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Raptor XL1100 Instruction Manual

July 2008

ECT000-0176 - Rev. B

XL1100 Cone Crusher Safety Section 1 - Installation Section 2 - Operation Section 3 - Maintenance Section 4 - Lubrication System Section 5 - Hydraulic Systems XL1100 Cross Section with Component Call Outs Index

ECT000-0176 - Rev. B - 07/08

ECT000-0176 - Rev. B - 07/08

Important FLSmidth Excel Contact Information Automation Related Questions

Sean Nelson

Office: (262) 968-9095 Ext. 108 Cell: (262) 951-1081 [email protected]

Engineering/Technical Related Questions

Joe Martinez

Office: (262) 968-9095 Ext. 102 Cell: (262) 951-8618 [email protected]

For a Quotation or to Place an Order

Ken Klemens

Office: (262) 968-9095 Ext. 114 [email protected]

Service Related Questions

Chris Wade

Office: (309) 353-9235 Ext. 260 Cell: (309) 267-9233 [email protected]

Shipping Related Questions

Bob Grinslade

Office: (309) 353-9235 Ext. 169 [email protected]

Warranty Information

Joe Martinez Chris Wade 24 Hour Emergency Support Hotline (309) 202-8300

ECT000-0176 - Rev. B - 07/08

ECT000-0176 - Rev. B - 07/08

Safety General Safety Instructions................................................................................................................ S-2 Slip and Trip Hazards............................................................................................................................ S-2 High Pressure Hydraulics/Gas Charged Accumulator................................................................... S-3 Clearing the Crusher Cavity................................................................................................................ S-3 Lifting and Moving Heavy Components.......................................................................................... S-4 Flying or Falling Objects...................................................................................................................... S-4 Confined Spaces................................................................................................................................... S-5 Respiratory Concerns.......................................................................................................................... S-5 High Noise Levels.................................................................................................................................. S-5 Crusher Control System Operating and Safety Interlocks........................................................... S-6 General Housekeeping........................................................................................................................ S-7 Proper Training and Indoctrination . ............................................................................................... S-7

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General Safety Instructions This Instruction Manual discusses only the basic safety concerns related to the operation and maintenance of the Raptor XL1100 Crusher. As with all machinery with moving components, attention to personal safety is of the utmost importance. The Raptor XL1100 Crusher is designed with safety factors in mind, with respect to structural steel, high pressure hydraulic components, electrical components, and drive components. All moving parts or potential pinch points are provided with guards. FLSmidth Excel provides all of the static and dynamic load requirements, as well as the clearance dimensions necessary to design a safe and sound platform for the operation and maintenance of the Crusher. The actual installation of the Crusher with respect to plant layout is the responsibility of the customer or agents of the customer. The Safety Section of this Instruction Manual is not to be construed to supersede any of the safety policies of the customer and applicable government agencies. Instead, the safety topics and recommendations should only be regarded as an aid in assisting the customer to write their own safety procedures pertaining to the operation and maintenance of the Raptor XL1100 Crusher. There are specific safety concerns related to the operation and maintenance of the Raptor XL1100 Crusher, and FLSmidth Excel has outlined these concerns in the following paragraphs. Moving Components and Potential Pinch Points: As with all mechanical equipment with exposed movable components, workers must be made aware of the dangers and adequately protected from these dangers. Following is a list of areas that must be guarded: • The Raptor XL1100 Crusher requires the gyrating motion of the Head Assembly in conjunction with the Bowl Assembly to provide the forces necessary to crush rock. The Crusher cavity of the Raptor XL1100 Crusher is large enough for a worker to fall into. Needless to say, the areas above the Crusher must be guarded against the possibility for someone to fall into the crushing cavity. • Drive power to the Crusher is normally transmitted from an electric motor through a jack shaft assembly with drive sheave, drive V-belts, and a driven sheave. This entire area of power transmission must be guarded to protect workers from accidentally falling into or placing a limb into pinch points of the drive arrangement, or against high speed rotating elements. As FLSmidth Excel is normally not involved in the layout of the Crusher drive, the manufacture

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and installation of the appropriate guarding is usually the scope of the customer or agents of the customer. Occasionally the electric motor is directly coupled to the Crusher. In this case, the worker must be protected from high speed rotating elements. • The Hydraulic Adjustment Mechanism operates with a series of four rotating pinions and one large ring gear. These areas have guards to protect workers hands. An alarm should sound to warn workers whenever the adjustment mechanism is about to be actuated. Workers must be instructed to stand clear. • Crushing activity can result in the rapid vertical movement of the Crusher Adjustment Ring Assembly, with motion as great as 5.22” (133 mm), during a major tramp iron event. Work platforms about the Crusher and overhead feed chutes must be designed to take this factor into consideration. Workers must be made aware of the potential for sudden, rapid movement of the Adjustment Ring during crushing operations. Note: A tramp iron event is when a large, uncrushable object passes through the crushing cavity. • Ensure that all guards are mounted in their proper position prior to operation of the Crusher. • Though proper guarding should protect the individual worker, it is still important that workers do not wear loose fitting clothing, ties, and rings, or have exposed long hair that can get caught up in machinery. Local safety procedures will apply in all instances.

Slip and Trip Hazards Working around a rock Crusher can present a number of potential slip and trip hazards. Rock spillage can cause slip and trip hazards. Oil leaks, from either the hydraulic system or the lubrication system, can cause slip hazards. During liner changes and other maintenance activities, it is frequently necessary to climb down into the internal area of the Crusher for maintenance and clean up. The interior of the eccentric assembly and the gear well areas will be wet with lubricating oil, which presents a serious slipping hazard. • Clean up all oil spills that may drain off on major Crusher components that have been removed from the Crusher or that may have developed from system leaks. • Use particular care when entering the oil wetted areas of the Crusher. Also, use care in keeping this area clean.

ECT000-0176 - Rev. B - 07/08

• Part of the maintenance procedure at every liner change is to clean the old grease from the Adjustment Ring Assembly threads and the Bowl Assembly threads. Ensure that this grease is collected and disposed of properly.

• Hydraulic oil is very flammable. Special care must be taken when doing hot work about the Crusher. It is imperative that the hydraulic power unit be electrically isolated, locked out, and all hydraulic circuits dumped of pressure.

• Rock spillage can occur about a Crusher. Ensure that spillage is cleaned up promptly to eliminate potential slip and trip hazards.

• The local control panel for the Hydraulic Power Unit has a red “panic” button type switch, that can be used to deenergize the hydraulic system in the event of major leak or fire. Workers must be instructed concerning the location and function of this switch. At no time should this switch be used as the means of electrically isolating the Hydraulic Power Unit for maintenance purposes.

• Wet Crusher feed conditions and excessive dust suppression water sprays can cause wet fines to accumulate on walkways. Wet fines tend to be very slippery, so this condition should be guarded against.

• Only workers trained in the maintenance and operation of the Raptor XL1100 hydraulic system should be allowed to work on the system.

High Pressure Hydraulics/ Gas Charged Accumulator The Raptor XL1100 Crusher uses an FLSmidth Excel supplied Hydraulic Power System, with hydraulic oil pressure up to 3,000 psi (204 bar). The hydraulic system maintains consistent crushing forces, allows for release of the crushing forces during a tramp iron event, provides clearing (lifting of the Adjustment Ring) when the Crusher is stalled with a full cavity, provides clamping forces to keep the Bowl Assembly from rotating during crushing, and provides Crusher adjustment as necessary by rotating the Bowl Assembly within the Adjustment Ring Assembly. The tramp release system uses a series of nitrogen charged accumulators to absorb the energy involved in vertical movement of the Adjustment Ring during a major tramp event and uses this stored energy to return the Adjustment Ring to the normal crushing position. The Raptor XL1100 Crusher operates with a lower pressure, high volume lubrication system that incorporates pressure relief valves, a filtration system, and either water or air heat exchangers. Crusher workers must be instructed to be aware of the following potential dangers: • Oil under high pressure presents a considerable danger when accidentally released by maintenance personnel. Workers must be instructed to electrically isolate and lockout the hydraulic power system and dump the hydraulic pressure whenever maintenance is to be carried out on the system.

• Only workers trained in the maintenance of these pressure vessels should be allowed to work on the nitrogen charged accumulators. • The lubrication system must be shut down, electrically isolated, and locked out whenever maintenance work involves removing the Crusher Head Assembly or working on the lubrication system by itself. This is particularly important when the lubricating oil is to be changed out. • Workers must be fully trained in the maintenance and operation of the Raptor XL1100 lubrication system.

Clearing the Crusher Cavity It is possible that the Crusher may stop (stall) while under load. This is normally due to power bumps or outages, or an uncrushable object that wedges into the crushing cavity. The Raptor XL1100 Crusher has a Cavity Clearing function that is designed to allow for the easy removal of rock product or tramp material, in the event that the Crusher stops with material in the crushing cavity. The clearing function works with the Hydraulic Power Unit and as such, dumps the Tramp Release Pressure and uses hydraulic jacks (Clearing Cylinders) to lift the Adjustment Ring and Bowl Assemblies to increase the clearance (gap) between the Bowl Liner and the Mantle on the Head. This increased clearance should allow material in the crushing cavity to fall through. The procedure for clearing the Crusher is described in the Operations portion of this instruction manual. Refer to Section 2

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Clearing a Crusher presents potential safety hazards that workers must be made aware of. Safety concerns relating to clearing a Crusher cavity are: • Workers must be aware that a Cavity Clearing cycle will result in the Adjustment Ring being lifted approximately 5.22” inches (133 mm). • Workers will have to have safe access to visually look into the crushing cavity to verify that the crushing cavity is clear. • It may be necessary to support the Adjustment Ring and Bowl Assemblies with safety blocks that are included in the Crusher Tools Assembly. • It is possible that an item of tramp metal will be so large that it cannot be released in a Cavity Clearing cycle. In this case, it will be necessary to mechanically hook the metal and pull it out with an overhead crane, or burn (reduce in size) the object with an oxy-acetylene lance or magnesium rod burning bars. Detailed procedures for carrying out a Crusher Clearing cycle are described in the Operations Section of this instruction manual. It is highly recommended that a crushing plant site have a written safety procedure to address the removal of tramp material.

Lifting and Moving Heavy Components The Raptor XL1100 Crusher has a number of very heavy assemblies that must be removed and installed during the change out of wear liners, and other maintenance routines. Crusher workers must be instructed about the following heavy lifting concerns: • The weights of major Crusher assemblies are listed in the Raptor XL1100 Instruction Manual as well as in the Parts Manual supplied with the Crusher. The weights of individual piece parts that make up a Crusher assembly are only found in the Parts Manual. • FLSmidth Excel supplies a Tool Assembly specifically designed for the installation and maintenance of the Raptor XL1100 Crusher. Often, there is only one Tool Assembly per group of Crushers supplied. This Tool Assembly has all of the lifting fixtures and

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specifically sized ring bolts necessary to maintain the Raptor XL1100 Crusher. Workers must be made aware of the importance of keeping the tools in an environmentally protective and secure storage area. • Trained riggers and crane operators along with suitably sized lifting capacity and rigging must be available when major Crusher maintenance is undertaken. • Most of the major components of the Raptor XL1100 Crusher are made up of machined castings. The actual weights shown are nominal weights determined by engineering methods. As castings, the actual weights can be considered to vary by as much as ±5%. • Many pieces that make up the various Crusher assemblies are at, or just over, what would be considered safe weight for a worker to lift. Again, workers must be instructed to check with the Parts Manual to determine the actual weight of the piece and to use proper lifting procedures. Weight lifting restrictions are the responsibility of the customer’s safety program and governmental agencies and are thus not addressed in this manual.

Flying or Falling Objects Gravity is used to introduce rock into the Crusher cavity. Overflow, worn chutes, or other possibilities for spillage can cause falling rock to present a safety hazard. Crushing action can cause rock to be ejected from the crushing cavity, particularly as rock is first being introduced into the cavity. • A safety skirt, normally of flexible rubber, is to be mounted between the feed chute and the Crusher feed hopper to keep rock from being ejected out or from spilling out if the Crusher cavity becomes overfilled. This ejected or falling rock can present a serious safety hazard, if allowed to happen. The rubber skirt will also serve as part of the system to control fugitive dust from the Crusher. The skirting is part of the feed chute arrangement and is not part of the scope of supply for the Raptor XL1100 Crusher. • Spillage can accumulate on a lower deck and present slip and trip hazards for workers. Good housekeeping is absolutely essential for safe Crusher operations.

ECT000-0176 - Rev. B - 07/08

• As crushing systems often involve a gravity flow design with pre and post screening applications, it is not uncommon to have one or more decks above and below the Crusher. Workers must be aware of any time people are working above them and likewise, any time people are working below them. Work should be coordinated to eliminate the potential for dropped tools and parts, areas under workers cordoned off, or adequate overhead protection should be provided.

Confined Spaces The discharge area under the Crusher is normally considered a confined space and should be treated as such. As routine maintenance procedures require the visual inspection of the underside of the Crusher, the Crusher lubrication lines, and the discharge cavity, the following concerns must be addressed: • Confined space work permits and procedures must be utilized whenever maintenance work is to be carried out under the Crusher or in the discharge cavity. • Electrically isolate and lockout the Feed Conveyor to the Crusher, the Crusher and the Discharge Conveyor. • The discharge area must be designed in such a way as to provide safe and easy access to the area under the Crusher. This is always an engineering challenge as the discharge area must be designed to eliminate spillage and allow for adequate dust control.

Respiratory Concerns The comminution of rock (crushing) produces rock dust. Rock dust is often fine enough to be carried into the lungs during normal breathing. All rock dust presents some health hazards, with some rock presenting especially serious health hazards. It is the responsibility of the customer to provide a system to control the escape of respirable rock dust or to provide personal protective equipment to protect the workers. Working on or about the Crusher also requires welding, thermal cutting, and the use of chemical reagents, all of which can present respiratory issues. Following are concerns that must be addressed: • When the Crusher is installed, areas about the Crusher mounting flange and about the Crusher countershaft

must be sealed up to prevent the escape of fugitive rock dust. The area about and between the feed chute and the feed hopper of the Crusher should also be sealed. FLSmidth Excel service technicians will be present during the installation of the Crusher to assist the customer or the customer’s agent in how to best seal up these areas. • Vacuum type dust collections systems and moisture type dust suppression systems should be programmed to interlock with the Raptor XL1100 Crusher Automated Control System as provided by FLSmidth Excel. • Water type dust suppression systems must be designed to not provide too much moisture that could effect the operation of the Raptor XL1100 Crusher. Too much moisture tends to cause Crusher product fines to stick to the Head Assembly, and this can lead to ring bounce. Too much moisture can also lead to crushed product material build up on the arms and in the discharge cavity, which can lead to serious damage to the Crusher. • Often the true seriousness of a dust control problem cannot be determined until after the Crusher has been in operation for a short period of time. Therefore, it is often necessary to over design for dust control system to insure proper control at the onset of crushing. • Working in the discharge area of the Crusher may agitate (kick up) respirable dust. • The epoxy based backing compound used with the Raptor XL1100 Crusher wear liners has a caustic agent that is both caustic by skin contact and by respirable fumes. Adequate personal protective equipment and ventilation is necessary when working with these chemicals.

High Noise Levels The very nature of crushing rock generates a high decibel level of noise. The actual noise generated is determined by the type of rock being crushed, the amount of energy being put into the rock, and the type of structure that the Crusher is mounted on. Typically, the decibel readings will be found to be in the 85 to 105 dB range. As it is very difficult to abate this noise from the area around the Crusher, it is often necessary to require the use of noise protection devices for workers. Following are some concerns:

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• The actual noise generated by a Raptor XL1100 Crusher will have to be determined by measurement during normal crushing operations. The customer will then have to determine what personal hearing protection is required for the worker, as well as what time exposure limits may have to be put in place. • Exceeding the Crusher force limits for the Raptor XL1100 Crusher will generate extremely high noise levels. Therefore, it is incumbent upon the operators to operate the Crusher within the design limitations. FLSmidth Excel has a system of accelerometers mounted on the Crusher adjustment ring that alert the operator to periods when the crushing forces are being exceeded (ring bounce).

Crusher Control System Operating and Safety Interlocks The Raptor XL1100 Crusher comes with an Automated Control System (ACS) that monitors the vital signs of the Crusher, as well as assists in operating the Crusher within the design limitations. Altering or isolating (jumper out) the interlocks of this system not only affects the mechanical well being of the Crusher, it can seriously effect the safety of the workers about the Crusher. • Never make changes to the Automated Control System without prior approval of FLSmidth Excel. • If it becomes necessary to make temporary changes to the Automated Control System and FLSmidth Excel cannot be contacted in a timely manner, ensure that approval has been provided by local mine operational and safety management, and that any changes are well documented. Tools used to maintain the Raptor XL1100 Crusher: Many components that make up assemblies of the Raptor XL1100 Crusher are assembled with interference fits. Therefore, maintenance workers will be required to use open flame and/or cryogenic agents in the installation and removal of various parts. Following is a list of safety concerns: • Open flames present obvious safety concerns for the workers. Because some parts have to be heated rapidly and thoroughly, it is important that more than one heating torch is used at the same time (two torches, two workers). It is imperative that workers be trained in the safe use of open flame heating devices.

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• Liquid nitrogen and dry ice are commonly used to chill components for assembly. Working with cryogenics presents unique safety hazards, and workers must be trained in the safe use of these agents and appropriate personal protective equipment. • Air impact tools are frequently used for assembly and disassembly work. Because of the size of the fasteners, these tools are frequently large and cumbersome. Workers need to be trained in the proper use of these compressed air tools. • The air impact tool is frequently used to turn jacking bolts that remove interference fit parts. In this case, it is important the part be removed as rapidly as possible, before heat can soak into the mating part. It is advisable that more than one person be assigned to a tool, so that the tool can be utilized without excessive fatigue to an individual worker. • Workers are to be trained in the standard safety practices with respect to the use of compressed air and compressed air tools. • Some fasteners used in the Raptor XL1100 Crusher require high torque values to establish proper preload. These high torque values can require the use of torque multipliers. Workers need to be trained in the safe utilization of these tools. • It is common to have to weld on feed and discharge chutes about a Crusher, as well as to weld lifting rings (D-rings) to Crusher wear materials to facilitate lifting the components into position. The Maintenance Section of this Instruction Manual lists specific cautions with respect to welding to manganese and high chrome white iron wear materials. • Under no circumstances should any welding be done on the actual cast components of the Crusher. Though such welding does not present any particular safety hazard, the high carbon steel alloy of these castings can be seriously compromised by improper welding techniques. It is imperative that FLSmidth Excel be contacted before any such welding be undertaken.

ECT000-0176 - Rev. B - 07/08

General Housekeeping Though housekeeping concerns have been mentioned with respect to Slip and Trip Hazards above, it is still important to reiterate this concern: • Always correct the causes of spillage as they occur, and clean up spillage as soon as possible. • Clean up all oil spills or other types of spills that would result in slip hazards. • Pick up and put away tools, cable rigging, wash down water hoses, air pressure hoses, and acetylene torch equipment immediately after they are used.

Proper Training and Indoctrination As working with the Raptor XL1100 Crusher presents many unique safety issues as described above, it is very important that workers receive proper hazard awareness training relating to these issues. Following are topics of job specific training: • All workers should become familiar with the general operation and maintenance of the Crusher. • Workers must be made aware of the specific safety hazards related to working about the Crusher. • Workers need to be trained in the safe use of tools and materials used in the maintenance and operation of the Crusher. As mentioned at the onset, this Section on Safety is only to be utilized as a guide to assist the customer in developing their own safety program with respect to working on and about the Raptor XL1100 Crusher. Any questions and concerns related to the safe operation and maintenance of the Crusher should be directed to the Engineering and Sales Department of FLSmidth Excel, located at: FLSmidth Excel Engineering and Sales Office 543 A. J. Allen Circle, Suite B Wales, Wisconsin, 53183, USA Phone: 1-262-968-9095 Fax: 1-262-968-9112

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ECT000-0176 - Rev. B - 07/08

Section 1 Installation Introduction........................................................................................................................................... 1-3 Initial Inspection.................................................................................................................................... 1-3 Installation Drawings Furnished........................................................................................................ 1-3 Foundation............................................................................................................................................. 1-3 Crusher Clearance Dimensions........................................................................................................... 1-3 Feed Arrangement................................................................................................................................ 1-3 Incorrect and Correct Feed Arrangement Figure 1-1.................................................................... 1-4 Discharge Arrangement....................................................................................................................... 1-4 Crusher Components and Sub-Assembly Weight .......................................................................... 1-5 Special Tool Required for Component Handling............................................................................. 1-5 Crusher Drive Motor.............................................................................................................................. 1-5 Raptor XL 1100 Lifting Weights Table 1-1..........................................................................................1-6 Tools Assembly Figure 1-2.................................................................................................................... 1-7 Tool Use Table 1-2.................................................................................................................................. 1-8 V-Belt Drives ..........................................................................................................................................1-9 V-Belt Types Figure 1-3......................................................................................................................... 1-9 Jackshaft Drive...................................................................................................................................... 1-9 Jackshaft Configuration Figure 1-4................................................................................................. 1-10 Main Frame Installation on a Concrete Foundation ................................................................... 1-10 Sole Plate Method............................................................................................................................... 1-10 Lifting Main Frame Assembly Figure 1-5......................................................................................... 1-10 Epoxy Grouting Requirements Table 1-3........................................................................................ 1-11 Full Main Frame Grout Method . ...................................................................................................... 1-11 Crusher Grouting Figure 1-6.............................................................................................................. 1-11 Sole Plate Installation A Figure 1-7.................................................................................................. 1-12 Sole Plate Installation B Figure 1-8 .................................................................................................1-12 Crusher Main Frame Installation on a steel Structure ................................................................ 1-12 Arm and Countershaft Arm Guard Installation ............................................................................ 1-13 Eccentric Assembly Installation ...................................................................................................... 1-13 Eccentric Assembly Lifting Figure 1-9............................................................................................. 1-13 Backlash and Root Clearance Table 1-4........................................................................................... 1-14 Countershaft Cartridge Assembly Installation ............................................................................. 1-14 Countershaft End Float Figure 1-10................................................................................................. 1-14 Holding the Countershaft Box Figure 1-11..................................................................................... 1-15 Countershaft Assembly Installations Figure 1-12......................................................................... 1-16 Countershaft and Backlash Tool Figure 1-13................................................................................. 1-16 Optimal Contact Pattern Figure 1-14............................................................................................... 1-17 Installing the Clearing Cylinders....................................................................................................... 1-17 Contact Pattern Corrections Figure 1-15........................................................................................ 1-18 Installing the Adjustment Ring Assembly....................................................................................... 1-18 Installing the Accumulators.............................................................................................................. 1-18

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Clearing Cylinder Weld Figure 1-16.................................................................................................. 1-19 Adjustment Ring Assembly Lifting Figure 1-17.............................................................................. 1-19 Accumulator Depressurization Figure 1-18.................................................................................... 1-20 Installing the Tramp Release Cylinders........................................................................................... 1-20 Accumulator Mounting Figure 1-19................................................................................................. 1-21 Removing the Tramp Release Cylinders......................................................................................... 1-21 Tramp Release Cylinder Mounting and Support Figure 1-20...................................................... 1-22 Installing the Socket Assembly......................................................................................................... 1-22 Socket Mounting Figure 1-21............................................................................................................ 1-23 Checking Socket Contact Figure 1-22.............................................................................................. 1-23 Installing the Head Assembly . ......................................................................................................... 1-23 Socket Liner Lifting Figure 1-23........................................................................................................ 1-24 Socket Assembly Figure 1-24............................................................................................................. 1-24 Installing the Adjustment Mechanism Assembly ......................................................................... 1-24 Feed Plate Assembly Figure 1-25...................................................................................................... 1-25 Drive Ring Support Figure 1-26......................................................................................................... 1-25 Adjustment Drive Assembly Installation Figure 1-27................................................................... 1-26 Adjustment Cap Centering Figure 1-28........................................................................................... 1-26 Bowl Assembly Installation............................................................................................................... 1-26 Root Clearance Figure 1-29................................................................................................................ 1-27 Lube System Placement and Installation....................................................................................... 1-27 Package Lubrication System Placement and Installation........................................................... 1-28 Piping Information . ........................................................................................................................... 1-28 Crusher Air Breather and Blower..................................................................................................... 1-28 Lube Tank Location Figure 1-30........................................................................................................ 1-29 Air/Oil Cooler Assembly...................................................................................................................... 1-29 Water/Oil Heat Exchanger................................................................................................................. 1-29 Countershaft Box Blower/ Filter Assembly Figure 1-31.............................................................. 1-30 Air Cooler Assembly Figure 1-32....................................................................................................... 1-30 Oil Heater............................................................................................................................................... 1-30 Hydraulic Power Unit ....................................................................................................................... 1-30 Hydraulic Power Unit Installation.................................................................................................... 1-31 Remote Mounted Pushbutton Control Panel Installation ......................................................... 1-31 Crusher to Power Unit Hose Connections...................................................................................... 1-31

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ECT000-0176 - Rev. B - 07/08

Introduction This Section provides information for the proper assembly and installation of the various components that make up a Raptor XL1100 Crusher. Due to the size and weight of these components, several will arrive as pre-assembled components (sub-assemblies) such as: the Main Frame, Adjustment Ring, Countershaft, Eccentric, Socket, Head, and Bowl. FLSmidth Excel highly recommends that this manual as well as the Parts Manual be read before completing the assembly of the Crusher or carrying out any maintenance on the Crusher.

Initial Inspection A complete inspection is recommended as soon as possible following delivery of the Crusher. Look for any damage that might have occurred during transit. Also, verify that all “shipped loose” items listed on the Bill of Lading, Freight Bill, or Manifest are accounted for. Immediately notify the carrier and FLSmidth Excel of any damage or shortages.

Installation Drawings Furnished The following installation drawings and other data for your Crusher are provided in a separate package called the Installation Drawing and Data Package: • Weights • Clearances and Crusher template • Unbalanced forces and WR2 • Crusher mounting and clearance drawing • Package Lubrication System general arrangement drawing • Hydraulic Power Unit general arrangement drawing • Power unit hydraulic schematic drawing • Power unit electrical schematic drawing • Air blower mounting and clearance drawing • Index for field connections • P & ID drawing • Crusher oil piping • Soleplate installation • Air cooler and piping general arrangement

Foundation The Mounting and Clearance Drawing will provide anchor bolt locations in the foundation, drive motor location, and various clearances required to mount the Crusher onto the foundation and to maintain the Crusher. A durable, solid, and level foundation is critical to the sound operation of the Crusher.

Important: Information data sheets with Crusher foundation loads are available from FLSmidth Excel. The foundation must be designed to accept these loadings. Unless otherwise agreed to in the purchase contract, the customer is responsible for the design of the foundation.

Crusher Clearance Dimensions Success of the operation and maintenance of the Crusher relies on a well-planned installation. Crusher clearances must be considered when designing the Crusher installation. Clearance must be provided above the Crusher for the installation and removal of the Head and Bowl Assemblies. Clearance should also be provided for the feed equipment such as chutes, feed hoppers, conveyors, and other related equipment. Adequate area and safe access is also required for the removal of the Countershaft Assembly. There must also be adequate volume in the discharge area between the Crusher and the discharge conveyor. Refer to the Mounting and Clearance drawing along with the Dimensional Data Sheets available from FLSmidth Excel to determine the clearances required in designing your foundation.

Feed Arrangement Proper design of the Crusher feed arrangement is critical in maximizing the crushing circuit efficiency. This involves providing an adequate amount of feed material to the Crusher. It also requires that feed entering the crushing cavity be evenly distributed and well blended. Proper control of the feed material into the Crusher maximizes capacity, product size, and life of components. Inadequate amount of feed material will cause the Crusher to run underpowered, resulting in uneven distribution of forces across the internal journal surfaces and burnt or damaged bushings. FLSmidth Excel recommends that feed circuits for Crushers in Short Head applications be designed to provide a buildup of material above the Feed Plate (referred to as a “Choke Fed” condition). When possible, it is beneficial to run a Standard Crusher in this “choke fed” condition as well. Use of a level sensor is essential to properly monitor the feed level. The feed size should be thoroughly mixed and evenly distributed around the crushing cavity. Uneven feed distribution will result in oversize product, reduced capacity, and “ring bounce”.

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FIG 1-1

Incorrect Method of Feed

Correct Method of Feed

1. Feed Conveyer Figure 1-1

2. Source Bin

3. Hopper

Incorrect & Correct Feed Arrangement

Note: Ring bounce occurs when the actual crushing forces exceed the design crushing forces. When this happens, the Adjustment Ring lifts or bounces quickly on and off the Main Frame Seat Liners. Extended periods of “ring bounce” will damage the Adjustment Ring, Main Frame Seat Liners, Main Frame, and other associated Crusher components.

(called “Tramp”) before they get into the crushing cavity. Excessive amounts of tramp material passing through the Crusher causes ring bounce (exceeds the design crushing forces) and can damage Crusher parts. Tramp material entering the crushing cavity can also stall the Crusher drive motor and/or burn the drive belts.

A Feed Box mounted over the Crusher can serve as a backstop to slow the velocity of material entering the crushing cavity and ensure the material falls vertically onto the Feed Plate. A Feed Spout mounted in the Feed Box and centered over the Feed Plate will aid in achieving proper feed distribution into the crushing cavity. Refer to Figure 1-1

Discharge Arrangement

If more than 15% of the feed material is smaller than the Close Side Setting in Short Head Crusher application, or more than 20% of the Close Side Setting in a Standard Crusher application, it is recommended that a screen be placed ahead of the Crusher to scalp off fines. Excessive fines in the feed will result in ring bounce or a reduction in feed rate. Maintaining a low percentage of fines or wet, sticky material is essential in optimizing the performance of the Crusher. Improper feed conditions are one of the principal causes of Crusher breakdowns. Installation of a metal detector and/or belt magnet is recommended to remove any metallic non-crushable items

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The construction recommendations shown on the Mounting and Clearance drawing should be followed. Replaceable wear material should be used to line the discharge compartment. Within the compartment, a shelf or ledge should be incorporated to make a “dead bed” of rock product for the Crusher discharge material to fall on. The dead bed is designed to absorb most of the energy of the falling material as it cascades onto the conveying equipment, as well as provide a wear buffer between the discharge structure and the falling, crushed product. If a discharge chute is used, it must be positioned at an angle of 45° or greater from horizontal. Moist Crusher product may require that the chute angle be increased, or special, low friction chute liner material be used. As shown on the Mounting and Clearance drawing, adequate clearance is to be maintained between the

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discharge equipment and the Crusher. The proper amount of clearance will stop material from building up under the Crusher and causing excessive wear to the Counterweight or entering the Crusher and causing internal damage.

Crusher Components and Sub-assembly Weights The weights of the Crusher components must be considered in designing the Crusher installation. The Crusher will be shipped in sub-assemblies because of shipping and handling restrictions. Overhead lifting equipment such as cranes, chain hoists, a mobile crane, cables, slings, and shackles must be sized accordingly. These weights are provided by FLSmidth Excel in the Installation Drawing and Data Package, and are also found in the Assembly and Parts Manual. Quite frequently, local maintenance personnel will only have access to the Assembly and Parts Manual. The weights lifted are CAD generated nominal weights. Because the assemblies are built with major steel castings, it is possible that the weights may vary by ± 5%. The typical Crusher assemblies that make up the Crusher are shipped as follows: • Main Frame Assembly (includes the Main Shaft, Main Frame Liners, and Lower Thrust Bearing) • Adjustment Ring Assembly (including Clamping Ring) • Bowl Assembly (including Bowl Liner and Hopper Assembly) • Tramp Release Cylinder Assemblies • Counter Shaft Box Assembly • Adjustment Mechanism Assemblies • Eccentric Assembly (including Counterweight) • Socket Assembly • Head Assembly (including Feed Plate and Mantle) • Crusher Drive Sheave • Hydraulic Power Unit • Lubrication Package • Air Cooler Assembly Note: The Bowl and Hopper Assembly can have a significant amount of material build up that will increase the overall weight. This should be taken into account when planning the lift for these components. Note: Many of the Assemblies are broken down into subassemblies, the weight of which can be found in the Assembly and Parts Manual.

Special Tools Required for Component Handling A Tools Assembly (tool kit) that includes: ring bolts, lifting plates, jacking bolts, and fasteners is furnished with the Crusher. The illustration demonstrates the tools furnished and the various lifting devices used for lifting the various assemblies. Refer to Figure 1-2 Refer to Table 1-2

Crusher Drive Motor The drive motor will normally be a 1000 horsepower, squirrel cage, induction motor with a continuous duty rating. The normal starting torque should be approximately 125%, and normal breakdown torque should be approximately 200%, within an acceptable voltage variance of ±10%. It is highly recommended that the Crusher Drive Motor be equipped with a reduced voltage starter. To maintain a continuous, high horsepower level, an electric motor with a 1.15 service factor is required. If a motor with a service factor of 1.0 is used, the planned operating horse power should be reduced by approximately 15%, and this will significantly reduce the performance of the Crusher. Stator thermostats and abrasive resistant insulation are recommended. The motor can be open drip proof or totally enclosed fan cooled, though the TEFC motors are more durable in the abrasive applications most Crushers operate in. FLSmidth Excel offers a Jackshaft Assembly with Idler Tension arrangement. Refer to Jackshaft Drive Information If this Jackshaft Assembly is not used, then it will be necessary to have adequately sized slide rails under the Jackshaft Assembly base. This is necessary to maintain proper belt tension as the V-belts stretch and wear during operation. If a Direct Drive Motor is to be used, the motor must be designed to handle the vibration, axial thrusting, and peak torques that can occur in this type of operation. The motor supplier should contact FLSmidth Excel regarding gear mesh frequency and rpms for motor design. Selection of the coupling joining the motor to the Crusher requires special consideration as it relates to shock and vibration.

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1-5

Raptor XL1100 Lifting Weights Main Lifting Items

(lbs.)

(kg)



Complete Crusher Main Frame Assembly (Includes Main Shaft and Frame Liner)

338,130

153,370

119,000

53,980

Bowl Assembly, Bowl Liner and Hopper Assembly 73,650 Adjustment Ring (Includes Clamping Ring) 47,370 Head Assembly, Feed Plate Assembly and Mantle 40,750

33,410

Countershaft Box Assembly

6,920

3,140

Eccentric Assembly (Includes Counterweight)

20,960

9,510

Mantle

11,920

5,400

Bowl Liner

14,650

6,650

Power Unit Lube-Air

Dry 2,300 Wet 3,790

Dry 1,043 Wet 1,720

Dry 4,250 Wet 10,140

Dry 1,043 Wet 4,600

Lube-Water

Dry 4,000 Wet 9,890

Dry 1,810 Wet 4,490

6,000

2,720

Air Cooler Note: Allowable Casting Weights Vary ±5% Table 1-1

1-6

ECT000-0176 - Rev. B - 07/08

21,680 18,480

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

Washers Ring Bolts Hoist Rings Jack Screws Bowl Lifting Pin Thread Template, 75mm Pitch Safety Block Line-Up Stud Charging Assembly Head Lifting Plate Eccentric Lifting Ring Lock Nut Wrench Head Ball Lifting Plate

Figure 1-2 Tools Assembly

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1-7

1-8

ECT000-0176 - Rev. B - 07/08

ITEM(S)

CLEARING CYLINDER ASSY.

HYDRAULIC ADJUST PINION

DRIVESHAFT PLATE

BOWL (TO TURN BOWL OVER MINUS LINER AND ADJUSTMENT CAP)

BOWL ASSEMBLY

HEAD ASSY. (TO TURN HEAD OVER WITHOUT MANTLE AND FEED PLATE)

LOCKNUT WRENCH

DRIVE RING

GEAR

ECCENTRIC ASSEMBLY

ECCENTRIC (MINUS COUNTERWEIGHT)

ECCENTRIC BUSHING

COUNTERWEIGHT

CLAMPING RING

COUNTERSHAFT

THRUST BEARING (UPPER)

THRUST BEARING (LOWER)

MAIN FRAME PIN BUSHING

MAIN FRAME PIN

MAIN SHAFT

SOCKET

SOCKET LINER

LOCKING NUT

HEAD BALL

LOWER HEAD BUSHING

UPPER HEAD BUSHING

HEAD ASSY. (WITH MANTLE AND LOCKING NUT MINUS FEED PLATE)

MAIN FRAME ASSEMBLY

Tool Use for the Raptor XL1100

2 - M16 RING BOLT

1 - M16 RING BOLT

2 - M12 RING BOLT

Table 1-2

4 - LIFTING HOOKS ON ADJUSTMENT CAP 4 - LINE-UP STUDS

4 - HHCS M30 X 150

HEAD BALL LIFTING PLATE

1 - M64 HOIST RING

2 - M36 HOIST RINGS

4 - M100 RING BOLT

4 - M36 RING BOLT

2 - M36 RING BOLT

1 - M36 RING BOLT

2 - M30 RING BOLT

1 - M24 RING BOLT

4 - M16 RING BOLT

2 - M20 RING BOLT

2 - M10 RING BOLT

1 - M10 RING BOLT

2 - HHCS M20 X 260

2 - BOWL LIFTING PIN

3 - HHCS M30 X 140

ECCENTRIC LIFTING RING

4 - HHCS M30 X 100 item

HEAD LIFTING PLATE

V-Belt Drive Driving the Crusher is normally accomplished using a set of 8V-Belts, though other metric type V-Belts can be used as long as they have a power transmission service factor of approximately 1.8. The V-belts reduce shock loads from being transmitted to the Crusher drive motor and maintain torque limitations by being able to slip in extreme power load conditions. The use of a V-belt Drive allows for various combinations of Sheave (Drive and Driven) diameters in order to change the speed of the Countershaft to fit different application requirements. There are two types of FIG 1-3 belts available, single or banded. Refer to Figure 1-3.

environment, so wear becomes another factor to watch for. With the FLSmidth Excel provided Idler Tensioner Jackshaft Assembly, belt tension can be checked by visual indicators. Belt wear and sheave wear can cause the belt ribs to ride deep in the groove, and either touch the bottom of the sheave groove or the top of the belt band (webbing), if these are banded belts. When this occurs, it is time to change either or both the drive belts and sheave(s), as the ability to transmit power is seriously reduced. Mounting the motor Sheave below the Countershaft or within 45° of the vertical centerline will require a change in the position of the outer countershaft bushing oil groove. Contact FLSmidth Excel if the drive sheave is to be mounted below the Crusher sheave so that the outer Countershaft Box bushing can be installed correctly prior to shipment of the Crusher.

Jackshaft Drive Figure 1-3

V-Belt Types

Either type of belt can be used on a standard sheave. However, FLSmidth Excel recommends the use of banded belts, in that they reduce the chance of rollover or belt whip. For V-Belt installations that use the direct tensioning method, tensioning is achieved by sliding the motor and Jackshaft Assembly away from the Crusher sheave. In this case, it is important to use the method of belt tensioning prescribed by the belt manufacturers instructions. With the belt deflection method of tensioning, it is important not to use the maximum force recommended by the belt manufacturers, as this force may exceed the capabilities of the bronze sleeve bearings in the Countershaft Box Assembly. FLSmidth Excel recommends that the middle force (average of the maximum and minimum) specified by the belt manufacturer be used when tensioning the V-Belts. It is better to have to adjust the belts more frequently than it is to suffer the consequences of a burned outer Countershaft Box bushing. Belts adjusted too loose will cause belt slip and possible stalling of the Crusher. If the FLSmidth Excel self-tensioning Jackshaft Assembly is not being used, FLSmidth Excel recommends using slide rails or similar means of belt tightening. A new set of belts should have the belt tension checked after 8 hours, and again after 24 hours of operation. From that point, the belts tension should be checked once weekly. V-Belts and Drive Sheaves operate in an abrasive

In order to transmit the 1000 horse power (750 kW), plus power surges, it is necessary to apply very high tensioning forces to the drive belts. This would require an expensive drive motor with a special shaft and bearings to handle this load, if the Crusher drive shaft was to be mounted directly to the motor shaft. To reduce motor cost and increase reliability, the Raptor XL1100 can be supplied with a jackshaft arrangement, where the drive sheave is mounted on a shaft that is supported in two roller bearings and the shaft is coupled directly to the motor. The Drive Motor/Jackshaft Assembly available from FLSmidth Excel includes a V-belt tensioning idler pulley arrangement. Separate instructions for mounting the Jackshaft Assembly on the foundation, aligning the Drive Motor to the Jackshaft, and adjusting the V-belt tensioning Idler Pulley are provided by FLSmidth Excel. Refer to Figure 1-4 The Jackshaft/Idler Tensioner Assembly available from FLSmidth Excel provides a unique arrangement for setting and maintaining proper belt tension. An idler pulley applies force to the flat side of the V-Belts on the slack side (side of the belts not pulling). This force increases the wrap on the drive sheave (smaller sheave) and maintains uniform tension to the drive belts. The force is achieved through two lever arms and coil springs compressed to a specific setting. The increased wrap on the drive sheaves significantly reduces the belt tension necessary to transmit the horse power, resulting in increased Countershaft bushing and Jackshaft bearing life.

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1-9

properties required to withstand the forces generated by a Raptor XL1100 Crusher. Epoxy grouting is a tough, vibration resistant, and resilient material with higher compressive strength. It requires less preparation, and typically is faster to pour than concrete grouting.

FIG 1-2

Sole Plate Method When using the sole plate method on an old foundation, the concrete foundation must be cleaned, and all oil soaked or deteriorated (cracked or otherwise compromised) concrete must be removed. In a new installation, or where the existing foundation is sound, it is best to chip out a pocket in the concrete to a depth of approximately 74mm and of an area to allow the sole plate to be set into the pocket with 20mm of clearance at the perimeter of the sole plate. The sole plate should be supported on 30mm of grout and the perimeter will be horizontally supported with grout to the top of the concrete. This will eliminate the necessity for grout dams, unless the external perimeter of the discharge pocket meets or intersects the internal perimeter of the sole plates. Refer to Figure 1-7

FIG 1-4 1. Crusher Sheave 2. Idler Pulley Figure 1-4

3. Motor Sheave 4. Drive Motor

45 MAX. TYP.

Jackshaft Configuration

Main Frame Installation on a Concrete Foundation There are two acceptable methods of installing the Raptor XL1100 Crusher to a concrete foundation. FLSmidth Excel recommends that sole plates be grouted in pockets on the concrete foundation, and that the Crusher then be set on these sole plates. There are machined pads on the bottom of the Crusher mounting flange. FLSmidth Excel offers sole plates that will match the machined pads on the bottom of the Crusher. Refer to Figure 1-6 The second method of mounting a Crusher to a concrete foundation involves supporting the entire bottom flange with a grout interface between the concrete and the steel. This method requires a special, high strength epoxy grout that more or less “pots” the Crusher in the grout, that in turn adheres to the concrete foundation. This method requires extensive use of dams and expansion joints. It also requires a large volume of grout, and may require that the grout be poured in sequential lifts. In all cases, FLSmidth Excel recommends the use of Epoxy Grout. Cementitious grout does not have the strength

1-10

1. Main Frame 2. Lifting Ring Bolts Figure 1-5

3. Lifting Holes 4. Lifting Cables

Lifting Main Frame Assembly

Warning:

Angle of the Lifting Cables must not exceed 45

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FIG 1-5 Epoxy Grouting Requirements



Crusher

XL1100 with

Pounds (Kilograms) of Backing Material Required 1/2” (13mm) Grout

3/4” (19mm) Grout

Sole Plates 114 lbs (52 kgs) 171 lbs (78 kgs) XL1100 without Sole Plates 422 lbs (192 kgs) 633 lbs (287 kgs)

All quantities include enough grout for an extra 3/4” (19mm) between forms and frame flange. If the foundation is irregular, increase amounts by 10%. Table 1-3

Full Main Frame Grout Method When mounting the Crusher on an old foundation, the concrete must be cleaned and all oil soaked or deteriorated (cracked or otherwise compromised) concrete must be removed. In a new foundation, the concrete surface must be roughed up by chipping. Important steps to follow in carrying out this method of mounting the Crusher are:

1. Crusher 2. Foundation 3. Sole Plates Figure 1-6

1. Select and procure an epoxy grout material per FLSmidth Excel instructions TR1000-0005.

Note: It is very important that the epoxy grout be stored at room temperature (air conditioned if necessary), and that the manufacturer’s instructions are fully followed for mixing and pouring.

2. Prepare the foundation as described above. 3. Manufacture 3/4” (19mm) thick steel washers to rest the Crusher on, and have on hand an adequate supply of shim stock of various thicknesses. Typical thickness would be sizes of .010”, .020” .050” & .10”. 4. Ensure that the top of the concrete foundation, as well as the inside walls, are fully armored to protect against erosion caused by falling crushed product. 5. Set Crusher on the 3/4” (19mm) step washers and shim to level as necessary. 6. Build wood or plywood forms (dams) to contain the epoxy while it is in the fluid state. Be sure to coat the side towards the epoxy with a release agent, such as paste wax. The forms should be kept approximately

4. Epoxy Grout 5. Mounting Hardware

Crusher Grouting

1 to 1.25” (25 to 32mm) away from the outside and inside of the main frame flange. 7. Build expansion joints at horizontal intervals per the specifications of the grout manufacturer.

Note: It may be best to set the expansion joints prior to setting the Crusher into position.

8. As soon as the epoxy grout is mixed, it should be poured, only pouring from one side of the forms and allowing the epoxy to flow to the other side. Never make more than one pour at a time, or pour from opposite sides of the forms. As the grout reaches hydrostatic level on the opposite side of the forms, move approximately two feet and continue with the pour. 9. Per manufacturer’s instructions, there may be a maximum thickness of pour, and it may be necessary to pour the grout in multiple lifts. 10. Remove the forms once the epoxy grout has cured.

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1-11

Crusher Main Frame Installation on a Steel Structure If the Crusher is to be mounted on a steel structure, great care must be made in engineering the structure to withstand the static and dynamic loads presented by the Raptor XL1100 Crusher in operation. The structure must be designed with all of the normal clearance concerns, as well as Crusher maintenance access. Sole plates that match the machined pads on the bottom of the Raptor XL1100 Crusher must also be part of the steel structure. As is with most fabricated steel structures, it is not always possible to ensure that the sole plates are in the same plane. In that case, it will be necessary to use full surface shims to provide uniform support under all four Crusher pads and to properly level the Crusher.

G 1-7 A

Important: Contact FLSmidth Excel prior to installing a Raptor XL1100 Crusher on a steel structure.

1. Sole Plates 2. Lifting holes 3. Jacking Holes Figure 1-7

4. Discharge Opening 5. Foundation 6. Countershaft opening Sole Plate Installation A

B

The Raptor XL1100 Crusher is very heavy and in nearly all cases, the Crusher will be disassembled to a bare Main Frame with Main Shaft prior to being lifted into position during the first step of Crusher installation and assembly. The Main Frame Assembly weighs approximately 59.6 short tons or 54 metric tons (check shipping weight bill as the Main Frame casting can vary by as much as ± 5%). The Main Frame is designed to be lifted by four 100mm ring bolts installed in the drilled and tapped holes for the clearing cylinders. To lift the Main Frame into position: 1. Install four 100mm ring bolts in the top of the Main Frame flange at 90 degree intervals. Refer to Figure 1-5

Note: The 100mm ring bolts are supplied in the Tool Assembly shipped with the Crusher.

2. Using proper sized rigging, lift the Crusher free from the wooden or steel cribbing that the Crusher was shipped on. 3. With adequate safety blocking, clean the bottom of the Crusher mounting flange, removing dirt, rust, and loose paint.

1. Main Frame 2. Sole Plate Figure 1-8

1-12

3. Epoxy

Sole Plate Installation B

4. Lift the Crusher into position, either resting upon the steel sole plates or on the 3/4” steel washers used to support the Crusher above the foundation. If grouted sole plates are used, wait until the grout has cured to approximately 80% of full strength per manufacturer’s instructions.

ECT000-0176 - Rev. B - 07/08

5. Using an accurate spirit level on the top of the mainshaft, check that the Crusher is level, being within 1/64” (0.4mm) per foot (30.5 cm.). 6. Check for a “soft foot” condition. That is, ensure that all four machined pads on the bottom of the Crusher are resting firmly on the sole plates or the 3/4” steel washers. 7. Shim the Crusher as necessary to achieve proper level, using shims the size of the sole plates if the Crusher is being set on sole plates, or the size of the 3/4” (19mm) steel washers. 8. Install the anchor bolts and tighten to approximately 5200 ft.-lbs. (7050 Nm) of torque. In the case where epoxy grout for a full frame is used, wait until the grout has cured to approximately 15,000 psi (103 MPa) as per manufacturer’s instructions. 9. Check the anchor bolts for tightness after the first day of Crusher operation, the first week, and every month thereafter.

Arm and Countershaft Arm Guard Installation The Arm Guards must be installed before the eccentric assembly is installed. Carry out the following steps to install the Arm Guards:

2. Make sure the capscrews that secure the Upper and Lower Thrust Bearings, as well as the capscrews that hold the Counterweight to the Eccentric and Gear, are tight. 3. Attach the Eccentric Lifting Plate, with the ring bolts, to the Eccentric using the 30mm hex head capscrews that were supplied with the Crusher Tools Assembly. Refer to Figure 1-2 4. Apply a coat of the same ISO EP150 oil used in Crusher lubrication system to the Main Shaft, Upper and Lower Thrust Bearings, and Eccentric Bushing bore. 5. With proper rigging (the Eccentric Assembly weighs approximately 21,000lbs. (9530 kg.), center the assembly over the Main Shaft and then carefully lower the Eccentric Assembly onto the Main Shaft until it is seated on the main frame Lower Thrust Bearing. If the Countershaft Cartridge Assembly is already installed, be sure that the Eccentric Gear and the Countershaft Pinion have properly meshed. Refer to Figure 1-9 6. Check the gear and pinion backlash and record this information. If the backlash and root clearance are incorrect, make corrections accordingly. Refer to Table 1-4

1. With suitable lifting equipment, lift the guards FIGand 1-9 center them on the Main Frame Arms.

Eccentric Assembly Installation The Eccentric Assembly consists of the eccentric with sleeve bushing and thrust bearing, the gear, and the counterweight. The Eccentric Assembly is normally delivered with the above components mounted and the assembly ready to be installed. Use the following directions to install the Eccentric Assembly: 1. Thoroughly clean the Main Shaft, Main Frame gear well, Eccentric Assembly, and Lower Thrust Bearing (bolted to the Main Frame hub). Carefully remove any scratches, nicks, or burrs that may be found on the Main Shaft, Lower Thrust Bearing, Upper Thrust Bearing, Eccentric Journal, and Eccentric Bushing. Use only soft polishing disks or emery cloth of 200 mesh or finer. Never use a high speed grinding disk on a journal or bearing surface.

1. Eccentric 2. Counterweight Figure 1-9

ECT000-0176 - Rev. B - 07/08

3. Hoist Rings 4. Lifting Chains

Eccentric Assembly Lifting

1-13

of approximately 190°F (106°C ) above ambient and tap the Countershaft on the sheave end to obtain the correct end float measurement.

Backlash and Root Clearance

Crusher Backlash XL1100

Root Clearance Minimum

0.144” - 0.129” (2.9 - 3.3mm)

f. If the end float measurement is too large, insert approximately .04” (1.0mm) of shim or feeler gauge between the Pinion and inner Bushing flange. Clamp the Pinion tight against the Inner Countershaft Bushing and heat the Flinger to the temperature specified above. Then push or tap the Oil Flinger against the outer Bushing flange and allow the Flinger to cool before removing the clamp and shim. Refer to Figure 1-11

0.246” (2.6mm)

Table 1-4

Countershaft Cartridge Assembly Installation The Countershaft Assembly consists of cast steel housing, bronze sleeve bearings, a countershaft, and a spiral bevel pinion. The rotating countershaft inputs rotation to the Eccentric Assembly about the Main Shaft at 90° to the axis of the Countershaft. Use the following procedures to install the Countershaft Cartridge Assembly: 1. The Countershaft Box is factory assembled with “end float” or clearance to allow for thermal expansion of bronze as the assembly heats up during operations. Prior to installing the Countershaft Cartridge Assembly, the end float should be checked:

2. The Wear Ring is a replaceable wear component made of a metal and plastic impregnated fabric rolled into a split ring. This ring fits into a recessed groove on the o.d. of the inner cartridge housing and serves to isolate any relative movement between the Countershaft Cartridge Housing and the inner bore of the Main Frame Arm and minimize wear to these two parts. Use the following steps to mount the wear ring: a. Using a non-petroleum based solvent, remove any grease or oil from the Wear Ring and the groove in the Countershaft Housing that the Wear Ring will ride in.

a. Bump or otherwise move the Countershaft until Oil Flinger contacts the Outer Countershaft Bushing and stops further movement. Refer to Figure 1-10

b. Apply an anaerobic adhesive (Super Glue) or other low viscosity adhesive to the groove and press the Wear Ring into position.

FIG 1-10

b. Measure the gap between the Pinion and the Inner Countershaft Bushing flange with a feeler gauge.

Min. End Float Max. End Float 0.031” (0.8mm) 0.061” (1.6mm)

If the end float is not correct, go to Step 1c. If end float is correct, go to Step 2.

c. With the Crusher Sheave removed, loosen the Sheave Bushing setscrews and slide the Bushing off the Countershaft. If there is a safety set collar mounted on the Countershaft, just loosen and slide it off. d. Remove the end cover from the Countershaft Cartridge. e. If the end float gap is smaller than specified, then heat the oil flinger to a temperature difference

1. 2. 3. 4. 5. 6. 7.

Inner Countershaft Bushing Countershaft Outer Countershaft Bushing Oil Flinger Sheave Bushing No Clearance Measure End Float Here Figure 1-10

1-14

ECT000-0176 - Rev. B - 07/08

Countershaft End Float

c. Apply pressure to the Wear Ring until the adhesive has set. This can best be done with two rings of mechanics wire wrapped around the Wear Ring and twisted up tight. d. Just prior to inserting the Countershaft Cartridge into the Main Frame, a light coating of grease should be applied to the Wear Ring.

Note: Later generation Raptor XL1100 Crushers will not have this Wear Ring.

3. The Raptor XL1100 Crusher utilizes gears of a spiral bevel design. Prior to the Crusher being shipped, the Crusher was test run at the factory and all the necessary adjustments were made to the gear set to obtain the correct gear backlash, root clearance, and tooth contact. If more than one Crusher is to be installed, it is very important that the Main Frame, Eccentric Assembly, and Countershaft Assembly be installed as the set that was used in the factory run in. These items were matched marked at the factory and will be noted in the Crusher installation package. The installation package will also detail the amount of shims that were used for both the Lower Thrust

Bearing and the Countershaft Cartridge when the Crusher was test run. As the Countershaft Cartridge will most likely be removed for shipment, these shims are shipped loose. 4. While inserting the Countershaft Cartridge Assembly into the Main Frame, use the following steps: a. Remove the Crusher Sheave QD bushing from the countershaft. The QD bushing was installed at the factory to hold the factory set end float. b. Place a suitable Nylon sling just outside the outer flange of the cartridge housing. An 8” diameter pipe should be made up to provide leverage to balance the weight of the Countershaft Cartridge Assembly once it is picked. The pipe is slipped over the section of exposed countershaft. Refer to Figure 1-12 c. Lift the assembly and carefully insert it as far as it will go through the Main Frame bore, while positioning the box centering half ring on the radiussed, guide plate in the bottom of the bore. Align the adjustment tab, welded to the countershaft housing outer flange, off center Refer to Figure 1-13

FIG 1-11

End Float 1. C-Clamp 2. Countershaft Box 3. Pinion Figure 1-11

4. No Clearance 5. Shim to Set End Float

Most likely, the Countershaft will have to be rotated to get the pinion to engage in the eccentric gear. Continue to slide the Countershaft Cartridge Assembly into the bore, until the longest pull up bolts can be started with a minimum of 7/8” (22mm) of thread. Do not remove the support sling until the outer cartridge housing flange has penetrated the fit area in the bore of the main frame at least 1.0” (25mm).

Note: Some Crushers will have bolt slots in the Countershaft housing flange and two opposing jack bolts for rotating the housing. This feature is designed to provide additional clearance between the pinion and eccentric gear, making it easier to initiate penetration of the pinion into the gear. These Crushers will have a locating bolt hole in the main frame and a clearance hole in the Countershaft housing flange. Ensure that these holes are aligned.

Holding the Countershaft Box

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1-15

FIG 1-12 FIG 1-13

1. 2. 3. 4.

Lifting Sling Countershaft Countershaft Box Centering Lug Installation Guide/Rest (Main Frame)

Figure 1-12 Countershaft Assembly Installation

d. Place the the initial stack of shims, .096” (2.45mm) between the Countershaft outer flange and the Main Frame, as noted on the Countershaft Box Assembly Drawing in the Crusher Installation and Parts Manual. The shims must be flat and all burrs and upsets removed. The Countershaft Box Assembly is pulled up tight to the Main Frame with six M42 x 140 hex head capscrews, along with special washers and lock washers. Tighten the capscrews until the countershaft box flange is tight against the main frame. 5. It is important to maintain a proper backlash and gear alignment to minimize the potential for damage to the teeth on the Gear and Pinion. Following is the procedure to check and adjust the backlash: a. Turn the Countershaft until the tooth marked with an “x” is straight up and place bluing on the pinion teeth. b. Install the eccentric with the two teeth on the gear with an “x” straddling the pinion tooth with the “x”. c. Pull outward on the Countershaft until the pinion is tight against the inner Countershaft bushing.

1-16

1. Countershaft Box 2. Countershaft Box Cover 3. Backlash Tool Figure 1-13

4. Adjustment Tab 5. Main Frame 6. Countershaft

Countershaft & Backlash Tool

d. Remove all bearing clearance between the Eccentric Bushing and Main Shaft by placing a hydraulic jack between the inner wall of the Main Frame and the Counterweight at the thickest section of the eccentric (light side of the counterweight). Use only enough force to push the Eccentric Bushing against the Main Shaft. If too much force is used, the Eccentric will tip slightly and the backlash measurement will not be accurate. e. Place a backlash measuring on the countershaft. (Drawings for such a tool can be provided by FLSmidth Excel if needed.) Using light force, rotate the countershaft in a clockwise direction until the pinion gear stops against the eccentric gear. Refer to Figure 1-13 f. Place a dial indicator with the stylus at the scribed mark on the backlash arm and zero the dial indicator. This mark represents the pitch diameter of the pinion, which is 24.297” (617.1mm). g. Rotate the Countershaft in a counter-clockwise direction until the pinion gear just touches the eccentric gear. The reading on the dial indicator

ECT000-0176 - Rev. B - 07/08

FIG 1-14 after the countershaft has been rotated will give you the rotational backlash. It is sometimes necessary to take multiple readings and to average out the results. Record the readings and compare with the specified backlash range. Refer to Table 1-4 h. Lift the Eccentric Assembly out of the Crusher and check the contact pattern on the eccentric gear made by the bluing on the pinion. Compare the contact pattern. Refer to Figure 1-14 i. The backlash is increased by adding shims under the Lower Thrust Bearing on the Main Frame, or decreased by removing shims. Refer to Table 1-4 j. Study the contact pattern, compare to the illustration, and follow the recommended adjustments by moving the Countershaft Cartridge in or out of the Main Frame using shims. Refer to Figure 1-15 k. Carry out another measurement of backlash and check of contact pattern. Repeat the adjustment process described above until a satisfactory backlash and contact is achieved. l. Once the correct backlash and contact pattern is obtained, install the M16 locating capscrew and tighten the six 42mm hex head capscrews and the two M30 jackscrews. 5. Mount the Crusher Sheave and QD Bushing onto the countershaft, following the instructions as outlined on the Crusher Sheave Assembly drawing as found in the Installation and Parts Manual.

Installing the Clearing Cylinders At least four of the eight Clearing Cylinders (Jacks) will not be installed when the XL1100 Main Frame Assembly arrives on site. Four of the drilled and tapped 100mm holes will be used to install Ring Bolts for the purpose of lifting the Main Fame Assembly. To install the Clearing Cylinders, proceed as follows: 1. Push the Clearing Cylinder rod down until the piston bottoms out.

1. Gear Figure 1-14

2. Pinion Optimal Contact Pattern

2. Lift the Jack and position it so that the piston rod and threaded head stub can be screwed into the 100mm drilled and tapped hole at the bottom of the top flange of the Main Frame. Note: This Clearing Cylinder is heavy (184 lbs.) so it will take at least two persons to work the Clearing Cylinder into position. Ideally, some sort of lifting platform or jacking device should be used to lift the Clearing Cylinders into position. 3. Attach a strap wrench around the cylinder head and turn the jack in a clockwise direction until the jack is tight against the main frame. 4. Tack weld the Clearing Cylinder Head to the Adjustment Ring. Refer to Figure 1-16 5. Repeat the above procedure for installing the remaining Clearing Cylinders. 6. Connect the Clearing Cylinders with the hoses and fittings supplied with the Crusher, per Clearing Cylinder Hose Assembly Drawing RXL1019-5003.

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1-17

1-15 1. Remove all protective coatings from the machined surfaces. 2. Attach four suitably sized, equal length, cables or chains and clevises to the cast on bosses on the Adjustment Ring. Note: The clevises have to be able to span the 2.75” (70mm) thick cast-on lifting bosses. It may be necessary to remove the Dust Shell if the lifting cables or chains are too short and a four-way spreader is not available. 3. Prior to lifting the Adjustment Ring Assembly, apply a light coat of anti-seize compound to the Main Frame Seat Liners on the Main Frame. Shim Pinion In

Shim Gear Up

4. Lift the Adjustment Ring Assembly into position, align it with the Main Frame Pins, and lower it into position. Refer to Figure 1-17 5. Connect the Clamping Circuit hydraulic oil line to the Adjustment Ring.

Shim Pinion Out 1. Gear

Shim Gear Down 2. Pinion

Figure 1-15 Contact Pattern Corrections

Installing the Adjustment Ring Assembly The Adjustment Ring Assembly is made up of: the Adjustment Ring with welded on fabricated Mounting Brackets for the Hydraulic Adjust Motors, the Clamp Ring and Clamp Cylinders with interconnecting hoses, the Dust Shell with seal, the Main Frame Pin Covers, and various Fasteners. The Adjustment Ring Assembly will normally arrive fully assembled and painted. All machined surfaces such as the Main Frame seating surface and threads will be coated with a preservative. Use the following steps to install the Adjustment Ring Assembly:

1-18

Note: If adequate clearance and lifting capacity is available, it is possible to install the Hydraulic Adjustment Assembly prior to setting the Adjustment Ring Assembly into position; otherwise, it is now possible to install the Hydraulic Adjust Assembly.

6. Prior to installing the Bowl Assembly, it is necessary to coat the Adjustment Ring and Clamp Ring threads with molybdenum disulfide grease (moly grease). FLSmidth Excel has provided a 42 lb. (19 kg.) can of 25% molybdenum disulfide anti-seize compound that is to be applied to the Adjustment Ring Assembly and Bowl Assembly threads at commissioning. The anti-seize compound does not have to be put on in great quantities. Using a 4“ (100mm) paint brush will work very well. Continue to use what is left in this can of anti-seize compound until it is used up. At that point, it is permissible to use a 3 - 5%, NLGI 1, moly grease. In high ambient temperature operations, NLGI 2 grease should be used.

Installing the Accumulators The Accumulators, four 10 gallon (38 liter) units per Crusher, are shipped loose and are to be installed once the Crusher Main Frame is mounted on the foundation. The Accumulator mounting brackets will already have been attached to the Main Frame bottom flange. The Accumulators are shipped without nitrogen precharge; however, it will be necessary to add pre-charge prior to operating the Crusher.

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3. Before mounting the Charging and Checking Assembly on the Accumulator, turn the T-handle on the air chuck out (counterclockwise) until it can no longer be turned. Also, close the bleeder valve located on the top of the Charging and Checkiing Assembly.

FIG 1-21

4. Turn the swivel on the air chuck onto the valve stem until hand tight and then tighten 1/4 turn with a small hand wrench. Do not overtighten the swivel. Excessive tightening can twist off the valve stem and/or distort the copper sealing washer in the air chuck which will cause a continuous leak of nitrogen.

FIG 1-19 1. Weld Point 2. Main Frame Flange Figure 1-16

3. Clearing Cylinder Spacer 4. Clearing Cylinder

Clearing Cylinder Weld

1. From the loose parts, obtain edge guards and place them in the accumulator base bracket holes. 2. Using a choker hitch, attach a nylon lifting strap around an accumulator and lift the accumulator into position on the accumulator base bracket. 3. Once the accumulator is resting on the base bracket, hold it as vertical as possible and fasten the Accumulator Clamp Bracket to the Accumulator. 4. From the loose parts, obtain the hydraulic fittings and manifold. Assemble them to bottom of the Accumulators. Refer to Figure 1-18 5. Repeat the above mounting procedure for the remaining three accumulators. Use the following Steps to Check the Accumulator Pre-Charge: 1. From the Tools Assembly, obtain the Charging and Checking Assembly, p/n RXL417-0003. Ensure that there is an adequate supply of dry nitrogen gas available if needed. Refer to Figure 1-2 2. Remove the valve guard from the top of the Accumulator and the valve cap from the gas valve stem (Schroeder valve). Refer to Figure 1-19

1. Main Frame 2. Main Frame Pins Figure 1-17

3. Pin Bushings 4. Adjustment Ring Assembly

Adjustment Ring Assembly Lifting

5. Turn the T-handle on the air chuck in until the shaft inside the chuck depresses the valve core in the gas valve and gas pressure begins to register. Do not screw the T-handle in until it stops, as this will bend the valve core. 6. The pressure at the gauge should read 1000PSI, ± 50PSI (6.9 ±0.3 MPa). If the pressure falls within these limits, check the next Accumulator. 7. If the pressure is above the high limit, slowly exhaust the excess gas out the bleeder valve until the recommended pressure is obtained.

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1-19

8. If the pressure is below the recommended minimum (less than 950 psi), connect the Charging Assembly while it is still attached to the Accumulator to a cylinder of Nitrogen gas with the 10’ (3m) hose and adapter fittings supplied with the Charging Assembly. Slowly open the valve on the nitrogen gas bottle and then screw in (clockwise) the T-handle on the Charging and Gauging Fixture until gas begins to flow into the Accumulator. Once proper pre-charge is established, screw out the T-Handle and close the valve on the nitrogen gas bottle and use the bleeder valve to bleed off pressure in the hose.

1. Accumulator 2. Gas Valve Stem 3. Valve Cap

4. Valve Guard 5. Washer

1. 2. 3. 4. 5.

6. 7. 8. 9.

9. Check for a gas leak at the valve stem using soapy water. 10. Replace the valve stem cap and the valve guard on the Accumulator. 11. Repeat the process on the remaining three accumulators. Return the Charging and Checking Assembly to secure storage. A special charging adapter, furnished with the tools, may be required to connect the gland nut to the pressure regulator valve, depending on the type of nitrogen bottle used.

WARNING

Use only nitrogen gas to charge the Accumulators. Any other gas may be explosive or may produce explosive mixtures in the system. Do not use oxygen.

Installing the Tramp Release Cylinders The Tramp Release Cylinders provide the force that holds the Adjustment Ring to the Main Frame during crushing. The actual force is determined by the hydraulic pressure applied to the Tramp Release Cylinders. Hydraulic pressure forces the piston and piston rod downward, pulling on the Adjustment Ring and the cylinder upward, pushing on the main frame flange. When crushing forces exceed the tramp release forces, the hydraulic oil is displaced out of the Tramp Release Cylinders and into the nitrogen charged Accumulators and the Adjustment Ring lifts. Whenever the Adjustment Ring lifts, the piston rod has to pivot slightly. This motion is accommodated by a set of cones (spherical washers) and spherical cups, with mating spherical surfaces that are mounted in the top of the Adjustment Ring flange and

1-20

Screw Bleeder Valve Gas Charging Valve Pressure Gauge Handle

Figure 1-18

Air Chuck Swivel Gas Valve Stem Accumulator

Accumulator Depressurization

the bottom of the upper Main Frame flange. The spherical cups are interference fit into the bores they reside in. The Main Frame Assembly will be delivered with the cups installed in machined receptacles (called bosses) that have been tack welded to the main frame. The Adjustment Ring Assembly will be delivered with the cups press fit in bores in the top of the Adjustment Ring. To install the Tramp Release Cylinders use the following steps: Refer to Figure 1-20

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6. Lift the Tramp Release Cylinder into position, being careful not to damage the threads on the top of the piston rod as the piston rod is passed through the holes in the Main Frame and the Adjustment Ring.

FIG 1-23

7. Once the piston rod is pulled up so that shoulder below the threads on the piston rod are exposed, thread the 80mm Hex Nut tight to the shoulder.

1. Accumulator 2. Hose Fittings 3. Relief Valve Manifold Block

8. Lower the piston rod on to the upper cone, disconnect the cable sling, and remove the ring bolt. 9. Connect all hydraulic hoses. See Tramp Release Hose Assembly drawing RXL1019-5002.

Figure 1-19

Accumulator Mounting

1. Using an overhead crane and a choker hitched nylon sling, set the Tramp Release Cylinder as close to the Crusher at the first deck below the Main Frame (normally at the top of the foundation). 2. Ensure that the lower cup is seated into the counter bore in the top of the cylinder head and the upper and lower spherical cups are still in position. 3. Install the 20mm Ring Bolt in the threaded hole at the end of the Tramp Release Cylinder piston rod. 4. Attached a clevis and cable sling of suitable strength and yet small enough to pass through the 80mm Hex Nut that will be threaded on the Tramp Release Cylinder piston rod. The sling must be long enough to pick the Tramp Release Cylinder up from the lower deck. Be sure that the cable sling is passing through the Hex Nut and the upper cone (resting in the cup on the Adjustment Ring flange) before the cylinder is lifted. 5. Make sure that the rubber Rod Seal is in position and that it adheres to the top of the Main Frame flange.

10. If the Hydraulic Power Unit is in service, partially pressurize the Tramp Release Circuit to force the Tramp Release Cylinder into position. It is now possible to attach the shackle and support cable that keeps the Tramp Release Cylinder from falling away under gravity. If the Hydraulic Power Unit is not in service, then the Tramp Release Cylinder will have to be lifted or jacked into position to allow the shackles and support cable to be installed. 11. If the Tramp Release Cylinders are being installed for the first time, repeat steps 1 through 8 for all 16 cylinders. Then carry out steps 9 & 10.

Removing the Tramp Release Cylinders 1. Install a 20mm ring bolt in the threaded hole at the top of the Tramp Release Cylinder piston rod. 2. Attach a clevis and cable sling of suitable strength, yet small enough to pass through the 80mm Hex Nut threaded on the piston rod. The sling must be long enough to lower the Tramp Release Cylinder to the next deck. 3. Detach the Support Shackle and Cable from the flange on the Main Frame. 4. Do a clearing cycle or allow gravity to lower the Tramp Release Cylinder and displace the hydraulic oil in the cylinder bore. 5. Be prepared to catch additional hydraulic oil that may be displaced and disconnect the hydraulic hoses.

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1-21

FIG 1-24

Installing the Socket Assembly The Socket Assembly consists of a Socket Sub-Assembly (socket and dowel pins) that has an interference fit on the main shaft, the bronze Socket Liner that has a slight interference fit with the Socket, and various components of the Anti-spin device. The Socket Assembly provides a spherical bearing surface for the head to gyrate on during crushing activities. 1. From the Tools Assembly, obtain two of the four 36mm socket line-up studs and turn them into the tapped holes in the top of the main shaft. Refer to Figure 1-21

1. Adjustment Ring 2. Main Frame Flange 3. Support Tab

4. Tramp Release Cylinder 5. Support Strap

Figure 1-20 Tramp Release Cylinder Mounting & Support

6. With an overhead lifting source, pull the piston rod upward and back off the 80mm Hex Nut. 7. Lower the Tramp Release Cylinder to the bottom Crusher flange. The upper cone will remain in the Main Frame cup. The lower cone will remain on the cylinder head. 8. While the Cylinder is still partially supported by the overhead lifting device, walk or slide the Tramp Release Cylinder off of the Main Frame flange and onto the surrounding foundation or access decking. 9. Carefully balance the Tramp Release Cylinder and disconnect the clevis and sling. 10. With a nylon sling and a choker hitch, lift the Tramp Release Cylinder away to a service bay. Note: It may be necessary to remove the upper decking to lift the cylinder away. 11. After the Hydraulic Power Unit is permanently set in place, connect the Hydraulic Hoses per Assembly Drawing RXL1019-5002.

1-22

2. Install two M16 ring bolts in the top of the Socket. Attach the ring bolts to suitable, equal length cable slings or chains to lift the Socket to about waist height. Note: It is very important that the Socket be lifted level prior to lowering on to the Main Shaft. Refer to Figure 1-21 3. Using at least two gas burners (one is not enough), heat the socket to about 125°F (70°C) above the ambient temperature of the Crusher Main Shaft. During the heating process, it is very important to keep the flame moving about the surface. Slowly spinning the Socket is one good method of evenly distributing the heat. 4. Once the proper temperature has been reached, line the Socket with the alignment studs and quickly lower the socket onto the Main Shaft. Make sure that the Socket has seated tightly against the top of the main shaft. Use a feeler gauge to check that the socket has in fact seated flat on the shaft. Refer to Figure 1-22 5. Remove the alignment studs and install the cap screws with lock washers through the Socket and into the Main Shaft. Alternately tighten the cap screws in small increments until a torque value of 2080 lbs-ft (2820 Nm) has been obtained. Recheck the torque after the socket has cooled to the same temperature as the main shaft. 7. Install four M16 ring bolts provided in the Tools Assembly into the tapped holes located around the outside diameter of the Socket Liner. Refer to Figure 1-23

ECT000-0176 - Rev. B - 07/08

8. Cool the socket liner to 54°F (30°C) below ambient temperature. Alternatively, the Socket can be heated while in place to create the same relative temperature differential. 9. Once the proper temperature difference has been achieved, lift and lower the Socket Liner over the locating dowels in the Socket, making sure the liner has seated firmly on the socket. Then remove the ring bolts from the socket liner. 10. Lift and place the Clutch Stub Shaft onto the socket and bolt in place using eight M16 X 70 hex head capscrews and lock washers. Torque the capscrews to 192 lbs-ft (260 Nm). Refer to Figure 1-24

The overruning clutch allows the Head Assembly to rotate in the direction of crushing (counterclockwise), and keeps the head from spinning in the no load direction (clockwise), as is normally associated with these types of Crushers. It is very important that the overrunning clutch be installed so that it free wheels in the counter-clockwise direction. If this is not allowed to happen, the Anti-Spin devices can break up under the load.

Installing the Head Assembly To install the head assembly, do the following: 1. From the tools, obtain the head lifting plate and the M64 hoist ring. Then turn the hoist ring into the lifting plate.

11. Place the key in the Key slot of the Clutch Stub Shaft. It is recommended that the key be held in place with an anaerobic adhesive.

2. Lift and place the lifting plate on the locking nut and bolt the plate onto the locking nut using four M30 X 160mm hex head capscrews from the tools.

12. Assemble the overruning clutch, clutch adapter link and mechanical overload clutch together. Once these parts are assembled, lift and lower them onto the clutch stub shaft. Refer to Figure 1-24

3. Properly clean the Eccentric, Socket Liner, Head Bushing bores, and Headball. Make sure all oil passages have been cleaned as well. Any scratches or nicks in the bushings, bearing, or journal surfaces must be smoothed out with fine emery paper or fine polishing pads.

FIG 1-25

4. Using the same lube oil used in the lubrication system, coat all the bearing surfaces on the Eccentric, Socket Liner, Head Bushing bores, and Head Ball.

FIG 1-26

1. Removal Hardware 2. Lifting Ring Bolts 3. Socket Figure 1-21

4. Alignment Pins 5. Main Shaft Socket Mounting

1. Feeler Gauge 2. Socket Figure 1-22

ECT000-0176 - Rev. B - 07/08

3. No Clearance 4. Main Shaft Checking Socket Contact

1-23

FIG 1-24

IG 1-27

1. Lifting Cable 2. Lifting Ring Bolt Figure 1-23

3. Socket Liner

Overload Clutch Clutch Stub Shaft Clutch Adapter link Overrunning Clutch Figure 1-24

Socket Liner Lifting

5. Attach suitable lifting equipment to the hoist ring and lift the head assembly up and over the Eccentric, making sure the lifting ring in the Head Lifting Plate is positioned toward the thick portion of the Eccentric and centered over it. Slowly lower the Head Assembly down into the Crusher. The offcenter position of the hoist ring slightly tilts the Head into a position that will not damage the Lower Head Bushing when installing the Head Assembly. If the ring bolt is not correctly positioned, damage to the Lower Head Bushing can occur. 6. Locate the Driveshaft Mounting Plate and the Universal Driveshaft from the loose parts. If these two parts are not bolted together, do it now using eight M8 X 25 socket head capscrews and lock washers. Also, make sure the gasket is placed on the mounting plate. Refer to Figure 1-25 7. Screw an M16 ring bolt in the top of the mounting plate. Attach suitable lifting equipment to the ring bolt and lift these parts up and over the head assembly. 8. Slowly lower the mounting plate and slide the splined shaft of the drive shaft into the Overload Clutch approximately 1” (25mm). Turn the mounting plate in a counterclockwise direction to line up the bolt

1-24

1. 2. 3. 4.

5. Socket Liner 6. Socket 7. Main Shaft

Socket Assembly

holes in the mounting plate with the tapped holes in the Head Stub. Then lower the mounting plate until it seats on the Head Stub. 9. Fasten the mounting plate to the head using eight M10 X 40 socket head capscrews and lock washers. 10. Attach suitable lifting equipment to the feed plate. Then lift and place it on the locking nut and attach using four M36 X 260 hex head capscrews and washers.

Installing the Adjustment Mechanism Assembly The Adjustment Mechanism Assembly is designed to rotate the Bowl Assembly in and out of the Adjustment Ring Assembly in order to make changes to the Crusher cavity setting, or to remove and install the Bowl Assembly for maintenance purposes. The Assembly consists of four Hydraulic Drive Assemblies that are mounted on the Adjustment Ring, and a Drive Ring that interacts with turning bars welded to the Adjustment Cap of the Bowl Assembly. The Hydraulic Drive Assemblies each consist of a hydraulic motor, hydraulic pressure released brake, a planetary drive, and a pinion that meshes teeth with the drive ring. Use the following steps to install the Adjustment Mechanism Assembly:

ECT000-0176 - Rev. B - 07/08

1. If the four turning brackets are not mounted on the Drive Ring, mount them at this time. 2. There are six drive ring support arms welded to the Adjustment Ring Assembly. Mount the drive ring support pads at this time. Refer to Figure 1-26 3. Mount the four Adjustment Drive Assemblies to the mounting adapter plates.

Note: There is one grease fitting at the top of the planetary to provide grease to a labyrinth seal. The Drive Assembly must be mounted on the adapter plate so that it is possible to access this grease fitting. Refer to Figure 1-27

4. Using suitable lifting equipment, lift and place the drive motor and mounting plate on the mounting weldments that were welded to the Adjustment Ring at the factory. Bolt the mounting plates to the mounting weldments, but leave the bolts loose at this time. 5. Install the hydraulic hoses and fittings that were shipped separately, per Adjustment Mechanism Hose Assembly Drawing RXL1016-5004. The hydraulic manifold blocks will already have been installed on the Main Frame at the factory.

6. Connect the Hydraulic Power Unit to the distribution manifold block on the lower flange of the Main Frame, once the Hydraulic Power Unit has been permanently set in place. 7. Using two M36 ring bolts and suitable rigging, lift the Drive Ring into position. 8. It will be necessary to have the Bowl Assembly in position in order to adjust the Drive Motor Assemblies. Following the Bowl Assembly Installation procedures outlined below, lift the Bowl into position, match the Bowl and Clamp Ring thread starts, and set the Bowl on the Clamp Ring. 9. Insert a M36 X 90 capscrew and jam nut into each turning bracket. Using these capscrews as jacking screws, center the Drive Ring on the Adjustment Cap as close as possible. Refer to Figure 1-28 10. Adjust the Drive Motor Assemblies, in or out, so the root clearance between the drive motor pinion and the Drive Ring is .25” (6mm) to .28” (8mm). Then tighten the adapter plate bolts to hold the drive

FIG 1-30

FIG 1-29

1. Drive Shaft Mounting Plate 2. Feed Plate 3. Locking Nut 4. Torch Ring Figure 1-25

5. 6. 7. 8. 9.

1. 2. 3. 4. 5. 6.

Head Stub Universal Drive Shaft Mantle Overload Clutch Head

Feed Plate Assembly

Adjustment Cap Turning Bracket Drive Ring Retainer Drive Ring Drive Ring Support Pad Drive Ring Support

Figure 1-26

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Drive Ring Support

1-25

FIG 1-31 1. Pinion Shield 2. Grease Zerk 3. Pinion 4. Adapter Plate 5. Adjustment Drive Motor 6. Brake Connections 7. Mounting Weldment 8. Rock Skirt 9. Drive Ring 10. Dust Shell 11. Adjustment Ring

Figure 1-27



Adjustment Drive Assembly Installation

motor assembly in place. Also, tighten the jam nuts on adjustment bolts in the drive motor plate. Refer to Figure 1-29

11. Mount a proximity switch bracket on the mounting plate at one of the drive motor locations as preselected by automation personnel. 12. Place the two proximity switches in any one of the four switch brackets to suit your wiring requirements. Refer to the instrument drawing that is in the installation package. 13. Attach the rock skirts to the four pinion shields, and mount the shields to the mounting plates at each Drive Motor location. 14. Mount the six drive ring retainers. Four of the six are used to mount vibration sensors, so these have to be set symmetrically about the Adjustment Ring Assembly. Refer to the Adjustment Mechanism FIG Assembly Drawing, RXL1016-5001, which is part of 1-33 the installation package

by FLSmidth Excel with the Crusher. The anti-seize compound is also to be applied to the Adjustment Ring and Clamp Ring threads. It is best to use a paint brush to apply the anti-seize. The moly based antiseize provides initial protection to the bowl threads as they work harden during crushing activities. 3. Attach suitable cable slings and clevises to the four lifting ears on the Adjustment Cap of the Bowl Assembly. Slowly set the Bowl Assembly in the Crusher on the Clamping Ring threads. When lowering the Bowl Assembly, make sure the guide bars in the Adjustment Cap engage the turning brackets that are mounted on the drive ring. 4. Using the overhead crane, lift the Bowl Assembly to take most of the weight off of the Clamp Ring threads. This is called “floating the bowl”. While “floating the Bowl”, turn the Bowl Assembly clockwise at least two full revolutions.

Bowl Assembly Installation Use the following procedure to install the Bowl Assembly: 1. Thoroughly clean the Bowl threads and ensure that the Adjustment Ring and Clamping Ring threads are also clean. Do not install the Bowl Assembly with the protective coating still in place. 2. Apply a light coat of the 25% molybdenum disulfide (moly) based anti-seize compound that was supplied

1-26

1. Adjustment Cap 2. Centering Bolt Figure 1-28

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3. Adjustment Bracket

Adjustment Cap Centering

e) Turn the High / Low selector switch to the Low position.

FIG 1-34

f) Turn the Local / Remote selector switch to the Remote position.

0.28 [7] 0.25 [6]

5. Refer to the Automated Control System (ACS) Instruction Manual for instructions on calibrating the Crusher close side setting.

Lube System Placement & Installation Oil Supply Regulation

1. Drive Ring 2. Pinion Figure 1-29

The Package Lube System is designed and sized to provide the necessary supply of clean and cooled lubrication oil. It should not be modified.

3. Pinion Shield 4. Adapter Plate

Normal supply oil flow to the Crusher is 200 - 225 gpm (757-851 lpm)

Root Clearance

Use the following procedure to rotate the Bowl Assembly: a) Turn the selector switch labeled Local / Remote located on the remote mounted manual control panel, at or near the Hydraulic Power Unit, to the Local position. b) Turn the Bowl removal speed selector switch labeled High/Low to the High position. c) Open the Clamping Circuit pressure dump valve before installing or removing the Bowl Assembly. This is to ensure that the Bowl or Adjustment Ring threads are not damaged during minimal thread engagement and automatic pressurization of the Clamping Circuit. d) Turn and hold the selector switch labeled Open / Close in the Close position. There will be a brief delay as the Hydraulic Power Unit depressurizes the clamping circuit pressure. The Bowl will then begin to turn in a clockwise direction. Note: When the selector switch is released, the Hydraulic Power Unit will automatically pressurize the clamping circuit. Turn the Bowl down until the desired close side setting is achieved.

Normal supply oil pressure at the Crusher should be: 20 to 38 psi (1.4-2.6 Bars). Oil pressure is highly temperature dependent, and it is best to assess oil pressure issues at normal operating temperatures. The amount of oil to fill the lubrication system reservoir is specific to Crusher(s) applications. The normal range is 500 U.S. Gallons (1893 Liters) to 550 U.S. Gallons (2090 Liters) Lubricating Oil Specifications

Use high grade paraffin (not naphthalene based) ISO EP 150 gear oil that meets the following requirements: 1. 2. 3. 4.

5. 6. 7. 8. 9.

High film strength High adhesiveness to metal surfaces Stable physical and chemical properties Must have extreme pressure (E.P.) properties such as sulfur phosphorus or other anti-weld agents which are compatible with metals used in the Crusher. The E.P. oil is preferred over straight industrial oil because of the higher pour point. High viscosity index Rapid water separation Resists foaming Provides rust and corrosion protection Includes anti-wear additives

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1-27

ISO Grade EP 150 Gear Oil

Viscosity:

135 to 165 cSt (Centistokes) at 40°C 13 cSt or Higher at 100°C 680 to 850 SUS (Saybolt, Universal Seconds) at 100°F 70 SUS at 210°F Viscosity Index of 90 or Higher

If the Crusher is to operate under abnormal conditions such as crushing hot materials or operating in extreme climates, contact the FLSmidth Excel Engineering Department for special lubricating oil recommendations. Important: The Crusher lubricating oil needs to meet the above requirements to protect its working parts. Not using the proper oil can damage the Crusher in a short period of time and void any warranties. All major oil companies make oil that meets the above requirements. If your local oil supplier cannot furnish oil that meets the above requirements, contact FLSmidth Excel’s customer service for assistance.

Package Lubrication System Placement and Installation The Package Lubrication System consists of a skid mounted oil reservoir, with one or two lube oil pump and motor assemblies, an oil filter assembly, and, if water cooled, a water/oil heat exchanger. Locate the lube system below and as near the Crusher as possible. To obtain the proper flow of drain oil from the Crusher to the lube system reservoir, the bottom of the reservoir must be at least 6’ (1.8m) below the underside of the Crusher mounting flange. Make sure that the Package Lube Skid is level before attaching to the foundation, using shims if necessary. Before wiring the pump motor, check the motor name plate for the correct voltage, frequency, phase, and electrical connection requirements. Refer to the service booklet from the motor manufacturer for operation and maintenance instructions. Unless specified differently in the contract, all electrical components required to operate the Package Lubrication System (motor starter, fuse protection, etc.) are to be furnished by the customer and must meet local electrical code requirements. With the pump motor properly wired, check the direction of rotation by briefly starting the motor. There is an arrow mounted on the top of the motor to indicate the correct direction of rotation.

1-28

Piping Information The factors listed below should be addressed when laying out the supply and drain oil piping to and from the Lube Package and Crusher: 1. The drain line should have a minimum pitch of 1” (25mm) of vertical change for every 12” (305mm) of horizontal change. Refer to Figure 1-30 2. The piping should be as direct and short as possible, with a minimum amount of elbows or other restrictions that can cause velocity head losses (pressure drop). 3. Install the FLSmidth Excel supplied flexible couplings in both the supply oil line and the return oil line per Drawing RXL1005-5001. These flexible couplings serve to dampen vibrations between the Crusher and the remaining oil lines. 4. Use unions or bolted, flanged joints at various locations to aid in the removal of any piping or lubricating equipment when necessary. 5. Avoid long vertical drops in the drain line. This will create an excessive vacuum inside the Crusher and causes dust to be pulled into the Crusher past the labyrinth “T” and “U” seals. If a vertical drain line cannot be avoided and vertical drop is more than 4’ (1.22mm), it will be necessary to install a vacuum break, air breather in an S trap. Contact FLSmidth Excel concerning the proper location of the S trap. Important: The lube supply oil piping and return oil piping must be cleaned of rust, scale, cutting chips, and other debris prior to assembly. The supply oil piping should then be disconnected at the Crusher and, with a flexible hose or other suitable means, connected to the return line. The lubrication pump is then operated for approximately 10 minutes to flush the supply oil line and return oil line. Alternatively, a “pig” can be pulled through the piping to clean out all potential contamination.

Crusher Air Breather and Blower The Raptor XL1100 Crusher is supplied with a Blower Assembly to introduce air into the Eccentric and Gear Well area of the Crusher, which provides a positive pressure to keep rock dust from migrating past the T and U Seals. This greatly reduces contamination of the lube oil and the associated wear problems.

ECT000-0176 - Rev. B - 07/08

FIG 1-35 1. 2. 3. 4.

Pump/Motor Assemblies Tank Oil Drain Line Oil Supply Line

5. Crusher 6. Minimum 4’(1.3m) plus 1”(25mm) for every 1’(0.3m) tank is away from the crusher.

Figure 1-30

Lube Tank Location

The Blower should be located in an area free from potential rock spillage. The location should be no more than 12’ (3.6m) from the Crusher. The Air Breather can be mounted directly onto the blower or in a more remote location where it can be easily serviced and the environment is relatively dust free. The maximum total distance of the Air Breather from the Crusher should not exceed 40 ft. (18.9 m) Refer to Figure 1-31

Before wiring the air cooler motor, check the motor name plate for the voltage, frequency, phase, and electrical connection requirements. Refer to the service booklet from the motor manufacturer for operation and maintenance instructions. All electrical equipment required to operate the air cooler motor (motor starter, fuse protection, etc.) is to be furnished by the customer and must meet local electrical code requirements.

When wiring the air blower motor, make sure the supply line meets the motor nameplate rating. Once the air blower motor has been electrically connected, the motor should be jogged to ensure the fan is rotating in the correct direction.

After the air cooler motor has been properly wired, start the motor and check its rotation. It should rotate the fan so air is forced through the radiator from the motor side. Refer to Figure 1-32

Water/Oil Heat Exchanger

Air/Oil Cooler Assembly Crushers using an air to oil heat exchanger (radiator type, air cooler) are supplied with a skid mounted Heat Exchanger Assembly with isolation valves, by-pass relief valves, and temperature monitoring devices already in place. Refer to Figure 1-32 The air to oil heat exchanger is best located between the Package Lube System and the Crusher. If the air cooler assembly is installed in a lube room, the room needs to be properly vented to provide an in-flow of outside, ambient air necessary to efficiently cool the oil. The assembly is normally base mounted to a concrete or fabricated steel foundation. Make sure that the Air Cooler Assembly is not subjected to excessive vibrations and that it is mounted level. It must also be mounted in an area relatively free from dust, mud, or other contaminants that could affect its ability to exchange heat.

Both tube and shell and plate type oil to water heat exchangers can be used. These heat exchangers are typically mounted on the Package Lubrication System and as such, are already plumbed in and leak tested. It will be necessary to field set the thermal couple actuated control valve(s) that regulates the flow of cooling water through the heat exchanger. The Water/Oil Heat Exchanger requires an uninterrupted supply of clean, salt-free, and corrosive-free water. If a water type heat exchanger is going to be used in freezing temperatures, safeguards must be incorporated to keep the water from freezing. The water supply and discharge connection for the heat exchanger are 2” NPT fittings. These supply and discharge lines are the supply of the customer and are to be installed once the Package Lube System has been installed.

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FIG 1-36 1. 2. 3. 4. 5. 6. 7.

Figure 1-31

Turbo Blower Filter Housing 4”(102mm) Flexible Hose Countershaft Box Crusher Main Frame Drip Shield Outlet Damper

Countershaft Box Blower/Filter Assembly

Oil Heater The Package Lube System includes one or more resistance type Oil Heaters to maintain a minimum operatingFIG oil 1-37 temperature in colder operating climates. The Oil Heaters are mounted in a thermal well. Equipment required for heater operation, such as magnetic contactor and fuse protection, is to be furnished by the customer, unless otherwise specified in the Crusher sales contract.

1. 2. 3. 4. 5.

Fan Outlet Inlet Drive Motor Drain

Hydraulic Power Unit Placement and Installation

The Hydraulic Power Unit is designed and sized to provide the necessary oil flow and pressures to operate the Bowl Clamping, Bowl Adjustment, and the Tramp Release systems. As the preset operating pressures have a critical effect upon the forces generated by the Crusher, the Hydraulic Power Unit should not be modified. Hydraulic Oil Specifications

Thoroughly inspect the inside of the reservoir for any contaminants before filling the Hydraulic Power Unit reservoir with oil. Remove any material with lint-free rags. Also, check the suction strainer for any material that may be stuck to the screen and clean if necessary. Use a high grade paraffin, not naphthalene, industrial hydraulic oil with high film strength, high adhesiveness to metal surfaces, and stable chemical and physical properties. The oil should also have a high viscosity index, rapid water separation, resist foaming, include corrosion protection, resist oxidation, and contain anti-wear additives. Figure 1-32

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Air Cooler Assembly

ISO Grade 32 Viscosity: 29 to 35 cSt (Centistrokes) at 40°C 6 cSt or Higher at 100°C or 135 to 165 SUS (Saybolt, Universal Seconds) at 100°F 45 SUS or Higher at 210°F Viscosity Index of 140 or Higher

There are six 30’ (9 m) long hydraulic hoses of various sizes that connect the Crusher to the Hydraulic Power Unit. These hoses are shipped loose and are to be field installed. The hoses include reusable couplings on one end. These provide the customer with the ability to shorten the hoses to fit the installation and reattach the fittings, and thereby avoid a safety hazard caused by a pile of coiled hydraulic hose.

Fire resistant hydraulic oil should not be used. This type of hydraulic oil may not be compatible with packing seals, accumulator bladders, hoses, and other parts of the power unit. It will adversely affect the special paint used inside the reservoir, as well as reduce the life of the pump.

The remote mounted pushbutton panel is shipped loose and requires electrical field connection to the terminal box located inside the Hydraulic Power Unit.

The reservoir is to be filled to the top of the oil level gauge. The oil level should be kept at the center of the oil level gauge during normal operation and regularly monitored. Cold Weather Oil Specifications

Cold oil will not flow freely through the hydraulic system, causing it to be almost solid. This is a particularly bad situation for the tramp release circuit, in which the oil must flow freely to and from the accumulator when the Crusher passes tramp iron or stalls. If the correct oil for a cold weather environment is not used, the power unit and/ or Crusher components could be damaged. If the ambient temperature will be 0°F (-20°C) or less for more than a few days, FLSmidth Excel recommends changing the entire hydraulic system oil to a cold weather type as specified below. ISO Grade 10 10 cSt (Min) at 130°F (54.4°C) 500 cSt (Max) at -40°F (-40°C) Pour Point of -75°F (-59.4°C) Max FLSmidth Excel does not recommend using the above cold weather oil all year round. Since the oil is designed for use in cold ambient conditions, occasional leakage past the tramp release and clamping cylinders may occur during warmer conditions.

Remote Mounted Pushbutton Control Panel Installation The remote mounted pushbutton panel includes a 30‘ (9 m) long multi-conductor electrical cord already attached to it. The other end of the electrical cord is to be wired to terminal strips in a connection box located inside the Hydraulic Power Unit. The electrical cord can be shortened to suit the installation. Use the Electrical Schematic Drawing for the Hydraulic Power Unit, that can be found in the Assembly and Parts Book, to make the proper connections.

Crusher to Power Unit Hose Connections Once the Hydraulic Power Unit is in position, the hoses from the power unit to the Crusher should be connected. All hose ports at the power unit and the main manifold block, mounted on the lower main frame flange, are stamped to identify each port. Therefore, when attaching the hoses from the manifold block to the power unit, just match the stamped markings and connect the hoses accordingly. Refer to the clearing cylinder, tramp release, and adjustment mechanism hose assemblies, which are furnished in the installation drawing package, for hose connection identifications.

Hydraulic Power Unit Installation The power unit should be placed in an area protected from falling rock and at no more than 30’ (9 m) from the Crusher. The remote-mounted pushbutton panel should be placed in a location that will allow the operator to observe the Crusher during a clearing or while turning the Bowl (setting adjustment).

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1-32

ECT000-0176 - Rev. B - 07/08

Section 2 Operation Typical Crusher Terminology ................................................................................................................2-2 Check List for Starting New Crusher....................................................................................................2-3 Pre-Start Up Procedures........................................................................................................................2-5 Countershaft Rotation...........................................................................................................................2-5 Break-In Instructions..............................................................................................................................2-5 Daily Crusher Operations.......................................................................................................................2-6 Vital Sign Monitoring..............................................................................................................................2-6 Production Control.................................................................................................................................2-7 Shut-Down Instructions.........................................................................................................................2-7 Setting the Crusher ...............................................................................................................................2-8 Setting the Crusher Figure 2-1..............................................................................................................2-8 Checking the Setting (Manually)..............................................................................................................2-8 Checking the Setting (Automated Calibrations) .......................................................................................2-8 Normal Operating Recommendations................................................................................................2-9 Adjustment Ring Movement.................................................................................................................2-9 Controlling Ring Bounce........................................................................................................................2-9 Determining Liner Wear.......................................................................................................................2-10 Adjustment Cap Position Figure 2-2..................................................................................................2-10 Grease Fittings Figure 2-3....................................................................................................................2-10 Thread Lubrication................................................................................................................................2-10 Bowl Thread Engagement Figure 2-4................................................................................................2-11 Difficulty Turning the Bowl.................................................................................................................2-11 Clearing the Crusher.............................................................................................................................2-11 Adjustment Ring Safety Blocks Figure 2-5.......................................................................................2-12 Clearing the Crusher with Tramp Metal Jammed in the Crushing Cavity .................................2-13 Inspection Periods.................................................................................................................................2-14

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Typical Crusher Terminology • Feed The material entering the Crusher to be crushed. • Feed Size The size distribution of the feed, with top size and bottom size restrictions. • Product Size The “desired” size distribution of the material after being crushed. • Liners The wear members (Mantle and Bowl Liner) that provide the actual crushing surfaces, normally made of Iron/Manganese alloy steel. • Head Assembly The gyrating component that with the Mantle imparts the crushing energy to the material to be crushed. • Bowl Assembly The stationary component that, with the Bowl Liner, provides the crushing surface to oppose the forces imparted by the Head and Main Shaft Assemblies. • Bowl Liner A casting with a machined seating surface that is mounted firmly in the Bowl. • Mantle A casting with a machined seating surface that is designed to mount firmly to the main shaft/head assembly. • Cavity The actual area between the bowl liner and the mantle where the crushing takes place. • Choke Fed Condition This is a steady state condition where the feed entering the crushing cavity matches the Crusher throughput and the cavity level is above the Feed Plate on the head. Optimum Choke Fed Condition is normally about 12” (300mm) above the Feed Plate.

• Discharge Setting (Close Side Setting) The closest dimension between the bowl liner and the mantle, in the parallel zone, during the gyrating action of the head. • Open Side Setting The greatest opening at the top of the crushing cavity during the gyrating action of the head. • Open Circuit Operation A crushing flow sheet where rock makes one pass through the Crusher. Typically a secondary application. • Closed Circuit Operation A crushing flow sheet where oversize rock is screened off and sent back through the Crusher. Typically a tertiary or quaternary application. • Primary Stage The first stage of crushing, with a Crusher sized to process run-of-mine rock. Usually a jaw or a gyratory Crusher. • Secondary Stage A Crusher sized to crush the discharge product from the Primary Crusher. If 25% of the feed from the Primary Stage is at, or smaller than, closed side setting of the Secondary Crusher, then a scalping screen will need to be ahead of the Crusher. • Tertiary Stage A Crusher sized to crush the discharge product from a Secondary Crusher. The Tertiary Crushers are normally operating in a closed circuit, with two Crushers for each Secondary Crusher. • Quaternary Stage A Crusher sized to crush the discharge from a Tertiary Crusher. These Crushers normally operate in a closed circuit, with two Crushers for each Tertiary Crusher.

• Parallel Zone That area of the crushing cavity where the bowl liner and mantle crushing surfaces become near parallel. This is where the cavity has the narrowest gap.

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Check List for Starting New Crusher A. Pre Start-Up

SATISFACTORY

UNSATISFACTORY

1. Shipping wedges have been removed from between the Mantle and Bowl Liner 2. Drive Ring centering bolts have been loosened and are positioned correctly 3. Crusher close side setting checked at _______” ( _______ mm) 4. V-Belt tension and alignment. 5. Relationship of countershaft bushing oil groove and drive location (Normal motor position 6 o’clock, motor below Crusher 12 o’clock) 6. Countershaft end float 0.031” (0.8mm) to 0.061” (1.6mm) 7. Grouting and fastening of Crusher to foundation 8. Design of foundation provides enough room for free fall of material to prevent build-up under Crusher 9. Lubrication System a. Correct pitch of drain line. Minimum pitch 1” per 12” (25mm per 305mm). b. Specify brand and type of oil in tank (ISO 150). Brand _______________________________ Type ISO 150 c. Piping has been installed properly. d. Auxiliaries such as pressure and temperature sensors along with the Countershaft box breather are properly installed. e. Rotation of the lube oil pump is correct. f. Oil piping has been flushed. g. Water control valve (on Water Cooled Lube Systems) has been set to provide 110°F (43°C) supply oil temperature. 10. Tramp Release Accumulators have been charged to specified pressure. 11. Hydraulics a. Specify brand name and type of oil in power unit tank. Brand _______________________________ Type ISO 32 b. Crusher to power unit and all circuit hoses are properly connected, bled, and checked for leaks. DO NOT pump any oil until the Crusher mounted accumulator has been charged. Refer to Section 1 for charging instructions. c. Check rotation of power unit pump. d. Remote mounted pushbutton panel is located where the operator can observe turning of the Bowl during adjusting. e. Accumulator has been charged to specified pressure. f. Cavity release system (1) When pressurized, the system holds pressure without fading. (2) Low pressure alarm light operates correctly. (3) Relief valve on pressure cycle operates properly. 12. Interlock and Safety Devices a. Check for proper operation of pressure and temperature sensors. b. Check interlock of Crusher and lube pump motor. Crusher drive motor cannot be started unless the lube pump motor is running. ECT000-0176 - Rev. B - 07/08

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Check List for Starting New Crusher B. Start the Oil Pump

SATISFACTORY

1. Oil drain line temperature is 60°F (16°C) before starting the Crusher.

C. Jog the Crusher

1. Countershaft rotates counterclockwise.

D. Start the Crusher 1. Run crusher no load until a drain line temperature of 80°F (27°C) is reached. Two hours minimum. 2. Countershaft is running at____________RPM. 3. Check below Crusher for any oil leaks. 4. Power draw running empty is__________Amps. 5. Crusher was run at 65% drive motor full load amps for two hours. 6. Relief valve stopped bypassing oil to tank at _______°F. 7. Feed distribution in crushing cavity checked. 8. Crusher was run at 80% drive motor full load amps for four hours.

E. After Eight Hour Initial Operation

1. Temperature differential between drain and feed line is __________. Temperature of drain line is __________ above ambient. 2. Oil inlet pressure is ___________ psi. 3. Drain line temperature is ____________. 4. Coast down time is ____________ seconds. 5. Any recommended changes to the installation have been given to the customer. 6. Verify that the drive belts have been re-tensioned per the belt manufacturers instructions.

Comments

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UNSATISFACTORY

Pre-Start-Up Procedures

Countershaft Rotation

FLSmidth Excel has a prescribed Check List for the installation and start-up (Commissioning) of a new Crusher. During commissioning, an FLSmidth Excel representative will be on site to ensure that proper installation and startup procedures are followed. These same procedures can be followed whenever a Raptor XL1100 Crusher has been relocated or has gone through a major rebuild. Use of proper start-up procedures will greatly reduce the potential for expensive break downs and ensure optimum utilization of the Crusher. Before you begin scheduled production with the Crusher, follow and check off the steps:

The Raptor XL1100 Crusher is designed to only run counterclockwise (as viewed from the Crusher Sheave). Under no circumstances should the Crusher be rotated in the opposite direction. The motor sheave (drive sheave) and Crusher sheave (driven sheave) combination is designed to provide optimum performance for a specific application. The Countershaft speed is to be checked and verified during the commissioning of the Crusher.

Critical points that should be verified before commencing the Crusher Start-up Check List are: • Verify that the proper lube oil and hydraulic oil is installed in the respective reservoirs. • Verify that the power supply (Voltage, Frequency, and available current) matches the name plate data on the motors supplied with the Crusher. • Bump all motors to ensure that they are rotating in the proper direction. • Run the lubrication system to verify that there are no leaks. • Operate the Hydraulic Power Unit, and pressurize or cycle all hydraulic circuits to verify that there are no leaks. • Check all fasteners related to items mounted on the Crusher, as well as ancillary components, such as guards and piping support brackets. • Verify that the crushing cavity is free of blocks and materials, and also that there is adequate clearance at the close side setting. • Test the discharge conveyor to verify that it is fully functional. • Inspect under the Crusher for obstructions in the discharge chamber. • Verify that the equipment feeding the Crusher (i.e. variable speed drive or vibrating feeder) is functioning properly. • Ensure that any dust collection or dust suppression system is fully functional.

Eccentric speed relates to Countershaft speed and has a major influence upon the productivity of the Raptor XL1100 Crusher. Increasing the Eccentric speed reduces the throughput and reduces the power draw. Decreasing the Eccentric speed increases the throughput and increases the power draw. Determination of the correct countershaft speed is a balance between maximizing Crusher throughput, while keeping the Crusher operating within power limitations. Therefore, it is very important that the Crusher be operated at the speed specified by FLSmidth Excel applications personnel. Sometimes, due to changes in feed conditions, it is necessary to change the Crusher speed to optimize Crusher performance. Other times, it may be necessary to make a change in mantle and bowl liner configurations. FLSmidth Excel will provide the assistance needed to ensure that the Raptor XL1100 Crusher performance is optimized.

Break-In Instructions Although the Crusher was run no-load at the factory, FLSmidth Excel recommends a field run-in as part of initial start-up or after a major overhaul of the Crusher. Proper break-in procedures are defined in Section D, Steps 1-8 of the Check List for Starting New Crusher. During a Crusher break-in, it is extremely important to closely monitor the oil temperature and power draw. Refer to Oil Temperature in Section 4. The Normal Raptor XL1100 Crusher Break-in Schedule is as follows: • Operate the Crusher at No Load for 2 hours. In very cold climates, it may be necessary to operate the Crusher until the return oil temperature reaches 80°F (27°C). • Operate the Crusher under a stable reduced load for 2 hours, with enough material to establish a uniform distribution of material about the crushing cavity. The best way to determine a stable reduced load condition

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is to observe the Crusher lubricating oil pressure. If the pressure is fluctuating rapidly with variations of 15 to 20 psi (1.0 to 1.4 bar), it is necessary to add more feed to the Crusher. Normally, the Raptor XL1100 Crusher will stabilize at about 60% of the full load amp rating of the Crusher motor. • Operate the Crusher for 4 hours at about 75% of the full load amp rating of the Crusher motor. • Commence full power operation after the initial 8 hour break-in above. It should be noted that rebuilt Crushers may require longer break-in periods to allow the new bushings to conform to the old journal surfaces.

Daily Crusher Operations The Raptor XL1100 Crusher is sold with an Automated Control System (ACS) that is designed to provide operational control of the Crusher, with respect to vital signs, operational interlocks with discharge, and feed conveyors and optimized production. The FLSmidth Excel supplied ACS can provide direct control of the Crusher to the Crusher operator, or it can provide local control with a communication link to a whole plant Programmable Logic Controller (PLC) or a Distributive Control System (DCS). The Automated Control System uses a Human Machine Interface (HMI) to display vital signs and operational parameters, and allows the Crusher operator to initiate start and stop functions. Following is a basic description of how the ACS functions:

Vital Sign Monitoring: • Crusher supply oil pressure in both analog and switch signals • Crusher supply and drain oil temperatures in both analog and switch signals • Oil Filter Condition (dirty/plugged) in an analog signal • Oil Flow (optional sensor) in an analog signal • Lube tank temperature in an analog signal • Lube tank level in a switch signal • Heat Exchanger Efficiency with analog input • Eccentric oil temperature in an analog signal • Drive Motor Power Draw (Amps/kW) with analog input • Crusher Speed/Belt Slip Detection (countershaft rpm) with analog input • Adjustment Ring Movement (Ring Bounce) with analog inputs from accelerometers

2-6

• Bowl Creep (Bowl turning under crushing forces) with relay inputs • Clamping Circuit Pressure in an analog signal • Tramp Release Pressure in an analog signal Vital Sign Monitoring compares actual analog sensor values against minimum and maximum set points. Typically, there are Warning set points that indicate potential problems and Alarm set points that require immediate action to protect the Crusher. Interlock to allow the start up of the Crusher: • Lubrication Pump is operating • Proper supply oil temperature • Proper return oil temperature • Adequate oil level in the Lube Oil Reservoir • Proper supply oil pressure • No Lubrication alarm faults with the vital sign monitor Interlock to allow the introduction of feed to the Crusher: • Discharge Conveyor Operating • Crusher Operating • No vital sign warnings The interlocks are maintained with relay switching of the motor control voltage for the various electric motors associated with operating the Crusher. Note: It is highly recommended that there are hardwire interlocks, in conjunction with the PLC switching interlocks for drive motors of the lubrication oil pump, the discharge conveyor, the Crusher, and the feeder system. The Automated Control System is normally programmed to stop the feed to the Crusher whenever a Vital Sign Warning or Alarm fault occurs. Feed cannot be reintroduced into the Crusher until the warning or fault has gone away.

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Production Control:

It is also advisable to have someone visually verify the above vital signs and check the actual oil flow return to the lube oil reservoir. The drain oil pipe should be approximately half full as the oil enters the reservoir. The lubrication system also has a by-pass pressure relief valve that has a return oil line to the reservoir. Low flow in the drain pipe, in conjunction with high flow at the relief valve return line, is an indication of a problem. Operating the Crusher in this situation can result in serious Crusher bearing failures.

• Cavity Level Sensor (usually ultrasonic) provides analog inputs. (Not usually of FLSmidth Excel scope of supply). • The Crusher Drive Motor starter (not usually of FLSmidth Excel scope of supply) provides an analog input of either kilowatts or amperes. • Crusher Setting (close side) is monitored and adjusted using proximity switch inputs at a Crusher Adjustment Mechanism drive pinion. • Crushing forces are monitored by a system of accelerometers that monitor Adjustment Ring lift. (Ring Bounce). Feed to the Crusher is modulated using a dual loop control program that integrates the Cavity Level inputs and Drive Motor power. The ACS strives to maintain consistent Cavity Level and optimum Power Draw, while keeping the Crusher operating within force limitations. FLSmidth Excel recommends the following Crusher startup procedures: 1. Start the Lubrication System at least two minutes prior to starting the Crusher to provide adequate lubrication to the Crusher prior to the Crusher being started. The drain line oil temperature must be equal to or greater than 60°F (16°C) before the Crusher is started. The Crusher Automated Control System (ACS) will energize the tank heater as necessary to maintain a lube oil reservoir temperature between 80°F (27°C) and 90°F (32°C), provided there is a safe oil level in the reservoir. In extremely cold conditions, it may be necessary to run the lubrication system during extended Crusher shut down periods to ensure that the required return oil start-up temperature can rapidly be achieved. 2. Once the lube system is started, the ACS begins a timing sequence of one minute of oil circulation before the Crusher can be started. The ACS will also check for potential lubrication system faults (alarms) such as: Low oil flow, low oil pressure at the Crusher, low lube oil reservoir level, low return oil temperature, and high return oil temperature.

Any of these alarms will prevent the Crusher from being started.

3. Start up the Crusher and run it empty (no-load) for five minutes. This time frame will allow the ACS to verify proper vital signs and respond if necessary. 4. Rapidly introduce feed into the Crusher cavity to bring the cavity level up to near choke fed conditions as soon as possible. As the feed level in the cavity approaches normal operating levels, the feeder speed should be slowed down to keep from over filling the Crusher cavity. The ACS is designed to use a dual loop control program to modulate feed to the Crusher, and maintain both a consistent cavity level and a uniform power draw.

Due to design characteristics, the Crusher should never be continuously operated below 65% drive motor full load amp rating. Refer to Section D in Check List for Starting New Crusher

Shut-Down Instructions 1. Stop the feed to the Crusher and allow the Crusher to run empty for approximately three minutes. 2. Stop the Crusher drive motor and monitor the time it takes for the Crusher Sheave to coast to a stop. This is called the coast down time, and it should be in the range of 60 to 90 seconds. The ACS is designed to monitor coast down time and data log this information. 3. If return oil temperatures are in the normal operating range (no alarms), allow the lubrication system to operate for five minutes. If the return oil temperature is in the warning or alarm stage, continue operation of the lubrication system until the time that the return oil temperature drops to within normal operating temperature range. If ambient temperatures are low and the Crusher will be down for more than four hours, it is recommended that the lubrication system not be shut down.

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Setting the Crusher Size of the crushed product is controlled by the close side setting of the Crusher. The close side setting is the gap between the Mantle on the Head and the Bowl Liner in the Bowl, in the parallel zone. Product size is usually determined as a percentage of the product material passing through a certain screen or mesh size. For example, P80 of .50“ (12.7mm) would be 80% passing thru a .50” (12.7mm) sized screen or mesh. Product size at a given close side setting is related to the material being crushed, the Countershaft speed of the Crusher, and the amount of material in the crushing cavity. The achievable close side setting is a function of the liner profile in service along, with the power and volumetric limitations of the Crusher. Refer to Figure 2-1 1. Changes in the Crusher setting are made by turning the Bowl clockwise (closed) to reduce the close side setting, or counterclockwise (open) to increase the close side setting. The actual setting change is related to the number of teeth of the Drive Ring or Drive Mechanism Pinion that rotate past a fixed point. There is a Crusher setting change of .016” (0.40mm) for each Drive Ring tooth.

FIG 1-8

2. The Crusher setting adjustment can be made remotely with the Automated Control System, or locally at the Hydraulic Power Unit control panel. Refer to the Instruction Manual for the Automated Control System for a detailed description of Crusher setting adjustments.

Checking the Setting (Manually) One of the methods used to check the close side setting is called “slugging” the Crusher. This is accomplished by passing a piece of lead or a ball of aluminum foil through the Crusher immediately after the feed to the Crusher has been stopped and there is no feed in the crushing cavity (before Head spin begins). Measuring the thickness of the compressed slug will provide the close side setting of the Crusher . Do not use zinc slugs to check the setting. Since zinc does not compress easily, the measurement may not be accurate.

Checking the Setting (Automated Calibrations)

The Automated Control System is designed with a calibration function to check and set a desired close side setting. This function requires turning the Bowl Assembly clockwise until there is metal to metal contact between the Mantle and the Bowl Liner. Once metal to metal contact is established, the Bowl Assembly is rotated counterclockwise until the desired setting is achieved. Two proximity switches are used to monitor the tooth count and direction of rotation of the Hydraulic Bowl Adjust drive pinion. Each tooth is equal to a change in close side setting of 0.0165” (0.42mm). Once a Calibration sequence is started, the ACS will carry out the following steps: • Stop feed to the Crusher. • Shut down the Crusher after proper time has been allowed for all of the rock in the crushing cavity to have passed through.

1. Bowl 2. Adjustment Ring 3. Bowl Liner Figure 2-1

2-8

4. Parallel Zone 5. Mantle 6. Head Setting the Crusher

• Time out the Coast Down of the Crusher. • Rotate the Bowl Assembly clockwise (closed) until metal to metal contact causes a pressure spike in the Hydraulic Drive Motor circuit. The ACS will count the number of teeth necessary to turn the Bowl

ECT000-0176 - Rev. B - 07/08

Assembly to achieve metal to metal contact. Once metal to metal contact is achieved, a zero close side setting is established. • Rotate the Bowl Assembly counterclockwise (open) until a predetermined close side setting is achieved. • The ACS monitors Liner wear, tracking the accumulate difference in open and closed Bowl rotation starting with the installation of new liners. After a calibration sequence has been completed, the operator can initiate the Crusher start-up sequence, followed by introduction of feed to the Crusher.

Normal Operating Recommendations Proper operation of the Crusher is critical in maximizing the life of the Crusher. FLSmidth Excel recommends operating as close to full power as possible without exceeding power draw peaks of 110%. Typically there is a lower average set point in the range of 90% that will allow the Crusher to operate within the peak power limits. Running at a low average power draw can also be harmful to the Crusher. The Crusher should never be continuously operated below 65% drive motor full load amp rating. It is also recommended that the Crusher operation be such that starting and stopping of feed to the Crusher be minimized. Starting and stopping of the feed places the Crusher bushings in short periods of unbalanced forces. Prolonged periods of operation with intermittent feed will shorten the life of Crusher sleeve bearings (bronze bushings). If the Crusher is going to run without feed for more than 30 minutes, it is better to shut the Crusher down and restart when feed becomes available.

Adjustment Ring Movement (Ring Bounce)

With the exception of passing tramp material, the Crusher Adjustment Ring should not be allowed to lift off the Main Frame while crushing. All efforts must be made to minimize the frequency of tramp material events. Lifting of the Adjustment Ring (Ring Bounce) occurs when the design forces of the Crusher are exceeded. Excessive Ring Bounce will lead to serious maintenance issues and can lead to expensive, catastrophic failure of major Crusher castings such as: the Main Frame, the Adjustment Ring, and the Head.

Controlling Ring Bounce Other than lack of lube oil to the Crusher, ring bounce presents the greatest potential for serious damage. Though the damage may not immediately be evident, the high GForces generated by the Adjustment Ring pounding on the Main Frame cause cyclic overload conditions. If allowed to continue, this cyclic loading will lead to the fatigue failure of the Main Frame and/or the Adjustment Ring. As mentioned previously, Ring Bounce occurs when the crushing forces exceed the design limits of the Crusher. Typical causes of Ring Bounce are: • Uncrushable material (Tramp Material) in the crushing cavity such as metal, wood, rubber, etc. The Crusher is designed to accommodate the occasional tramp event, but not a constant supply of tramp material. • Operating at too tight a close side setting. The crushing forces exceed the design limitations. • Excessive fines in the feed to the Crusher. Excessive amounts of fine material fill the voids that the large pieces of rock need to expand into while being crushed. • Feed segregation as the feed enters the crushing cavity. In this condition, the fines in the feed tend to gather on one side of the crushing cavity (see too much fines above) and the coarser material to the other side. This causes unbalanced crushing forces that not only can cause ring bounce, but can also cause unbalanced forces on the lower head bushing and the eccentric bushing. Refer to Figure 1-1 • Too much moisture in the feed. This causes the feed to stick to the Head (pancake), and there is not enough void space for the rock being crushed to expand into. With the exception of operating with too tight a close side setting, all of the conditions described above are related to operational or design factors outside the Crusher. It is extremely important that every effort be made to correct the problems that can lead to ring bounce. Usually these problems are recognized and corrected during the commissioning of the Crusher. However, problems can arise over the life of operation and need to be corrected immediately.

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FIG 2-3

Determining Liner Wear

Monitoring liner wear is extremely important. If liners become too thin, they can become loose, crack, or flex excessively and cause serious damage or wear to the seating surfaces of the Bowl and/or the Head. The following information is intended to help determine when the liners have worn to the point of needing to be replaced. • When a new set of liners are installed, mark a line on the Dust Shell at the bottom of the Adjustment Cap. From this line, another line can be added representing the approximate amount of Bowl travel that can be expected during the normal wear life of a set of liners. This distance is available from FLSmidth Excel Engineering and is to be used as a guide for estimating liner life. Accurate liner wear is best established during Crusher operation. • Liners are castings supplied by various manufacturers. As such, they will vary somewhat in dimensions and liner life. Always look for signs of looseness and cracking of the liners.

1. Grease Zerk 2. Adjustment Ring 3. Main Frame Figure 2-3

• When the second mark referred to above is achieved, the liners should be weighed and then cut and a profile made of the wear pattern. From the weight, the percentage of liner material can be calculated. From the profile, a wear pattern will be evident and it

4. Main Frame Seat Liner 5. Fulcrum Bar Grease Fittings

will be possible to determine if the succeeding pairs of liners can be run for a longer period of time. • Liners may start to cup at the bottom and cause a reduction in throughput (measured in tons per hour). In some cases, throughput can decrease to the point that the liners have to be changed out without being fully worn. If this is the case, contact the Engineering Department of FLSmidth Excel for assistance. It may be necessary to make a change in the liner profile or a change in the feed size to the Crusher.

FIG 2-2

• After several liner changes, the difference between new and worn liners should be relatively consistent using the same liner configuration and close side setting. Establishing an average vertical travel of the Bowl will enable the customer to determine when the liners will need to be changed. Refer to Figure 2-2

Thread Lubrication 1. Adjustment Cap 2. Bowl 3. Dust Shell Figure 2-2

2-10

4. Position of Adjustment Cap 5. Adjustment Ring

Adjustment Cap Position

It is critical that the threads in the Bowl, Adjustment Ring, and Clamping Ring are always well lubricated. Evenly distributed grease fittings are located around the perimeter of the Adjustment Ring to provide proper thread lubrication. Refer to Figure 2-3

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5. Crushing with the Bowl in the same position for extended periods of time without properly lubricating the threads.

FIG 3-2

6. If the Bowl will not move using the hydraulic adjust motors, contact FLSmidth Excel customer service to discuss options on how to free up the Bowl. Note: In some applications, the rock is not very abrasive, so adjustment for liner wear does not occur at regular and frequent intervals. In this case, it is important that the Bowl be rotated out one full turn and then back to Crusher setting at least once per month. This, along with greasing the Adjustment Ring threads, will help distribute the grease about the threads and greatly reduce the potential for damage to the Adjustment Ring and Bowl thread.

Clearing the Crusher

1. Adjustment Ring 2. Bowl Figure 2-4

3. Crushing Position 4. Released or Turning Position

If the Crusher stops or stalls while crushing under load, no attempt should be made to restart the Crusher while there is still rock in the crushing cavity. Trying to restart the Crusher in this condition can damage the drive motor and drive related components of the Crusher. A stalled Crusher can occur for a number of reasons such as:

Bowl Thread Engagement

• Power bumps and power outages. The relationship of the Bowl, Adjustment Ring, and Clamping Ring threads in both the crushing and adjusting positions is illustrated. FLSmidth Excel recommends using lithium based grease like NLGI No. 1 containing 3% or more molybdenum disulfide by weight. If a high temperature material is being crushed, use high temperature grease with the same 5-10% molybdenum disulfide by weight. Refer to Figure 2-4

Difficulty Turning the Bowl Difficulty in turning the Bowl is often the result of galled or damaged threads. Thread galling or damage is usually the result of the following reasons: 1. Use of a Bowl and Adjustment Ring thread grease that does not meet the recommendations of FLSmidth Excel. 2. Not following a recommended lubrication schedule for the Adjustment Ring threads. 3. Damaged or worn Dust Shell seal that allows dust and other contaminants to get into the thread area of the Adjustment Ring and Bowl.

• Operating too close to the motor control limits, resulting in motor shut down. • Rapid loss of oil pressure causing emergency shut down of the Crusher. • Crushed product build up under the Crusher. • Tramp material too large for the Crusher tramp release system to pass. • Improper belt tension resulting in slipping or burned drive belts. Clearing a Raptor XL1100 Crusher with rock in the cavity has to be done locally, with personnel able to visually verify that the cavity has been cleared. That is why the Crusher is supplied with a push button control panel to operate the Hydraulic Power Unit at the Crusher. This panel is to be mounted in such a way that the person operating can have an unobstructed view of the Crusher and a view of the Hydraulic Power Unit. Use the following procedure to clear the Crusher:

4. Excessive ring bounce.

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2-11

FIG 2-5 1. Ensure that all personnel in the area are aware that a Clearing Function is about to be made, and make sure that every one is away from the Adjustment Ring of the Crusher. 2. At the Push Button Control Panel, turn the Local/ Remote switch to the Local position. 3. Turn and hold the Tramp Pressure Reset / Clear selector switch in the Clear position. This is a spring loaded switch, so it has to be held in position. As soon as the switch makes contact, the hydraulic pressure to the Tramp Release Cylinders will be dumped to zero. Simultaneously, the hydraulic pump motor will start and hydraulic oil will be pumped into the Clearing Circuit. After a short period of time, the Adjustment Ring with Bowl Assembly will start to rise, opening the gap between the Bowl Liner and the Mantle on the Head Assembly. The maximum Clearing stroke is 5.22” (133mm). 4. Hold the Adjustment Ring at the full stroke for approximately 30 seconds. This should be sufficient time for material to flow out of the crushing cavity. Release the Clearing Switch, and allow gravity to bring the Adjustment Ring back into position on the Main Frame. If there is a sound of crushing rock, then the cavity is not clear. 5. Check the crushing cavity, and look for rock with a flashlight. 6. It is possible that some of the material in the crushing cavity is too large or too sticky to slide out of the crushing cavity. If this happens, it will be necessary to commence another Clearing Cycle and raise the Adjustment Ring with Bowl Assembly. With the assemblies raised (holding the Tramp Pressure Reset / Clear selector switch in the Clear position), place the four safety blocks (supplied with the Tools Assembly) between the Adjustment Ring and Main Frame at the Main Frame Pin locations 90 degrees apart. Refer to Figure 2-5 7. Someone will have to use a long bar to push rock from the crushing cavity. This will require that the person stand on the Adjustment Ring and deflect the rubber skirt that seals the bottom of the Feed Chute and the Rock Hopper in the Bowl Assembly. Follow all appropriate safety rules that may apply.

2-12

1. Main Frame Pin Bushing 2. Adjustment Ring Figure 2-5

3. Main Frame Pin 4. Safety Block 5. Main Frame

Adjustment Ring Safety Blocks

8. Once the crushing cavity is clear, a clearing cycle can be initiated one more time and the Safety Blocks removed. Once the Safety Blocks are removed, release the Clear selector switch and allow the Adjustment Ring with Bowl Assembly to settle back down on the Main Frame. 9. Visually verify that the Adjustment Ring has properly seated back onto the Main Frame. If this is not the case, another Clearing Cycle is necessary. Never pressurize the tramp release cylinders if the Adjustment Ring is not sitting level on (square to) the Main Frame. This will damage the tramp release cylinders. 10. At this time, turn the selector switch to Tramp Release Reset. The system is designed to not allow Tramp Release Pressurization without the operator acknowledging that the Safety Blocks have been removed. Turning the selector switch to Tramp Release Reset completes this acknowledgement. It is now possible to re-pressurize the Tramp Release System, either manually at the Push button Control Panel or by turning the Local Remote switch to Remote and allowing the PLC to carry out an automatic re-pressurization.

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Clearing the Crusher with Tramp Metal Jammed in the Crushing Cavity

4. De-energize and lock out the Hydraulic Power Unit.

Occasionally, a piece of tramp metal too large to pass through the Crusher will become jammed in the crushing cavity, and even releasing the Tramp Release System pressure and doing a Clearing Cycle will not free the tramp metal. It is possible that there is still significant force being placed on the tramp metal by the spring in the steel members of the Crusher. In this case, removing the tramp metal can be very dangerous, as the metal can be expelled from the crushing cavity with enough velocity to do bodily harm. There are two methods of attempting to remove tramp metal jammed in the crushing cavity: • The first method of choice is to position a large steel hook under the tramp metal, and use an overhead crane or other lifting device to pull the metal up and out of the cavity. As the cavity is primarily wedge shaped, a small amount of upward movement will rapidly reduce the forces trapping the metal. • The second method is to burn the metal out of the cavity, using magnesium burning bars or oxyacetylene lances. In this method, a long rod or torch is used to reach into the cavity from a safe distance as the metal is slowly melted away. The metal is cut in such a way that it slowly collapses under the forces of compression, yet the Bowl Liner and Mantle are undamaged. This requires that the person doing the burning can see the metal as it is being burned, yet is positioned in such a way that any sudden ejection of the material will be in a direction away from that person. Both methods present some danger as a person has to have a clear view of the jammed metal in the crushing cavity. The metal will normally shoot upward toward the feed plate of the head, so the person attempting to remove the metal has to make sure to stand to the side, about 90 degrees to the metal. For safety, the following steps should be taken: First method described above: 1. De-energize and lock out the Crusher drive motor. 2. Dump the Tramp Release Pressure. 3. Perform a clearing cycle and install the four safety blocks between the Adjustment Ring and the Main Frame.

5. Use a long pole or rod to slip a hook or sling around the tramp metal. 6. Stand to the side as an overhead lifting device attempts to pull the metal out of the crushing cavity. Second method described above: • Carry out steps 1 through 4 listed for the First Method. • Secure a “Hot Work Permit” from appropriate management and follow all procedures. • Protect the discharge conveyor or any other flammable materials in the discharge area of the Crusher. • Position oneself about 90 degrees to the jammed metal. • Commence burning the metal, trying to work on the narrowest section without actually burning into the manganese steel liners. • Burn slowly as to allow the metal to slowly collapse on itself. • Once the metal is loose in the cavity, attempt to push it through or pull it up and out. Remember, it will be hot. • Once the cavity is cleared, the Crusher may be restarted. Note: After a major tramp event, it is always important to monitor the Crusher closely, observing return oil temperature and oil pressure, as well as listening for any unusual sounds. Anything out of the ordinary most likely indicates internal damage, and Crusher maintenance should take the Crusher down for inspection.

Warning

While placing the safety blocks between the Main Frame and Adjustment Ring, hold the Tramp Pressure Reset / Clear selector switch in the Clear position. If the selector switch is released from the Clear position at any time during the clearing cycle, the Adjustment Ring and Bowl will lower.

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2-13

Inspection Periods

Warning

Do not try to manually remove any material from the crushing cavity unless the safety blocks have been put in place. Do not enter the crushing cavity. A rod or a hook of some type should be used to push or pull material about the crushing cavity until it drops through. Never place feet or hands between the Main Frame and Adjustment Ring, even after the Safety Blocks are in position.

To keep the Crusher in good operating condition, FLSmidth Excel recommends scheduling daily, weekly, monthly, and yearly inspections with a written log of what was done and found. Repairs can be made in advance to avoid major breakdowns. Refer to the Maintenance Section of this manual for suggested daily, weekly, monthly, and yearly check lists.

Warning

NEVER REPRESSURIZE THE TRAMP RELEASE CIRCUIT WITH THE SAFETY BLOCKS INSTALLED BETWEEN THE ADJUSTMENT RING AND MAIN FRAME. The Safety Blocks will be expelled under enough force to kill or do great bodily harm. Re-pressurization of the Tramp Release circuit with the Safety Blocks installed will also place unusually high stresses on the tramp release system components, main frame and adjustment ring that can lead to premature failure of these parts.

2-14

ECT000-0176 - Rev. B - 07/08

Section 3 Maintenance General Maintenance Information..................................................................................................... 3-2 Ordering Replacement Parts............................................................................................................... 3-3 Periodic Inspections.............................................................................................................................. 3-3 Daily Checks and Maintenance........................................................................................................... 3-4 Weekly Checks and Maintenance....................................................................................................... 3-5 Monthly Checks and Maintenance..................................................................................................... 3-5 Annual Checks and Maintenance....................................................................................................... 3-6 Liner Change Checks and Maintenance............................................................................................ 3-6 Lubrication Maintenance Chart ......................................................................................................... 3-7 Lubrication.............................................................................................................................................. 3-8 Grease Fittings Figure 3-1................................................................................................................... 3-8 Hydraulic System................................................................................................................................... 3-8 Oil Contamination Guidelines Table 3-1............................................................................................ 3-9 Installing the Tramp Release Cylinder............................................................................................. 3-11 Replacing the Accumulator............................................................................................................... 3-11 Checking the Accumulator Pre-Charge.......................................................................................... 3-11 Accumulator Depressurization Figure 3-4.................................................................................... 3-11 Accumulator Mounting Figure 3-5.................................................................................................. 3-12

Wear Part Replacement Bowl Liner Change Out....................................................................................................................... 3-12 Lifting Bowl Assembly Figure 3-6.................................................................................................... 3-13 Bowl, Wedge and Liner Parts Figure 3-7........................................................................................ 3-13 Bowl Liner Removal............................................................................................................................ 3-13 Wedge Assembly Figure 3-8............................................................................................................. 3-14 Bowl Liner Installation........................................................................................................................ 3-14 Helix High Point Location Figure 3-9.............................................................................................. 3-15 Checking Bowl Liner Seating Surface Figure 3-10........................................................................ 3-15 Bowl Liner Installation Figure 3-11.................................................................................................. 3-16 Bowl, Bowl Liner Seating Surface.................................................................................................... 3-17 Mantle Replacement........................................................................................................................... 3-17 Installing or Removing the Head Assembly Figure 3-12............................................................. 3-17 Procedure for Replacing a Worn Mantle........................................................................................ 3-18 Mantle Replacement Figure 3-13..................................................................................................... 3-18 Cutting the Torch Ring Figure 3-14................................................................................................. 3-18 Locking Nut Wrench Figure 3-15..................................................................................................... 3-18 Lifting Lug Figure 3-16....................................................................................................................... 3-19 Lifting a New Mantle Figure 3-17..................................................................................................... 3-19 Installing the New Mantle.................................................................................................................. 3-19 Seating the Mantle Figure 3-18........................................................................................................ 3-20 Main Frame Liner Replacement........................................................................................................ 3-20 Installing the Mantle Figure 3-19..................................................................................................... 3-21 Arm Guard Replacement.................................................................................................................... 3-21 Procedure to Remove the Socket Assembly................................................................................. 3-21 Main Frame Liner Assembly Figure 3-20........................................................................................ 3-22 Procedure to Remove the Eccentric Assembly............................................................................. 3-22 Counterweight Liner Replacement.................................................................................................. 3-23 Lower T-Seal Removal Figure 3-21.................................................................................................. 3-24 Change Out of Clamping Cylinders.................................................................................................. 3-24

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3-1

General Maintenance Information Maintenance involving the disassembly of the Crusher requires a thorough understanding of the components that make up the Crusher, and how they interact during the operation of the Crusher. Maintenance can usually be categorized as routine or repair. In all cases, great care must be taken while performing any maintenance to avoid causing damage to Crusher components. The following precautions should be observed when a Crusher is being worked upon: 1. Parts that have machined or bearing surfaces should be handled with special care, as these parts are usually designed to close tolerances or are a critical journal surface. These parts should be properly supported and not allowed to contact hard surfaces. Set these parts on wooden blocking or rubber mats. 2. All parts removed from the Crusher that have machined surfaces or journal surfaces should be oiled or coated with a rust preventative if the parts are to be left out of the machine for an extended period of time. 3. Great care should be taken when handling and installing bronze bushings. Ramming or pounding a bushing during installation may cause distortion or other damage. 4. Mating parts that have either a press or sliding fit should have a coating of light oil. This will prevent rusting in place. 5. Thoroughly clean and oil any machined parts prior to installing them into the Crusher. Do not install any part that has a bearing or journal surface without first coating it with oil. 6. Head and eccentric bushings are to be stored in a vertical position. If these bushings are stored lying on their side, they will become out-of-round over time. This can make it difficult to install the bushing and may lead to scrapping the bushing. 7. All threads on the Adjustment Ring, Clamp Ring, and Bowl, as well as the threads on the Head Stub and Locking Nut thread, are to be coated with moly grease (at least 3% molybdenum disulfide grease by weight). The moly grease provides a barrier to keep the thread surfaces, which are of similar material,

3-2

from galling as they slide past each other. The Crusher was initially assembled with an anti-seize (grease) compound that contains 25% by weight molybdenum disulfide. This anti-seize compound protects the threads as they work harden during initial operations. Under severe conditions, it may be advisable to continue using this compound as a thread lubricant (consult the Parts Manual supplied with the Crusher for part number). 8. Certain components, such as the Socket Assembly, require thermal procedures during installation or removal. These parts can be damaged by improper heating techniques, so it is important to use the following procedures when heating Crusher components: a) Whenever possible, the heating of these parts should be done with an immersion oil bath, a temperature controlled oven, or an induction heater. Establishing a uniform, soaking heat of minimum temperature necessary for installation is very important. b) Target temperatures are not to be exceeded. Overheating can damage parts by affecting the metallurgy and causing residual stress concentrations. c) Cutting torches are not acceptable for use as a heating tool. Concentrated heat from a cutting torch will result in hot spots that may cause dimensional distortions or cause residual stress concentrations and can adversely surface harden parts. Excessive localized heating can cause stress cracks. d) Oxygen/acetylene or oxygen/propane torches are not recommended, and should only be used with great care. If this is the only method of heating that is available, there are specifically designed burner tips that provide a diffused flame and these should be used exclusively for flame heating purposes. e) If flame heating of gearing must be used, avoid direct flame contact with the hardened surfaces. Warm the bore and internal faces, and allow the heat to slowly soak to the outside.

ECT000-0176 - Rev. B - 07/08

f) Apply heat rapidly and evenly when heating parts for removal, and then remove the part as quickly as possible to minimize heat transfer to the mating part.

3. Exact quantity of parts ordered.

g) Do not quench cool heated parts with liquids. If quicker cooling is required, it should be limited to the motion of ambient air (fan or compressed air steam).

5. Complete shipping instructions; a freight delivery address and the method of shipment.

Ordering Replacement Parts Your Crusher was supplied with a Parts Manual that provides a graphic representation of all the assemblies and subassemblies of the Crusher and all of the parts that make up these assemblies. Whenever maintenance is to be carried out on the Crusher, use the Parts Manual to develop a list of what parts it may be necessary to replace. FLSmidth Excel keeps in stock a generous supply of replacement parts to provide fast service on all orders for repairs and replacements. To avoid delay and the chance of the wrong part being furnished, the following information should be provided when placing an order:

4. Complete name and part number as shown in the Parts Manual.

Genuine FLSmidth Excel parts should be used for the optimum operation and maintenance of these Crushers.

Periodic Inspections To keep the Crusher in good operating condition, it is necessary to carry out inspections (daily, weekly, monthly, and yearly). Liner changes provide access to the interior of the Crusher and are excellent times to conduct a thorough inspection. During inspections, assessment of the general condition of wear parts and bearing surfaces can be determined, and maintenance actions scheduled accordingly to prevent major breakdowns. It may be necessary to adjust the inspection intervals to match operating conditions. Refer to Daily, Weekly, Monthly, and Annual Checks and Maintenance Forms

1. Crusher model and size 2. Crusher serial number. The number can be found on the Crusher name plate and on the cover of the Parts Manual.

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3-3

Daily Checks and Maintenance

Check

Normal Condition

1

Check oil tank level

2

Check lube oil pressure at the Crusher

20-38 psi (1.4-2.6 Bars)

3

Check oil inlet temperature at the Crusher

100°F to 130°F (38°C to 54°C)

4

Check cavity level and power draw

5

Check close side setting

6

Check oil piping for leaks

7

Check tramp release circuit pressure

1800 psi

8

Check clamping circuit accumulator pre-charge pressure

1000 psi

9

Check clamping circuit pressure

2800 psi

10 Check feed distribution in crushing cavity 11 Check the Crushers discharge area to make sure it’s clear and the discharge conveyer is running properly 12 Check the Main Frame arms for buildup of material 13 Check the Counterweight Guard for wear 14 Check Crusher coast down time

60 to 90 seconds

15 Check for any loose fasteners 16 Check for any unusual noises 17 Check for cracked, loose, or worn Liners 18 Determine remaining Liner life 19 Check the Adjustment Ring for movement 20 Check oil tank strainer basket under the inspection cover in the lube tank for debris and drain line oil flow 21 Check Tramp Release circuit Accumulator pre-charge pressure 22 Check Sheaves (Crusher and Motor) for build-up of material

3-4

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1500 psi

Weekly Checks and Maintenance





Check

1

Check the condition of the Countershaft Box Blower

2

Check the condition of the lube and Hydraulic Power Unit tank breathers

3

Check for wear and tightness of Feed Plate, Bowl Liner, and Mantle

4

Make sure the Adjustment Ring threads are lubricated with the Bowl unclamped using the recommended grease

5

Check the V-belts for tightness and alignment

6

Check the Crusher and Motor Sheaves for cracks and tightness of the bushings

7

Check the Main Frame Liners, Frame Arm Guards, Counterweight Guard, Countershaft Box Guard, and bottom of Head for wear

Normal Condition

Monthly Checks and Maintenance

Check Normal Condition

1

Check the engagement of the adjust motor pinion teeth with the Drive Ring teeth

2

Check and lubricate the adjust motor per the manufacturers specifications

3

Have the lube and hydraulic oils analyzed and change if required

4

Check the Countershaft end float

5

If the close side setting has not changed more than one inch, turn the Bowl in and out a few times

6

Check Clamping Circuit Accumulator pre-charge pressure



ECT000-0176 - Rev. B - 07/08

See Oil Contamination Chart in Section 3 0.061” - 0.031” (1.6mm - 0.8mm)

1000 psi

3-5

Annual Checks and Maintenance





1

Completely disassemble the Crusher. Inspect all bearing surfaces along with Gear and Pinion contact for wear

2

Check the Main Frame, Head, and Bowl for signs of fatigue cracking

3

Check all piping and fasteners for tightness

4

Check fit of the Main Shaft in the Main Frame bore.

Check

Normal Condition

Check

Normal Condition

Liner Change Checks and Maintenance





1

Check and re-condition the seating surfaces on the Bowl and Head if necessary

2

Check the Head Bushing, Head Ball, Socket Liner, Eccentric and Dust Shell for wear

3

Check the Head Locking Bolt and Feed Plate for wear. Replace if required

4

Check the Main Frame Liners, Arm Guards, Countershaft Box Guards, and Counterweight Guard for wear and re-condition if necessary

5

Check for thread galling and wear on the Bowl, Adjustment Ring, and Clamping Ring

3-6

ECT000-0176 - Rev. B - 07/08

Lubrication Maintenance Chart

Location

Lubrication

Interval

Method

Oil: ISO 150 (630-770 SUS @ 100° F) (With E.P. Additives)

Change every 2000 hours (if required)

Circulation

2

Hydraulic Power Unit (not Oil: shown), Tramp Release ISO 32 (135-165 SUS @ 100° F) Cylinders, Clamping Cylinders

Change every 2000 Hours (if required)

Circulation

3

Bowl and Head Surfaces Only Do Not Oil Mantle or Bowl Liner (contacting the epoxy backing)

Oil: ISO 150 (630-770 SUS @ 100° F)

Every liner change

4

Bowl, Clamping Ring, and Adjustment Ring Threads (unclamp bowl before greasing)

Grease: Lithium Base NLGI No. 1 with 3% Molybdenum Disulfide (by wieght)

40 hours: every liner change

5 Locking Bolt Threads

Grease: Lithium Base NLGI No. 1 with 3% Molybdenum Disulfide (by wieght)

Every liner change

Manual, brush

Main Frame and Adjustment 6 Ring Seating Surface

Grease: Lithium Base NLGI No. 1 with 3% Molybdenum Disulfide (by wieght)

2000 hours

Manual, brush

During assembly

Manual, brush

2000 hours

Grease fitting

Change every 1000 hours (if required)

Pour

1 Crusher Circulating Oil

7 Countershaft Box Wear Strip Grease 8 Mechanical Overload Clutch

Grease: Grade 1 to 1.5 Lithium Base Non-EP

Oil: 9 Hydraulic Drive Assembly EP 80W90 Gear Oil

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Manual, brush Grease fittings Manual, brush

3-7

Lubrication

FIG 3-1

Thread Lubrication: It is critical that the threads in the Bowl, Adjustment Ring, and Clamping Ring are always well lubricated. Grease fittings are located around the perimeter of the Adjustment Ring to provide additional thread lubrication during Crusher operations between liner changes. Refer to Figure 3-1 The relationship of the Bowl, Adjustment Ring, and Clamping Ring threads in both the crushing and adjusting positions is illustrated. FLSmidth Excel recommends using lithium based NLGI No. 1 grease, containing 3%-5% molybdenum disulfide by weight. If a high temperature material is being crushed, use a high temperature grease with the same 3%-5% molybdenum disulfide by weight. Refer to Figure 2-4 Crusher Lubrication

The Raptor XL1100 Crusher is designed to operate with ISO EP 150 Gear Oil at normal ambient temperatures. To ensure proper lubrication of the Crusher, the oil level must be within the prescribed range of the oil level site gauge on the oil reservoir. Oil level should be checked daily and oil added as necessary. The Raptor Crushers are equipped with a low oil level sensor that will provide a warning of low oil level in the reservoir. Refer to Section 4 of the Instruction Manual for detailed lube oil specifications. Under the oil reservoir inspection hatch, there is a removable 10 mesh strainer basket designed to catch large particle contamination as the drain oil returns to the reservoir. This strainer basket should be checked daily for signs of contaminants and bronze or lead from the Crusher bushings. Oil Filter

The Package Lube System includes a full flow oil filtration system with external pressure relief to ensure adequate oil flow to the Crusher in the event of blockage at the filters. A pressure differential switch monitors the pressure drop across the filter system and sends an analog signal to the FLSmidth Excel supplied Automated Control System (ACS) to indicate dirty and plugged filter element conditions. Filter replacement is addressed in the Lubrication Section of this Instruction Manual. Oil Contamination

Use of contaminated oil or oil that has lost its properties will accelerate bearing and journal wear and result in expensive repair costs. Oil samples should be taken and analyzed on a regular basis. Most Crusher operators sample the oil once per month. If

3-8

1. Grease Zerk 2. Adjustment Ring 3. Main Frame Figure 3-1

4. Main Frame Seat Liner 5. Fulcrum Bar Grease Fittings

the oil sample indicates an unusual increase in any of the contaminants, a thorough inspection of the Crusher should be made to find the source(s). Oil analysis can also provide clues to the possible source(s) of contamination. Silica limits must be interpreted in relationship to copper and iron levels. If high silica is accompanied by high copper and/or iron, the oil is considered abrasive and should be replaced at first opportunity. Refer to Table 3-1 Lube Oil Change Interval: The normal oil change interval is every 2000 hours of operation, or as determined necessary by lube oil sampling or visual inspection. The lube oil should be changed after any major Crusher bushing failure that results in high lubrication oil temperatures. The oil will smell burnt.

Hydraulic System Hydraulic Power Unit

The Raptor XL1100 Crusher has a specially designed Hydraulic Power Unit to provide hydraulic forces for the Tramp Release System (oil over nitrogen gas), the Bowl Clamping System, the Clearing System, and the Hydraulic Adjustment Mechanism. This is a sophisticated system with a dual hydraulic pump arrangement, electric solenoid control valves, pressure relief valves, and digital monitoring system. It is extremely important that efforts be made to keep the hydraulic system and hydraulic oil free from contamination. The Hydraulic System is designed to use ISO 32 hydraulic

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oil. At higher ambient temperature (in excess of 105°F (41°C) it may be necessary to switch to ISO 46 hydraulic oil. A detailed specification for the hydraulic oil can be found later in this Instruction Manual. Refer to Section 5 Hydraulic Oil Change Interval

The hydraulic oil should be changed once a year at a minimum, or sooner if conditions dictate. A frequently plugged hydraulic oil filter is a good indication that it is time to change the hydraulic oil. The inside of the oil reservoir should also be thoroughly cleaned, as well as the magnetic suction strainer. The following signs are typical indications of the need to change the hydraulic oil and clean the hydraulic system: 1. Plugged filter indication on the hydraulic oil filter. 2. Irregular operation of the hydraulic circuits that may include high oil temperatures.

Do not rely on the Push/Pull power button on the manual control panel. 2. Open both the tramp release and clamping system dump valves so both system pressures are at zero Close both valves once both systems have been completely depressurized. 3. Drain all the oil from the power unit reservoir. Unless there is a serious issue with oil contaminations, the oil in the release and clamping systems and their lines can be left in place when the reservoir is drained and cleaned. 4. Remove the round “clean-out” reservoir cover and filler pipe strainer. 5. The inside of the reservoir should be cleaned with a solvent and dried with lint free rags or wipes. 6. Reinstall the filler pipe strainer, suction strainer, and “clean-out” cover.

3. Existence of emulsions. 4. Hydraulic oil that shows indications of any or all of the following: Dark (burnt) color; cloudy or milky appearance; rancid or burnt smell; incorrect oil viscosity. Cleaning the Hydraulic System

To clean the hydraulic system, do the following: 1. Following proper lockout procedures, turn off and lock out the electrical power to the hydraulic power.

7. Fill the reservoir with the hydraulic oil. Refer to Hydraulic Oil Specifications in Section 5 Changing the Oil Filter

Depending upon the manufacturer of the Hydraulic Power Unit, the oil filter is located either inside or outside of the cabinet. A visual indicator located on the top of the filter will signal when replacement of the cartridge is required. This signal will automatically reset when the cartridge has been changed.

Oil Contamination Guidelines

ACCEPTABLE

HIGH



COPPER (Cu)

Below 100 PPM

Above 210 PPM



ALUMINUM (Al)

Below 5 PPM

Above 10 PPM



IRON (Fe)

Below 20 PPM

Above 50 PPM



SILICA (Si)

Below 25 PPM

Above 65 PPM



CHROMIUM (Cr)

Below 0.5 PPM

Above 1.5 PPM



LEAD (Pb)

Below 70 PPM

Above 190 PPM



CONTAMINATION LEVEL (TOTAL SOLIDS)

Below 0.1%

Above 0.2%



WATER

Below 0.1%

Above 1.0%

Table 3-1

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The procedure for removing a Tramp Release Cylinder from the Crusher is as follows:

To change the filter cartridge, do the following: 1. Use proper lockout procedures to electrically isolate the Hydraulic Power Unit. Do not rely on the Push/Pull power button on the remote/manual control panel. 2. As a matter of safety, dump the pressures in both the clamping and tramp release systems, using the dump valves as described above.

1. Do a clearing cycle to displace as much oil as possible from the Tramp Release Cylinders. Do not re-pressurize the Tramp Release Cylinders. 2. Open the dump valve for the Tramp Release Circuit to ensure there is no residual pressure. Leave the dump valve open throughout the maintenance procedure.

3. Remove the filter canister cover. 4. Remove the filter element from the housing and clean the housing with a mild solvent. 5. Place the new, clean element in the housing, centering it on the element locator. 6. Inspect the cover o-ring and replace if necessary. 7. Install the canister cover. Hydraulic Drive Assembly Service

The lubricating oil in the planetary gear reducer should be changed out every 12 months of operation. There is one grease fitting at the labyrinth seal at the top of the planetary gear reducer. This seal should be greased every 6 months. Due to the complicated and precise design of the Hydraulic Drive Assembly, any disassembly or work on internal parts should be left to trained service technicians. Removing the Tramp Release Cylinders

A leaking Tramp Release Cylinder should be replaced or removed and rebuilt as soon as possible. Tramp Release Cylinder leaks normally occur at the seal in the cylinder head, and this is indicated by oil at the top of the cylinder. It is also possible to have oil leaking past the piston, which will manifest itself as oil leaking from the breather at the bottom of the cylinder. A leaking condition can result in excessive repressurization of the hydraulic Tramp Release Circuit by the Automated Control System (ACS). If the repressurization cycles exceed a prescribed limit, the ACS will take action to shut feed off to the Crusher and shut down the Hydraulic Power Unit.

Warning

Do not, UNDER ANY CIRCUMSTANCES, disconnect any of the hoses from any of the components in the Release System without making sure that there is zero pressure in the system. A hose being disconnected under high pressure is very dangerous and can cause serious harm from the escaping high velocity oil and the possibility of being hit by a whipping hose. 3. Disconnect the cable that tethers the Tramp Release Cylinder to the Main Frame, and allow the weight of the Tramp Release Cylinders to displace any oil that may remain in the cylinders. 4. Disconnect the hydraulic hoses. Note: There will still be some hydraulic oil displaced, so be prepared to catch this oil in a container. 5. There is a tapped hole at the end of the piston rod to install 20mm ring bolt. From an overhead lifting device, attach suitable cable or nylon sling to the piston rod and take a light strain on the Tramp Release Assembly to free up the 80mm spherical nut. 6. Remove the 80mm nut from the piston rod and slowly lower the Tramp Release Cylinder through the hole in the Adjustment Ring and the corresponding hole in the Main Frame. Pay particular attention to not damaging the piston rod or the piston rod thread. 7. Once the cylinder assembly is lowered to the deck at foundation level, the cable or sling will have to be reattached to lift it away, or the cylinder assembly placed on a conveyance to carry to the location of repair. 8. The Tramp Release Cylinder has rebuild kits referenced in the Parts Books under the Tramp Release Cylinder Assembly. FLSmidth Excel highly

3-10

ECT000-0176 - Rev. B - 07/08

recommends that a customer have a spare Tramp Release Cylinder Assembly on hand to change out as needed. The Tramp Release Cylinders operate under high pressure, so only persons fully trained in such repairs should work on these components.

Installing the Tramp Release Cylinder To install the tramp release cylinder, follow the tramp release cylinder installation instructions as outlined in Section-1 of the Instruction Manual.

1. Following proper lockout procedures, turn off and lock out the electrical power to the Hydraulic Power Unit. Do not rely on the Push/Pull power button on the remote/manual control panel. 2. Depressurize the Tramp Release Circuit using the circuit dump valve as shown previously. Leave the dump valve open throughout the maintenance procedure.

Replacing the Accumulator An Accumulator that no longer holds nitrogen pre-charge requires immediate attention. This is typically a result of a damaged internal bladder; however, a bleed off of nitrogen pressure can also occur through a defective charging valve (Schroeder Valve). Note: The nitrogen pre-charge can only be checked with the Tramp Release Circuit depressurized. Low pre-charge is the primary cause of failed Accumulator bladders.

1. Accumulator 2. Gas Valve Stem 3. Valve Cap

4. Valve Guard 5. Washer

1. 2. 3. 4. 5.

6. 7. 8. 9.

Once a bladder has failed, the accumulator will fill with hydraulic oil and no longer serve the purpose of absorbing energy as the oil is displaced from the Tramp Release Cylinders during a tramp event. It is this stored energy that rapidly returns the Adjustment Ring to the seated position on the Main Frame. Since the hydraulic oil can no longer be displaced into the accumulator and against a compressible gas, great pressures occur, which cause overload conditions during a tramp iron event or period of excessive crushing forces. The Raptor XL1100 Crusher Tramp Release system is designed with a pressure relief system that reduces excessive crushing forces by dumping hydraulic oil to atmospheric pressure during a major overload condition. This is a backup system, and should not be relied upon as a substitute for proper maintenance of the systems Accumulators.

Checking the Accumulator Pre-Charge The Tramp Release System Accumulators should be checked for proper pre-charge at a minimum of every 140 hours (approximately once a week). If the pressure has dropped more than 50 psi below the specified pre-charge of 1000 psi, dry nitrogen gas should be added to the Accumulator. If the pre-charge pressure cannot be held, the Accumulator should be repaired or replaced. Following is the procedure to dismount the Accumulator:

Screw Bleeder Valve Gas Charging Valve Pressure Gauge Handle

Figure 3-4

ECT000-0176 - Rev. B - 07/08

Air Chuck Swivel Gas Valve Stem Accumulator

Accumulator Depressurization

3-11

Bowl Liner Change Out

Warning

Do not, UNDER ANY CIRCUMSTANCES, disconnect any of the hoses from any of the components in the Release System without making sure that there is zero pressure in the system. A hose being disconnected under high pressure is very dangerous and can cause serious harm from the escaping high velocity oil and the possibility of being hit by a whipping hose. 3. Remove the valve guard from the top of the Accumulator. Refer to Figure 3-4 4. Turn the T-Handle on the Air Chuck all the way out on the Checking and Charging Assembly supplied with the Crusher Tool Assembly. Close the Bleeder Valve and thread the Air Chuck Swivel onto the Valve Stem (Schroeder Valve) on the Accumulator.

Note: Do not over tighten the Air Chuck Swivel more than a quarter turn. Over tightening can twist off the Valve Stem and/or damage the copper washer in the Air Chuck, causing leakage.

Use the following procedures to remove the Bowl Assembly from the Crusher during Crusher inspection or a liner change: 1. Turn the Local / Remote selector switch located on the Push Button Control Panel for the Hydraulic Power Unit to the “Local” position. 2. Turn the High / Low selector switch on the Control Panel to the High position. This selects the speed of the Hydraulic Adjustment Mechanism and increases the speed of Bowl removal. 3. Open the Clamping Circuit manual pressure dump valve before installing or removing the Bowl Assembly. This eliminates all Clamping circuit pressure and the potential to damage the Bowl or Adjustment Ring threads while the Bowl is being rotated out. It also eliminates the possibility of thread damage during minimal thread engagement if automatic pressurization of the Clamping Circuit occurs.

5. Turn the T-handle down until its internal shaft depresses the valve core stem on the Accumulator bladder. You can now read the pressure of the FIG 3-7 nitrogen in the accumulator. 6. To remove the nitrogen pre-charge, slowly open the Bleeder Valve until the pressure gauge on the charging valve reads zero, loosen the Air Chuck, remove, and store the assembly. 7. Remove the hoses from the manifold block at the bottom of the Accumulator. Refer to Figure 3-5

1. Accumulator 2. Hose Fittings 3. Relief Valve Manifold Block

8. Using a chocker configuration, attach a suitable nylon lifting strap around the Accumulator. 9. Unfasten the Accumulator Clamp Bracket and then lift the Accumulator up and off the mounting bracket, being careful not to damage the manifold block. 10. For Accumulator installation, follow the instructions as outlined in Section 1 of this manual. Note: FLSmidth Excel recommends that the customer have a spare Accumulator on hand. 11. The rebuild kit will have written instructions on how to rebuild an Accumulator. Only persons trained in servicing high pressure vessels should perform this work.

3-12

Figure 3-5

ECT000-0176 - Rev. B - 07/08

Accumulator Mounting

FIG 3-8

Bowl Liner Removal To remove the Bowl Liner from the Bowl, proceed as follows: 1. Support the Bowl Assembly with the bottom of the Bowl Liner resting on at least three wooden blocks. This will support the Bowl Liner when removing the wedge bolts. Without this support, it is possible that the weight of the Bowl Liner can expel a wedge, and/ or wedge bolt, with enough force to cause injuries. Refer to Figure 3-7

1. 2. 3. 4.

Lifting Cable Feed Hopper Anchor Shackle Adjustment Cap Lifting Lug Figure 3-6

5. Bowl Liner 6. Adjustment Cap 7. Bowl

2. Remove all the old grease, rust, and dirt from the Bowl threads. With the threads thoroughly cleaned, inspect the threads for galling, and repair as defined in Determining Bowl Thread Wear later in this section.

Note: This can be done at any time prior to installing the Bowl Assembly back into the Crusher.

Lifting Bowl Assembly

3. Attach suitable clevises and lifting cables to the two lifting holes at the top of the Bowl Hopper, and lift 4. Connect four lifting cables or chains of equal length it out of the Bowl. This will provide access to the to the lifting pads on the top of the Adjustment Cap of wedges that hold the Bowl Liner in place. Note: There the Bowl Assembly. Center the crane over the Bowl will probably be a lot of rock fines in the wedge bolt Assembly, and take a slight strain with the overhead FIG 3-9 areas that will have to be cleaned out. crane to take some of the Bowl Assembly weight off of the Adjustment Ring, Clamp Ring, and Bowl threads. 5. Turn and hold the Open / Close selector switch located on the Control Panel to the Open position. There will be a brief delay as the Automated Control System ensures that the clamping circuit is depressurized. The Bowl will then begin to turn counterclockwise out of the Crusher. Turn the Bowl until the end of the bottom thread of the Bowl just passes the start of the top thread on the Clamping Ring. At that point, the Bowl Assembly will visibly tilt in the Adjustment Ring. Release the Open / Close selector switch to stop the turning of the Bowl.

Warning

If the Bowl is turned a full turn past the start of the top thread of the Clamping Ring, the Bowl will drop the 2” height of one full thread and could receive thread damage. 6. Lift the Bowl Assembly away, and place it on hardwood blocking, being sure the weight is being supported by the Bowl Liner. Refer to Figure 3-6 & Figure 3-7.

1. 2. 3. 4. 5. 6.

Lock Plate Cotter Pin Bolt Stop Square Head Bolt Spherical Nut Epoxy Backing

Figure 3-7

ECT000-0176 - Rev. B - 07/08

7. 8. 9. 10. 11. 12.

Bowl Bowl Liner Wedge Retainer Wedge Loosen Nut 0.5” (13mm) Wood Block

Bowl, Wedge, and Liner Parts

3-13

the blocking so that the support is now under the skirt of the bowl so that the liner is free to drop. It may take the use of a heavy sledge hammer or other tool to break the Bowl Liner free. After removing the Bowl free of the Liner, set the Bowl on wood blocking.

4. Remove the wedge retainers, cotter pins, and lock plates from each of the wedges, and set aside for reuse. Refer to Figure 3-8 5. Using a wire brush, clean the wedge bolt threads, lubricate, and then back off the spherical nuts approximately 0.5” (12mm). 6. If any of the wedges do not loosen when the spherical nut is backed off, strike the wedges with a hammer. 7. With all the wedges loose, unscrew all the spherical nuts far enough to allow for removal of the square head bolts and wedges.

Warning

It is important to follow the wedge removal procedure as outlined above. If not, the wedges could propel outward and cause bodily harm when they break loose. 8. With all the Liner retention hardware removed, lift the Bowl Assembly off the Bowl Liner. Note: Proper installation of the Bowl Liner includes the application of a light coat of oil to the Bowl in the area of the backing material prior to pouring. This ensures that the backing material will not stick to the Bowl. Not placing a light oil film on the bowl can make it very difficult to remove the liner. If this happens, it will be necessary to lift to the Bowl Assembly and reposition

FIG 3-10

9. Inspect the seating surface of the Bowl for ridges or steps caused by working of the bowl liner during operations.

Note: This is normally caused by wearing a bowl liner too thin, or having the bowl liner come loose. Grind any proud areas to maintain a continuous conical Bowl Liner seating surface in the Bowl. If the ridge or step is abnormally deep, refer to the Bowl Liner Installation later in this section.

Warning

Improper seating of the Bowl Liner on ridges or steps in the seating surface of the Bowl can cause the Bowl Liner to come loose creating additional down time to rework and the chance for very expensive weld and machining repairs.

Bowl Liner Installation Use the following procedure to install a Bowl Liner: Note: A change in liner configuration may require a change in the Adapter Ring. 1. Remove all the paint from the seating surface on the Bowl Liner. 2. Place the Bowl Liner on wood blocking, making sure the blocking will allow the Bowl to fully seat on the Bowl Liner. Note: It is important to get the bowl liner as level as possible. 3. Place chalk marks at the apex of each of the helixes on the Bowl Liner. Refer to Figure 3-9 4. Clean the inside of the Bowl, and apply a coat of light oil to prevent the epoxy backing from adhering to the Bowl.

1. 2. 3. 4.

Bolt Stop Lock Plate Cotter Pin Square Head Bolt Figure 3-8

3-14

5. Spherical Nut 6. Wedge 7. Wedge Retainer

Wedge Assembly

5. Lower the Bowl onto the Bowl Liner, making sure the chalk marks (step 2 above) line up with the wedge slots in the Adapter Ring of the Bowl. 6. With a 0.010” (.25mm) feeler gauge, check for clearance between the Bowl seat and the Bowl Liner seat. It should not be possible to get the feeler gauge

ECT000-0176 - Rev. B - 07/08

FIG 3-11 10. Inspect the inclined surface on the nose of each wedge to make sure there are no gouges, heavy indentations, or proud surfaces. Dress as necessary with a high speed grinder to create a smooth upward, ramping surface. Place the wedges on the adapter ring between the stop blocks, and push the wedges forward until they contact the Bowl Liner. 1. Bowl Liner 2. Chalk Mark Above High Point of Helix 3. High Point of Helix Figure 3-9

Helix High Point Location

in for more than 20% of the circumference. If the gap between the Bowl seat and the Bowl Liner seat is excessive, the Bowl Liner may not be usable.

Note: It is best to replace damaged or questionable wedges.

11. Each of the wedges should contact the helix of the Bowl Liner from about 35 to 50 per cent up the inclined surface of the wedge. Add or remove shims under the wedges to obtain the desired contact points on the helix. Once the proper wedge contact on the helix is established, tack weld the shims in place. Refer to Figure 3-11 12. Place a shim on top of the wedges to a height that is even with the top of the adapter ring. Then place and bolt the wedge retainers onto the adapter ring at each wedge location. The shims will keep the

Note: Occasionally a bowl liner may be distorted after machining, and may no longer be suitable for use. Before replacing the liner, lift the bowl andFIG 3-12 rotate it 180 degrees and see if this makes a positive change.

7. Remove the bowl, place a 0.25” (6mm) bead of silicone sealant full circle at the bottom of the Bowl Liner seat, and replace the bowl, ensuring that the seating surfaces are properly aligned. 8. Take a measurement between the Bowl Liner flange and the inside of the Bowl at four places 90 degrees apart. This is to make sure the Bowl and the Bowl Liner are properly centered. If these measurements are not fairly equal (you are measuring from an “as cast” surface), lift the Bowl and reseat it on the Bowl Liner until they are. Note: A large pry bar will help. A cocked Bowl Liner can come loose during operation and cause serious damage to the Bowl seating surface. Refer to Figure 3-10 9. Thoroughly clean the threads on each wedge bolt, apply an anti-seize compound to the threads, and screw on the spherical nuts, making sure that the spherical side faces away from the head of the bolt. Refer to Figure 3-11

Note: It is best to replace damaged or questionable wedge bolts.

1. 2. 3. 4.

Bowl Fiberglass Insulation Bowl Liner Epoxy Backing Material

5. 0.010” (0.25mm) 6. Feeler Gauge 7. Wood Block

Figure 3-10 Checking Bowl Liner Seating Surface

ECT000-0176 - Rev. B - 07/08

3-15

wedges from tipping when tightening and possibly coming loose during Crusher operations. Note: Bowl Liners are castings, and occasionally there will be occurrences where the top of the wedge bolt will project above the top of the Adapter Ring. This will necessitate placing shims on the wedge retainer plates. 13. Place the square head bolts with spherical nuts (see Step 6) behind the wedges, making sure the bolt is horizontal and the heads are under the horizontal bolt retainers that are welded in the slots in the Bowl. The bolt retainers hold the heads of the bolts in place during tightening and prevent the bolts from sliding up during Crusher operations. If the bolts come up, the Bowl Liner will become loose. Note: A change in liner profiles may require a change of Adapter Ring, and it will most likely be necessary to relocate the bolt retainers. Also, a change in Bowl Liner manufacturer may also result in a necessary change.

FIG 3-13

14. With a sledging wrench, alternately tighten each spherical nut in a crisscross pattern until all the wedges are tight in the Bowl Liner helix. 15. Check once again, the contact between the Bowl seat and the Bowl Liner seat at the bottom, using a 0.010” (0.25mm) feeler gauge. You should not be able to get the feeler gauge in for more than 20% of the seating surface. All openings caused by Bowl seating surface wear should be packed with caulking to prevent the backing material from leaking out when poured. Refer to Figure 3-10 16. Fill the entire space behind the Bowl Liner with the FLSmidth Excel epoxy backing compound recommended in the Parts Manual. Be sure to stop pouring before the backing compound reaches the level of the bottom of the Adapter Ring. Carefully follow the safety and mixing instructions supplied in each kit of epoxy backing compound. Refer to Figure 3-10 17. After the epoxy has cured, repeat the tightening process for each wedge bolt. If time does not permit to wait for the epoxy to cure, still carry on with the repeat of the tightening process. The epoxy curing time is extremely temperature dependent. If the Bowl and Bowl Liner are cold, it will be necessary to heat up these pieces to approximately 70° to 80°F (21° to 27°C). Normal curing time is about 8 hours at the above ambient temperature. 18. Place the lock plates over the spherical nuts and attach them to the wedges using cotter pins. Refer to Figure 3-11 19. Using fiberglass insulation or other water resistant materials, cover the area above and around the wedge bolts, and completely fill the areas of the bowl. This will help prevent dirt and dust from accumulating around these parts while making it easier to remove them during the next Liner change. Refer to Figure 3-10

1. 2. 3. 4.

Incline Midpoint Wedge Lock Plate Bolt Stop Welded to Bowl 5. Square Head Bolt Figure 3-11

3-16

6. Tack Weld Shim on this Surface, if Required 7. Bowl Ring 8. Must Have Clearance 9. Bowl 10. Bowl Liner Bowl Liner Installation

20. Lift and place the Hopper into the Bowl, making sure the Hopper engages the slots in the top of the Bowl. Apply silicone sealant to the horizontal surface of the bowl liner flange. When the Hopper is set into position, this will provide a seal between the bottom of the hopper and the top of the Bowl, and help in keeping rock fines from getting into the wedge bolt area.

ECT000-0176 - Rev. B - 07/08

FIG 3-14B

FIG 3-14A

1. Safety Engineered Hoist Ring 2. Head Lifting Plate 3. Equal Clearance 4. Heavy Side of Eccentric 5. Maximum Clearance 6. Minimum Clearance

Figure 3-12

Installing or Removing the Head Assembly

Mantle Replacement 21. Following the steps defined in the Bowl Installation Instructions detailed earlier: Lubricate the Bowl, Clamping Ring, and Adjustment Ring threads prior to installing the Bowl in the Crusher.

Note: If any of the Bowl threads have been refurbished (e.g. weld repaired and machined), it is important to apply to the threads the same break-in grease (antiseize compound) used by the factory. This material is available from FLSmidth Excel, and significantly reduces wear and galling of new or rebuilt Bowl or Adjustment Ring threads. Use RXL000-0079.

22. Install the bowl back into the Crusher following the instructions in Section 1 as outlined in Installing the Bowl Assembly.

Bowl, Bowl Liner Seating Surface Extended periods of crushing operation will eventually cause wear of the Bowl seating surface, requiring weld repair and machining. The Bowl is made of a high strength alloy casting, which requires special welding procedures. Contact FLSmidth Excel for reconditioning instructions.

It is necessary to remove the Head Assembly from the Crusher to carry out the Mantle replacement. Procedure to Remove the Head:

1. Remove the Feed Plate from the Locking Nut. 2. Secure the 64mm hoist ring (supplied in the tools assembly) in the tapped hole on the top of the Head lifting plate. Bolt the Head lifting plate to the Locking Bolt using the capscrews supplied in the tools assembly, making sure the hoist ring in the Head Lifting Plate is positioned toward the closed side of the crushing cavity. The off-center position of the hoist ring slightly tilts the Head into a position that will not damage the Lower Head Bushing when removing the Head. If the hoist ring is not correctly positioned, the Lower Head Bushing damage can occur as the Head Assembly is being removed. Refer to Figure 3-12 3. With the lifting rigging relatively centered over the Head, slowly lift the Head Assembly straight up until it clears the Crusher. 4. Place the Head on suitable cribbing. DO NOT support the Head using the Head Skirt. The Head Skirt was not designed to support the Head Assembly, particularly when worn. Note: Many customers fabricate a special stand to facilitate the changing of Mantles and other maintenance items related to the head.

ECT000-0176 - Rev. B - 07/08

3-17

FIG 3-15

FIG 3-16

1. Feed Plate 2. Cap Screws 3. Locking Nut Figure 3-13

4. Torch Ring 5. Head Stub 6. Mantle

1. Torch Ring 2. Direction of Cutting Torch (to avoid damaging the Locking Bolt or Head)

Mantle Replacement

Procedure for Replacing a Worn Mantle

Figure 3-14

Cutting the Torch Ring

FIG 3-17

Refer to Figure 3-13 Crushing forces create a self-tightening action that keeps the Locking Nut tight against the Torch Ring and Mantle, forcing the Mantle down onto the tapered seating surface of the Head. To relieve this stress, it is necessary to cut the Torch Ring. 1. First, grind away all stitch welds that attach the Locking Nut to the Torch Ring, and the Torch Ring to the Mantle. 2. Using an oxy-acetylene torch, cut through, or nearly through, the Torch Ring. Great care must be taken not to damage the threaded head stub. Refer to Figure 3-14 3. Mount the Locking Nut Wrench on the Locking Nut. Use 30mm capscrews from the Tools Assembly to hold the wrench in place. Refer to Figure 3-15 4. Slug the Locking Nut Wrench counterclockwise until the Locking Nut turns easily. At this point, remove the Locking Nut Wrench and set it aside. 5. Use two 20mm Ring Bolts and attach an overhead lifting device to the Locking Nut. Finish backing off the Locking Nut until it can be lifted off the Head Stub and set aside.

3-18

1. Lifting Ring Bolts 2. Locking Nut 3. Torch Ring Figure 3-15

4. Locking Nut Wrench 5. Mantle 6. Head

Locking Nut Wrench

6. It is now possible to remove the Mantle with the Torch Ring still in place. Weld two or three D-Rings to the Mantle, using a manganese or stainless steel rod. Refer to Figure 3-16 7. Lift the Mantle away, being careful not to damage the threads on the Head Stub. Refer to Figure 3-17

ECT000-0176 - Rev. B - 07/08

FIG 3-19 4. Using the lifting lugs that are cast at the bottom of the new Mantle, set the Mantle on the Head, centering the Mantle about the head stub, using a suitable pry bar. Refer to Figure 3-18 5. Use a 0.010” (0.25mm) feeler gauge to check the contact between the Mantle and the Head at the bottom of the mating seating surface. One should not be able to get the feeler gauge in full depth over more than 20% of the seating surface.

1. 4” (102mm) 2. 2” (51mm) 3. 0 2” (0 51mm) Figure 3-16

4. R 2” (R 51mm) 5. 2” (51mm) Lifting Lug

Installing a New Mantle Properly installing a new Mantle is a very critical maintenance process. If the Mantle comes loose, serious damage can occur to the Head. A Head may crack due to the repetitive blows from a loose Mantle. At the very least, the mantle seating surface on the Head will have to undergo very expensive weld repair and machining. Following is the proper procedure for installing a new Mantle: 1. Clean and inspect the Mantle seating surface on the Head for excessive wear, ridges, and other upsets that may affect the ability of the new Mantle to properly seat on the head.

Note: This type of damage to the seating surface is normally caused by operating with too thin a worn mantle or having a mantle come loose.



Grind any proud areas to maintain a continuous FIG 3-17 conical seating surface. If the ridges or steps are abnormally deep, it may be necessary to send the head to a repair facility and have the seating surface rebuilt.

6. If the contact at the seating surface is questionable, it is advisable to heat the bottom of the Mantle to approximately 50°F (28°C) above ambient. 7. Again, if the contact at the seating surface is questionable, apply a caulk or sealant at the bottom of the seating surface to keep backing material from flowing out when it is poured into the void area between the Mantle and the Head. 8. Again, make sure that the Mantle is centered on the Head, and then set a new Torch Ring in place. 9. Apply an anti-seize compound to the Locking Nut and Head Stub threads.

With the same lifting ring bolts used to remove the Locking Nut, set the Locking Nut in place. Hand turn it clockwise until it seats on the Torch Ring. The distance from the Locking Nut and the Torch Ring should be uniform, full circumference. If the distance is not even, do not try to even it out by tightening the Locking Nut. This distance can be evened by either bumping the top of the Mantle to reposition it on the Head or by lifting the bottom of the Mantle on the

2. Inspect the condition of the threads on the Head stub and the threads in the Locking Nut for galling or other damage. Hand dress the threads as necessary. 3. Apply a light oil to the machined surface of the Head, where backing material is installed.

1. Lifting Cable 2. Anchor Shackle Figure 3-17

ECT000-0176 - Rev. B - 07/08

3. Lifting Lugs 4. Mantle (worn) Lifting the Mantle

3-19

FIG 3-20



low side. Keep in mind that the Mantle must also seat properly on the Head seating surface. Once a relatively even distance has been achieved, it is possible to tighten the Locking Nut. Refer to Step 1 and Figure 3-18

10. Mount the Locking Nut Wrench. With the wrench firmly attached to the Locking Bolt, strike the side of the wrench with a sledge hammer or suspended weight to turn the Locking Nut in a clockwise direction. Refer to Step 3 of Removing the Old Mantle 11. Keep tightening until a scribed mark between the Locking Nut and the Torch Ring show that the Locking Nut is advancing less than 0.040” (1mm) per blow. 12. Fill the space between the Head and Mantle to the top of the pouring holes in the Mantle with FLSmidth Excel’s High Performance Backing Compound. Carefully follow the safety and mixing instructions of the manufacturer that are found in each kit of backing compound. A pouring trough made from any flexible sheet material, such as cardboard, can be used to pour the epoxy into the pouring holes in the Mantle. Refer to Figure 3-19 13. After the epoxy has cured, repeat the tightening process for the Head Nut. If time does not permit waiting for the epoxy to cure, carry on with the repeat of the tightening process. The epoxy curing time is extremely temperature dependent. If the Head and Mantle are cold, less than 60 F (16 C), it will be necessary to heat up the two pieces to

approximately 70° to 80°F (21° to 27°C). Normal curing time is about 8 hours at the above heated temperature range. 14. Grind 0.25” (6mm) wide and deep slots, 5” (125mm) long and at 90 degree intervals about the contact between the Locking Nut and the Torch Ring, and between the Torch Ring and the Mantle. Weld these slots with a Nickel Chromium or stainless steel rod. This is to ensure self-tightening as the Locking Nut follows the Torch Ring and Mantle as the Mantle attempts to rotate under crushing forces.

Note: The epoxy backing material kits should be stored at room temperature, or in a temperature range between 60° to 90°F (16° to 33°C). The Head and Mantle also need to be in the same temperature range prior to pouring the backing material. If the metal is too cool, the exothermic reaction may stop and the backing material will not set properly. If the metal is too hot, the backing material may set prior to flowing to the bottom of the void between the mantle and head. If the mantle and or head are colder than 60°F (16°C) then heat should be applied to the two components prior to adding the backing compound. It may be necessary to continue to add heat if the ambient temperature is quite cold. If there are issues with too high a temperature for the Mantle or Head, it will be necessary to set the two pieces in a shaded area and it may be necessary to pour the grout at night.

CAUTION: If weld on lifting D-Rings are used to lift the Mantle, be sure they are strong enough to handle the weight and that the proper weld rod is used to weld the steel lugs to the manganese Mantle. Refer to Figure 3-17

Main Frame Liner Replacement

1. Locking Nut 2. Equal Distance 3. Torch Ring Figure 3-18

3-20

4. Mantle 5. Head Stub 6. Head

The Main Frame Liners should be inspected every time the Crusher is torn down for Mantle and Bowl Liner replacement. The best way to check for wear is to use a straight edge over the vertical face of the liner sections. The most pronounced wear will be 24” to 30” (610 to 760mm) down from the Main Frame Liner Clamps, so a straight edge of approximately 48” (1220mm) of length will do. The Main Frame Liners are made of 1/2” (12.7mm) thick AR plate that is rolled into four sections. The determination of wear can be made by measuring the distance from the straight edge to the exposed surface of the Main Frame Liner. Following is the procedure for replacing the Main Frame Liners:

Seating the Mantle

ECT000-0176 - Rev. B - 07/08

FIG 3-21

6. Clamp each liner section in place. Occasionally, some trimming of the sides and the bottom may be necessary to establish a clearance fit. 7. Tack weld the head of each Liner Clamp capscrew to the Liner Clamp to ensure that they do not vibrate out.

Arm Guard Replacement

1. Mantle 2. Head 3. Feeler Gauge Figure 3-19

4. 0.010” (0.25mm) Maximum 5. Pouring Trough 6. Epoxy Backing Material Installing the Mantle

1. With the Bowl Assembly and Head Assembly removed, set up to measure the Main Frame liner wear. Be sure to cover the Socket Assembly, Eccentric Assembly, and Gear Well area with a clean tarp or other plastic material to keep the internals of the Crusher clean while working on the Main Frame Liners. 2. If the Main Frame Liners are deemed too worn to last through another Crusher Liner Change Out, remove the old Main Frame Liners. This will require welding D-Rings and rigging to an overhead lifting device prior to removing the liner clamps. 3. Lift away and dispose of the worn Main Frame Liners.

Note: While the Main Frame Liners are removed, it is an excellent time to check the Arm Guards for possible replacement.

4. Weld a D-Ring symmetrically located (for balance lift) off the inside arc of the new Main Frame Liners. Note: The D-Rings are being welded to AR plate, so care must be taken to ensure proper weld penetration into the plate. 5. Lift a liner into position, and hang on the liner blocks that are welded to the Main Frame.

Note: The contour at the bottom of the liner and how it fits with the Main Frame arms with Arm Guards installed.

There are three Arm Guard Liners, two for the regular arms and one for the arm with the Countershaft Cartridge, that are subject to abrasive wear as crushed product falls over the Main Frame Arms. These Arm Guards should be inspected for wear every time the worn Bowl Liner and Mantle are changed out. The Arm Guards are made of a high chrome, white iron casting to increase wear life. If it is found that the guards require replacement, use the following procedures to change them out: 1. Remove the Bowl Assembly, the Head Assembly, the Socket Assembly, and the Eccentric Assembly per procedures in this Instruction Manual. 2. Attach suitable rigging, and lift the guards out of the Crusher. 3. Weld lifting Rings to the replacement guards. Refer to Figure 1-8 4. Attach suitable rigging to the guards and place them in the Crusher. Center the guards on the arms and remove the lifting rings.

Procedure to Remove the Socket Assembly The Socket Assembly is comprised of Anti-Spin Components, the bronze Socket Liner and the Socket. The Anti-Spin Components have to be removed from the assembly prior to removal of the Socket Liner and the Socket. The Socket Liner has a slight interference fit with the Socket and can normally be removed using the supplied 20mm jacking screws and no heat. The Socket has a relatively tight interference fit on the Main Shaft, so it has to be rapidly heated using gas torches to achieve a temperature differential between the Socket and the Mainshaft. The Socket is then removed using the supplied 36mm jacking screws. Use the following procedure to remove the Socket Assembly from the Main Shaft: 1. Using slings, safely remove the Mechanical Overload Clutch, the Clutch Adapter, and the Overrunning Clutch from the Spindle bolted to the Socket. All three components will come off as one piece.

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3-21

FIG 3-22

1. 2. 3. 4. 5. Figure 3-20

Main Frame Main Frame Liner Cap Screw Liner Clamp Liner Plate

Main Frame Liner Assembly

2. Install four M16 ring bolts, as supplied with the Tools Assembly, in the tapped holes located around the top of the outside diameter of the Socket Liner. Refer to Figure 1-23 3. Lubricate (best to use an anti-seize compound) the four 20mm jack screws supplied in the Tools Assembly, and install them into the Socket Liner. Refer to Figure 1-23

and this requires two propane gas burners or acetylene rose bud torches. It is important to keep moving the flames. If a flame is held in one spot too long, stress concentrations can be induced in the forged, high strength alloy steel that the Socket is made from and can lead to cracking.

5. Lift the Socket Liner out of the Crusher using the ring bolts previously installed.

10. As the Socket approaches the desired temperature, begin to tighten each jackscrew in small increments and in a circular pattern. If the Socket will not move, more heat is necessary. Once the Socket begins to easily move, stop the heating process and commence tightening of the jackscrews as rapidly as possible. It is best to have two persons to alternately handle an air impact tool. Speed is most important; however, it is important that the jackscrews be tightened in small increments so the Socket will not cock and jam on the Main Shaft.

6. Remove the four 36mm hex head capscrews that hold the Socket to the Main Shaft.

11. Attach rigging to the two previously installed M16 ring bolts and lift the Socket away.

4. Tighten each jackscrew in a circular pattern in small increments, so as to not cock the Socket Liner during removal. If the Socket Liner resists removal, it will be necessary to apply some heat to the upper portion of the Socket flange.

7. Install 2 M16 ring bolts. 8. Lubricate with anti-seize and install the four supplied 36mm jack screws in the threaded holes in the Socket. 9. Heat the lower flange of the Socket rapidly and evenly until the flange has increased in temperature approximately 116°F (65°C) above ambient. It is important to heat the socket as rapidly as possible,

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Procedure to Remove the Eccentric Assembly The Eccentric Assembly is a heavy component that weighs approximately 21,000 lbs (9,500 kg.). A special lifting ring has been supplied in the Tools Assembly for the removal and installation of the Eccentric Assembly. This lifting ring is designed to balance the lift. Using ring bolts in the three 30mm tapped holes in the top of the Eccentric is not a safe alternative. Use the following procedure for removing the Eccentric Assembly:

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1. Attach the Eccentric Lifting Ring with three 30mm capscrews that are supplied in the Tools Assembly. Position the Eccentric Lifting Ring with an eye bolt in the center of the thickest portion of the Eccentric to establish a balanced lift. Refer to Figure 1-9 2. Attach the properly selected rigging to the two hoist rings on the eccentric lifting ring, center the rigging and slowly lift the Eccentric Assembly. Make sure that the rigging is centered over the Eccentric Assembly so that the assembly doesn’t swing (pendulum) once it clears the Main Shaft. If the Eccentric Assembly swings, the Eccentric Gear can damage the Main Shaft. 3. Set the Eccentric Assembly on hard wood blocking or rubber mat to protect the Eccentric Gear. 4. Ensure that the Crusher internal areas are clean and then install the Eccentric Assembly, Socket Assembly, Head Assembly and Bowl Assemblies into the Crusher, following their installation instructions as outlined in Section 1 of this manual.

Counterweight Liner Replacement The Counterweight has a weld on ring of rolled AR plate that serves to protect the Counterweight from wear caused by crushed product bouncing into the rotating Counterweight and by material build up on the Main Frame Arms that tends to crowd into the rotating Counterweight. To replace a worn Counterweight Liner, use the following procedure: 1. Remove the Bowl the Assembly and Head Assembly from the Crusher following the instructions as outlined earlier in this section. 2. Unbolt the Counterweight from the Eccentric by removing the 36mm HHCS.



Note: These capscrews have been installed with Loctite so it will be necessary to heat the capscrews to weaken the Loctite bond. There are two 36mm HHCS in clearance holes in the Counterweight flange. These are not to be removed, as they keep the Eccentric Gear from falling away from the Eccentric.

3. Install four M36 Ring Bolts in the drilled and tapped lifting points of the inner flange of the Counterweight.

4. Attach suitable rigging and lift the Counterweight away.

Note: The break away force may be double that of the weight of the Counterweight, so select rigging accordingly.



Note: The Counterweight will not be balanced, so the Counterweight will rapidly tilt once it is free from the Eccentric. Be very careful while lifting the Counterweight clear of the journal surface of the Eccentric.

5. Once the Counterweight is clear, cover the Socket Assembly and Crusher gear well with a clean tarp or suitable plastic sheeting to keep this area clean. 6. Set the Counterweight on blocking. Note: This is a good time to inspect the T and U Seals, as well as the bottom end of the Counterweight for unusual wear. 7. Due to the heat that will be created when cutting out the existing welds holding the counterweight liner to the counterweight, it will be necessary to remove the lower T-seal. Care should be taken when removing the T-seal segments as they can be cleaned and reused if still in good condition. Find a joint in the seal and begin to work this area loose. Once loose, one can drive a scraper under the seal and it will easily break free. Refer to Figure 3-21 8. To remove the worn liner, air-arc gouge the plug welds and seam weld. Then lift the liner clear of the Counterweight. 9. Place the new liner over the outside of the Counterweight, align, and tighten the liner around the Counterweight as much as possible. It is advantageous to weld temporary stop blocks to keep the new Counterweight Liner from dropping too far. 10. With the liner in place and even with the bottom of the Counterweight, weld the liner to the Counterweight as shown on the Eccentric Assembly drawing in your Parts Manual. 11. Weld the Counterweight Cover to the Counterweight Liner as shown on the Counterweight Assembly drawing in your Parts Manual. 12. Install the T-seal per instructions on the Eccentric Assembly drawing in your Parts Manual.

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13. Clean the old Loctite and oil from the 36mm tapped holes in the Eccentric Gear. This is best done with a 36mm standard, bottom hole tap. Also clean the 36mm hex head capscrews. 14. Attach rigging and lower the Counterweight onto the Eccentric. It is difficult to do, but very important to lift the Counterweight level. Note: There is an alignment dowel pin in the Eccentric that has to match up with a hole in the Counterweight mounting flange to ensure proper Eccentric Assembly balance. Use Loctite 277 and install the 36mm hex head capscrews and quickly torque the capscrews to 2016 ft.lbs.

Note: If other maintenance requires or there is a reason to inspect the Eccentric Bushing, Eccentric Gear, and/or Thrust Bearings, it will be necessary to remove the Socket and Eccentric Assemblies. The Counterweight can then be removed from the Eccentric Assembly while it is out of the Crusher.

1. Remove the Bowl Assembly. 2. Unbolt and remove the Dust Shell. 3. Deenergize the Hydraulic Power Unit and lock it out. Then open the Clamping Circuit dump valve to depressurize the Clamping Circuit. 4. Unscrew and remove the 8 M42 hex head capscrews that provide a limit to the vertical travel of the Clamp Ring. Also, remove the 8 tube spacers that the M42 capscrews pass through. 5. Disconnect the hydraulic hose that connects the ported passage in the Adjustment Ring to the daisy chain of hoses to the Clamping Cylinders. 6. Install two M36 Ring Bolts, and attach proper rigging to lift the Clamp Ring away. 7. Set the Clamp Ring on blocking at a minimum of 12” (310mm) high, although it is best placed at working height.

Change Out of Clamping Cylinders There are 16 Clamping Cylinders mounted in the Clamp Ring, being installed from the bottom. Excessive ring bounce can lead to damage to the seals in the Clamping Cylinders, and the resultant leak of hydraulic oil will cause excessive repressurization cycles of the Hydraulic Power Unit. A leaking Clamping Cylinder will manifest itself by oil leaking out from under the bottom of the Dust Shell on top of the Adjustment Ring Assembly. Use the following procedure to change out Clamping Cylinders:

8. Disconnect the hydraulic hoses from the Clamping Cylinder fittings, and then remove the hydraulic T fitting from the hydraulic adapter that is threaded into the Clamping Cylinder. 9. Remove the two M10 capscrews and the Clamping Cylinder Bracket. 10. It is now possible to push the Clamping Cylinder out of the bore in the Clamp Ring. Sometimes corrosion makes it difficult to remove the Clamping Cylinder, so it is necessary to drive the cylinder out with a mallet and soft material of some sorts.

FIG 3-23 1. 2. 3. 4. 5. 6. 7. 8.

Figure 3-21

3-24

Lower T-Seal Removal

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Eccentric Gear Upper U-Seal Counterweight Cover Expanding Foam Counterweight Liner Lower T-Seal Counterweight

11. Once the Cylinder is out, clean and oil the bore. A nickel based anti-seize applied to the bore will reduce corrosion. Note: Loctite 569 will need to be reapplied to the threads. 12. Remove the ORB-JIC Adapter from the Clamping Cylinder just removed and install it in the replacement Clamping Cylinder. 13. Install on the replacement Clamping Cylinder any ring shims that may have been on the Clamping Cylinder flange. 14. Install a new Clamping Cylinder by sliding it up into the Clamp Ring bore and aligning the threaded holes on the top of the Clamping Cylinder with the Clamping Cylinder Bracket that is still on the Clamp Ring. 15. Reverse steps 7 through 1 above to connect the replacement Clamp Ring and re-install the Clamp Ring. 16. Pressurize the Clamping Circuit and check for leaks.

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3-26

ECT000-0176 - Rev. B - 07/08

Section 4 Lubrication System Description..............................................................................................................................................4-2 Lubricating Oil Specifications..............................................................................................................4-2 Crusher Operating Oil Temperature...................................................................................................4-3 Lube System Installation......................................................................................................................4-3 Piping Information................................................................................................................................4-4 Oil Tank Breather...................................................................................................................................4-4 Oil Filtration............................................................................................................................................4-4 Oil Contamination..................................................................................................................................4-4 Oil Coolers...............................................................................................................................................4-4 Air Cooler.................................................................................................................................................4-5 Water Cooler...........................................................................................................................................4-5 Water Cooled Lube System..................................................................................................................4-5 Water Strainer Cleaning.......................................................................................................................4-5

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Description This section covers the description of the Lubrication System and its related components, along with installation and removal of those components. The two types of lubrication packages available are air and water cooling. Selection depends on the cooling requirements. Both systems are designed to operate at a maximum pressure of 200 psi (13.8 bar). The Package Lubrication Systems are skid mounted and consist of the following: • Reservoir with an oil level sensor, temperature sensor, and oil heaters

There is a portion of the lube oil that supplies oil to lubricate the Countershaft Box bushings. The oil flow to the Countershaft Box is determined by the size of the supply line and fittings. The oil flow drains from the Countershaft Box into the Main Frame oil sump, where it combines with the rest of the lubricating oil and returns to the Package Lube System reservoir.

Lubricating Oil Specifications Use high grade paraffin (not naphthalene) based ISO EP 150 gear oil that meets the following requirements: 1. 2. 3. 4.

• Submerged oil pumps attached to vertically positioned electric drive motors, which are mounted to the top of the oil reservoir supplying 200 gpm (1757 Lpm) • Main system relief valve set at 200 psi (13.8 bar) • Filter system with 50 psi (34 bar) internal bypass and separate filter differential pressure sensor • Various isolation valves • Temperature Transducers in the oil return line, the reservoir, and the supply line immediately after the oil cooler • Water cooled systems have the heat exchanger mounted on the Package Lube skid • Air cooled systems have a remote mounted (radiator type) heat exchanger The oil supply is piped to the bottom of the Crusher Main Shaft. A small portion of oil is tapped off to lubricate the Countershaft Box Assembly. Oil flows through the center of the Main Shaft, where it lubricates the Head Ball, Socket Liner, and (during no load operations) the Upper Head Bushing. There are intersecting cross-ports in the Main Shaft that carry the bulk of the oil flow to lubricate the Eccentric bushing and the lower head bushing. The majority of oil flow for this system is designed to provide cooling (heat transfer) from the bearing surfaces within the Crusher. Oil exiting the bearing surfaces gravity flows through the slots in the Counterweight and lubricates the Gear and Pinion on its way to the gear well and Main Frame sump. The oil then flows back to the Package Lube System reservoir.

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5. 6. 7. 8. 9.

High film strength High adhesiveness to metal surfaces Stable physical and chemical properties Must have extreme pressure (E.P.) properties, such as sulfur phosphorus or other anti-weld agents which are compatible with metals used in the Crusher. The E.P. oil is preferred over straight industrial oil because of the higher pour point. High viscosity index Rapid water separation Resist foaming Provides rust and corrosion protection Includes anti-wear additives

ISO Grade 150 Viscosity:

135 to 165 cSt (Centistokes) at 40°C 13 cSt or Higher at 100°C or 680 to 850 SUS (Saybolt, Universal Seconds) at 100°F 70 SUS or Higher at 210°F Viscosity Index of 90 or Higher

If the Crusher is to operate under abnormal conditions, such as crushing hot materials or operating in extreme climates, contact FLSmidth Excel’s customer service for special lubricating oil recommendations. It is very important that Crusher lubricating oil meet the above requirements to protect its working parts. Not using the proper oil can damage the Crusher in a short period of time and void any warranties. Any major oil company makes oil that meets the above requirements. If your local oil supplier cannot furnish oil that meets the above requirements, contact FLSmidth Excel’s customer service for assistance.

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Crusher Operating Oil Temperature

Lube System Installation Skid Mounted Lube System

The preferred operating temperature of the lube oil supplied to the Crusher is 100°F (38°C) to 130°F (54°C). Do not operate the Crusher if the drain line temperature reaches 140°F (60°C). There are three temperature transducers mounted in the electrical box located on the end of the oil reservoir. The transducers are wired to the Automated Control System and monitor oil temperatures from three locations on the lube system. Refer to the Parts Book for the lube system transducer locations. If the Crusher oil is cooled by an air to oil cooler, there is a temperature transducer mounted on the cooler assembly in the outlet piping. Refer to the Parts Book for the transducer location on the air cooler. Reservoir Oil Temperature

A temperature probe is mounted in the reservoir and connected to a temperature transducer in the electrical control panel. The analog signal from the temperature sensor is used by the Automated Control System (ACS) to control the Oil Heaters and to monitor the “start permissible” for the Lube Oil Pump. Drain Oil Temperature

A temperature sensor mounted in the Crusher drain line connection is used by the ACS to activate high oil temperature warning and alarm conditions. Refer to the Automated Control System manual for operational information and instructions. Supply Oil Temperature

The type of cooling system will dictate the location of the Crusher supply oil temperature sensor. The following is a description of those systems and locations: Oil to Water Cooling

The Supply Oil Temperature probe is mounted adjacent to the connection on the Package Lube System and is wired to the transducer in the electrical box. The sensor provides a constant analog signal to the Control System. Refer to the Automated Control System manual for operational information and instructions. Air Cooled

The Supply Oil Temperature sensor is mounted in the Cooler Assembly piping to the Crusher and is wired to the Automated Control System (ACS). Refer to the ACS manual for operational information and instructions.

Locate the lube system below and as near the Crusher as possible. To obtain the proper flow of drain oil from the Crusher to the lube system reservoir, the bottom of the reservoir must be at least 6 feet (1.8 meters) below the underside of the Crusher mounting flange and 25mm (1”) for every 305mm (1 foot) the lube system is located away from the Crusher. Level the Package Lube Skid before attaching to the foundation. Before wiring the pump motor, check the motor name plate for the voltage, frequency, phase, and electrical connection requirements. Refer to the service booklet from the motor manufacturer for operation and maintenance instructions. All electrical equipment required to operate the pump motor (motor starter, fuse protection, etc.) is to be furnished by the customer and must meet local electrical code requirements. With the pump motor properly wired, check the direction of rotation by briefly starting the motor. There is an arrow mounted on the top of the motor to indicate the correct direction of rotation. The Lube Package reservoir is seperated into sections designed to provide continuous large particle filtration by means of a weir effect. Each section consists of a vertically adjustable baffle factory set at its lowest position to make sure the oil level in teh pump section of the reservoir never drops below the pump suction during initial start-up of the pump. The baffles can be raised to improve filtration if the Lube Package is located near the Crusher and the oil level in the pump section does not drop below the suction port before drain oil flows back into the pump section of the reservoir. Air Cooler System

Crushers using an air to oil heat exchanger (radiator type air cooler assembly) are supplied with a skid mounted heat exchanger assembly with a by-pass relief valve. The air to oil heat exchanger (air cooler assembly) is best located between the Package Lube System and the Crusher. If the air cooler assembly is installed in a lube room, the room needs to be properly vented to provide an in-flow of ambient air necessary to efficiently cool the oil. The air cooler assembly (skid) should be fastened to a foundation. Make sure that the air cooler assembly is not subjected to excessive vibrations and is mounted level. Before wiring the air cooler motor, check the motor name plate for the voltage, frequency, phase, and electrical

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connection requirements. Refer to the service booklet from the motor manufacturer for operation and maintenance instructions. All electrical equipment required to operate the air cooler motor (motor starter, fuse protection, etc.) is to be furnished by the customer and must meet local electrical code requirements. After the Air Cooler motor has been properly wired, bump the motor to check direction of rotation. The fan should rotate so the direction of the air flow is away from the motor side of the Cooler.

Piping Information The factors listed below should be addressed when laying out the supply and drain oil piping to and from the Lube Package and Crusher: 1. The drain line should have a minimum pitch of 1” (25mm) of vertical change for every 12” (305mm) of horizontal change. 2. The piping should be as direct and short as possible with a minimum amount of turns, dead pockets, and similar obstructions. 3. Install unions or bolted, flanged joints to aid at various locations in the removal of any piping or lubricating equipment when necessary. 4. Minimize the vertical drop of the drain line. Too large a rush of drain oil can create a vacuum inside the Crusher and pull dust into the Crusher past the labyrinth “T” and “U” seals. If a vertical drain line cannot be avoided and vertical drop is more than 4” (1.22m) long, contact FLSmidth Excel’s customer service department for instructions for installing and maintaining a drain line trap. Important: The lube supply oil piping and return oil piping must be cleaned of rust, scale, cutting chips, and other debris prior to assembly. The supply oil piping should then be disconnected at the Crusher and, with a flexible hose or other suitable means, connected to the return line. The lubrication pump is then operated for approximately 10 minutes to flush the supply oil line and return oil line.

Oil Tank Breather The oil reservoir is sealed from dust and moisture and includes a breather mounted on top surface of the tank. This breather allows the reservoir to maintain atmospheric pressure. A weekly check should be made to make sure dust and debris does not build up around the breather. The reservoir breather is not cleanable and should be replaced.

Oil Filtration The Package Lube System includes a duplex type oil filter with differential pressure relief valve, replaceable filter elements, and a differential pressure sensor used to indicate dirty, plugged, and damaged filter element conditions. These signals are sent to and processed by the Automated Control System (ACS). Unscrew the filter housing cover to access the filter elements. Located beneath the inspection cover is a removable/ cleanable strainer basket designed to catch large particle contamination as the drain oil drains back from the Crusher into the tank.

Oil Contamination Use of contaminated oil or oil that has lost its properties will accelerate bearing wear and create expensive parts replacement requirements. Oil samples should be taken and analyzed on a regular basis. Most Crusher operators use a one month interval. If, over the oil sample interval, there is an unusual increase in any of the contaminants, a thorough inspection of the Crusher should be made to find the source(s). The type of contamination may indicate whether the source is internal (e.g. metallic contact) or a result of dust infiltration. Oil analysis can also provide possible sources of contamination causing excessive bushing and socket liner wear. Silica limits must be interpreted in relationship to copper and iron levels. If high silica is accompanied by high copper and/or iron, it is considered abrasive and the oil is rated unacceptable.

Oil Coolers The lubrication system includes an oil cooler designed to maintain the drain oil temperature of the Crusher between 100°F (38°C) and 130°F (54°C). The two most common types of cooling are oil to air (radiator type cooler) and oil to water (tube and shell type cooler).

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There is a relief valve located in a bypass line around either of the cooler designs. This allows pressure relief due to plugged internal passages or cold thick oil. This valve is factory set and should not be adjusted. If there is a change in cooler efficiency, check the relief valve to make sure it is not stuck open allowing un-cooled oil to by-pass the cooler. If so, it should be replaced immediately.

FLSmidth Excel customer service for instructions. Keeping the control valve clean is the only maintenance that’s required. Regular inspection and cleaning of the valve can be done through its inlet and outlet. FLSmidth Excel recommends cleaning the temperature sensor part of the control valve during every oil change to maintain a consistent control of the supply oil temperature.

Air Cooler

Water Control Valve

The oil to air cooler is a radiator type cooler that transfers the heat of the oil to air by use of a fan. This stand-alone assembly is best mounted between the Crusher and Lube Package.

Troubleshooting If the control valve does not seem to be holding a steady temperature or the oil is not being cooled enough, do the following:

To maximize the efficiency of the air cooler, FLSmidth Excel recommends periodically cleaning the cooler to remove dust and dirt that builds up in the core.

1. Check the water strainer located on the water inlet side of the cooler for any debris. Refer to the Lube Package Assembly in the customer Parts Book

Water Cooler The Lube Package mounted oil to water cooler is a tube and shell design that transfers the heat of the oil (circulated through the shell) into the water (circulated through the tubes). Contact FLSmidth Excel customer service for operation and maintenance instructions for the water heat exchanger. FLSmidth Excel recommends using an uninterrupted water supply from the plant water system. Using this system in freezing temperatures should be avoided unless safeguards are incorporated to keep the water from freezing. The water supply and discharge connection for the heat exchanger are 1” NPT fittings. The supply and discharge lines are the supply of the customer and are to be installed once the Package Lube System is properly installed.

Water Cooled Lube System Components

The required flow of water (gallons per minute/liters per minute) is dictated by the water temperature. This is accomplished using a water control valve that is mounted on the water inlet port of the oil to water cooler on the Lube Package. The valve automatically controls the flow of water by use of a non-electrical temperature sensor mounted in the side of the lube tank that increases the water flow as the temperature of the oil in the tank (source of supply) increases. The water control valve must be set to provide 110°F (43°C) supply oil temperature.

2. Check for any external conditions which may cause the control valve to operate improperly, such as low and/or fluctuating water supply or pressure, damaged or blocked valves or other components in the water circuit, too small of a supply line, kinked or broken control valve capillary tube, or a dirty bulb. 3. Check for foreign material under the control valve seat possibly causing the valve not to close. 4. If after cleaning the bulb, the water control valve does not open, there is a possibility that the gas in the temp sensor bulb has escaped, requiring replacement of the bulb. This can be checked by placing the bulb in hot water to see if the valve opens. 5. Water leaking from the valve body may indicate a loose part in the valve or damaged bellows. Either condition will require replacement of the valve. 6. If the water control valve makes a chattering noise, this may indicate loose parts within or near the valve.

Water Strainer Cleaning Depending upon the quality of the cooling water, it may be necessary to clean the strainer weekly. To clean the strainer screen, shut off the water supply, remove the strainer cap and screen, clean the screen, reassemble the screen and cap, and turn the water back on.

If for some reason, the valve needs adjusting, contact

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Low Oil Level

A sensor mounted on the side of the reservoir monitors the oil level and provides a switch signal to the Automated Control System (ACS). Oil Heater

The Lube System includes oil heaters mounted in the reservoir for maintaining proper oil temperature in cold operating conditions. The heaters are operated by the Automated Control System (ACS). Electrical equipment required for heater operation, such as magnetic contactor and fuse protection, are to be furnished by the customer and must meet local electrical code requirements. Oil Pressure Sensor

An analog pressure sensor is supplied as standard equipment and provides Crusher protection in the case of lost oil pressure. The sensor is wired to the Automated Control System (ACS). The control logic programmed into the ACS activates low oil pressure warning and alarm conditions on the touch screen in the operators control room.

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Section 5 Hydraulic Systems Description............................................................................................................................................. 5-2 Hydraulic Power Unit Installation..................................................................................................... 5-2 Remote Mounted Push Button Control Panel Installation.......................................................... 5-2 Hydraulic Oil Specifications................................................................................................................ 5-2 Cold Weather Oil Specifications......................................................................................................... 5-3 Hydraulic System Pre-Start................................................................................................................ 5-3 Hydraulic Power Unit Controls.......................................................................................................... 5-4 Remote Push Button Panel Indicator Lights................................................................................... 5-4 Service Box Switches........................................................................................................................... 5-5 Hydraulic Power Unit Start Up and Operation............................................................................... 5-6 Bleeding and Pressure Testing the Tramp Release and Clamping System............................... 5-6 Bleeding the Tramp Release System................................................................................................ 5-6 Bleeding the Clamping System.......................................................................................................... 5-7 Changing the Oil Filter......................................................................................................................... 5-8 Hydraulic Oil Change............................................................................................................................ 5-8

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Description

Hydraulic Power Unit Installation

This section covers the description of the Hydraulic System and its related components, along with installation and removal of those components. All Raptor XL1100 Crushers are furnished with a hydraulic tramp release, cavity clearing, clamping systems, and hydraulic adjust systems.

The power unit should be carefully placed in a protected area from falling rock and no more than 30’ (9 m) from the Crusher. The remote mounted pushbutton panel should be placed in a location that will allow the operator to observe the Crusher during a clearing or while turning the Bowl (setting adjustment).

Hydraulic tramp release cylinders hold the Adjustment Ring firmly to the Main Frame with the top end secured to the Adjustment Ring by a hex nut and the bottom end forced against the bottom of the Main Frame Flange by hydraulic pressure. A non-crushable item passing through the crushing cavity or adjusting the close side setting too tight will cause the Adjustment Ring to lift off the frame. Lifting of the Adjustment Ring will extend the cylinder, and force oil from the rod side of the cylinder to an Accumulator mounted on the Crusher. When the non-crushable item has passed through the crushing cavity or the setting has been opened, the compressed nitrogen in the bladder of the Accumulator will force the oil back into the tramp release cylinders and reseat the Adjustment Ring on the Main Frame. If for any reason the Crusher stops with rock in the crushing cavity, the Adjustment Ring and Bowl Assemblies can be raised off the Main Frame to open the crushing cavity and clear the Crusher. This is automatically done by depressurizing release cylinders and pressurizing the Clearing Cylinders. This extends the Clearing Cylinders and pushes the Adjustment Ring and Bowl Assembly upward. The clamping system consists of a set of clamping cylinders installed in the Clamping Ring which is mounted on top of the Adjustment Ring. When the clamping cylinders are pressurized, the Clamping Ring is raised and locks the Bowl in place during crushing. Control of these systems is done by a Hydraulic Power Unit consisting of a cabinet with an integral oil tank with replaceable breather, vertically mounted electric motor, submerged hydraulic pump, solenoid valves, oil filter and pressure transducers. All are protected by a removable cover with door. Included with the Hydraulic Power Unit is a remote mounted pushbutton control panel connected to the Hydraulic Power Unit by a 30’ (9 m) long cable. The power unit can be controlled locally at the remote mounted pushbutton panel or at the Automated Control System (ACS) touch screen.

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There are six 50’ (15 m) long hydraulic hoses that connect the Crusher to the Hydraulic Power Unit. Refer to the Parts Book for connection locations. These hoses are shipped lose and are to be field installed. The hoses include reusable couplings on one end. This provides the customer with the ability to shorten the hoses to fit the installation and reattach the fitting, and thereby avoid a safety hazard caused by a pile of coiled hydraulic hose.

Remote Mounted Pushbutton Control Panel Installation The remote mounted pushbutton panel includes a 30’ (9 m) long multi-conductor electrical cord attached to it for connecting to the electrical box located inside the Hydraulic Power Unit. FLSmidth Excel recommends shortening this cable to suit the installation. Use the Hydraulic Power Unit electrical schematic drawing furnished in the Parts Book to make the proper connections.

Hydraulic Oil Specifications Thoroughly inspect the inside of the reservoir for any contaminants before filling the Hydraulic Power Unit tank with oil. Remove any material with lint free rags. Also, check the suction strainer for any material that may be stuck to the screen and clean if necessary. Use a high grade paraffin, not naphthalene, industrial hydraulic oil with high film strength, high adhesiveness to metal surfaces and stable chemical and physical properties. The oil should also have a high viscosity index, rapid water separation, resist foaming, include corrosion protection, resist oxidation, and contain anti-wear additives. ISO Grade 32 Viscosity:

ECT000-0176 - Rev. B - 07/08

29 to 35 cSt (Centistrokes) at 40°C 6 cSt or Higher at 100°C or 135 to 165 SUS (Saybolt, Universal Seconds) at 100°F 45 SUS or Higher at 210°F Viscocity Index of 140 or Higher

Fire resistant hydraulic oil should not be used. This type of hydraulic oil may not be compatible with packing seals, Accumulator bladders, hoses, and other parts of the power unit. It will adversely damage the special paint used inside the reservoir, as well as reduce the life of the pump.

and pressurize (pre-charge) the tramp release system Accumulator, do the following:

The reservoir is to be filled to the top of the oil level gauge. Approximately 200 US gallons (757 Liters) will be required. An additional 50 gallons (189 liters) of oil will be required to initially fill and bleed the clamping, release and clearing systems.

2. At the power unit, turn the Operation-Service selector switch to the Service position.

The oil level should be kept at the center of the oil level gauge during normal operation and regularly monitored.

Cold Weather Oil Specifications Cold oil will not flow freely through the hydraulic system, causing it to be almost solid. This is a particularly bad situation for the tramp release circuit, in which the oil must flow freely to and from the Accumulator when the Crusher passes tramp iron or stalls. If the correct oil for a cold weather environment is not used, the power unit and/ or Crusher components could be damaged. If the ambient temperature will be 0°F (-20°C) or less for more than a few days, FLSmidth Excel recommends changing the entire hydraulic system oil to a cold weather type as specified below. ISO Grade 10 10 cSt (Min) at 130°F (54.4°C) 500 cSt (Max) at -40°F (-40°C) Pour Point of -75°F (-59.4°C) Max FLSmidth Excel does not recommend using the above cold weather oil all year round. Since the oil is designed for use in cold ambient conditions, occasional leakage past the tramp release and clamping cylinders may occur during warmer conditions.

Hydraulic System Pre-Start Tramp Release System

(Checking Pre-Charge and Charging the Accumulator) The tramp release system Accumulator is mounted on the Main Frame and contains a bladder that is “pre-charged” with nitrogen gas to a specific pressure. Refer to the hydraulic schematic in the Parts Book for the required pressure. This pressure needs to be regularly checked. The pre-charge pressure can only be checked when the tramp release circuit pressure is zero. With no pressure in the tramp release system, the Accumulator bladder is free to expand inside the Accumulator and thereby give you an accurate reading of the pressure in the bladder. To check

1. At the remote mounted push button panel, turn the Local - Remote selector switch to Local.

3. Eliminate all the tramp release circuit pressure using the tramp release pressure dump valve located at the tramp circuit manifold block. Make sure the pressure on the tramp release circuit pressure transducer reads zero before going any further. Refer to the Parts Book for the dump valve and release system pressure transducer locations. 4. Push the power button in on the remote push button panel. This will turn all power off to the Hydraulic Power Unit. With the power unit shut off, the control system will not pressurize the tramp release circuit pressure if someone should turn the Operation Service selector switch in the Operation position during this process. 5. Remove the valve guard, cap, and washer from the Accumulator. 6. Locate the charging assembly supplied with the tools from FLSmidth Excel. Turn the T-handle on the air chuck all the way out or until it bottoms. The screw on the bottom of the bleeder valve must be closed. Screw the air chuck swivel onto the valve stem until hand tight and then a quarter turn to compress the seal.

Do not over tighten the swivel more than a quarter turn. Over tightening can twist off the valve stem and/or damage the copper washer causing leakage.

7. Turn the T-handle in on the air chuck so the shaft completely depresses the valve core in the Accumulator stem. The pressure gauge on the gas charging valve should read 1500 psi (103 bar) ±50 psi (3 bar). If the pressure is within this range, proceed to Step 12. If the pressure is above the range, slowly open the bleeder valve on the bottom of the gas charging valve to exhaust excessive nitrogen gas out of the Accumulator bladder. When the pressure falls into the range, quickly close the bleeder valve and go to Step 12. If the pressure is below the specified limits then proceed to Step 8.

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8. Attach the swivel end of the hose to the gas charging valve. This connection just needs to be hand tight. Connect the other end of the hose assembly to the regulator on the top of a nitrogen bottle. Use commercially available “oil pumped dry nitrogen“. 9. Slowly open the valve on the nitrogen bottle to allow the nitrogen to pass into the Accumulator bladder at a controlled rate. Close the nitrogen bottle valve at frequent intervals to let the gas charging pressure gauge settle. When the pressure defined in Step 7 has been reached, quickly close the valve on the nitrogen bottle. 10. Turn the T-handle on the air chuck out until it bottoms. This will compress the valve core and allow it to seat in the Accumulator stem. 11. Disconnect the hose assembly from the nitrogen bottle and the swivel connector from the end of the hose from the gas charging valve. 12. Disconnect the air chuck from the Accumulator valve stem. 13. Store the hose assembly, gauging assembly, and nitrogen bottle in a dust free atmosphere that is out of the weather. Plug the ports on the gauging assembly and both ends of the hose assembly to keep them free of dust and contaminates. 14. Brush a soapy solution on the gas valve to check for any leakage of gas. Depress the core once or twice to seat it if any leaks are found. If the leakage continues, either tighten the core or replace it altogether. 15. Thread the valve cap onto the valve stem. 16. Thread the valve guard onto the Accumulator. 17. Close the release system pressure dump valve. 18. Twist and pull the power button located on the remote mounted control panel. This should cause the power unit to pressurize the release system back to its working pressure. Refer to Service Switches later in this section for instructions on how to manually pressurize the tramp release system. 19. Once the release system has been pressurized and checked, close the cover on the Hydraulic Power Unit.

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20. For a new or repaired Tramp Release Accumulator, the pre-charge pressure should be checked weekly. Clamping Circuit System

(Checking Pre-Charge and Charging the Accumulator) FLSmidth Excel recommends regularly checking the clamping circuit Accumulator pre-charge pressure. The Accumulator is located inside the Hydraulic Power Unit. Follow the same procedure used to check and charge the tramp release Accumulator for the clamping circuit Accumulator. The only difference is the pre-charge pressure. Refer to the hydraulic schematic in the Parts Book for the required pressure.

Hydraulic Power Unit Controls Do not operate the Hydraulic Power Unit until after reading the following information.

Warning

Pressing the Push/Pull Power Button located on the remote push button panel will only turn off the electric power to the controls. Use caution when troubleshooting the power unit or making any adjustments. Always lock out the main power supply and the electrical controls before servicing the power unit and the Crusher.

Remote Push Button Panel Indicator Lights Push to Stop - Twist or Pull to Start To energize the power unit control circuit, twist or pull this button out. The green Power On Light will illuminate indicating that the control circuit has been activated. Care must be taken when trouble shooting or performing any power unit adjustments, as electrical power will still be present at some of the terminals even with the power push button pushed in the off position. Local-Remote

This selector switch will typically remain in the Remote position unless performing any of the Local functions described below. With this selector switch in the Local position the following operations can be conducted at the remote mounted push button panel: a) Turning the Bowl in or out (Liner change or setting adjustment).

ECT000-0176 - Rev. B - 07/08

b) Clearing the crushing cavity followed by resetting the automatic pressurization of the tramp release control circuit. (See description of Tramp Pressure Reset selector switch.) c) Changing the adjustment motor speed (High or Low) Tramp Pressure Reset - Clear

Turning this selector switch to the Clear position and holding it there will raise the Adjustment Ring and Bowl Assemblies off the Main Frame, and thereby clear the crushing cavity of material. When clearing, the tramp release circuit pressure is automatically dropped to zero When clearing of the Crusher is complete, turn the switch to the Tramp Pressure Reset position. This action will energize the tramp release system automatic pressurization control circuit. Hi Speed - Low Speed

This switch controls the speed of the Hydraulic Bowl adjust motor. The High speed position is used primarily for installation and removal of the Bowl. The Low speed position is typically used for adjusting the close side setting. It is not recommended to use the High speed setting for adjusting the Crusher. Open-Close

Turning this switch to the Open position will turn the Bowl in a counterclockwise direction and increase the close side setting. Conversely, turning the switch to the Close position will turn the Bowl assembly in a clockwise direction and decrease the close side setting. Power On

This green light is illuminated when the Push to Stop - Twist or Pull to Start switch is pulled indicating activation of the Hydraulic Power Unit control circuit. Remote

This blue light is illuminated when the Local-Remote selector switch is turned to the Remote position indicating that control of the Hydraulic Power Unit (close side setting adjustments) can only be made from the Automated Controlled System (ACS) touch screen. No control of the Hydraulic Power Unit is possible at the remote mounted control panel when the selector switch is in this position. Low Clamp Pressure

This red light will illuminate when the clamping circuit pressure falls below 2200 psi (152 bar).

Note: Automatic pressurization of the clamping circuit occurs at 2400 psi (165 bar). Low Tramp Pressure

This red light will illuminate when the tramp release circuit pressure falls below 1200 psi (83 bar). Note: Automatic pressurization of the tramp release circuit occurs at 1400 psi (97 bar). Service Mode

This amber light will illuminate when the selector switch located on the service switch box on the side of the electrical terminal box inside the Hydraulic Power Unit is changed from the Operation to Service position.

Service Box Switches There are two selector switches located on the service switch box mounted on the side of the electrical terminal box inside the Hydraulic Power Unit. Refer to the Parts Book The switches provide the ability to troubleshoot the tramp release and clamping systems from the Hydraulic Power Unit without the need to operate the controls on the remote pushbutton panel. Refer to the Parts Book. The following is a description of the switches and their functions: Operation - Service

During normal operation of the Hydraulic Power Unit, the switch should be in the Operation position. Turning the switch to the Service position provides the ability to manually pressurize the tramp release and clamping circuit pressures, and illuminates the amber Service Mode light on the remote pushbutton panel. The automatic pressurization feature of the control system is also disabled during this time. Turning the switch to the Operation position disables the Tramp Press - Clamp Press switch on the service switch box and turns the Service Mode amber light on the remote pushbutton panel off. Automatic pressurization of the clamping and tramp release circuits by the control system is enabled. Again, this is the recommended position for normal Crusher operation. Tramp Press - Clamp Press

This is a “spring return to center” selector switch. Holding the switch in the Tramp Press position manually energizes the pressurization of the tramp release circuit. Holding the selector switch in the Clamp Press position manually energizes the pressurization of the clamping circuit.

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Hydraulic Power Unit Start-up and Operation The Hydraulic Power Unit has two modes of operation: Local or Remote. The selector switch for these two modes is located on the remote mounted push button panel. For the power unit to operate in either of these modes, the Push to Stop - Twist or Pull to Start pushbutton must be pulled to energize the power unit control circuits and illuminate the green Power On Light. With the selector switch in the Remote position, the power unit is controlled by the Automated Control System (ACS) and all the switches on the remote pushbutton panel are inoperable with the exception of the Push to Stop - Twist or Pull to Start pushbutton. The switch should remain in the Remote position during normal crushing operation. (Refer to the Remote Push Button Panel Switch and Button Functions located earlier in this section for a description of the functions available in the Local mode.) In the Remote mode, the control system monitors the tramp release and clamping circuit pressures and automatically pressurizes as required. Normal close side setting adjustments can be made from the control system touch screen. (Refer to the Automated Control System Instruction Manual for operating instructions.) In either mode, the pump motor will be off and only start if any type of power unit operation is performed. Once the operation has been completed, the motor will automatically shut off. If, while operating, the power unit in either the Remote or Local mode either of the red Low Tramp Pressure or red Low Clamp Pressure warning lights illuminates and a check of the related circuit pressure sensor verifies a loss of circuit pressure, there has likely been a malfunction of the hydraulic system. The Crusher should be shut down and the hydraulic problem corrected before the Crusher is restarted if either one or both of these warning lights are activated.

Bleeding and Pressure Testing the Tramp Release and Clamping Systems During initial Crusher start-up, and whenever the tramp release or clamping circuit components have been disconnected, it is necessary to remove any air that may be trapped. If the tramp release and clamping circuits are being pressurized for the first time, monitor the oil level sight gauge and add oil as required. Do not pressurize the tramp release or clamping circuits unless the associated Accumulator has been pre-charged with the correct nitrogen pressure. Pressurizing the Accumulator without pre-charging will damage the bladder and require replacement.

Warning

No attempt should ever be made to bleed any hydraulic circuit when the circuit is fully pressurized. A loose connection may break free allowing high pressure oil to escape causing bodily harm. Always wear suitable eye protection when bleeding any of the circuits.

Bleeding the Tramp Release System To bleed the tramp release system, do the following: 1. Verify that there is adequate hydraulic oil in the reservoir. 2. Turn the Local - Remote selector switch (located on the remote pushbutton panel) to the Local position. 3. Open the door on the front of the Hydraulic Power Unit and turn the Operation - Service selector switch (located on the side of the electrical connection terminal box) to the Service position. Refer to the Parts Book for switch locations. 4. Open the tramp release system pressure dump valve (located on the backside of the tramp release circuit manifold block) all the way open. Refer to the Parts Book for the release system dump valve location.

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ECT000-0176 - Rev. B - 07/08

5. If the green Power On light on the remote pushbutton panel is illuminated, go to step 6. If the light is not on, pull the Push to Stop - Twist or Pull to Start push button to turn the power unit on. 6. During the bleeding of the tramp release circuit, it will be necessary to run the pump for short periods of time to maintain a circuit pressure of 200 psi (14 bar). This pressure is more than adequate to maintain an adequate flow of oil necessary to bleed the system without creating a hazardous high pressure condition. 7. At the service switch box inside the power unit, turn and hold the Tramp Press - Clamp Press selector switch in the Tramp Press position. Adjust the tramp release system dump valve until 200 psi (14 bar) of pressure is maintained, as indicated on the tramp release system pressure transducer located on the circuit manifold block. Refer to the Parts Book for the tramp release system pressure transducer location. 8. While still holding the switch in the Tramp Press position, loosen the lower hose connection on each tramp release cylinder. Any air in the line will spit out, and eventually only oil will leak from the loosened hose connection. At that point, tighten the hose connection. 9. With all the tramp release cylinders bled, release the Tramp Press - Clamp Press selector switch. Completely close the tramp release system dump valve. 10. Turn and hold the Tramp Press - Clamp Press selector switch (located on the service pushbutton box on the side of the electrical terminal box inside the power unit) in the Tramp Press position until the normal operating pressure is achieved, as indicated on the tramp release system pressure transducer. This will release the valve core and allow it to seat in the Accumulator valve stem. 11. Check all the tramp release system connections to make sure there are no leaks. 12. Turn the Operation - Service selector switch to the Operation position. 13. Turn the Local - Remote selector switch to the Remote position.

Bleeding the Clamping System To bleed the clamping system, do the following: 1. Verify that there is adequate hydraulic oil in the reservoir. 2. Turn the Local - Remote selector switch to the Local position. 3. Open the door on the front of the Hydraulic Power Unit and turn the Operation - Service selector switch to the Service position. Refer to the Parts Book for location of the switch. 4. Open the clamping system pressure dump valve all the way open. Refer to the Parts Book for the valve location. 5. If the green Power On light on the remote pushbutton panel is illuminated, go to step 6. If the light is not on, pull the Push to Stop - Twist or Pull to Start pushbutton to turn the power unit on. 6. During the bleeding of the clamping circuit, it will be necessary to run the pump for short periods of time to maintain a circuit pressure of 200 psi (14 bar). This pressure is more than adequate to maintain an adequate flow of oil necessary to bleed the system without creating a hazardous high pressure condition. 7. At the service switch box inside the power unit, turn and hold the Tramp Press - Clamp Press selector switch in the Clamp Press position. Adjust the clamp system dump valve until 200 psi (14 bar) of pressure is maintained as indicated on the clamp system pressure transducer located on the circuit manifold block. Refer to the Parts Book for the clamp system pressure transducer location. 8. While still holding the switch in the Clamp Press position, loosen the hose connection at the Adjustment Ring. Any air in the line will spit out and eventually only oil will leak from the loosened hose connection. At that point, tighten the hose connection. 9. With the clamp circuit completely bled, release the Tramp Press - Clamp Press selector switch. Completely close the clamp system dump valve. 10. Turn and hold the Tramp Press - Clamp Press selector switch (located on the service pushbutton

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box on the side of the electrical terminal box inside the power unit) in the Clamp Press position until the normal operating pressure of 2800 psi (193 bar) is achieved as indicated on the clamp system pressure transducer. 11. Check all the clamping system connections to make sure there are no leaks. 12. Turn the Operation - Service selector switch to the Operation position. 13. Turn the Local - Remote selector switch to the Remote position.

Changing the Oil Filter Located on the Hydraulic Power Unit is a high pressure oil filter. Refer to the Parts Book for the filter location. The filter includes a replaceable cartridge. A visual indicator located on the top of the filter will signal when replacement of the cartridge is required. This signal will automatically reset when the cartridge has been changed. To change the filter cartridge, do the following: 1. At the remote pushbutton panel, push the Push to Stop - Twist or Pull to Start to turn the power control circuit off. Also, lock out the power source so the system cannot be accidentally started while changing the filter cartridge. 2. As a matter of safety, dump the pressures in both the clamping and tramp release systems using the dump valves on the respective valve modules. 3. Loosen and remove the filter canister. 4. Remove the dirty element from the housing, and clean the housing with a mild solvent. 5. Place the new, clean element in the housing, centering it on the element locator. 6. Inspect the canister o-ring, and replace if necessary.

After the hydraulic system has been in service for a period of time, the following signs are typical indications of the need to clean the hydraulic system: 1. Buildup of contaminates in the reservoir and components within the hydraulic system. 2. Irregular operation of the hydraulic circuits that may include high oil temperatures. 3. Existence of emulsions. 4. Poor condition of the oil that may be indicated by a dark color, cloudy or burnt appearance, rancid smell, or an incorrect oil viscosity. To clean the hydraulic system, do the following: 1. Turn off and lock out the power to the power unit motor, and push the Push to Stop - Twist or Pull to Start to turn off the power unit control circuit. 2. Open both the tramp release and clamping system dump valves so both system pressures are at zero. Close both valves once both systems have been completely depressurized. 3. Drain all the oil from the power unit reservoir. Oil in the release and clamping systems and their lines can be left in place when the reservoir is drained. Refer to the Parts Book for the location of the oil drain plug and clean-out cover. 4. Remove the round “clean-out” reservoir cover. 5. Remove the suction strainer from the pump inlet inside the reservoir and check for build-up of contamination. Metal particles found on the strainer are an indication of wear in the system. FLSmidth Excel recommends locating and eliminating the cause of the wear before putting the Hydraulic Power Unit back into service. 6. The inside of the reservoir should be cleaned with a solvent and then dried with lint free rags. 7. Reinstall the strainer, then the reservoir cover.

7. Install and hand tighten the canister.

Hydraulic Oil Changing At a minimum, all the oil should be replaced in the entire hydraulic system once a year. The inside of the oil reservoir should also be thoroughly cleaned along with the removal of any contaminates from the suction strainer.

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Cleaning the Hydraulic System

8. Fill the reservoir with the hydraulic oil defined in Hydraulic Oil Specifications earlier in this section.

ECT000-0176 - Rev. B - 07/08

Index Accumulator Depressurization Figure 3-4................................................................................................. 3-11 Accumulator Depressurization Figure 1-18................................................................................................. 1-20 Accumulator Mounting Figure 3-5............................................................................................................... 3-12 Accumulator Mounting Figure 1-19.............................................................................................................. 1-21 Adjustment Cap Centering Figure 1-28........................................................................................................ 1-26 Adjustment Cap Position Figure 2-2............................................................................................................. 2-10 Adjustment Drive Assembly Installation Figure 1-27................................................................................. 1-26 Adjustment Ring Assembly Lifting Figure 1-17........................................................................................... 1-19 Adjustment Ring Movement............................................................................................................................ 2-9 Adjustment Ring Safety Blocks Figure 2-5................................................................................................... 2-12 Air Cooler Assembly Figure 1-32.................................................................................................................... 1-30 Air Cooler ............................................................................................................................................................ 4-5 Air/Oil Cooler Assembly................................................................................................................................... 1-29 Annual Checks and Maintenance..................................................................................................................... 3-6 Arm and Countershaft Arm Guard Installation .......................................................................................... 1-13 Arm Guard Replacement................................................................................................................................. 3-21 Backlash and Root Clearance Table 1-4......................................................................................................... 1-14 Bleeding and Pressure Testing the Tramp Release and Clamping System.............................................. 5-6 Bleeding the Clamping System........................................................................................................................ 5-7 Bleeding the Tramp Release System............................................................................................................... 5-6 Bowl Assembly Installation............................................................................................................................. 1-26 Bowl Liner Change Out.................................................................................................................................... 3-12 Bowl Liner Installation Figure 3-11............................................................................................................... 3-16 Bowl Liner Installation..................................................................................................................................... 3-14 Bowl Liner Removal.......................................................................................................................................... 3-13 Bowl Thread Engagement Figure 2-4........................................................................................................... 2-11 Bowl, Bowl Liner Seating Surface.................................................................................................................. 3-17 Bowl, Wedge and Liner Parts Figure 3-7...................................................................................................... 3-13 Break-In Instructions.......................................................................................................................................... 2-5 Change Out of Clamping Cylinders............................................................................................................... 3-24 Changing the Oil Filter....................................................................................................................................... 5-8 Check List for Starting New Crusher............................................................................................................... 2-3 Checking Bowl Liner Seating Surface Figure 3-10..................................................................................... 3-15 Checking Socket Contact Figure 1-22........................................................................................................... 1-23 Checking the Accumulator Pre-Charge........................................................................................................ 3-11 Checking the Setting (Automated Calibrations) . ........................................................................................ 2-8 Checking the Setting (Manually)...................................................................................................................... 2-8 Clearing Cylinder Weld Figure 1-16............................................................................................................... 1-19 Clearing the Crusher Cavity.............................................................................................................................. S-3 Clearing the Crusher with Tramp Metal Jammed in the Crushing Cavity ............................................. 2-13 Clearing the Crusher........................................................................................................................................ 2-11 Cold Weather Oil Specifications....................................................................................................................... 5-3 Confined Spaces.................................................................................................................................................. S-5 Contact Pattern Corrections Figure 1-15..................................................................................................... 1-18 Controlling Ring Bounce................................................................................................................................... 2-9 Countershaft and Backlash Tool Figure 1-13............................................................................................... 1-16 Countershaft Assembly Installations Figure 1-12....................................................................................... 1-16 Countershaft Box Blower/ Filter Assembly Figure 1-31............................................................................ 1-30 Countershaft Cartridge Assembly Installation . ......................................................................................... 1-14

ECT000-0176 - Rev. B - 07/08

Index Countershaft End Float Figure 1-10.............................................................................................................. 1-14 Countershaft Rotation....................................................................................................................................... 2-5 Counterweight Liner Replacement............................................................................................................... 3-23 Crusher Air Breather and Blower................................................................................................................... 1-28 Crusher Clearance Dimensions........................................................................................................................ 1-3 Crusher Components and Sub-Assembly Weight ....................................................................................... 1-5 Crusher Control System Operating and Safety Interlocks.......................................................................... S-6 Crusher Drive Motor........................................................................................................................................... 1-5 Crusher Grouting Figure 1-6........................................................................................................................... 1-11 Crusher Main Frame Installation on a steel Structure . ............................................................................ 1-12 Crusher Operating Oil Temperature................................................................................................................ 4-3 Crusher to Power Unit Hose Connections................................................................................................... 1-31 Cutting the Torch Ring Figure 3-14.............................................................................................................. 3-18 Daily Checks and Maintenance......................................................................................................................... 3-4 Daily Crusher Operations................................................................................................................................... 2-6 Description........................................................................................................................................................... 4-2 Description........................................................................................................................................................... 5-2 Determining Liner Wear.................................................................................................................................. 2-10 Difficulty Turning the Bowl............................................................................................................................. 2-11 Discharge Arrangement.................................................................................................................................... 1-4 Drive Ring Support Figure 1-26...................................................................................................................... 1-25 Eccentric Assembly Installation .................................................................................................................... 1-13 Eccentric Assembly Lifting Figure 1-9........................................................................................................... 1-13 Epoxy Grouting Requirements Table 1-3...................................................................................................... 1-11 Feed Arrangement............................................................................................................................................. 1-3 Feed Plate Assembly Figure 1-25................................................................................................................... 1-25 Flying or Falling Objects.................................................................................................................................... S-4 Foundation.......................................................................................................................................................... 1-3 Full Main Frame Grout Method ..................................................................................................................... 1-11 General Housekeeping....................................................................................................................................... S-7 General Maintenance Information................................................................................................................... 3-2 General Safety Instructions............................................................................................................................... S-2 Grease Fittings Figure 3-1................................................................................................................................ 3-8 Grease Fittings Figure 2-3............................................................................................................................... 2-10 Helix High Point Location Figure 3-9............................................................................................................ 3-15 High Noise Levels................................................................................................................................................ S-5 High Pressure Hydraulics/Gas Charged Accumulator.................................................................................. S-3 Holding the Countershaft Box Figure 1-11.................................................................................................. 1-15 Hydraulic Oil Change.......................................................................................................................................... 5-8 Hydraulic Oil Specifications............................................................................................................................... 5-2 Hydraulic Power Unit ..................................................................................................................................... 1-30 Hydraulic Power Unit Controls......................................................................................................................... 5-4 Hydraulic Power Unit Installation.................................................................................................................. 1-31 Hydraulic Power Unit Installation.................................................................................................................... 5-2 Hydraulic Power Unit Start Up and Operation.............................................................................................. 5-6 Hydraulic System Pre-Start............................................................................................................................... 5-3 Hydraulic System................................................................................................................................................ 3-8 Incorrect and Correct Feed Arrangement Figure 1-1.................................................................................. 1-4 Initial Inspection................................................................................................................................................. 1-3 Inspection Periods............................................................................................................................................ 2-14

ECT000-0176 - Rev. B - 07/08

Index Installation Drawings Furnished...................................................................................................................... 1-3 Installing or Removing the Head Assembly Figure 3-12........................................................................... 3-17 Installing the Accumulators............................................................................................................................ 1-18 Installing the Adjustment Mechanism Assembly ...................................................................................... 1-24 Installing the Adjustment Ring Assembly.................................................................................................... 1-18 Installing the Clearing Cylinders.................................................................................................................... 1-17 Installing the Head Assembly ........................................................................................................................ 1-23 Installing the Mantle Figure 3-19.................................................................................................................. 3-21 Installing the New Mantle............................................................................................................................... 3-19 Installing the Socket Assembly...................................................................................................................... 1-22 Installing the Tramp Release Cylinder........................................................................................................... 3-11 Installing the Tramp Release Cylinders......................................................................................................... 1-20 Introduction........................................................................................................................................................ 1-3 Jackshaft Configuration Figure 1-4............................................................................................................... 1-10 Jackshaft Drive.................................................................................................................................................... 1-9 Lifting a New Mantle Figure 3-17.................................................................................................................. 3-19 Lifting and Moving Heavy Components......................................................................................................... S-4 Lifting Bowl Assembly Figure 3-6.................................................................................................................. 3-13 Lifting Lug Figure 3-16.................................................................................................................................... 3-19 Lifting Main Frame Assembly Figure 1-5...................................................................................................... 1-10 Liner Change Checks and Maintenance.......................................................................................................... 3-6 Locking Nut Wrench Figure 3-15................................................................................................................... 3-18 Lower T-Seal Removal Figure 3-21................................................................................................................ 3-24 Lube System Installation................................................................................................................................... 4-3 Lube System Placement and Installation..................................................................................................... 1-27 Lube Tank Location Figure 1-30...................................................................................................................... 1-29 Lubricating Oil Specifications........................................................................................................................... 4-2 Lubrication Maintenance Chart ...................................................................................................................... 3-7 Lubrication........................................................................................................................................................... 3-8 Main Frame Installation on a Concrete Foundation ................................................................................. 1-10 Main Frame Liner Assembly Figure 3-20...................................................................................................... 3-22 Main Frame Liner Replacement..................................................................................................................... 3-20 Mantle Replacement Figure 3-13.................................................................................................................. 3-18 Mantle Replacement........................................................................................................................................ 3-17 Monthly Checks and Maintenance................................................................................................................... 3-5 Normal Operating Recommendations............................................................................................................ 2-9 Oil Contamination Guidelines Table 3-1......................................................................................................... 3-9 Oil Contamination............................................................................................................................................... 4-4 Oil Coolers ............................................................................................................................................................ 4-4 Oil Filtration......................................................................................................................................................... 4-4 Oil Heater .......................................................................................................................................................... 1-30 Oil Tank Breather................................................................................................................................................. 4-4 Optimal Contact Pattern Figure 1-14............................................................................................................ 1-17 Ordering Replacement Parts............................................................................................................................ 3-3 Package Lubrication System Placement and Installation......................................................................... 1-28 Periodic Inspections........................................................................................................................................... 3-3 Piping Information .......................................................................................................................................... 1-28 Piping Information............................................................................................................................................. 4-4 Pre-Start Up Procedures................................................................................................................................... 2-5 Procedure for Replacing a Worn Mantle...................................................................................................... 3-18

ECT000-0176 - Rev. B - 07/08

Index Procedure to Remove the Eccentric Assembly.......................................................................................... 3-22 Procedure to Remove the Socket Assembly............................................................................................... 3-21 Production Control............................................................................................................................................ 2-7 Proper Training and Indoctrination ............................................................................................................... S-7 Raptor XL 1100 Lifting Weights Table 1-1........................................................................................................ 1-6 Remote Mounted Push Button Control Panel Installation......................................................................... 5-2 Remote Mounted Pushbutton Control Panel Installation . ..................................................................... 1-31 Remote Push Button Panel Indicator Lights................................................................................................. 5-4 Removing the Tramp Release Cylinders....................................................................................................... 1-21 Replacing the Accumulator............................................................................................................................ 3-11 Respiratory Concerns........................................................................................................................................ S-5 Root Clearance Figure 1-29............................................................................................................................. 1-27 Seating the Mantle Figure 3-18..................................................................................................................... 3-20 Service Box Switches.......................................................................................................................................... 5-5 Setting the Crusher . ........................................................................................................................................ 2-8 Setting the Crusher Figure 2-1......................................................................................................................... 2-8 Shut-Down Instructions.................................................................................................................................... 2-7 Slip and Trip Hazards.......................................................................................................................................... S-2 Socket Assembly Figure 1-24.......................................................................................................................... 1-24 Socket Liner Lifting Figure 1-23...................................................................................................................... 1-24 Socket Mounting Figure 1-21......................................................................................................................... 1-23 Sole Plate Installation A Figure 1-7................................................................................................................ 1-12 Sole Plate Installation B Figure 1-8 ............................................................................................................... 1-12 Sole Plate Method............................................................................................................................................. 1-10 Special Tool Required for Component Handling.......................................................................................... 1-5 Thread Lubrication........................................................................................................................................... 2-10 Tool Use Table 1-2................................................................................................................................................ 1-8 Tools Assembly Figure 1-2................................................................................................................................. 1-7 Tramp Release Cylinder Mounting and Support Figure 1-20.................................................................... 1-22 Typical Crusher Terminology ........................................................................................................................... 2-2 V-Belt Drives ....................................................................................................................................................... 1-9 V-Belt Types Figure 1-3...................................................................................................................................... 1-9 Vital Sign Monitoring......................................................................................................................................... 2-6 Water Cooled Lube System............................................................................................................................... 4-5 Water Cooler........................................................................................................................................................ 4-5 Water Strainer Cleaning..................................................................................................................................... 4-5 Water/Oil Heat Exchanger............................................................................................................................... 1-29 Wedge Assembly Figure 3-8........................................................................................................................... 3-14 Weekly Checks and Maintenance..................................................................................................................... 3-5

ECT000-0176 - Rev. B - 07/08