CAT Armored Face IMPACT ROLL CRUSHER SB 0815 Cleveland Cliff Operation & Maintenance Manual

BI019791 April 2013

Operation and Maintenance Manual IMPACT ROLL CRUSHER SB 0815

SAFETY.CAT.COM

Operating manual Impact roll crusher SB 0815 Project:

"Cleveland Cliff"

Object-No.: 55278500000000 Mach.-No.: 552

HAZEMAG & EPR GmbH Brokweg 75 D-48249 Dülmen

Phone: Fax:

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

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

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 2009

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

Components ............................................................ 25 Technical description ............................................. 26 Crusher housing and substructure ..................................26 Impact roll........................................................................26 Impact heads...................................................................27 Roll height adjustment.....................................................28 Roll drive and drift ...........................................................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 .......................................................39

Operation of the crusher plant ............................... 40 General ...........................................................................40 Roll height adjustment.....................................................41

Maintenance............................................................. 44 Maintenance acc. to schedule .........................................45 Lubrication.......................................................................46 Changing the impact heads.............................................47 Tensioning the V-belts.....................................................48 Changing the V-belts.......................................................50

Spare parts and special tools ................................ 51

1

About this manual

1

2

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 0815 Object-No.: 55278500000000 Mach.-No.: 552

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

service

safety

Object-No.: 55278500000000

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.

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.

3

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.

4

Object-No.: 55278500000000

2

For your safety

5

6

For your safety state of the art

Original parts

further operating manuals

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.

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.

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.

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

Assembly and repair

Object-No.: 55278500000000

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.

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.

7

General Safety instructions safety equipment

symbol plates EMERGENCY-STOP

lock-out

moving parts

means of attachment

replacing components

8

Familiarise yourself with your working environment.

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.

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.

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.

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.

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

handling of hydraulic fluids maintenance, repair

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.

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

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

laying hydraulic hoses

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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.

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

9

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.

10

Object-No.: 55278500000000

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

Object-No.: 55278500000000

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.

11

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.

12

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3

Storage and transport

13

14

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

sample inspection

natural ageing

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.

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.

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.

Object-No.: 55278500000000

15

Before transport

temperature below freezing

electrical and electronic components

Warning!

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

Disconnect the electrical supply.

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 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!

16

Object-No.: 55278500000000

4

Assembly

17

18

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.

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.

Object-No.: 55278500000000

19

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.

20

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5

Technical data

21

22

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

Object-No.: 55278500000000

Feeding material: Final product size: Throughput: Total weight:

Coal 0 - 150 mm + oversize approx. 3500 t/h approx. 15230 kg

Length: Width: Height:

approx. 3000 mm approx. 2570 mm approx. 1415 mm

Impact roll diameter: Impact roll width: Passage height under roll: R.P.M: Circumferential speed: Impact elements: Drive power:

840 mm 1480 mm 194 - 274 mm 530 rpm 23,3 m/s 6 pcs.

350 HP

23

Main components The crusher plant SB 0815 consists of the following main components (see also figure 7): the substructure with pan the impact roll the crusher housing the drive with V-belt pulley and protecting cover the drift with V-belt pulley and protecting cover the roll height adjustment the lubrication material flow

The impact roll crusher SB 0815 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"!

24

Object-No.: 55278500000000

Components Figure 7: Crusher plant SB 0815

Conveying direction

Bit inspection doors

Water spray fitting

without roof without roof

Item

Description

1 2 4 5 6 7 8 10 11 12,13

Substructure cpl.

Impact roll cpl.

Crusher housing cpl.

Drive cpl.

Drift cpl.

V-belt protecting cover cpl.

Protecting cover cpl.

Hydraulical height adjustment cpl. (not drawn) Central lubrication cpl. (not drawn) Type shield with fastening elements (not drawn)

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Weight (kg) 6745,00 3784,00 2285,00 520,00 825,00 954,00 41,00 62,50 6,00

25

Technical description Crusher housing and substructure The housing of the crusher plant and the substructure 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.

There is a device for a customer sided water spray system at the crusher housing (see Figure 7).

Impact roll

Height adjustment

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.

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 either by a hydraulic pump (hand pump) or by valves.

The roll height adjustment will be realized by the customer.

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

Figure 8: Impact roll 32Nm Torque

without V-belt pulley

300Nm Torque

Detail X

26

1 2 3 9 10 14 17 20 26

Impact roll Crusher shaft Bearing housing Spacing plate 40mm Spherical roller bearing Tensioning nut Cone grease nipple Clamping element Spacing plate 20mm For parts not listed here, please refer to the spare part list supplied

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Impact heads We recommend using the following impact heads: Impact elements manufactured from wear resistant material. They are fastened to the impact roll with a thread bolt and a hexagonal nut.

The impact heads can be turned and re-used when they are worn onesided.

Figure 9: Impact head Torque = 7700Nm

Impact roll

1 2 3

Impact head Thread bolt Hexagonal nut

Important!

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

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27

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 can be pressured by a hydraulic pump or by valves.

Pressure fluid is oil (customer sided face hydraulic).

The roll height adjustment will be realized by the customer. Included in delivery are only the hydraulic cylinders and the fastening elements.

Important!

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

Figure 10: Hydraulical roll height adjustment

Roll adjustment

Fitting "A"

Tensioning the V-belts

Fitting "B"

1 2

Hydraulic cylinder (roll) Hydraulic cylinder (V-belt) For parts not listed here, please refer to the spare part list supplied

Important!

The hydraulic cylinders for tensioning the V-belts are located in this component (Roll height adjustment) also. How to tension will be described in chapter 6 "Operation - Tensioning the V-belts"!

28

Object-No.: 55278500000000

Roll Drive and drift The impact roll of the crusher plant will be driven by an electric motor with V-belt drive.

The V-belt pulley of the motor is fastened to the crusher shaft with a clamping element.

The roll drive is covered with a protection cover.

Figure 11: Roll drive

Assembly dimension

1 2 3

Motor console V-belt pulley Clamping element For parts not listed here, please refer to the spare part list supplied

The V-belt pulley of the impact roll is fastened to the crusher shaft with a clamping element. This clamping element transmits the torque.

Crusher centre

Figure 12: Drift

Torque=270Nm

1 2 3 4 5 6 7

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V-belt pulley Washer Clamping element O-Ring O-Ring Hexagonal bolt Locking plate

29

The belt drive of the impact roll is covered with a protection cover. For tensioning the V-belts, the drive will be moved with a hydraulical tensioning device.

Important!

Find more information for tensioning the V-belts in chapter 6 "Operation Tensioning the V-belts"!

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 13: Central lubrication

Right

Left

1 2 6

Connecting piece Cone grease nipple 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"!

30

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

Pitch

Tightening torque

(mm)

(mm)

d

P

8.8

10.9

MA(Nm) 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

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

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)!

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

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31

Permissible media Lubricating greases Properties

Base: NLGI-class: Penetration: Attitiude in the presence of water: Temperature of application:

Lithium soap 2 265 to 295 (0,1 mm) practically non-soluble -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 lubricant type used as 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:

Customer sided face hydraulic (viscosity depends on the temperature of environment)

Important!

The roll height adjustment will be realized by the customer!

Observe the respective operating manuals of the manufacturers!

32

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Recommended hydraulic fluids

Description acc. DIN51519 ISO-viscosity class

VG 46

Company denotation

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

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

Admissible temperature range in oil tank

from 30°C - 40°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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33

34

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6

Operation

35

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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. motors etc.

Before commissioning Execute the following work before commissioning: 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.

Pay attention that you have visual contact between the operating field and the crusher plant.

Check the cooling of the electric mototrs.

Check the direction of rotation of the electric motors.

Check the electrical connections.

Check the function of the electrical plant, especially the EmergencyStops switches.

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.

Object-No.: 55278500000000

37

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

operation

switch off

emergency stop switch

38

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.

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

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

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.

All drives must stop immediately.

Object-No.: 55278500000000

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!

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.

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.

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39

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: - Belt drive at the roll dirve - Belt drive - motor 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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Object-No.: 55278500000000

Roll height adjustment The roll height adjustment will be realized by the customer.

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 (one time 40mm and two times 20mm = 80mm total).

There are two hydraulic cylinders. They will be fastened at the impact roll (piston rod at the bearing housing, piston base at the pan).

Pressure fluid is oil / face hydraulic.

Important!

The impact roll is in neutral position (lowest position) when BOTH spacing plates of 20mm and ONE spacing plate of 40mm are located ABOVE the bearing housing. TWO spacing plates of 40mm thickness are located UNDER the bearing housing (see figure 15)!

Notice!

The both spacing plates 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. The hydraulic cylinders can be pressured either by a hydraulic pump or by the customer sided face hydraulic. Lowering is analogous (see figures 14 and 15).

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 fastening borders at the crusher housing.

Figure 14: Fastening borders

Fastening borders on both sides

Loosen the screw connections between crusher housing and bearing housing. For this the tensioning nut must be loosened (see operating manual from P&S in the annex). 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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41

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 inflow of hydraulic oil to the cylinders must be controllable. So, the uneven weight distribution can be compensated.

Lower the impact roll slowly.

The flow of hydraulic oil out off the cylinders must be controllable.

Take care that the impact roll does not cant while lowering.

Fasten the bearing housing. Necessary torque = 32Nm. 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.

Retighten the belt drive.

Perform a test run.

(Figure 15: Roll height adjustment on the next page)

42

Object-No.: 55278500000000

Figure 15: Roll height adjustment 2,3 1

Attention!

Here shown with one spacing plate of 40mm thickness under the bearing housing; In fact TWO spacing plates of 40mm thickness must always remain under the bearing housing!

1 2 3

Spacing plates (20mm and 40mm thickness) Threaded rod Tensioning nut

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!

Object-No.: 55278500000000

43

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. motors, hydraulic components etc.!

Danger!

When working at the electrical equipment the plant must be shutoff 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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Object-No.: 55278500000000

Check safety devices for completeness and damage and replace them if necessary Substructure with pan, crusher housing

Impact roll

Impact head

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

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

Check impact heads for tight seat, completeness and wear. Replace the impact heads when the wear limit of 20mm has been reached (see "Changing the impact heads")

X

X

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.

Drive, drift, protecting covers

X

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

Check all fastening screws for tight seat, retighten loose screws and replace missing ones Hydraulic components Visual inspection of all components. Check that: Height adjustment, - hoses are not pinched or trapped. lubrication - 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.

Lubrication 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

Object-No.: 55278500000000

in standstill

in operation

every 8 hours resp. daily

Maintenance work

every 50 hours

Component

every 200 hours

Maintenance acc. to schedule

X

X

X

X X

X

X

X

X

45

Lubrication Component

Quantity of lubricating points

Bearings, impact roll

2

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

Figure: 16: Lubricating points

Grease nipple

Grease nipple

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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Object-No.: 55278500000000

Changing the impact heads Notice!

The impact heads must be replaced at the latest when the wear limit of 20mm has been reached (see figure 17)!

Danger!

When replacing the impact heads the crusher plant must be lockedout and secured against restarting!

Warning!

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

Warning!

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

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

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

Notice!

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

Warning!

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

Figure 17: Impact head, wear limit

Wear limit

Hexagonal nut Torque M = 7700Nm Threaded bolt

Impact head

Object-No.: 55278500000000

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Tensioning the V-belts The V-belts will be tensed with the hydraulic cylinders and a hydraulic pump respectively with the face hydraulic.

Danger!

When checking the V-belt tension the crusher plant must be shutoff and secured against restarting!

Warning!

The impact roll runs over for a few minutes after shut-off!

Important!

For checking the V-belt tension the provided cover at the V-belt protecting cover must be opened (see figure 18)!

Warning!

Operating the crusher plant without assembled protecting cover is not allowed. The covers for checking the V-belt tension and the doors must be closed and locked. The covers must be assembled also (see figures 18 and 19)!

Important!

Observe the tightening torques of the screw connections!

Figure 18: V-belt protecting cover with closed doors Cover at the protecting cover for checking the belt tension

Figure 19: V-belt protecting cover with opened doors

Left door

48

Cover (must be dismantled for tensioning and releasing the V-belts)

Top cover (must be dismantled for changing the V-belts when the roll is in its heighest position) Right door

Object-No.: 55278500000000

Aligning and tensioning the V-belts is to be made as follows (observe figures 19 and 20): Open and lock the left door at the V-belt protecting cover.

Remove the cover.

Loosen the four screws (1) for approx. 2 to 4mm.

Loosen the hexagonal nuts (2 and 3).

By giving pressure to the cylinder fitting A the piston rods extend. By moving the motor console the V-belts will be tensioned.

If the desired tension is reached (pay attention to manufacturer notes!) the screws (1) have to be tightened again.

Anew check of the V-belt tension. At correct tension the counter nuts (2) have to be tightened again. At incorrect tension the V-belts have to be tensioned once more.

Finally take the pressure from the cylinders.

Assemble the cover.

Close and lock the left door at the V-belt protecting cover.

Figure 20: V-belt tensioning device

X

2

3

Releasing 1

Tensioning Fitting A

1 Fitting B

View X

1

Object-No.: 55278500000000

1

49

Changing the V-belts Danger!

When changing the V-belts the crusher plant must be shut-off and secured against restarting!

Warning!

The impact roll runs over for a few minutes after shut-off!

Changing the V-belts is to be made as follows (observe figures 19 and 20): Open and lock the two doors at the V-belt protecting cover.

Remove the cover (if the roll is in its heighest position the top cover must be removed also).

Loosen the four screws (1) for approx. 2 to 4mm.

Loosen the outer hexagonal nut (2) up to the bolt end.

By giving pressure to the cylinder fitting B the piston rods retract. By moving the motor console the V-belts will be released and can be removed.

Pull over new V-belts and tension them (see "Tensioning the Vbelts").

Assemble the cover(s).

Close and lock both doors at the V-belt protecting cover.

Warning!

It can be dangerous when dismounting and pulling over the V-belts if hands come between the V-belts and the V-belt groove!

Notice!

Check the V-belt tension at the latest after 4 operating hours and retension it if necessary!

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Object-No.: 55278500000000

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 elements cpl. (Order-No. 55272733000000) Lubricant Tools (above all torque wrenches)

Object-No.: 55278500000000

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