CAT Armored Face Conveyor Impact roll crusher SB 0916 Hillsboro II Operation & Maintenance Manual

EM020881-0 (EN-US)

BI020000 August 2013

Operation and Maintenance Manual IMPACT ROLL CRUSHER SB0916

SAFETY.CAT.COM BI020000

EM020881-0 (EN-US)

© 2013 CATERPILLAR ALL RIGHTS RESERVED

CAT, CATERPILLAR, THEIR RESPECTIVE LOGOS, “CATERPILLAR YELLOW” AND THE “POWER EDGE” TRADE DRESS, AS WELL AS CORPORATE AND PRODUCT IDENTITY USED HEREIN, ARE TRADEMARKS OF CATERPILLAR AND MAY NOT BE USED WITHOUT PERMISSION.

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Operating manual Impact roll crusher SB 0916 Project:

"Hillsboro II"

Object-No.: 55279300000000 Mach.-No.: 605

Translation of original operating manual (Übersetzung der Originalbetriebsanleitung)

HAZEMAG & EPR GmbH Brokweg 75 D-48249 Dülmen

Phone: Fax:

++49 (0) 2594 / 77-0 ++49 (0) 2594 / 77-303 BI020000

Email: info@hazemag.de Internet: www.hazemag.de

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Amendments and alterations to this publication are not subject to notification. HAZEMAG & EPR GmbH (Hazemag) reserves all rights to this publication. Its content is protected by copyright. No part of this publication may be reproduced in any way or form without the prior written approval of Hazemag.

Hazemag declines all liability for direct or indirect consequences of printing errors.

HAZEMAG & EPR GmbH, Dülmen 2012

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Content About this manual ....................................... 3 Before starting work ................................................ 3 Who is this operating manual intended for? ..................... 3 What is the purpose of this operating manual? ................ 3 Characters and symbols used .......................................... 4

For your safety ............................................ 7 Personnel .................................................................. 7 General safety instructions ..................................... 8 Operating conditions ............................................. 12 Intended use ................................................................... 12 Unauthorized use ............................................................ 12

Storage and Transport.............................. 15 Storage .................................................................... 15 Storing the equipment ..................................................... 15

Transport ................................................................ 15 Before transport .............................................................. 16 Transport of the components .......................................... 16

Assembly ................................................... 19 What to observe prior to assembly ....................... 19 Who is allowed to carry out assembly work? .................. 19 Assembly notes .............................................................. 19

Dismantling............................................................. 20

Technical data ........................................... 23 Technical data sheet .............................................. 23 Main components ................................................... 24

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Components ........................................................... 25 Technical description............................................. 26 Crusher housing and substructure .................................. 26 Impact roll........................................................................ 27 Impact element................................................................ 28 Roll height adjustment ..................................................... 29 Central lubrication ........................................................... 30

Tightening torques ................................................. 31 Screws resp. nuts with metric coarse thread DIN 13....... 31

Permissible media .................................................. 32 Lubricating greases ......................................................... 32 Hydraulic fluids ................................................................ 32

Operation .................................................... 37 Commissioning of the crusher plant .................... 37 Before commissioning ..................................................... 37 Notes for electrics ........................................................... 38 Test run and start up ....................................................... 38

Operation of the crusher plant .............................. 39 General ........................................................................... 39 Roll height adjustment ..................................................... 40

Maintenance............................................................ 43 Maintenance acc. to schedule ......................................... 44 Lubrication ....................................................................... 45 Changing the impact elements ........................................ 46

Spare parts and special tools ................................ 47

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Decommissioning and waste management ................................... 51 Notes for dismantling ............................................ 51 Procedure ............................................................... 51 Waste management................................................ 51

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1

About this manual

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About this manual This chapter provides important information making it easier for you to use this manual. You will also be given information on the structure of the manual and the symbols and characters used.

Before starting work applicable operating manual crusher type

This operating manual is designed for the following crusher plant. It is only permitted to be used for this crusher plant (subject to change): MinPro crusher plant SB 0916 Object-No.: 55279300000000 Mach.-No.: 605

new operating manual

Send for a new manual immediately if the present manual is no longer complete or has become illegible.

Who is this operating manual intended for?

This operating manual is intended for those persons who work with or on the crusher plant.

It is the customer's / operator's responsibility that all persons, who work with this plant, know this operaring manual. It must be realized and accessible.

This includes persons: are in charge of transport perform assembly/disassembly work operate the crusher plant eliminate faults perform daily routine work on site perform maintenance work perform repair work Supervisory personnel who: initiate and/or supervise the activities just indicated

What is the purpose of this operating manual? cost-effectiveness

This operating manual is intended to help you working efficiently and safely with our product. It contains important information on all the activities releated to the crusher plant.

Pay special attention to the safety instructions.

service

safety

If any details are not clearly understood, please contact our service department. Our service address is given on the title and on the first side of this operating manual.

Read the chapter "For your safety" with special attention. This chapter contains important information indicating possible hazards.

Observe the information given and follow the procedural instructions.

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Characters and symbols used The following characters and symbols are used for safety instructions and important information in the operating manual. Try to memorize the symbols and their meanings.

Danger!

Points in the text marked with this symbol draw your attention to immediately impending danger. Possible consequences are: very serious injury or even death.

Warning!

These points contain information on dangerous situations.

Possible consequences are: very serious injury or even death.

Caution!

This symbol draws attention to dangerous situations. Possible consequences are: light to moderately serious injury and machine damage.

Notice!

Points in the text marked with this symbol draw attention to harmful situations. Possible consequences are: damage to the crusher plant or damage in the immediate vicinity.

Important!

Points in the text marked with this symbol contain useful tips and information intended to facilitate work for you. They do not warn about harmful or dangerous situations.

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2

For your safety

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For your safety Pay special attention to this chapter. The safety instructions and rules of procedure will help you to avoid hazardous situations and to perform the necessary work as safely as possible. state of the art

The crusher plant has been manufactured in accordance with the state of the art and generally recognized safety standards and regulations.

You and others can nevertheless be exposed to dangerous situations e.g. as a result of environmental influences, machine damage or operator errors.

Do not make any alterations or modifications which could impair the safety of the crusher plant. All modifications and changes must be approved by Hazemag.

Original parts

Use only original spare parts from Hazemag.

Note that the use of parts from other manufacturers will avoid the guarantee.

Please refer to the spare parts lists for the order numbers.

In addition to this operating manual be sure to also observe the respective legal provisions and regulations for accident prevention in your country.

further operating manuals

Please read also the operating manuals of the components required for operation, e.g. gearboxes, electric motors, etc., carefully and thoroughly.

Clarify any questions before starting work.

Personnel Operation

The crusher plant may only be operated by qualified trained personnel.

It is the customer's responsibility to guarantee this. In case of (further) training need, the customer can order training at the manufacturer.

Operate the operating field respectively the electrical control system only if you have a profound knowledge of the control elements and their functions. It is necessary that you have been task trained on the respective control system.

Danger!

Incorrect operation endangers yourself and others!

Incorrect operation of the machine is often the cause of very serious accidents!

Ensure that nobody is present in the conveyor or in the danger area of the crusher plant (e.g. feeding area, discharge area) before starting the crusher plant.

Check that all protective devices (e.g. emergency-stop) have been fitted to the crusher plant and function properly Clean the control panel regularly. Ensure that the operating symbols are clearly legible so that operating errors and resultant accidents are prevented.

Assembly and repair

As a fundamental rule, installation and repair work may only be carried out by personnel who have been adequately trained for these particular requirements.

Installation and repair work on: the saftey components (pressure relief valves, extinguishers, etc.) the electrics (controls, signallin devices, etc.) the hydraulics may only be carried out by the service engineers from Hazemag or by specially qualified personnel of the operator.

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General Safety instructions Familiarise yourself with your working environment. safety equipment

Start the crusher plant only when it is in a good and safe condition and all protective devices, e.g. EMERGENCY STOP devices, cover plates, etc. are correctly installed.

Danger!

It is forbidden to stay in the area of possible falling material!

The operator must fix, mark and if necessary enlarge this area during test run and commissioning!

Keep the signalling and lighting systems in a proper functional condition.

Observe the acoustic and optical start-up warnings of the crusher plant.

symbol plates EMERGENCY-STOP

lock-out

Observe the symbol plates on the crusher plant.

Press the EMERGENCY-STOP switch immediatelyin the event of faults or irregularities in operation. Report any peculiarity to your superior so that the necessary measures can be taken immediately.

Secure the crusher plant against unauthorized and unintentionally restarting while performing: maintenance work inspection work repair work Attach a sign at the possible restarting point with the reference that work are proceeding and restarting is forbidden.

Never enter a conveyor if the crusher plant is not secured against restarting.

moving parts

Never allow parts of your body to come between parts which could move, such as e.g.: rolls hydraulical height adjustments Couplings and drive flanges Storage and transport Secure all moving parts.

Never stay under unsupported parts or suspended loads.

means of attachment

Connect the lifting equipment only to the points of attachment provided for that purpose.

Observe the different load limits of the attachment points. Also observe the instructions on the transport sheets.

Only use means of attachment which are in good condition.

Never use chains or steel cables without approval.

Do not damage the machined or polished surfaces of shafts, sealings, etc.

Maintenance and repair Be sure to observe the specified maintenance and inspection intervals.

Inform the supervisory personnel and the crew about maintenance and repair work.

replacing components

Sign dismantled, defect components. So you avoid the mistakenly reinstallation.

Check these components immediately and lead them to repair if possible.

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protective devices

Refit protective devices removed immediately after completion of the work and check that they function properly.

Work on hydraulics (if any) Notice!

Only use hydraulic fluids approved by Hazemag. These fluids have been tested at Hazemag and ensure a reliable operation of the hydraulic system.

Be sure to observe the manufacturer's instructions for use.

We expressly point out that the approval of the listed products relates only to the pure technical use in our hydraulic systems. The responsibility for the constituents used in the hydraulic concentrates lies solely with the respective manufacturer.

Further important information is given in DIN 24320 respectively 51524 parts 1 and 2.

handling of hydraulic fluids

Avoid direct contact between the skin and hydraulic fluids. Hydraulic fluid can penetrate the skin and cause serious infections.

maintenance, repair

You are only allowed to work on the hydraulic system if you have and can prove to have special knowledge of hydraulics.

Important!

Inspect and maintain all components of the hydraulic system such as e.g. pump stations, filter systems etc. as specified in the respective operating manuals.

Ensure that no dirt enters the hydraulic system during repair work. Dirt in the hydraulic system can cause great damage to the complete hydraulic system. Flush out the hydraulic lines thoroughly before connecting.

Warning!

Hydraulic fluids escaping under high pressure can cause serious injury or death. Be sure to depressurize the hydraulic system.

After finishing repair work, check all connectors and connections for leaks before pressurizing the system again.

Observe the date of manufacture stamped on the hydraulic hoses. Never use any hydraulic hoses which are more than 2 years old, even if they show no visible signs of damage.

Figure 1: Typical hydraulic hose

Date of manufacture Manufacturer Hose type with internal diameter

Never try to hold a jumping hose. Depressurize the respective line immediately.

Never try to repair damaged hydraulic hoses.

Replace hydraulic hoses at the first suspicion of damage. laying hydraulic hoses

Lay the hydraulic hoses properly behind the backets and clamps provided for that purpose.

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Lay hydraulic hoses such that they: always have a little slack.

Figure 2: Laying hydraulic hoses, slack

CORRECT

WRONG

are not twisted.

Figure 3: Laying hydraulic hoses, twisting

CORRECT

WRONG

are not bent directly behind the connections (distance min. 1.5 x nominal diameter) Figure 4: Laying hydraulic hoses, bending

CORRECT

WRONG

cannot chafe.

Figure 5: Laying hydraulic hoses, crossing

CORRECT

WRONG

are not kinked. are not subjected to tensile loads.

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are protected against thermal radiation. are accessible at all times.

Push hydraulic hoses into the sockets only by hand. Never try to drive the hydraulic hoses in with a tool as this may damage the connections. When installing the hoses ensure that they cannot be: torn out, kinked, squeezed, driven over or twisted (Figure 6). by the movement of the crusher plant.

Figure 6: Laying hydraulic hoses, connection to moving parts

CORRECT

noise emissions

environmental acceptability

WRONG

Others Always wear your personal protective equipment. This also includes ear protectors as the noise emitted by the crusher plant may at times exceed 85 dB(A), (e.g. when the plant is being emptied).

When working with oils, greases, and other chemical substances, observe the safety regulations applicable to the respective product.

Dispose of cleaning rags etc. which have been soiled with oil, grease, or other chemical substances in an environmentally safe manner.

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Operating conditions Intended use The crusher plant will be used in a coal mine.

Employ the crusher plant only for its intended use!

The intended use is: Conveying and crushing coal

Unauthorized use Applications not expressly listed as intended uses are unauthorised uses and not allowed to be performed with the crusher plant.

Such unauthorized use includes i.a.: Transporting persons or objects of any kind Crushing other material

Hazemag accepts no liability for any damage resulting from any such unauthorized use.

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3

Storage and transport

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Storage and transport This chapter contains important information on the correct storage and safe transport of the crusher plant.

Observing the notes and instructions will increase the service life and the availability of the crusher plant.

You will be able to carry out the transport work safer and faster.

Reading this chapter carefully will help you to make your day-to-day work easier.

Storage corrosion protection

Components provided with a temporary corrosion protection are protected for a period of about six months.

Before delivery, the hydraulically operated equipment is operated with a test medium which is drained to the extent possible prior to shipment.

The medium remaining in the equipment protects the internal parts against corrosion for at least six months.

Storing the equipment no direct exposure to sunlight

dirt and moisture

Protect the equipment against direct exposure to sunlight. Store the electrical equipment, electronic components, spare parts made of rubber or plastics – such as seals and hoses – as well as hydraulic fluids only in closed rooms at temperatures between 15°C and 25°C. Protect all parts of the equipment stored outdoors against moisture and dirt, e.g. using tarpaulins.

The connecting surfaces of hydraulic components must be protected against corrosion and sealed with blind plates. Protect the hydraulic plug connections and the connectors of the electric cables with the caps and plugs supplied.

sample inspection

After a storage period of approx. two years, a sample inspection should be performed to determine whether the measures taken and the method of storage have prevented damage.

Upon request, the inspection can be carried out by Hazemag.

natural ageing

Even when properly stored, seals and hoselines are subject to natural ageing. Do not use these components if they have been stored for more than two years.

Important!

Take care to ensure that new supplies are stored separately from existing stock and that removal takes place on the "first in, first out" principle.

Transport Warning!

Only use load handling devices complying with the respective technical and legal regulations for the transport of loads.

You could be seriously injured or even killed by falling loads. Only use permissible load handling devices.

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Before transport Warning!

Before starting transport, remove any loose material from the crusher plant.

Disconnect the electrical supply. temperature below freezing

Before transporting the equipment at temperatures below freezing, all hydraulic components operated with emulsion (HFAE bzw. HFAS) must be completely drained and then filled with a preserving fluid (e. g. CV 50).

Transport of equipment at temperatures as of and below -21°C is only permissible when certain measures were taken to meet these requirements already at the design and manufacturing stages.

Nevertheless, individual parts and devices of this equipment must not be subjected to sudden impact loads at such low temperatures but may only be loaded statically or quasi- statically.

During transport of this equipment at such temperatures using industrial trucks take care to ensure that parts and devices are not subjected to sudden impact loads.

Therefore, the speed of the trucks must be adapted to the prevailing conditions when transporting equipment at very low temperatures and on poor roads.

electrical and electronic components

Electrical and electronic components must be removed for overseas transport or prolonged storage outdoors unless these components or the complete equipment have been protected against harmful environmental influences by suitable packaging.

At temperatures below zero electric cables are only allowed to be transported on drums.

Transport of the components It is planned to transport the impact roll crusher as a completely assembled unit.

For transporting the substructure is provided with lifting points. These are generally welded eyes or screwed 3D load hooks.

All lifting points have a number werlded on or engraved showing their permissible load-carring capacity ("3" or "3t" means the load-carring capacity of the lifting point is max. 3000kg).

Danger!

You could be seriously injured or even killed by falling loads.

Observe the safe working load of the lifting eyes and keep a safe distance to suspended loads.

Warning!

Only use permissible lifting equipment!

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4

Assembly

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Assembly What to observe prior to assembly Who is allowed to carry out assembly work?

Assembly work is only allowed to be carried out by personnel having received adequate training to perform these tasks.

Work on: the safety components (pressure relief valves, fire extinguishing equipment etc.) the electrical equipment (control units, signalling devices, etc.), and the hydraulic equipment (cylinders, directional control valves, hoses etc.) should only be carried out by Hazemag service engineers or by specially trained personnel.

A set of different tools and devices should be available at the points of assembly, including Hoists with adequate lifting capacity Load handling devices with adequate lifting capacity Torque wrenches

Assembly notes Observe the valid accident prevention instructions and the special safety instructions.

Secure the working area.

The sequence of operations during installation must be adapted to the individual conditions prevailing at the site. It is recommendable to prepare a list specifying the individual steps to follow for assembly.

Caution!

Serious damage can be caused to the crusher plant and the drive units due to incorrect assembly!

Caution!

Please take care to observe the respective separate operating manuals (i.g. motors etc.)!

Notice!

Blows on the motor shaft will damage the roller bearings! Therefore always use a mounting and pulling-off device for installation and removal of the coupling parts!

Dirt could enter the couplings if the O-rings of the flange plate are not correctly installed. This can result in serious damage to the couplings.

Insure that the O-rings are in the correct position during installation of the flange plate.

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Danger!

Be sure to tighten all bolts to the specified torques.

Components which were stored or transported at below freezing temperatures must not be thrown or pushed. Care must be taken that these parts are slowly exposed to the ambient temperature. They should not be put into operation before they have reached this temperature.

Sensitive components must be handled with special care.

At temperatures below zero, electric cables have to be transported on drums and are not allowed to be unwound!

Dismantling Stop the crusher plant.

Disconnect the electrical supply.

When dismantling the power unit, care should be taken that all exposed shafts, hubs, labyrinth paths, and flanges are protected against corrosion, dirt, and mechanical damage.

Particular care should be used in the treatment of machine parts that can get damaged easily.

When disconnecting hose lines, the hose ends should be plugged by blind or screw plugs.

Loose parts (screws, bolts etc.) should be kept in suitable boxes, well arranged and protected against dirt and damage.

Important!

Dismantling is peformed using the same tools and devices as for assembly.

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5

Technical data

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Technical data This chapter contains the most important technical data on the crusher plant.

Furthermore the crusher plant will be described.

Further data can be found in the spare part lists and in the separate operating manuals for the individual components such as e.g. motors.

At the end of this chapter you will find information on bolt tightening torques; greases, etc.. Read this chapter carefully and pay attention in particular to the safety advices.

Technical data sheet General

Dimensions

Impact roll crusher

Feeding material:

Coal

Feed size:

1500 x 500 x X mm

Final product size:

0 - 200 mm

Throughput:

approx. 4000 t/h

Total weight:

approx. 16,1 t

Length:

approx. 3080 mm

Width:

approx. 2878 mm without gearbox approx. 3270 mm with gearbox

Height:

approx. 1580 mm

Impact roll diameter:

931 mm

Impact roll width:

1523 mm

Passage height under roll:

194 - 314 mm

R.P.M:

455 rpm

Circumferential speed:

22,2 m/s

Impact elements:

12 pcs.

Drive power:

500 HP

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Main components The crusher plant SB 0916 consists of the following main components (see also figure 7): the substructure with pan the impact roll with impact elements the crusher housing the roll height adjustment the gearbox holder the lubrication material flow

The impact roll crusher SB 0916 is a continuous flow crusher which will be integrated into the stageloader of a coal mining installation. It is designed for breaking the coal mined to a size which allows it to be transported on a downstream belt system.

The material to be broken is taken through the crusher by means of the stageloader. Larger lumps of coal are crushed by the impact roll while smaller pieces pass underneath the roll.

Important!

The section above is a general description of the crusher plant.

Find more detailed information, descriptions and operating instructions for adjustments, maintenance work and similar on the following pages ("Technical description") and in chapter 6 "Operation"!

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Components Figure 7: Crusher plant SB 0916

Item

Description

1 2 3 4 5 11 12 13,14

Substructure cpl.

Impact roll cpl.

Impact element cpl.

Crusher housing cpl.

Hydraulical height adjustment cpl.

Gearbox holder cpl.

Lubrication cpl.

Type shield with fastening elements

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Weight (kg) 7650,00 4998,00 365,00 2807,00 162,00 148,00 10,00

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Technical description Crusher housing and substructure The housing of the crusher plant and the substructure with pan are manufactured from wear resistant material and in welded construction.

The crusher housing is screwed to the substructure.

Welded guidings in the pan warrant a faultless run of the chain.

For active dust suppression the crusher housing is provided with a port for connecting the spraying system.

Screwed-in flat jet nozzles are facing into the crusher housing. The customer sided water fitting will be connected to the nozzle reception pipe. Over this pipe the water is routed into the crushing chamber via the flat jet nozzles.

Figure 8: Spray pipe

1 2 3

Flat jet nozzle

Spray pipe

Spray pipe Flat jet nozzle 1/4" Coupling clamp

Crusher housing

In order to prevent wear and clog of the nozzles the water should be filtered. The mesh size of the filter should be at least 500µm. The water pressure for spraying should be in the 2 to 10 bar range.

Water consumption depends on the pressure and is as follows for a spraying unit with 4 nozzles: at 2 bar

approx. 1,6 liters / minute

at 5 bar

approx. 2,5 liters / minute

at 10 bar

approx. 3,5 liters / minute

Notice!

The maximum pressure is 50 bars. This pressure must not be exceed.

Operating without water is impermissible!

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Impact roll The impact roll is also designed in welded construction.

The roll is fastened and balanced on the crusher shaft with clamping elements.

The impact roll is shifting in bearing housings and spherical roller bearings.

Connection to the crusher housing is via threaded rods.

Height adjustment

Spacing plates are available for adjusting the passage height between the roll and the conveyor.

The height adjustment is by means of hydraulic cylinders which are powered by a hydraulic pump (hand pump).

(Find more details on the following pages and in chapter 6 - "OperationRoll height adjustment".)

Figure 9: Impact roll

300Nm Torque

1 2 4 7 9 15 19 23 30 45

Impact roll Crusher shaft Bearing housing Clamping element Spherical roller bearing Spacing plate 40mm Threaded rod Cone grease nipple Protecting cover for crusher shaft Shaft protection for shaft end For parts not listed here, please refer to the spare part list supplied

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Impact heads The impact elements are manufactured from wear resistant material.

They are equipped with carbide segments.

The impact elements are fastened to the impact roll with a hexagonal bolt and a support plate and locking plate.

Figure 10: Impact element Torque 2300Nm

Carbide segment

1 2 3 4 5

Impact nose Hexagonal bolt Support plate Locking plate O-Ring

Important!

Find further instructions for work at the elements in chapter 6 "Operation"!

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Hydraulical roll height adjustment The final product size while crushing can be varied with the height adjustment.

The impact roll can be adjusted in its height by means of hydraulic cylinders. These cylinders will be pressured by a hydraulic pump (hand pump).

Pressure fluid is oil (see "Hydraulic fluids" at the end of this chapter).

Important!

How to adjust the height of the impact roll will be described in chapter 6 "Operation - Roll height adjustment"!

Figure 11: Hydraulical roll height adjustment

1 5 8 9 40-43

Hydraulic cylinder Hydraulic pump Manometer Pressure relief valve Hose lines For parts not listed here, please refer to the spare part list supplied

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Central lubrication The bearings of the impact roll will be supplied with grease via the central lubrication system.

The bearings will be greased from the right hand and the left hand crusher side.

Figure 12: Central lubrication

Right

Left

1 Connecting piece 2 Cone grease nipple 6,7 High pressure hose For parts not listed here, please refer to the spare part list supplied

Important!

Find more details in chapter 6 "Operation - Lubrication"!

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Tightening torques Screws resp. nuts with metric coarse thread DIN 13 Tightening torques at µtotal = 0,14 Thread

Pitch

(mm)

(mm)

d

P

8.8

10.9

12.9

M8

1,25

23

32,5

39

M10

1,5

46

65

78

M12

1,75

80

113

135

(M14)

2

127

178

215

Tightening torque MA(Nm)

M16

2

195

275

330

(M18)

2,5

270

380

455

M20

2,5

380

535

640

(M22)

2,5

510

720

865

M24

3

655

920

1100

(M27)

3

965

1360

1630

M30

3,5

1310

1845

2215

(M33)

3,5

1780

2500

3000

M36

4

2290

3220

3860

(M39)

4

2970

4170

5000

M42

4,5

3670

5160

6190

(M45)

4,5

4590

6450

7740

M48

5

5540

7790

9350

When using screws and nuts together but different types of strength, the lower tightening torque is valid!

Torques for clamping elements Component

Clamping element

Torque

Impact roll

TLK 400, 240x305

320 Nm

Important!

The tightening torques given in the spare part drawings must be observed during assembly and all maintenance work.

It is very IMPORTANT to follow these settings (specifications)!

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Permissible media Lubricating greases Properties

Base:

Lithium soap

NLGI-class:

2

Penetration:

265 to 295 (0,1 mm)

Attitiude in the presence of water: practically non-soluble Temperature of application: -25 to + 130oC Recommended lubricating greases: Supplier

Type

ARAL

Aralub HLP 2

BP

BP Energrease LS-EP 2

ESSO

BEACON EP 2

MOBIL

MOBILUX EP 2

SHELL

Shell Alvania EP Grease 2

BECHEM

High-Lub L474-2

FUCHS

Renolit LX 2 Renolit LEP 2 HD

When the equipment is lubricated in our works for the first time the lubricating grease is: BP Energrease LS-EP 2 Important!

The greases listed in the above mentioned table can be mixed.

Other products may only be used if the supplier can guarantee that they are equivalent.

Differently composed lubricating greases must not be mixed as this may change the consistency, i.e. the mixture can become thinner so that the lubricating effect is not sufficient.

It may also be dangerous t ouse lubricating greases having the same saponification base but different origins.

In case of doubt, the manufacturer of the lubricating grease to be used should be contacted as to the compatibility of the grease in question.

Hydraulic fluids Roll height adjustment:

approx. 5 litres mineral oil DIN 51524 (viscosity depends on the temperature of environment)

Observe operating manuals of manufacturers!

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Recommended hydraulic fluids

Description acc. DIN51519 ISO-viscosity class

Company denotation

VG 46

Aral Vitam DE 46

46

30

BP Energol HLP 46

46

30

FUCHS RENOLIN B15

46

32

Mobil DTE 25

44

29

Shell Tellus Oel 46

46

30

Texaco Rando Oil HD-B46

44

29

Viscosity in mm²/s (cSt) mm²/s (cSt) 40°C 50°C

Admissible temperature range in oil tank

from 30°C - 80°C

Minimal starting temperature

0°C

Important!

Please check with Hazemag if other oil types should be used, for authorization, so as to maintain the warranty!

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6

Operation

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Operation Commissioning of the crusher plant The commissioning may only be executed from authorized and specially trained personnel.

Notice!

Observe the notes given in the respective operating manuals of the crusher components additional, e.g. motor, gearbox etc.

Before commissioning Execute the following work before commissioning: Important!

Check the oil level of the gearbox and fill up if necessary!

Clean the crusher plant and the working area from tools, all aids, etc.

Check all screw connections and fastening elements (bolts, etc.) for tight seat, especially at the impact roll and the drives.

The impact roll must be free to rotate.

At crushers with height-adjustable roll the spacing plates fitted must be of the same quantity and thickness on both sides.

The roll must not grind against the side wall of the housing. The distance to the housing wall must be the same over the whole circumference.

The minimum distance between the top surface of the conveyor and an impact head with the roll in its lowest position is approx. 40 mm at the outer edges.

Existing protecting devices must be assembled respectively fastened according to instructions.

All lubricating points must be filled with grease sufficient. Only then a faultless lubrication is possible from the beginning.

If any: Check the hydraulic fittings and hydraulic lines for leakages and damages.

Check the correct installation of the supply lines.

Check all hydraulic connections.

Danger!

Percussive hydraulic hoses can cause very serious injuries or even death!

After eliminating all founded faults the commissioning of the crusher plant can be executed.

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Notes for electrics The crusher plant is supplied without electrical equipment. It is the responsibility of the operator to arrange for the installation and availability of all necessary functions.

Please observe the applicable regulations and guidelines for the electrical system. Additionally, follow the general requirements mentioned below and observe any special regulations which may apply for the respective application. start-up phase

Actuate acoustic and optical start-up warning signals before starting the crusher. All persons who may be in the hazardous area should be given enough time to leave the respective area before the roll is allowed to start rotating.

The drive of the crusher roll must always be actuated before starting the conveyor drive.

The conveyor drive is only allowed to start when the crusher roll runs at rated speed.

When a Turbo coupling is installed, the electric motor should be switched on directly. If this is not possible, a change over from star to delta connection must take place within 3 seconds.

operation

The conveyor drive must stop automatically when the speed of the roll has dropped to 90% of its rated speed.

The roll drive must stop when the limit temperature of the Turbo coupling is reached and/or the fusible plug actuates.

The conveyor and roll drive must stop immediately if the conveyor chain fails/breaks.

switch off

The conveyor drive must be stopped before the roll drive.

The roll has to continue running for a short while after the conveyor drive has been switched off.

emergency stop switch

All drives must stop immediately.

Test run and start up Danger!

During the test run no person may be in the danger area of the crusher plant.

There could be faults, which have an effect on standard operation, e.g. assembly faults.

Because of such faults very serious injury or even dead can be the result!

Warning!

For safety reasons there should always be at least two persons when performing the test run.

The valid safety instructions of the mechanics and electrics must be observed! e.g.: -

Never operate switches, valves, control devices, etc. unauthorized

Danger!

Always wear protecting helmet, goggles, hearing protection, safety shoes and safety gloves!

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Check the following points during the test run: Perform test run of approx. 0.5 hours at no load: Particularly check temperature of the bearings, running noises, leakages at bearing points, vibrations etc.

Perform trial run under load: Increase load gradually up to rated load. While doing so, check drives for rises in temperature, running noise, vibration, and leakages.

Check function of the safety devices.

Check for uniform and equal current consumption of the electric motors.

Check that the gearboxes run smoothly.

Warning!

In case of faults, inexplicable noises and movements shut-off the crusher plant immediately over the emergency-stop switch!

After checking the test run can be continued.

When no faults are founded during the test run respectively all founded faults are eliminated the crusher plant can be put into operation.

Retighten screw connections

Because of setting of the screw connections respectively the components, screws can become loose.

The following mentioned screw connections of the crusher plant must be retightened after a first operating time of approx. 50 hours.

Pay attention to the respective torque.

Drive connections at the crusher plant: - Gearbox - Connecting flange at the roll - Gearbox - Motor - Gearbox - Gearbox holder Crusher housing - inlet side Crusher housing - outlet side Face connections pan - stageloader Attachments at the substructure with pan

Select tightening torque

Take the torque of the respective screw connection from the corresponding spare part drawing.

If the spare part drawing gives no other information, the torques of table "Tightening torques - Screws resp. nuts with metric coarse thread DIN13" in chapter 5 are valid.

Operation of the crusher plant General During normal operation please observe the following: Avoid to switch the crusher plant on and off without need.

Feed the material at a fairly constant rate, if possible.

Avoid overloading.

Take care to ensure that the plant is serviced regularly.

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Roll height adjustment Danger!

The passage height may only be adjusted when the crusher plant is in standstill!

It must be secured against unauthorized restarting!

The passage height under the roll can be adjusted in different positions by means of hydralic cylinders (three times 40mm = 120mm total).

There are three hydraulic cylinders. Two of them will be fastened at the impact roll (piston rod at the bearing housing, piston base at the pan).

The third cylinder will be fastened at the gearbox holder (piston rod at the holer for the gearbox, piston base at the holder for the pan).

The hydraulic cylinders will be pressured via a hydraulic pump.

Pressure fluid is oil (see "Hydraulic fluids" in chapter 5 "Technical data").

Important!

The impact roll is in neutral position (lowest position) when ONE spacing plate of 40mm is located UNDER the bearing housing and the rest of the spacing plates (3 pcs.) are located ABOVE the bearing housing (see figure 14)!

Notice!

The spacing plate of 40mm under the bearing housing may not be removed!

The desired passage height will be achieved by uniformly raising or lowering the impact roll by means of the hydraulic cylinders attached underneath the bearing housing.

The following describes the procedure for raising the impact roll.

Lowering is analogous (see figures 13,14).

Notice!

The quantity and thickness of the spacing plates located under respectively above the bearing housing must be the same on both sides!

Loosen and remove the 4 clamping borders at the crusher housing.

Figure 13: Clamping borders

Clamping borders on both sides

Loosen the screw connections between crusher housing and bearing housing. The threaded rod is equipped with a hexagonal end (30mm width) on both sides. Hold against with a wrench so that the threaded rod does not rotate while the nut is being loosened.

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Remove the required spacing plates located above the bearing housing on both sides. Take care that there are two bolts (∅20mm) on the top side of each spacing plate which come approx 10mm into the above located plate.

Raising the impact roll is by means of the hydraulic cylinders located at the side of the crusher housing, under the bearing housing. As noted above they will be pressured by a hydraulic pump respectively the customer sided face hydraulic.

Notice!

Uneven raising of the bearing housings can lead to damages of the bearings and sealings. While raising the level difference on both sides must not be more than maximal 20mm!

The above removed spacing plates will be placed under the respective bearing housing.

The flow of hydraulic oil to the cylinders can be controlled over the stop valves. So, the uneven weight distribution can be compensated.

Lower the impact roll slowly.

For this open the safety relief valve at the hydraulic pump slowly.

Take care that the impact roll does not cant while lowering. If necessary regulate with the stop valves.

Fasten the bearing housing. Necessary

torque = 2000Nm.

The roll must be free to rotate. The distance between impact roll and side wall of housing must be equal allover the circumference.

Press grease at both nipples on the front side of the bearing housing.

This protects the threaded rods against corrosion and the disassembly will become easier.

The position of the gearbox must be fitted / adapted adequately.

Perform a test run.

(Figure 14: Roll height adjustment on the next page)

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Figure 14: Roll height adjustment

2,3 1

1

1 2 3 4

Spacing plates 40mm thickness Threaded rod Collar nut Hydraulic cylinder

4

Warning!

No overpressure must be build up when the piston rod extends!

Danger!

The entrance to the annulus of the cylinder must never be blocked, because the movements of the cylinder can build up pressure extremely. Serious injuries or even death can be the result when pressure passes out off defect lines!

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Maintenance Warning!

At work in the danger area of the roll or work at it directly, the roll must be locked!

For this wedge the roll either with the crusher housing or with the conveyor (i.g. with wooden wedges).

Notice!

Regular maintenance increases the saftey in operation and the durability of the crusher plant.

Damages at the crusher plant can be the result of an insufficient executed maintenance. Those damages can lead to high costs.

Furthermore the warranty can fail.

Important!

All necessary maintenance work may only be executed from authorized and specially trained personnel by observing the valid safety instructions and accident prevention instructions.

Use only ORIGINAL spare parts from Hazemag if components must be replaced!

Important!

Take additional care to the operating manuals of components like e.g. gearbox, motor, hydraulic components etc.!

Danger!

When working at the electrical equipment the plant must be shut-off und has to be secured against restarting!

The plant must be neutralized, grounded and short-circuited!

Observe the relevant valid safety instructions!

The necessary maintenance work, the time intervals and if the work must be carried out "in operation" or "in standstill" are given in the table on the following pages.

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Substructure with pan, General visual check, report deformations and crusher housing, damages, check welded seams gearbox holder

Impact roll

in operation

in standstill

Check safety devices for completeness and damage and replace them if necessary

every 8 hours resp. daily

Maintenance work

every 50 hours

Component

every 200 hours

Maintenance acc. to schedule

X

X

X

X

X

Check all fastening screws for tight seat, retighten loose screws and replace missing ones

X

X

General visual check, report deformations and damages, check welded seams

X

X

Check all fastening screws for tight seat, retighten loose screws and replace missing ones

X

X

Check bearing temperature, when ≥ 60°C + environment temperature: find out the reason and remedy it (if necessary consultate the manufacturer)

X

X

X

X

Lubrication work: see "Lubrication" on the next page!

Impact head

Height adjustment and lubrication

Lubrication

Check impact elements for tight seat, completeness and wear. Replace/Change the impact element when the carbide segments are worn (see "Changing the impact elements") Important!

Check the torques of the fastening screws during the first days after assembly and retighten them if necessary.

Retighten the fastening screws with the respective torque after the first week.

Visual inspection of all components. Check that: - hoses are not pinched or trapped.

- hoses have no bubbles or blisters.

- hoses or the outer sheaths of the hoses are not abnormally rigid or hard.

- the outer sheath of the hoses is not damaged.

- the connectors are securely inserted in the sockets.

- connections are leak-tight.

Check function; visual check; screw off the hoses from the lubricating points, perform lubricating service and check if grease comes out off the hose ends

X

X

X

X

X

X

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Lubrication Quantity of lubricating points

Lubricating quantity per hour

Bearings, impact roll

2

200 gram per day (approx. every 10 operating hours) per bearing

Connection crusher shaft gearbox (manual, see operating manual of subdeliverer also)

1

200 gram per week

Component

Figure: 15: Lubricating points

Grease nipple

Grease nipple

Grease nipple of gearbox

The following grease points are not connected to the central lubrication system and have to be lubricated separately.

Bearings of electric motor (see operating manual of supplier) Threaded rod of bearing housing (depending on frequency of use) Important!

For lubricating the above mentioned lubricating points, only use lubricating greases of water hazard class 0, as the lubrication system is a total loss system.

It is absolutely necessary that you observe the relevant environmental protection regulations.

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Changing the impact heads Notice!

The impact elements must be replaced at the latest when the carbide segments are worn!

Danger!

When replacing the impact elements the crusher plant must be locked-out and secured against restarting!

Warning!

The impact roll must be locked (wedging the crusher housing or the conveyor with e.g. wooden wedges)!

Warning!

The impact roll continues to turn for a few minutes after being stopped!

Observe the following when replacing the impact elements: The impact elements must be replaced completety including all connecting elements.

Seating surfaces of the impact elements at the impact arm must be checked for damage before installing a new element. The contact surfaces must be level.

Before installing the impact elements all contact surfaces and the screws must be greased. We recommend Altemp Q NB 50.

Notice!

Unlock the locking device before (re) commissioning. The roll must be free to rotate!

Warning!

Never operate the crusher plant when the impact elemements are worn or incomplete!

Fig. 16: Impact element Torque 2300Nm

1 2 3 4 5

Impact head Hexagonal bolt Support plate Locking plate O-Ring

Carbide segment

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Spare parts and special tools In order to minimize production losses (caused by necessary repairs) we recommend to always having a minimum stock of the following spare parts and the tools required for repair available.

Impact element cpl. (Order-No. 23081303803002) Lubricant Tools (above all torque wrenches)

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7

Decommissioning and waste management

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Decommissioning and waste management Notes for dismantling Warning!

Work on hydraulc and electric devices has to be performed exclusively by personnel with special/expert knowledge in this specific field!

Important Follow the general safety instructions mandatory!

Nonobservance can lead to injuries and/or damage to property!

Procedure When decommissioning for scrap disposal observe the following: Disconnect the electrical supply Dismantling and emptying of all hollow parts and aggregates which are filled with operating liquids, i.g. motors, gearboxes, fluid tanks, hydraulic lines and hydraulic cylinders Dismantling of particular components To avoid/minimize dangers and environmental pollution observe the following: For assistance provide the instructed personnel with the spare part lists Separate the material to abet recycling Recycle discharged oil according to the prescriptions of the local authorities Electronic parts have to be recycled separately Important!

Pay attention to the detailed manuals of the subsupplied components!

Waste management Important!

All disposed material and dismantled parts have to be recycled according to the valid legal prescriptions!

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