity liquids are involved.
CAUTION Shut OFF, lockout and tag all power to the circulating oil lubrication system before performing any, inspection, maintenance, adjustment or lubrication on the pumping unit. 1. Loosen the setscrews over the outer end cap (3) and the inner end cap (9). 2. Turn the inner end cap (9) clockwise (when looking from the shaft end of the pump) until it projects slightly from the bracket (17) exposing approximately three (3) threads of the inner end cap. 3. Turn the outer end cap (3) clockwise (when looking from the shaft end of the pump) until the rotor (22) is tight against the head (27) and the rotor shaft cannot be turned. 4. Make a reference mark on the end of the bracket opposite a notch on the outer end cap on K size pumps. Turn the outer end cap counterclockwise five notches from the reference mark made on the end of the bracket. On HL size pumps, turn the outer end cap counterclockwise three notches from the reference mark made on the end of the bracket. Each .250 inch (6.35 mm) travel on the circumference of the outer end cap is equivalent to approximately .0015 inch (.038 mm) end clearance. 5. Tighten the inner end cap (9) with a spanner wrench. Tap the spanner wrench lightly but do not over-tighten as it will only damage the threads. 6. Tighten all the setscrews that hold the inenr end cap and the outer end cap to prevent them from turning in the bracket. 8
7. Check the rotor to determine if it turns freely. If it is tight or does not turn freely, add more end clearnace. 8. Remove any warning tags and lockout devices before turn ON power to the circulating oil lubrication system. PUMP SAFETY RELIEF VALVE The safety relief valve mounted on the head of the pump is of the spring-loaded poppet design. The spring holds the poppet against the seat in the valve body with a given force, determined by the spring size and how tightly the spring is compressed by the adjusting screw. During operating, the pump discharge pressure pushes against the underside of the poppet. When the force exerted by the liquid under the poppet exceeds that exerted by the spring, the poppet lifts and the liquid starts to flow throught the relief valve. As the discharge pressure builds up, more of the liquid flows through the valve until a pressure is reached when all of the liquid being pumped is going through the valve. This pressure is the relief valve setting. Pressure Adjustment The pressure setting of the safety relief valve should be 175 psi (1207 kPa). Follow the instructions below carefully to adjust, check or reset the safety relief valve. See Figures 10 and 11. 1. Remove the valve cap covering the adjusting screw. Looser, the locknut that locks the adjusting screw so the pressure setting will not change during operation of the pump. The pressure gauge, in the discharge line after the pump, must be used for actual adjustment operation. 2. Close the shutoff valve(s) in the discharge line following the oil filtering unit(s). With the discharge line closed at a point beyond the pressure gauge, the gauge will now show the maximum pressure that the safety relief valve will allow while the pump is in operation. VALVE BODY POPPET
SPRING VALVE CAP
UNDERSIDE OF POPPET WHERE OIL PRESSURE IS EXERTED
ADJUSTING SCREW OIL INLET
OIL OUTLET
FIG. 10 — Internal view of pump safety relief valve.
3. Turning the adjusting screw clockwise will increase the pressure setting of the safety relief valve. Turning 17x11113–03.0003
Lubrication Pumps
MAINTENANCE AND REPAIR
for Crusher Circulating Oil Lubrication Systems
March 2000 Supersedes November 1998
the adjusting screw counterclockwise will decrease the pressure setting of the safety relief valve. 4. When the pressure setting adjustment is completed, tighten the locknut to hold the setting. Replace the valve cap covering the adjusting screw.
1. Mark the valve and pump head to be sure these parts will be reassembled in the same relative position. 2. Remove the valve cap (1). 3. Measure and record the length of extension of the adjusting screw (2). See dimension ”A” on Figure 11. 4. Loosen the locknut (3) and back out the adjusting screw (2) until the spring tension is released. 5. Remove the bonnet (5), spring guide (4), spring (7) and poppet (8) from the valve body (6). 6. Clean and inspect all parts for wear and damage. If any parts show excessive wear or are damaged, install a new safety relief valve.
LIST OF PARTS 1. Valve Cap
6. Valve Body
2. Adjusting Screw
7. Valve Spring
3. Lock Nut
8. Poppet
4. Spring Guide
9. Cap Gasket
5. Bonnet
10. Bonnet Gasket
FIG. 11 – Cutaway view of pump safety relief valve.
Safety Relief Valve Disassembly (FIG. 11)
CAUTION Shut OFF, circulating performing adjustment valve.
17x11113–03.0003
lockout and tag all power to the oil lubrication system before any, inspection, maintenance, or lubrication on the safety relief
Safety Relief Valve Assembly Assembly of the safety relief valve is the reverse of disassembly. The adjusting screw (2) should be at the same setting as it was before disassembly (see dimension ”A” on Figure 11). Replace the valve in the same position as that from which it was removed. The valve cap must be pointing to the suction port. Remove any warning tags or lockout devices before turning ON power to the circulating oil lubrication system. PUMP TROUBLESHOOTING The circulating oil lubrication pump will give long and satisfactory performance when properly installed and maintained. If trouble does develop, one of the first steps toward finding the difficulty is to install a vacuum gauge at some point in the suction line and a pressure gauge at some point in the discharge line. Readings on these gauges will often give a clue as to where to start looking for the trouble. The troubleshooting guide should help to pinpoint the cause of most problems that may be encountered and suggest ways to avoid and correct the cause.
9
Lubrication Pumps
MAINTENANCE AND REPAIR
for Crusher Circulating Oil Lubrication Systems
March 2000 Supersedes November 1998
TROUBLESHOOTING GUIDE TROUBLE 1. High reading on vacuum gauge (suction port).
CAUSE
CORRECTION
a. Suction line blocked – gate valve closed.
a. Unblock suction line. Open gate valve
b. Liquid too viscous to flow through piping.
b. Heat liquid or install immersion heater in tank.
c.
c.
Lift too high.
d. Suction piping too small. 2. Low reading on vacuum gauge a. Air leak in suction line. (suction port).
Modify piping to lower lift.
d. Increase piping size. a. Locate source of air leak and eliminate. Tighten pipe fittings.
b. End of suction line not in liquid.
b. Check tank level.
c.
c.
Pump is dry.
Prime pump.
3. Fluttering, jumping or erratic a. Liquid coming to pump in slugs. a. Check for air leaks and eliminate reading on vacuum gauge air leaks or insufficient liquid source. Check tank level (suction port). above end of suction pipe. b. Vibration from cavitation, b. Air leaks causing foaming in oil – misalignment or damaged parts. eliminate source. Check coupling alignment and pipe alignment. See “Pump Disassembly” for replacement of damaged parts. 4. High reading on pressure gauge a. Liquid too viscous. (discharge port).
a. Heat liquid or install immersion heater.
b. Gate valve partially closed.
b. Open gate valve all the way.
c.
c.
Clogged filter.
d. Liquid in pipes too viscous. 5. Low reading on pressure gauge a. Pump worn. (discharge port).
Check filter element and replace if clogged or dirty.
d. Heat piping. a. See “Pump Disassembly”.
6. Fluttering, jumping or erratic a. See “Cause” and “Correction” reading on pressure gauge (disunder Trouble, No. 3. charge port). 7. Pump does not deliver liquid.
a. Loss of prime caused by air leak a. Check for air leaks and eliminate. or low tank level. Check level of tank. Prime pump by hand until liquid begins to flow. b. Suction and/or discharge valves b. Check valves to be sure they are not opened. open. c.
10
Faulty motor or reducer.
c.
Inspect motor or reducer. Repair or replace if necessary.
d. Pump worn.
d. See “Pump Disassembly”.
e. Head position incorrect.
e. See Figure 1.
17x11113–03.0003
Lubrication Pumps
MAINTENANCE AND REPAIR
for Crusher Circulating Oil Lubrication Systems
March 2000 Supersedes November 1998
8. Pump starts, then loses it prime.
9. Noisy pump.
a. Tank empty.
a. Check tank level.
b. Air leaks in suction line or packing.
b. Locate air leaks and eliminate. Install new packing.
c.
c.
Pump worn.
a. Misalignment.
See “Pump Disassembly”.
a. Check coupling alignment – realign if necessary.
b. Bent pump shaft, or broken rotor b. Repair or replace parts if necesor idler tooth. sary. c.
Loose mounting bolts or loose c. piping.
Tighten bolts. Brace piping.
d. Foreign object in suction line or d. Inspect for and remove foreign suction port. object. e. See “Cause” and “Correction” under Trouble, No. 7. 10. Pump not up to capacity.
a. See “Cause” and “Correction” under Trouble, No. 7.
11. Pump takes too much power.
a. Packing gland drawn too tight.
a. Loosen nuts on packing gland until it is slightly loose.
b. Pump misaligned.
b. Check alignment and realign if necessary.
c.
Check parts for evidence of drag c. or contact in pump.
Increase clearance where necessary. Replace parts if worn or damaged.
d. See “Cause” and “Correction” under Trouble, No. 4 12. Noisy bearings, localized hearing a. Lack of lubrication. at bearings or lip seal, smoke and rapid bushing wear.
a. Grease all pump lube fittings before starting system. Consider use of auxiliary lubricating equipment.
13. Uneven wear or wear on a certain a. Misalignment. section, i.e., one side of casing or packing gland or part of head.
a. Check coupling alignment and pipe alignment. See “Pump Disassembly” for replacement of damaged parts.
14. Pump stalls.
a. Pump running dry. Uneven a. Be sure sufficient liquid is in the expansion of parts caused by system and that it is being frictional heat of moving surfaces delivered to the pump. against each other.
15. Evidence of abrasion and corro- a. Dirt or contaminants entering the a. Locate source of contaminants sion of pump parts. lube system. and eliminate. Replace filter element and flush lube system completely. Disassemble pump and clean or replace parts.
17x11113–03.0003
11
Lubrication Pumps
MAINTENANCE AND REPAIR
for Crusher Circulating Oil Lubrication Systems
March 2000 Supersedes November 1998
PUMP REDUCER Installation and Alignment The pumping unit components, including the pump reducer, were properly aligned during assembly. However movement during shipping and setup may have disturbed the alignment. The following instructions are provided for checking the alignment of the reducer and for setting alignment during installation of the reducer, should it ever require removal from the pumping unit. For correct alignment of the coupling, see instructions on “Coupling Alignment” in this section.
5. Rotate the reducer in the slots of the bracket until the high speed coupling half is at the exact center height of the motor coupling half. See Figure 9. 6. Tighten the reducer to the reducer mounting bracket securely.
BREATHER
MOUNTING BOLTS
CAUTION Shut OFF, lockout and tag all power to the circulating oil lubrication system before performing any inspection, maintenance, adjustment or lubrication on the pump reducer.
INPUT SHAFT
1. Fasten the reducer bracket securely to the baseplate. See Figure 8.
HELICAL REDUCER HIGH SPEED COUPLING
ADJUSTMENT SLOTS IN BRACKET
OUTPUT SHAFT
REDUCER MOUNTING BRACKET LOW SPEED COUPLING
MOTOR
REDUCER MOUNTING BRACKET PUMP
FIG. 9 –Installing the reducer on the reducer mounting bracket.
7. Align the high speed shaft coupling half with the coupling half of the motor shaft. Refer to Figure 3 and instructions on ”Coupling Alignment” in this section (it may be necessary to loosen the motor mounting bolts to properly align the coupling halves.) Tighten coupling halves on each shaft and fasten the motor securely to the baseplate.
FIG. 8 – Installation of pump reducer on baseplate.
2.
Mount the reducer on the reducer bracket finger–tight. The breather cap must be located on the top side of the reducer and the drain plug on the bottom. See F
3. Place the coupling halves on the high and low speed reducer shafts. See Figure 8. 4. Align the low speed shaft coupling half with the coupling half on the pump shaft. Refer to Figure 3 and the instructions on “Coupling Alignment” in this section. (It may be necessary to shim the reducer mounting bracket to the exact center height of the pump shaft. Tighten the coupling halves on each shaft. 12
8. Make a final alignment check of both the high speed low speed couplings after all the mounting bolts have been tightened. Realign if necessary. Reducer Lubrication The pump reducer requires approximately 8 oz (.24 l) of lubricating oil when empty. When checking the reducer oil level or when adding oil to the reducer, drain or fill the reducer to the oil level plug in the side of the reducer case. Remove the breather and add the proper amount of oil for the ambient temperature of operation. See Figure 10.
Ambient Temperature
Type of Oil Required
Above 32o F. (0o C)
AGMA #3 or ISO VG 100
Below 32o F. (0o C)
AGMA #1 or ISO VG 32 17x11113–03.0003
Lubrication Pumps
MAINTENANCE AND REPAIR
for Crusher Circulating Oil Lubrication Systems
March 2000 Supersedes November 1998
CAUTION
BREATHER AND FILL HOLE
Shut OFF, lockout and tag all power to the circulating oil lubrication system before performing any inspection, maintenance, adjustment or lubrication on the pump reducer. 1. Remove the coupling guards. 2. Disconnect the motor and pump couplings, and remove the capscrews holding the reducer mounting bracket to the baseplate. See Figure 8.
OIL LEVEL PLUG
DRAIN PLUG
FIG. 10 – Lubrication fittings on the pump reducer.
3. Remove the coupling halves from the high and low speed shafts, and remove the mounting bracket from the reducer. Place the reducer on a clean, sturdy work surface. 4. Remove the breather (2) and drain plug (1). Drain all lubricant from the reducer. 5. Remove the nuts (5) and capscrews (4) holding the gear case (23) and the gear case cover (7) together. 6.
After the first 100 hours of operation drain, flush and refill the reducer with the proper grade of new oil. Check the oil level every 2,000 hours of operation or every six. (6) months, whichever occurs first. Add oil as necessary. Periodically check the area under the reducer for any signs of leakage. If leakage is noticed, check the oil level more frequently. Once each year drain, flush and refill the reducer with the proper grade of new oil.
IMPORTANT Before operating the reducer, be sure to add the proper amount and type of oil. Do not overfill the reducer.
After the first few hours of operation, inspect the reducer for leaks. If leakage between the gear case and cover cannot be stopped by tightening the nuts or capscrews, replace the gasket. Leakage around either shaft indicates a damaged lip seal which should be replaced. The operating temperature on the outside of the reducer case, after a few hours of operation, should not be more than 75 F (24 C) higher than the ambient air temperature. The oil in the reducer must never exceed 200–F (930 C). Reducer Disassembly (FIG. 11) Before starting disassembly, study the exploded view of the reducer in Figure 11 to help determine part relationships. The reducer parts are indexed in a logical sequence of disassembly, which should prove to be a useful aid in dismantling the reducer. 17x11113–03.0003
Lightly tap on the gear case cover (7) to loosen it from the gear case (23). Separate the gear case cover from the gear case by carefully prying alternately at opposite ends with a screwdriver. Do not force the separation of the gear case cover and the gear case. Be careful not to damage the gasket (8) or the machined surfaces of the gear case cover and gear case. Remove the gear case cover and the gasket from the gear case.
7. Grasp the pinionshaft (20) and gear shaft (16), and pull both assemblies simultaneously from the gear case (23). 8. Use a conventional gear o, bearing puller to remove the gear shaft bearings (11 and 12) from the gear shaft (16). Remove the beveled spacer (13) and press the gear (14) off the gear shaft (16). 9. Use a bearing puller and remove the pinionshaft bearings (17 and 18) from the pinionshaft (20). On reducer size 7.65 to 1 ratio, remove the spacer (13) from the pinionshaft (20). 10. Remove the lip seals (22) from the gear case cover (7) and the gear case (23) only if they show signs of deterioration or damage. The lip seals must be pressed or driven out (from the inside to the outside) on both the gear case cover and the gear case. 11. Inspect all parts for damage and excessive wear. Parts that are damaged or partially worn, such as seals and bearings, should be replaced while the unit is disassembled. Clean all parts thoroughly before assembling the reducer. Reducer Assembly (FIG. 11) 1. Install the pinionshaft bearings (17 and 18) on the pinionshaft (20). Be sure the bearings are seated firmly against the shoulders on the pinionshaft. 13
Lubrication Pumps
MAINTENANCE AND REPAIR
for Crusher Circulating Oil Lubrication Systems
March 2000 Supersedes November 1998
ITEM
NAME OF PART
ITEM
NAME OF PART
ITEM
NAME OF PART
1 2 3 4
Drain Plug Breather Pipe Plug (Set–2) Capscrew (Set–7)
11 12 13 14
Ball Bearing Ball Bearing Spacer (7.65 to 1 Ratio – 2 Req’) Gear
19 20 21 22
Snap Ring (for 6.27 to 1 ratio only) Pinion and Shaft Snap Ring (Set–2_ Lip Seal (Set–2)
5 6 7 8
Nut (Set–7) Dowel Pip Locating (Set–2) Gear Case Cover Gasket
15 16 17 18
Key Gear Shaft Ball Bearing Ball Bearing
23
Gear Case
FIG. 11 – Exploded view of pump reducer.
IMPORTANT Reducers with 6.27 to 1 ratio requires a snap ring (19). The snap ring (19) must be installed in the groove on the pinionshaft (20) before bearing assembly. The pinionshaft bearing (18) must be seated against the snap ring (19). Reducers with 7.65 to 1 ratio require two spacers (13), one on the pinionshaft(20) and one on the gear shaft (16). The pinionshaft spacer must be installed first, with the beveled edge toward the bearing (18). Install the bearing on the pinionshaft and seat it firmly against the spacer. 2. Install the key (15) in the keyway on the gear shaft (16). Press the gear (14) on the gear shaft, seating it firmly against the shoulder on the shaft. 3. Install the spacer (13) on the small diameter end of the gear shaft (16) with the beveled edge toward the gear (14). Install the gear shaft bearing (11) on the gear shaft and seat it firmly against the spacer. Install the second gear shaft bearing (12) on the large diameter end of the gear shaft and seat it firmly against the shoulder on the shaft. 14
4. If the lip seals (22) were removed during disassembly, place the gear case cover (7) and the gear case (23), gasket side down, on a clean surface that will not mar the gasket face. Install the snap rings (21) in the gear case cover and the gear case. Apply gasket sealer on the outside diameter of each lip seal. Install the new lip seals, with the lip toward the inside of the gear case cover and the gear case, and drive the lip seals in place seating them against the snap rings. Use a wood block large enough to cover the entire lip seal and drive it evenly into position. Apply lubricant to the lip seal lips. 5. Block the gear case, open side up, to provide at least 3–1/4 in (8.3 cm) clearance between the bottom of the gear case and the assembly block. 6. Make sure the pinion and gear shaft keyways are free of burrs and sharp edges to prevent damaging the lip seal lips during shaft installation. Grasp the pinion and gear assemblies, with the gear teeth meshed, and insert both assemblies simultaneously into the gear case. Rotate the gear shaft slightly as it is pushed through the lip seal. Tap the end of the pinionshaft and gear shaft with a hardwood block to 17x11113–03.0003
Lubrication Pumps for Crusher Circulating Oil Lubrication Systems
MAINTENANCE AND REPAIR March 2000 Supersedes November 1998
seat the bearings (12 and 17) in the gear case counterbores. 7. Place the gasket (8) on the gear case (23). If the gasket is the least bit damaged, discard it and use a new gasket. 8. Align the gear case cover (7) with the ends of the pinionshaft and gear shaft, and carefully press the gear case cover in place. Rotate the pinionshaft during assembly as it is pushed through the lip seal. Tap the gear case cover with a hardwood block to seat the bearings (11 and 18) in the gear case cover counterbores. 9. Install the capscrews (4) and ruts (5), and tighten
17x11113–03.0003
them securely, alternating around the gear case to present distortion, binding or cracking the gear case cover or gear case. , 10. Install the drain plug (1) and breather (2). Install the reducer on the reducer mounting bracket and the baseplate. See instructions on ”Installation and Alignment” in this section. Refer to Figures 8 and 9. 11. Fill the reducer with the proper amount and type of lubricant. See instructions on ”Reducer Lubrication” in this section. See Figure 10. 12. Install all guards. Remove any warning tags or lockout devices before turning ON power to the circulating oil lubrication system.
15
Nelson Liquid FIlters
OPERATION AND MAINTENANCE March 2000
GENERAL DESCRIPTION
PRE–OPERATIONAL FLUID TEST
This Nelson liquid filter is installed in the external lubrication system to remove solid contaminants such as dirt, rust, scale, sand and metal particles from the crusher lubricating oil. Removable access opening covers are provided to facilitate the replacement of the filter elements contained inside the main body of the unit and to permit cleaning the interior of the vessel. Single element filters are provided on 20 and 30 GPM lubrication systems, and double element filters are provided on 40, 50, 60, 80 and 85 GPM lubrication systems. See Fig. 1 and Fig. 2. Suitable mounting supports are provided for anchoring the unit. Inlet, outlet, vent. drain and pressure connections are provided on all units.
Give the filter a fluid test prior to putting it in full operation. 1. Check and make sure that the valve (7405-0) on the inlet side of the filter is completely closed.
PRE–OPERATIONAL CHECK Before submitting the unit to a fluid test: 1. Inspect the filter cover to be sure that the proper 0–ring has been placed between the flange and cover. 2. Check all flange bolts for tightness. 3. Check mounting bolts and screw s on all accessory items to be sure they are tightened securely. 4. Check all hose lines to be sure they have not been flattened or kinked. If hose is damaged, replace it with new hose. 5. Check all pipe and pipe fittings to be sure they are tightened sufficiently to prevent leaks. Do not over– tighten threaded connections. Stripping of threads may occur and result in leaking connections–
17x0098-01.0003
2. Start the pump motor. 3. Loosen the vent in the filter cover to permit any entrapped air to bleed out of the filter enclosure as it is being filled with oil. 4. Partially open the valve (7405-0) on the inlet side of the filter, allowing a flow of oil to slowly and completely fill the filter.
IMPORTANT Be careful to prevent hydraulic hammer, in the lu- brication system piping, whenever opening or closing valves controlling oil flow through the filters. Ham- mering can severely damage filter elements and main body connections. 5. Allow the vent plug to remain open long enough to permit entrapped air to escape from the vented unit. As soon as a small amount of oil is seen to flow from the loosened vent plug, close the plug securely. 6. Open the valve (7405-0) in the filter inlet line completely to allow, the full flow of oil through the filter. 7. Inspect all connections for leaks. Tighten connections where necessary. If tightening connections fails to stop leaks, it indicates faulty gaskets or damaged fitting or threads. Replace all faulty parts and re-check for leaks.
1
Nelson Liquid FIlters
OPERATION AND MAINTENANCE March 2000
AIR VENT COVER BOLT WASHER
AIR VENT
FILTER COVER COVER BOLT
O–RING
WASHER
BYPASS RELIEF VALVE
FILTER COVER O–RING
BYPASS RELIEF VALVE FILTER ELEMENT
FILTER ELEMENT COUPLING FILTER ELEMENT
FILTER ELEMENT
HEX NUT INLET PORT
HEX NUT
FILTER HOUSING FILTER HOUSING
INLET PORT PRESSURE GAUGE PORT iNLET SIDE
DRAIN PORT PRESSURE GAUGE PORT OUTLET SIDE OUTLET PORT
PRESSURE GAUGE PORT iNLET SIDE
DRAIN PORT PRESSURE GAUGE PORT OUTLET SIDE
17–390–206–401
FIG. 1 – Nelson Filter – Single Element
2
OUTLET PORT
17–490–284–401
FIG. 2 – Nelson Filter – Double Element 17x0098-01.0003
Nelson Liquid FIlters
OPERATION AND MAINTENANCE March 2000
IMPORTANT
OPERATION After the initial installation of the filter is complete. including the fluid test for leaks, the filter is ready for operation. As the filter is used, make daily pressure differential readings. As the filter removes dirt and sediment from the product, it builds up on the filtering surfaces. Eventually, this retards the flow of the product through the elements and causes an increase in the pressure differential. MAINTENANCE There are no moving parts in the basic filter unit. Maintenance, is limited to the occasional replacement of the elements contained inside the main body of the unit. The frequency of filter element replacement is dependent on the amount of solids contaminant in the incoming product stream.
IMPORTANT For maximum performance efficiency, the elements must be replaced when the differential pressure across the filter reaches 20 PSI. When the pressure differential readings indicate that replacement of the elements is necessary, the following procedures must be observed. ELEMENT REPLACEMENT A decal, applied to the front of each filter unit, contains the Svedala Industries part number of replacement filter elements. See Fig. 3.
Use only Nelson filter replacement elements. Do not mix elements of different manufacture.
To change the filter element, shut the crusher down, stop the lube oil pump, and close the valve (7405-0) on the inlet side of the filter. A check valve (7720-0) in the filter discharge line will prevent oil back up into the filter. Drain the oil from the filter, using the drain plug at the side of the shell. Remove the filter cover and lift out the dirt filled element. Remove the bypass valve from the dirty element. Flush dirt out through the filter drain. Install a clean element, making sure that it is properly seated in the filter shell. Install the bypass valve assembly and fasten the cover securely in place. Be careful not to damage the seal. Use the following procedure to place the filter unit in service. 1. Check and make sure that the valve (7405-0) on the inlet side of the filter is completely closed. 2. Start the pump motor. 3. Loosen the vent in the filter cover to permit any entrapped air to bleed out of the filter enclosure as it is being filled with oil. 4. Partially open the valve (7405-0) on the inlet side of the filter, allowing a flow of oil to slowly and completely fill the filter.
IMPORTANT
FOR FILTER ELEMENT REPLACEMENT, USE SVEDALA INDUSTRIES FILTER PART NO. 17-105-973-01 17-106-034-001
FIG. 3 — Filter Element Replacement Decal
17x0098-01.0003
Be careful to prevent hydraulic hammer in the lu- brication system piping whenever opening or closing valves controlling oil flow through the filters. Ham- mering can severely damage filter elements and main body connections.
5. Allow the vent plug to remain open long enough to permit entrapped air to escape from the vented unit. As soon as a small amount of oil is seen to flow from the loosened vent plug, close the plug securely. 6. Open the valve (7405-0) in the filter inlet line completely to allow full flow of oil through the filter
3
Basco 500 Heat Exchanger
OPERATION AND MAINTENANCE
for External Lubrication Systems on SUPERIOR and HYDROCONE Crushers
May, 1979 New
BASCO TYPE 500 HEAT EXCHANGER INSTALLATION
INSPECTION
The heat exchanger is mounted on the external lubrication package at the factory and arranged so that the hot lubricating oil passes through the shell and around the exchanger tubes. Fittings for cooling water piping are cast into one of the bonnets at the end of the exchanger
Periodically remove bonnets at each end of the heat exchanger. Inspect zinc pencils for erosion or oxidation. Scrape to a bright surface, and replace pencil if more than half corroded away. Examine tubes for scale and clean if necessary. After cleaning, examine for erosion or corrosion.
OPERATING At start-up or after maintenance inspection, be sure that both the shell and tube sides are vented and full of liquid. Improper venting and fouling are the most common causes of heat exchanger malfunction. If air tends to accumulate in the system, follow a periodic venting program.
17x10647
CLEANING Interior tube surfaces can be flushed with a high velocity water stream, or cleaned with wire brushes or rods, if scaled.
1
OPERATION AND MAINTENANCE
Waterman Flow Regulators
June 1993
INTRODUCTION Flow regulators (7805–0) are used on all SUPERIOR and HYDROCONE crusher circulating oil lubricating systems with the split flow arrangement. These flow regulators are rated at 20 to 250 psi (137 to 1724 kPa). Figure 1 shows the direction of flow and model number location for the flow regulator used on each split flow arrangement. Figure 2 shows a typical flow regulator installation. The complete model number identifies the model designator (190L, for all sizes), the pipe size, and the flow rate in GPM. Here is an example of the typical model number:
ARROW SHOWS DIRECTION OF FLOW
XXX XX–XXX
COMPLETE MODEL NUMBER STAMPED HERE
FIG. 1 – Flow regulator used on all crusher circulating oil lubrication systems with the split flow arrangement. Flow Rate in GPM Pipe size in 1/8” increments (8 x 1/8” = 8/8” = 1”) Model designator
SPLIT FLOW ASSEMBLY
FLOW REGULATOR 7805–0
SK030992JJB18
FIG. 2 – Typical split flow connections on a crusher circulating oil lubrication system showing flow regulator installation.
17X11105–01
1
OPERATION AND MAINTENANCE
Waterman Flow Regulators
June 1993
TROUBLESHOOTING GUIDE TROUBLE 1. Too much or too little oil being delivered to the crusher.
2. No oil being delivered to the crusher.
CAUSE
CORRECTION
a. Partial blockage of oil flow in piping or in flow regulator.
a. Locate source of blockage and clear, Disassemble flow regulator and clean thoroughly.
b. Contaminants or abrasives causing scoring, scratches and distortion of flow regulator components, resulting in malfunction.
b. Locate source of contamination and eliminate. Replace oil filter. Disassemble regulator and clean thoroughly. Replace flow regulator if parts are damaged.
c.
c.
Excessive wear or broken internal parts in flow regulator.
Replace flow regulator.
d. Malfunction of other components in the circulating oil lubrication system.
d. Refer to troubleshooting section for other components in the circulating oil lubrication system.
a. Complete blockage of oil flow.
a. Locate source of blockage and clear. Disassemble flow regulator and clean thoroughly if it is the source of blockage.
b. Broken internal parts in the flow regulator.
b. .Replace flow regulator.
c.
c.
Pump failure.
See troubleshooting section for circulating oil lubrication system.
TROUBLESHOOTING Malfunction of the flow regulator is basically limited to two conditions: “Too much or too little oil being delivered to the crusher,” or “No oil being delivered to the crusher.” The troubleshooting guide shows the possible “cause” and “correction” under each condition.
Disassembly Disassemble the flow regulator parts in the . same order as the numbers assigned to the parts in the exploded view (Fig. 3). 1. Remove the flow regulator from the split flow piping arrangement.
NOTE
2. Using a snap ring pliers, remove the large retaining ring (1) from the outside of the body (7). Remove the sleeve (2) from the body subassembly (8).
The cause of “incorrect” or “no” flow of oil may not be the result of a malfunctioning flow. regulator. Check out other components of the circulating oil lubrication system when trouble occurs.
3. To remove the piston (5) and spring (6) from the body (7), clamp the body subassembly (8) securely in a vise with the piston end up.
WARNING MAINTENANCE The flow regulator, requires no maintenance other than an inspection of the parts during disassembly and the replacement of worn or damaged units.
2
Piston is spring loaded. Improper removal of the small retaining ring in the body ill cause the piston and spring to shoot out of the body, re- sulting in personal injury to anyone in its path. Keep face away from the piston end of the body.
17X11105–01
OPERATION AND MAINTENANCE
Waterman Flow Regulators
June 1993
ITEM
PART
1 2 3 4 5 6 7 8
Retaining Ring, Large Sleeve Packing Rings Retaining Ring, Small Piston Spring Body Body Subassembly
FIG. 3 – Exploded view of the flow regulator.
4.
Use a small diameter length of rod with a flat end, and insert it into the piston end of the body until the end of the rod makes contact with the piston head. Push down the spring loaded piston (5) with the rod, but just far enough to relieve the tension on the small retaining ring (4). Remove the small retaining ring with a snap ring pliers. Release the tension on the piston by slowly raising the rod until there is no more spring tension on the piston. Remove the piston (5) and spring (6) from the body (7). See Figure 4.
Assembly Reassembly of the flow regulator is the reverse of disassembly. See Figure 4 for cutaway view of assembled flow regulator showing internal construction and parts relationship.
PACKING RINGS BODY
SLEEVE
5. Clean and inspect parts thoroughly. If evidence of scratches, scoring or distortion are found on the piston, spring or body, a new flow regulator must be installed.
IMPORTANT Flow regulator parts are matched to insure proper working characteristics. Any attempt to rework or re- place individual parts may affect the operation of the flow regulator and the circulating oil lubrication sys- tem.
17X11105–01
SMALL RETAINING RING
PISTON
SPRING
LARGE RETAINING RING
3
INSTALLATION AND MAINTENANCE
Universal Flow Monitors
Instructions for retrofitting earlier Universal flow meters (single electric switch models) with a quick–setting cam, Part No. 995–A S Universal flow meters with electric switches in rectangular control boxes shipped before March, 1989 have switch– setting adjustable cams with set screws. The current ad justable cam does not use a set screw, and is much easier and faster to adjust. You can install this new quick–selling cam on earlier model flow meters containing a single switch. TO INSTALL THE NEW CAM Warning: Shut off electric power to the control box before opening It. 1. Remove the nameplate/cover and window from the control box. 2. Remove the pointer. 3. Remove the old cam. 4. To remove the switch take off the two brass hex nuts and lift switch off the brass mounting studs. 5. The quick–setting cam has three parts: the spring, the cam ring. and the “bevel gear” piece. Install as follows: 6. Slip the spring over the dial post in the control box. 7. The cam ring has an 0–ring inside. See that it is in place. 8. Put the “bevel gear” into the cam ring, serration toward the O–ring. Arrange so that one of the two little set screws is visible between the cam surfaces. 9. Slip these parts over the dial post against the spring. 10. Push the bevel gear down the dial post until it bottoms out on the dial face. Tighten the set screw. 11. Push down on the cam ring and rotate 180 degrees to uncover the second set screw. Release pressure and tighten screw.
Instructions for setting the electric switch point on Universal flow meters equipped with the new quick–setting cam. The cam is usually set at the factory to actuate the switch at some specific flow (and specifically when flow is increasing or decreasing). TO CHANGE THE SETTING Warning: Shut off electric power to the control box before opening It. 1. Remove the nameplate/cover and window from the control box. 2. The cam that actuates the switch is located just under the pointer. The position of the cam dictates the flow rate at which the cam will throw the switch. 3. Turn the pointer so that it points at the desired flow rate on the scale. Against low spring forces you can do this by grasping the pointer itself (and holding it in position while you adjust the cam). Some flow meters with higher spring forces have an opening on the opposite side, where a wrench (supplied with those units) can be used to turn an extension of the shaft. Flow meters with very high spring force and no extended shaft can be handled by removing the bowl (under the housing). The vane is then grasped and turned. To get the edge of the vane out of its recessed seat use a socket head screw wrench as a lever, inserting it into one of the vane set screws.
DIAL POST
Press down cam ring and rotate to change cam position
No. 995–AS 1.
SPRING
2 . C AM R IN G O–RING 3. BEVEL GEAR POINTER, WASHERS, SCREW
12. Put one of the plastic spacers supplied on each of the two brass mounting screws. 13. Replace switch. 14. Replace pointer, pointing it to the zero line (lowest scale marking) before tightening screw. 15. Refer to instructions on other side to set switch point. 17X0099-01.0003
4. While holding the pointer/shaft/vane in the desired position, depress the cam ring fully (approx.1/16 inch) and rotate it until the switch actuates (clicks). Release your downward pressure and the cam ring will lock at that position. 5. It you can’t hear the switch click you can determine contact closure with an ohmmeter connected across the switch terminals. 6. To check the setting. direct the pointer again to the desired flow rate, noting where the switch actuates. Note that the switch should actuate on decreasing flow. Due to switch deadband, in order to check the setting 1
INSTALLATION AND MAINTENANCE it is necessary to move the pointer above the desired actuation flow rate and then rotate it back to similate a decreasing flow condition. Make adjustments as necessary. 7. It’s much easier to set the switch point if you can do it with actual flow present. Adjust the flow to the desired point where you want a signal to occur and turn the cam to actuate the switch as outlined above. 8. Replace windows and nameplate/cover before turning on electric power.
Installation and Maintenance Instructions for Series MN Flow Meters
Universal Flow Monitors
ENGINEERING DATA Standard max. temperature: 200 oF Optional max. temperature: 400 oF Maximum operating pressure (3:1 safety factor): 300 psi Readout accuracy, full scale: 2% Pressure drop (increases over rated flow range): 1.9 to 2.5 psi (ave. 2.2) Inspect contents of shipment for shipping damage. All damage claims should be made to the shipping agent before installing. INSTALLATION The materials used in constructing this flow meter were selected for a specific fluid and application. (See original customer order.) It should not be used with different fluid without consulting factory. This is an in–line device that can be mounted in any position without affecting performance. Simply thread your piping into the NPT Ports, being sure that the flow goes into the port marked ”IN.” (Do not use Teflon tape to seal pipe threads in cast iron housings.) To insure accuracy, control valves should be installed downstream of the flow meter. This unit has one electric switch. ELECTRIC SWITCH Make connections in accordance with the wiring diagram below. (Switch may be removed to facilitate wiring it.)
This medium–body flow monitor is designed and built to withstand the rigors of industrial service, and remain accurate. It will easily pass flows to approximately 1–1/2 times its rated capacity.
TO PREVENT ELECTROCUTION OR SERIOUS BODILY INJURY, DISCONNECT, TAG AND LOCK- OUT ALL POWER BEFORE WORKING ON ANY ELECTRICAL COMPONENTS OR CONTROLS.
3–wire SPDT
Wiring Diagram
HOW IT WORKS Fluid enters at A, passes around the semicircular vane B, exits at outlet C. The vane resists the flow because of the spring D. The further the vane is pushed the larger the passageway E becomes. This minimizes the increase in pressure drop. The vane shaft turns to operate the pointer F and remote signal switch G. 2
SWITCH SPECS: 3-wire SPDT switches are rated 15A at 125, 230 & 480 VAC; 1/2A at 125 VDC or 1/4A at 250 VDC (res.). SETTING THE SWITCH POINT The cam that actuates the switch is located on the dial assembly mounted inside the control box. The position of the cam dictates the switch point, i.e., the flow rate at which the cam throws the switch. (Usually, the switch point is set at 80% of full flow.) To set or reset the switch point, proceed as follows: 17X0099-01.0003
Universal Flow Monitors
Shut off electric power to control box before opening it. Remove cover and window from control box, then loosen the cam screw. Insert a screwdriver into the pointer screw, and direct the pointer along the scale to the flow rate you wish to signal. Then rotate the cam until the switch actuates (clicks), and tighten the cam screw. To adjust the setting under flow conditions, simply ad just the flow to the flow rate you wish to signal. Then loosen the cam screw and rotate the cam until the switch actuates (clicks). Tighten the cam screw and the switch is set for that flow rate. For ease and accuracy in determining contact closure an ohmmeter can be connected across terminals. To check the setting, direct the pointer again to the switch point, noting when the switch actuates and make fine adjustments as necessary. Due to switch deadband, in order to check the setting it is necessary to move the pointer above the desired actuation flow rate and then rotate it back to similate a decreasing flow condition. CALIBRATION All flow meters are individually calibrated (for a specific fluid) before leaving the factory. Scales are therefore not interchangeable. Be sure any scale removed is put back on the same meter. CHANGING THE SPRING Remove the spring cover and the main spring. Place the new main spring onto the shaft and attach it by sliding the hole on the inside tip of the coil over the flat head rivet. There are two holes to choose from. Use the one that enables you to place the outside spring loop over the roll pin with only 1/4 turn (90º) clockwise.
17X0099-01.0003
INSTALLATION AND MAINTENANCE
NOTE: On older units, a screw is used instead of the flat head rivet. The orientation of the screw is either Oº, 90º, 180º, or 270º away from the roll pin, in a counterclockwise direction. If you find that the screw is at 0º or 270º, it must be removed and inserted into the opposite side of the shaft prior to following the above procedure. PERIODIC MAINTENANCE Using a valve to vary the flow, observe the pointer tracking the flow rate. If the flow monitor does not respond properly, it is probably due to foreign material building up around the swinging vane and hanging it up. The vane can sometimes be jogged loose by manipulating the pointer. If your flow monitor has the optional extended shaft, remove the spring cover plug (22) at the rear of the unit to gain access to the shaft end. Using the cleanout wrench (23) supplied, vigorously pivot the shaft back and forth a few times. which will jog the foreign material from the swinging vane. If it doesn’t free up, it may be necessary to remove the bowl and clean the vane and flow chamber with a brush or knife. REPLACEMENT PARTS Every Universal flow meter has a nameplate stamped with a model number that describes the unit in detail, including materials of construction of all working parts, and all options. On page 4 is a guide to decode the model number. (The symbols shown should not be used to order parts. See page 5 for part descriptions and part number.) If your model number contains a ”Z” followed by digits you have a non–standard option. For an explanation contact the factory with the complete model number. It is recommended that all parts be ordered from Universal Flow Monitors, Inc. UNIVERSAL FLOW MONITORS, INC. 1755 East Nine Mile Road Hazel Park, Ml 48030–0249 248–542–9635 / FAX: 248–398–4274
3
INSTALLATION AND MAINTENANCE
Universal Flow Monitors
TYPICAL ORDERING CODE taken from nameplate. AM GM O
– – D S – –
– B –
400 100 15
WB – – WW – – MN A S
– – B
30 30 30
SERIES Medium size Normal pressure = MN For air = A or AD For gas = GM For lube or coolant = O or OK For water (to 90GPM) = WB For water (to 500GPM) = WW HOUSING MATERIAL Aluminum = D Aluminum, nylon bowl = A Aluminum (hard coated) = E Brass = F Brass, nylon bowl = B Cast iron = C Cast iron, nylon bowl = G Cast iron, nickel plated = R Cast iron, nickel plated & Teflon impregnated = N Carbon steel = M Naval Bronze = U Naval Bronze, nylon bowl = W Stainless Steel (304) = S Stainless Steel (316) = I INTERNAL MOVING PARTS Stainless Steel (3O4 & 416) = S Stainless Steel (316) = I Monel = L Titanium = T Hastelloy B = H Hastelloy C = C SEAL MATERIAL Buna N = B Ethylene propylene = E Viton = F Kalrez (all) = J Teflon (lip seal) = T (on GM Series) Kalrez (shaft) Teflon (static) = K (on GM Series) T (on MN Series)
MAX FLOW RATING
SCALE CALIBRATION AIR PRESSURE VALVE FLOW CONTROL No symbol = no value All brass valve = V
4
SM 90P – SM – – GM – V
6 – 6 90P 6 320S
2 2 1
N N N
R R R
ID 100U ID 50D PM 2D
GM – GM – GM –
6 – 6 – 6 60V9
1 1 1
N N N
R R R
ID E E
V – V
1U 2D 10D INITIAL SWITCH SETTING SPECIAL OPTIONS ID = Stainless Steel ID tab HT = High temperature service (to 400o F) PM = Roll pin modification (for panel mounting) E = Ext ended shaft FLOW DIRECTION R = Left to right L = Right to left U = Up D = D own CONTROL BOX N = Oil & dust tight W = Weatherproof (NEMA 4) X = Corrosive service, weatherproof (NEMA 4X) READOUT OPTIONS 0 = Local indicator only 1 = One 3–wire SPDT switch 2 = Two 3–wire 3 = One 4–wire SPDT switch 4 = Two 4–wire 5 = One hermetically–sealed 3–wire 6 = Two hermetically–sealed 3–wire 7 = One SPDT explosion–proof switch 8 = One 1K potentiometer 9 = O ne pot & one 3–wire 10 = One pot & one 4–wire 11 = One pneumatic switch 17 = One DPDT explosion–proof switch 18 = Two SPDT explosion–proof switch 19 = Two SPDT explosion–proof switch 30 = Transducer – no switch 31 = Transducer and one 3–wire SPDT switch 33 = Transducer and one 4–wire SPDT switch 35 = Transducer and one 3–wire SPDT hermetically–sealed switch 40 = No transducer – no switch 41 = No transducer – one 3–wire SPDT switch 43 = No transducer – one 4–wire SPDT switch 45 = No transducer – one 3–wire SPDT hermetically–sealed switch
FLUID CHARACTERISTICS PORT SIZE
17X0099-01.0003
INSTALLATION AND MAINTENANCE
Universal Flow Monitors
Recommended spare parts (If used in your particular model)* Symbol 1
Part Name Housing
Housing (2” port)
2
3 4
Bowl
Spring Cover Butterfly Assembly
5 6
Shoe Shaft*
7 8 9 10
Spring Plate Bearing Spring Bowl O-Ring
11
Shaft Seal (4 req)
12 13 14
Dowel Pin (2 req) Spring Pin Butterfly Screw
15 16
17X0099-01.0003
Rivet Spring Cover Cap Screw (4 req)
Part Number 406 406-E 407 462 46 7-S 46 7-I 408 399 399-E 400 401 401-R
Material Aluminum Aluminum Hard-Coated Brass Carbon Steel 30 4 S ta in les s St eel 31 6 S ta in les s St eel Naval Bronze Aluminum Aluminum Hard-Coated Brass Cast Iron Cast Iron, Nickel-Plated Cast Iron, Nickel-Plated and Teflon-Impregnated Carbon Steel 30 4 S ta in les s St eel 31 6 S ta in les s St eel Naval Bronze Aluminum Brass Bronze Cast Iron Carbon Steel 30 4 S ta in les s St eel 31 6 S ta in les s St eel Glass-Filled Nylon Glass-Filled Nylon 304 Stainless Steel 31 6 S ta in les s St eel Hastelloy B Hastelloy C Monel Titanium Teflon 304 Stainless Steel 31 6 S ta in les s St eel Hastelloy B Hastelloy C Monel Titanium Stainless Steel Stainless Steel Stainless Steel Buna Viton EPR Teflon Kalrez Buna Viton EPR Kalrez Teflon Glyde Stainless Steel Stainless Steel 18-8 Stainless Steel Titanium Hastelloy B Hastelloy C Monel 316 Stainless Steel
401-N 402 40 3-S 40 3-I 437 419 420 421 422 423 42 4-S 42 4-I 425 306 314-S 31 4-I 457 394 363 362 310 301-S 30 1-I 454 390 360 356 305 303 304 348 349 350 351 362 338 339 340 341 343 324 321 319 370 455 398 371 317
Stainless Steel
713
Symbol * 17 18 19
20
21 22 23 24 *
25
26 27 38 29 30 31
*
32 33 34 35 36 37 38 39
*
40 41 42 43
Part Name Material Spring Cover Gasket Vellumoid Bowl Screw (4 req) Steel 31 6 S ta in les s St eel Stop Pin Assembly Aluminum (metal bowls only) Brass Cast Iron Carbon Steel 304 Stainless Steel 316 Stainless Steel Extended Shaft* 304 Stainless Steel 316 Stainless Steel Hastelloy B Hastelloy C Titanium Monel Ext ended Shaft Spring Cover Nylon Spring Cover Plug 18-8 Stainless Steel Cleanout Wrench Steel Control Box Glass-Filled Nylon Polysulphane Standard Switch (1 or 2) 3-wire SPDT 4–wire SPDT 3–wire Hermetically Sealed Pneumatic Switch Dial Glass-Filled Nylon Cam Glass-Filled Nylon Indicator Pointer Aluminum Standard Scale Gravoply Washer (3 req) Stainless Steel Box t o Housing Gasket Buna N Viton Pointer Screw Stainless Steel Lockwasher (2 req) 410 Stainles s Steel Cam Screw Steel Dial Screw Steel Sw it ch R et ai ne r Nut (2 req) Brass Tag Sc rew ( 2 R e) 18 -8 St ai nl es s St eel SEMS Screw 18-8 Stainless Steel Nameplate Aluminum Stainless Steel Control Box Gasket Viton Buna N am e Pl at e S cr ew (4 req) Stainless Steel Va lv e ( op ti ona l) Up to 1/4” Brass 1/2” and 2” Brass Control Box Lens Acrylic
Part Number 309 328 3 32 763 764 765 766 767-S 767-I 302-S 302-I 472 473 357 361 307 336 355 700 701 704 703 706 780 129 728 315 726 318 918 919 322 719 705 323 710 7 20 793 751 786 787 800 715 316 442 788
If the flow through the meter is from right to left, it must be so stated when ordering these parts.
5
42-65 SUPERIOR MK-II
Section 6 — Index
Gyratory Crushers
6. HYDROSET Control System Page 6-1 6-2 6-4 6-5 6-5 6-5 6-6 6-6 6-6 6-6 6-6 6-6 6-7 6-7 6-7 6-7 6-7 6-8 6-8 6-8 6-11 Appendix
Description Index General Information — Oil Supply System Cylinder Assembly — Removal And Inspection — Bushing Removal — Bushing Assembly — Replacing HYDROSET Oil Seal — HYDROSET Cylinder Cover Assembly — Piston And Clamp Plate Assembly — Replacing The Assembly — Alternate Method - Replacement of HYDROSET Oil Seal — Seticator Probe Assembly Balance Cylinder — Seals Repair Kit — Piston Repair Kit Relief Valve Oil Supply System — Oil Filter — Relief Valve — Bleeding Air From System Control Valve Assembly
17X0115-04.9911
6
6-1
42-65 SUPERIOR MK-II
Section 6 — HYDROSET Control System GENERAL INFORMATION Principal parts of the HYDROSET control system include a cylinder assembly, balance cylinder assembly (for primary crushers) and the oil supply system. The cylinder assembly for HYDROSET control includes those parts connected to the crusher itself — step support piston (2205-0), oil seal (2305-0), clamp plate (2325-0), and cylinder (2005-0). For illustration, see Fig. 6-1. The balance cylinder assembly (8075-0) for primary crushers prevents the mainshaft assembly from dropping suddenly when forced upward by crushing pressures. It is installed with a check valve (8525-0), which regulates the flow of oil to the balance cylinder. A more complete description is given on page 6-8. Catalog Number 2005-0 2050-1 2050-2 2055-0 2060-0 2090-0 2120-0 2140-0 2205-0 2205-1 2205-2 2217-0 2225-0 2260-0 2275-0 2276-0 2280-0 2305-0 2325-0 2325-1 2325-2 2325-4
6-2
Description HYDROSET cylinder Lower HYDROSET cylinder bushing Upper HYDROSET cylinder bushing Lower HYDROSET cylinder bushing bolt Upper HYDROSET cylinder bushing bolt nut HYDROSET cylinder dowel Bottom shell drain plug HYDROSET cylinder O-ring Piston Piston plug Piston plug capscrew Plug Piston dowel Piston wearing plate Step washer retainer Step washer retaining ring Step washer Oil seal Clamp plate Clamp plate retaining ring Bolt Washer
Gyratory Crushers
NOTE The piston wearing plate (2260-0, Fig. 6-1) is sup- plied with a wear indicator as standard equip- ment. The wear indicator consists of a cavity that is machined into the non-wearing (back) side of the piston wearing plate which is filled with a silver powder and sealed with a threaded plug. When wear reaches the depth at the bottom of the oil grooves in the piston wearing plate, the cavity is opened and the silver powder is released into the lubrication oil. An oil analysis will show the pres- ence of the silver powder, indicating the piston wearing plate (and/or mainshaft step) is worn out and requires replacement. Catalog Number
Description
2340-0 2340-8 2345-0 2345-8 2346-0 2505-0 2506-0 2510-2 2515-0 2515-1 2515-3 2530-0 2605-1 2606-0 2606-1 2606-2 2606-8 2630-0 2650-0 2650-8 2651-0
Measuring tube holder Gasket Measuring tube plug Seal ring Measuring tube holder plug HYDROSET cylinder cover HYDROSET cylinder cover O-ring Position indicator capscrew HYDROSET cylinder cover bolt HYDROSET cylinder cover nut HYDROSET cylinder cover locknut HYDROSET cylinder drain plug Position indicator Cover plate guard Capscrew Spring washer O-ring Measuring tube Position indicator adaptor O-Ring Capscrew
17X0115-04.9911
42-65 SUPERIOR MK-II
Section 6 — HYDROSET Control System
Gyratory Crushers
2345–0 2345–8
2340–0
2630–0 DETAIL “E”
2205–1 2205–2 (NOT SHOWN) 2140–0
2225–0
2275–0
2276–0
2280–0 2260–0 2060–0
2120–0
2217–0 2005–0
SEE DETAIL “E”
2050–2
SEE DETAIL “D”
2050–1
2325–0 2090–0
2205–0 2515–0 2515–1 2515–3
2505–0 2055–0
2305–0
2325–1 2325–2 2325–4
2506–0 2530–0
2606–1 2606–2
2606–0
2606–6 SEE DETAIL “C”
2650–8
2650–0 THREADS TO BE LOCKED WITH LOCTITE #242 2510–2 TORQUE 32 FT–LBS (42 N–m)
2630–0
THREADS TO BE LOCKED WITH LOCTITE #242
2340–0
DETAIL “C”
2651–0 TORQUE 18 FT–LBS. (25 N–m) 2606–8 2605–1
2340–0 2340–8
2346–0 DETAIL “D”
2325–0 SK083095–JJB–1
FIG. 6-1 — HYDROSET Cylinder Assembly 17X0115-04.9911
6-3
42-65 SUPERIOR MK-II
Section 6 — HYDROSET Control System
Gyratory Crushers
OIL SUPPLY SYSTEM The system includes a HYDROSET storage tank (7005-0), a motor driven gear pump (8105-0) and a control valve assembly (8608-0). All components are mounted on the external lubrication system base. Fig. 5-1, Section 5 shows the system arrangement. The system control valve assembly consists of a base plate where all external connections are made and a valve block which is bolted to the base plate. See Fig. 6-2. With this control valve assembly, the HYDROSET pump is arranged to operate in both directions.
4. Non-return valve 4 closes and the pump now sucks oil from the crusher through the valve. 5. The excess oil pumped to port A opens the overflow valve 6 and oil flows through filter 11 back to the tank. C. Correct setting The HYDROSET pump is stationary and the pressure in the HYDROSET system keeps the main non-return valve 3 closed. Fig. 6-3 shows the schematic flow diagram for the System B oil supply system and Fig. 6-4 shows the wiring schematic. An adjustable relief valve 5 is provided. This is set at 4.5 MPa (650 psi) to protect the pump from overloads when the setting is being decreased.
Backwards
Forwards
8606–0
FIG. 6-2 — Control valve assembly
A. Setting decrease - depressing the “raise” push button 1. The HYDROSET pump is started (forwards), resulting in a depression at port A. 2. The depression moves the sleeve 1 over towards the right so that oil flows from the tank through ports T and A to the pump. 3. Oil is pumped to port B and pushes the spindle 2 towards the right. 4. The pump pressure opens the main non-return valve 3 with allows the oil to pass freely to the crusher. B. Setting increase - depressing the “lower” push button 1. The pump is started (backwards) and oil is sucked from the tank through port T, non-return valve 4 and port B. 2. The pump pressure at port A pushes the spindle 2 to the left and opens the main non-return valve 3. 3. There is now a direct connection from the crusher. 6-4
Forward
1 2 3 4 5 6 7 8
Shut–off valve (8225–0) Hydroset pump (8104–0) Non–return valve Non–return valve Overflow valve Relief valve 650 psi (4.5 MPa) Pilot controlled non–return valve Relief valve 1090 psi (7.5 MPa)
FIG 6-3 — Oil supply system sc hematic 17X0115-04.9911
42-65 SUPERIOR MK-II
Section 6 — HYDROSET Control System
Gyratory Crushers
PB RAISE
PB LOWER MR
MOTOR STARTER FORWARD MF OL
MF
MOTOR STARTER REVERSE MR
by placing a jack with the proper blocking under the cylinder assembly. Take up on the jack until it is supporting the weight of the assembly. Insert the lowering rods and remove the nuts from the studs (2020-0). Unscrew the nuts on the lowering rods a distance equal to the maximum downward movement of the jack. Then allow the jack to lower the assembly down to the nuts. Repeat this procedure until the assembly has been removed. Place the assembly on a skid and pull it out from under the crusher.
CAUTION 115 V
Use extreme care in removing the cylinder as- sembly. Be sure the jack is level and solid.
SK102192JJB-1
FIG. 6-4 — Electrical schematic for HYDROSET control.
Emergency Manual Valve Actuation The control valve has a manual actuation facility for emergency use if contamination in the oil has blocked the valve so that normal motorized setting increase is impossible. This manual actuation facility is provided by components 7-10 shown in Fig. A. Manual operation is carried out as follows: 1. Unscrew cap 8. 2. Push in pin 7. If this cannot be done by hand, place a 10 mm dia. ball or other suitable object in the cap and screw the cap back on so that the pin is pushed in. 3. Start the pump for setting increase and lower the mainshaft to the desired position. 4. Stop the pump. 5. If a ball has been used inside the cap, remove it. 6. Replace the cap. 7. At the first suitable opportunity, remove the valve block (4 attachment screws on the top) and clean it. CYLINDER ASSEMBLY If maintenance is required on the cylinder assembly for HYDROSET control, remove the entire assembly from the crusher. Removal And Inspection Block up the mainshaft at the bottom shell arms, lowering the mainshaft to that point. This will avoid having full mainshaft weight on the cylinder lowering mechanism during removal. Then disconnect the lubrication and hydraulic lines, and drain the oil from the crusher by removing the bottom shell drain plug (2120-0) from the bottom of the HYDROSET cylinder flange. In removing the cylinder assembly, it is customary to leave the eccentric in place unless some work is necessary on it. The eccentric support plate (1905-0), held up by cap screws (1910-0), will retain the eccentric in position while the cylinder assembly is not in place. The cylinder assembly can be lowered by means of three lowering rods. (See Fig. 6-5.) Removal is accomplished most easily 17X0115-04.9911
When the cylinder assembly is free of the crusher, remove the step washer (2280-0) and the piston wearing plate (2260-0) from on top of the piston (2205-0). Screw an eyebolt into the tapped hole in the center of the piston. The piston can now be hoisted out of the hydraulic cylinder.
WARNING The clamp plate (2325-0) may adhere to the bottom of the piston (2205-0) during removal and fall off the piston after it has been removed from the hydraulic cylinder, causing injury or death. Be sure the clamp plate (2325-0) re- mains in the hydraulic cylinder. A slight jar can be used to separate the clamp plate (2325-0) from the bottom of the piston (2205-0). Screw eyebolts into the clamp plate (2325-0) and hoist it out of the hydraulic cylinder. Removing The Bushing Remove the upper bushing bolts (2060-0) from the flange of the hydraulic cylinder upper bushing (2050-2). Then jack the bushing from the cylinder, using the tapped holes provided for that purpose in the flange of the bushing. The lower bushing must be removed from the bottom of the hydraulic cylinder. Remove the lower bushing bolts (2055-0) from the flange of the hydraulic cylinder lower bushing (2050-1). Then jack the bushing from the cylinder using the tapped holes in the bushing flange. Inspect the wearing surfaces of the lower bushing, piston, and clamp plate carefully. These surfaces should be free of wear and scratches which might cut the HYDROSET oil seal. Take special pains to inspect the HYDROSET oil seal. This seal must withstand pressures up to approximately 2000 psi and should have no nicks or cracks. Any chip out of the seal means leakage and consequent inability of the crusher to maintain its setting. This seal should be inspected closely and handled carefully at all times. 6-5
Section 6 — HYDROSET Control System Bushing Assembly The upper and lower HYDROSET cylinder bushings (2050-1 and -2) are a close clearance fit. Chill with dry ice before attempting to install them in the HYDROSET cylinder. They may also be slightly out of round until installed in the thicker, more stable containment of the cylinder. Before actually installing them in the cylinder, install two long guide bolts, 180o apart, in holes in the cylinder and in the bushing flange so that the joint bolt holes will match when the bushing is seated in the cylinder. Start the bushings into the cylinder squarely, and push into place. Replacing The HYDROSET Oil Seal Remove screws (2325-2) which hold the seal retainer ring (2325-1) to the clamp plate (2325-0). Remove the clamp plate and oil seal. Install the new oil seal (2305-0) into the clamp plate (2325-0) such that the pressure side will be toward the retainer ring (2325-1). Install the retainer ring with screws (2325-2) and washers (2325-4).
42-65 SUPERIOR MK-II Gyratory Crushers
NOTE Coat all parts with oil before assembling. Replacing The Assembly First install O-ring (2140-0) into the groove on the upper face of the cylinder (2005-0). Next, place the assembly under the crusher and place the 1.75” diameter lowering rods (3) into position (See Fig. 6-5). Raise the assembly into place using the lowering rods and the hydraulic jack (Fig. 6-5). After the assembly is in place, tighten the nuts (2020-2) evenly (1400 ft. lbs. - 1898 N-m) and replace the lubrication and hydraulic piping.
NOTE Use Loctite #242 on screw threads and torque the .375” screws to 2.4 ft. lbs. (32.5 N-m). HYDROSET Cylinder Cover Assembly The HYDROSET cylinder cover (2505-0) fastens to the bottom of the cylinder (2005-0) with bolts (2515-0) and nuts (2515-1 and 2515-3). An O-ring (2506-0) is used to seal between the cover (2505-0) and the lower bushing (2050-1). To assemble the cover (2505-0), first place the O-ring (2506-0) into the cover groove. Next, install 1” diameter roll pin (2090-0) into the cover roll pin hole and then, either raise the cover up to the cylinder with the three piston lowering rods (see Fig. 6-6) or lower the cylinder onto the cover plate. Be sure the roll pin (2090-0) seats into the corresponding cylinder roll pin hole. Install bolts (2515-0) with nuts (2515-1 and 2515-3). Torque to 1400 ft. lbs. (1898 Nm) Piston and Clamp Plate Assembly Lightly coat the upper and lower cylinder bushings with oil. Place two 0.75” eyebolts in the top of the clamp plate assembly (2325-0) and lower it into the cylinder (2005-0) until it rests on the cover plate (2505-0). Next, insert a lifting eyebolt into the top of the piston (2205-0). Lift and lower the piston (2205-0) into the cylinder (2005-0) until it rests on top of the clamp plate (2325-0). Replace the piston wearing plate (2260-0) being sure the dowel (2225-0) enters the hole in the bottom of the wearing plate so that the plate is flat on the top of the piston (2205-0). Place the stepwasher (2280-0) on top of the piston wearing plate with the concave side up. Install the stepwasher retainer (2275-0) on top of the stepwasher. Then install retaining ring (2276-0) to hold the parts to the piston (2205-0). 6-6
Lowering rod
Hydraulic jack
Block
FIG. 6-5 — HYDROSET cylinder removal and installation
Alternate Method — Replacement Of HYDROSET Oil Seal The piston, clamp plate with oil seal (2305-0) and cover plate can be removed from the hydraulic cylinder (2005-0) without removing the hydraulic cylinder assembly from the crusher. The entire assembly is lowered on the cover plate with lowering rods and jack after the cover plate bolts (2515-0) have been removed. Note that the piston and clamp plate are not fastened together. The piston simply sets on the clamp plate and the parts are held together by the weight of the piston. For disassembly of the HYDROSET oil seal from the cover plate see “Replacing the HYDROSET Oil Seal” in this section. The HYDROSET oil seal may be removed from the crusher without removing the piston. This procedure is the same as removing the piston except that a piston stop plate, which is furnished with the tools, is inserted in a groove about 1 inch (25.4 mm) above the bottom of the piston after the piston has been lowered far enough so that 17X0115-04.9911
42-65 SUPERIOR MK-II
Section 6 — HYDROSET Control System
Gyratory Crushers
the groove is below the bottom plate flange.Then this plate is bolted to the bottom plate holding the piston in the cylinder while the clamp plate and seal is lowered by means of the lowering rods or a jack. See Fig. 6-6.
WARNING The clamp plate (2325-0) may adhere to the bottom of the piston (2205-0) and fall off the pis- ton, causing injury. A slight jar can be used to separate the clamp plate (2325-0) from the bot- tom of the piston. (2205-0).
PISTON STOP PLATE PISTON LOWERING RODS (3)
FIG. 6-6 — Removal of HYDROSET oil seal with bottom plate assembled to crusher.
Seticator Probe Assembly SUPERIOR MK-II crushers are usually furnished with a mainshaft position indicator system for electronic monitoring of the position of the mainshaft in the crusher. The SETICATOR probe assembly, as part of the system, is directly attached to the bottom of the HYDROSET cylinder assembly. Refer to FIG 6-1 for assembly, bolt torques and Loctite sealant placement. Also refer to the separate instruction manual for the Mainshaft Position Indicator System. BALANCE CYLINDER Large chunks of feed in the chamber of primary crushers sometimes force the mainshaft upward in a quick “jumping” action. A balance cylinder is furnished only with primary crushers to make the piston follow the mainshaft up when it is raised by jumping and ease the shaft down to its original 17X0115-04.9911
position. This is accomplished by the balance cylinder (8075- 0) and check valve (8525-0). See Fig. 6-7 and 6-8. Under normal operating conditions, the balance cylinder contains a fixed quantity of oil and nitrogen. After the system has been bled of air and with the shaft raised hydraulically to its operating position, the balance cylinder must be charged with 90 psi (620 KPa) of nitrogen . NOTE: Pre-charge pressure must be measured after the HYDROSET system is filled with oil and the mainshaft assembly is supported on a column of oil underneath the HYDROSET piston. The pre-charge pressure is less than the hydraulic pressure produced by the weight of the mainshaft assembly (even when the mantle is in a totally worn condition) and more than that produced by the weight of the crusher piston. For example, when the 42-65 mainshaft assembly rises, the hydraulic pressure will drop below 90 psi. The nitrogen in the balance cylinder will force oil into the HYDROSET system and make the piston rise with the shaft. When the mainshaft is released and starts to drop, the pressure in the hydraulic system builds up to more than 90 psi (620 KPa), forcing the oil back into the balance cylinder. To prevent the mainshaft from returning to its original position too rapidly, the check valve meters the oil returning to the balance cylinder. See Fig. 6-9. Seals Repair Kit (8075-4) A seals repair kit (8075-4) consisting of items 7, 8, 9, 10 and 12 shown in Figure 6-8a is available. The kit contains the correct quantities for one (1) balance cylinder. Piston Repair Kit (8075-8) A piston repair kit (8075-8) consisting of items 4, 5, 6 and 15 as shown in Figure 6-8a is available. The kit contains the correct quantities for one (1) balance cylinder.
RELIEF VALVE Two relief valves (8645-0) are located in the HYDROSET control pipe line. They are set at 750 pounds per square inch (5171 KPa). Their purpose is to relieve the pressure in the hydraulic system if it becomes excessive. See Fig. 6-8. The relief valve normally requires little maintenance. If it is believed to be inoperative, it may be checked by attaching it to a high pressure device, such as a hydraulic jack, high pressure grease gun or gauge line of a hydraulic press, with a gauge, and noting the pressure at which the valve operates. This should be within 10% of that stamped on the valve. Be sure that the pressure side, marked “P,” is attached to the high pressure pipe, and that the relief side, marked “R”, is away from the pressure and open to atmospheric pressure. DO NOT PLUG RELIEF END AT ANY TIME. 6-7
42-65 SUPERIOR MK-II
Section 6 — HYDROSET Control System
Gyratory Crushers
Check Valve
Oil Pressure is Higher Than Nitrogen Pressure
Balance Cylinder Normal Crushing
Nitrogen Under Pressure
Upwarding Jumping of Mainshaft Caused by an Occasional Rock Position or Tramp Iron in Crushing Chamber.
Free Flow of Oil Thru Check Valve. Restricted in Opposite Direction.
Piston
Clamp Plate Loose Step Bearing Components. When the Mainshaft Jumps, the Balance Cylinder Forces Oil Under Piston to Keep the Piston Clamp Plate, Piston, Piston Wear Plate, Step Washer, Step, and Shaft Tight Together, Preventing Separation and Damage.
Check Valve
Floating Piston
Oil Pressure is Less Than HYDROSET Oil Pressure When Mainshaft Jumps.
Charging Valve
FIG. 6-7 — How the balance cylinder operates.
OIL SUPPLY SYSTEM - FIG. 5-1, SECTION 5 AND PAGE 6-3, SECTION 6 Oil Filter (8609-1) The oil filter (8609-1) mounted between the control valve and the HYDROSET tank is of the full flow type which requires all of the oil to pass through it. The filter element (8609-9) is the throw-away type. When a filter change is carried out – which should be each time the HYDROSET oil is changed or every six 6-8
months – relieve the pressure in the system by lowering the mainshaft to its bottom position. Unscrew the filter element and replace with a new one. Relief Valve The relief valve is mounted on the base plate of the control valve. It is tested at a setting of 1090 psi (7.5 MPa) and sealed before delivery.
17X0115-04.9911
42-65 SUPERIOR MK-II
Section 6 — HYDROSET Control System
Gyratory Crushers
8075-3 PRESSURE GAUGE 8075-4
8076-0 8076-1 8076-4
8075-0
8026-0
(INCH) 0.25” NPT1 (FEMALE) BLEEDER PORT 8565-0 8565-4
8085-0 8556-0 8540-0 8540-1 8521-0 8525-0 8530-0 8028-0 8755-8
(INCH) 1.0” NPT1 (FEMALE) HYDROSET OIL INLET PORT 8425-0 8645-0 8645-1
8555-0
8556-0 8556-1 8565-0 8565-4
8558-0
SK080897-JJB-2
FIG 6-8 — Balance Cylinder and HYDROSET Piping
17X0115-04.9911
6-9
42-65 SUPERIOR MK-II
Section 6 — HYDROSET Control System
Gyratory Crushers
) m N 5 7 9 6 E 4 . 1 1 1 U S O B Q O T L T R 5 – . 3 O 3 T 8 T 1 F 1 (
1
N P O U L K F C E A 8 T B
W E T R E C 3 E S S 1 G 7 P A N I Y N R T – N U B O O P T U S I C P U 4
N P O U L K F C E A 9 T B P A U N C - U 0 U B 1
7 1 8 1
G 2 N 1 A I N N R 6 U – G O I B O N U T L C O E P E T D I E S E P L I U S P P G I N O 1 P I H 1
D O R N O T S I 5 P
2
E V L A V R I 4 A 1
5 1
T T I I K N K R O I I I R A T A P P P E I E R R R C N S S L O E A T D E S I S P G R O E 4 8 L B – – A 5 5 M T 7 7 A U 0 0 C N 8 8
1 – B J J – 8 9 5 2 8 0 K S
Y T I T 4 N 2 3 1 2 1 1 2 8 4 A U ) ) ) 4 Q T 0 1 P 2 – ) – N ” ) ” 0 ” 5 T 0 . 1 ) ) 5 ) 2 1 – T . P ( ” ) 2 G R A . 0 5 N ( ( A N N O M 7 ” . N U W O H 5 A 0 E U S J ( L 2 G B ( S ( E . ( M B T T D D 0 R A ( U ( L G C U U N P P N S E N N O O R R T U E I R T V L X X E E R C P – – I E A E E I I A U P P O S V H H T T . O N 0 1 2 3 4 5 6 7 8 T 1 1 1 1 1 1 1 1 1 R A P
R E D N I L Y Y C T I T 3 E 1 1 1 1 1 1 2 2 2 C N N A A U Y E L Q D A ) ) R O P B Y N N E B T R L I ) O O E V E P O V O B E A L L – O C U U D D N F F E N E C T C I U E U T – O D E B ( T ( ( M E R G U G A D N P C E O N N N N N N G U P U R E D A O O O N I K K T T T T D N I T C C I L S S S R N R L A I I I – A A A O R B B P P P O B B T P S I L . S O T N R T 1 2 3 4 5 6 7 8 9 A R P A P
FIG 6-8a — Balance Cylinder
6-10
17X0115-04.9911
42-65 SUPERIOR MK-II
Section 6 — HYDROSET Control System
Gyratory Crushers
DIRECTION OF FREE FLOW BALANCE CRUSHER CYLINDER
BLEEDING AIR FROM THE SYSTEM The oil supply system requires air to be removed during the original start-up of the system or when a break in the line occurs. Start the pump by depressing the “raise” push button so that oil is pumped to the crusher. Open the upper bleed port until bubble free oil comes out. The upper air bleed port is located at the lower end of the balance cylinder (8075-0). See Fig. 6-8. Close the air bleed port and stop the HYDROSET pump when the shaft has been raised 0.125 to 0.25 inches. Remove pipe plug (2530-0). (Fig. 6-1) at bottom of HYDROSET cylinder cover (2505-0) to bleed air from the cylinder. Repeat the air bleeding procedure at both points until bubble free oil flows out.
RING SEAT DISC SPRING BODY FIG. 6-9 — Check valve for HYDROSET system — with balance cylinder.
17X0115-04.9911
6-11
SUPERIOR Crusher Control Valve
Catalog Number 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
Qty. 1 1 1 1 1 1 1 1 1 2 1 1 1 1 3 1 1 1 1
17X0143.9503
Description Spring cage Manual operating knob Sleeve Piston Seat Distance ring Plug Ball retainer Distance pin Spring Spring Valve house Base plate Valve plug Valve seat Spring Return spring Screw washer Ball retainer
Parts List
Catalog Number 33 34 38 39 50 51 52 53 54 55 56 57 58 59 60 61 62 63
Qty. 1 1 1 1 1 4 5 1 1 3 1 1 1 4 1 1 1 1
Description Damping Ring Valve plug Distance screw Banjo connection O-ring O-ring O-ring O-ring Seal ring Steel ball Steel ball Plug Set screw Screw Seal ring Washer O-ring Seal ring
1
Section 7 — Index
42-65 SUPERIOR MK-II Gyratory Crushers
7. Bottom Shell Assembly
Page 7-1 7-2 7-2 7-2 7-3
Description Index Dust Collar Bottom Shell Bushing — Removal — Assembly
7
17X0115-04.9911
7-1
42-65 SUPERIOR MK-II
Section 7 — Bottom Shell Assembly
Gyratory Crushers
The bottom shell assembly (Fig. 7-1) consists of the bottom shell (1005-0) with arm and side liners (Fig. 7-2), bottom shell bushing (1200-0) with key (1210-0), and dust collar (1400-0) with gasket (1430-0). It serves as the mounting base for the entire crusher. DUST COLLAR The dust collar has an interference fit with the turn of the bottom shell hub. The collar is secured to the bottom shell with bolts on the inside of the collar. The mainshaft must be removed to provide access to the bolts. Take care when removing the collar to prevent damage to the gasket (1430-0) between the collar and bottom shell. The collar can be removed from the short interference fit with the bottom shell by using jack bolts in the threaded holes provided. When reassembling the dust collar, be careful with the gasket installation. Large holes in the gasket must line up with the oil return holes in the bottom shell and in the dust collar. The upper counterweight splash ring (1420-0) bolts to the dust collar (1400-0) lifting eyebolt holes (3) with fasteners (1421-0). BOTTOM SHELL BUSHING The bronze bottom shell bushing is keyed with a straight
DUST COLLAR 1400-0 1010–2
type key (1210-0). Assembly and removal is from the top, after removal of the spider, mainshaft assembly, dust collar and eccentric. Removal Bottom shell bushing removal after a bearing failure is easily accomplished, using the eyebolts provided and lifting the bushing out with a crane. Overheating shrinks the bushing in the normal slight clearance fit with the bottom shell, and very little resistance occurs. The hoisting hitch should have a spreader bar at the eyebolts between the two hoisting slings to prevent collapsing of the bushing top from the strain on the cables. The eyebolt holes are relatively small, so a small amount of pressure should be applied for pulling. If a good, reusable bottom shell bushing has to be removed for any reason, the fit may be snug. Bushings sometimes go out of round from removal of the clamping device on the machine tool after manufacture. If the bushing does not show evidence of coming out with a taut hitch in the eyebolt holes, it may be necessary to use one of the following methods to remove it: 1. Block the bushing bottom with plywood and shrink the bushing by soaking in pulverized dry ice. 2. Fit a steel plate or bar on the bushing bottom and jack it out from cribbing underneath the crusher. This normally can be done with a ten or twenty ton jack.
1405-0 1405-2 1405-4 1408-0 (NOT SHOWN) 1800–0
SPLASH RING 1420-0
1421–0 GASKET 1430-1
1010-7 1010-8
BOTTOM SHELL 1005-0
1020–1 AIR INLET CONNECTOR 1675-0
1255–0 1261-0 1261-4
1365-0 1365-1 1365-2 1365-3
LUBE LINE TO BOTTOM SHELL BUSHING 1250-0 1260–0
1321–0
1030–1 KEY 1210-0
1505-0 1505-1 1505-2 1505-3
BOTTOM SHELL BUSHING 1200-0
3030–0
2020-0 2020-1 2020-3
SK070299–JJB–5
FIG. 7-1 — Bottom shell assembly
7-2
17X0115-04.9911
42-65 SUPERIOR MK-II
Section 7 — Bottom Shell Assembly
Gyratory Crushers
POSITION SLOTTED WEDGES 1352-1 UNDER EACH LINER BOLT OF THE BOTTOM ROW OF HOLES
POSITION PLAIN WEDGE 1352-0 IN APPROXIMATE POSITIONS AS SHOWN
1326-2 R.H. SHOWN 1326-1 L.H. OPPOSITE
45.0O
1322-1 L.H. SHOWN 1322-2 R.H. OPPOSITE
45.0O
1320-1 L.H. SHOWN 1320-2 R.H. OPPOSITE
1321-2 R.H. SHOWN 1321-1 L.H. OPPOSITE
PINIONSHAFT END
CENTER LINE BOTTOM SHELL
TOP VIEW
SK031092JJB-18
FIG. 7-2 — Bottom shell liner assembly Catalog Number
Description
1010-2 1010-7 1010-8 1320-1 1320-2 1321-1 1321-2 1322-1 1322-2
Narrow Arm Liner Pinionshaft Arm Liner L.H. Pinionshaft Arm Liner R.H. Side Liner Adjacent Pinionshaft L.H. Side Liner Adjacent Pinionshaft R.H. Side Liner Opposite Pinionshaft L.H. Side Liner Opposite Pinionshaft R.H. Side Liner Intermediate L.H. Side Liner Intermediate R.H.
Assembly Before installing a new bottom shell bushing, inspect the surface of the bottom shell bore. The bore should be relatively smooth, round and not tapered. Remove any burrs or protrusions. Make certain that the end of the bushing, marked “top,” is upward. If the bushing is inserted upside down, the oil holes in the bushing will not match the annular oil feed groove in the bottom shell and lubricating oil will flow into the eccentric and bushing. Chill the bottom shell bushing with the key in place in a refrigerator, or by using dry ice chipped extremely fine in the bore. If dry ice is used, cover the bushing with an insulating blanket or tarpaulin. Two hours of chilling is usually sufficient to allow easy entrance into the bottom shell bore. The reason for chilling the bottom bushing, although a slight clearance fit in the bottom shell bore, is 17X0115-04.9911
Catalog Number
Description
1326-1 1326-2 1352-0 1352-1 1365-0 1365-1 1365-2 1365-3
Side Liner Adjacent Narrow Arm L.H. Side Liner Adjacent Narrow Arm R.H. Side Liner Plain Wedge Side Liner Slotted Wedge Side Liner Bolt Nut Washer Locknut
that they frequently go out of round after removal from the machine tool in manufacturing. Chilling allows easy entrance with less chance of metal pick up and bushing distortion. If chilling is not sufficient to do the job, it may be necessary to use a jack to replace the bushing. Place a heavy bar or I-beam across the top of the bottom shell and hold it in place by bolting. Use a small jack between this bar and a plate laid over the bottom shell bushing. The jack will force the bushing into the bore.
NOTE Never use a hammer or sledge to drive the bushing into place. Hammering will peen the bronze, reducing bearing clearance and possibly causing bearing failure during crushing operations. 7-3
42-65 SUPERIOR MK-II
Section 8 — Index
Gyratory Crushers
8. Eccentric Assembly
Page 8-1 8-2 8-2 8-3 8-4 8-4 8-4 8-4 8-5 8-5 8-5 8-5 8-5 8-5 8-7 Appendix
Description Index General Information Eccentric Assembly Removal Eccentric Assembly Replacement Eccentric Bushing Eccentric Driving Gear — Removal — Inspection — Reassembly Lower Counterweight Assembly — Removal — Assembly Upper Counterweight — Removal — Assembly Bevel Gear Installation And Maintenance – 17X0118.9403
8
17X0115-01.9612
8-1
42-65 SUPERIOR MK-II
Section 8 — Eccentric Assembly
Gyratory Crushers
ECCENTRIC ASSEMBLY The eccentric assembly consists of the eccentric (1805-0), the eccentric bushing (1810-0), and the eccentric gear (1850-0) the lower counterweight (1812-0), the upper counterweight assembly (1811-0), and keys (1820-0 and 1855-0). The eccentric rests on the eccentric wearing plate (1880-0) and is held in place by the eccentric support plate (1905-0). See Fig. 8-1 for arrangement. Eccentric Assembly Removal The eccentric can be removed after removing the cylinder assembly. Leave the eccentric support plate screws (1910-0) in place, so the support plate holds the eccentric in the crusher while the cylinder is removed. Then lower the eccentric separately on the lowering rods. Refer to “Cylinder Assembly Removal And Inspection,” Section 6, page 6-5. Use a hydraulic jack along with the lowering rods to facilitate lowering the eccentric, in the same manner as the cylinder assembly is lowered. Place a small dolly or skid under the assembly for easy removal from under the crusher.
CAUTION Use extreme care in removing the eccentric assembly. Be sure the jack is level and solid. Occasionally, due to an accident, an eccentric will
seize while operating. If the seizure is between the shaft and the eccentric bushing (1810-0), the crushing mantle will rotate at eccentric speed and will not raise or lower the full amount with the HYDROSET control when the crushing chamber is empty. The crusher will stall when material is fed into the crushing chamber. If the eccentric bushing is badly seized, it will stay on the shaft when the eccentric is removed. It will probably be necessary to cut the bushing to remove it from the shaft. (Be careful not to damage shaft, should cutting be necessary.) If the seizure is between the eccentric and the bottom shell bushing (1200-0), the drive sheave cannot be turned. To remove the eccentric under these conditions is often difficult. If the eccentric cannot be removed as usual, remove the top shell, mainshaft assembly, dust collar (1400-0), and the cylinder assembly. Lower the eccentric support plate one inch (2.54 cm). Place a hydraulic jack on top of the eccentric and under a cross beam bolted to the bottom shell. Warming and chilling the eccentric several times may help to crack the eccentric loose. Do not attempt to push the eccentric up. Inspect the eccentric to determine if wearing surfaces are scored or show evidence of excessive wear or heating. Also inspect the inside of the eccentric bushing for wear, scoring and dark spots which indicate that it has been subjected to excessive heating. Mike the eccentric to check for out-of-roundness or taper.
UPPER COUNTERWEIGHT 1811-0
LOWER COUNTERWEIGHT 1812-0 ECCENTRIC GEAR KEY 1855-0
PIPE
LOWERING ROD 8955-0
SK021392-JJB-3
O-RING 1920-0 ECCENTRIC SUPPORT PLATE 1905-0
1910-0 1910-4 ECCENTRIC GEAR 1850-0 ECCENTRIC BUSHING 1810-0 ECCENTRIC 1805-0 ECCENTRIC WEARING PLATE 1880-0
FIG. 8-1 — Eccentric assembly, showing location in bottom shell, with support and wearing plates.
8-2
17X0115-01.9612
42-65 SUPERIOR MK-II Gyratory Crushers
Section 8 — Eccentric Assembly
Eccentric Assembly Replacement 1. Assemble the eccentric in reverse order to that for disassembly. Center the eccentric on the wearing ring and eccentric support plate. Position the support plate so that the oil drain hole lines up with the hole in the HYDROSET cylinder flange. 2. Inspect the eccentric support plate O-ring (1920-0). Replace if damaged. Use a light grease to hold the Oring in the support plate groove. 3. As the assembly is raised, guide the eccentric so that the mainshaft enters the eccentric bushing bore. Guide the eccentric as it enters the bottom shell bushing. If using a jack, watch for any binding of the top of the eccentric with the bushing — there will be a significant increase in the amount of force required to continue raising the eccentric. If this occurs, lower the eccentric slightly and rock it back and forth on the lowering rods to properly engage the bushing as it moves upward. 4. After the eccentric enters the bottom shell bushing, it should move easily to its top position. As the drive gear engages the pinion, rotate the pinion slightly, back and forth, to mesh the teeth.
Building joist Hydraulic jack Block Bevel gear Plate
Eccentric
Eccentric bushing
Steel blocks
07–010–275
FIG. 8-3 — Removing eccentric bushing.
5. When the eccentric assembly is in position, attach it to the bottom shell with screws (1910-0), securing the eccentric support plate. 6. Check the gear and pinion backlash and tooth contact. See “Bevel Gear Installation And Maintenance,” in the Appendix.
FIG. 8-2 — Eccentric assembly shows oil groove in eccentric.
17X0115-01.9612
FIG. 8-4 — Miking eccentric bore opposite keyway before assembly
8-3
Section 8 — Eccentric Assembly ECCENTRIC BUSHING The removal of the eccentric bushing is normally an easy operation after the upper counterweight assembly (1811-0) is removed. (See “Removal - Upper Counterweight” in this section.). In a few cases it is possible to tap or drive the bushing out the top with a piece of wood and hammer with the eccentric on its side. If this operation is difficult, force the bushing out of the eccentric bore, as shown in Fig. 8-3. When replacing the bushing, it should go into the eccentric bore with a push fit. It is keyed to the eccentric and should be assembled by placing the key in the eccentric bushing and pushing the bushing with key into the bore. Chilling the bushing (key in place) with finely chipped dry ice is recommended. See Fig. 8-5. Cover with an insulating blanket until frost appears on the outside diameter — usually a minimum of two hours. The bushing must be pressed in, not pounded, as this will peen over the top of the sleeve, decreasing the inside diameter. If no other means are available, press it in by placing a jack between a stone bin or strong joist and the eccentric and pressing the bushing down into the eccentric.
42-65 SUPERIOR MK-II Gyratory Crushers
NOTE Never use a hammer or sledge to drive the bushing into place. Hammering will peen the bronze, reducing bearing clearance and possibly causing bearing fail- ure during crushing operations. ECCENTRIC DRIVING GEAR Removal The eccentric driving gear has a slight interference fit on the eccentric. The recommended method for removal is to press it off, using a hydraulic jack. The gear seats against a shoulder on the eccentric, and is usually removed with the eccentric upside down. See Fig. 8-6 for an illustration of gear removal. Inspection Inspection of the eccentric driving gear primarily involves looking for broken teeth or excessive wear.
NOTE It is common to get some early pitting in the gear teeth. However, However, once the gear set has aligned itself, the pinion teeth should polish the driving gear teeth over their full length and pitting should decrease. Excessive wear may be caused by improper backlash between the gear and pinion, by operating the crusher at a setting closer than that for which it was designed, by unclean oil, or pinion improperly set. When replacing worn gears, use proper thickness of gasket to align the pitch lines of the gear and pinion. BUILDING JOIST JACK PLATE OVER ECCENTRIC ONLY ECCENTRIC GEAR
07–010–631
FIG. 8-5 — Installing chilled bushing in eccentric.
8-4
FIG. 8-6 — Eccentric gear removal for all crushers. Gear is installed below a small flange on eccentric. 17X0115-01.9612
42-65 SUPERIOR MK-II Gyratory Crushers
Reassembly The assembly of the gear on the eccentric involves the following steps. 1. Install Install the the key in the eccentric eccentric to to the proper proper depth depth of engagement with the gear. The square key is held in place by a 5/8” hex socket head screw. The key cannot be assembled to the eccentric with the gear in place. 2. Check both portions portions of the fit fit and and st stop op shoulder shoulders s for burrs or bruises. Remove excess material until flush with the adjacent surfaces. 3. The gear gear,, with with or without without the the lower lower counter counterweight weight,, must be shrunk on the eccentric. Heat the gear in oil brought up to approximately 300 o F (150o C). When the oil starts smoking, it is near the flash point, which is above 300o F (150o C) for most oils.
NOTE If heating torches (Fig. 8-7) are used to expand the gear, the lower counterweight (1812-0) should be re- moved as it is lead filled and local heating could melt the lead. See “Removal - Lower Counterweight” in this section.
CAUTION Be extremely careful when handling heated oil and machine components. 4. Place the heate heated d gear gear on edge supports supports with at least least 1” (25 mm) clearance underneath (teeth upwards.) 5. Install Install the the three three 0.75” 0.75” eyebolt eyebolts s in top of the the eccentr eccentric. ic. Lift and lower it into the bore of the gear until the shoulder on the eccentric is in contact with the face of the gear.
FIG. 8-7 — Heating eccentric gear before assembly on eccentric. 17X0115-01.9612
Section 8 — Eccentric Assembly LOWER COUNTERWEIGHT (1812-0) The lower counterweight is held in place by three hex socket head capscrews (1812-1) and is retained from horizontal movement by dowels (1812-5).
Removal (See Fig. 8-8) 1. Lower the eccentri eccentric c assemb assembly ly onto onto blocks, blocks, a minimum minimum of 12” high, using three 1.0” diameter eyebolt holes in the top of the upper counterweight (1811-0). The blocks should be positioned under the lower counterweight (1812-0), between screws (1812-1). 2. Remove the three 0.75” diameter diameter screws screws (1812-1). (1812-1). 3. Lift the eccentric eccentric assemb assembly ly off off the the lower lower counter counter-weight. weigh t. If counterweight lifts with the eccentric assembly, use a pry bar between the counterweight and the gear to break it loose.
Assembly (See Fig. 8-8) 1. Block Block up the counte counterwe rweigh ightt (1812-0 (1812-0)) between between bolt bolt holes, a minimum of 12” off the floor. 2. Install three three 1.0” 1.0” diamet diameter er eyebol eyebolts ts in the top top of the upupper counterweight (1811-0). Lift and lower the eccentric assembly onto the lower counterweight (1812-0). Be sure the two dowel pins in the lower counterweight seat into the dowel holes in the gear (1850-0). 3. Fasten Fasten the lower lower counter counterweig weight ht to the the gear gear with thre three e hex socket head screws (1812-1) and hardened washers (1812-2). Torque Torque the 0.75” diameter screws to 395 Ft.-Lbs. (535 N-m).
UPPER COUNTERWEIGHT ASSEMBLY ASSEMBLY (1811-0) The upper counterweight assembly is made up of the upper counterweight (1811-5) and retaining ring (1811-8). The retaining ring is shrunk fit into the bore of the counterweight and prevents the eccentric bushing (1810-0) from moving up in the eccentric. In the event where the eccentric bushing is seized on the shaft, the retaining ring will be pressed out of the counterweight as the shaft is lifted out.
Removal (See Fig. 8-9) The upper counterweight assembly is fastened to the top of the eccentric with four hex socket head capscrews (1811-1 and 1811-6). 1. Rem Remove ove scre screws ws (181 (1811-1 1-1 and and 181 1811-6). 1-6). 2. Install Install three three 1.0” diameter diameter eyebolt eyebolts s into into the the lifting lifting holes in the top of the counterweight assembly and lift it off the eccentric. 3. Press out the the retaining retaining ring (181 (1811-8) 1-8) through through th the e top of the counterweight. Normally the retaining ring should not be removed from the counterweight unless it is severely damaged or bent. 8-5
42-65 SUPERIOR MK-II
Section 8 — Eccentric Assembly
Gyratory Crushers
LIFTING EYEBOLT
UPPER COUNTERWEIGHT 1811-0 ECCENTRIC ASSEMBLY 1800-0 DOWEL PINS 1812-5
GEAR 1850-0
LOWER COUNTERWEIGHT 1812-0
1812-1 1812-2 BLOCKS SK022192-JJB-8 FIG. 8-8 — Lower counterweight removal and assembly
1811-1 1811-6 1811-5
1811-8
1810-0
ECCENTRIC ASSEMBLY REF.
SK031894-JJB-1 FIG. 8-9 — Upper counterweight assembly
8-6
17X0115-01.9612
42-65 SUPERIOR MK-II Gyratory Crushers
Assembly (See Fig. 8-9) 1. Remove any burrs or upset metal in the bore of the counterweight and on the outside diameter of the retaining ring. 2. Pack the retaining ring in chipped dry ice for two hours or heat the counterweight to 250 o F. (121o C.). 3. Press the retaining ring into the counterweight through the top until it seats on the shoulder in the bore of the counterweight. The narrow face of the retaining
17X0115-01.9612
Section 8 — Eccentric Assembly
ring must be assembled such that it is in contact with the shoulder in the bore of the counterweight. 4. Place the counterweight assembly on top of the eccentric and fasten it to the eccentric with screws (1811-1 and 1811-6). Torque the 0.75” diameter screws to 337 Ft.-Lbs. (457 N-m) and the 0.5” diameter screws to 95 Ft.-Lbs. (129 N-m).
8-7
Curved Tooth Spiral Bevel Gear Installation And Maintenance
42-65 SUPERIOR MK-II Gyratory Crushers
GENERAL Bevel gears of the curved tooth spiral type are used in the Model 42-65 Superior crushers.The following information is to assist you in installing and maintaining these gears. Since the tooth bearing “markings” (area of contact) of spiral bevel gears vary with each gear installation, the following information pertains to the ideal installation. Some slight apparent misalignment will occur with all installations because the gears are not rigidly mounted. However, tooth bearing “markings” which show obvious serious misalignment should be corrected. When reinstalling gears, note and check the bearing “markings” under heavy loads and accept these as normal. Then, using the charts provided on spiral bevel gear misalignment, make the necessary adjustments to maintain the proper tooth bearing for the gears.
CONTACT
BACKLASH
FIG. 1 — Backlash in the plane of rotation
PITCH LINE Backlash — The clearance between the teeth, measured on the pitch line of the gear is used to determine if the gears have correct amount of backlash. The following formula Is suggested for checking the PITCH LINE backlash: CMS (Circumferential Movement of Sheave) = PLB (Pitch Line Backlash) x PDS (Pitch Diameter of Sheave)
ASSEMBLING AND INSTALLING SPIRAL BEVEL GEARS 1. Check to make certain the gear and pinion are properly located on the eccentric and pinion shaft. 2. Check the tooth bearing (area of contact). 3. Check for correct amount of backlash. 4. Tighten all lock nuts, bolts, etc., on the mountings. 5. Lubricate gears properly before operating under power.
MEASURING BACKLASH Spiral bevel gears are machined to have a definite amount of backlash (clearance) as determined by the pitch of the gears and the operating conditions. The correct amount of backlash is necessary for safe and proper operation of gears. Insufficient backlash results in noisy gears, excessive wear, scored tooth surfaces, and breakage. See FIG. 1. When checking the backlash of the gears, move the eccentric assembly toward the pinion to remove all clearance between the eccentric and the bottom shell bushing. If the crusher is assembled, put a block of wood in the crushing chamber on the side opposite the pinion. Raise the mainshaft assembly, using the Hydroset control. Applying 50 psi pressure above the level caused by the static load of the mainshaft assembly should be sufficient to push the combined mainshaft and eccentric assemblies toward the pinion to remove all clearance between the eccentric and bottom shell bushing. Be sure to use accurate instruments to measure backlash. A dial indicator is recommended if available. 17X0118.9403
PDP (Pitch Diameter of Pinion) Example: A Model 42-65 Superior crusher has a 40.0 PDS. What should the PITCH LINE backlash measurement be on the sheave pitch diameter? See Table for correct backlash and solve as below. .051 x 40 CMS = = .133 inches minimum 15.3 CMS =
.061 x 40 15.3
Type of
P.D. Pinion
= .159 inches maximum
Model
Gears
(in.)
(mm)
Pressure Angle
42-65
Spiral
15.3
388.6
20
“Pitch Line” Backlash (in.)
(mm)
.051 .061
1.30 1.55
TO SET BACKLASH 1. Use “Blueing” to check tooth bearing. 2. Adjust to get the proper tooth contact by adding or removing gasket between the bottom shell and pinionshaft housing. See below and photos on last page for illustrations. 3. Check backlash as previously outlined. 4. If backlash is incorrect, adjust it by rotating the pinionshaft assembly. The pinionshaft housing flange has slotted holes for this purpose. Loosen the bolts (1505-0) which hold the assembly to the bottom shell. The pinionshaft center line is 1/2” from the housing center line in the horizontal plane. Rotating the assembly raises or lowers the pinion to change the backlash. Jack bolts are mounted in the bottom shell adjacent to the pinionshaft to facilitate rotating the assembly. See Section 9 “Gear and Pinion Backlash Adjustment”. 1
42-65 SUPERIOR MK-II
Curved Tooth Spiral Bevel Gear Installation And Maintenance
Gyratory Crushers
PINION TOE CENTER
GEAR HEEL
DEDENDUM
FIG. 2 — Ideal tooth bearings for spiral bevel gears.
TOOTH BEARING OF CURVED TOOTH SPIRAL BEVEL GEARS Spiral bevel gears are produced to run with a localized tooth bearing. Since the area of contact does not cover the whole gear tooth, a slight tolerance in positioning the gears in assembly and some displacement under operating loads is possible without any resultant strain on the ends of the teeth. The ideal tooth bearing is slightly high on the pinion and low on the gear, as shown in FIG. 2. Under light load its length is usually one-half the total length to allow for adjustment for smooth operation. Usually the tooth bearing will shift toward the heel under heavy load — for this reason gears are cut so they will bear nearer the toe. See FIG. 3 for gear tooth nomenclature.
2
ADDENDUM PROFILE
LARGE END
FIG. 3 — Gear tooth nomenclature.
17X0118.9403
TOOTH BEARINGS ON DRIVEN GEAR — CURVED TOOTH SPIRAL BEVEL GEAR The following pictures represent the possible tooth bearings on a gear member of a pair of correctly machined bevel gears . . . their causes and corrections. Remember, however, that these are deviations from the ideal situation
NORMAL GEAR PATTERN Note centralized wear pattern on both pressure and non-pressure side of teeth.
PINION IN 0.020” (0.5mm) Results in heavy heel bearing on pressure side of tooth. Corrective action — move pinion away from center line of crusher until normal gear pattern results.
17X0118.9403
and the gears will NOT have ideal areas of contact. If serious misalignment occurs and cannot be corrected, contact the nearest Svedala Industries sales office.
PINION OUT 0.020” (0.5mm) Results in heavy toe bearing on pressure side of tooth. Corrective action — move pinion towards center line of crusher until normal gear pattern results.
BEVEL GEAR DOWN, PINION UP 0.020” (0.5mm) Results in abnormal backlash. Corrective action — loosen bolts (1505-0) and rotate pinionshaft housing assembly clockwise to lower pinion until normal gear pattern results and correct backlash is obtained.
3
42-65 SUPERIOR MK-II
Section 9 — Index
Gyratory Crushers
9. Pinionshaft Assembly
Page 9-1 9-2 9-4 9-4 9-5 9-6 9-6
Description Index General Description Removal From Bottom Shell Disassembly Reassembly Replacement In Crusher Gear And Pinion Backlash Adjustment
9
17X0115-04.9911
9-1
42-65 SUPERIOR MK-II
Section 9 — Pinionshaft Assembly
Gyratory Crushers
GENERAL INFORMATION SUPERIOR gyratory crushers are equipped with a cartridge type, anti-friction bearing, pinionshaft assembly. Bearings are pool lubricated with a filler hole on the upper front surface of the housing for adding lubricant. An oil
level sight gauge assembly is provided to maintain the oil at the proper level. The entire pinionshaft assembly can be removed from the bottom shell when maintenance is required. See Fig. 9-1 and 9-2 for illustrations.
1.0”–8UNC LIFT HOLES
3030-0
1.0”–8UNC LIFT HOLE 3231-0 3240-2 3231-1 3190-2 3170-2 3090-2
3305-0 3005-0
3650-0 3555-0
101.6MM (4.00”) OPERATING OIL LEVEL
3515-0 3050–0 3090-1
3210-4 3505-0 3220-0 TORQUE TO 157-166Nm (116–123 FT–LBS) 3575-0
3540-0
TO PINIONSHAFT OIL LEVEL SIGHT GAUGE (DRAIN PORT)
3170-1 3070-2 3190-1
3160-0
3210-0 3210-4 TORQUE TO 157-166Nm (116–123 FT–LBS)
3150-0
3240-1
SK063099–JJB–1
FIG. 9-1 — Pinionshaft assembly Catalog Number
Catalog Number
Description
Description
3005-0
Housing — Pinionshaft
3210-0
Bolt — Pinion end seal plate
3030-0
Gasket — Pinionshaft housing
3210-4
Lockwasher
3050-0
Pinion
3220-0
Bolt — Sheave end seal plate
3070-1
Bearing — Pinionshaft (Pinion end)
3240-1
Gasket — Pinion end seal plate
3070-2
Bearing — Pinionshaft (Sheave end)
3240-2
Gasket — Sheave end seal plate
3090-1
Spacer — Pinion end
3305-0
Cup — Pressure relief pinionshaft housing
3090-2
Spacer — Sheave end
3505-0
Shaft — Pinion
3150-0
Lockwasher (Sheave end)
3515-0
Key — Pinion
3160-0
Lockwasher (Pinion end)
3540-0
Bolt — Pinionshaft housing jack
3170-1
Seal — Pinionshaft oil (Pinion end)
3555-0
Key — Crusher sheave
3170-2
Seal — Pinionshaft oil (Sheave end)
3575-0
Plug
3190-1
Plate — Pinion end seal
3650-0
Retainer — Pinion
3190-2
Plate — Sheave end seal
9-2
17X0115-04.9911
42-65 SUPERIOR MK-II
Section 9 — Pinionshaft Assembly
Gyratory Crushers
TO SUIT INSTALLATION 3342–2 3342–1 3575–0 3341–7
3344–5
6.4 [0.25]
3344–3 3342–6
C/L PINIONSHAFT 3341–2
3341–9 3341–1 3341–3
6.4 [0.25]
101.6 [4.00]
OIL LEVEL RED LINE ON SIGHT GAUGE
3341–7 3342–3
3344–4
3344–2
3341–8 3344–5
3341–6
3341–5
NOTES: 1. SIGHT GAUGE MAY BE ASSEMBLED ON EITHER SIDE OF PINIONSHAFT TO SUIT INSTALLATION. 2. REMOVE PIPE PLUG (3575–0) FROM PINIONSHAFT HOUSING, ASSEMBLE NIPPLE (3342–2) AND PIPE TEE (3342–1). REASSEMBLE PIPE PLUG AS SHOWN. 3. SIGHT GAUGE TO BE LOCATED AS CLOSE TO THE PINIONSHAFT AS POSSIBLE. CUT HOSES (3341-2 & 3344–2) TO LENGTH AND INSTALL REUSABLE HOSE ENDS (3344–3 & 3344–4) (SUPPLIED). 4. MIN. WELD PER AWS CLASS E–60XX, UNLESS OTHERWISE SPECIFIED.
SK063099–JJB–2
FIG. 9-2 — Pinionshaft oil level sight gauge assembly Catalog Number
Description
Catalog Number
Description
3341-0 3341-1 3341-2 3341-3 3341-5 3341-6 3341-8 3341-9 3342-1
Pinion Oil Level Sight Gauge Assembly Oil Level Sight Gauge Flexible Hose Assembly Anchor Block Pipe Tee Pipe Plug Pipe Nipple Channel Pipe Tee
3341-7 3342-2 3342-3 3342-6 3344-2 3344-3 3344-4 3344-5 3575-0
Reducing Bushing Pipe Nipple Street Elbow – Lower Street Elbow – Upper Flexible Hose Assembly Swivel Hose End Swivel Hose End Hose Adapter Pipe Plug
17X0115-04.9911
9-3
42-65 SUPERIOR MK-II
Section 9 — Pinionshaft Assembly REMOVAL FROM BOTTOM SHELL To remove the pinionshaft assembly from the crusher, take the following steps (refer to Fig. 9-1 and 9-2 for parts relationship): 1. Remove drive belts by pulling the drive motor toward the crusher sheave to loosen. 2. Remove the driven sheave from the pinionshaft. After removing the attaching bolts to the sheave hub, use draw bolts in the threaded holes provided. 3. Remove the sheave hub after removing the clamp plate from the end of the pinionshaft. 4. Drain the oil by removing drain pipe plug (3341-6). 5. Disconnect the hose assemblies to the oil sight gauge at the pinion housing. 6. Remove the nuts from the attaching studs or bolts from the flange on the pinionshaft housing that holds the assembly in the bottom shell. 7. Use the two square head withdrawal bolts provided in the flange of the pinionshaft housing to remove the assembly from the fit in the bottom shell opening. 8. Install eyebolt in the threaded hole on top of the pinionshaft housing, attach sling and apply slight crane or ratchet hoist pressure to the assembly. 9. Place a pipe as a counterbalance over the exposed end of the pinionshaft where the sheave was removed. Apply hand pressure to the pipe to balance the pinionshaft assembly and remove from the crusher. NOTE: For direct driven crushers, remove the extension shaft between the motor and the crusher pinionshaft. Do not disturb motor alignment. DISASSEMBLY After the pinionshaft assembly has been removed from the crusher, placed on blocks and the oil drained, it can be dismantled. 1. Opposite the pinion end, remove seal plate (3190-2) with oil seal (3170-2). 2. With a hammer and screw driver, drive the lockwasher (3150-0) tang out of the locknut (3090-2) groove. Unscrew the locknut and remove it and the lockwasher (NOTE: left-handed threads). 3. Remove the seal plate bolts (3210-0) and washers (3210-4) on the pinion end. 4. Press the pinionshaft (3505-0) with the pinion end bearing (3070-1), seal plate (3240-1), pinion (3050-0), and opposite pinion end inner bearing cone (inner race with rollers and cage) with cone spacer out of the housing (3005-0). The opposite pinion end bearing double cup (outer race) with outer bearing cone will remain in the housing (3005-0). See Fig. 9-3 for method of removal. 5. Remove the pinion retaining ring (3650-0) and press off the pinion (3050-0) from the shaft. The pinion is shrunk fit to the shaft with .004 to .006 inch (0.10 to 0.15 mm) interference. See Fig. 9-4 for method of removal. 9-4
Gyratory Crushers
6. Remove pinion end seal plate (3240-1) with oil seal (3170-1). 7. Remove pinion end lockwasher (3150-0) and locknut (3090-1). See Step 2 for method. 8. Press off bearings (3070-1). Bearings are shrunk fit to the shaft (0.001 to 0.003 inch tight) (0.025 to 0.076 mm). 9. Remove the double cup (outer race) from the housing (3005-0). Cup is loose fit in the housing (0.001 to 0.003 inch loose) (0.025 to 0.076 mm). 10. Clean up all parts and replace those that have been damaged or have failed.
HYDRAULIC JACK SUPPORT
PLATE
BLOCKS
SK030592JJB-15 FIG. 9-3 — Method of removing pinionshaft from housing
NOTE Timken two-row bearings are shipped as sets and components should not be interchanged with other bearing sets.
NOTE Assemble the bearing cone and cup raceways with faces stamped “A” facing the same direction. Like- wise with faces stamped “C”. Cone faces stamped “B” should face each other. 17X0115-04.9911
42-65 SUPERIOR MK-II
Section 9 — Pinionshaft Assembly
Gyratory Crushers
BUILDING JOIST
HYDRAULIC JACK BAR PINION PLATE
BLOCKING PINION SHAFT
BLOCK
FIG. 9-4 — Method of removing pinion.
REASSEMBLY
NOTE Heat bearing cones and the pinion in oil not exceed- ing 300 o F. when needed for shrink fit assembly. 1. Assemble one heated bearing cone onto the pinion end of the pinionshaft. Clamp the cone tightly against the shaft shoulder and maintain the clamping force until the cone has cooled. Check that no gap exists between the shaft shoulder and bearing cone. 2. Assemble the double cup and cone spacer of the pinion end bearing onto the pinionshaft (3505-0), checking to make sure face stampings are aligned correctly. Assemble the remaining pinion end bearing cone onto the pinionshaft and clamp the bearing assembly tightly against the shaft shoulder while it cools. 3. After the pinion end bearing has been fitted onto the shaft and is cool, remove the clamping load. Apply a bead of Loctite 518 Gasket Eliminator to both faces of the lockwasher (3160-0) where it will seal on the faces
17X0115-04.9911
on the bearing cone and locknut. Assemble the lockwasher and locknut onto the pinionshaft, clamping the bearing to the shaft shoulder. NOTE: Locknuts are left-hand threaded and the drive end locknut (3090-2) is longer than the pinion end locknut (3090-1). Lock the locknut into place by bending a lockwasher tang into a locknut groove. Wipe off any excess sealant. 4. With the pinionshaft housing (3005-0) supported horizontally, insert the drive end of the pinionshaft (3505-0) into the pinion end of the housing until the drive end bearing shoulder of the pinionshaft extends beyond the pinionshaft housing. 5. Assemble the drive end bearing, lockwasher, locknut, and sealant in the manner described in Steps 1, 2 and 3. 6. After the bearing has cooled, insert the pinionshaft (3505-0) into the housing (3005-0) until the drive end bearing shoulder comes to rest against the seat inside the housing. Insert the drive end seal plate (3190-2) into place and measure the gap between the seal plate and housing. Add a gasket that is 0.010” (0.25 mm) thicker than the gap and torque the seal plate with oil seal (3170-2) into place. NOTE: The lip on the sheave end oil seal (3170-2) should face toward the bearing. 7. Locate contaminant discharge port on Protech labyrinth seal (3170-1) and mark position on the face of the seal with paint or a grease pencil. Install Protech seal in seal plate (3190-1), marking sure to line up contaminant discharge port with one of the mounting holes. Then, secure pinion end seal plate (3190-1) with oil seal (3170-1) and gasket (3240-1). NOTE: Make sure to locate the contaminant discharge port on the Protech labyrinth seal so that it is pointing down when the pinionshaft assembly is installed in the crusher. 8. Place the pinion key (3555-0) into the shaft keyway. Assemble the heated pinion gear (3050-0) onto the shaft. Promptly insert the retaining ring (3650-0) into place on the shaft. Use the retaining ring as a locater for the pinion gear by making sure the pinion is against the retaining ring. The pinion has an interference fit of 0.004” to 0.006” (0.10 to 0.15 mm) with the shaft. 9. Use the grease fitting at the drive end seal plate to in ject enough grease to fill the gap seal around the locknut to exclude dirt. Do this while rotating the shaft to ensure the grease is distributed evenly. Use a grease of NLGI No. 2 or No. 3 consistency such as Mobilux EP2 or equivalent. 10. Remember to fill the pinionshaft housing with a preservative oil to prevent corrosion of the pinionshaft and bearings during periods of non-use. Fill to the proper oil level (approximately 6 quarts [7.6 liters]). Lubricant recommendations are discussed in Section 13.
9-5
42-65 SUPERIOR MK-II
Section 9 — Pinionshaft Assembly
Gyratory Crushers
REPLACEMENT IN CRUSHER 1. To reinstall the pinionshaft assembly: a. Position the counterbalancing pipe on the bare sheave end of the shaft. Place the gaskets (3030-0) on the bolting flange of the pinionshaft housing. CAUTION: ALWAYS USE THE ORIGINAL THICKNESS OF GASKETS WITH THE SAME PINION AND GEAR. ANY CHANGE FROM THE ORIGINAL WILL CHANGE THE TOOTH CONTACT PATTERN ON THE PINION AND GEAR. b. Install eyebolt in the threaded hole on top of the pinionshaft housing. c. Position the pinionshaft assembly in the bottom shell opening (see Fig. 4-8, in Section 4). The close clearance fit in the bottom shell may require some movement of the assembly with the pipe counterbalance to engage the leads of the fit. As the pinion reaches the gear it may be necessary to turn the pinionshaft to engage the teeth of the pinion and gear to complete the entrance.
2. 3. 4. 5. 6.
7.
d. Draw up the attaching bolts evenly and securely. e. Set the proper backlash between gear and pinion. See “Gear and Pinion Backlash Adjustment” in this section. f. Re-connect the hose assemblies (3341-2) (Fig. 9-2) from the oil sight gauge to the pinionshaft housing. g. Remove oil fill plug (3575-0) and fill to the correct oil level with the proper oil. See Fig. 9-2 for correct level. See Section 13 “Lubrication” for type of oil. Install the crusher sheave hub. Install the sheave to the hub and tighten securely. Align the motor sheave and tension drive belts. If direct driven, replace the extension shaft. Realign the couplings if the motor has been changed. If a new pinion, gear or eccentric has been installed, check backlash and tooth contact, per “Bevel Gear Installation and Maintenance,” in Appendix to Section 8. Replace drive guard.
1505-0 1505-1 1505-2 1505-3 “A”
3006-0 3006-2
“B”
SK022792JJB-10 FIG. 9-5 — Backlash adjustment between eccentric and pinion gears is accomplished by pinionshaft housing rotation. Front elevation shows parts arrangement, with pinionshaft housing mounted in bottom shell.
GEAR AND PINION BACKLASH ADJUSTMENT Fig. 9-5 shows a front elevation of the pinionshaft assembly mounted in the bottom shell. Slotted holes (“A”) are provided in the pinionshaft housing flange for bottom shell to pinionshaft housing studs (1505-0), so that the housing can be rotated about its center line. The pinionshaft center line is offset from the housing center line in the horizontal plane. Rotating the housing in a clockwise direction will cause the pinion gear to move downwards, toward the eccentric drive gear. Counterclockwise rotation will cause the pinion gear to move away 9-6
from the eccentric gear. Rotational adjustment in either direction to the correct backlash setting for the gear and pinion is accomplished by means of jack bolts (3006-0) mounted on the bottom shell housing and bearing on a flanged portion of the pinionshaft housing (“B”). Hex nuts (3006-2) are provided to lock the jack bolts in the desired location after adjusting gear and pinion backlash. Backlash for the 42-65 SUPERIOR crusher should be 0.051 to 0.061 inches (1.29 to 1.55 mm). 17X0115-04.9911
42-65 SUPERIOR MK-II
Section 10 — Index
Gyratory Crushers
10. Mainshaft Assembly
Page 10-1 10-2 10-3 10-3 10-3 10-3 10-3 10-3 10-3 10-5 10-5 10-5 10-6 10-7 10-7 10-7 10-7 10-7 10-7 10-8 10-8 10-8 10-8
Description Index General Information Removal Head Nut — Removal — Installation Mantle — Removal — Assembly On Mainshaft — Zincing — PLASTIC PACK Epoxy Backing Dust Seal — Removal — Inspection — Assembly Splash Curtain Mainshaft Sleeve — Removal — Assembly Mainshaft Step — Removal — Inspection — Assembly
17X0115-04.9911
10
10-1
42-65 SUPERIOR MK-II
Section 10 — Mainshaft Assembly
Gyratory Crushers
GENERAL INFORMATION The mainshaft assembly (Fig. 10-1) consists of the mainshaft (4005-0), mantle (4175-0), head nut (4205-0), mainshaft sleeve (4025-0), mainshaft step (4075-0), dust seal (4305-0), dust seal retainer (4350-0) and splash curtain (4405-0). The assembly provides the terminal moving force to perform the crushing.
NOTE The mainshaft step (4075-0), Fig. 10-1) is supplied with a wear indicator as a standard feature. This wear indicator consists of a cavity that has been machined into the back (non-wearing) side of the mainshaft step. The cavity is filled with a silver powder and sealed with a threaded plug. When wear reaches the depth at the bottom of the oil grooves in the mainshaft step, the cavity is opened and the silver powder is realeased into the lubrication oil. An oil analysis will show the presence of the silver powder which indicates the mainshaft step (and/or piston wearing plate) is worn out and needs replacement. EYEBOLT 4050-0
4027-0 4027-2
CLAMPING RING 4026-0 MAINSHAFT SLEEVE 4025-0 HEAD NUT 4205-0 DOWEL 4220-0
MAINSHAFT 4005-0 BACKING MANTLE 4175-0
4435-0 4435-1 UPPER DUST SEAL RETAINER RETAINER 4325-0 4330-0 4330-4
CLAMP 4425-0
SPLASH CURTAIN 4405-0
4365-0 LOWER DUST SEAL RETAINING RING 4350-0
MAINSHAFT DOWEL 4035-0
DUST SEAL 4305-0 MAINSHAFT STEP 4075-0 SK021792-JJB-4
MAINSHAFT STEP RETAINER 4135-0 FIG. 10-1 — Mainshaft assembly
10-2
17X0115-04.9911
42-65 SUPERIOR MK-II
Section 10 — Mainshaft Assembly
Gyratory Crushers
REMOVAL The spider must be removed before attempting to remove the mainshaft assembly. Except for small settings, the mainshaft assembly can be removed without removing the top shell. For lifting use the factory installed eyebolt on top of the shaft assembly. A shackle is required between the eyebolt and crane hook. See Appendix, Section 4, for eyebolt dimensions. Use a standard shackle adequate to lift the mainshaft assembly. The mainshaft can be withdraw from the eccentric bushing with the hoisting hook directly over the eyebolt. The mainshaft is at a small vertical angle so care should be taken when lifting it to prevent seizure in the bushing. Do not force withdrawal unless there has been a bearing seizure as it may damage the eccentric bushing. Handle the mainshaft carefully when putting it into a repair well or when laying it down. Do not damage journal surfaces. surfaces. If the mainshaft has to be laid down horizontally, place a piece of plywood or belting under the end of the shaft or step bearing before tilting (Fig. 10-2). Be careful to avoid damaging the mainshaft step at the base of the shaft.
shaft sleeve and head nut have right hand threads; be careful not to damage them when working on the assembly. bly. A bar or set hammer may be placed against the lugs on the nut and struck with a sledgehammer. If the nut is firmly set and will not loosen with sledge and set even after after applying kerosene, it can be heated with a torch and then removed by sledging. If the nut or mantle are peened at the joint where they bear against each other it will be necessary to chip or burn the joint open. Installing The Head Nut
NOTE Prior to installing the mantle, the head nut should be run all the way down on the sleeve threads to be sure it turns freely. After the mantle has been assembled on the mainshaft and backed with zinc or PLASTIC PACK, examine the threads on which the nut is to be assembled. Remove the zinc splatter and any other foreign material that might prevent assembly of the head nut. Assemble the nut on the sleeve and drive it down for a tight fit on the mantle. Place dowel pins in slots that line up (two locations) and weld them to the head nut (only) per AWS class E70XX. MANTLE
FIG. 10-2 — Lifting 42-65 crusher mainshaft during installation. Note protective belting under mainshaft step.
HEAD NUT Self-tightening head nuts (4205-0) are used, assuring a tight assembly between the mantle and shaft taper. Crushing action turns the nut and mantle downward for a secure fit. The standard design is a one piece head nut which threads onto the threaded portion of the mainshaft sleeve. Head Nut Removal (See Fig. 10-1) To remove the head nut from the mainshaft, the dowel pins (4220-0) must be drilled out. They lock the self-tightening nut (4205-0) to the mantle so that when the mantle turns the nut turns also, maintaining a tight assembly. assembly. The main17X0115-04.9911
Removal Mantles are usually removed only when beyond further use. However, it is possible to salvage a mantle by cutting of the head nut. The value and availability of the used mantle must be weighed against that of a new head nut before cutting. There is a small hole in the head nut for starting the cut. Assuming that the mantle is to be scrapped, make a torch cut around it approximately one-fourth to one-half inch (6-12 mm) below the head nut and mantle joint. Use one of the vacant half-round dowel holes in the mantle for starting the cut. Remove the top piece that was cut around. This usually relieves the pressure against the head nut so that it can be salvaged for reuse. The mantle can be removed from the mainshaft with a crane, after welding lifting lugs on the upper portion. Stand clear when removing, as pieces of plastic and zinc may fall and cause injury. Assembly On Mainshaft (See Figs. 10-1, 10-3 and 10-4) A. One Piece Mantle 1. Remove any burrs burrs from from the the shaft shaft tape taperr that that may may come come in contact with the backing and act as a key, moving downward when the manganese stretches. Fill any depressions with Babbittrite to match the surrounding taper. 2. Coat the shaft shaft ttape aperr lightly lightly with with oil oil for zinc zinc or with bees bees-wax or a silicone mold release for PLASTIC PACK backing. Petroleum products can prevent proper curing of PLASTIC PACK backing. 10-3
42-65 SUPERIOR MK-II
Section 10 — Mainshaft Assembly 3. Place Place the the mains mainshaf haftt in the the repai repairr bay. bay. 4. Lower the the mantl mantle e over the the taper taper on the the mains mainshaf haftt and block up under the mantle so that when the head nut is in place there will be approximately 1/4” (6.4 mm) of the threads on head nut above the threads on the mainshaft sleeve. See Figs. 10-3 and 10-4 for mantle location (dimension A). 5. Wedge Wedge up the bott bottom om of tthe he mantl mantle e until until the top top of the the mantle is tight completely around the bottom of the head nut. 6. Remove Remove the head nut caref carefully ully and measu measure re the the gap between the mantle and mainshaft (B dimension) at four evenly spaced points. 7. Cente Centerr the bott bottom om of the mant mantle le lip lip on the the taper taper of the head center area with four small oak wedges, 1” (25.4 mm) wide x 1/4” (6.4 mm) thick at small end by 3/4” (19 mm) thick at large end by approximately 3” (77 mm) long. 8. Again check check the the contac contactt of the mantle mantle to the the head head nut. nut. 9. Block Block the the opening opening at the the bottom bottom of of the lower lower mantl mantle e section before pouring zinc or plastic. 10. Evenly heat the mantle mantle to approximately approximately 200 o F. (92o C.) when the zinc is ready to pour at 1000 o F. (540 o C.). If plastic backing is used, no preheating of the mantle is necessary. Back off the head nut, making sure that the mantle does not move. NOTE: The head nut may be spaced away from the mantle and three or more parallels (or spacers) placed between the mantle and head nut with the head nut tightened against the parallels to insure that no movement occurs. If a pouring spout is designed properly, the backing can be poured into the space between the parallels into the cavity between the mantle and head center. 11. Pour the zinc zinc or plastic to the the top of. or 1.0” (25 (25 mm) below, the tapered turn. Do not fill the cavity under the head nut with backing. Exceeding this level will prevent tightening the head nut. 12. After pouring, assemble nut on shaft. Drive nut for a tight fit on mantle. Assemble dowel pins in slots that line up. Weld pins to the head nut (only) per AWS class E70XX. 13. Remove Remove lifting lugs from the the mantle after after pouring. B. Two Piece Mantle 1. Follow Follow step steps s 1 throug through h 3 above, above, unde underr “A”. “A”. 2. Low Lower er the the mantle mantle sect section ions s over over the tape taperr on the the mainshaft and block up under the lower mantle section. With shims, set a 0.375” (9.6 mm) gap between mantle sections at the three closest positions (where the gaps are parallel)) around the circumference. When the head nut is in place, there will be approximately 1/4” 96.4 mm) of threads on the head nut above the threads on the mainshaft sleeve. See Figs. 10-3 and 10-4 for mantle location (dimension A) 3. Wedge Wedge up the bott bottom om of tthe he mantl mantle e until until the top top of the the mantle is tight completely around the bottom of the head nut. 10-4
Gyratory Crushers
4. Remove Remove the head nut carefully carefully and measu measure re the the gap between the mantle and mainshaft (B dimension) at four evenly spaced points.
EYEBOLT 4050-0 CLAMPING RING 4026-0
“A”
MAINSHAFT SLEEVE 4025-0 HEAD NUT 4205-0 DOWEL 4220-0
MANTLE
“C” ZINC OR PLASTIC
“B”
HARDWOOD SHIM
SK022692JJB-11 FIG. 10-3 — Mantle location in preparation for pouring backing
5. Center Center the bott bottom om of the mant mantle le lip on on the tap taper er of the head center area with four small oak wedges, 1” (25.4 mm) wide x 1/4” (6.4 mm) thick at small end by 3/4” (19 mm) thick at large end by approximately 3” (77 mm) long. 6. Rem Remove ove the upp upper er man mantle tle sectio section. n. 7. Block Block the the opening opening at the the bottom bottom of of the lower lower mantl mantle e section before pouring zinc or plastic. 8. Evenly Evenly heat heat the the mantl mantle e to approxim approximately ately 200 o F. (92o C.) when the zinc is ready to pour at 1000 o F. (540 o C.). If plastic backing is used, no preheating of the mantle is necessary. 9. Pour zinc or or plastic plastic to fill fill the the cavity cavity betwe between en the the mantle mantle section and mainshaft. 17X0115-04.9911
42-65 SUPERIOR MK-II
Section 10 — Mainshaft Assembly
Gyratory Crushers
MANTLE LOCATION AND BACKING Dimensions For Mantle Location A
B
C
PLASTIC PACK
Zinc Weight
Crusher Size
In.
MM
In.
MM
In.
MM
Kits*
Lbs.
Kg.
42-65
36.0
914
.38
9.7
.56
14.2
20
2000
905
*PLASTIC PACK backing material is sold in 22 lb. (10 Kg.) kits, each providing approximately 380 cubic inches (6228 cm3) of poured and set material.
FIG. 10-4 — Dimensions for mantle location, reference Fig. 10-3, and required quantities of plastic or zinc backing for mantle installation.
10. Position the upper mantle section on the mainshaft and, with wooden shims, set approximately 3/8” (9.6 mm) gap between mantle sections at the three closest positions (where the gaps are parallel) around the circumference. 11. Plug space between the mantle sections. Each section must be zinced or plastic packed independent of the other; the zinc or plastic in the lower section must not join the zinc or plastic in the upper section. 12. Center and locate upper mantle section in position using hardwood shims and wedges. Align top surface of mantle with head nut; it must bear on full circumference. Remove head nut; carefully shim between mantle and mainshaft. 13. Follow steps 10 through 13 above, under “A”. Zinc Backing
1. Follow the “Assembly” directions previously given, items 1 through 13 under “A” or items 1 through 13 under “B”, depending on whether a one piece or two piece mantle is being installed. Do not heat the mantle for normal use of PLASTIC PACK backing. 2. Thoroughly mix PLASTIC PACK resin and hardener as instructed in “Directions For Use.” 3. If temperature is below 60 o F. (15.5 o C.), special provisions are needed so backing will flow and cure. Heat parts to be bonded, as well as unmixed resin and hardener, to 70-80 o F. (21-26.6 o C.).
NOTE For low temperature applications — as low as 23 o F. (-5 o C.) we recommend KOL-SET low temperature backing material. Consult Factory for details.
General a. Preheat mantle sections to approximately 200 o F. (93o C.) before pouring so that zinc will not chill. b. Use only prime western zinc. c. Thoroughly clean the inside of the mantle and mainshaft taper, and make sure they are dry.
4. Seal the bottom gap (lower mantle to mainshaft) and the gaps between mantle sections (if applicable) with plaster of paris or a water-based putty. DO NOT use oil-based putty. 5. Pour mixed PLASTIC PACK backing into the cavity between the mantle and head center.
CAUTION
NOTE
Molten zinc coming in contact with moisture can cause explosions and endanger person- nel. Molten zinc is poured at 1000 o to1100 o F. (540 o to 590 o C.) d. Seal the bottom gap (lower mantle to mainshaft) and the gaps between mantle sections with Babbitrite, or equivalent oil-based putty, before pouring.
CAUTION Do not use water-based putty where zinc is used. PLASTIC PACK Epoxy Backing Unless specifically requested by the purchaser, all SUPERIOR gyratory crusher mantles are backed with PLASTIC PACK epoxy backing. The amount of plastic backing required for each crusher size is detailed in “Directions For Use – PLASTIC PACK,” 17X0085, in the appendix to section 4. 17X0115-04.9911
Keep the PLASTIC PACK backing level below the top of the head center. Exceeding this level will prevent tightening the head nut. 6. To determine the height of plastic backing in the pour, use either a flexible electrical wire or an annealed soft iron wire in the lifting hole opposite the pouring hole. Grasp the wire, with the fingers, at the desired pour height. Pour the plastic slowly, and completely withdraw the wire to observe for plastic. 7. Allow the PLASTIC PACK backing to cure for twelve hours. Again try to tighten the head nut and line up two dowel holes for insertion of dowels. Insert two snug-fitting dowels into the holes, approximately to the depth of 1/4” (6.4 mm). Do not allow the other end of the dowel to touch any interior part of the mainshaft assembly. 8. Remove lifting lugs from the mantle. DUST SEAL The dust seal ring is free to move between the retaining rings beneath the mantle (Fig. 10-5). It is an easy sliding fit on the dust collar and is the only barrier between the crushing chamber and the oil system inside the crusher. 10-5
42-65 SUPERIOR MK-II
Section 10 — Mainshaft Assembly
Gyratory Crushers
The enclosed ring-type dust seal consists of three ma jor parts; the upper dust seal retaining ring (4325-0) which is attached to the mainshaft with screws and does not normally need to be removed; the plastic dust seal ring (4305-0); and the lower dust seal retainer (4350-0). As delivered the crusher is equipped with a one piece dust seal ring (4305-0) which requires removal of the mainshaft to replace the ring. A two piece dust seal ring (4305-0) is also available (Fig. 10-6), which does not require removal of the mainshaft in order to replace the ring.
1. Block up or use jacks between the bottom shell arms and the lower dust seal retainer (4350-0). 2. Follow Step 2, above. Next, lower the lower dust seal retainer (4350-0) and dust seal ring onto the bottom shell arms. 3. Remove the mainshaft from the crusher. Splash curtain
Dust seal ring Dust collar Retainer
Removal - One Piece Dust Seal Ring 1. Lift the mainshaft from the crusher. 2. Remove retaining ring bolts (4365-0). Use four of these bolts in the tapped holes of the retaining ring to jack the lower retaining ring (4350-0) from the upper retaining ring (4325-0).
NOTE Support the lower retaining ring (4350-0) so it cannot fall and damage the mainshaft journal. 3.
Slide the retaining ring and dust seal ring over the end of the shaft. A second method of removing the dust seal ring is to remove the lower retaining ring (4350-0) and dust seal ring (4305-0) prior to removing the mainshaft from the crusher. This procedure is as follows:
FIG. 10-5 — Dust collar and seal arrangement. Splash curtain bolted to mainshaft.
USE BONDING CEMENT SUPPLIED WITH SEAL BETWEEN JOINTS 5.0 .1 MAX.
.1 MAX. SECTION A-A
SK022692JJB-12
O-RING BONDED TO SEAL WITH LOCTITE 910 ADHESIVE
SECTION B-B
FIG. 10-6 — Two piece dust seal ring
10-6
17X0115-04.9911
42-65 SUPERIOR MK-II Gyratory Crushers
Removal - Two Piece Dust Seal Ring With the two piece dust seal ring (4305-0) it is not necessary to remove the mainshaft assembly from the crusher. To remove the dust seal ring, block or crib up from the bottom shell arms to the under side of the lower retaining ring (4305-0). Remove the retaining ring bolts (4365-0) and use four of the bolts in the tapped holes of the retaining ring to jack the lower retaining ring from the upper retaining ring. Lower the retaining ring to rest on the bottom shell arms. The dust seal ring can then be removed by cutting it in two pieces. Inspection Inspect the polished surfaces of the upper and lower retaining rings and smooth all rust or score marks which might scratch the plastic dust seal ring. Check the fit between the upper (4365-0) and lower (4350-0) retaining rings. This fit must be tight (0.004 to 0.009 inches tight) as any motion between these parts will wear the fit and eventually break bolts (4365-0). Assembly – One Piece Dust Seal Ring With the mainshaft out of the crusher, proceed as follows: 1. Place the dust seal ring (4305-0) on top of the lower dust seal retainer (4350-0) and raise the retainer and seal to the underside of the upper dust seal retainer (4325-0). 2. Bolt the lower retaining ring (4350-0) to the upper retaining ring (4325-0) with bolts (4365-0). 3. Check the clearance between the lower retaining ring and the dust seal ring. This clearance should be 0.03 to 0.09 inches (0.76 to 2.29 mm) with new parts. Wear allowance is 0.125 inches (3.2 mm). Use shims if necessary between the retaining rings to give at least the minimum clearance. 4. After installation, make sure that the ring is free to move in the retainer. 5. Use caution when lowering the mainshaft into the crusher since the seal has to be fed onto the dust collar fit from underneath. The material is relatively fragile compared to the weight of the mainshaft and could be broken. An alternate method is to place the lower retaining ring (4350-0) and dust seal ring (4305-0) over the dust collar, onto the bottom shell arms. Lower the mainshaft into the crusher and then follow steps 1, 2 and 3 above. Assembly – Two Piece Dust Seal Ring With the mainshaft in the crusher, proceed as follows: 1. Place each half of the dust seal ring around the dust collar (1405-0). Apply bonding cement to each joint and bolt each joint together (See Fig. 10-6). 2. Slide the dust seal ring up into the upper retaining ring and bolt the lower retaining ring (4350-0) to the upper retaining ring (4325-0) with bolts (4365-0). 3. Check the clearance between the lower retaining ring and the dust seal ring. This clearance should be 0.03 to 0.09 inches (0.76 to 2.29 mm) with new parts. Wear 17X0115-04.9911
Section 10 — Mainshaft Assembly allowance is 0.125 inches (3.2 mm). Use shims if necessary between the retaining rings to give at least the minimum clearance. SPLASH CURTAIN A splash curtain (4405-0) is provided to prevent lube oil from splashing up over the dust collar and leaking out onto the crushed product. The curtain is bolted to the mainshaft with the splash curtain retainer (4415-0), which is welded to the shaft, and the splash curtain retainer clamp (4425-0).
CAUTION Splash curtain bolts must be installed with heads facing outwards to prevent interference with the dust collar. MAINSHAFT SLEEVE A sleeve (4025-0) is shrunk over the upper portion of the mainshaft, so that the bearing journal may be easily renewed if it becomes worn or scored. The standard mainshaft sleeve for the 42-65 SUPERIOR crusher is threaded on the outer diameter of the lower portion for mounting the head nut (Fig. 10-7). A clamping ring (4026-0), secured to the top of the mainshaft by capscrews (4027-0), bears on the upper rim of the mainshaft sleeve to prevent upward movement due to pressure from the manganese mantle during crusher operation. Mainshaft Sleeve Removal 1. Remove the capscrews and clamping ring. 2. Cut on one side with an air arc or acetylene cutting torch to within one-sixteenth to one-eighth of an inch of the basic mainshaft journal. Try not to cut into the mainshaft as this may act as a stress riser and promote mainshaft breakage. 3. Use a hand chisel to complete the cut. 4. Drive wedges into the joint to provide clearance and remove the sleeve. Inspect the turned surfaces of the mainshaft and the sleeve. Smooth any irregularities or rust that may have developed and clean both parts thoroughly. Mainshaft Sleeve Assembly 1. Coat the outside of the shaft with a mixture of molydisulphide and oil on the area designated “B” on Fig. 10-7. 2. Heat the sleeve in an oil bath to 300o F. (150o C.). 3. Slip the sleeve over the shaft until the upper rim of the sleeve is flush with the top of the mainshaft. 4. Install the sleeve clamping ring, using capscrews (4027-0) and washers (4027-2) and torque to 2,000 Ft.-Lbs. (2712 N-m).
NOTE Be extremely careful when heating oil and handling heated components. 10-7
42-65 SUPERIOR MK-II
Section 10 — Mainshaft Assembly
Gyratory Crushers
MAINSHAFT STEP
4027-0 4027-2
Removal The mainshaft assembly is supported on a three-piece step bearing, including the bronze step (4075-0), which is secured to the bottom of the mainshaft with snap ring retainer (4135-0). To remove the step, thread the lowering rod provided into the tapped hole in the bottom of the shaft. Draw the lowering bar up snugly against the bottom of the step with the lowering rod nut. Remove the snap ring retainer and lower the step to a skid.
27” (42-65 and 50-65) 30” (54–75)
4050-0
4005-0 4026-0
4025-0
NOTES: HEAT MAINSHAFT SLEEVE TO 300 F FOR ASSEMBLY. COAT THIS AREA (7.0”) OF MAINSHAFT WITH MOLYDISULPHIDE PASTE BEFORE INSTALLING THE SLEEVE. INSTALL TOP OF MAINSHAFT SLEEVE FLUSH WITH TOP OF MAINSHAFT. TORQUE CAPSCREWS TO 2000 FOOT POUNDS. THREADED AREA OF SLEEVE FOR INSTALLING HEAD NUT
FIG. 10-7 — Mainshaft and threaded sleeve assembly. Catalog Number
Description
4005-0 4025-0 4026-0 4027-0 4027-2 4050-0
Mainshaft Mainshaft Sleeve Sleeve Clamping Ring Washer 1.625 Socket Head Capscrew 1.5 x 3.5 Lifting Eyebolt
10-8
Inspection Inspect the bottom surface of the step for excessive wear, scoring or any signs of failure. The step is of high lead bronze, which provides maximum lubricating properties without deformation. Normally, the surface will polish highly. The bronze may become blackened, but if it is smooth and has few score marks it will work itself into the desired polished condition. Assembly To assemble the step, using the lowering rod, raise it into position over the projection on the bottom of the mainshaft. Make sure that the hole in the step engages the dowel in the bottom of the shaft. Insert the snap ring into the groove in the projection on the bottom of the mainshaft to hold the step in place.
17X0115-04.9911
42-65 SUPERIOR MK-II
Section 11 — Index
Gyratory Crushers
11. Top Shell Assembly
Page 11-1 11-2 11-2 11-2 11-2 11-3 11-3
Description Index General Information Removal Inspection Assembly Steps In Concave Removal Concave Placement
11
17X0115.9403
11-1
42-65 SUPERIOR MK-II
Section 11 — Top Shell Assembly
Gyratory Crushers
GENERAL INFORMATION The principal components of the top shell assembly are the top shell (5005-0) and the concaves. See Fig. 11-1 for parts arrangement. It acts as a support for the spider assembly and a retention base for the concave crushing surfaces. Removal Removing the top shell from the bottom shell requires the application of pressure to separate the interference taper fit between the two. Here is the recommended procedure. 1. Remove all attaching bolts (1540-0) from the top and bottom shell flanges. 2. Place hardened steel wedges with a slope of 0.1” per inch of length in the four wedge slots provided in the top shell flange. See Fig. 11-2. 3. Evenly apply a twelve or sixteen pound sledgehammer to the four wedges, after hitching the top shell to an overhead crane or hoist. Use steady overhead pressure to assist in removal. Watch for sudden movement of the top shell when it breaks loose from the fit.
After removal, lubricate machined surfaces of both the bottom and top shell fits to prevent rusting. Place the top shell on timbers to protect the machined surfaces. Inspection Inspect the taper on machined surfaces of the top and bottom shells to see that surfaces are not rusting or that there is no working between surfaces. Assembly Place the top shell (5005-0) on the bottom shell (1000-0). Check the gap between flanges at 90 o increments. The gap should be 0.075 to 0.114 inches (1.90 to 2.90 mm). Draw the top shell down evenly all around. A 0.004” (.1 mm) feeler may be used to determine whether the top shell has been drawn down tight. If there is any clearance between the top shell and bottom shell it is an indication that the tapers of the two pieces are not engaged. Find the cause and remedy. There should be nothing to prevent these two surfaces from being drawn together.
Spider Assembly
Top tier concaves
Third tier concaves
Top shell
Second tier concaves
Bottom tier concaves
Bottom shell assembly
Concave support ring
FIG. 11-1 — Top shell assembly
11-2
17X0115.9403
42-65 SUPERIOR MK-II Gyratory Crushers
After the crusher has been operated a few hours the nuts holding the top shell and bottom shell together sometimes loosen a slight amount. After a little operation, these nuts should be checked again and drawn down as tightly as possible. Steps In Concave Removal 1. Remove all residual stone from around the spider rim liners in the truck dump pit. Also remove any covering over the joint between the rim liners and the concrete flooring. 2. Remove the spider assembly. 3. Locate the key concave in the top row. It is usually found under a protective arm of the spider assembly. It can be recognized by the parallel sides on the outer section (in plan view). The balance of the regular concaves in the top row will have sides profiled as if generating from a radius. 4. Using an air arc, remove zinc or plastic in the two vertical side joints of the key concave. 5. Remove the key concave, using a chisel pointed bit in the wedge slots cast into the back of the concaves. See Fig. 11-3. A large paving breaker or air operated pile driver, suspended from an overhead crane, is suggested as a chisel power source. 6. Remove the balance of the regular concaves in the top row in the same manner. 7. Each succeeding row has a key concave and is removed in the manner outlined in steps 4-6, above.
FIG. 11-2 — Wedge inserted in slot between top and bottom shells.
17X0115.9403
Section 11 — Top Shell Assembly In some instances the operator may desire to change the lower set of concaves only. There are various methods for removing the lower set of concaves without removing the upper sets. One method is to line up all the key concaves when the concaves are first installed so they can all be removed without disturbing any of the other concaves. Then the lower set can be removed in the usual manner, set out or replaced, and re-zinced. Thus, only the key concaves of the upper tiers need be removed and replaced. Another method used is to burn through one of the lower concaves on three sides, starting at the bottom to give the slag room to run out of the cut. If the concave is burned properly, it will sometimes fall out when struck on the face with a 12 or 14 pound (5.4-6.4 kg) sledge. If it is not loose, drive a long tapered wedge or chisel bar behind concave to remove it. Then the remainder of the lower set can be removed and reset. Concave Placement See Section 4, p. 4-8, for details on concave installation. If the concave support ring (6050) is worn off a new plate ring, made in sections, may be put in the space in the joint between the top and bottom shell and allowed to project far enough to serve as a support.
FIG. 11-3 — Removing key concave in top tier.
11-3
42-65 SUPERIOR MK-II
Section 12 — Index
Gyratory Crushers
12. Spider Assembly
Page 12-1 12-2 12-3 12-3 12-4 12-5 12-5 12-5 12-5 12-6 12-6 12-6
Description Index General Information Removal Inspection Assembly to Top Shell Spider Bushing — Removal — Inspection — Assembly Spider Lubrication System — Monitoring Spider Oil Level and Setting Control Panel Timer Spider Arm and Rim Liners
12
17X0115-03.9808
12-1
42-65 SUPERIOR MK-II
Section 12 — Spider Assembly
Gyratory Crushers
GENERAL INFORMATION The spider assembly has a taper fit with the top shell. Main components include the spider (5605-0), spider bushing (5675-0), spider bearing oil seal (5705-0), spider cap
5755-1
5760-0 5760-4
COVER SEALANT 5755-2
(5650-0), arm shields (5150-0) and rim liners. See Fig. 12-1 and 12-2 for detail, and Fig. 12-3 for illustration of typical separate spider hub, arms and rim. SK021892JJB-7 5750-0 SPIDER CAP 5650-0
SPIDER 5605-0 SPIDER BUSHING 5675-0 5685-0 5685-4
ARM SHIELD 5150-0 5160-0 5160-1 5160-2 5160-3 5160-5
OIL SEAL 5705-0 SCRAPER 5706-0
LUBE HOSE 5240-0 SPIDER JOINT BOLT 5311-0
SPIDER JOINT STUD 5310-0
FIG. 12-1 — Spider assembly
SPIDER BUSHING 5675-0
DUAL OIL SEALS 5705-0 LIP UPWARDS
SK021892JJB7A FIG. 12-2 — Spider bearing oil seal arrangement
12-2
17X0115-03.9808
42-65 SUPERIOR MK-II
Section 12 — Spider Assembly
Gyratory Crushers
Removal Removing the spider assembly from the top shell requires application of pressure to separate the interference taper fit between the spider rim and top shell. To apply this pressure there are several options: For all options first remove all attaching fasteners (5310-0 and 5311-0). 1. Standard Jackscrew Separator — four 2.5 - 8UNC jackscrews (5007-1) are threaded into collars (5007-2) which are seated in counterbored holes in the top shell flange (Fig. 12-4). With these jackscrews, apply pressure to break the fit. The jackscrews should be turned a measured amount in sequence to prevent the spider from getting cocked in the top shell. The sequence should be as follows: Turn the first screw. Next turn the second screw which is 180 o apart. Next, turn the third screw which is 90 o from the second. Then turn the fourth screw which is 180 o from the third. Repeat the sequence. In addition, strain applied with an over-head crane will assist. 2. Hydraulic Shell Separator — The hydraulic shell separator is an optional item that must be ordered with the crusher. It consists of four hydraulic cylinders (5008-1) which are threaded into collars (5008-2) which are seated in counterbored holes evenly spaced in the top shell flange. See Fig. 12-5. With the use of a hydraulic hand pump (5008-4), the jacks push up the spider and break the joint fit. As an additional assist, the shaft can be raised to apply pressure as follows: Lower the mainshaft. Place heavy steel blocks between the head nut and spider arms, and apply the vertical force of the HYDROSET control as you would a powerful jack. Put the HYDROSET control in the “raise” position. Again, steel wedges and an overhead crane can be useful as an assist in spider removal. After removing the spider, lubricate the tapered machined surface of both the spider and the top shell to prevent rust. Rust destroys the fit between the top shell and spider. Place the spider on timbers to protect the machine surfaces. Inspection Inspect the taper on machined surfaces of the top shell and spider to see that surfaces are not rusting or that there is no working between surfaces. Movement would be indicated by smooth bright spots below which will be seen iron dust. Taper fit wear between the spider and top shell can only be measured by gauges available exclusively from Svedala Industries, Inc.. Consult your regional Svedala Industries, Inc. representative or distributor, or contact the Field Service Department, Crushing & Screening Division, Appleton, WI.
17X0115-03.9808
FIG. 10-3 — Spider hub, arms and rim
COLLAR 5007-2
TOP SHELL 5005-0
2.5” - 8UNC JACKSCREW 5007-1 SK030592JJB-13 FIG 12-4 — Spider - top shell jackscrew separator
12-3
42-65 SUPERIOR MK-II
Section 12 — Spider Assembly
Gyratory Crushers
5011-3 TOP SHELL 5005-0
5011-2 or -7
5011-3
5008-1 0.19
5008-8
5011-1 or -2 5010-0 5010-2 5010-4
5009-0 5010-1
5008-4 5008-2 SECTION A-A
SK030592JJB-14
SECTION B-B
FIG. 12-5 — Optional spider - top shell hydraulic separator Catalog Number
Description
Catalog Number
Description
5008-1 5008-2 5008-4 5008-8 5009-0 5010-0 5010-1
Hydraulic Cylinder Hydraulic Cylinder Collar Hydraulic Hand Pump Hydraulic Hose 20 Ft. Long Hydraulic Manifold Capscrew Hydraulic Manifold Bracket
5010-2 5010-4 5010-5 5010-6 5011-1 5011-2 or 7 5011-3
Washer Lockwasher Hose Support Clamp Self Tapping Screw Hydraulic Hose 6 Ft. Long Hydraulic Hose 10 Ft. Long Hydraulic Hose 20 Ft. Long
Assembly To Top Shell
NOTE It is recommended that the spider bushing (5675-0) be installed after the spider is in place on the top shell to prevent the possibility of damaging the seals (5705-0) when lowering over the mainshaft. 12-4
1. Inspect the taper fits of both the spider and top shell. Remove all burrs, bruises and any interfering accumulation of rust or dirt. Coat both taper fits with oil or anti- seize compound. Do not use white lead as it will harden, making subsequent removal of the spider assembly difficult. 2. Inspect the jackscrew collars (5007-2) and insure the jack screws are retracted. In the case of the hydraulic shell separator, ensure the pistons are retracted. 17X0115-03.9808
42-65 SUPERIOR MK-II
Section 12 — Spider Assembly
Gyratory Crushers
NOTE Collars (5007-2 or 5008-2) must be in place before spider assembly. 3. Make a level hitch on the spider assembly and lower over the mainshaft into the matching taper fits of the spider and top shell. Position as level as possible so that the bolting flanges are as close to parallel as possible. Check the gap between flanges at 90 o increments. The gap should be 0.139 to 0.187 inches (3.53 to 4.75 mm). If the spider bushing seal is in place, carefully feed it around the mainshaft so that no pinching or damage to the seal occurs. 4. Tighten down two bolts, 180o apart, making sure that the gap between the spider and top shell is equal. Then install two bolts opposite each other and 90 o from the first two, also ending up with an equal gap between the two shells. Install the balance of the bolts at approximately the same tightness as the first four. Continue to tighten the bolts in sequence approximately the same number of turns until a 004” feeler gauge cannot be inserted between the bolting flanges at any point in the circumference.
CAUTION Torque the jackscrew separator jackscrews (5007-1) shown in Fig. 12-4, against the spider flange (5605-0) to 150 ft. lbs. or remove them entirely to prevent the jackscrews (5007-1) from dropping out due to vibration during crush- er operation. 5. Assemble shaft scraper (5606-0) into the spider hub. 6. Install spider bushing (5675-0) with oil seals in spider hub. 7. After the crusher has been operated a few hours, the nuts holding the top shell and spider together sometimes loosen a slight amount. After a little operation, these nuts should be checked again and drawn down as tightly as possible. Use a .004” (.1 mm) feeler gauge while the crusher is crushing to determine if there is any movement between the top shell and spider. If there is, it will be possible to push the feeler in between the spider and top shell. The movement can also be noticed by placing the finger on the joints. Movement indicates the tapers are not engaged properly.
er (5750-0), a cover (5755-1), cover sealant (5755-2), and fastener hardware (5760-0, 5760-4). It must be removed to access the spider bushing (5675-0). See Fig. 12-1. Removal 1. Clean the cover top to prevent contamination into the spider bearing. 2. Remove capscrews (5760-0). 3. Lift off cover (5755-1). After removing cover, remove sealant from cover bottom and from spider hub and clean breather (5750-0). Assembly 1. Place a bead of sealant (5755-2) as provided around the spider hub. Use Permatex No. 2C if factory supplied sealant is not available. 2. Attach cover (5755-1) with capscrews (5760-0) and lockwashers (5760-4). 3. Install breather (5750-0). SPIDER BUSHING Removal The spider bushing can be removed from the top shell while the crusher is still assembled. There is a tapered fit between the spider bushing and the spider hub. First, remove spider bushing bolts (5685-0) and washers (5685-4). The bushing may now be jacked out of the spider hub by screwing jack bolts into the eight tapped holes provided for this purpose in the spider bushing flange. If the reason for removing this bushing is to replace it, it may be more expeditious to chip a groove down the bushing bore to loosen it. This will destroy the bushing. The spider must be removed from the top shell to do this. Inspection Check the clearance between the spider bushing and the mainshaft sleeve at the fulcrum point before removing the bushing from the crusher. The fulcrum point is the point of the smallest diameter in the hourglass-shaped spider bushing. If the clearance between the mainshaft sleeve and spider bushing at the fulcrum point is equal to or greater than the value shown in Fig. 12-6, one or both items must be replaced. Inspect bushing surface as well as dimensions. If it is worn or badly scored discard it. Inspect mainshaft sleeve and replace if necessary. If a new bushing is installed, check its outside surface and the inside surface of the bore of the spider before assembly. As Manufactured
SPIDER VENT ASSEMBLY The spider vent assembly vents the spider bearing oil reservoir and keeps contaminants out. It consists of a breath-
17X0115-03.9808
Maximum
Size
Inches
Mm.
Inches
Mm.
42-65
.022 - .044
.56 - 1.12
.145
3.68
FIG. 12-6 — Spider bushing/mainshaft sleeve clearances
12-5
42-65 SUPERIOR MK-II
Section 12 — Spider Assembly
Gyratory Crushers
Assembly When the bushing is placed in the spider hub, there will be a gap of approximately 1/16” (1.6 mm) between the bottom of the bushing flange and the top face of the spider. The flange must be pulled down tightly on the spider with the spider bushing bolts. Tighten bolts evenly to prevent the bushing from becoming cocked in the spider hub.
NOTE Shaft scraper (5706-0) must be assembled into the spider hub before assembling the bushing.
Spider Bearing Oil Seal Spider bearing oil seals (5705-0) are designed to take the eccentric motion in the seal in crusher operation. See Figs. 12-2 for detail. For 42-65 SUPERIOR crushers, dual oil seals are pressed into a counterbore in the bottom of the bushing. The bushing must be removed in order to replace these seals. The seals can then be tapped out the bottom. Install new seals by pressing them into position in the spider bushing counterbore. Install so that the lips of the seals will be pointing toward the flanged end of the bushing (upward).
SPIDER LUBRICATION SYSTEM The crusher is supplied with an automatic spider lubrication system as a standard feature. The system consists of an electric-hydraulic barrel pump, a 6-ft. (1.83m) x 0.75” (19mm) inside diameter delivery hose assembly, and a NEMA 4 (IP65) control cabinet assembly. The barrel pump fits a standard 400 lb. refinery oil drum and is powered by a 1/2 HP (0.37 Kw), 4 pole motor. The delivery hose assembly fits between the barrel pump and the spider bearing hose assembly which is mounted on the spider (see Fig. 12-1, Lube Hose 5240-0). The control cabinet is complete with a circuit breaker, a solid state timer with adjustable “cycle time” (1/2 minute to 32 hours) and “on time” (12 seconds to 13 minutes), and a motor starter with overload heater elements. See the Spider Lube System Outline, Spider Lube Panel, Spider Lube Schematic drawings and the separately supplied instruction manual.
12-6
Monitoring Spider Oil Level and Setting Control Panel Timer Recommendations for operation: 1. Install system so that the control panel has power only when the crusher motor is running. 2. Initial oil fill should be done with the shaft at its lowest position and fill level should be 1.0” (25 mm) above the spider bushing flange. Level should be recorded at each check. 3. Set initial control panel timer settings according to Table 1. These initial control panel timer settings will result in an oil level increase of approximately 2.0” (51 mm) in a 500 hour time frame if no oil leakage occurs from the spider bearing. Normally some leakage occurs and will vary from machine to machine. It is up to the operator to determine the leakage level and adjust the control panel timer accordingly. 4. Monitor the oil leakage from the spider bearing seals on a daily basis, by observing the amount of oil present on the upper mainshaft journal and head nut area. If the amount of leakage appears excessive or has increased noticeably from previous daily observations, check the level weekly until the spider bearing oil seal can be replaced, to determine that the level of oil in the spider bearing is not dropping faster than oil is being added. (Note: oil level should be checked with the mainshaft in its lowest position) 5. Under normal conditions, check the spider bearing oil level every 500 hours of operation or every 30 days, whichever occurs first. (Note: oil level should be checked with the mainshaft in its lowest position) Ad just the control panel timer per Table 2. 6. Continue to adjust timer setting until rate of oil loss equals oil that is added.
Crusher Size
“Total Cycle Time” (Minutes)
“On Time” (Minutes)
42-65
24
0.2
50-65
24
0.2
54-75
17
0.2
60-89
12
0.2
60–110
9
0.2
Table 1 — Initial Timer Settings
17X0115-03.9808
42-65 SUPERIOR MK-II
Section 12 — Spider Assembly
Gyratory Crushers
Oil Level Above Spider Bushing Flange
Control Panel Timer Setting Adjustment
A) Level greater than 2.0” (51mm)
A) Increase “Total Cycle Time” by 2.
B) Level greater than or equal to 1.0” (256 mm) but less than or equal to 2” (51 mm)
B) Leave the time settings the same.
C) Level less than 1.0” (25 mm)
C) This means oil is leaking out faster than oil is being added. Increase “On Time” by 2 or decrease “Total Cycle Time” by 1/2. Begin to check the level weekly and continue to adjust the timer settings per this Table until oil level increases. Once level starts to increase, checks can be extended to 500 hours or 30 days, whichever occurs first. Table 2 — Control Panel Timer Adjustments
SPIDER ARM AND RIM LINERS Arm and rim liners are easily removed by lifting them off after removing the fasteners. Observe liners regularly for excessive wear. They protect the spider from possible damage. A wear concentration on one arm liner may indicate an uneven feed arrangement, which can result in
17X0115-03.9808
shock loading on the bearings. Arm and rim liners should be fitted so that no rocking occurs on any contact point. After locating liners, insert plugs through holes provided in them until they contact the spider arm or rim, then weld plugs to the liner.
12-7
42-65 SUPERIOR MK-II Gyratory Crushers
Section 13 — Index
13. Lubricant Recommendations
Page 13-1 13-2 13-2 13-2 13-2 13-2 13-3
Description Index General Information Circulating Oil Specifications HYDROSET Control Pinionshaft Assembly Spider Bearing Typical Recommendations
13
17X0115-04.9911
13-1
Section 13 — Lubricant Recommendations GENERAL INFORMATION Four major areas of the SUPERIOR gyratory crusher requiring lubricants are the circulating lubrication system, HYDROSET control, pinionshaft assembly and spider bearing. Use only high quality lubricants in the crusher, to help insure proper lubrication. Consult a local oil company representative for recommendations on specific products which will meet these general specifications.
42-65 SUPERIOR MK-II Gyratory Crushers
Use oil in the HYDROSET control of the same general type (mild extreme-pressure gear oil) as is used in the circulating oil system. However, use the light grade with 300 SSU at 100o F. (ISO VG 68) viscosity at all times, regardless of temperature. See “General Specifications,” in Appendix to Section 3 for the required quantity of HYDROSET oil for the 42-65 SUPERIOR crusher.
NOTE CIRCULATING OIL SYSTEMS Oil in the circulating lubrication system must cool and lubricate the step bearings, eccentric wearing plate, eccentric bushing, bottom shell bushing, bevel gear and pinion. Since this is a circulating system, the oil used must be light enough so that it can be easily pumped, filtered, cooled and returned to the holding tank by gravity, yet heavy enough to properly lubricate the various components. Fill the lube oil tank (7005-0) to a level approximately 1” (25 mm) below the sieve. See “General Specifications,” in Appendix to Section 3 for lube tank capacity. Oil conditioning package is 30 GPM for the 42-65 SUPERIOR crusher. CIRCULATING OIL SPECIFICATION 1. Mild extreme pressure gear oil. 2. High stability against oxidation with mild extreme-pressure characteristics. 3. Foaming tendency at a minimum. 4. Timken film strength of 60 minimum. 5. Viscosity index of 80 minimum. This must be a natural property of the oil, and not obtained through use of viscosity index improvers which reduce oil stability. 6. Oil viscosity will depend on oil temperature during operation. If return oil temperature can be maintained between 100o F. (38o C.) and 115o F. (46 o C.), use an oil with the following viscosity year around: 300 SSU at 100o F. (38 o C.) (ISO VG 68) 50 SSU at 210o F. (99 o C.) If operating conditions are such that the return oil temperature cannot be maintained below 115 o F. (46 o C.), use a slightly heavier oil with the following viscosity: 750 SSU at 100o F. (38 o C.) (ISO VG 150) 70 SSU at 210o F. (99 o C.)
NOTE It is essential that the proper type and viscosity of oil, as outlined above, is used. This will help assure prop- er lube system and crusher operation.
HYDROSET CONTROL In the HYDROSET control, oil is used to raise or lower the piston, and adjust the crusher setting. A light oil is recommended in the HYDROSET control system. 13-2
Never use an oil heavier than 300 SSU at 100 o F. (38 o C.) (ISO VG 68) viscosity in the HYDROSET control. DO NOT use a regular hydraulic oil. PINIONSHAFT ASSEMBLY (See FIG. 13-1) Pinionshaft assembly lubrication is a separate system; oil from the external system never enters the pinionshaft housing. However, the same grade of oil is used in both systems. Be sure to use new or very clean oil, when changing or adding to the pinionshaft lubricant. The oil supply in the housing should be ample for a long period of time, unless the oil seals are damaged and leaking. Inspect oil regularly and change if dirty. Oil is poured into the housing through a pipe plug (3575-0) opening on top of the housing. Maintain oil level at the center of the sight gauge (3341-1) adjacent to the housing. For true oil level readings, inspect level only when the crusher is not operating.
NOTE Do not overfill the pinionshaft. Too much oil will cause overheated bearings. SPIDER BEARING The crusher mainshaft has both rotary and gyratory motion at slow speed and exerts fairly high pressures on the bearing surfaces. An oil pool is used to lubricate this bearing. Since ferrous metals are used in both the mainshaft sleeve and the spider bushing, the oil should contain an “extreme-pressure” additive. Oil is retained in the bearing cavity by two spring-loaded oil seals (5705-0) which are pressed into the bottom of the spider bushing (5675-0) with the lip facing upward. (See Fig. 12-2). Oil is added and drained from the cavity through the spider lube hose (5240-0). The cavity is vented from a mushroom type vent (5750-0) at the top. The oil level should be maintained at approximately 1.0 inch (25 mm) above the spider bushing flange. Initial oil quantity with the mainshaft in its lowest position is approximately 6 gallons (22.7 liters). During the first week of operation, watch the oil level closely to determine the amount of oil which must be added daily to maintain an oil level one inch above the top of the bushing. An unusual amount of oil on the shaft below 17X0115-04.9911
42-65 SUPERIOR MK-II
Section 13 — Lubricant Recommendations
Gyratory Crushers
the spider may indicate damaged oil seals. In this event, a larger amount of oil will have to be added daily until the damaged seals can be replaced. The dual oil seal spider bearing is designed to use a heavy oil as its lubricant. The oil used should have the same general specifications used in the circulating oil system. However, in general, an oil with a viscosity of about 2,000 SSU at 100o F. (38o C.) (ISO VG 460) is most suitable. Depending on the ambient temperature and crusher operating conditions, it may be desirable to use a slightly lighter or heavier oil in the spider bearing.
TYPICAL RECOMMENDATIONS Here is a partial list of lubricant producers and their products. Regard these as typical recommendations. Lubricants with equivalent specifications from other producers may be used.
Texaco Gulf Mobil Exxon
300 SSU Oil (ISO VG 68) Meropa 68 EP Lub S50 Mobilgear 626 Spartan EP 68
750 SSU Oil (ISO VG 150) Meropa 150 EP Lub S70 Mobilgear 629 Spartan EP 150
2000 SSU Oil (ISO VG 460) Meropa 460 EP Lub S150 Mobilgear 634 Spartan EP 460
TO SUIT INSTALLATION 3342–2 3342–1 3575–0 3341–7
3344–5
6.4 [0.25]
3344–3 3342–6
C/L PINIONSHAFT 3341–2
3341–9 3341–1 3341–3
6.4 [0.25]
101.6 [4.00]
OIL LEVEL RED LINE ON SIGHT GAUGE
3341–7 3342–3
3344–4
3344–2
3341–8 3344–5
3341–6
3341–5 SK063099–JJB–2
FIG. 13-1 — Pinionshaft assembly oil level sight gauge Catalog Number
Description
Catalog Number
Description
3341-0 3341-1 3341-2 3341-3 3341-5 3341-6 3341-8 3341-9 3342-1
Pinion Oil Level Sight Gauge Assembly Oil Level Sight Gauge Flexible Hose Assembly Anchor Block Pipe Tee Pipe Plug Pipe Nipple Channel Pipe Tee
3341-7 3342-2 3342-3 3342-6 3344-2 3344-3 3344-4 3344-5 3575-0
Reducing Bushing Pipe Nipple Street Elbow – Lower Street Elbow – Upper Flexible Hose Assembly Swivel Hose End Swivel Hose End Hose Adapter Pipe Plug
17X0115-04.9911
13-3
42-65 SUPERIOR MK-II
Section 14 — Index
Gyratory Crushers
14. Operation
Page 14-1 14-2 14-2 14-2 14-3 14-3 14-3 14-4 14-4 14-5 14-6 14-6 14-7 14-7 14-7 14-7 14-7 14-8 14-8 14-8 14-8 14-8 14-8 14-8 14-8
Description Index Preparation For Start-up Starting Lubrication System HYDROSET Control Check-out Drive Inspection Starting The Crusher Setting Crusher For Product Sizing Break-in Period Operating Limits Trouble-Shooting Chart Preventive Maintenance Daily Maintenance Check Weekly Maintenance Check Major Maintenance Checks — Spider Assembly — Top Shell Assembly — Bottom Shell Assembly — Bottom Shell Bushing — Eccentric Bushing — Eccentric And Gear — HYDROSET Cylinder Assembly — Pinionshaft Assembly — Eccentric Wear Plate — Eccentric Support Plate — Mainshaft Assembly
14
17X0115-05.0003
14-1
42-65 SUPERIOR MK-II
Section 14 — Operation
Gyratory Crushers
PREPARATION FOR START-UP 1. Thoroughly clean the lubrication oil tank (7005-0) and fill with the recommended oil (see Section 5, “Lubrication”). For required quantities of both lubricating and HYDROSET control oil see “General Specifications,” in the Appendix to Section 3.
NOTE Thoroughly flush all lube oil lines before pumping oil into the crusher. Disconnect both lube inlet lines at the crusher and flush the system a minimum of four hours. Failure to properly flush the lube lines may re- sult in contaminants entering the crusher bearings. After flushing has been completed, replace the lube oil filter elements with the spare elements provided. 2. 3.
4. 5.
6. 7.
Thoroughly clean the oil tank for the HYDROSET control system and fill it with the recommended oil. Drain the preservative oil from the pinionshaft assembly and refill with the correct amount of the recommended oil (see Section 13, “Pinionshaft Assembly”). The preservative oil used by Svedala Industries, Inc., “Nucle Oil,” is generally compatible with the recommended lubricating oil, and flushing should not be required. Fill the spider bearing cavity with the recommended lubricant (see Section 13, “Spider Bearing”). Pipe water to the lube oil cooler (7705-0). If an air-to-oil cooler is being used, check piping connections and fan rotation, and drain preservative oil. Check wiring of all lubrication and HYDROSET control system components. Check drive alignment and belt tensioning.
CAUTION Do not operate the crusher without having a suitable drive guard, conforming with statutory requirements, in place. STARTING LUBRICATION SYSTEM 1. Open the hand valve (7405-0) on the pump suction line and filter inlet line. 2. Make sure oil in the tank is at proper operating temperature (see Section 3, “Lubrication”). If an immersion heater has been installed and put in operation, oil should be at approximately 90o F. (32o C.).
NOTE If lubricating oil is too cold, lube system operation will cause high pressures and possibly damage system components. 3. Start the lube oil pump (7205-0) and inspect system piping for leaks. Tighten any loose joints or fittings. 14-2
IMPORTANT See cautionary note under item 1 in “Preparation For Start-up.” DO NOT operate lube system without first flushing it thoroughly. 4. Check operation of oil feed line flow monitors (see page 5-6). 5. Check pressure drop across the oil filter (7505-0). With a clean filter cartridge, and oil at operating temperature, pressure drop should be 3 to 6 psi (.2 to .4 kg/cm2), with no oil flowing through the bypass line. Bleed air from the filter through the plug in the cover. HYDROSET CONTROL CHECK OUT Oil Supply System with a Reversible Gear Pump 1. The valve (8225-0) on the pump suction line between the tank and the control valve (8608-0) must be open. 2. Port “C” of the control valve must be connected to the crusher. 3. The check valve (8525-0) must be installed with the free flow arrow pointing toward the crusher. (Section 6, Fig. 6-9) 4. Any high points in the HYDROSET line between the control valve and the crusher should have a high pressure (1500 psi minimum) bleeder valve to remove air from the HYDROSET line. Air entrapment in the high points of a line would allow a spongy mainshaft, producing an erratically sized product under crushing loads. See Section 6, Fig. 6-8 for bleeder valve location. 5. Check pre-charge nitrogen pressure in the balance cylinder with a tire gauge (or with a permanently installed dial gauge of 0 to 200 psi, if provided). Pressure should be as follows: With mainshaft weight on the HYDROSET oil: Size 42-65 crushers. . . . . 90 psi (620 KPa) If the balance cylinder is losing pre-charge pressure, check the filler valve for leakage. Other causes for pressure loss may be a leaky piston or scored cylinder wall — both will require disassembly, inspection and repair of the balance cylinder. 6. Fill the HYDROSET tank with lubricating oil. See Section 13 for recommendation. 7. The system has a reversible gear pump and the pump motor is connected to run in both directions. Pushing the “raise” button starts the pump in the forward direction pressurizing the control valve assembly and allows oil to pass freely to the crusher, raising the mainshaft. Releasing the “raise” button stops the pump and a check valve in the control valve assembly keeps oil from returning back to the tank. To lower the mainshaft, push the “lower” button which starts the pump in the reverse direction, pressurizing the control valve assembly and allows oil to pass freely back to the tank, lowering the mainshaft. See Section 6 for valve details. Releasing the “lower” button stops the pump and 17X0115-05.0003
42-65 SUPERIOR MK-II Gyratory Crushers
8.
9.
10.
11.
the check valve in the control valve assembly stops oil from returning to the tank. With the plug removed from the bottom of the crusher, put the HYDROSET control in the “Raise” mode and hold until clear oil runs out of the plug hole. A cloudy or milky color indicates air entrainment in the oil which must be removed. When clear oil runs out, install the plug and tighten securely. See Section 6, “Bleeding Air From Systems”. Again put the HYDROSET control in the “Raise” mode and bleed the air or air entrained oil at any high points in the HYDROSET line. Check the HYDROSET line thoroughly for any oil seepage or leaks at all connections, after raising the mainshaft assembly to operating position. Check the line again after operating under load. Crushing pressures frequently expose leaks that are not visible from the static weight of the mainshaft assembly. Raise and lower the mainshaft assembly several times, several hours apart, and repeat the bleeding operation to insure that air entrained in the oil escapes to the HYDROSET system high points for bleeding out. The bottom of the crusher will require only the initial bleeding.
DRIVE INSPECTION 1. Check the alignment of the drive and driven sheaves by stretching a piece of music wire from the driven sheave face diameter to the drive sheave face diameter. Then move the motor on the sliding type base to align the two sheaves. 2. The drive belt tension should be so that a force of 13 lbs. for “C” section belts, 26 lbs. for “D” section belts, 36 lbs. for “E” section belt and 36 lbs. for “8V” section belts, as determined by a spring loaded scale located in the center of the unsupported belt length, will defect a belt 1/64” for each inch of unsupported belt length. STARTING THE CRUSHER 1. The oil level in the lubrication tank should be 1” (25 mm) below the oil screen before starting the pump. Check the total flow of oil at the oil return entrance into the tank by using a measuring can and a stopwatch. TOTAL FLOW =
GALLONS MEASURED x 60 SECONDS SECONDS TO FILL MEASURE
2. Before starting up the crusher, check the backlash of the pinion and gear. See “Bevel Gear Installation and Maintenance,” in the Appendix to section 8. The backlash listings may be exceeded by 25% but should not be less than listed. Recheck the backlash after operating temperatures have leveled off. 3. After the lube pump is started and the oil return is entering the tank, phase in the crusher for correct rotation. This requires a momentary energizing of the crusher drive motor. Correct pinionshaft rotation is clockwise, as viewed in front of the pinionshaft driven 17X0115-05.0003
Section 14 — Operation
sheave. If incorrect, reverse two electrical leads to obtain clockwise rotation. 4. The crusher may be run idle for several hours break-in if clockwise mainshaft spin is not over 12 rpm. If over 12 rpm spin occurs, introduce a light feed of enough material into the crusher to prevent excessive spin. A rubber tire or two suspended from ropes, or similar ob ject, can be put into the crushing chamber if no feed is available. The idle break-in period should continue until the oil return temperature levels off. During the break-in period, small, fine pieces of bronze may accumulate on the oil return screen in the tank, due to lapping of step bearing components into full contact. This may approach one or two teaspoons in quantity, but will diminish. 5. Audible noise is normally heard during break-in as follows: a. An uneven gear noise that coincides with each gyration of the mainshaft assembly is due to the unloaded eccentric and gear moving around in the bearing clearances. The dynamic mainshaft force may also cause pinion gear overrun. This noise will lessen when the crusher is under load. b. A slight slapping sound underneath the crusher mainshaft assembly is from the dust seal slapping the dust collar, and is normal. c. During the warm-up period, the lubrication pump may make noises due to cold oil and a degree of cavitation from air entrainment. The air leaves cold oil much more slowly than from warm oil due to the viscosity change. 6. Problem areas during start-up and their identification: — High oil return temperature (in excess of 115o F. (46o C.) with 300 SSU viscosity oil at 100 o F. (ISO VG 68) or in excess of 130 o F. (54o C.) with 750 SSU viscosity oil at 100o F.) (ISO VG 150) may be due to insufficient cooling water, or incorrect fan rotation, if air to oil cooling is used. — Lack of oil flow and/or lack of oil flow indication in the lubrication line using a flow regulator may be due to its being installed backwards. Arrow must be in direction of flow. Setting The Crusher For Product Sizing For crusher without mainshaft position indicators, drop a round wooden ball (or other lightweight material) approximately the size of the desired setting through the crusher. Ball may be attached to a manila rope and dropped through the chamber to the crushing point at the widest opening. The ball should just pass through to determine the open side setting. Actuate the HYDROSET mechanism to raise or lower the mainshaft to obtain the proper setting. Check again with the ball. The crusher open side setting should normally be that for which the crusher was originally intended as sold. Crushing action should start at the optimum (as designed) point on the mantle, well up in the crushing chamber, to re14-3
42-65 SUPERIOR MK-II
Section 14 — Operation
Gyratory Crushers
duce development of injurious ski slides on the mantle or hooks on the concaves. BREAK-IN PERIOD When operating a new crusher, or when new bearings have been installed, operate initially with a light load. This will allow the new bearings to “wear in” before they are subjected to heavy loads. 1. Run the crusher at one-half capacity for a minimum of two hours and a maximum of one day. 2. Make the initial feed adjustments so that material is evenly distributed around the chamber, with no segregation of coarse and fine materials. 3. Check return oil temperature frequently to be sure it remains within safe limits. Check oil cooler operation.
NOTE If electrical interlocks have been provided for the lube system as recommended in Section 5, “Suggested Control Systems,” and return oil temperature rises above the safe operating limit, a “high oil tempera- ture” warning signal will be actuated and the crusher drive motor will be shut down. 4. Inspect all lubrication and HYDROSET control piping fittings for leaks. Check pinionshaft and spider bearing seals for leaks. 5. Check oil tank sieve for metallic chips. A small amount of bronze and steel flakes is normal during initial break-in.
14-4
6. Recheck all bolts for tightness. 7. Gradually increase crusher load until full load operation is reached. 8. Make final feed adjustments.
NOTE Feed must be evenly distributed around the entire crushing chamber, with coarse and fine material well mixed.
OPERATING LIMITS Always operate the SUPERIOR crusher within the following limits: 1. Keep horsepower draw within the maximum specified for the crusher. 2. Keep return oil temperature within safe limits, less than 115o F. (46o C.) when a 300 SSU (ISO VG 68) oil is used and less than 130 o F. (54o C.) when a 750 SSU (ISO VG 150) oil is used. Pressure in the HYDROSET control, horsepower draw and return oil temperature are affected by the crusher setting, crusher capacity, and hardness of the material being crushed. If high but steady horsepower draw occurs, relieve the load by increasing the crusher setting or reducing the amount of feed to the crusher. If horsepower draw is erratic, the cause may be unevenly distributed feed, feed segregation, packing in the crushing chamber, or air in the HYDROSET control system.
17X0115-05.0003
Section 14 — Operation
42-65 SUPERIOR MK-II Gyratory Crushers
TROUBLE SHOOTING CHART Trouble
Cause
Crusher stoppage
Packing in crusher chamber.
Correction
Clean out chamber by lowering head. Reset crusher and restart. Check crusher setting to be sure it is not smaller than recommended. Check feed regulation Tramp iron. Remove obstruction by lowering head. Reset and restart crusher. If head cannot be lowered because obstruction is wedged too tightly, loosen the top shell. A long acetylene lance may be used to cut out the obstruction, if other methods fail. Blocked oil line (causes lubrica- Clean oil lines. Clean lubrication oil storage tank screen. tion pump to overload). Cold oil (increased oil viscosity Heat oil before starting crusher. causes lubrication pump to overload).
Crusher fails to maintain Oil leakage. setting
Check all piping for leakage. Oil leakage would be appreciable since leakage of a drop periodically would not change the setting even over eight hours. Check valve in control valve as- Inspect check valve for damaged parts and replace . sembly is leaking, allowing oil to return to tank. Air in system. Close side setting opens during crushing. When crusher is empty, head will return to the setting erratically. Bleed oil lines. HYDROSET oil seal. If none of the above remedies correct the trouble, either the oil seal is worn or cracked or the HYDROSET cylinder is worn. Install new seal or repair cylinder.
Breaking mantles
Unusual crusher noises
Oil too hot
17X0115-05.0003
Weaving of mantle on the head caused by elongation of the mantle through work hardening in localized areas.
Check mantle for tightness occasionally by shutting off the feed so the crushing chamber may be observed. As the last part of the feed is being crushed, study the joint between the head nut and the mantle. If the mantle is loose, movement will occur at the joint. These difficulties can sometimes be overcome by the use of special mantles. Consult factory, giving details of feed size, type of material being crushed, product desired and tonnage. Incorrect gear backlash causes Reset gear backlash to the proper value. See Section 9 a high frequency rattle by the ”Gear and Pinion Backlash Adjustment”. pinion bottoming on the gear. Excessive load causes a grind- Excessive load may cause pressures to develop being noise near the bottom of the tween gear teeth and on the step bearing surface. Incrusher or step bearing is fail- spect screen in the oil tank for excessive amounts of ing. bronze or lead flakes. Movement between the top and Replace broken bolts. Tighten the nuts. If taper joint is bottom shells (breakage of worn or rusted and the fit is destroyed, build up taper by bolts). welding and machining. Note: Crusher may be operated TEMPORARILY by shimming the taper joint. No cooling water or water too Check water supply and temperature. warm. Packing in chamber. Clean out chamber by lowering head. Check crusher setting to be sure it is not smaller than recommended. Check feed regulation. Bearing trouble beginning. Check screen of oil tank tor excessive flakes of bronze or lead. Check bearings.
14-5
42-65 SUPERIOR MK-II
Section 14 — Operation
Gyratory Crushers
PREVENTIVE MAINTENANCE Operating conditions vary so widely that it is impossible to recommend one schedule of preventive maintenance for all crushers. Follow some sort of regular inspection and keep records of the periodic inspections and maintenance of your crusher. This recognition of maintenance procedure will keep your crusher in good working condition and prevent costly breakdowns. One of the best rules in crusher maintenance is to keep a record of actual operating hours. Then, after a predetermined period of operation, give the crusher a thorough major inspection. The length of this operating period will vary with the type of product and the number of hours of operation, and can best be determined from experi-
ence. New equipment, however, should be examined after a relatively short period of operation. The next major inspection period can be lengthened somewhat. Follow this system until a maximum period of operation is reached, and adhere to it as the operating schedule between inspections. Systematic inspections of your crusher will result in less maintenance — less down-time — fewer repair bills. Maintenance checks will help in determining wear — detecting failures before they cause serious damage. Crushers operating many hours each day will require more frequent checks.
DAILY MAINTENANCE CHECK Lubrication system
Check amount of oil in storage tank. Oil level should be about 1” (25.4 mm) below sieve before starting. Check oil filter pressure drop. Change filter element when pressure drop reaches 25 psi (1.76 kg/cm 2). Check oil pump and grease if necessary.
Hydraulic system
Check oil storage (it should be full when crushing head is in lowest position). Do not fill tank after setting the head as it will overflow if the head is lowered considerably. After starting crusher and starting feed, check oil lines for leaks. Leaks will cause the crusher to lose its setting.
Spider bearing & pinionshaft Check lubricant in the spider bearing. Lubricant level should be about 1” (25.4 mm) housing. above spider bearing. If frequent filling becomes necessary check oil seal. Check oil level on pinionshaft housing when crusher is not running. General
Check V-belts for wear, looseness, turning and breaks. With the crusher running, check for loose bolts and parts — tighten where necessary. With the crusher running, check oil screen for metal chips. A small amount of chips will occasionally appear on the screen; however, a sudden increase indicates excessive pressures on the bearing surfaces — and possible failure. Check for excessive noise when crusher is operating. Check return oil temperature every hour until it levels off. Check oil temperature when changing shifts and at shutdown. Inspect concaves for tightness.
14-6
17X0115-05.0003
Section 14 — Operation
42-65 SUPERIOR MK-II Gyratory Crushers
WEEKLY MAINTENANCE CHECK
Lubrication system
Check all of the items on the Daily Maintenance Chart. Check for dirt and sludge. If dirty, check the filter and change cartridge if necessary. Change oil when there is dirt suspended in it or when a large amount of sludge has formed in the bottom of the storage tank. Drain the tank, clean and refill with new oil when necessary. Check sediment separators in oil inlet lines to crusher, and clean if necessary.
Check all oil lines and crusher joints for leaks. Lubricate the oil pump motor, if necessary. Check oil pump for noise and indication of wear. Pinionshaft
Check oil level. Oil level should not change unless oil seals are damaged or leaking. Replace if necessary.
General
Check space between head nut and bottom of spider to determine amount of wear. Check dust seal for wear and dust seal retainer for tightness to prevent breaking of bolts. Check mantle and concaves for wear and cracks. Inspect concaves for manganese growth in joints. Toward end of allowable mainshaft adjustment, inspect bottom two rows frequently for wear. Manganese growth from work hardening and stretching across the original concave spacing may cause elongation of joint bolts between top and bottom shells, and separation in the taper fit. If this occurs, initiate a program for regularly air arcing out the peened space between concaves, vertically and horizontally.
MAJOR MAINTENANCE CHECKS Disassemble the crusher. Inspect the major parts and subassemblies as follows. Refurbish and repair, or replace, as required. For specific information on disassembly and reassembly of major components, refer to the applicable section of this manual. Spider Assembly 1. Check the clearance between the spider bushing and mainshaft sleeve before removing the spider or spider bushing from the crusher. The fulcrum point is the point of smallest diameter in the hour-glass-shaped bushing. If the clearance between the mainshaft sleeve and spider bushing at the fulcrum point is equal to or greater than 0.145” (3.68 mm) one or both components must be replaced. 2. Inspect spider bushing seals (5705-0) for nicks, cracks and wear. Replace worn or damaged seals. 3. Check spider arm and rim liners for wear, and for loose fits. They protect the spider from wear and possible damage. Excessive wear on one arm liner may indicate an uneven feed arrangement. Correct the feed to even up the wear pattern and relieve shock loading on bearings. 4. Check taper fit with the top shell. Wear in this fit can only be measured by gauges which are available only from Svedala Industries, Inc.. Remove burrs, bruises, or accumulated rust and dirt. Coat both taper fits with oil or anti-seize compound before reassembly. Do not 17X0115-05.0003
use white lead, which can harden and make subsequent removal of the spider assembly difficult. Top Shell Assembly 1. Check the interference taper fits of the top shell to the bottom shell and to the spider assembly for fretting or wear. Clean up as required. Wear in fits can be measured by gauges which are available only from Svedala Industries, Inc.. 2. Check general condition of concaves for unusual wear patterns, excessive manganese growth or other trouble symptoms. Bottom Shell Assembly Check for wear on components, including: 1. All liners, arms, hub and other surfaces subject to abrasion. 2. Taper joint with top shell (see item 1 under “Top Shell Assembly”). 3. Bore of hub and keyway (see “Bottom Shell Bushing,” below). 4. Dust collar (1400-0). Check for wear on the O.D., or sealing area. Excessive wear can cause oil contamination leading to accelerated step bearing wear, gear wear, etc. Check the dust collar gasket — a faulty gasket may lead to excessive oil loss. If drain holes have not been properly cut in the gasket, oil may overflow the dust collar and contaminate the product. 14-7
42-65 SUPERIOR MK-II
Section 14 — Operation
Bottom Shell Bushing 1. Check for wear, scoring or burning and heat checks in the bore. Remove any burrs or protrusions. 2. Check bushing for cracks, particularly around the keyway, before reusing.
Gyratory Crushers
8. 9.
rests on the clamp plate, for smoothness. Dress it with a flat file, if necessary. Replace the cylinder cover O-ring each time the bottom plate cover is removed. Inspect the HYDROSET cylinder lower bushing face in the O-ring seal area for burrs or scratches. Check the cylinder for flatness on the top of the upper flange. Remove any burrs or bruises. Check the bottom flange in the same manner. Replace the HYDROSET cylinder O-ring each time the cylinder is removed.
Eccentric Bushing 1. Check for wear, scoring, or burning and heat checks in the bore. 2. Before approving reuse of the bushing, check for cracks, particularly around the keyway.
10.
Eccentric And Gear 1. Check for wear, scoring or burning and heat checks on the eccentric turn. 2. Inspect closely for cracks if the eccentric has been burned badly. 3. Inspect and polish the bottom of the gear where it rotates on the eccentric wear plate. 4. Remove all burrs and sharp edges from gear teeth. Inspect teeth for cracks.
Pinionshaft Assembly 1. Remove burrs and sharp edges from pinion teeth before reassembly in the bottom shell. 2. If the two oil seals have been leaking, replace them. Oil loss from the sheave end oil seal may be either from a damaged seal or a grooved spacer. 3. Check both pinion and sheave end spacers. Replace if rough or grooved. 4. Inspect bearings for evidence of fatigue, grooving, spalling of race or rolling elements wear or cage deterioration. Replace, if necessary.
HYDROSET Cylinder Assembly 1. Inspect step washer for wear and roughness. Hone surfaces if rough. Inspect bottom for flatness. Replace, if necessary. Wear limits are 3/8” (9.5 mm) on all crushers. 2. Inspect piston wear plate for wear, burns, roughness and flatness. If burned, but in relatively small areas, it may be reused. Hone off any roughness. If seriously burned, replace it. If worn or not flat, replace it. If it is not flat, inspect the piston top surface for flatness. Extreme wear plate wear may be a symptom of either oil contamination or extreme HYDROSET pressure during operations. Wire edges on outside surfaces is an indication of high operating pressure. Wear limits at edges are 3/8” (9.5 mm) on all crushers. 3. Inspect the HYDROSET piston for flatness on top and for gall and score marks on the diameter. If the piston is not flat on top, re-machine or replace it. If gall or score marks are not too great, hand hone them and reuse the piston. Avoid using if marks could score the cylinder wall. 4. Inspect the lower HYDROSET cylinder bushing for score marks, particularly vertical grooving in the seal area. If there are gall or vertical marks, replace the bushing, unless they can be removed by hand honing. Under extreme operating pressures, small depth grooves (visible to the eye) can pass large quantities of oil. 5. The upper HYDROSET cylinder bushing is not so critical, with respect to gall or score marks. It may be reused if honed smooth and not out of round. If worn excessively, replace it. 6. Replace the HYDROSET oil seal if worn or nicked due to oil contamination. 7. Inspect the clamp plate for vertical score marks in the packing recess. Inspect the top, where the piston 14-8
11.
Eccentric Wear Plate If worn, but smooth, with oil slots in good condition, reuse it. If rough and worn, replace it. Eccentric Support Plate 1. Remove burrs and bruises. Check for flatness on bottom side. If not flat, also check to top of the HYDROSET cylinder flange. Excessive pressures can be the cause of a bent plate and flange. 2. Replace the support plate O-ring each time the support plate is removed. Mainshaft Assembly 1. Change the mantle, if badly worn. Normally, manganese will crack or break when approximately 1” (25.4 mm) thickness remains. 2. Inspect mainshaft sleeve for wear. If grooved by wear, or if vertical score marks are evident, replace the sleeve. 3. Inspect the head nut and mainshaft sleeve threads for burrs. Remove all burrs. 4. Inspect the lower bearing journal for grooves, wear, bruises and heat checks. If not too deep, remove them by hand polishing. If deep, remove them by re-machining. 5. Inspect the mainshaft taper. If indented from wear, or for other reasons, stone down the area to match surrounding surfaces. Fill indentations to contour with Babbittrite, Devcon or a similar heat-resistant material so that the mantle and its backing will not be keyed to the shaft. Otherwise, the self-tightening head nut cannot perform its function. 6. Inspect the mainshaft step bearing for wear, burns or roughness. If badly worn, or burned, replace it. If roughened slightly, hand polish and check with bluing 17X0115-05.0003
42-65 SUPERIOR MK-II Gyratory Crushers
Section 14 — Operation
for contact with the step washer. If 50% contact can be obtained, it may be reused. 7. Inspect the dust seal for wear on both the thickness and bore. If worn 1/8” (3.175 mm) or more in inside diameter, replace it. Check for cracks that can be caused by product build-up under the head. Check the dust seal retainer to make sure the lower edge has not worn down to knife edge sharpness. Check attaching bolts for tightness.
17X0115-05.0003
14-9
42-65 SUPERIOR MK-II Gyratory Crushers
Section 15 — Index
15. Low Temperature Operation
Page 15-1 15-2 15-2 15-2 15-2 15-3 15-3 15-3 15-3
Description Index Making Starting and Running Easier in Cold Weather — Additional Oil Heaters — Heating Cables on Oil Lines — Synthetic Oils — Blanking Off the Oil Cooler Radiator — Insulated Oil Tank — Continuous Running of the Lubrication Oil Pump — Modified Oil Monitor Interlocks
15
17X0115.9403
15-1
42-65 SUPERIOR MK-II
Section 15 — Low Temperature Operation MAKING STARTING AND RUNNING EASIER IN COLD WEATHER All of the suggestions listed are based on making the oil flow more easily and thus improve the movement of oil through the crusher. The suggestions described below are not given in any special priority. The order in which the suggested measures are applied must be judged in each individual case. It may be best to use a combination of several suggested measures. 1. Additional oil heaters 2. Heating cables on oil lines 3. Synthetic oils 4. Blanking off the oil cooler radiator 5. Insulated oil tank 6. Continuous running of the lubrication oil pump 7. Modified oil monitor interlocks 1. Additional Oil Heaters Under very cold weather conditions it may be necessary to install extra heaters in the lube tank in order to keep the oil warm. The standard lube tank is furnished with three – 2 KW heaters and has mountings available for adding one to three additional 2 KW heaters. To add additional heaters all that is required is to remove the 2-1/2” pipe plug from the mounting coupling, thread in the heater and wire the heater. Heater — 2 KW, Cat. No. 8825-0 2. Heating Cables on Oil Lines At low temperatures, the oil in the lines between the tank unit and the crusher can solidify and form a “plug” which stops oil flowing to the crusher during starting. This problem can be minimized by insulating the oil lines and installing heating cables. Before heating cables are installed, the slope of the return oil line should be increased, if this is possible. The heating cable should have a rating of 8 – 10 W/m and 40 mm thick insulation should be used. Install the heating cable on the underside of the oil line and use electrical tape to keep the cable in place. In the case of oil lines larger than 50 mm in diameter and/or when it is desired to heat the oil to a temperature 50o C above the ambient temperature, the heating cable can be led backwards and forwards on the same line. Heating cables are in many countries considered as high voltage equipment and must therefore be installed by an authorized electrician, in compliance with the relevant regulations. Heating cable is normally supplied for 120 or 240 V. It is often most convenient to purchase the heating cable from a local supplier who can also install it. If required, Svedala Industries, Inc. can supply suitable heating cable but it is probably still most convenient to turn to a local electrician for installation. 15-2
Gyratory Crushers
The heating cable which Svedala Industries, Inc. recommends is of a self-regulating type, which needs no thermostat since over-heating cannot occur. 3. Synthetic Oils During recent years, synthetic oils have appeared on the market. These oils are in all respects superior to mineralbased oils. Unfortunately they are expensive. However, the higher price can be outweighed by the advantages provided by the oil. According to Mobil, the characteristics of synthetic oils can in general be described as: Advantages — Longer life thanks to high stability which gives longer intervals between oil changes. — Easier starting at low temperatures. — Lower energy consumption due to lower friction. — Wider temperature range. — Elimination of the risk of dangerous oxidation and “coking”. Fields of use In all types of enclosed spur gears and worm gears and in bearings at high temperature and under heavy loads. For easier starting in low ambient temperatures. For higher safety margins in heavily loaded mechanisms. Characteristics — Maximum lubricating effect. — Lower friction than corresponding mineral oils. — Very good protection against corrosion and foaming. — Very high oxidation stability. — Completely free from aggressive aromatics. In the case of a HYDROCONE or SUPERIOR crusher, it could be said that a synthetic oil provides the same starting conditions as an equivalent mineral oil, but at a temperature about 10 o C lower. In other words, it starting difficulties are experienced with a mineral-based oil at -10 o C, for instance, the use of suitable synthetic oil will mean that the temperature can drop to about -20 o C before similar difficulties are experienced. The following synthetic oils can be recommended for HYDROCONE and SUPERIOR crushers. Other brands can also be used but the selection of a suitable type must be discussed with the supplier. Supplier
Type
Min. Pour point (o)
Viscosity (cSt) at 40oC
Mobil
Mobilgear SHC150
–55
143
Texaco
SYN-STAR EP150
–35
150
The oils mentioned here can be mixed with mineralbased lubricating oils but the crusher and oil tank should be carefully emptied so that the synthetic oil is diluted as little as possible. If a change is made to a synthetic lubricating oil it is also advisable to change over to a synthetic HYDROSET oil. 17X0115.9403
42-65 SUPERIOR MK-II
Section 15 — Low Temperature Operation
Gyratory Crushers
This is in order to reduce the dilution which can occur in the lubricating oil if there is any leakage past the HYDROSET packing. In addition, a synthetic oil will give smoother operating than a mineral oil in valves and pipes. The oil normally used in the HYDROSET system is a grade with viscosity 68 cSt at 40 o C but when synthetic oil is used, a grade with viscosity 31 cSt at 40 o C can be selected. The following synthetic oils can be used in the HYDROSET system. Supplier
Type
Min. Pour point (o)
Viscosity (cSt) at 40oC
Mobil
SHC 626
–52
66
Mobil
SHC 624
–57
31
Texaco
SYN-STAR RNO 68
–46
65
Other brands can also be used but the selection of a suitable type must be discussed with the suppliers. Whatever the type selected, it must be possible to mix the lubricating and HYDROSET oils used in the crusher. In order to maximize the life of the expensive synthetic oil, we recommend that special care is taken with cleanliness and the maintenance of dust seals and filters. 4. Blanking Off the Oil Cooler Radiator During operation it can occasionally happen that the crusher suddenly stops for no apparent reason. One explanation for a sudden stop like this can be that the oil temperature has reached the level at which the cooling fan cuts in. If the air is cold, the oil can be cooled so efficiently in the cooler that the viscosity increases and oil “solidifies” in the relatively small passages of the radiator. This increases pressure drop, which either reduces the oil flow and the crusher stops because insufficient oil passes the flow monitors; or oil by-passes the cooler with little cooling and the crusher stops because too hot of oil passes the high temperature shut-down switch in the return line. The easiest way to avoid stoppages of this kind is to blank off the radiator so that a smaller mass of air is passed
17X0115.9403
through the radiator core. The degree of blanking must be determined by trial-and-error in each individual case. 5. Insulated Oil Tank During the winter, one way of making the most of the heat put into the oil tank (with the heating elements, from friction in the crusher, etc.) is to insulate the tank. This means that the oil in the tank does not cool down as rapidly and after a cold night it will be easier to start the crusher since the oil temperature is higher than it would be if the tank were not insulated. When the ambient temperature rises (i.e. when winter gives way to spring) it may be necessary to remove the insulation if the cooling capacity of the system is insufficient. Svedala Industries does not have standard off-theshelf insulation kits. Insulation can easily be installed by the plant personnel. Suitable material is Rockwool 1330-00, 50 mm thick. The insulation material must be protected from moisture as it will otherwise lose its insulating properties. 6. Continuous Running of the Lubrication Oil Pump During cold weather it may be difficult to start the crusher since oil has solidified in the oil lines and in the crusher itself. This can be avoided or minimized if the oil pump is allowed to run continuously during the time when the crusher is standing still., The heaters in the oil tank must be switched on and the crusher’s feed opening must be covered over to avoid excessive cooling by cold air passing freely through the crushing chamber. If this is allowed to happen, the heating power installed in the tank will probably be insufficient. 7. Modified Oil Monitor Interlocks When a HYDROCONE or SUPERIOR crusher is to be started it can sometimes be useful to by-pass the oil monitor interlocks for a short period during the starting phase. The crusher motor can then be started without the oil monitors giving a “crusher ready to start” signal. With the crusher in motion the oil is effectively heated by friction so that it becomes easier for the oil to pass through the bearings and other restricted passages. This results in higher oil flow through the crusher.
15-3