2 CV215-229-01 - OM - S226 051-02 en PDF [PDF]

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operation & maintenance manual

S 226.051.en

SANDVIK CV215-CV229

This document is valid for:

Serial no. / Machine no.

Sign.

SANDVIK CV215-CV229 © Copyright 2010 Sandvik SRP AB. All rights reserved. No parts of this document may be reproduced or copied in any form or by any means without written permission from Sandvik SRP AB. All data and information in this manual may be changed without further notice. Reservations for misprints. Document number: S 226.051.en Original instructions Issue: 20110117 Version: 02

Sandvik Stationsplan, SE-233 81 Svedala, Sweden Phone: +46 (0)40 409000, Fax: +46 (0)40 409260 www.sandvik.com

OM Sandvik CV215-CV229

1. Principles of operation 1.1 1.2 1.3 1.4

Control of crushed product sizes ........................................ Rotor speed ........................................................................ Bi-flow® .............................................................................. Vibration protection.............................................................

11 11 11 12

2. Safety precautions 2.1 Hazard information ............................................................. 2.1.1 Warning signs ........................................................ 2.1.2 Risk levels.............................................................. 2.1.3 Prohibition signs..................................................... 2.1.4 Mandatory signs..................................................... 2.1.5 Other signs............................................................. 2.2 Personnel............................................................................ 2.2.1 Personal protection ................................................ 2.3 General safety precautions................................................. 2.3.1 Machine safety guards........................................... 2.3.2 Safety interlock system .......................................... 2.3.3 Crusher safety inspection procedure. .................... 2.3.4 Vibration protection ................................................ 2.3.5 Electrical safety...................................................... 2.3.6 Welding .................................................................. 2.3.7 Hydraulic system.................................................... 2.3.8 Lifting and moving loads ........................................ 2.3.9 Feed and jams ....................................................... 2.4 Emissions ........................................................................... 2.4.1 Dust........................................................................ 2.4.2 Noise...................................................................... 2.4.3 Radioactivity...........................................................

14 14 14 15 15 15 15 16 17 17 18 18 19 20 20 20 21 21 22 22 22 22

3. Component identification 3.1 3.2 3.3 3.4

© 2010 Sandvik SRP AB

Exterior of crusher .............................................................. Interior of crusher................................................................ Component identification reference list............................... Rotor and wear parts ..........................................................

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4. Start up procedure 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9

Before start-up .................................................................... Initial start-up ...................................................................... Operation ............................................................................ Noise levels......................................................................... Vibration.............................................................................. Flow of material................................................................... Dust emission ..................................................................... Feed control ........................................................................ Bi-Flow® control..................................................................

30 31 34 34 34 35 35 35 36

5. Shut down procedure 5.1 Shut-down........................................................................... 40

6. Inspection and servicing 6.1 6.2 6.3 6.4 6.5 6.6 6.7

General recommendations.................................................. Lubrication .......................................................................... Grease requirement ............................................................ Recommended greases...................................................... Bearing cartridge................................................................. Operating temperature........................................................ Grease discharge................................................................

42 43 44 46 46 47 47

7. Rotor servicing 7.1 Access ................................................................................ 7.2 Cleaning out rotor ............................................................... 7.3 7.3 Rotor tip assembly ....................................................... 7.3.1 HP & LP / EP Rotor Tip Assembly ......................... 7.3.2 Rotor Tip Assembly ................................................ 7.3.3 Rotor Tip Assembly ................................................ 7.3.4 Selection Of Rotor Tips .......................................... 7.3.5 Removal / Installation Removal.............................. 7.3.6 Installation .............................................................. 7.4 Upper and lower wear plates removal ................................ 7.4.1 Upper Wear Plate................................................... 7.4.2 Upper & Lower Wear Plate Assembly .................... 7.5 Distributor plate................................................................... 4

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OM Sandvik CV215-CV229 7.5.1 Premature Wear..................................................... 7.5.2 Selection Of Distributor Plate................................. 7.5.3 Distributor Plate ..................................................... 7.5.4 Removal................................................................. 7.5.5 Refitting.................................................................. 7.6 Feed tube........................................................................... 7.6.1 Uneven Wear ......................................................... 7.6.2 Cracking and Breakage ......................................... 7.6.3 Removal................................................................. 7.6.4 Installation.............................................................. 7.7 Trail plates .......................................................................... 7.7.1 Removal................................................................. 7.7.2 Installation.............................................................. 7.8 Rotor body .......................................................................... 7.8.1 HP Rotors .............................................................. 7.8.2 LP / EP Rotors ....................................................... 7.8.3 Top wear plate........................................................ 7.8.4 Top edge wear ....................................................... 7.8.5 Streaming Wear ..................................................... 7.8.6 Bottom edge wear.................................................. 7.8.7 Rotor wear protection plates – Top wear plate....... 7.8.8 Cavity Wear Plates ................................................

57 57 57 58 58 59 60 60 61 62 63 65 65 66 66 66 67 67 68 69 69 71

8. Rotor build-up 8.1 Primary function.................................................................. 74 8.2 Secondary function ............................................................. 74

9. Rotor tuning 9.1 General information ............................................................ 9.1.1 Rotor ...................................................................... 9.1.2 Different material characteristics............................ 9.1.3 Tuning on site......................................................... 9.1.4 Primary function ..................................................... 9.1.5 Basic principles ...................................................... 9.2 Adjustment of rotor build-up................................................ 9.2.1 Adjustment Of Rotor Build-Up................................ 9.2.2 Rotor servicing ....................................................... 9.2.3 Rotor Rebuilding .................................................... © 2010 Sandvik SRP AB

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10. Rotor removal 10.1 Removal.............................................................................. 82 10.2 Rotor installation ................................................................. 85

11. Rotor balancing 11.1 Assembly of Rotor Balance Machines ................................ 90 11.2 Balancing procedure ........................................................... 92 11.3 Rotor balancing troubleshooting ......................................... 94

12. Maintenance 12.1 12.2 12.3 12.4 12.5 12.6

The rotor balance machine ................................................. Crushing chamber build-up................................................. Chamber wall (low build-up) ............................................... Excessive build-up .............................................................. Chamber gussets................................................................ Toe-board............................................................................

96 96 97 97 97 98

13. Crushing chamber 13.1 13.2 13.3 13.4

Cavity ring ......................................................................... Hopper Bi-Flow®............................................................... Hopper body ..................................................................... Control plate...................................................................... 13.4.1 Removal ............................................................... 13.4.2 Assembly.............................................................. 13.5 Hydraulic rotor feed throttle gate....................................... 13.5.1 Normal running adjustment .................................. 13.5.2 Removal ............................................................... 13.6 Cylinder............................................................................ 13.6.1 Removal ...............................................................

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14. Crusher servicing 14.1 Feed tube centralisation and height adjustment ............... 106 14.2 Wear skirt.......................................................................... 107 14.2.1 Removal............................................................... 108 14.2.2 Installation............................................................ 108 14.3 Safety interlock ................................................................. 109 14.4 Vibration switch................................................................. 109 14.5 Inspection doors and hatches........................................... 109 14.6 Crusher base and discharge chutes ................................. 110 14.7 Base liners ......................................................................... 111 14.7.1 Removal................................................................ 111 14.7.2 Assembly .............................................................. 111 14.8 Gusset wear castings ....................................................... 112 14.9 Grease discharge chute.................................................... 112 14.10Belt guards ....................................................................... 112 14.11Motors............................................................................... 112 14.12Bearing cartridge.............................................................. 113 14.13Bearing cartridge seals .................................................... 114 14.14Bearing cartridge removal from base ............................... 117 14.15Bearing cartridge refitting in base .................................... 119 14.16Drive belt tensioning......................................................... 121 14.16.1 Procedure for Adjustment and/or Removal of wedge belts .......................................................... 121 14.16.2 Re-fitting and tensioning of wedge belts .............. 121 14.16.3 Measuring ............................................................ 122 14.16.4 Adjustment ........................................................... 123 14.16.5 Dual Drive ............................................................ 124

15. Bolt torque reference chart 15.1 Bolt Torque Settings Nm (ft lbs) ........................................ 128

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1. Principles of operation

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1. Principles of operation

The Sandvik CV215-229 autogenous crusher uses a rock lined rotor that accelerates a continuous rock stream into a stone lined crushing chamber. Material fed into the top of the machine is accelerated in the crusher's rock lined rotor, achieving exit velocities in excess of 45 meters per second. The rotor continuously discharges material into the crushing chamber. This process replenishes the rock lining, while at the same time maintains a continuous chain reaction of crushing and grinding. A second stream of material (Bi-Flow®) can be fed into the crushing chamber in a controlled and directed flow. This Bi-Flow® can further increase the amount of energised material within the Crushing Chamber, thus improving the energy transfer. This, in combination with other variables of rotor diameter, speed and crushing chamber profile, maximises power efficiency, ensures the lowest operating cost (cost per Tonne) and provides an efficient means of controlling the grinding and crushing action, to either increase or decrease the production of fines.

1 1 2 3 4

Bi-Flow® Port Bi-Flow® adjustment gates Bi-Flow® material The position of the throttle gate controls the flow of material into rotor. Excess material unable to flow through to the rotor, overflows through the Bi-Flow® ports. 5 Material from the rotor and the Bi-Flow® material recombine. A constant cloud of airborne particles move around the crushing chamber. Particles are retained for 5-20 seconds before losing energy and falling from the crushing chamber. 6 The rotor accelerates material and continuously discharges it into the crushing chamber. Particle exit velocities in excess of 45m/s

2 4 3

5

6

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1. Principles of operation

1.1 Control of crushed product sizes The crusher offers a number of controllable options that can affect the final product grading. Listed below are two of the main options, that in general iterms describe the effects of those adjustments.

1.2 Rotor speed Increasing rotor speed increases the particles kinetic energy and increases the reduction achieved. However, rotor throughput (T.P.H.) will decrease as rotor speed increases.

1.3 Bi-flow® Increasing the Bi-Flow® flow up to 20% of the crushers maximum rotor throughput, increases the crushers optimum maximum capacity and reduction ratios. Increases of Bi-Flow® above 20% generally decreases the reduction ratio achieved whilst increasing the capacity of the crusher. Crushing Chamber Profile: Material size, moisture content, and feed capacity will effect the amount and shape of retained material within the Crushing Chamber. This can be adjusted by the removal of the bolted in Chamber Gussets if the retained material is excessive, or by the fitting of more (or modified shaped) gussets if the retained material is not sufficient. Rotor Diameter: Rotor diameters are constant for each model. Changes to the Tip Speed (M/sec.) of the rotor is achieved either by adjustment to the drive pulleys, or by the utilisation of an electrical speed inverter (increase or decrease speed). (Continued)

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1. Principles of operation

Min. % Bi-Flow Feed

Feed

Products High speed Products Low speed

Max.% Bi-Flow

Decreased rotor speed

Sieve size

Sieve size Feed gradation

Screen aperture

Changing the size distribution of the feed to the crusher will affect size distribution

When operating in closed circuit the final product size produced by the crusher is controlled by the screen aperture

Product screen Undersize 5mm

Feed

Product screen Undersize 10mm

Product 1 Product 2 Feed2

Feed1 Crusher discharge

5mm 10mm Screen aperture

1.4 Vibration protection Full wiring instructions are supplied with the vibration protection system. Machines without a vibration protection system will not be covered by warranty.

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2. Safety precautions To ensure maximum safety, always read this section carefully before doing any work on Sandvik equipment or making any adjustments.

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2. Safety precautions

2.1 Hazard information 2.1.1 Warning signs

General danger

Dangerous voltage

Risk of crushing

Hanging load

Risk of crushing

Flying fragments

2.1.2 Risk levels Throughout the manual, risk levels are indicated with “DANGER”, “WARNING” or “CAUTION”. The “DANGER” and “WARNING” levels are accompanied by a warning sign (see above). Failure to observe information marked “DANGER!” can result in life-threatening injuries! DANGER! Failure to observe information marked “WARNING!” can result in personal injury and/or serious damage to, or destruction of, equipment! WARNING! CAUTION!

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Failure to observe information marked “CAUTION!” can result in damage to equipment!

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2. Safety precautions

2.1.3 Prohibition signs

Do not remove guards

Do not clear crusher while operating

Do not open inspection door while operating

2.1.4 Mandatory signs

Disconnect current

Read the manual

2.1.5 Other signs

Point where the whole machine can be safely lifted from.

2.2 Personnel All work on the equipment is to be carried out only by trained or authorized personnel. – “Trained” means that the person in question has been given practical instruction by an authorized person on how the various tasks are to be carried out. – “Authorized” means that a person has undergone a theoretical and practical test of knowledge, organized by Sandvik SRP AB. He/she is therefore judged to have the knowledge and competence to carry out the tasks assigned to the appropriate role. All expected work tasks on this production equipment have been defined by Sandvik SRP AB as belonging to one of three categories – work roles – based on different competence profiles. These three work roles are: • • •

Installation Operation Maintenance (Continued)

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2. Safety precautions

Sandvik SRP AB provides technical documentation appropriate to all three work roles: • Installation manual • Operator’s manual • Maintenance manual and Spare parts catalog Sandvik SRP AB can provide adequate training for all three work roles and can carry out authorization of trained personnel. The technical documentation from Sandvik SRP AB covers only work on the production equipment itself – it does not cover work tasks associated with other equipment or routines at the site. It is the responsibility of the plant management to assign responsibility for: • • • • •

The production equipment and the work area around the equipment All personnel in the vicinity of the equipment Compliance with national and local safety regulations Checking that all safety devices are fully operational It is the responsibility of the owners to assess the required level of education for non professional personnel, is satisfactory for the safe operation and maintenance of the crusher. • Risk assessments and method statements must be performed to assess the hazards of material being crushed. Specific attention must be paid to risk from explosion (combustible material) that may be caused by heat or friction within the crushing chamber and or hazardous dust (silica) etc. Sandvik SRP AB declines all responsibility for injury or damage resulting from non-compliance with the instructions in this manual.

2.2.1 Personal protection Sandvik SRP AB strongly recommends that personal protective equipment is always worn when working in the vicinity of the equipment. Sandvik SRP AB strongly recommends to use a safety harness when working above, inside or under the equipment. The Sandvik SRP AB recommendation for personal protective equipment includes:

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Ear protection

Safety helmet

Eye protection

Protective gloves

Safety boots

Mask or respirator apparatus when appropriate

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2. Safety precautions

2.3 General safety precautions Always switch off power and lock out the equipment (so that it cannot inadvertently be switched on) before any maintenance work is started. Also ensure that it is not possible for anyone else to switch the power on while maintenance work is being carried out. Avoid staying on the equipment, unless necessary for maintenance work.

WARNING! CAUTION!

Risk of crushing If the crusher is mounted on rubber dampers, there is a risk of crushing between the oscillating parts of the crusher and the stationary frame. Clear the feed arrangement from process material before any maintenance work is carried out inside or below the crusher, to prevent stones from falling down.

2.3.1 Machine safety guards Do not remove guards Make sure that all guards are in place and functioning, to prevent exposure to flying fragments and rotating parts. Never operate the PROHIBITION! equipment unless guards are mounted. Rotating parts Exposure to rotating parts of the equipment must be prevented by guards. Always attach guards after maintenance work. WARNING!

WARNING!

Flying fragments Fragments ejected upwards may fall down in the vicinity of the equipment. Provide adequate guards and warning signs at appropriate places around the danger zone.

Platforms with guard rails shall be installed around the crusher’s feed opening. Walkaways, stairs and ladders must be designed in accordance with applicable regulations. (these parts are not included in the crusher’s standard specification). Make sure all defective guards and dust sealing components are checked, repaired and replaced before starting the equipment.

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2. Safety precautions

2.3.2 Safety interlock system The Safety Interlock System is designed to prevent the crushing chamber service door from being opened while the machine is in operation, or on shutdown, before sufficient time has elapsed to allow the rotor to stop rotating. The interlock also prevents accidental start-up while the crusher is being serviced, or when the door is left open. Under no circumstances should any maintenance work or internal inspection be carried out on the crusher, until it has been locked out using the Safety Interlock System. NOTE!

For installation and maintenance of the safety interlock system refer to the Mechanical Safety Interlock System Manual.

2.3.3 Crusher safety inspection procedure. P

PROHIBITION! NOTE!

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Safety interlock system The crusher must be isolated using the Safety Interlock System (see the Safety interlock manual) before any inspection or maintenance activity is undertaken.

If the operations of ancillary equipment (e.g. feeders, conveyors) present any danger to this inspection or maintenance activity, these must also be isolated.

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2. Safety precautions

2.3.4 Vibration protection A vibration protection system protects the machine from the effects of severe vibration. With this installed, the machine will be shut down and/or an alarm sounded if vibration becomes excessive. In normal operation, the crusher has a slight vibration which varies from time to time, due to the wear and replacement of material within the rotor. As material wears away it is continually replaced. Consistent or excessive vibration should always be investigated. A likely cause is breakage of a rotor tip or uneven build-up within the rotor. High pitched vibration may be caused by poor rotor taper lock seating or a bent shaft.

Recommended position for Vibration Switch

P

Vibration All machines must have a vibration protection system properly fitted and connected. WARNING!

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2. Safety precautions

2.3.5 Electrical safety CAUTION!

P

Only electrical personnel working according to European Standard EN 50110 or similar are permitted to perform electrical operations on the crusher. Dangerous voltage Personnel must regard all electrical equipment as live until it is proven dead by proper testing procedures.

DANGER!

Make sure all broken or damaged electrical cables and connectors are checked, repaired and replaced before starting the equipment.

2.3.6 Welding CAUTION!

Only welders qualified according to European Standard EN 287 or similar are permitted to perform welding operations on the crusher.

CAUTION!

Welding on the crusher is only permitted when and as described in the manual. For all other welding operations on the crusher local Sandvik service personnel must be consulted.

If welding an item to the crusher, the earth must be attached to the item itself. If a crusher component is to be welded, the earth should be attached as near to the welding area as possible. NO welding should be done on the rotor whilst it is in the machine. P

WARNING!

Toxic gases Inhalation of welding fumes can be dangerous to health. Always follow instructions provided by the welding equipment supplier. Some parts of the crusher are made of manganese steel. Long-term exposure to manganese oxide can affect the nervous system.

2.3.7 Hydraulic system Only personnel certified in hydraulics are permitted to perform operations on the hydraulic system.. P

WARNING!

Hydraulic systems Pressurized oil is dangerous if released incorrectly. Relieve all pressure before carrying out maintenance or repair work on the hydraulic system.

CAUTION!

Never adjust pressure relief valves beyond the recommended values.

CAUTION!

Hydraulic oil can get very hot in operation. Allow the oil to cool before working on the hydraulic system

Make sure all defective hoses, valves or fittings are checked, repaired and replaced before starting the equipment.

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2. Safety precautions

2.3.8 Lifting and moving loads CAUTION!

Only personnel with adequate lifting training are permitted to perform lifting operation. .

P

Hanging load Never work or stand underneath a crane that is lifting material. Keep a safe distance from a hanging load. WARNING!

Make sure that the capacity of the lifting equipment is adequate and that the equipment itself is in good working order. If a lifting tackle has to be made up by joining separate components, make sure that the joints are secure and have the same lifting capacity as the rest of the tackle. NOTE!

Always use lifting tackle certified in accordance with local conditions. Always engage the safety clips on lifting hooks to prevent the tackle from slipping off. Use ropes or poles to steady and manoeuvre loads. Do not use hands or feet. Make sure that the route and the destination are free from obstacles before moving a suspended load. It must be possible to lower the load to the floor quickly and safely in an emergency. When depositing loads, keep the lifting equipment in place until the stability of the load has been checked

2.3.9 Feed and jams Always follow local regulations when attempting to clear a jam. P

Risk of crushing Never stand inside the crusher when a blockage is broken up. You maybe pulled sharply downwards together with the material in the PROHIBITION! crushing chamber and crushed. Never use a bar or rod to clear blockages in the feed hopper, bar or rod could touch spinning rotor and cause severe injury.

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2. Safety precautions

2.4 Emissions 2.4.1 Dust P

Health hazard Crushing and processing material will create dust. Such dust can be more or less dangerous to the health. Use a breathing mask. DANGER!

Sandvik SRP AB strongly recommends using additional equipment for dust encapsulation and dust extraction. Such equipment is not included in the crusher’s standard specification. Sandvik SRP AB declines all responsibility for any health hazards caused by dust generated when processing minerals in the crusher.

2.4.2 Noise P

Health hazards Crushing and processing material will create noise. Such noise can be more or less dangerous to the hearing. Use ear protection. WARNING!

2.4.3 Radioactivity P

DANGER!

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Health hazards Radon is a radioactive gas that occurs naturally in bedrock. Radon may cause lung cancer. Mineral type, ventilation and water are all factors that influence the contents of radon gases.

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3. Component identification

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3. Component identification

3.1 Exterior of crusher This section has been included to help you identify the various components and parts of your crusher. These terms will be used throughout the manual and parts listings that are provided. The letters refers to the table below for the correct terminology for that item.

N A P

Q

C

R

CV228/CV229

B

O

F1 O

F2 D1

H

D2

K T2

T1 N S

CV218/CV217 CV215/CV216

Q R P C

A

B D2 D1 O

H K

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3. Component identification

3.2 Interior of crusher The letters refers to the table below for the correct terminology for that item.

J1 I

CV228/CV229

E1

L M

G

D2

E2 D1

T2

T1

I

J2 CV218/CV217 CV215/CV216

L U M D1

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G

E2 D2

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3. Component identification

3.3 Component identification reference list

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Letter

Description

A

Crushing chamber

B

Support frame

C

Motor mount assemblies

D1

Support leg short

D2

Support leg short

E1

Hydraulic cylinder bracket

E2

Hydraulic cylinder bracket

F1

Leg gusset

F2

Leg gusset

G

Crusher drive pulley

H

Crusher base

I

Feed kit holder assembly

J1

High profile rotor

J2

Low profile rotor

K

Skid frame

L

Grease chute

M

Grease duct

N

Feed hopper

O

Guard assembly

P

Hydraulic unit

Q

Hydraulic cabin

R

Grease keg

S

Grease hand pump

T1

Support leg long

T2

Support leg long

U

Bearing cartridge assembly

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3. Component identification

3.4 Rotor and wear parts Sandvik LP / EP Rotor

1

3

2 4 1 2 3 4 5 6 7 8 9 10 11 12

Distributor plate Top wear plate Trail plate Upper wear plate lower wear plate 5 Rotor body Top cavity wear plate Bottom cavity wear plate Back-up tip Rotor tip Rotor boss Taper lock

7

9 8

10

6

11

12

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3. Component identification

Sandvik HP Rotor

1 2 1 2 3 4 5 6 7 8 9 10 11

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Distributor plate Top wear plate Trail plate Upper wear plate Lower wear plate 5 Top cavity wear plate Middle cavity wear plate Bottom cavity wear Plate Rotor Body Back Up Tip R o t o r Tip

4 3

6 10

7

9

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4. Start up procedure

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4. Start up procedure

This section describes the full start-up procedure, including the initial commissioning start-up. The start-up procedure should be used after a major repair such as bearing cartridge replacement or crushing chamber refurbishment has taken place.

4.1 Before start-up a) Be completely familiar with the crusher, take the time to read this manual. b) Have all electrical connections checked, including the operation of the vibration switch. (See the Vibration switch manual). c) Check pulley alignment and drive belt tensions. See section 14.16 Drive belt tensioning. d) Check rotor rotation - it must be counter-clockwise when viewed from above. Damage Severe damage to the rotor will result if the rotation is incorrect. DANGER!

e) On dual motor drive machines it is essential that the direction of both motors is correct and the same. If no electronic test equipment is available to prove this, the wedge belts must be removed and the motors started in the normal way, the direction of each motor can then be checked. When all connections are complete ensure all pvc shrouds are refitted and any unused holes are blanked off to maintain the IP rating of the enclosure. f) Check that the safety interlock device is connected and functioning. g) Make sure all bolts are tightened to the correct torque. See section 15.1 Bolt Torque Settings Nm (ft lbs) for correct torque details. h) Loosen the transport bolts located through the rubber anti-vibration mounts by two full turns. i) Ensure that the feed tube / Feed Kit Holder assembly is centralized. See section 14.1 Feed tube centralisation and height adjustment. j) Check that all wear parts are correctly fitted in the rotor. See ssection 3.4 Rotor and wear parts. k) Remove all tools from on or within the crusher. l) Ensure that all guards, doors, hatches and safety pins are in place. m) Ensure grease hoses are full of grease before connection to the bearing cartridge.

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4. Start up procedure

4.2 Initial start-up a) Confirm ammeter is operating accurately. (Use clip-on ammeter to check accuracy). b) Run the crusher with rotor fitted without load for 30 minutes. Apply a single application of grease to each of the three grease points. See greasing procedure in section 6.3 Grease requirement Initial Feeding Of Crusher

a) The machine can now be run with a load. Feed material should be no larger than the maximum allowable feed size for the crusher model being commissioned. b) Feed a small sized chip or all-in product, preferably 5mm [¼ in.] for the first half minute or so. A few cubic meters/yards of material is enough. This allows an even build-up of stone in the rotor and promotes good balance. c) If coarse feed must be used at the start, some vibration can be expected for several hours until fines are able to work their way through the voids in the initial rotor build-up and bring the density of each rotor build-up into equilibrium. d) When first feeding the rotor there will usually be an 'out of balance' stage for about 30-60 seconds. Do not stop the feed to the rotor at this point but feed it as much as possible until the vibration settles down. In normal operation there is intermittent detectable vibration about 30% of the time. This can be felt when standing on the machine and is most noticeable with largest feed sizes. This is due to stone lodging by one rotor tip, causing a build-up and then being worn away. The condition is normal and no cause for concern provided the machine returns to normal running after a few seconds.

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4. Start up procedure

After 10 Minutes

a) Ensure that the feed falls centrally within the Feed Hopper. The feed should fall squarely into the hopper and the Hydraulic Rotor Feed Throttle should be adjusted to obtain the required motor amps draw / throughput. Whether using rotor only or rotor and Bi-Flow®, the Feed Hopper should be choke fed at all times. b) Check motor power draw. If motor(s) are overloaded, reduce feed volume or adjust the Hydraulic Rotor Feed Throttle Control, until load is corrected. See section 13.5 Hydraulic rotor feed throttle gate. If dual drive motors are running at different amps check belt tensioning. See section 14.16 Drive belt tensioning. c) After 30 minutes running, stop the machine, remove belt guards and check bearing cartridge temperature (Use a digital thermometer). The temperature should not exceed 70 °C [160 °F]. If temperature exceeds this, continue to run machine with no load for a further 30 minutes and check again. If high temperatures continue contact your service centre for advice. If temperature is within normal range (see section 6.5 Bearing cartridge), replace guards. d) Inspect rotor and Bi-Flow® assembly. Ensure that all rotor parts are in place. Ensure that the feed tube is still centralized in the rotor. See section 14.1 Feed tube centralisation and height adjustment. e) Test vibration switch. See Vibration Control System instruction manual.

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After 30 Minutes

a) Stop machine and check build-up in rotor. For ideal build-up, see rotor tuning section 9.2 Adjustment of rotor build-up. b) Check crushing chamber build-up. See section 12.2 Crushing chamber build-up for ideal build-up c) Make sure feed tube is in correct position in rotor, i.e. central in rotor feed hole and extending into rotor. See section 14.1 Feed tube centralisation and height adjustment d) Check that rotor tip assemblies are intact and tight. e) Check belt tensions. See section 14.16 Drive belt tensioning. After 4 Hours

a) b) c) d) e)

Check build-up in rotor, crushing chamber and base. Check bearing temperatures. (See below). Check belt tensions. Grease at the end of the shift, and perform daily inspections as listed. Once the machine has settled down to normal running, further adjustment of the Bi-Flow® can be under-taken. See section 13.5 Hydraulic rotor feed throttle gate

Bearing Operating Temperature

Normal bearing temperature is 30 ° to 40 °C [54 ° to 72 °F] above feed material or ambient temperature. A short duration temperature rise of approximately 10 °C [18 °F] can be experienced when bearings are lubricated. The maximum permissible bearing temperature for continuous running is:

© 2010 Sandvik SRP AB

70 ° C (160 ° F)

Normal temperature service

150 ° C (300 ° F)

High temperature service

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4.3 Operation During operation it is important that the operator pays attention to the following: Ammeter Reading - watch for major fluctuations

High amps could indicate high feed rates, extreme build-up in the chamber or the base, blocked discharge chutes, incorrect Hydraulic Rotor Feed Throttle adjustment, mechanical or electrical problems. Low amps could indicate low feed rates, incorrect Hydraulic Rotor Feed Throttle adjustment, drive belt slippage, or electrical problems. Unbalanced amps in a dual drive unit could indicate incorrectly tensioned drive belts, electrical or mechanical problems.

4.4 Noise levels An increase in noise level could indicate bearing failure, drive belt slippage, scouring of build-up in crushing chamber, feed tube rubbing on rotor.

4.5 Vibration An increase in vibration could indicate: a) b) c) d) e) NOTE!

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Uneven wear on wear parts Unbalanced rotor due to uneven build-up in rotor Failure of anti-vibration pads. Loose rotor. Loose pulley taper lock.

The Vibration switch fitted to the crusher will, if correctly adjusted, sense out-of-balance vibration and shut down the crusher before any damage or danger to personnel occurs.

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4.6 Flow of material Changes in feed conditions could require adjustment of the Bi-Flow® Adjustment Gates and or the Hydraulic Rotor Feed Throttle. Increases in moisture content may increase build-up in the rotor, hopper, crushing chamber and base. Observing the discharge of the crusher will often warn an operator of build-up problems.

4.7 Dust emission The crusher should not emit dust while being fed material. If the crusher is emitting dust the following should be checked: Feed rate - Very low feed rates may cause the crusher to discharge dust from the discharge chutes. Settings of the Bi-Flow® Adjustment Gates and Hydraulic Rotor Feed Throttle. These should ideally be set to achieve choke feeding of the Feed Hopper.

4.8 Feed control The aim of Hydraulic Rotor Feed Throttle, is to govern the ratio of feed to the rotor and Bi-Flow®. The reason for controlling this feed distribution is very dependent on the product requirement of the operator. The following describes the different uses of the control: a) To protect the motor(s) from overload. b) To achieve the absolute highest efficiency of crushing (reduction) by using the optimum Bi-Flow® ratio and the consistent running of the motors at full capacity. c) To maximise the production of a particular size fraction by control of the product gradation produced. Variation of the Bi-Flow® ratio will allow complete control of the gradation curve. The rotor feed volume is varied by adjustment of the Hydraulic Rotor Feed Throttle. Coarse adjustment is made by selection of the correct sized Feed Control Plate. Fine adjustment is made by movement of the Hydraulic Rotor Feed Throttle. The feed opening should not be reduced to a point where bridging of the feed opening may occur. (Continued)

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Adjust the Bi-Flow® Adjuster Gates, so that material Bi-Flows evenly through 360°. See section 4.9 Bi-Flow® control.

1 2 3 4

Bi-Flow® Rotor Throttle Bi-Flow® Control Plate Bi-Flow® Adjuster Gate Bi-Flow® Port

1

2

3

4

4.9 Bi-Flow® control When using the Bi-Flow® mechanism, it is advisable to adjust the Bi-Flow® Adjuster Gates, to ensure that the flow of material is equal through all six Gates. This may necessitate positioning some Bi-Flow® Adjuster Gates higher or lower than others, depending upon the direction of the flow of material into the Feed Hopper. In the case of reduced tonnage throughput and / or reduced levels of BiFlow®, it is possible to operate the Hopper utilising two or three Bi-Flow® ports only. It is essential however that two or three port operation of the BiFlow® system, is set up so that the Bi-Flow® gates in operation are equally spaced, i.e. 180º for two port or 120º for three port. This will ensure the optimum positioning of Bi-Flow® material in the crushing chamber and result in optimum crushing performance when feeding reduced Bi-Flow® tonnages. As mentioned previously, choke feeding of the Feed Hopper is the preferred mode of operation.

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Dust Control

If excessive dust is emitted from the bottom of the machine, this may indicate that the unit is being under-fed. If the feed rate cannot be increased, close off the feed opening by adjusting the feed control plate and Hydraulic Rotor Feed Throttle to minimize the intake of air. As mentioned previously choke feeding of the hopper is the preferred method of operation, which will also significantly reduce dust being vented to atmosphere. Any Bi-Flow® adjustment gates not in use should be completely closed and those in use opened only to the minimum open setting required. While it is not generally necessary to suppress dust within the crusher (either by dry dust collection or mist spray suppression), the turbulent activity within the crushing chamber makes it an ideal environment for the addition of small quantities of water by means of mist sprays to effectively control dust in other parts of the process plant downstream of the crusher. However, on start-up or shut-down with no material flowing into the crusher (completing start-up of plant prior to crusher) there will be a discharge of dust caused by the crusher pumping large volumes of air. We recommend the following: • •

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Minimising the time that the crusher is running without material being fed. Fitting of mist sprays close to the discharge that is activated automatically from motor power on/off control so as to control the dust emission on start-up and shut-down.

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5. Shut down procedure

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5. Shut down procedure

Extended periods of running out the circuit with low feed rates to the crusher can result in undue wear to the crushing chamber and rotor body. If possible stop the main feed conveyor to the crusher without running the system circuit clear. At the very least be aware of the excessive wear that takes place and minimise the run-out time.

5.1 Shut-down a) Shut down feed device (conveyor or feeder) before the crusher. b) Observe ammeter unload prior to disconnecting power from the crusher. c) Time run-down time of rotor and record in the Sandvik VSI Daily Log Book. Measuring the run-down time of the rotor will provide a good guide to the condition of the bearing cartridge. The commissioning records for your unit will have the rotor run-down time recorded. This will be located in the owners manual. If you cannot locate this contact your Sandvik Service Engineer. d) Prior to any servicing or maintenance ensure that the Safety Interlock System is activated. See section 2.3.2 Safety interlock system

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6. Inspection and servicing

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6. Inspection and servicing

6.1 General recommendations Sandvik CV215-229 is a rugged machine which is mechanically simple and extremely easy to maintain. The machine does however require ROUTINE and REGULAR inspections and attention. The machine should not be ignored for lengthy periods, during which potentially serious damage to wear parts may remain undetected. Long service and consistent trouble-free operation are the rewards of regular inspection. NOTE!

Rotor wear parts are designed to protect the rotor body from wear. They are not involved in the crushing action of the machine. Consequently it is not possible to determine the state of wear of these parts from the product discharging from the crusher. To ensure trouble-free operation of the crusher it is necessary to inspect the condition of the rotor wear parts and the rock build-up within the machine on a regular basis. Any wear parts that are unable to complete another shift should be replaced. Sandvik recommends that you should carry out the following every 8 to 10 hours of operation: a) Grease Bearing Cartridge. b) Inspect Exterior Of Crusher. c) Inspect Interior Of Crusher. d) Inspect Rotor Sandvik recommends the use of a Sandvik VSI Daily Log Book to record inspection and replacement of parts. Service personnel will find the log book extremely helpful in assisting you to maximize the life of the wear components in your crusher.

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6. Inspection and servicing

6.2 Lubrication Bearing Cartridge. NOTE!

The Bearing cartridge must be greased every 8 to 10 hours of operation.

The best practice is to grease the bearings when the bearing cartridge is at operating temperature while the machine is running near the end of each production shift. Grease hose and grease discharge for CV228/CV229

1 Grease Hose 2 Grease Discharge

1

2

Grease hose and grease discharge for CV218/CV217/CV216/ CV215

1 Grease Hose 2 Grease Discharge

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Grease unit 1 2 3 4 5

Grease Hand Pump Lever for Bi-Flow throttle Lever for motor 1 Distribution block with tell-tale Lever for motor 2 (Dual Drive Crushers only) 6 Hydraulic Hand Pump 7 Tool box

1

2 3

4

5 6

7

6.3 Grease requirement The following amounts are recommended for every 8-10 hours of operation. Quantities stated below are total (divide by 3 for each grease point). Model CV215 30g [1.06 oz] - 30cc - 15 full pumps of Sandvik VSI Grease Pump CV216 45g [1.59 oz] - 45cc - 22 full pumps of Sandvik VSI Grease Pump CV217 45g [1.59 oz] - 45cc - 22 full pumps of Sandvik VSI Grease Pump CV218 &CV228 45g [1.59 oz] - 45cc - 22 full pumps of Sandvik VSI Grease Pump CV229 45g [1.59 oz] - 45cc - 22 full pumps of Sandvik VSI Grease Pump

The Sandvik VSI Grease Lubrication system fitted to the crusher is a manually operated, keg mounted pump. It delivers metered quantities of grease to all three greasing points of the Bearing Cartridge Assembly. This system negates the need for use of grease guns via grease nipples, which can cause contamination problems and or the wrong type of grease being used. The 15 kg keg of grease fitted to the crusher when new, is sufficient for approx. one full years operation of the crusher (assuming 8-10 hours per day running) (Continued)

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The grease pump feeds grease into a three outlet progressive distributor that sub-divides the grease and feeds via high pressure hoses to the bearings. The progressive distributor is fitted with a "tell-tale" visual indicator, to give the operator a visual indication that the system is functioning correctly as the pump is operated. Replacement kegs of grease can be purchased from your local Sandvik agent. If the visual "tell-tale" stops working during operation it should be investigated immediately. Reasons for non operation indicate either that the grease keg is empty and requires replacement or that air has become trapped in the system. If there is evidence of air becoming trapped within the distributor block or high pressure hoses, it will be necessary to "bleed" the system. This can be done by: a) Ensure that the Follower Plate inside the grease keg, is sat flat on top of the grease within the keg and is not restricted by the pump cylinder. b) Remove the high pressure hoses from the bottom of the Bearing Cartridge Assembly and operate the grease pump to ensure that consistent clean grease is discharged from the ends of all three high pressure hoses. c) Re-connect the high pressure hoses to the base of the Bearing Cartridge Assembly. NOTE!

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There is no set sequence that the hoses have to be connected, any hose can be fitted to any connection point on the Bearing Cartridge Assembly. However be sure that the high pressure hoses are connected so as to ensure that they are well clear of the main drive wedge belts.

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6.4 Recommended greases Bearing cartridges are pre-lubricated with two types of grease upon assembly, depending upon whether the crusher is to be operated at Normal (LT) or High Temperature (HT). Please see the table below for the operating parameters of the two main grease types.

6.5 Bearing cartridge -20 to 65 -4 to 149) Normal service Bearing cartridge All speeds

60 to 100 (140 to 212) High temperature Bearing cartridge All speeds

CV215

1300 to 2200

CV216

1300 to 2200

CV217

1300 to 2200

CV218/228

1100 to 1800

CV229

1100 to 1800

CV215

1300 to 2200

CV216

1300 to 2200

CV217

1300 to 2200

CV218/228

1100 to 1800

CV229

1100 to 1800

Sandvik VSI Semi-Synthetic LT

Sandvik VSI Semi-Synthetic HT

All new Bearing Cartridge Assemblies are pre-lubricated with the grease type listed above, for the varying applications. Please note that the Bearing Cartridge Assembly in the crusher presents a very unique set of operating conditions for the bearings and for this reason, selection of alternative grease types is not a straight forward task. Consideration must also be given to mix ability of any new grease with the grease already in the bearing cartridge. Mixing (especially of different thickener types) causes unpredictable lubrication conditions and possibly premature failure of the bearing cartridge. If you wish to use a grease that is not on the list, please consult your Sandvik representative to confirm its suitability for the specific application in question. This will be determined based on your particular application It is not recommended that you use an equivalent grease as promoted by various oil companies and organisations without first consulting Sandvik.

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6.6 Operating temperature Normal bearing temperature is 30 ° to 40 °C [54 ° to 72 °F] above feed material or ambient temperature. A short duration temperature rise of approximately 10 °C [18 °F] may be experienced when bearings are lubricated. The temperature on the outside of the bearing cartridge during continuous running should not exceed: 70 ° C (160 ° F)a

Normal temperature service

150 ° C (300 ° F)

High temperature service

a. Actual bearing temperatures may be as high as150ºC [300ºF] for normal running.

6.7 Grease discharge Ensure that the grease discharge is away from the drive belts and grease hoses are undamaged. It is also a good practice to perform a weekly inspection of the grease discharge to ensure that it is not blocked, which may lead to pressure buildup inside the cartridge; breakdown of grease inside, etc. Excessive build-up of grease Excessive build-up of grease may cause an overflow of grease onto the drive belts, causing premature failure of the drive belts. WARNING!

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The rotor assembly is the main wearing component of the crusher, and regular and timely inspection of wear parts will extend the life of the rotor. If wear parts are not replaced when required, severe damage or even total destruction of the rotor body may result.

7.1 Access While wear patterns and wear rates can be observed with the rotor in place, it may be necessary or desirable to remove the rotor from the crusher to replace any worn wear parts. In this manual we have assumed that the parts are being replaced with the rotor in the machine. The major problem with this can be the removal of the build-up of material in the rotor around the wear parts.

7.2 Cleaning out rotor The most successful method of removing the build-up is by using water. If a hose pipe is available at the crusher it is quite in order to "wash out" the build-up by inserting the hose pipe into the rotor, via the Chamber Inspection Door. If a hose pipe is not available near the crusher it may be possible to remove build-up with a scraper bar or chipping hammer. If this is not possible, it may be necessary to remove the rotor from the crusher for the removal of the rotor wear parts. Please observe the correct shut-down procedures. See section 5. Shut down procedure. Prior to any internal inspection/service ensure that the Safety Interlock System is activated. See section 2.3.2 Safety interlock system

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7.3 7.3 Rotor tip assembly 7.3.1 HP & LP / EP Rotor Tip Assembly 1 2 3 4

Rotor Tip Back-Up Tip Washer Tip Locating Domed Nut

1

2

3

4

7.3.2 Rotor Tip Assembly Rotor Tips Rotor tips must be checked to determine the amount of wear on the inserts. Tips need to be replaced once 95% of the insert has been removed at the centre of the wear track. Ensure that the rotor tips are tightly held and not broken, cracked or badly chipped. LP / EP Rotors

HP Rotors

95% of the insert worn

95% of the insert worn

95% of the insert worn

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7.3.3 Rotor Tip Assembly Rotor Tips Normal Wear

The rotor tips are wearing normally. Replace when less than 3mm [1 /8 in.] of insert remains at the centre of the wear, or if tip will not last another shift. Cracked or Chipped Inserts

Tramp iron in feed. Remove tramp iron. Oversize feed material. Investigate cause of oversize. Reduce maximum feed size. Off Centre Wear

The rotor tips are wearing at the top or bottom not in the centre. Trail plates may require adjustment.

7.3.4 Selection Of Rotor Tips A range of rotor tips are available to suit differing feed material characteristics, operating conditions and type of rotor (LP / EP or HP). The rotor tips supplied with your machine have been carefully chosen to suit your requirements. However, changing feed material can require the re-selection of the rotor tips. For information regarding rotor tip options, contact your Sandvik representative.

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7.3.5 Removal / Installation Removal Unscrew the Tip Locating Domed Nuts by two turns and impact the head of the nuts with a hammer. This will break away build-up that holds the Tip Plate in place. Fully release the location nuts and washers. The worn Tip Plate can now be pulled forward from the Tip Carrier and removed from the rotor. (Access is through the Crushing Chamber Inspection Door.)

1 Crushing chamber inspection door

1

5 1 2 3 4 5

Rotor Tip Back-Up Tip Washer Tip Locating Domed Nut Tip Carrier

2

1

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7.3.6 Installation Ensure that all mating surfaces on the Rotor Tip Plate and Rotor Tip Carrier are free of any high spots (dirt, stones etc.). Position the Tip Plate behind the Tip Carrier and align the two location studs through the location holes in the rear of the Tip Carrier. Ensure that the Tip Plate is flush with the mating face of the Tip Carrier and that the Tip Location flange fit snuggly around the front face of the Tip Carrier. Tighten the Tip Location nuts to the specified torque setting. When fitting Rotor Tips into a HP type rotor, make sure that the ends of the tips abut to each other. This can be achieved by loosely fitting all three tip sections and placing a small wedged screwdriver under the bottom tip and also over the top tip and then securing in place. Ensure that tip assembly is pulled up tight and that there is no movement in the parts. See bolt torque settings section 15. Bolt torque reference chart. NOTE!

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Rotor tips must be changed as sets (in the case of HP rotors, it is permissible to change three middle section tips or three top section tips etc.). Do not replace single tips or a rotor out-of-balance condition may result.

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7.4 Upper and lower wear plates removal Replace upper and lower wear plates when it is obvious that they will not last another shift. Replace once there is less than 3-5 mm. [1 /8 - 3 /16 in.] of plate remaining at the centre of the wear path at the discharge edge or inside edge. Removal of the wear plates can be achieved by:

1

2 1 - 2.Tap the wedge inwards toward the centre of the rotor. This will help in removal of any retained stone bed within the rotor, which must be cleaned away before removal of the wedges and wear plates. See section 7.2 Cleaning out rotor. Then remove the wedges.

3

3a 3 - 3a.Push the Upper and or Lower wear plates back towards the Trail Plates, until they are released from the front rotor location clip.

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4 4. The Wear Plates can then be removed from the rotor.

7.4.1 Upper Wear Plate Rapid upper wear plate wear is an indication that either the Feed Tube is worn or that excessive tonnage rotor throughputs are being experienced or large / oversize feed is being processed. Exposed to wear Upper wear plates

The upper and lower wear plate profiles shown above have been used as examples only. There are different profiles for different rotors, but the principle is the same. Lower wear plates

7.4.2 Upper & Lower Wear Plate Assembly a) Ensure that all mating surfaces are clean and free of any dust / stone etc. b) Place either the upper or lower wear plate into the rotor, with the long straight side locating against the inner face of the rotor wall. c) Pull the wear plate forward until it locates in the front rotor clip and abuts against the tip carrier. d) Fit the rotor wear plate location wedges and using a hammer tap the wedges to firmly lock the wedges and upper or lower wear plates in the rotor. 56

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7.5 Distributor plate The distributor plate wears in three places initially, opposite each rotor port. The wear then spreads out around the surface of the distributor plate as shown below. (Maximum wear.) Replace distributor plate once there is only 3-5 mm. [1 /8 - 3 /16 in.] of casting left at the thinnest point

Worn Section of Distributor plate 3-5 mm

Maximum wear

7.5.1 Premature Wear Generally caused by oversize feed or material dropping from a conveyor or screen chute directly onto the distributor plate.

7.5.2 Selection Of Distributor Plate Different types and shapes of distributor plate are available. Please contact your dealer for more information.

7.5.3 Distributor Plate Removal/Installation

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7.5.4 Removal a) Clear away the stone bed within the rotor that covers the Distributor Plate b) Remove Distributor Location Pins. c) With the aid of a screwdriver, lift the Distributor Plate from the Rotor Top Plate. d) Remove via the Feed Hole in the top of the rotor.

7.5.5 Refitting a) Ensure the top plate surface is clear of obstructions before fitting the distributor plate to ensure that it seats correctly and to ensure that the Distributor Plate Location Pins will align with the fitting holes in the sides of the Distributor Plate and Rotor Top Plate. b) Ensure that the Distributor Locating Cap Screw is in place and tightened. c) Place the Distributor Plate on the Rotor Top Plate, ensuring that the counterbore in the base of the Distributor Plate fits easily over the cap head of the Rotor Locating screw. d) Align the Distributor Plate, so that one straight side aligns with the rotor wall and that the location holes in the sides of the Distributor Plate align with the holes in the rotor Top Plate. e) Fit the Distributor Locating pins into the three sides facing each rotor port. Ensure that the pins go fully into the rotor Distributor Plate and tighten the screws securely.

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7.6

7. Rotor servicing

Feed tube Replace the Feed Tube just before the bottom lip is exposed by a maximum of 6mm above the rotor Top Wear Plate. This wear can be checked by looking through the viewing slot cut in the Feed Kit Holder Wear Skirt. The feed tube should wear evenly up the casting. Maintaining the correct position of the feed tube in the rotor will result in increased life for the upper wear plates.

1 1 2 3 4

Wedge Feed tube clamp plate Feed Tube Maximum permitted wear

2

3

4

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7.6.1 Uneven Wear Feed tube wearing on one side - feed tube not centralised. To centralise feed tube, see section 14.1 Feed tube centralisation and height adjustment.

7.6.2 Cracking and Breakage Feed tube cracking on bottom edge - excessive rotor build-up is rubbing on feed tube and causing overheating. Adjust trail plates to reduce build-up. Feed tube breaks - can be caused by excessive build-up in rotor, stones wedging between feed tube and rotor feed hole and Rotor Top Wear Plate or the feed tube coming loose (check feed tube clamp plate).

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7.6.3 Removal a) Open crushing chamber inspection door (1) after operation of time delay interlock.

1 Crushing chamber inspection door

1 b) Remove wedge (2) and open door on feed kit assembly door c) Remove the Feed Tube Clamp plate Wedges (2 off), (will need to remove build-up within the Feed Kit Holder) d) Remove the Feed Tube Clamp Plate (3). e) Lift Feed Tube out (4). 2 3 4 5

2

Wedges Feed tube clamp plate Feed tube Feed tube locating plate

3 4

5

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7.6.4 Installation a) Lower Feed Tube into Feed Tube Holder Location Plate, ensuring that the holder is free from stones etc. b) Refit Feed Tube Clamp Plate. c) Lock Feed Tube Clamp Plate onto position with the two Location Wedges and finally check the feed tube is centrally located. d) Close feed kit assembly door and re-insert wedge.

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7.7 Trail plates Check trail plates regularly for signs of wear. Replace if badly worn. If the rotor build up is not satisfactory, adjust the Trail Plates. Maintaining the profile edge of the Trail Plates maximises rotor tip life and is very cost effective. LP/EP Rotors

HP Rotors

1 1 1 Trail plates 2 Tip assembly 3 Build-up

2

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The trail plates are the heart of the rotor. The position and profile shape of the trail plate controls the size of the rotor build-up and the flow of material through the rotor. Incorrectly positioned or worn trail plates can result in premature wear on every rotor wear part. See section 9. Rotor tuning Due to the importance of the Trail Plate within the rotor, all rotors are fitted with Tungsten Carbide along the front profile edge, in order to achieve maximum life of the Trail Plates, rotor and rotor wear parts. P

Build up WARNING!

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The use of different sized trail plates (through uneven wear or uneven fixing position) can create uneven build-up which may cause severe vibration. Ensure that trail plates are matched in size and shape and are bolted into the same location positions.

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7.7.1 Removal a) Access through service door. b) Remove trail plate retaining bolts. Take note of which position location holes the Trail Plates are fitted to. c) If trail plate is held in by the build-up, a sharp blow with a hammer will break away the build-up and allow the trail plate to fall free.

7.7.2 Installation a) Clean out any remaining build-up. b) Position trail plate and insert bolts into the threaded holes in the Trail Plates and tighten.

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7.8 Rotor body The following areas are subject to normal wear - the comments provide a guide to causes of unusual rapid wear.

7.8.1 HP Rotors 2

1 1 2 3 4 5

Top Edge Top wear plate Streaming Cavity Wear Bottom edge

3

5

4

7.8.2 LP / EP Rotors 1

1 2 3 4 5

2

Top edge Top wear plate Streaming Cavity wear Bottom edge

3

5 4

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7. Rotor servicing

7.8.3 Top wear plate Feed tube too short and material is discharging over the top of the rotor. Replace feed tube or remove dust build-up.

7.8.4 Top edge wear Feed Kit Wear skirt and/or Cavity Ring are worn. Replace worn parts. Seesection 14.2 Wear skirt and section 13.1 Cavity ring. HP Rotors

LP/EP Rotors

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7.8.5 Streaming Wear This is more prevalent in wet and/or very abrasive fine applications, and is caused by dust streamlining around the Tip and or Cavity Wear Plates. Effects can be reduced by sealing the gap between the top and bottom edges of these components with a silicone rubber or urethane sealant. If the rotor has been in service for some time it is important to check possible wear on Rotor Tip Carrier. If wear is severe, remove the rotor and repair. HP Rotors

1

1 Check for wear here and seal if necessary with silicone sealant 2 Check Tip Carrier for wear here 3 Check for wear here and seal if necessary with silicone sealant

2

3 LP / EP Rotors

1 1 Check for wear here and seal if necessary with silicone sealant 2 Check Tip Carrier for wear here 3 Check for wear here and seal if necessary with silicone sealant

2

3

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7. Rotor servicing

7.8.6 Bottom edge wear Can be a feature of high tonnage operation or indicative of excessive build-up in the base that is rubbing on the rotor. Reduce build-up by reducing moisture content of feed or introducing water spray system and Transmission non stick liner kit.

HP Rotors

LP/EP Rotor

7.8.7 Rotor wear protection plates – Top wear plate The Top Wear Plate should not wear rapidly, but it should be inspected and replaced before the rotor body is damaged. If it is necessary to renew the Top Wear Plate, the rotor should be removed from the crusher and the stone bed and wear parts removed. Remove the worn Top Wear Plate, Fit the new Top Wear Plate and re-balance the rotor.

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The remaining rotor wear parts can then be re-fitted as described previously and the rotor re-fitted to the crusher. HP Rotors

LP/EP Rotors

1

1

1 Top wear plate

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7.8.8 Cavity Wear Plates The cavity wear plates should be replaced before wear progresses to the body of the rotor. Remove the bolts holding the wear plate to the rotor body and replace. Always replace the Cavity Wear Plates in sets, e.g. either all Tops, Bottoms or for HP rotors all middles with new sets to maintain balance.

LP / EP Rotors

HP Rotors

1

1 1 Cavity Wear Plate

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8. Rotor build-up

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8. Rotor build-up

8.1 Primary function The build-up in the rotor needs to protect the internal walls of the rotor and most importantly protect the rotor tip from direct wear and impact.

HP Rotors

LP/EP Rotors

8.2 Secondary function The build-up in the rotor can influence the wear patterns of the wear parts in order of importance: • Rotor tips • Cavity wear plates • Upper and lower wear plates • Distributor plate While large build-ups tend to assist in the protection of the above wear parts - particularly the rotor tips - they can greatly increase feed tube wear. See section 9. Rotor tuning

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9. Rotor tuning

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9. Rotor tuning

9.1 General information 9.1.1 Rotor The success of the crusher is centred on its rotor. If the rock build-up within the rotor is ideal, then wear on the upper and lower wear plates will be even, the rotor tips fully utilized, and the lowest consumable cost per tonne of product will be achieved.

9.1.2 Different material characteristics Unfortunately, the build-up characteristics are never the same for any two materials, indeed the nature of the build-up will vary with rotor speeds, rotor sizes, feed rates, feed sizes, and feed moisture.

9.1.3 Tuning on site It is normal that some tuning will be required as each rotor is placed into service. Tuning relates to controlling the build-up of material within the rotor. This is done by altering the size, position, shape, or style of the trail plates.

9.1.4 Primary function The main purpose of tuning is to ensure that the build-up within the rotor extends from the trail plate to the inserts in the rotor tip, and that the wear is centralized across the rotor tips. Insufficient build-up will result in tip exposure. This will lead to early failure of the rotor tips through the chipping of the inserts by direct contact with the larger stones in the feed. Insufficient build-up of material will expose the supporting metal of the rotor tips. This will also lead to premature failure of the inserts by direct abrasion from the stone flow through the rotor. This can also result in the rotor tips wearing in front of the inserts which will eventually lead to their falling out of the carrier plate.

9.1.5 Basic principles In tuning the rotor one should try to maximise the build-up within the rotor to achieve:

76

•

A build-up of rock within the rotor to protect the wear parts and not restrict the feed path through the crusher.

•

A build-up that clears the side and bottom of the feed tube, preventing premature feed tube wear.

•

An equal flow through each rotor port, equalising the wear on the rotor tips.

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9. Rotor tuning

9.2 Adjustment of rotor build-up The width and position of the trail plates will control the amount and characteristics of the build-up in the rotor. The following is meant only as a guide, as rotor build-up is dependent on many factors: material type, moisture content, rotor speed, etc., and trial and error will have to be employed to determine the correct trail plate position for each application.

Generally: •

Wide trail plates make the material build-up deeper

•

Narrow trail plates make the material build-up shallower.

2 1 Build-up too low 2 Trail plate

1

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If build-up is not up to rotor tip - Increase trail plate width until build-up approaches rotor tip and covers the centre distributor.

2 1 Ideal build-up 2 Trail plate

1

If build-up is rubbing on feed tube - Reduce trail plate width until build-up starts to pull back from rotor tip

9.2.1 Adjustment Of Rotor Build-Up Increasing the width of the trail plate increases the depth of the rotor build-up. Decreasing the width of the trail plate decreases the depth of the rotor buildup. Increasing or decreasing the effective width of the Trail Plate is achieved by the positioning of the Trail Plate against the Trail Plate Holder in the rotor. Two location positions are available, giving either wide or narrow Trail Plate positions whilst using the same profile shaped tungsten edged Trail Plate. NOTE!

All Trail Plates should be the same size and shape or an out-of-balance situation may result.

9.2.2 Rotor servicing P

Premature failure Do not attempt to weld on rotor while it is in the machine or arcing damage will cause premature failure of the bearings. WARNING!

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9.2.3 Rotor Rebuilding a) b) c) d) e) f) g) h) i)

Remove rotor. See section 10. Rotor removal. Clean out all wear parts and build-up. Do not weld on balance machine. Spin rotor on balance machine to check for low spots on periphery. Mark them. Build-up top edge to original diameter and roundness Build-up bottom edge to original diameter and roundness. Replace top plate as required. Effect any internal repairs Balance rotor 1

2

1 Hardface flush with top edge 2 Build-up to original diameter with mild steel (low hydrogen) 3 Hardface inside edges with 1 layer of hardface to 2.5 mm (0.10")

3

4 Hardface plate edges with 3 runs of hardface 5 mm (0.20") deep 5 Hardface bottom edge with 1 layer of hardface to 2.5 mm (0.10") deep

4

2.5mm

5mm

5 21mm

NOTE!

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Use hardface wire/pin Filarc P26154 or ESAB OK 852 or equivalent (550 HB). Frequent minor rebuilding is cheaper than infrequent major rebuilding work.

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10. Rotor removal

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10. Rotor removal

10.1 Removal a) Remove hydraulic rotor throttle control pipes, via quick release hydraulic couplings.

b) Remove hopper and crusher roof in one lift. NOTE!

The hopper may be removed from the roof first if the lifting equipment does not have sufficient capacity to lift both assemblies together. Disconnect the Hydraulic Rotor Feed Throttle from the hydraulic ram and slide back as far as possible. This will allow the hopper to be removed. c) Remove Feed kit holder

(Continued)

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10. Rotor removal

. d) Remove Distributor Plate. e) Remove the Distributor Locating Cap Screw. f) Remove the top plate bolts and the top plate. g) Attach the Rotor Lifting Plate.

HP Rotors

d

e f

Bolt down with four bolts and tighten bolts in series until fully screwed in to force rotor off taper lock

LP/EP Rotors

d e f

g

(Continued)

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Top Plate for 73LP and 73EP rotors

. NOTE!

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The cut out slot in the outside diameter of the Top Plate is to permit the fitting of the Top Plate through the feed hole in the 73LP and 73EP rotors (rotor top and top wear plate fit between this slot on assembly).

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10. Rotor removal

10.2 Rotor installation The life of the bearing cartridge is greatly reduced when the rotor is running with excessive vibration for long periods. When this vibration is extreme, there is potential for catastrophic failure, i.e. shaft breakage. One factor which has a direct influence on the smooth running of the crusher is the fit between bearing cartridge and rotor. The correct procedure for securing a rotor to a bearing cartridge is as follows: 1. Preparation

Thoroughly clean the shaft, key, taper lock, rotor boss and top seal plate. Coat these surfaces with light oil or dewatering fluid and wipe down prior to assembly. Ensure the key screw is not proud of the outer face of the key. 2. Taper lock fitting

Place a small wedge or screwdriver in the split on the top of the taper lock to expand it slightly. Place the taper lock, large end downward, on the shaft so that it sits hard down on the top seal plate, and over the taper lock location pin. Remove the wedge or screwdriver and remove any burrs on the taper lock left behind. 1 Top seal plate

3

1

2 Taper lock locating pin 3 Rotor taper lock

2 NOTE!

Do not expand the taper lock any more than necessary to achieve a snug sliding fit onto the shaft. Excessive expansion of the taper lock can break it. 3. Rotor taper check

If the rotor being fitted has just been repaired and/or reconditioned around the taper area (i.e. has undergone extensive welding that may cause distortion), it is recommended that the fit between rotor and taper lock be checked prior to final fitting. To do this, blue the bore of the rotor boss and lower onto the taper lock on the shaft. (Use the rotor lifting plate). Ensure the taper is properly seated under the weight of the rotor and then remove. You should see a blue mark on the taper lock indicating contact with the rotor boss. This mark should cover at least 80% of the circumference and 80% of the length of the taper.

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4. Rotor fitting Fit the Rotor Location Pin into any hole in the Rotor Taper Lock. Fit the rotor lifting plate to the rotor boss and lower the rotor onto the taper lock, guiding the hole in the Rotor Lifting Plate, over the Rotor Locating Pin. NOTE!

The rotor must be lowered square to the shaft onto the taper lock. Failure to do so may result in a poor mating of the tapered surfaces and hence vibration problems. Check the 2 mm [1 /16 in.] difference in height between the rotor boss and taper lock to ensure that the rotor has seated on the taper lock squarely. Remove the lifting plate bolts evenly, allowing the rotor to slide onto the taper lock under its own weight. Remove the Rotor Locating Pin. With the rotor firm on the taper lock there must be at least 2 mm [1 /16 in.] between the top of the taper lock and the top of the rotor boss. Rotor installation Rotor locating pin

Min 2mm

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10. Rotor removal

5. Securing bolts

Insert the bolts through the top plate into the taper lock and tighten evenly. This pulls the taper lock up tight on the shaft and rotor boss. Fit the additional 4 outer bolts through the top plate into the rotor boss and tighten. This fills the holes that are necessary for removal and provides positive drive between taper lock and rotor boss in addition to the friction fit of the taper. Torque to 250 Nm [190 ft lbs]

Top plates

6. Final check

Stand on top of the rotor (if possible) and try to rock it from side to side. If there is excessive movement or if you feel the rotor "settle" at all, recheck the torque on all bolts. Note that there will be a small movement of the shaft within the bearings. This is normal. This check simply confirms that the rotor is properly seated on the taper lock. 7. Distributor plate fitting

The distributor plate must now be fitted to protect the taper assembly. First locate and tighten the Distributor Location Cap Screw, and then fit the Centre Distributor Plate as previously described. 8. Replace and centralize the Feed Kit Holder assembly. 9. Replace the Roof assembly and Hopper. 10. Reconnect hydraulic rotor throttle control pipes.

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11. Rotor balancing

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11. Rotor balancing

11.1 Assembly of Rotor Balance Machines (For both HP / LP and EP Rotors) These machines require full assembly as follows: a) Assemble the two side plates of the frame with the joining plates, bolts, washers and nuts supplied. b) For 85 rotors only, fit the adapter sleeve to the balance shaft c) Clean the bearings in solvent to remove all traces of dirt, grease, oil, etc. Fit the bearings to the balance shaft. d) Rest the shaft assembly on the frame. The shaft should rotate freely. 1 Bearing 2 Taper to suit either 73EP, 73LP or 85HP and 85LP 3 Clamp Plate 4 Bolt and Washer 5 Balance Shaft 6 Bearing 7 Side Plate 8 Bolt, Nut and Washer 9 Joining Plate

1

2

3

4

5

6

7 8

9 e) Ensure the balance frame is level. f) Remove bearing from the end of shaft that passes through the rotor g) Insert the balance shaft through the rotor. (Continued)

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11. Rotor balancing

h) Locate rotor on taper, ensure that the two tapers fit evenly, fit rotor clamp plate, washers and bolts and tighten. i) Fit bearing back onto shaft and tighten grubscrew. j) Using suitable lifting apparatus position the rotor and balance shaft on the support frame.

1 2 3 4

Clamp Plate Washer Bolt Bearing

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11.2 Balancing procedure a) Thoroughly clean out rotor of all rock, dirt, old wear parts and any old welded on weights from a previous balance, see figure 3. Check for perforations in the inner and outer walls. b) Check taper in rotor boss is clean and free from damage c) Remove weights from previous balance and set rotor up level in rotor balancing frame. d) Gently rotate the rotor and allow it to wind down to a stop. The heaviest point on the rotor is now at the bottom. e) With chalk mark the blades A, B and C, see figure 1. f) Add weights to the blade A (fig. 1) until blade B is at top dead centre. Each time a weight is added give the rotor a gentle push in the direction you are working and allow the rotor to settle to the new balance point. This helps overcome bearing friction. g) When blade B has settled at Top Dead Centre, pull it around 90 ° and hold it steady there by hand (fig. 2) h) Add weights to the blade you are holding down (B) until it doesn't try to go up or down. i)

Sometimes the blade B won't take enough weights to balance the rotor. If this is the case cut a piece of 50 mm × 12 mm [2 in. × ½ in.] flat bar 200 mm [8 in.] long and weld it onto the B section where indicated (figure 3). Use a small tack weld so the weight is easy to remove for the next balance. Repeat the whole balancing exercise.

j)

When you think the rotor is balanced, rotate the rotor in 90° steps four times. If the rotor does not move from each stop, it is balanced.

k) Tighten the balance bolts. l)

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Keep spare weights in a safe place.

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Rotor balancing T.D.C.

T.D.C.

A

B

B

A C

C

Figure 1. Typical rotor position after step 4. Add weight to 'A' until 'B' moves to T.D.C.

Figure 2. Step 6: 'B' is pulled around 90° from T.D.C. Add weights to 'B' until rotor does not try to turn.

Weight

Figure 3. Step 8: If you can't get enough weights into position 'B', weld flat weight inside rotor as shown and start again.

NOTE!

To check that the rotor is now properly balanced, remove one balance weight and confirm that the rotor is out-of-balance. IF SO: Replace the weight. The rotor is now balanced. IF NOT: There may be a fault with the balance machine. The balance machine should be sensitive enough to detect an out-of-balance condition less than the effect of one balance weight. Refer to Troubleshooting, section 11.3 Rotor balancing troubleshooting

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11.3 Rotor balancing troubleshooting If the rotor fails to balance properly, check the following: •

Make sure there is no loose material in the rotor that could be moving as the rotor is turned. • Make sure the rotor balance machine is level and the bearings are totally clean. • Make sure the tapers are in good condition. • Make sure the bearings are not damaged or worn. After all checks have been made, attempt to balance the rotor again from stage 1

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12. Maintenance

12.1 The rotor balance machine The rotor balance machine is designed to give many years of trouble-free operation. However, as with any precision machinery, proper care must be taken to ensure this is the case. • • •

Wrap a cloth around the taper on the balance machine when not in use. Remove the bearings from the shaft and store in a container of light machine oil. Store all components in a clean environment.

12.2 Crushing chamber build-up • • • • •

The chamber should have a full rock lining covering all items of the structure except for the faces of the chamber gussets (see below). The outer wall must not be exposed. The feed areas must be free of fines build-up and debris. Build-up should not be excessive, i.e. blocking material flow routes or encroaching on moving parts. Initially, the bottom crushing chamber gussets may protrude through the build-up. These will soon wear to their ideal level. This is quite normal.

On stopping the crusher, if the time between shutting off the feed and the rotor stopping is more than 5 minutes, air movement in the crusher may blow away much of the lighter material from the stone bed, giving the impression of insufficient build-up. In these cases, stone beds will be re-instated shortly after starting to feed material again. This can be confirmed by 'crashstopping' the plant, to minimise the chance of air blowing material away. Minimum Ideal Maximum Bare steel should not show here.

ROTOR

Initially, the bottom crushing chamber gussets may protrude through the build-up. These will soon wear to their ideal level. This is quite normal.

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12.3 Chamber wall (low build-up) Damage caused by large feed, very dry feed, or rounded feed. Tuning of the gussets will assist in holding a build-up. Alternatively, the addition of fines to a rounded or bony feed and or adding some water will enable the build-up to form.

12.4 Excessive build-up Feed moisture content too high and/or high fines content. Tuning of the gussets will assist in reducing build-up. Alternatively, remove moisture and/ or reduce fines content. Frequent operation of the crusher running light/empty may reduce stability of the build-up and increase the likelihood of gusset and/or casing wear.

12.5 Chamber gussets Chamber gussets can be added or removed as required. Add gussets to improve poor build-up conditions. Remove gussets to reduce excessive build-up. Gussets can be replaced when excessively worn.

1 1 Chamber gussets 2 4 Lifting points welded to outside of crushing chamber.

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12.6 Toe-board The toe-board should be replaced when 12 mm [½"] remains as shown.

1

1 Toe-board ring

12 mm

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13.1 Cavity ring The cavity ring is a secondary wear part and under normal conditions wears little but needs checking. The cavity ring should be replaced when it has worn to the level shown below (5mm). If the Chamber Shield section of the Cavity Ring Assembly becomes worn it must be replaced.

1 Chamber shield

1

13.2 Hopper Bi-Flow® The opening of the Bi-Flow® port can be altered by moving the Bi-Flow Adjuster Gates up or down. Adjust gates individually so that the Bi-Flow® material passes through evenly over all ports. Adjusting Bi-Flow® Adjuster Gate height a) b) c) d)

Remove build-up from hopper. Lift shield up vertically and out toward centre of hopper. Holding shield close to wall of hopper, lift to desired height. Replace shield on brackets.

1

2

1 Slots for height adjustment 2 Bi-Flow® port gate

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13.3 Hopper body It is important to check the general condition of the hopper. Material flow from the conveyor/feeder and/or chute work may create wear in the hopper structure. Adjust flow of material to correct.

13.4 Control plate Once worn, this plate will need replacement. Note that various opening sizes are supplied. Choose the size that allows the control gate to operate at the middle of its adjustment when the rotor feed is at its optimum.

13.4.1 Removal a) Clear away the build up of material in the hopper and lift out the Control Plate. b) Ensure that the locating surface is free from stone and dust.Assembly

13.4.2 Assembly a) Place the Control Plate inside the three location blocks, welded to the Feed Hopper Base. b) Ensure that the Control Plate sits flat on the Feed Hopper Floor c) Adjust the Hydraulic Rotor Feed Throttle to achieve desired operating parameters.

1

1 Control plate

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13.5 Hydraulic rotor feed throttle gate 13.5.1 Normal running adjustment Adjustment of the Throttle Gate is done manually via a hydraulic hand pump and double acting ram. The drawing below shows the position of the hydraulic operating lever for either opening or closing the Throttle Gate. Opening the gate increases the throughput of material to the rotor (increases motor amp loading) and closing the Throttle Gate reduces the throughput of material to the rotor (decreases motor amp loading).When not in use the hydraulic Throttle Gate lever should always be in the neutral position. CV228/CV229 Bi-Flow Throttle gate

1 1

2 3

4

5

Motor 1

Motor 2

CV218/CV217/CV216/CV215

6

Grease Hand Pump

2 Lever for Bi-Flow throttle 3 Lever for motor 1 4 Distribution block with tell-tale 5 Lever for motor 2 (Dual Drive Crushers only) 6 Hydraulic Hand Pump

If the edges of the Throttle Gate are excessively worn, it is necessary to replace it.

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13.5.2

13. Crushing chamber

Removal a) Remove hydraulic rotor throttle control pipes via quick release hydraulic couplings. b) Release Roof Swing Bolts and remove Hopper and Roof in one lift. c) Remove clevis pin from the hydraulic ram assembly. d) Slide Throttle Plate back to release from the retaining guides.

1 Throttle Gate

1

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13.6 Cylinder 13.6.1

Removal

a) b) c) d)

1 2 3 4

Remove ram cover (1) kit. Remove R-clips (3) from clevis pin (2) at both ends of hydraulic ram Remove clevis pins (2). Remove ram.

Ram cover Clevis pin R-clip Hydraulic cylinder

1

4 2 3

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14.1 Feed tube centralisation and height adjustment Every time the Feed Kit Assembly is refitted to crusher, it is important to check that the feed tube is located centrally and at the correct height in the rotor feed hole. Height Adjustment Add or remove shims from below the three arms of the Feed Kit Assembly to set required height. Centralisation

a) Loosen the Lock Nut on each of the three arms of the Feed Kit Assembly. b) By tightening one of the screws against the inner rolling of the Crusher Roof Assembly, it is possible to move the Feed Kit Assembly horizontally and thus centralize the Feed Tube within the Rotor Feed Hole c) When the Feed Tube is central within the Rotor Feed Hole, release all three adjustment bolts on the arms of the Feed Kit Assembly. d) Tighten by hand the three location bolts against the inner rolling of the Roof Assembly, and then slacken back, to give 1mm clearance and then lock the adjuster bolt with the lock nut. NOTE!

It is important that the Feed Kit Assembly is not held tightly within the Roof Assembly by the three adjustment bolts. The adjustment bolts are for adjusting horizontally only and not for retaining the Feed Kit Assembly..

Ensure feed tube is centralised in rotor

(Continued)

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1 1 2 3 4

2

3

Shims Lock nut Adjustment bolt Feed kit holder assembly

4

14.2 Wear skirt Like the cavity ring, this is a secondary wear part and under normal conditions wears little, but needs checking. It should be replaced when wear on the rotor top edge increases

Check for wear

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14.2.1 Removal a) Remove hydraulic rotor throttle control pipes via quick release hydraulic couplings. b) Release Roof Swing Bolts and remove roof and hopper in one lift. c) Lift Feed Kit Assembly out of chamber. d) Remove bolts and Spacer Washers holding wear skirt in place. e) Remove wear skirt, noting the position of the Feed Tube Viewing port cut into the Wear Skirt.

14.2.2 Installation a) Bolt wear skirt into place (ensuring that the Feed Tube Viewing Port is in the same position as previous) using wear skirt bolt set and spacer washers. b) Replace Feed Kit Assembly c) Replace the Roof Assembly and re-fit the Roof Swing Bolts d) Reconnect hydraulic rotor throttle control pipes

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14.3 Safety interlock Regularly check that the safety interlock device is offering the operator or maintenance staff adequate protection. Ensure that the Dust Caps are in place over the locks and that they are secured to prevent dust entry. Check the operation of the Time Delay Unit. Replacement components can be sourced via your local Sandvik dealer.

14.4 Vibration switch It is very important to check regularly that the vibration switch is operating. For detailed information refer to the Vibration Switch manual provided with the machine for instructions.

14.5 Inspection doors and hatches • •

Ensure all inspection hatches, doors, guards and locks are secure. Ensure safety pin is in inspection door.

1 Safety pin

1

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14.6 Crusher base and discharge chutes It is very important that material does not build-up under the rotor. This can cause severe wear and possibly damage bearings and/or the main shaft. Build-up should not impede flow of material to the discharge chutes. Discharge chutes must be kept clear. In moist feed applications the discharge chutes need to be checked for possible build-up. Check if external discharge chutes design restricts the flow, i.e. size or angle.

1

1 Excessive Build-up 2 Maximum Build-up 3 Ideal Build-up

2 3

Excessive Build-up

Excessive build-up can be caused by: (1) Moisture content of feed too high (2) High percentage of fine material in feed (3) A combination of 1 and 2 Low friction liners are fitted as standard to the Base and Discharge Chutes, in order to prevent the above problems occurring. However, if the problem persists it may be necessary to fit a Base Water Spray System and possibly Transmission Base Liners. Please contact your local Sandvik dealer for further information. In cases of high tonnage and/or abrasive material, (mining applications etc.), hardened steel base and chute liners can be fitted as an option to the above low friction liners.

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14.7 Base liners Non-stick Hi-Flow liners are fitted as standard. High wearing hardened steel liners can be fitted as an option. Both types of liners are fitted and removed in the same way

14.7.1 Removal a) Remove rotor as previously described. b) Remove R clip retaining pins from the location wedges. c) Use a hammer to tap the wedges clear of the locating brackets. d) Fit a clamp to the top edge of the liner and lift clear. e) Repeat the above process for the remaining liners.

14.7.2 Assembly a) Ensure all mating surfaces are clean and free from grit and dirt, paying special attention to the locating blocks in the bottom of the crusher base. b) Lower the liner into the base and locate the bottom edge behind the locating blocks in the bottom of the crusher base. c) Remove the lifting straps and push the liner over the locating bracket situated around the top edge of the crusher base. d) Re-fit the wedges and tap home with a hammer. e) Re-fit the R-clips to the wedges, ensuring that the head of the R-clip faces the rotation of the rotor. f) Repeat the process for the remaining liners

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14.8 Gusset wear castings Check wear castings on bearing cartridge gusset. Replace as required.

1

2

3

1 Gusset wear castings 2 Base Liners 3 Wedges and R-clip (Base Liners)

14.9 Grease discharge chute Check weekly that the grease discharge chute is not building up with grease. Clean out as required. Seesection 6. Inspection and servicing. P

Premature failure Excessive build-up of grease may cause an overflow of grease onto the drive belts, causing premature failure of the drive belts.

WARNING!

14.10 Belt guards Ensure that all guards are in place and secure.

14.11 Motors Check for missing bolts, bearing noise, excessive shaft float or damage and obstruction to fan cover. Grease according to motor manufacturer's instructions.

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14.12 Bearing cartridge 1 2 3 4 5 6

1

Grease filled Labyrinth Seal Radial Bearing Grease Retaining Ring Radial Bearing Thrust Bearing Grease Hose Connections

2 3

4 5 6

The bearing cartridge is a grease filled, sealed bearing assembly which can be removed in one piece (shaft, bearings, seals and housing) for overhaul and inspection. When the new bearing cartridge has run between 100 and 150 hours, begin a series of routine checks on the run down time of the rotor (time from power being cut to rotor stops turning). A significant decrease in the run down time over a period will indicate that the bearings (crusher or motor) are deteriorating. Once the time falls below two minutes the bearings should be checked at the next routine service time. Operators should become familiar with the sound of the bearings running. If this noise changes, especially if it begins rumbling, this will also indicate that the bearings are deteriorating. If, when standing on top of the rotor during servicing, the shaft can be rocked from side to side with excessive float, then the radial bearings are worn. If noload current begins to increase slowly over a period of time, this is an indication that the crusher bearings are worn. Upper seals should be replaced and labyrinth repacked with grease at yearly intervals.

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14.13 Bearing cartridge seals Many premature bearing cartridge failures can be attributed to the condition of the Top Seal Plate labyrinth seals within the cartridge. It is recommended these upper labyrinth seals are renewed at intervals of 2000 hours. The inspection/replacement can be achieved with the Bearing Cartridge Assembly remaining in the base of the crusher and with the rotor removed. Every care should be taken during inspection to ensure that the Bearing Cartridge Assembly remains free of dust. The lower seals cannot be inspected or replaced and are very unlikely to cause a premature failure. To inspect/replace upper seals: a) Remove the top key and slide top seal plate vertically off the Main Shaft (a screwdriver inserted in the gap between the Upper Bearing Retaining Ring and Top Seal Plate will assist this operation) b) Remove the o-ring from within the top seal plate. This is a static seal and may have a flat surface from contact against the shaft. If the seal is not broken or obviously damaged in any other way, it can be re-used. (Continued)

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c) Inspect the labyrinth between the bearing and the outermost seal. This should always be fully packed with clean grease. If the grease is not clean, the v-ring seals are not effective and must be replaced. If the labyrinth is not completely packed with grease, there could be a problem with the grease supply to the bearing cartridge (check hoses, etc.) or with the lubrication schedule. See section 6. Inspection and servicing.

1 1 2 3 4 5 6

2 3

Taper Lock Locating Pin Top seal plate O-Ring V-Ring Seal, Outer V-Ring Seal, Inner Top Key

4 5

6

(Continued)

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d) Remove the two v-ring seals from the Top Seal Plate. These should not be worn, cracked or broken. NOTE!

CV218,228 and 229 Bearing Assemblies have only one top V ring seal fitted to the Top Seal Plate and one fitted to the upper bearing retaining ring.

Sharp edge

Normal Condition

Broken edge

Worn

Broken

Cracked

e) Refit/replace seals as necessary, pack the labyrinth with grease, refit top seal plate, pin and key. f) Refit the rotor and start the crusher. Apply twice the normal amount of grease to each grease point and continue with normal operation. P

Crusher Do not run crusher without rotor fitted. WARNING!

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14.14 Bearing cartridge removal from base a) Remove hopper and crusher roof in one lift. b) Remove the rotor. See section 10. Rotor removal c) Loosen off belt tension using the Hydraulic Motor Mount Tensioning system, see section 13.5 Hydraulic rotor feed throttle gate, and remove drive belts. d) Remove crusher pulley. In larger models, use a threaded rod (in the threaded hole in shaft) and use a support to assist in lowering pulley.

1 Lock Nut 2 Nut 3 Support 4 Threaded Rod 5 Allow room to undo taper lock 6 4×¾" UNC threaded holes for jacking off taper lock

1

3 4

2

4 3 5 6 (Continued)

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e) Remove grease hoses and grease chute f) Release bottom taper rings by removing the taper ring bolts in the outer bottom taper ring. g) Refit 4 of these bolts back into the tapped extractor holes to extract the outer taper ring. h) Remove the bottom taper rings.

i)

Remove the top flange bolts.

j)

Insert lifting eye bolt into the top of the shaft.

k) Lift out bearing cartridge.

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14.15 Bearing cartridge refitting in base a) Remove all traces of grease, protective coatings, dust, etc., from machined surfaces using thinners or similar solvent. b) Ensure all mating surfaces are free from rust, dents, scratches, etc. c) Apply a thin layer of heavy machine oil to the mating surfaces of the bearing housing, cartridge housing and taper rings. d) Lower bearing cartridge into top of cartridge housing and check to see that the three grease points are clear, full of grease and free of debris. e) Check orientation of cartridge. The grease discharge slot must align with the grease discharge chute. f) Locate bearing cartridge centrally with top flange and loosely fit by hand the bolts / nuts. g) Fit bottom taper rings (inner and outer) and lightly screw in bottom taper ring bolts. h) Refer to Bearing Cartridge Bolt Torque Settings. See section 15. Bolt torque reference chart. i)

Starting on top flange, torque down bolts top and bottom in a "star" sequence (Fig.1) in two stages. Torque bolts in order from 1 to 8. Repeat for bottom taper ring.

j)

Refit grease hoses, making sure they are not twisted or blocked. section 6. Inspection and servicing for identification of grease points on bearing housing. Ensure that grease hoses are not able to fall onto drive belts during operation. (Continued)

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k) Refit pulley and drive belts and tension using the Hydraulic Motor. l)

Refit rotor.

Figure 1

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14.16 Drive belt tensioning Correct tensioning is the most important factor necessary for long, satisfactory drive belt operation. Too little tension will result in slippage, causing rapid belt and pulley wear, and poor efficiency. Too much tension results in excessive strain on belts, bearings (especially motor bearings), and shafts. In order to ensure trouble free and rapid operation of this maintenance procedure, the crusher is fitted with a Hydraulic Motor Mount Adjuster. This system makes adjustment of the drive belt tension very quick and easy.

14.16.1 Procedure for Adjustment and/or Removal of wedge belts a) Slacken the Motor Mounting Plate Location Bolts on either side of the Motor Mounting Plate (two Motor Mounting Plates for dual drive machines). b) Position the hydraulic operating lever for Motor 1 in the release position. See section 13.5 Hydraulic rotor feed throttle gate. c) Pump the hydraulic hand pump to slacken the drive belts on motor 1. d) Position the hydraulic operating lever in the neutral (central) position. e) For dual drive machines, position the hydraulic operating lever for motor 2 in the release position. f) Pump the hydraulic hand pump to slacken the drive belts on motor 2. g) Remove the worn wedge belts.

14.16.2 Re-fitting and tensioning of wedge belts a) Refit matched set of wedge belts. b) Position the Hydraulic operating lever for Motor 1 in the tension position. c) Pump the hydraulic hand pump to tension the drive belts on Motor 1. d) Check belt tension through the belt tension inspection panel and when at correct tension, tighten the Motor Mounting Plate Location Bolts. e) Return the hydraulic operating lever for Motor 1 to the neutral (central) position. f) For dual drive machines, position the hydraulic operating lever for Motor 2 in the tension position. g) Pump the hydraulic hand pump to tension the drive belts on Motor 2.

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h) Check the tension through the belt tension inspection panel and when at correct tension, tighten the Motor Mounting Plate Locating Bolts. i)

Return the hydraulic operating lever for Motor 2 to the neutral (central) position.

14.16.3 Measuring a) Select the second belt from the bottom. b) Measure the force required to deflect the belt the distance as set out below: Apply force on belt through V-belt inspection hatch towards centre of belt span Specified deflection distance

Force and deflection for each model and belt type can be found on the Belt Tension/Deflection Chart, overleaf

c) For measuring the force and deflection, Sandvik recommends the use of a tension gauge (supplied in the Toolkit as standard) similar to the one represented. Using the belt tension gauge at the centre of the belt span, follow these instructions: – Set the large 'O' ring on the designated deflection as per the Belt Tension/Deflection Chart. – Push the belt tension gauge against the second to bottom belt until the large 'O' ring is even with the top of the next belt. Ensure that the gauge is in the centre of the belt section, and always test the belts on the tight (or driven) side of the belts. – Remove the gauge and observe that the small 'O' ring has moved from its original setting at zero to the number of kg [lb] required to deflect the belt.

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14.16.4 Adjustment a) Slightly loosen off motor mount bolts b) Tighten (or loosen) tension by adjusting hydraulic belt tension cylinders as described above. c) Adjust belt tension as per the Belt Tension/Deflection Chart. (For dual drive, adjust both exactly the same). Model

Deflection distance mm (in.)

96 (9.7)

27 (1.06) 27 (1.06)

CV218/CV228

96 (9.7)

CV217

76 (7.8)

24 (0.94)

CV216

76 (7.8)

24 (0.94)

CV215

69 (7.0)

20 (0.78)

Deflection in mm

NOTE!

Normal running tension n (kgf)

CV229

Setting force in kgf

The above maximum belt tension/deflection values relate to QXPC belt sections, and have been formulated to accommodate the various centre distances that motor frame sizes or sheave diameters will provide on each model. Tension Range Belt tension should be monitored regularly (at least weekly), but does not need adjustment if within 10% of the above stated figures. Running In New Belts (This includes the initial commissioning of the

crusher). After 30 Minutes After thirty minutes running it is recommended that the tension should be checked and re-tensioned if necessary, to the above Tension / Deflection values. After 4 Hours If necessary re-tension to the above Tension / Deflection values

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14.16.5 Dual Drive Belt Tension/Balanced Motor Amps

On dual drive machines, one motor may draw less current than the other, i.e. it appears lazy. For the motors to do equal work the belt drives must be set up with equal tension. On dual drive machines, a small difference in belt tension between drives can make a big difference in motor amps. Follow the normal static adjustment procedure as explained above, but make special effort to adjust the two drives to exactly the same values. Motors amperes should be within approximately 10% of each other Some possible causes of unbalanced motor amperes if the motors will not draw similar amps by altering belt tension, check:

a) The motor or starter electric terminals. Have a qualified electrician check motor or starter terminals. If dirty they will need cleaning and re-fitting. b) The starter has a fault. To confirm starter fault exists, have a qualified electrician check the following: With the machine under load: – Read both ammeters and record amps on ammeter 1 and ammeter 2. – Stop the machine. – Swap motor wiring over at starter contactors. – Restart the machine. The ammeter readings should have swapped, i.e. No. 1 should read what No. 2 used to, and vice versa. If this doesn't happen, the electrician must check the function of the starter components c) Belt alignment - Make sure sheaves are in line using a straight edge or string line. d) Motors - They should be of the same brand and type and preferably be manufactured in the same batch (check with motor manufacturer or agent). Different manufacturers and sometimes different batches of motors have different winding specifications. (Continued)

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e) Belts - The belts should be matched, i.e. all the same brand at least, and a matched set if possible. Pulleys: – Check pulley axes are parallel and grooves are properly aligned with one another - any dust build-up entering under the motor mount will cause the pulleys to be out of parallel, with higher tension on belts at one end of the pulley.

X



– Check pulley diameters. For equal power transmission, the pitch diameters of the driving pulleys must be within 0.5mm [0.02"] of each other. This can be checked by measurement as shown. Check grooves at each end of the pulley - any taper in pulley length will cause problems. Vernier Caliper / Ground bar stock to suit groove

Check each end

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15. Bolt torque reference chart

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15. Bolt torque reference chart

15.1 Bolt Torque Settings Nm (ft lbs) Model

Rotor size

Rotor tip plate Cavity wear plate Trail plate bolts

Rotor top, plate bolts

Distributor plate Centralising bolt

Bearing cartridge Top flange

Bearing cartridge Bottom taper ring bolts

CV229

85HP

50 (37)

250 (184)

250 (184)

250 (184)

130 (96)

CV218/ CV228

85HP

50 (37)

250 (184)

250 (184)

250 (184)

130 (96) 130 (96)

CV217

73LP

50 (37)

250 (184)

250 (184)

250 (184)

CV216

73LP

50 (37)

250 (184)

250 (184)

250 (184)

130 (96)

CV215

73EP

50 (37)

250 (184)

250 (184)

250 (184)

130 (96)

Note: All threads must be lightly lubricated before assembly.

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