raptor xl300&400 rev 00 08-08

Raptor XL300/XL400Instruction Manual

August 2008ECT000-0337 Rev 00

ECT000-0337 - Rev. 00 - 08/08

Section 1 Safety

Section 2 General Crusher Information

Section 3 General Installation Information

Section 4 Main Frame Assembly

Adjustment Ring Assembly

Tramp Release Assembly

Section 5 Countershaft Box Assembly

Countershaft Assembly

Sheave Assembly

Section 6 Eccentric Assembly

Section 7 Socket Assembly

Section 8 Head Assembly

Mantle Assembly

Feed Plate Assembly

Section 9 Bowl Assembly

Bowl Liner Assembly

Hopper Assembly

Section 10 Bowl Adjustment Mechanism Assembly

Section 11 Lubrication System

Section 12 Hydraulic Systems

Section 13 Operating Instructions

XL300 Cross Section with Component Call Outs

XL400 Cross Section with Component Call Outs

Index

XL300/XL400 Cone Crusher

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Section 1

SafetySafetyThis section of the Instruction Manual provides only basic safety procedures and is in no way intended to replace safety codes, insurance requirements, federal, state and local laws, rules and regulations.

Safety Begins and Ends With YouIt is the responsibility of each person to know and follow all the required safety procedures.

Unfortunately, injury is often not just limited to those who do not follow required procedures. The safety of everyone relies on everyone.

Safety and The Crusher Even the safest machine must be operated in accordance with the manufacturers recommendations. Review this Instruction Manual and become familiar with the hazards of the Crusher and associated equipment. Refer to the “Operating Instructions” Section of this Manual.

Develop safety procedures in the operation and maintenance of the Crusher. Check for loose, damaged or worn parts and report unsafe situations immediately. Only use comparable type and quality replacement parts such as those supplied by Excel.

Do not make any adjustmentsor repairs of any kind

while the Crusher is operating!

Always follow standard lockout procedures using warning tags before working on the Crusher. Each person working on the Crusher should have their own personal padlock, warning tag(s) and ONE key.

Stay away from all moving parts of the Crusher. Loose clothing, watches and rings create a hazardous situation.

Safety Glasses, Hard Hat and Safety Shoes are critical when around the Crusher and other machinery. Ear protection is suggested along with minimizing exposure time when the Crusher is in operation.

Keeping the area around the Crusher and other machinery clean provides a safer working environment. Do not allow material to build-up around the Crusher.

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Section 2

General Crusher InformationIntroductionThis manual provides information for properly installing, operating and maintaining the XL300/XL400 Crusher.

It is recommended that this manual be read before installing and operating the machine.

Initial InspectionA 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. Notify the carrier immediately of any damage or shortages.

Information FurnishedThe following information for your XL300/XL400 Crusher is provided by the factory and includes:

• MountingandClearancedrawing.

• IndexforFieldConnectionsdrawing.

• OperationandmaintenanceinformationforequipmentnotmanufacturedbyExcel.

• CrusherPartsBook.

Repair PartsExcel carries an extensive supply of replacement parts.To avoid delay and incorrect parts being furnished, the following information is required when ordering:

1. Crusher size

2. Crusher serial number

3. Name of part, part number and the quantity of parts ordered

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Section 3

General Installation Information

Crusher Clearance Dimensions .................................................................................................................... 3-2

Foundation ................................................................................................................................................... 3-2

Weight of Complete Crusher and Assemblies Table 3-1 ......................................................................... 3-2

Belt Types Figure 3-1 ...................................................................................................................................... 3-3

Crusher and Subassembly Weights.............................................................................................................. 3-3

Discharge Arrangement ................................................................................................................................. 3-3

Feed Arrangement .......................................................................................................................................... 3-3

V-Belt Drive ................................................................................................................................................... 3-3

Crusher Motor .................................................................................................................................................. 3-4

Hydraulic System Information ..................................................................................................................... 3-4

Piping Information .......................................................................................................................................... 3-4

General Assembly & Disassembly Information .......................................................................................... 3-5

Special Tools Furnished with the Raptor Crusher Figure 3-2 ................................................................ 3-6

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Weight of Complete Crusher andWeight of Assemblies That Require Frequent Handling

XL300 XL400 Pounds (Kilograms) Pounds (Kilograms)

Complete Crusher 36,116 (16,382) 51,896 (23,540) Complete Crusher less Bowl, Hopper and Head Assembly 27,881 (12,647) 40,651 (18,439)

Bowl Assembly, Bowl Liner and Hopper Assembly 7,376 (3,346) 10,171 (4,613) Main Frame Assembly 10,663 (4,837) 14,919 (6,767) Head Assembly, Feed Plate Assembly and Mantle 4,647 (2,108) 7,521 (3,411)

Countershaft Box Assembly 893 (405) 1,230 (558)

Eccentric Assembly 2,398 (1,088) 3,944 (1,789)

Socket 120 (54) 183 (83)

Socket Liner 100 (45) 140 (64)

Mantel 1,815 (823) 2,845 (1,290)

Bowl Liner 1,870 (848) 3,392 (1,539)

Table 3-1

3-2

FoundationThe Mounting and Clearance Drawing, furnished by Excel, will provide you with mounting position of the foundation bolts, drive motor location and various clearances required to mount the Crusher onto the foundation. A durable, solid and level foundation is critical to the safe operation of the Crusher.

ImportantInformation data sheets with Crusher foundation loads are available from Excel. The foundation must be designed to accept these loadings. The customer is responsible for the design of the foundation.

Crusher Clearance DimensionsSuccess of the operation and maintenance of the Crusher relies on a well planned installation. Crusher clearances must be considered when designing the foundation. 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 is also required in front of the foundation for the removal of the Countershaft Assembly. Another requirement is the room needed under the Crusher for a discharge conveyor and/or chute.

Refer to the Mounting and Clearance drawing along with the Dimensional Data Sheets available from Excel to determine the clearances required in designing your foundation.

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It is recommended that a screen be placed ahead of the Crusher in the circuit to remove fine or sticky material. This will help avoid conditions such as bridging and ring bounce. Installation of a metal detector or magnet is recommended to remove any non-crushable items (called “Tramp”) before they get into the crushing cavity. Excessive amounts of tramp material passing through the Crusher can cause ring bounce, damage Crusher parts and possibly stall the Crusher drive motor.

Discharge ArrangementThe 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” for the Crusher discharge material to fall on. The dead bed is designed to absorb most of the energy of the falling material before cascading onto the conveying equipment.

If a discharge chute is used, it must be positioned at an angle of 45° or greater from horizontal. If wet discharge material is present then the chute angle should be increased.

As shown on the mounting and clearance drawing, adequate clearance is to be maintained between the discharge equipment and the Crusher. The proper amount of clearance will stop material from building up under the Crusher and eventually interfering with its operation.

V-Belt DriveDriving the Crusher is accomplished using a set of 8V-Belts. They reduce shock loads from being transmitted to the Crusher drive motor. Various combinations of Sheave diameters are used to change the speed of the Countershaft to fit different application requirements. There are two types of belts available, single or banded. Refer to Figure 3-1

Either type of belt can be used on a standard sheave. The advantage of banded belts is that they reduce the chance of rollover or belt whip.

3- 3

Crusher and Subassembly WeightsAnother consideration must be the weights of the Crusher and components. Sizing of overhead lifting equipment such as cranes, chain hoists or a mobile crane must take into consideration the weights associated with handling of the entire Crusher during installation. The lifting equipment must also be able to lift the various Crusher assemblies and individual replacement parts. Refer to Table 3-1 for the weights of the Crusher and assemblies. These weights are also furnished on a Crusher informational data sheet available from Excel Crusher Technologies.

Feed ArrangementProper 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 an even distribution of blended material sizes within the crushing cavity.

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 Bushings.

Excel recommends that feed circuits for Crushers in Short Head applications be designed to provide a build-up 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 required to 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”.

Note: Ring bounce occurs when 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.

A feed box mounted over the Crusher can serve as a backstop to insure the material falls vertically onto the Feed Plate. A feed spout mounted on the box and centered over the Feed Plate will aid in providing a uniform distribution of feed around the crushing cavity.

Figure 3-1 Belt Types

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For V-Belt installation and adjustment, refer to the belt manufacturers instructions. It is important to follow these instructions as belts adjusted too tight will cause high Countershaft Box and/or drive motor bearing temperatures with the possibility of bearing failure. Belts adjusted too loose will cause belt slip and possible stalling of the Crusher. Excel recommends using slide rails or similar means of belt tightening.

Mounting the motor Sheave below the countershaft and within 45° of the vertical centerline will require a change in the mounting position of the outer countershaft bushing oil groove. Contact Excel Crusher Technologies if either of these mounting positions are going to be used so the bushing can be installed correctly prior to shipment of the Crusher.

Crusher MotorThe drive motor should be a squirrel cage induction motor; continuous duty rated, with normal starting torque (approximately 125%) and normal breakdown torque (approximately 200%) within ±10% acceptable voltage variance. It is recommended that the Crusher be equipped with a reduced voltage starter.

To maintain a continuous horsepower level, an electric motor with a 1.15 service factor is required. If a service factor of 1.0 is used, the horsepower rating appearing on the motors nameplate should be approximately 15% higher than the recommended operating horsepower. The Crusher power draw however is to be held to 400 horsepower on the XL400 and 300 horsepower on the XL300.

With the use of a V-belt drive, the following considerations should be addressed when ordering the motor:

1. Motor bearings to be sized to handle overhung loads for the sheave and belt pull.

2. The motor is to have 360° radial belt pull capacity.

3. Motor shaft diameter must be able to withstand peak torque and simultaneous bending due to belt pull and Sheave weight.

4. The motor shaft must be a proper length to accommodate the motor Sheave bushing or hub and also provide clearance between the motor housing and the rim of the Sheave.

Piping InformationThe type of oil to be used to lubricate the Crusher is outlined in detail in Section 11. The lubrication system is designed to operate at a maximum of 125 PSI (8.6 Bars).

Refer to the Crusher piping and lubricating system and Mounting and Clearance drawings provided by Excel for piping connection size and locations. Factors listed below should be addressed when laying out the piping of the feed and drain lines as follows:

1. The slope of the drain piping from the Crusher to the Lube Package must be at least 1” (25 mm ) of vertical change for every 12” (305 mm) of horizontal change.

2. The supply and drain piping should be as direct and short as possible with a minimum amount of turns, dead pockets and any other obstructions.

3. Install a flexible coupling or short hose between the drain connection at the Crusher and the piping to accommodate Crusher movement.

4. The use of pipe unions is helpful in the removal of any piping or lubricating equipment when required.

5. All oil piping should be cleaned (remove chips and cuttings) before operating the lubrication system so as to avoid introducing this material into the Crusher bearings and oil pump.

6. Prior to initial Crusher startup, all piping connections should be checked for leaks.

Hydraulic System Information Refer to the Hydraulic Power Unit and Mounting and Clearance drawings supplied by Excel for information regarding the Power Unit to Crusher connection locations. The type of oil to be used in the hydraulic system is specified in Section 12.

The Power Unit should be placed in a protected area no more than 30 feet (9 meters) from the Crusher. Its placement should also allow the operator to observe the Crusher during the lifting of the Adjustment Ring (called “Clearing the Crusher”) and setting adjustments. The hoses used to connect the Hydraulic Power Unit to the Crusher are 30 feet (9 meters) long. Reusable couplings are attached to the end of each of these hoses for adjusting the lengths. This eliminates them from being coiled into a pile and causing a safety hazard.

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General Assembly & Disassembly InformationThe XL300/XL400 Crusher is shipped fully assembled. Lifting the Crusher onto the foundation should only be accomplished using the lifting hooks located at the four corners of the lower Main Frame flange.

All other lifting areas are designed to lift only subassemblies or individual parts and not the entire Crusher.

The following sections in this book will provide detailed instructions for disassembly and assembly of various subassemblies and parts that make up the Crusher. In some rare instances, the Crusher might be required to be shipped in subassemblies. The following sections will guide you in assembling the machine.

In the following sections there are instructions and illustrations that refer to the lifting and turning of various subassemblies and parts that make up the Crusher. For good safety practices follow these instructions and illustrations. When required, use the special tools furnished with the Crusher. See Figure 3-2

3-5

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Figure 3-2Special Tools Furnished with the Raptor Crusher

1 Ring Bolts 2 Washers 3 Head Lifting Plate 4 Eccentric Lifting Ring 5 Charging Assembly 6 Safety Block 7 Line-up Stud 8 Jackscrew 9 Lockbolt Wrench 10 Thread Template 2” Pitch 11 Hoist Ring

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Section 4

Main Frame, Adjustment Ring andTramp Release Assemblies

Main Frame Assembly Figure 4-1 .................................................................................................................. 4-3

Crusher Grouting Figure 4-2 ........................................................................................................................... 4-4

Crusher Installation on a Concrete Foundation .......................................................................................... 4-4

Crusher Installation on a Steel Structure ..................................................................................................... 4-5

Epoxy Grouting Requirements Table 4-1 ..................................................................................................... 4-5

Lifting of the Crusher Figure 4-3 ................................................................................................................... 4-5

Main Frame Flange Spacers Figure 4-4 ........................................................................................................ 4-6

Main Frame Liners and Arm Guards ............................................................................................................... 4-6

Main Frame Arm Guard Figure 4-5 ................................................................................................................ 4-7

Main Frame Liner Figure 4-6 ........................................................................................................................... 4-7

Replacing the Lower Thrust Bearing and Shims ......................................................................................... 4-7

Replacing the Main Shaft ................................................................................................................................. 4-7

Lower Thrust Bearing and Shims Figure 4-7 ............................................................................................... 4-8

“U” Seal Replacement ....................................................................................................................................... 4-8

U-Seal Replacement Figure 4-8 ..................................................................................................................... 4-8

Main Frame Pin XL300 Figure 4-9a .................................................................................................................. 4-9

Main Frame Pin Replacement XL300 .............................................................................................................. 4-9

Main Frame Pin XL400 Figure 4-9b ............................................................................................................... 4-10

Main Frame Pin Bushing Replacement XL300 ............................................................................................ 4-10

Main Frame Pin Replacement XL400 ............................................................................................................ 4-10

Main Frame Pin Bushing Replacement XL400 ............................................................................................ 4-11

Replacing the Main Frame Ring .................................................................................................................... 4-11

Main Frame Ring Figure 4-10 ........................................................................................................................ 4-11

Main Frame Seat Liner and Fulcrum Bar Frame 4-11 .............................................................................. 4-12

Main Frame Seat Liner and Fulcrum Bar ..................................................................................................... 4-12

Determining Main Frame Seat Liner Wear.................................................................................................. 4-12

Determining Adjustment Ring Wear............................................................................................................ 4-13

Determining Seat Liner Wear Figure 4-12 .................................................................................................. 4-13

Maximum Vertical Seat Liner Wear Table 4-2 ............................................................................................ 4-13

Installing the Main Frame Seat Liner and Fulcrum Bar ............................................................................ 4-14

Main Frame Seat Liner and Fulcrum Bar Figure 4-13 .............................................................................. 4-14

Adjustment Ring Assembly Removal ........................................................................................................... 4-14

Tramp Release Cylinder Strap Figure 4-14 ................................................................................................ 4-15

Adjustment Ring Placement Figure 4-15 ................................................................................................... 4-15

Clamp Ring Spacers and Capscrews Figure 4-16 ...................................................................................... 4-16

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Installing the Adjustment Ring Assembly ................................................................................................... 4-16

Removing the Tramp Release Cylinder ....................................................................................................... 4-16

Tramp Release Cylinder Assembly Figure 4-17 ......................................................................................... 4-17

Installing the Tramp Release Cylinder ......................................................................................................... 4-17

Accumulator Depressurization Figure 4-18 ............................................................................................... 4-18

Replacing the Accumulator ........................................................................................................................... 4-18

Accumulator Mounting Figure 4-19 ............................................................................................................ 4-19

Removing the Clamping Ring ....................................................................................................................... 4-19

Installing the Clamping Ring ......................................................................................................................... 4-19

Checking for Thread Wear Figure 4-21 ....................................................................................................... 4-20

Clamp Cylinder Travel Figure 4-20 ............................................................................................................... 4-20

Determining Adjustment and Clamping Ring Thread Wear .................................................................... 4-20

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Description Refer to Figure 4-1This section covers descriptions of the Main Frame, Adjustment Ring, and Tramp Release Assemblies along with installation and removal instructions.

The Main Frame is typically bolted to a foundation and provides a rigid support for the Crusher components while transmitting the crushing force to the foundation.

To protect the inside of the Frame from wear, Main Frame Liners are welded to the Frame and Arm Guards protect the three arms of the Frame.

An Adjustment Ring sits on the conical surface of the Frame and consists of threads on its inside diameter. The threads provide the means for turning the Bowl Assembly into and out of the Crusher along with the adjustment of the Crusher

close side setting. Clamping Cylinders are mounted in the Clamping Ring and position it above the Adjustment Ring. The Clamping Ring also contains threads on its inner diameter. When the Clamping Cylinders are pressurized, the Clamping Ring lifts slightly and locks the Bowl Assembly in place. This prevents the Bowl from turning during crushing.

The Dust Shell with integral seal is bolted to the top of the Adjustment Ring. The Dust Shell and its seal protect the Clamping Ring, Clamping Cylinders and Bowl threads from dust and dirt.

Hydraulic Tramp Release cylinders are used to hold the Adjustment Ring to the Main Frame. One end of each cylinder is bolted to the Adjustment Ring while the other end is attached to the Main Frame by use of a pin. A non-crushable item (tramp) passing through the crushing cavity

1. Main Frame 2. Adjustment Ring 3. Clamping Ring 4. Clamping Cylinder 5. Dust Shell

Figure 4-1 Main Frame, Adjustment Ring and Tramp Release Assemblies

6. Dust Shell Seal 7. Main Shaft 8. Lower “U” Seal 9. Arm Guard 10. Main Frame Liner

11. Tramp Cylinder 12. Main Frame Pin 13. Fulcrum Bar 14. Main Frame Pin Bushing 15. Seat Liners

16. Main Frame Ring 17. Lower Thrust Bearing

4-3

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or overloading the Crusher will cause the Adjustment Ring to lift off the Frame. The ring lift will extend the cylinder and force oil from the rod side of the cylinder to an Accumulator, mounted on the Main Frame, compressing the pre-charged nitrogen gas in the Accumulator. When the non-crushable item has passed through the crushing cavity and the Crusher overload condition has passed, the compressed nitrogen in the accumulator will force the oil back into the Tramp Release cylinders, retracting them, and reseating the Adjustment Ring on the Main Frame.

The Main Shaft is secured in the Main Frame hub by use of an interference fit. The Eccentric Assembly rotates around the fixed Main Shaft. The Socket Assembly is mounted on the top of the Main Shaft and supports the Head Assembly.

A thrust bearing is bolted to the top of the Main Frame hub and supports the rotating Eccentric Assembly. Shims located under the thrust bearing can be inserted or removed and are used to adjust the position of the Gear and Pinion relative to one another.

Pins mounted in the Adjustment Ring match up with holes in Bushings located in the Main Frame and prevent the Adjustment Ring from turning during crushing. The pins also serve as guides to properly reseat the Adjustment Ring on the Main Frame following the passing of tramp material.

Mounted around the top of the Main Frame gear well is a replaceable “U” shaped seal. This seal, along with its mating “T” shaped seal in the Eccentric Assembly, form a labyrinth to prevent oil leakage and the infiltration of dust into the Crusher.

Crusher Installation on aConcrete FoundationExcel recommends the use of grout when mounting the Crusher on a concrete foundation. There are two types of grouting material available: cementitious or epoxy. Epoxy grouting is a tough, vibration resistant and resilient material that requires less preparation before pouring than concrete grouting. This makes epoxy grouting the better choice.

To grout the Main Frame Assembly onto a concrete foundation, do the following:

1. Select the grout material.a) If epoxy grouting is going to be used, torch cut

four washers .38” (10mm) thick and place them over the four foundation bolts.

b) If cementitious grouting is going to be used, make four hardwood blocks. These blocks are to support the Main Frame 2” ( 50mm ) to 2.5” (60mm) above the foundation. Cementitious grout material shrinks when it sets and the wood blocks will shrink with it.

Refer to Figure 4-2

2. Attach the proper lifting equipment to the Frame lifting hooks located near the bottom of the Main Frame flange. Refer to Figure 4-3

Before lifting the Crusher, make sure the hoses to the tramp release cylinders located above the lifting hooks have been disconnected and the cylinders have been turned inward. Shipping caps should be installed in the cylinder ports and hose ends.

WarningUse only the Main Frame Lifting Hooks

to lift the Crusher!

3. Place the Main Frame on the foundation and on top of the steel washers or wood blocks.

4. If cementitious grouting is used, go to Step 5. If epoxy grouting is used, place customer supplied “C” shaped steel shims on top of the steel washers. This will provide the approximate desired .5” (12mm) to .75” (20mm) epoxy thickness between the Main Frame and foundation.

5. Construct and install wood forms around the inside and outside of the lower Main Frame flange to

4-4

1. Crusher 2. Foundation 3. Epoxy Grout 4. Foundation Bolt 5. Wood Forms

Figure 4-2 Crusher Grouting

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contain either the epoxy or cementitious grouting material while it’s being poured.

Refer to Figure 4-2

Coat the forms with several layers of paste wax prior to installation to prevent the grouting material from adhering to the forms. These forms should be kept .5” (12mm) to .75” (20mm) from the outside of the Frame flange. Place the forms against the inner underside of the foundation and Main Frame flange. Use a caulking material to seal all seams and joints to prevent grout leakage when being poured.

6. If cementitious grouting is to be used, go to 6b.

6a. Follow the instructions below for pouring epoxy grouting.

1. Follow the epoxy grouting manufacturers mixing and pouring instructions. Pour the epoxy in one area at a time and allow it to spread approximately 2 feet (0.6 meters ) on either side of the spot that’s being poured. This will prevent air from being trapped under the flange. Next, move to another area where the previous pour has stopped and pour again. Repeat this process until the grouting has been completed. The epoxy should not be poured into more than one place at a time.

The approximate number of pounds or kilograms needed to grout the Crusher with a .5” to .75” (12mm to 20mm) thickness.

Refer to Table 4-1

2. When the grouting has hardened to the manufacturers recommendations, tighten the nuts on the foundation bolts to safely secure the Crusher.

6b. Follow the instructions below for pouring cementitious grouting.

1. The foundation surface should be cleaned and in a rough condition in the areas where the grouting is to be poured when using to the manufacturers recommendations. The areas must also be kept completely saturated with water to prevent water from being absorbed from the grout mix. Remove any standing water from the foundation just before pouring.

2. When the grouting has hardened to the manufacturers recommendations, tighten the nuts on the foundation bolts to safely secure the Crusher.

Crusher Installationon a Steel StructureIf the Crusher is to be mounted on a steel structure or trailer, the Frame must be shimmed because of discontinuities of the Crusher and the steel structure surfaces. For mounting the Crusher on a steel structure, do the following:

1. All weld spatter and slag is to be removed from the area where the Crusher is to be mounted. Ground all protruding welds flush on the adjacent surfaces.

1/2” (12mm) 3/4” (20mm) Grout Grout

XL300/XL400 99 lbs (45 kgs) 143 lbs (65 kgs)

Epoxy Grouting Requirements

Pounds (Kilograms) of Backing Material Required

All quantities include enough grout for an extra .5” (12 mm) between forms and frame flange. If the foundation is irregular, increase amounts by 10%.

Crusher Size

Table 4-1

4-5

1. Main Frame 2. Lifting Hooks in Main Frame

Figure 4-3 Lifting the Crusher

3. Adjustment Ring 4. Lifting Cables

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2. Torch cut four .25” (6.0mm) thick spacers to the same contour as the Main Frame flange. Refer to Figure 4-4 Dimensions for fabricating a spacer can be found on the Mounting and Clearance Drawing available from Excel. The spacers are then to be placed onto the steel structure and over the anchor bolts or bolt holes.

3. Attach the proper lifting equipment to the Frame lifting hooks located near the bottom of the Main Frame flange. Refer to Figure 4-3

Before lifting the Crusher, make sure the hoses to the tramp release cylinders located above the lifting hooks have been disconnected and the cylinders have been turned inward. Shipping caps should be installed in the cylinder ports and hose ends.

4. Lift the Main Frame and place it on the steel structure above the shims.

5. Level the Crusher by inserting shims the same shape as the ones torch cut in Step 2 but with slots to clear the anchor bolt when they are slid between the spacers and Main Frame flange.

6. Tack weld the spacer and shims to the steel structure to avoid them from working loose due to vibration.

7. Firmly seat the Crusher on the structure by tightening the anchor bolts. The anchor bolts should be long enough to pass through the entire depth of the support beam.

8. After the Crusher has been firmly anchored to the structure, recheck to make sure the Crusher is still level.

9. Check the anchor bolts for tightness after one day, one month, six months and one year and tighten if necessary.

Main Frame Linersand Arm GuardsThe Main Frame Liners and Arm Guards should be checked for wear during every Mantle and Bowl Liner change.

With the Head Assembly out of the Crusher, the Arm Guards are easily accessible for inspection and changing if required. Refer to Figure 4-5

If the Main Frame Liners are worn to the point of replacement, do the following:

XL3001. Inspect the Arm Guard Angle and Liner Clip. If

significant wear is found, discard the worn piece(s).

2. Weld a lifting eye to the worn Main Frame Liner. Be sure to preheat parts to 70°F (20°C) to 100°F (40°C) above ambient. Stainless Steel rod or equivalent should be used to attach the lifting eye to the worn Main Frame Liner. Support the Main Frame liner with a suitable lifting device.

3. Remove the Hex Head Capscrews and Liner Clips from the Main Frame liner.

4. Remove the worn liner. Caution: Do NOT be under the suspended load. Serious injury can occur.

5. Using a Plate clip or other suitable lifting device, hoist the replacement Main Frame Liner into the Crusher.

6. Seat the Main Frame Liner on to the Arm Guards to fit against the Crusher barrel.

7. Retain the Main Frame Liner with the Liner Clip, Hex Head Capscrew and Spring Washer.

8. Preheat Main Frame liner and Arm Guard Angle to 70°F (20°C) to 100 °F (40°C) above ambient. Stainless Steel rod or equivalent should be used to weld Arm Guard Angle to Main Frame Liner above the Arm Guard.

4-6

Figure 4-4 Main Frame Flange Spacers

1. Shims 2. Steel Structure or Trailer

3. Main Frame Flange 4. 12” (305mm) x 12” (305mm) Square Spacers

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1. Liner Welded to Main Frame 2. Main Frame Liner 3. Arm Guard

Figure 4-5 Main Frame Arm Guard

4. Main Frame 5. Liner Welded to Arm Guard

XL4001. Weld a lifting eye to the worn Main Frame Liner. Be

sure to preheat parts to 70°F (20°C) to 100°F (40°C) above ambient. Stainless Steel rod or equivalent should be used to attach the lifting eye to the worn Main Frame Liner. Support the Main Frame liner with a suitable lifting device.

2. Cut the welds using a grinder or Acetylene torch at the top of the worn Main Frame Liners holding them to the Main Frame (be careful not to undercut into the Main Frame).

3. Remove the worn liner. Caution: Do NOT be under the suspended load. Serious injury can occur.

4. Place each section of the new Frame Liner sections into the Main Frame relative to the Arm Guards to allow for welding. Refer to Figure 4-5 When welding the new Main Frame Liners to the Main Frame preheat the Main Frame 70°F (20°C) to 100°F (40°C) above ambient.

Replacing the Main ShaftReplacement of a Main Shaft requires a proper fit between the Shaft and Main Frame hub. Installing a Shaft should only be done by an Excel trained technician. Contact Excel Crusher Technologies customer service department in such a situation.

Note: During the annual check, inspect the fit of the Main Shaft in the hub of the Main Frame.

Use a feeler between the Shaft and bore at the top of the hub. The fit should be feeler tight all the way around. Use a feeler gauge between the Shaft and bore at the bottom of the hub. Measure at four points 90° apart and calculate the average clearance. This value should not exceed .0023” (.06mm). If there is clearance at the top or the bottom clearance exceeds the value listed, contact Excel Crusher Technologies customer service department immediately.

Replacing the Lower Thrust Bearing and ShimsTo replace the Lower Thrust Bearing due to damage or wear or to add or remove shims to adjust Gear/Pinion backlash, do the following:

1. To access the lower thrust bearing, remove the Bowl, Head, Socket and Eccentric Assemblies. Removal instructions can be found in the respective sections of this manual.

2. Remove the socket head capscrews and spring washers that retain the thrust bearing to the frame hub. Refer to Figure 4-7

Figure 4-6 Main Frame Liner

1. Main Frame 2. Main Frame Liner

4-7

ECT000-0337 - Rev. 00 - 08/08

3. Use the two M10 ring bolts supplied by Excel in the special tools to lift the Thrust Bearing out of the Crusher.

4. Inspect and remove any burrs or upset edges on the new Thrust Bearing and shims that would not allow flat contact on the top surface of the Main Frame hub.

5. To determine the correct amount of shims to be placed between the Main Frame and Thrust Bearing, see Section 6, Checking Backlash Between the Gear and Pinion. If additional shims are required, place them on top of the existing shim stack. If a new Thrust Bearing is to be installed, lift and lower the Thrust Bearing (using the same M10 ring bolts) on the shim stack making sure the Bearing and shims are seated properly and that the holes in these parts are aligned with the tapped holes in the Main Frame for securing.

6. Insert the socket head capscrews, along with new spring washers, through the Thrust Bearing and shims and screw them into the tapped holes in the Main Frame. Using a crossing pattern, tighten all the capscrews to 51 ft/lbs (69 N-m). Recheck torque after all components have returned to ambient temperature.

“U” Seal ReplacementThere is a “U” shaped seal located in a groove around the top of the Main Frame gear well. Refer to Figure 4-8 This seal can only be inspected whenever the Eccentric Assembly or Counterweight is out of the Crusher. Seal replacement is required if any damage is found. This seal not only prevents oil from leaking out of the Crusher, but keeps contamination out of the Crusher. To replace the seal, do the following:

1. Remove the damaged seal and scrape out any old glue residue left in the seal groove.

2. Completely clean the groove with an oil free solvent such as acetone or alcohol and let dry.

3. If the new seal is shiny on the bottom and is coated with a mold release agent, use a coarse sand paper to remove just enough off the bottom and sides of the seal to completely remove the shine. It is important that the release agent be completely removed so the adhesive used to hold the seal in the Eccentric groove will adhere to the seal.

4-8

1. Socket Head or Hex Head Capscrew 2. Lower Thrust Bearing 3. Shims 4. Main Frame 5. Spring Washer 6. Main Shaft

Figure 4-7 Lower Thrust Bearing and Shims

Figure 4-8 U-Seal Replacement

1. Apply Activator to Bottom and Sides of “U” Seal 2. “U” Seal 3. Apply Adhesive to Sides and Bottom of Frame Seal Groove 4. Apply Seal 5. Main Frame

ECT000-0337 - Rev. 00 - 08/08

The seal could become loose and work itself out of the groove during Crusher operation if the release agent is not completely removed.

4. Apply a very thin coat of activator to the bottom and sides of the seal. Too much activator will result in a partial cure that may not provide complete bond of the adhesive.

5. Apply a thin coat of adhesive to the bottom of the groove in the Main Frame. Apply just enough adhesive to the seal groove to obtain a minimal squeeze out when the seal is pressed in place in Step 6.

6. After the adhesive has been applied, quickly place the seal into the frame groove. Place a steady force on the bottom of the seal to maintain contact between the bottom of the groove and the seal. A satisfactory handling bond will occur in approximately three minutes.

Main Frame Pin Replacement – XL300The Main Frame Pins are pressed into the Main Frame and serve two purposes. They stop the Adjustment Ring from rotating on the Frame during crushing operation and they guide the Adjustment Ring back into position when ring lift occurs due to a tramp event or overpowering the Crusher. Adjustment ring lift, or sometimes called “Ring Bounce”, is not normal and can usually be corrected by adjusting the close side setting, using a different liner configuration, or by properly distributing the feed around the feed opening. Adjustment Ring movement, due to improper Crusher operation will cause wear to the Main Frame Pins and Pin Bushings, which are mounted in the Adjustment Ring. This wear can be seen by looking at the underside of the Adjustment Ring and at the top and bottom of the Pin Bushings. The rotation of the Head, while under load, will turn in a counter-clockwise direction. For that reason, the Bowl and Adjustment Ring will want to turn in the same direction causing the Pins and Pin Bushings to wear more on one side. To replace the Main Frame Pins, do the following:

1. Remove the Bowl Assembly from the Crusher following the instructions in Section 9, Bowl Removal.

2. Remove the Adjustment Ring from the Crusher following the instructions detailed later in this section under Adjustment Ring Assembly Removal.

3. Remove the hex bolt and fender washer from the bottom side of the Main Frame Pins.

Refer to Figure 4-9a

4. To remove the pins, heat the Main Frame pin boss while driving the pin out the top of the Main Frame. An aid to removing the pin would be to lance the pin prior to heating the Main Frame and driving it out.

5. To install the replacement Main Frame Pins, cool the Pins and heat the Main Frame to create a temperature difference of 374°F (208°C).

6. After the pins have been installed, and bottomed out on the bottom of the Main Frame counter bored hole, reinstall the hex bolt and fender washer.

If there are pin bushings that require replacing, then follow the instructions Replacing the Main Frame Pin Bushing – XL400 later in this section. Otherwise, install the Adjustment Ring back onto the Frame following the instructions Installing the Adjustment Ring Assembly described later in this section.

4-9

Figure 4-9a Main Frame Pin XL300

1. Main Frame Pin 2. Adjustment Ring 3. Main Frame Pin Bushing 4. Pin Retainer

ECT000-0337 - Rev. 00 - 08/08

Main Frame Pin Bushing Replacement – XL300To replace the Main Frame Pin Bushings, do the following:


2. Remove the Adjustment Ring from the Crusher following the instructions Adjustment Ring Assembly Removal described later in this section.

3. Remove the set screws, located at the Adjustment Ring, and the caps from those bushings that are being replaced.

4. Heat the Adjustment Ring pin bushing bosses and drive the bushings out of the bottom of the Adjustment Ring.

5. The replacement bushings are to be packed in dry ice for at least two hours before being installed.

6. The following instructions are to be conducted at each bushing location where the bushing is being replaced. Just prior to installing a cooled pin bushing, heat the Adjustment Ring boss for 10 to 15 minutes. Drop the cooled pin bushing quickly into the Adjustment Ring bore making sure that the bottom of the bushing is flush with the bottom of the Adjustment Ring. After the bushings have been installed, reinstall the set screws and the caps.

Before mounting the Adjustment Ring back onto the Main Frame, check for wear on the Main Frame Pins to determine if any or all need replacing. If there are Pins that require replacing, follow the instructions Main Frame Pin Replacement – XL300 described earlier in this section. Otherwise, install the Adjustment Ring onto the Frame following the instructions Installing the Adjustment Ring later in this section.

Main Frame Pin Replacement - XL400The Main Frame Pins are pressed into the Adjustment Ring and serve two purposes. They stop the Adjustment Ring from rotating on the Frame during crushing operation and they guide the Adjustment Ring back into position when ring lift occurs due to a tramp event or overpowering the Crusher. Adjustment ring lift, or sometimes called “Ring Bounce”, is not normal and can usually be corrected by adjusting the close side setting, using a different liner

configuration or by properly distributing the feed around the feed opening. Adjustment Ring movement, due to improper Crusher operation will cause wear to the Main Frame Pins and Pin Bushings, which are mounted in the Main Frame flange. This wear can be seen by looking at the underside of the Adjustment Ring and at the top and bottom of the Pin Bushings. The rotation of the Head, while under load, will turn in a counter-clockwise direction. For that reason, the Bowl and Adjustment Ring will want to turn in the same direction causing the Pins and Pin Bushings to wear more on one side. To replace the Main Frame Pins, do the following:


2. Remove the Adjustment Ring from the Crusher following the instructions detailed later in this section under Adjustment Ring Assembly Removal.

3. Remove the pin retainer from the Main Frame Pins. Refer to Figure 4-9b

4. To remove the pins, heat the Adjustment Ring pin boss while driving the pin out the bottom of the ring. An aid to removing the pin would be to lance the pin prior to heating the adjustment ring and driving it out.

4-10

1. Main Frame Pin 2. Adjustment Ring 3. Main Frame Pin Bushing 4. Retaining Ring 5. Pin Retainer

Figure 4-9b Main Frame Pin XL400

ECT000-0337 - Rev. 00 - 08/08

5. To install the replacement Main Frame Pins, cool the Pins and heat the Adjustment Ring to create a temperature difference of 300°F (167°C).

6. After the pins have been installed, reinstall the Main Frame pin retainers.

If there are pin bushings that require replacing, then follow the instructions Replacing the Main Frame Pin Bushing later in this section. Otherwise, install the Adjustment Ring back onto the Frame following the instructions Installing the Adjustment Ring Assembly described later in this section.

Main Frame Pin Bushing Replacement - XL400To replace the Main Frame Pin Bushings, do the following:


2. Remove the Adjustment Ring from the Crusher following the instructions Adjustment Ring Assembly Removal described later in this section.

3. Remove the retaining rings, located at the bottom of the pin bushings, from those bushings that are being replaced.

4. Heat the Main Frame pin bushing bosses and drive the bushings out of the top of the frame.

5. The replacement bushings are to be packed in dry ice for at least two hours before being installed.

6. The following instructions are to be conducted at each bushing location where the bushing is being replaced. Just prior to installing a cooled pin bushing, heat the Main Frame pin boss for 10 to 15 minutes. Drop the cooled pin bushing quickly into the main frame bore making sure that the bushing flange bottoms on the main frame pin boss. After the bushings have been installed, reinstall the retaining rings on the pin bushings.

Before mounting the Adjustment Ring back onto the Main Frame, check for wear on the Main Frame Pins to determine if any or all need replacing. If there are Pins that require replacing, follow the instructions Main Frame Pin Replacement - XL400 described earlier in this section.

Otherwise, install the Adjustment Ring onto the Frame following the instructions Installing the Adjustment Ring Assembly later in this section.

Replacing the Main Frame RingThe Main Frame Ring is a replaceable wear ring that is press fit into the inner bore of the Main Frame and supports the Pinion end of the Countershaft Box Assembly Refer to Figure 4-10 This machined ring eliminates the need for expensive rework of the inner Main Frame bore where wear is normally experienced due to the working between the Countershaft Box and the Main Frame. To replace the Frame Ring, do the following:

1. Remove the Countershaft Box, Bowl, Socket and Eccentric Assemblies. It is possible to access and inspect the Main Frame Ring by only removing the Countershaft Box Assembly. However, removal of the Frame Ring can be difficult with the tight spaces, if the remaining assemblies listed above are not removed.

2. Using an abrasive disk cutting wheel, carefully cut two or three grooves nearly through the Main Frame Ring. Care must be taken to avoid cutting into the Main Frame bore. These grooves will relieve much of the interference fit that is designed between the Frame Ring and Main Frame bore.

4-11

Figure 4-10 Main Frame Ring

1. Main Frame 2. Main Frame Ring

ECT000-0337 - Rev. 00 - 08/08

3. Using a bronze pin, drive the Main Frame Ring out from the inside.

4. Clean the Main Frame bore and dress out any burrs or upsets on the fit surface.

5. Create the proper minimum temperature difference between the Frame Ring and Main Frame bore.

Temperatrue Difference Between Frame Ring and Main Frame Bore

XL300 138°F (77°C) XL400 122°F (68°C)

Install the Main Frame Ring in the bore (it may be necessary to tap the ring with a soft hammer) and physically hold the Frame Ring in position until the Frame Ring is solidly held by the Main Frame.

Main Frame Seat Liner and Fulcrum BarWelded to the top flange of the Main Frame is a Seat Liner and Fulcrum Bar. Refer to Figure 4-11

These parts should be regularly checked for wear. Deviations in feed to the Crusher along with slight movement between the Adjustment Ring and Main Frame can cause small amounts of wear. This wear will increase if an excessive amount of Adjustment Ring movement (Ring Bounce) is allowed.

The bronze Seat Liner provides a replaceable seating surface for the Adjustment Ring. The bronze Seat Liner is a softer material than the steel Main Frame and Adjustment Ring.

Welded to the top of the Main Frame Flange is a Fulcrum Bar. Refer to Figure 4-1 There should always be clearance between the top of the Fulcrum Bar and the underside of the Adjustment Ring. The clearance is greatest when the Main Frame Seat Liners are replaced. Even though it rests on a bronze Seat Liner, over long periods of operation, the seating surface of the Adjustment Ring will wear. The seating surface of the Adjustment Ring should be re-conditioned when the required clearance between the top of the Fulcrum Bar and the Adjustment Ring is no long achievable after replacing the Main Frame Seat Liners.

There is a possibility of adjustment ring failure (i.e. cracking) if the adjustment ring is allowed to directly contact the Fulcrum Bar during crushing operations.

Determining Main Frame Seat Liner WearThe Mainframe Seat Liners need to be inspected weekly or after every major tramp event. This requires doing a crusher clearing to lift the adjustment ring. The safety block should be installed and the seat liner segments inspected for detachment or cracked welds.

To determine the amount and rate of Seat Liner wear, do the following:

1. Number each of the five main frame pin bosses in a clockwise direction, by painting or stamping, starting with the boss just left of the countershaft box.

Refer to Figure 4-12

2. Measure and record the gap between the top of the Main Frame pin bushing boss and the bottom of the Adjustment Ring pin boss. Refer to Figure 4-12

3. Every six months or after a known period of excessive ring bounce, take gap measurements at these points and compare them with the original measurements from Step 2. The difference in the measurements will tell you how much if any wear has taken place. Due to casting variations, this gap is the only place to take accurate measurements.

4. The maximum allowable difference between the original and a check measurement is .31” (8mm).

4-12

1. Fulcrum Bar 2. Seat Liner

Figure 4-11Main Frame Seat Liner and Fulcrum Bar

3. Seating Surface 4. Main Frame

ECT000-0337 - Rev. 00 - 08/08

The Seat Liner and Fulcrum Bar need replacing when the wear has reached this amount of drop, as there is only .06” (1.5mm) thickness left on the seat liner. Refer to Table 4-2

If the gap from one side of the Crusher to the other varies by .25” (6mm), after subtracting them from the original measurements, this indicates that the Seat Liner has worn on one side and the Adjustment Ring is tilted. This scenario is caused by an uneven distribution of feed in the Crusher. When the ring tilt is between .25” (6mm) to .38” (10mm), the Seat Liner and Fulcrum Bar need to be replaced.

The fulcrum bar must be replaced at the time the seat liners are being replaced. Replacement procedure for installing a new seat liner and fulcrum bar can be found later in this section.

Determining Adjustment Ring WearWhen a new Frame Seat Liner and Fulcrum Bar is replaced, there is a gap between the top of the Fulcrum Bar and the underside of the Adjustment Ring that must be held. Refer to Figure 4-11 As previously mentioned, the Adjustment Ring seating surface will wear over a long period of time. The Adjustment Ring seating surface will eventually wear enough to where the desired gap will not be able to be held even with the installation of new Frame Seat Liners and Fulcrum Bar.

For the Adjustment Ring to seat properly on the Main Frame, holding the desired gap between the Adjustment Ring and Fulcrum Bar after new ones have been installed is very important.

To determine the gap between the Adjustment Ring and Fulcrum Bar, do the following:

1. If not already done, remove and replace the Main Frame Seat Liners and Fulcrum Bar as instructed in Installing the Main Frame Seat Liner and Fulcrum Bar described later in this section.

2. Insert balls of clay or putty at various spots on top of the Fulcrum Bars.

3. Place the Adjustment Ring on the Main Frame making sure it’s properly seated.

4. Lift the Adjustment Ring off the Frame and measure the thickness of the clay or putty.

a. If the thickness of the clay or putty measures the minimum clearance allowed, .04” (1mm) or less, machine the top of the Fulcrum Bar to obtain the proper clearance.

Maximum Vertical Seat Liner Wear 5/16” (8mm)

Seat Liner Wear Example

Original Recorded Measurement 1-9/16” (40mm)

Periodic Dimensional Check Measurement 1-1/4” (32mm)

Difference 5/16” (8mm)

Table 4-2

4-13

1. Adjustment Ring 2. Main Frame Pin 3. Paint or Stamp Numbers 1.2.3. etc. Here 4. Measure and Record Wear Dimensions Here 5. Seat Liner 6. Main Frame 7. Fulcrum Bar 8. 1/32 (1mm) to 5/32 (4mm) Clearance required after new seat liners are installed

Figure 4-12 Determining Seat Liner Wear

ECT000-0337 - Rev. 00 - 08/08

b. If the thickness of the clay or putty measures the maximum clearance allowed, .16” (4mm) or more, use weld to build-up the top of the Fulcrum Bars and machine to obtain the proper clearance. Contact Excel customer service for dimensions, welding and machining procedures.

5. If the measurement varies from one side of the Crusher to the other by a .25” (6mm) or more, this indicates the Adjustment Ring seating surface has worn excessively on one side and that the ring is tilted on the Main Frame. Again, this is caused by uneven feed distribution.

Installing a new Frame Seat Liner and Fulcrum Bar WILL NOT correct this problem.

The Adjustment Ring seating surface will have to be reconditioned. Contact Excel customer service department for welding and machining procedures.

Installing the Main Frame Seat Liner and Fulcrum BarTo install new Main Frame Seat Liners and Fulcrum Bars, do the following:

1. Remove the Bowl Assembly following the instructions in Section 9, Bowl Removal.

2. Remove the Adjustment Ring following the instructions Adjustment Ring Assembly Removal later in this section.

3. Remove the worn Seat Liners and Fulcrum Bar segments from the Main Frame by grinding off the welds. Do not use air arc, as this can infuse carbon into the steel of the Main Frame and cause embrittlement.

4. The Seat Liner consists of segments and each segment is to be welded to the Frame individually. The vertical joints are not to be butt welded. Refer to Figure 4-13 Use welding rod 0.16” (4mm) AMPCO ROD #10 or AWS #E CU AL-A2 or #R CU AL-A2. These rods require an amp setting between 130A and 190A and reverse polarity. The welding surfaces must be preheated between 70°F (20°C) to 100°F (40°C) above ambient to remove all moisture and ensure proper weld penetration.

5. The Fulcrum Bar is also made of segments and made to be welded to the Main Frame individually. Use 7018 Weld Rod to mount the Fulcrum Bar to the Main Frame. The welding surfaces must be preheated between 70°F (20°C) to 100°F (40°C) above ambient to remove all moisture and ensure proper weld penetration. Refer to Figure 4-13

6. Check the clearance between the Fulcrum Bar and the underside of the Adjustment Ring as outlined under Determining Adjustment Wear earlier in this section. If the gap is found to be correct, then install the Adjustment Ring back onto the Frame following the instructions Installing the Adjustment Ring Assembly later in this section.

Adjustment Ring Assembly RemovalTo remove the Adjustment Ring Assembly from the Crusher, do the following:


2. Remove the Drive Ring as instructed in Section 10, Setting Adjust Mechanism off the Adjustment Ring.

4-14

1. Fulcrum Bar 2. Bronze Main Frame Seat Liner 3. Gap Between Fulcrum Bar Segment 4. Gap Between Main Frame Seat Liner Segments .75” (20mm)

Figure 4-13Main Frame Seat Liner and Fulcrum Bar

ECT000-0337 - Rev. 00 - 08/08

8. Unbolt the Dust Shell and remove it from the top of the Adjustment Ring.

9. Again, check that the Clamping Circuit Pressure is zero. Locate and disconnect the clamping circuit hose connection. Refer to Figure 4-15

10. Remove the hex head capscrews, washers and spacers used to contain the Clamping Ring on the Adjustment Ring. Refer to Figure 4-16

11. Disconnect the electric setting adjust motor and proximity sensors.

12. Remove the Vibration Sensors mounted on the Adjustment Ring. Be careful not to damage the cords as they are permanently secured to the Sensors.

4-15

1. By-pass Tube 2. Strap 3. Space Between By-pass Tube and Tramp Release Cylinder

Figure 4-14 Tramp Release Cylinder Strap

3. Electrically isolate the Hydraulic Power Unit and depressurize the Tramp Release Cylinders as instructed in Section 12, Hydraulic Systems. Make sure the tramp circuit pressure is zero by checking the value displayed on the tramp circuit pressure transducer.

4. Depressurize all the Clamping Cylinders as instructed in Section 12, Hydraulic Systems. Make sure the clamp circuit pressure is zero by checking the value displayed on the clamp circuit pressure transducer.

5. Unscrew the nuts that secure the top of the Tramp Release Cylinders to the Main Frame. These nuts were factory installed with Loctite and must be heated to 400°F (205°C) to be able to remove.

6. Place a strap around all of the Tramp Release Cylinders located between the cylinder tube and by-pass tube. Install wooden wedges between the Tramp Release Cylinders and the Main Frame. This strap and wooden wedges will hold the Tramp Release Cylinders in a vertical position and not allow them to fall when the Adjustment Ring is lifted off of the Main Frame. Refer to Figure 4-14

7. Opposite the countershaft on the adjustment ring, disconnect the hose that supplies hydraulic oil to the clamping cylinders from the hydraulic power unit. Refer to Figure 4-15

Figure 4-15 Adjustment Ring Placement

1. Clamping Cylinder Hose Connection 2. Indexing Hole Location on Adjustment Ring 3. Countershaft Centerline 4. Indexing Hole in Clamping Ring 5. Indexing Hole in Adjustment Ring

ECT000-0337 - Rev. 00 - 08/08

13. Remove the Clamping Ring using the ring bolts provided with the Special Tools.

14. Remove the Adjustment Ring using the ring bolts provided with the Special Tools.

15. Check the Adjustment Ring, Clamping Ring and Bowl threads as instructed in Adjustment and Clamping Ring Thread Wear later in this section.

Installing the Adjustment Ring AssemblyTo install the Adjustment Ring onto the Main Frame do the following:

1. Install the Adjustment Ring using the ring bolts provided with the Special Tools making sure that the clamping cylinder hose connection is located opposite the Countershaft. If the Tramp Release Cylinders were left attached to the Mainframe, carefully lower the Adjustment Ring and guide the cylinder rods into the mating holes.


2. Install the Clamp Ring using the ring bolts provided with the Special Tools making sure that the indexing holes in the Adjustment and Clamping Ring are aligned. Refer to Figure 4-15

If the indexing holes are not aligned, the Adjustment Ring and Clamping Ring threads will not be correctly oriented and the Bowl will not screw into the Adjustment Ring.

3. Insert the tube spacers into the holes in the Clamping Ring followed by the cap screws with washers mounted on them. Refer to Figure 4-16

4. Connect the hydraulic supply hose (vertical hose section coming from the Adjustment Ring) to the Clamping Cylinder hose loop. Check all the clamp cylinder hose connections to make sure they are tight before proceeding to Step 5.

5. Lift and place the Dust Shell on the top of the Adjustment Ring and bolt in place.

6. Thread the spherical nuts onto the top of the tramp release cylinders following the instructions Installing the Tramp Release Cylinder later in this section.

7. Lift and place the Drive Ring and its support brackets, as instructed in Section 10, on the Drive Ring Support.

8. Connect the setting adjust motor electrical connections and proximity sensor cables.

9. Connect the Vibration Sensors to the Drive Ring support brackets.

10. Apply a liberal coat of molybdenum disulfide grease to the Adjustment Ring and Clamping Ring threads.

Removing the Tramp Release CylinderWhen a leaking Tramp Release Cylinder is found, it should be replaced or removed and rebuilt immediately. A leaking cylinder will allow excessive Adjustment Ring movement. A leaking condition can also be indicated by excessive repressurization of the tramp circuit by the Control System. Refer to the Control System Instruction Manual for accessing the tramp release system pressure and pressurization trends. External leaks can be observed by oil leaking out from between the cylinder bearing and the cylinder tube or from between the cylinder rod and rod bearing. An internal leak (not visibly detectable) involves hydraulic oil bypassing the piston seals from the rod side to the piston side. This will

4-16

1. Clamping Ring 2. Capscrew 3. Flat Washer

Figure 4-16 Clamp Ring Spacers and Capscrews

4. Tube Spacer 5. Adjustment Ring

ECT000-0337 - Rev. 00 - 08/08

result in the constant loss of tramp circuit pressure causing excessive pressurization. Pressure check the cylinder to verify internal leaking of a cylinder.

To remove a tramp release cylinder from the Crusher for replacement or reconditioning, do the following:

1. Shut off power to the Hydraulic Power unit and lock it out.

2. Depressurize the tramp release circuit pressure as instructed in Section 12, Hydraulic Systems. Make certain the tramp release system pressure is zero.

WarningDo 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 all the hoses from the tramp release cylinder.

4. Attach a sling around the cylinder to be removed and to a suitable lifting device. The sling should pass between the cylinder and bypass tube so the tube will not be damaged when the cylinder assembly is being lifted off the Crusher.

5. Remove the nut from the top of the Tramp Release Cylinder. These nuts secure the cylinders to the Adjustment Ring and were factory installed with Loctite. They must be heated to 400°F (205°C) to remove. Refer to Figure 4-17

6. At the bottom of the tramp release cylinder assembly is a clevis pin with cotter pins in both ends. Remove the cotter pin and drive the clevis pin out of the tramp release cylinder clevis.

7. Slowly lower the cylinder assembly while guiding the cylinder rod down through the adjustment ring hole being careful not to damage the cylinder threads and hydraulic fittings. Once the cylinder assembly is clear of the Crusher, lift it up and out of the way.

8. The Tramp Release Cylinder has rebuild kits referenced in the Parts Books under the Tramp Release Cylinder Assembly.

Installing the Tramp Release CylinderTo install a new or rebuilt Tramp Release Cylinder, do the following:

1. Attach a sling around the cylinder so the cylinder hangs as vertical as possible with the clevis down. The sling should pass between the tramp release cylinder and the integral bypass tube so the tube will not be damaged when the cylinder assembly is being lifted.

2. Carefully lift the cylinder and guide the top cylinder rod up through the Adjustment Ring so as not to damage the rod threads. Slide the cylinder clevis onto the Main Frame rib.

3. Remove any burrs from the clevis pin and coat it with moly grade anti-seize grease before installing it through the cylinder clevis and frame rib. Install a cotter pin in each end of the clevis pin.

4. Clean the threaded portion of the rod and the spherical nut threads with an oil free solvent such as acetone or alcohol and coat the threads with Loctite 277.

4-17

1. Clevis Pin 2. Main Frame 3. Adjustment Ring 4. Tramp Release Cylinder Assembly 5. By-pass Tube 6. Spherical Nut 7. .75” (20mm)

Figure 4-17 Tramp Release Cylinder Assembly

ECT000-0337 - Rev. 00 - 08/08

5. Install the spherical nut with the rounded side down onto the rod until a distance of 0.75” (20mm) between the cylinder shoulder and the bottom of the Adjustment Ring is achieved.


6. Connect the hoses to the cylinder.

7. Bleed the tramp release system of any trapped air following the instructions in Section 12. After bleeding, pressurize the tramp release system and check the distance between the bottom of the adjustment ring and tramp release cylinder shoulder and correct if necessary. Refer to Figure 4-17

Replacing the AccumulatorA defective Accumulator requires immediate attention. It is typically a result of a damaged internal bladder and results in the inability to maintain pre-charge pressure. This condition can result in the Accumulator filling with hydraulic oil. Since oil is normally displaced from the tramp release cylinders into the Accumulator during tramp events or overload conditions, with no nitrogen gas to compress, the tramp release system will not operate as designed and excessive forces will be produced within the Crusher components.

The pre-charge in the Tramp Release Accumulator should be checked at a minimum of every 40 hours (approximately once a week). If the pressure is not at the specified pre-charge pressure or the pre-charge pressure cannot be held, then the Accumulator should be replaced. To replace the accumulator, do the following:

1. Shut off power to the Hydraulic Power Unit and lock it out.

2. Depressurize all the Tramp Release Cylinders as instructed in Section 12, Hydraulic Systems. Make certain the tramp release circuit pressure is at zero.

WarningDo Not UNDER ANY CONDITION disconnect any of the hoses from any component 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 4-18

4. Turn the T-Handle on the air chuck all the way out on the Charging Assembly supplied with the Special Tools. The screw on top of the bleeder valve must be closed. Screw the air chuck swivel onto the Accumulator 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.

4-18

1. Screw 2. Bleeder Valve 3. Gas Charging Valve 4. Pressure Gauge 5. Handle

Figure 4-18 Accumulator Depressurization

1. Accumulator 2. Gas Valve Stem

3. Valve Guard

6. Air Chuck 7. Swivel 8. Gas Valve Stem 9. Accumulator

Fig 4-18Fig 4-18

ECT000-0337 - Rev. 00 - 08/08

5. Turn the T-handle down until its internal shaft depresses the valve core stem on the Accumulator. Slowly open the screw on the bottom of the bleeder valve until the nitrogen gas starts to escape. Allow the gas to escape until the pressure gauge on the charging valve reads zero. Then remove the charging assembly and return it back with the rest of the tools.

6. Remove the hoses from the tee at the bottom of the Accumulator. Refer to Figure 4-19

7. Remove the Accumulator clamp securing the Accumulator to the Main Frame and lift it off its base.

8. Remove the fittings from the bottom of the old accumulator and install them on the new one.

9. Lift and set the new Accumulator on the base and install the clamp.

10. Connect the hoses to the tee at the bottom of the Accumulator.

11. Pre-charge the accumulator following the instructions in Section 12, Hydraulic System Pre-Start Tramp Release System. Damage can occur to the Accumulator bladder if the tramp release system is pressurized before the accumulator is pre-charged.

12. Bleed the tramp release system of any trapped air following the instructions in Section 12. After bleeding, pressurize the tramp release system and check for leaks.

Removing the Clamping RingTo remove the Clamping Ring, do the following:

1. Remove the Bowl Assembly following the instructions in Section 9, Bowl Removal.

2. Remove the Drive Ring as instructed in Section 10 from the Adjustment Ring.

3. Depressurize the Clamping Cylinder by turning the Local – Remote selector switch to the Local position.

Open the door on the front of the Hydraulic Power Unit and turn the Operation – Service selector switch to the Service position.

Refer to Figure 12-2 and Figure 12-8

Open the clamping system pressure dump valve all the way open. Ensure the Clamping Circuit pressure is zero.

4. Unbolt the Dust Shell and remove it from the top of the Adjustment Ring.

5. Disconnect the Clamping Cylinder hose from the Adjustment Ring.

6. Remove the hex head capscrews, washers and spacers used to hold the clamping ring in place.


7. From the tool box obtain the ring bolts and thread them into the tapped holes in the top of the clamping ring. Then attach proper lifting equipment to the ring bolts and lift the clamping ring off the adjustment ring.

Installing the Clamping RingTo install the clamping ring on the adjustment ring, do the following:

1. Install the Clamping Ring on the Adjustment Ring using the ring bolts provided with the Special Tools making sure the indexing holes in the Adjustment and Clamping Rings are aligned. Refer to Figure

4-19

1. Accumulator Clamp 2. Accumulator

Figure 4-19 Accumulator Mounting

3. Accumulator Base 4. Hose Fittings

Fig 4-19

ECT000-0337 - Rev. 00 - 08/08

4-15 If the indexing holes are not aligned, the Bowl will not screw into the Adjustment Ring.

2. Insert the tube spacers into the holes in the Clamping Ring followed by the capscrews with washers mounted on them. Refer Figure to 4-16

3. Connect the loose end of the hose attached to the Clamp Cylinder opposite the Countershaft Box to the 90° elbow mounted in the top of the Adjustment Ring. Check all the Clamp Cylinder hose connections to make sure they are tight.

Determining Adjustment and Clamping Ring Thread WearWhenever the Bowl Assembly is removed from the Crusher, the Adjustment Ring, Clamping Ring and Bowl threads should be checked for galling and wear.

The clamping system consists of a set of Clamping Cylinders Refer to Figure 4-20 installed in a Clamping Ring which is mounted on top of the Adjustment Ring. When pressurized, the cylinders slightly raise the Clamping Ring and lock the Bowl Assembly in place. The extreme crushing forces passing through the threads inevitably will result in

thread wear. As the condition of combined thread wear approaches the maximum travel of the clamp cylinders, the Bowl will become more and more difficult to hold in position during crushing. Eventually, if the threads are not refurbished, it will become impossible to maintain the desired close side setting.

To check the Adjustment Ring, Clamping Ring and Bowl thread for wear, do the following:

1. Clean the thread thoroughly by removing all grease and dirt.

2. Use the thread checking template supplied with the Special Tools on the Adjustment Ring, Clamping Ring and Bowl threads. Refer to Figure 4-21

3. Measure the gap between the thread template and each of the thread flats. Refer to Figure 4-21 Add the gap measurement taken from the Bowl threads, the gap measurement taken from the Adjustment Ring and the designed thread clearance of 0.16” (4.1mm). If the sum of these measurements matches or exceeds the maximum allowable clamp cylinder travel of 0.59” (15.0mm), the threads should likely be reconditioned. Contact Excel customer service before getting to this condition for welding and machining procedures.

4. Dress off all upsets and gouged steel caused by galling of the Bowl, Adjustment Ring and Clamp Ring threads.

1. Adjustment Ring and Clamping Ring Threads 2. Bowl Threads 3. Thread Checking Template 4. Distance to be Measured

Figure 4-21 Checking for Thread Wear

4-20

Figure 4-20 Clamp Cylinder Travel

Note: Cylinder is shown upside down for clarity

1. Piston 2. Piston Retainer 3. Cylinder 4. Piston Seal

ECT000-0337 - Rev. 00 - 08/08 5-1

Section 5

Countershaft Box, Countershaft and Sheave Assemblies

Countershaft Assembly Figure 5-1 ................................................................................................................ 5-2

Countershaft Box Installation ......................................................................................................................... 5-2

Countershaft Box Seal Figure 5-3 .................................................................................................................. 5-3

Countershaft End Float Figure 5-2 ................................................................................................................ 5-3

Countershaft Assembly Installation (Method-A) Figure 5-4 ..................................................................... 5-4

Countershaft Assembly Installation (Method-B) Figure 5-5 ..................................................................... 5-4

Countershaft Box Temperature Sensor Installation .................................................................................. 5-5

Forcing Countershaft Box into Main Frame Figure 5-6 ............................................................................ 5-5

Temperature Probe Figure 5-7 ....................................................................................................................... 5-5

Countershaft Box Assembly Removal ........................................................................................................... 5-6

Countershaft Box Removal Figure 5-8 ......................................................................................................... 5-6

Crusher Sheave Removal ................................................................................................................................. 5-7

Crusher Sheave Assembly Figure 5-9 ............................................................................................................ 5-7

Crusher Sheave Installation ............................................................................................................................. 5-7

Countershaft Installation ................................................................................................................................. 5-8

Countershaft Removal ..................................................................................................................................... 5-8

Holding the Countershaft Figure 5-10 .......................................................................................................... 5-8

Pinion Replacement .......................................................................................................................................... 5-9

Pinion Location Figure 5-11 .......................................................................................................................... 5-10

Bushing Removal Plate Figure 5-12 ............................................................................................................ 5-10

Countershaft Bushing Removal ................................................................................................................... 5-10

Removing the Countershaft Bushing by Ramming Figure 5-13 ........................................................... 5-11

Countershaft Bushing Figure 5-15 .............................................................................................................. 5-11

Countershaft Bushing by Jacking Figure 5-14 .......................................................................................... 5-11

Countershaft Bushing Installation ............................................................................................................... 5-11

“Inner” Countershaft Bushing Oil Groove Location Figure 5-16 ............................................................ 5-12

“Outer” Countershaft Bushing Oil Groove Positions Figure 5-17 .......................................................... 5-12

Drive Motor Positioned Below Motor Sheave Figure 5-18 ..................................................................... 5-13

Oil Leakage Out of the Drive End of the Countershaft ............................................................................ 5-13

Countershaft Box Pinion and Seal Figure 5-19 ......................................................................................... 5-14

Oil Leakage Out of the Pinion End of the Countershaft Box .................................................................. 5-14

ECT000-0337 - Rev. 00 - 08/085-2

Description Refer to Figure 5-1This section covers descriptions of the Countershaft Box, Countershaft and Crusher Sheave Assemblies along with installation and removal instructions.

A power source (electric motor) transmits power to the Countershaft via a set of V-Belts or direct drive equipment. The Countershaft has a bevel pinion gear mounted on one end and drives a gear that is mounted on the underside of the Eccentric Assembly. Supporting the Countershaft are two bronze sleeve bushings that are inserted in each end of the Countershaft Box. Dowels in the Countershaft Box prevent any rotation of the bushings in the Countershaft Box bores. The bushing flange absorbs thrust loads from either the pinion or the Oil Flinger. An oil Flinger is pressed on the drive end of the Countershaft. The centrifugal force of the rotating Oil Flinger prevents oil from leaking past the drive end bushing. This oil then collects in the end of the Countershaft Box and drains back to the Crusher sump area through a passage in the Countershaft Box. A piston ring type oil seal is held in place by a tight fit in the cover. The piston ring groove in the Oil Flinger forms a labyrinth seal

and rotates around the piston ring to keep oil from leaking past the running clearance between the Countershaft and cover bore. The Countershaft Box is held in the Main Frame by an interference fit and a set of capscrews around the outer flange. An o-ring and wear ring located on the pinion end of the Countershaft Box mates with surfaces on the Frame Ring. A guard is mounted on the Countershaft Box to protect it from wearing from the falling material in the Crusher.

Countershaft Box InstallationTo install the Countershaft Box Assembly in the Crusher, do the following:

1. The Countershaft Box is factory assembled with “end float” or clearance to allow for in and out movement of the Countershaft in the Box. Refer to Figure 5-2 When installing a repaired or replacement Countershaft Box Assembly, Excel recommends checking the end float by doing the following:

1. Pinion 2. Countershaft 3. Oil Flinger 4. Cover (Installed with Salastic) 5. O-Ring 6. Countershaft Box Guard

Figure 5-1 Countershaft Assembly

7. Outer Countershaft Bushing 8. Inner Countershaft Bushing 9. Countershaft Box 10. Piston Ring Seal 11. Wear Ring

ECT000-0337 - Rev. 00 - 08/08 5-3

a. Pull on the Pinion until the Flinger contacts the outer Countershaft Bushing.

Refer to Figure 5-2

b. Measure the gap between the Pinion and the inner Countershaft Bushing flange with a feeler gauge. If the end float is not correct, go to Step C. If it’s correct, go to Step 2.

Min. End Float Max. End Float XL300 0.031” (0.8 mm) 0.061” (1.6 mm) XL400 0.031” (0.8 mm) 0.061” (1.6 mm)

c. Loosen the Sheave Bushing capscrews and slide the Bushing off the Countershaft. If the Bushing is tight on the Countershaft, a wedge can be used in the cut section of the Bushing (making sure not to damage the Bushing) to spread it apart enough to slide it off the shaft. If there is a safety set collar mounted on the Countershaft, just loosen and slide it off.

d. Remove the Cover from the Countershaft Box.

e. If the end float gap is smaller than specified, then heat the flinger and tap the Countershaft on the sheave end to obtain the correct end fl oat measurement.

Temperature Difference Above Ambient

XL300 289o F (160o C) XL400 289o F (160o C)

If the end float measurement is too large, insert a feeler gauge of appropriate thickness (defined in Step B) between the Pinion and inner Bushing flange. Clamp the Pinion tight against the Bushing and heat the Flinger to the temperature specified above. Refer to Figure 5-10 Then push the Flinger against the outer Bushing flange and allow the Flinger to cool before removing the clamp and feeler gauge.

2. The O-Ring forms an oil seal between the Countershaft Box and Main Frame. Coat it with clean grease and stretch it over the Pinion end of the Box.

Refer to Figure 5-3

3. The Wear Ring is a pliable wear component with a split construction designed to isolate any movement of the Countershaft Box in the Frame Ring while minimizing wear between the two parts. Apply clean grease to the Wear Ring and install it in the groove located on the Pinion end of the Countershaft Box just before sliding the Countershaft Box Assembly into the Frame Ring.

1. Main Frame 2. Countershaft Box 3. O-Ring 4. Wear Ring

1. Inner Countershaft Bushing 2. Countershaft 3. Outer Countershaft Bushing 4. Oil Flinger 5. Sheave Bushing 6. No Clearance 7. Measure End Float Here

Figure 5-2 Countershaft End Float

Figure 5-3 Countershaft Box Seal

ECT000-0337 - Rev. 00 - 08/085-4

4. The Countershaft Box Assembly should be inserted in the Main Frame using one of two following methods. (Note: The Guard is to be mounted on the Box before inserting in the Frame.)

a. Using a sling attached to the Countershaft Box Assembly, place a long piece of pipe over the Sheave end of the Countershaft to balance the assembly. Refer to Figure 5-4 Lift the assembly and insert it as far as it will go through the outer Main Frame bore while carefully positioning the box centering lug on the Main Frame guide plate. Do not remove the Sheave end sling until the surface that fits into the Main Frame has been inserted into the outer frame bore at least 1.0” (25mm).

b. If a long pipe cannot be used due to space restrictions, attach another sling toward the Pinion end of the Countershaft Box. Refer to Figure 5-5 Lift the assembly and insert it into the outer frame bore as far as possible and rest the inner Countershaft Box flange on the guide plate in the Main Frame. Remove the lifting sling from the Pinion end of the box and

lower it through the inside of the frame and reattach it to the Pinion end of the Countershaft Box. With the Pinion end sling in place, lift the Countershaft Box and guide it into the Frame as far as it will go while at the same time carefully positioning the Countershaft centering lug on the Main Frame guide plate. Do not remove the Sheave end sling until the surface that fits into the Main Frame has been inserted into the outer frame bore at least 1.0” (25mm).

5. Apply Anti–Seize to the jackscrews provided with the special tools. The Anti-Seize protects the threads from damage caused by the pulling forces. Insert the jackscrews equally spaced through the holes located in the outer Countershaft Box flange until they thread into the tapped holes in the Main Frame.

6. Create the proper minimum temperature difference between the Main Frame and Countershaft Box. In small increments, alternately tighten the jackscrews to prevent binding of the interference fit of the outer Main Frame bore and the corresponding surface of the Countershaft Box. Tighten the jackscrews until they bottomed out in the tapped holes of the Main Frame.

Minimum Temperature Difference Between the Main Frame and Countershaft Box

XL300 113°F (63°C) XL400 102°F (57°C)

1. Lifting Sling 2. Sheave Bushing (or Set Collar Direct Drive) 3. Countershaft Box Centering Lug 4. Frame Support Guide

Figure 5-4Countershaft Assembly Installation (Method-A)

Figure 5-5Countershaft Assembly Installation (Method-B)

1. Wear Ring 2. O-Ring 3. Countershaft Box Guard 4. Lifting Sling 5. Add Counterbalancing Pipe Here 6. Centering Lug on Countershaft Box 7. Guide/Rest (Main Frame) 8. Pinion

ECT000-0337 - Rev. 00 - 08/08 5-5

7. Once the jackscrews have bottomed out in the tapped holes in the Frame, remove them and place washers or spacers on the jackscrews. Refer to Figure 5-6 Step 2 Repeat the small incremental tightening until they bottom out.

8. Remove the jack screws. Place the Lock Washers on the cap screws that hold the Countershaft Box Assembly in the Main Frame. Apply Anti-Seize to the cap screws. Install the cap screws into the Main Frame.

9. Press the Countershaft Box Assembly into the Main Frame by alternately tightening the capscrews until the Countershaft Box flange is tight against the Frame. Refer to Figure 5-6 Step 3

10. Install the Crusher Sheave onto the Countershaft as instructed in Crusher Sheave Installation that can be found later in this section.

Countershaft Box Temperature Sensor InstallationAn analog temperature sensor is mounted near the Countershaft Box and measures the outer box bearing temperature. The signal from this sensor is monitored by a Control System. The system will signal an alarm on the Panelview touchscreen. The setpoint in the Control System should be factory set to activate at 130°F (54°C). The most common cause of high outer box bushing temperature is over tensioning the drive belts. This sensor is typically shipped loose to avoid damage in transit. To install the Countershaft Box bushing temperature sensor, do the following:

1. Remove the pipe plug from the tapped hole that the sensor will mount in and install the Mounting Adaptor. Refer to Figure 5-7

2. Locate the sensor and its cover from one of the shipping crates along with the associated temperature probe, mounting adapter, mounting clamp and cable. Refer to the Crusher Oil Piping Assembly in the parts book to help with proper part number identification.

Figure 5-6 Forcing Countershaft Box into Main Frame

1. Main Frame 2. Washer Spacers 3. Jackscrew 4. Countershaft Box 5. Lockwasher 6. Regular Countershaft Box Hex Head Capscrews 7. No Clearance

Step 1

Step 3Step 2

1. Temperature Sensor Cable 2. Temperature Sensor

Figure 5-7 Temperature Probe

3. Mounting Adapter 4. Countershaft Box

To Control System

ECT000-0337 - Rev. 00 - 08/085-6

3. Slide the temperature probe into the adapter until the probe contacts the Countershaft Box Bushing. Tighten the nut on the mounting adapter to secure the probe in place. Do not over tighten the nut. This can cause damage to the probe cable.

4. Using the mounting clamp supplied, locate the sensor near the Crusher in an easily accessible area. This will provide easy viewing of the local display on the sensor.

Countershaft Box Assembly RemovalTo remove the Countershaft Box from the Main Frame do the following:

1. Remove the outer box bushing temperature sensor by loosening the mounting adapter nut and sliding the probe out of the box making sure not to damage the probe and/or cable. Refer to Figure 5-7

2. Attach a lifting sling around the Crusher Sheave and lift just enough to take the slack out of the sling. This will keep the Sheave from sliding off the Countershaft when it breaks loose from the tapered fit of the Sheave Bushing.

3. Follow the instructions in the Crusher Sheave Removal section (located later in this section) and remove the Sheave from the Countershaft.

4. Remove all the oil piping attached to the Countershaft Box and plug the openings.

5. Remove the six capscrews that secure the Countershaft Box to the Main Frame.

6. Using the jackscrews provided in the tools, thread them into the three equally spaced tapped holes in the Countershaft Box flange until they bottom out. Refer to Figure 5-8

7. Attach a lifting sling around the Sheave end of the Countershaft Box and lift to just take the slack out of the sling. Refer to Figure 5-4 The sling will keep the Countershaft Box from falling when the Box is removed from the Main Frame bore as instructed in Step 8.

8. There is an interference fit between the Main Frame bore and the Countershaft Box. Therefore, to remove the Box without damaging the fit, alternately tighten the jackscrews in small increments to prevent binding of the Box in the Frame bore. Continue jacking until the box is free of the Frame.

Heating of the Main Frame may be necessary if the jackscrews do not move the box. Heat the outer 6” (152 mm) of the Main Frame to create a temperature difference as specified below and alternately tighten the jackscrews as instructed above.

Minimum Temperature Difference Between the Main Frame and Countershaft Box

XL300 113°F (63°C) XL400 102°F (57°C)

9. There are two methods used to remove the Countershaft Box Assembly from the Crusher as follows:

a. Place a long piece of pipe over the Sheave end of the Countershaft to offset the heaver pinion end of the assembly when the Countershaft Box Assembly is being lifted by the sling that was attached to the box in Step 6. Refer to Figure 5-4, Method A

b. If a long pipe cannot be used due to space restrictions, attach a sling at the pinion end of the Countershaft Box. Refer to Figure 5-5, Method B Then lift the assembly and remove it out of the Crusher far as possible. Then lower

1. Main Frame 2. Jackscrews 3. Countershaft 4. Cover

Figure 5-8 Countershaft Box Removal

5. Countershaft Box 6. Oil Flinger 7. Lifting Sling

ECT000-0337 - Rev. 00 - 08/08 5-7

the box so the inner box flange rests on the guide plate in the Main Frame. Move the lifting sling from the inside of the Frame to the outside and attach it as close as possible to the pinion end of the Countershaft Box. With the pinion end sling in place, lift the Countershaft Box and guide it out of the Crusher.

Crusher Sheave RemovalTo remove the Crusher Sheave, do the following:

1. Wrap a lifting sling around the Crusher Sheave and lift just enough to take the slack out of the sling. This will keep the Sheave from sliding off the countershaft when it breaks loose from the tapered fit on the Sheave Bushing.

2. Remove the combination take-up and back-up capscrews from the hub of the Sheave.

Refer to Figure 5-9

3. Take two of the cap screws that were just removed. Lubricate the threads of the two cap screws and thread them into the tapped holes in the sheave hub. Alternately, tighten the cap screws against the sheave bushing flange until the sheave breaks loose.

If there is difficulty in breaking the sheaves loose, hit the end of the Counter Shaft with a Babbitt hammer while applying pressure to the sheave bushing flange.

If force does not work, heat the sheave with propane torches to expand the bore. First, heat the outside of the sheave in the area of the belts. Then heat will be applied to the center hub. Once the sheave is expanded, hit the end of the Counter Shaft with a Babbitt hammer. This action should break the sheave free.

4. When removing the Countershaft Box Assembly from the Crusher, do not remove the Sheave Bushing from the Countershaft. This will ensure that the Countershaft and Pinion do not slide out of the Box while handling the assembly. The Bushing can be safely removed after the Countershaft Box Assembly is set on appropriate cribbing by removing the clamp screw and sliding the bushing off the countershaft. If the Bushing is difficult to remove, insert a wedge or screwdriver in the split of the Bushing to enlarge the bore.

Crusher Sheave InstallationTo mount the Crusher sheave onto the countershaft, do the following:

1. Before mounting the Sheave onto the Countershaft, check the end float by following the Countershaft Box Installation instructions, Steps 1 and 2 earlier in this section. If the Sheave Bushing was not removed from the countershaft, proceed to Step 5.

2. With the end float checked and corrected if necessary, gently tap the Sheave key into the countershaft keyway.

3. Check the tapered surface and bore of the Sheave Bushing as well as the tapered bore in the Sheave and remove any dirt, paint, rust, lubricants and scratches. The Bushing and Sheave bore surfaces must be clean to ensure the Sheave is secure to the Countershaft. Do not lubricate the bushing or the sheave bore.

4. Loosen the Sheave Bushing clamp screw and slide the Bushing onto the Countershaft until it’s tight against the oil flinger. Then tighten the clamp screw to lock the Bushing in place on the Countershaft. Use a wedge or screwdriver in the split of the Bushing to install on the Countershaft if required.

1. Oil Flinger 2. Sheave 3. Sheave Hub 4. Countershaft

Figure 5-9 Crusher Sheave Assembly

5. Combination Take-up and Back-off Capscrews 6. Bushing Flange 7. Set Screw

ECT000-0337 - Rev. 00 - 08/08

5. Lift and slide the Crusher Sheave on the Sheave Bushing and align the holes in the Sheave with the tapped holes in the Bushing Flange.

6. Install the capscrews in the Sheave and screw them into the tapped holes in the Sheave Bushing flange. Alternately tighten the bolts in small increments until the torque value defined on the Drive Assembly drawing in the parts book is achieved. Over tightening could cause the Sheave to crack. When correctly assembled, there should be a clearance of approximately 0.375” (10mm) between the Sheave hub and Bushing flange. Do not try the make up this clearance. This gap is designed to attain a proper grip of the tapered fit between the Bushing and Sheave. Be sure to follow the torque requirements of the bushing manufacturer as over tightening the capscrews could cause the Sheave to crack.

Countershaft RemovalTo remove the Countershaft and Pinion from the Countershaft Box, do the following:

1. Remove the Countershaft Box Assembly from the Crusher as instructed in Countershaft Box Assembly Removal earlier in this section.

2. Loosen the Sheave Bushing clamp screw and slide the Bushing off the Countershaft. A wedge or screwdriver used in the split of the Bushing can help open the Bushing bore. Then remove the Sheave key from the Countershaft keyway.

3. Remove the oil flinger cover from the Countershaft Box.

4. There is a slight interference fit between the oil flinger and Countershaft. The oil flinger must first be heated the proper temperature above ambient before it can be properly removed from the Countershaft.

Temperature Difference Above Ambient XL300 289°F (160°C) XL400 289°F (160°C)

Position a pry bar between the flinger and the Countershaft Box and apply pressure. When the flinger starts to move, apply force to both sides of the flinger and slide it off the Countershaft.

5. The Countershaft and Pinion are now free to be slid out of the Countershaft Box.

6. With the Countershaft removed, check the shaft run out. If the measured value exceeds 0.004” (0.102mm), the Shaft must be replaced. Also check the Shaft for any twisting. Operating the Crusher with a bent or twisted Countershaft will cause excessive vibration and the potential for premature box bushing failure.

Countershaft InstallationTo install the Countershaft and Pinion into the Countershaft Box, do the following:

1. Use an emery cloth to remove any burrs and buff any scratches found on the Countershaft, the inside of the Countershaft Box and the surfaces of the Countershaft Box Bushings.

5-8

1. C-Clamp 2. Countershaft Box 3. Pinion

Figure 5-10 Holding the Countershaft

4. No Clearance 5. Shim

ENDFLOAT

Rev. B - 03/08

ECT000-0337 - Rev. 00 - 08/08

2. Coat the Countershaft Bushings with lube oil and carefully slide the Countershaft into the Countershaft Box until the Pinion contacts the Countershaft Bushing Flange.

3. Place a 0.031” (0.8mm) to 0.062” (1.5mm) thick shim between the Pinion and Countershaft Box Bushing Flange to establish the required end float. Then clamp the Pinion to the Countershaft Box.


4. There is a slight press fit between the oil flinger and Countershaft. The oil flinger must first be heated to the proper temperature of above ambient before it can be properly installed on the Countershaft.


Slide the flinger onto the Countershaft until it bumps the Countershaft Bushing Flange.

5. There is a piston ring seal mounted in a groove in the oil flinger which provides an oil seal with the cover. Make sure the ring is free to turn in the flinger groove. Apply a light coat of grease before installing the seal.

6. Check the inner bore of the cover and make sure it’s smooth and has no grooves worn into it by the piston ring. If a groove is starting to show, machine the bore to clean-up. A ring that is allowed to wear too deep into the cover will make removing the cover difficult.

7. Remove any old Silastic from the cover and the cover mounting surface on the Countershaft Box. Next place a bead Silastic RTV (see parts book for Excel part number) on the cover and inside the bolt circle.

8. Slide the cover onto the oil flinger and bolt it to the Countershaft Box.

9. Install the Sheave Bushing onto the Countershaft by following the instructions Crusher Sheave Installation, Step 2, 3 and 4 described earlier in this section.

5-9

10. Remove the clamp holding the Pinion to the Countershaft Box and spacer.

11. The Countershaft Box assembly is now ready to be installed back into the Crusher. Follow the instructions Countershaft Box Installation detailed earlier in the section.

Pinion ReplacementThe Pinion should be inspected for wear and damage any time the Countershaft assembly is removed from the Crusher. Excessive Pinion wear typically includes pitting and galling of the teeth surfaces. Damage may include broken teeth. The causes of such conditions may be:

1. Incorrect Gear/Pinion backlash setting which will cause damaging tooth contact.

2. Dirty lube system oil.

3. Operating the Crusher in an overloaded condition. Worn Pinions will likely experience tooth breakage which in turn will cause excessive vibration. These conditions will eventually lead to damage of other internal Crusher components. An excessively worn Pinion should be replaced. To maximize the benefits of installing a new Pinion, it’s recommended that the Eccentric Gear be replaced at the same time. Use of a new Pinion with an existing Gear requires checking the root clearance and backlash and adjusting if necessary. Follow the instructions Checking Root Clearance and Backlash in this section.

To replace the Pinion, do the following:

1. Remove the Countershaft Box assembly from the Crusher following the instructions Countershaft Box Assembly Removal described earlier in this section.

2. Remove the Countershaft and Pinion from the Countershaft Box following the instructions Countershaft Removal described earlier in this section.

3. Using a torch, evenly heat the Pinion to create the proper temperature difference as compared to the Countershaft.


ECT000-0337 - Rev. 00 - 08/08

When the specified temperature has been reached, continue to apply heat while bumping the Pinion. When the Pinion starts to move, slide it off the Countershaft.

4. Heat the new Pinion to the above temperature difference and quickly slide the Pinion onto the correct end of the Countershaft so the end of the shaft is sticking out of the Pinion the specified by measurement “A” distance. Refer to Figure 5-11

Countershaft Bushing RemovalIf either of the two Countershaft Box Bushings are found to be loose in the Countershaft Box as a result of wear, first remove the Bushing(s) and check the Box bore(s) to verify that they are within factory specifications and then change the loose Bushing(s). Operating the Crusher with inadequate lubrication, in an overloaded condition or with over tensioned V-Belts could cause the Bushings to over heat, fail and seize in the Countershaft Box making them difficult to remove. To remove Bushings that are tight in the Countershaft Box, do the following:

1. Remove the Countershaft Box assembly from the Crusher following the instructions detailed in Countershaft Box Assembly Removal described earlier in this section.

5-10

2. Remove the Countershaft from the Countershaft assembly following the instructions listed in Countershaft Removal earlier in this section.

3. A steel bushing removal plate is to be fabricated by the customer. Refer to Figure 5-12

4. The narrow part of the removal plate is to be slid into the Bushing until it’s positioned behind the Bushing. Refer to Figure 5-12 Turn the plate 90° until it contacts the Bushing.

5. Hold the plate in place and thread a 1” (25mm) diameter rod (threaded on both ends) into the nut that was welded to the removal plate. Make the rod a few inches longer than the Bushing.


6. Drill a 1.12” (30mm) hole in the center of a 1” x 3” x 12” (25mm x 75mm x 305mm) steel bar. Place the bar onto the threaded rod and hold it in place with a

Figure 5-12 Bushing Removal Plate

1. Slide Centering Plate through Bushing and turn 90° to Bear against end of Bushing 2. Countershaft Bushing 3. Bushing Removal Plate 4. Flats to be narrower than Inside Diameter of Bushing 5. Diameter of Plate to be larger than inside of Bushing 6. 1” (25mm) 7. Weld 1” (25mm) Hex Nut to Plate

1. Pinion 2. Countershaft 3. Measurement “A” .20” (5mm)

Figure 5-11 Pinion Location

ECT000-0337 - Rev. 00 - 08/08 5-11

1” hex nut. Refer to Figure 5-14 Slide a timber or a piece of pipe into the opposite end of the box and ram it against the removal plate to force the Bushing out of the box bore. If ramming will not move the bushing, then go to Step 7.

7. Thread a longer rod than the one previously used in Step 6 into the removal plate nut. Mount the steel bar onto the new rod and place wood blocking between the steel bar and the Countershaft Box flange. Refer to Figure 5-14 Tighten the 1” hex nut on the rod as a jackscrew until the Bushing is pulled against the steel bar. Place additional blocking under the bar and tighten the hex nut until the bushing is again drawn to the bar. Repeat this procedure until the bushing is pulled free of the Countershaft Box bore.

Countershaft Bushing InstallationTo install a new Countershaft Bushing do the following:

1. First measure the Bushing and Countershaft Box inside and outside diameters. Countershaft bushings are manufactured to provide a 0.001” (0.025 mm) tight to 0.002” (0.051 mm) loose fit in the Box bore. If the measurements indicate that a tighter interference fit than 0.001” (0.025 mm), then the Countershaft Box bore must be machined to obtain the proper fit between the Bushing and Countershaft Box bore.

1. Countershaft Box 2. Bushing Removal Plate 3. Dowel 4. Flat Bar 5. Countershaft Bushing 6. Threaded Rod 7. Timber

Figure 5-13Removing the Countershaft Bushing

by Ramming

Figure 5-14Countershaft Bushing Removal by Jacking

1. Flat Bar 2. Blocking 3. Countershaft Bushing

4. Countershaft Box 5. Bushing Removal Plate 6. Threaded Rod

Figure 5-15 Countershaft Bushing

1. Steel Guide Rods 2. Countershaft Bushings 3. Countershaft Box

ECT000-0337 - Rev. 00 - 08/085-12

If the interference fit is too tight, the Bushing bore will collapse when the Bushing is installed. This will reduce the running clearance between the Bushing bore and Countershaft causing premature Bushing failure with the possibility of the Bushing seizing to the Countershaft. Excessive heat can reduce the Countershaft Box bore diameter.

2. Remove the two dowels from the face of the Countershaft Box flange.

3. Make two rods the same diameter as the removed dowels and 1” (25 mm) longer than the Bushing. Insert the rods in the dowel holes.


4. The inner and outer Countershaft Bushings are identical. The position of their longitudinal oil groove in the Countershaft Box bore is what changes. To determine the oil groove position, do the following:

a. Position the inner Bushing (Pinion end) with the oil groove at the top of the of the Countershaft Box bore, or at the 12:00 o’clock position.


b. Position of the oil groove in the outer bushing, Sheave end, is normally at the bottom of the Countershaft Box bore or at the 6:00 o’clock position. This oil groove position accommodates all applications in which the drive motor is

positioned horizontally on either side of the Crusher along with applications in which the motor is located above the Crusher while not more than 45° on either side of the vertical centerline.

If the drive motor is positioned 45° below the Crusher on either side of the vertical centerline, the bushing oil groove must be located at the top center or at the 12:00 o’clock position. Refer to Figure 5-17 and 5-18

5. The new Bushing must be chilled to create the proper temperature difference of between the Bushing and Box.

Temperature Difference Between Bushing & Box XL300 121°F (67°C) XL400 70°F (39°C)

6. With the Bushing diameter sufficiently reduced, quickly slide the Bushing into the Countershaft Box bore using the rods (installed in Step 3) as guides.

If the Bushing is not installed quickly enough and

Figure 5-17“Outer” Countershaft Bushing

Oil Groove Positions

1. Normal 6:00 O’clock Position for Horizontal Drive or Vertical Drive Pulling Upward 2. Oil Groove 3. 12:00 o’clock Position for Vertical Drive Pulling Downward 4. Outer Countershaft Bushing 5. Countershaft Box

1. Oil Groove is at 12:00 o’clock Position 2. Inner Countershaft Bushing 3. Countershaft Box

Figure 5-16“Inner” Countershaft Bushing

Oil Groove Location

ECT000-0337 - Rev. 00 - 08/08 5-13

it gets stuck in the Countershaft Box bore, place a block of wood across the face of the Bushing (for protection of the Bushing) and use two clamps to pull the Bushing the rest of the way in. Evenly tighten the clamps to ensure the Bushing does not cock in the Countershaft Box bore.

7. Remove the guide rods and replace them with the dowel pins. Set the end float and complete the assembly of the Countershaft Box per Countershaft Installation procedures outlined earlier in this section.

8. The Countershaft Box assembly is now ready to be installed back into the Crusher. Follow the instructions Countershaft Box Installation located earlier in the section.

1. Crusher Vertical Centerline 2. Motor Sheave

Oil Leakage Out of the Drive End of the CountershaftThere are many causes of oil leaking from the drive end of the Countershaft. One cause may be an incorrect pitch of the oil drain line creating a condition in which the oil cannot properly drain from the Countershaft Box. Other possible conditions are as follows:

1. Check for a worn or damaged Piston Ring Seal in the Oil Flinger groove. To replace the Piston Ring Seal, Refer to Figure 5-1 and do the following:

a. Remove the Crusher Sheave following the instructions Crusher Sheave Removal earlier in this section.

b. Remove the flinger cover and Sheave bushing following the instructions Countershaft Removal, Steps 2 and 3, found earlier in this section.

c. Remove the worn or damaged Piston Ring Seal from the groove in the Oil Flinger. Clean the groove and install the new Piston Ring Seal.

d. Install the Oil Flinger Cover and Sheave Bushing following the instructions Countershaft Installation, Steps 5 thru 9, earlier in this section.

e. Mount the Crusher Sheave following the instructions Crusher Sheave Installation, Steps 5 and 6, earlier in this section.

2. Check the long cored passage in the lower section of the Countershaft Box for sludge build-up. Build-up will limit oil flow to the Flinger area and cause oil to leak out from between the Countershaft and Flinger Cover.

3. Check the pitch of the Crusher oil drain line. The drain line should have a minimum pitch of 1” (25mm) vertical rise for every 12” (305 mm) of horizontal run. If the pitch is too shallow, the oil will not flow properly out of the Crusher and leak out from between the Countershaft Box area. This problem will be increased with cold oil conditions.

4. Check the inside of the drain line for dirt, sludge build-up or a collapsed hose. Any restriction to proper oil flow will cause oil leakage.

Figure 5-18Drive Motor Positioned Below Motor Sheave

3. Crusher Sheave 4. 45°

ECT000-0337 - Rev. 00 - 08/085-14

Oil Leakage Out of the Pinion End of the Countershaft BoxOil leakage out from between the Countershaft Box and inner Main Frame fit requires the replacement of the wear strip and o-ring. Refer to Figure 5-19 To replace these parts, do the following:

1. Remove the Countershaft Box assembly following the instructions Countershaft Assembly Removal earlier in this section.

2. Inspect the inner bore of the Main Frame. Replace the Frame Ring if the inside bore of the Ring is excessively worn. Refer to Replacing the Frame Ring in Section 4 for instructions.

3. Remove the Wear Ring and O-Ring from the Countershaft Box.

4. Check both sides of the Countershaft Box wear ring groove. If these surfaces show wear, the Countershaft Box should be reconditioned back to factory specifications. Refer to Figure 5-19 Contact Excel service department for specific instructions.

5. If the Countershaft Box seal area is not excessively worn or damaged, remove the old Silastic from the seal area and replace the Wear Ring and O-Ring following the instructions detailed in Countershaft Box Installation described earlier in this section.

1. O-Ring 2. Wear Ring 3. Main Frame

Figure 5-19 Countershaft Box Pinion and Seal

4. Frame Ring 5. Countershaft Box 6. Wear Ring Groove

Worn

New

ECT000-0337 - Rev. 00 - 08/08 6-1

Section 6

Eccentric AssemblyCounterweight Assembly Figure 6-1 ............................................................................................................ 6-2

Eccentric Assembly Installation ...................................................................................................................... 6-2

Backlash and Root Clearance Figure 6-3 ..................................................................................................... 6-3

Checking Backlash Between the Gear and Pinion ...................................................................................... 6-3

Lifting Eccentric Assembly Figure 6-2 .......................................................................................................... 6-3

Backlash and Root Clearances Table 6-1 ...................................................................................................... 6-4

Eccentric Assembly Removal .......................................................................................................................... 6-4

Replacing the Counterweight Guard ............................................................................................................. 6-4

Shim Thickness Table 6-2 ................................................................................................................................. 6-4

Upper Thrust Bearing ....................................................................................................................................... 6-4

Upper Thrust Bearing Wear Figure 6-4 ......................................................................................................... 6-5

Groove Depth Table 6-3 ................................................................................................................................... 6-5

Upper Thrust Bearing Figure 6-5 ................................................................................................................... 6-5

Eccentric Bushing .............................................................................................................................................. 6-6

“T” and “U” Seal Replacement Figure 6-6 ..................................................................................................... 6-6

“T” and “U” Seal Replacement ........................................................................................................................ 6-6

Bushing Lock Removal Figure 6-7 ................................................................................................................. 6-6

Removing the Eccentric Bushing ................................................................................................................... 6-7

Eccentric Bore Inspection ................................................................................................................................ 6-7

Eccentric Bushing Removal Figure 6-8 ......................................................................................................... 6-7

Main Shaft Inspection ....................................................................................................................................... 6-7

Eccentric Bushing Alignment Figure 6-10 .................................................................................................... 6-8

Eccentric Bushing Alignment Figure 6-9 ...................................................................................................... 6-8

Eccentric Bushing Installation ........................................................................................................................ 6-8

Adjusting the Gear Backlash for Wear .......................................................................................................... 6-9

Gear Replacement ............................................................................................................................................. 6-9

Removal of the Gear and Counterweight .................................................................................................... 6-9

Lifting Counterweight and Eccentric Figure 6-11 .................................................................................... 6-10

Assembling the Gear and Counterweight .................................................................................................. 6-10

Gear Mounting Holes Figure 6-12 ................................................................................................................ 6-11

Capscrew Torque and Gear Heating Table 6-4 .......................................................................................... 6-11

ECT000-0337 - Rev. 00 - 08/086-2

Description Refer to Figure 6-1This section covers description of the Eccentric Assembly and related components along with installation and removal instructions.

The Eccentric with its tilted and out-of-round outside diameter rotates around the Main Shaft, which is fixed in the Main Frame. The Head has a bore that matches the outside diameter of the Eccentric and follows an elliptical path as the Eccentric is rotated. Locked in the Eccentric bore is a bronze bushing which provides a bearing for the Main Shaft. Bolted to the bottom of the Eccentric is a bevel gear that is driven by the Countershaft Pinion. The Eccentric Assembly rests on a set of Thrust Bearings. The rotating bronze Upper Thrust Bearing is bolted to the bottom of the Eccentric and the fixed steel Lower Thrust Bearing is bolted to the Main Frame. Shims are placed between the Lower Thrust Bearing and Main Frame to adjust the backlash between the Gear on the Eccentric and Pinion on the Countershaft. Bolted to the Eccentric is a Counterweight consisting of a heavy and light side. The heavy side of the Counterweight is located opposite the heavy side of the Eccentric to reduce the unbalanced forces associated with the rotating Eccentric and Head Assemblies. A Guard is bolted to the outside of the Counterweight to protect it from wear caused by the discharge material. Mounted around the top and bottom of the counterweight are replaceable “U” and “T” shaped

seals. These seals, along with adjoining seals in the Head and Main Frame, form a labyrinth to prevent oil leakage and the infiltration of dust into the Crusher.

Eccentric Assembly InstallationTo install the Eccentric Assembly in the Crusher, do the following:

1. Thoroughly clean the top of the Main Shaft, Main Frame gear well, Eccentric Bushing bore, Upper Thrust Bearing (bolted to the underside of the Eccentric) and Lower Thrust Bearing (bolted to the Main Frame). Remove any scratches, burrs or nicks.

2. Make sure the capscrews that secure the Upper and Lower Thrust Bearings are tight.

3. From the Tools Assembly, attach the Eccentric Lifting Plate with the ring bolts to the Eccentric using the hex head capscrews. Refer to Figure 6-2

4. Apply a light coat of oil to the Main Shaft, Upper and Lower Thrust Bearings and Eccentric Bushing bore.

5. Carefully lower the Eccentric Assembly onto the Main Shaft while making sure to position one of the large cast slots in the Counterweight above the

1. Eccentric 2. Eccentric Bushing 3. Counterweight 4. Counterweight Guard 5. Gear

Figure 6-1 Counterweight Assembly

6. Upper Thrust Bearing 7. Upper U-Seal 8. Lower T-Seal 9. Caulking 10. Alignment Dowl

ECT000-0337 - Rev. 00 - 08/08 6-3

Pinion. Continue to lower the Eccentric Assembly until seated on the Lower Thrust Bearing. Refer to Figure 6-2

6. The backlash between the Gear and Pinion should now be checked. Follow the instructions outlined in the next section Checking Backlash Between the Gear and Pinion.

Checking Backlash Between the Gear and PinionIt is important to maintain a proper backlash setting to minimize wear of the Gear and Pinion teeth. To check and/or adjust the backlash, do the following:

1. Loosen the drive belts or direct drive coupling.

2. Either rotate the Eccentric until one of the large cast slots in the Counterweight is positioned over the Pinion or set the backlash with the Counterweight temporarily removed from the Eccentric.

3. Slightly rotate the Countershaft to vertically position a gear tooth. Refer to Figure 6-3

4. Pull outward on the Countershaft (toward the Crusher Sheave) until the Pinion is tight against the Inner Countershaft Box Bushing.

5. Remove all bearing clearance between the Eccentric Bushing and Main Shaft by inserting a hydraulic jack between the inner wall of the Main Frame and the Counterweight on the side opposite side the Countershaft Box. 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 measurement will not be accurate.

6. Rotate the Countershaft until the Pinion tooth just touches the gear tooth. Refer to Figure 6-3

7. Using a feeler gauge, measure the clearance between the Gear and Pinion teeth. Refer to Figure 6-3 and Table 6-1

8. If the measurement from Step 7 is less than the value listed in Table 6-1, remove the Eccentric Assembly and add shims under the Lower Thrust Bearing as instructed in Section 4, Replacing the Lower Thrust Bearing and Shims. Adding

1. Gear 2. Backlash 3. Gear Tooth Must be Vertical to take an Accurate Measurement 4. Root Clearance 5. Pinion

Figure 6-2 Lifting Eccentric Assembly

1. Lifting Cables 2. Ring Bolts 3. Heavy Side of Eccentric 4. Main Shaft 5. Gear 6. Pinion

Figure 6-3 Backlash and Root Clearance

7. Main Frame 8. Lower Thrust Bearing 9. Upper Thrust Bearing 10. Eccentric 11. Lifting Ring 12. Upper U-Seal

ECT000-0337 - Rev. 00 - 08/08

shims under the Lower Thrust Bearing will increase the clearance between the Gear and Pinion teeth. If the measurement from Step 7 is greater than the value listed in Table 6-1, shims must be removed to reduce the clearance between the Gear and Pinion teeth. Refer to Table 6-2 for approximate changes in backlash as related to different shim thickness.

Eccentric Assembly RemovalTo remove the Eccentric Assembly, do the following:

1. Attach the Eccentric Lifting Ring using the hex head capscrews. Position the Eccentric Lifting Ring with an eye bolt in the center of the thickest portion of the Eccentric. Any other position will create Eccentric tip due to unbalanced load. Refer to Figure 6-2

2. Carefully lift the Eccentric Assembly using adequate hoisting equipment. Refer to Table 3-1 for weights.

3. Once the Eccentric Assembly is out of the machine, place it on wood blocking or other protective material.

6-4

XL300 .020 - .040” .094” .116” (.508 - 1.016mm) (2.39mm) (2.95mm) XL400 .025 - .045” .136” .158” (.640 - 1.150mm) (3.45mm) (4.01mm)

Backlash and Root Clearances

Crusher Size Backlash Root Clearance Min. Max.

Table 6-1

Replacing the Counterweight GuardThe Counterweight is protected from discharge material wear by a bolt on replaceable Counterweight Guard. If the Guard is not regularly checked and replaced, wear will occur to the Counterweight requiring costly repair. Unwanted wear of the Counterweight can also create an out-of-balance condition causing foundation problems. To replace the Counterweight Guard, do the following:

1. Remove the capscrews holding the Guard on the Counterweight. It may be necessary to use a moderate amount of heat because of the Loctite used by the factory when installing the Guard hardware.

2. Lift and remove the old Guard from the Counterweight Assembly.

3. Remove any remaining Silastic sealing material applied by the factory from the bottom outer edge of the Counterweight.

4. Install the new Guard on the Counterweight and bolt in place, using Loctite 271.

5. Using Silastic material, seal the seam between the bottom inner diameter of the Guard and the bottom outer diameter of the Counterweight except in the area of the two drain holes spaced 180° apart.

Refer to Figure 6-1

A daily inspection of the Crusher discharge area will insure that there is no material build-up or bridging occurring on the Main Frame arms or foundation discharge area that can create wear to the bottom of the Counterweight. A Head Skirt is available from Excel that can deter the Counterweight Guard wear while reducing build-up of material on the Main Frame Arms.

Upper Thrust BearingThe bronze Upper Thrust Bearing mounted to the underside of the Eccentric Assembly, should be checked for wear any time the Eccentric Assembly is removed from the Crusher. Nicks and scratches should be buffed out as well. Bearing wear will eventually cause the following two major problems:

A. As the Upper Thrust Bearing wears, the position of the Gear bolted to the bottom of the Eccentric will lower relative to the Pinion teeth resulting in a change to the backlash. This is corrected by placing shims

Table 6-2

Shim Thickness

Shim Thickness Approximate Change in Backlash XL300 XL400 .1181” .076” .075” (3.0mm) (1.92mm) (1.90mm)

.0669” .040” .040” (1.7mm) (1.02mm) (1.02mm)

.0157” .006” .007” (0.4mm) (0.16mm) (0.17mm)

ECT000-0337 - Rev. 00 - 08/08 6-5

under the steel Lower Thrust Bearing which raises the Gear relative to the Pinion and reestablishes the proper backlash setting. Refer to Checking Backlash outlined earlier in this section.

B. Normal wear of the bronze Upper Thrust Bearing reduces the size and shape of the oil grooves which limits the amount of lubrication eventually resulting in excessive heat and bearing failure. Replace the Bearing when the minimum groove depth value is reached. Refer to Table 6-3

Never allow either the Upper or Lower Thrust Bearings to wear to point in which contact of the capscrews securing the bearings occurs.

To replace the upper thrust bearing proceed as follows:

1. Turn the Eccentric Assembly upside down on wood blocking to access the Upper Thrust Bearing.

2. Remove the socket head capscrews and lock washers that bolt the Upper Thrust Bearing to the Eccentric. Refer to Figure 6-5

3. Use the ring bolts supplied with in the Tools Assembly to lift and remove the Upper Thrust Bearing from the Eccentric.

4. Before installing the new Thrust Bearing in the Eccentric, check it for burrs or upset edges to ensure it will sit flat on the Eccentric.

5. Using the same ring bolts used to remove the old Bearing, lift and install the new Bearing onto the Eccentric making sure the mounting holes line up. Use a feeler gauge between the Bearing and Eccentric to check that the Bearing is seated flat against the Eccentric.

6. Tighten the six socket head capscrews that fasten the Bearing to the Eccentric using a crisscross pattern.

1. Upper Thrust Bearing 2. Hex Head Capscrew 3. Spring Washer

Figure 6-5 Upper Thrust Bearing

1. Minimum Groove Depth 2. Original Groove Depth 3. Upper Thrust Bearing

Figure 6-4 Upper Thrust Bearing Wear

4. Eccentric Bushing 5. Eccentric 6. Gear

Table 6-3

Groove Depth

Crusher Size Groove Depth Original Minimum

XL300 .38” (9.5mm) .33” (8.4mm) XL400 .44” (11mm) .38” (9.7mm)

ECT000-0337 - Rev. 00 - 08/086-6

“T” and “U” Seal ReplacementA replaceable one-piece “T” shaped seal is located in a groove on the underside of the Counterweight while a replaceable one-piece “U” shaped seal is located in a groove around the top of the Counterweight. Refer to Figure 6-6 They are designed to prevent dust from getting into the Crusher. Inspect them for damage, wear or build-up of oil and dust anytime the Counterweight is removed. They are to be replaced as follows:

1. Remove the damaged seal and scrape out any residue from the groove.


3. If the new seal is coated with a shiny mold release agent used in its manufacturing process, use coarse sandpaper to remove just enough of the coating from the bottom and sides of the seal so as to completely remove the shine. The adhesive will not adhere to any parts of the seal containing the release agent.

The seal may fall out of the Eccentric grove during operation if the release agent is not completely removed from the seal.

4. Apply a thin coat of activator to the bottom and sides of the seal. Too much activator will create a partial cure of the adhesive.

5. Apply a thin coat of adhesive to the bottom of the Eccentric groove. Apply just enough to obtain a minimal squeeze out.

6. After the adhesive has been applied, quickly place the seal into the Eccentric groove. Apply a steady force to the bottom of the seal to maintain contact between the bottom of the groove and the seal. A handling bond will occur in approximately three minutes.

Eccentric BushingExcel recommends checking the Eccentric Bushing for wear to the inside diameter and/or looseness in the Eccentric bore whenever the Eccentric Assembly is removed from the Crusher. There are four pockets in both the top inside diameter of the Eccentric and the top outside diameter of the Bushing. When factory assembled, the pockets are aligned

Figure 6-6 “T” & “U” Seal Replacement

1. Counterweight 2. Upper U-Seal 3. Clean bottom of seals using course sand paper to remove surface “Shine” before applying activator and adhesive to bottom of groove in counterweight 4. Lower T-Seal

Figure 6-7 Bushing Lock Removal

1. Locking Material 2. Eccentric Bushing 3. Drill a Series of Holes in Locking Material in Cored Pockets 4. Cored Pockets 5. Eccentric

ECT000-0337 - Rev. 00 - 08/08 6-7

and filled with an epoxy locking compound. This prevents the Bushing from turning in the Eccentric. If the Bushing has turned in the Eccentric bore, it must be removed and checked. Measure the inside and outside diameters in three places (top, middle and bottom) to make sure the I.D. has not changed or that the Bushing diameter has not “pulled in”. Contact Excel with the measurements to see if the Bushing is useable or if it must be replaced.

Removing the Eccentric BushingTo remove the Eccentric Bushing, do the following:

1. Remove the Counterweight following instructions listed in Removal of the Gear and Counterweight located later in this section.

2. The epoxy locking compound that fills the pockets must be removed by drilling holes and removing any material that would prevent the Bushing from being removed. Refer to Figure 6-7

3. Turn the Eccentric upside down on wood blocking high enough to allow the Bushing to be lowered clear of the Eccentric. Refer to Figure 6-8

4. Manufacture a round plate from 1” (25mm) thick steel with a diameter slightly smaller than the Eccentric

bore that will be used to remove the Bushing from the Eccentric. The outside diameter of the plate should be smooth and tapered so it does not damage the Eccentric bore. Refer to Figure 6-8

5. Set the plate on the bottom of the Bushing making sure it does not contact the Eccentric bore.

6. Apply force to the plate until the Bushing is free of the Eccentric.

Note: If the Bushing will not come out following the steps listed above, cutting through the Bushing wall using a heavy duty circular saw as detailed in Section 8, Replacing the Lower Head Bushing, Steps 3 to 5 may be necessary.

Eccentric Bore InspectionThe Eccentric bore is to be inspected for rough spots and smoothed out prior to the installation of a new Eccentric Bushing.

The Eccentric bore should be measured top to bottom every 4“ and 60° apart at each location. These measurements will show:

• Anyhighspotsinthebore• Iftheborehasworntoanoversizecondition• Iftheborehaspulledinduetoexcessiveheat

Contact Excel to verify the bore measurements. High spots can be ground off a bore that has shrunk unevenly. However, if the bore has pulled in to the point and that hand grinding is not practical, the bore should be machined back to original size. Machining is also required if the bore is found to be worn out of round. It’s recommended to contact Excel prior to any machining.

Main Shaft InspectionInspection of the Main Shaft is recommended whenever the Eccentric is removed from the Crusher. This is especially important if the condition of the Eccentric Bushing requires replacement. Remove any bronze or lead using only a fine emery cloth by rubbing in a circular and horizontal direction. Measure the O.D. of the Main Shaft every 60 degrees of angle and at 4 inch intervals top to bottom, starting in the middle of the socket fit area. Contact Excel to determine if the condition of the Main Shaft requires replacing.

1. Eccentric 2. Wooden Timber 3. Steel Plate

Figure 6-8 Eccentric Bushing Removal

4. Wooden Blocking 5. Eccentric Bushing

ECT000-0337 - Rev. 00 - 08/086-8

If the Eccentric Bushing is seized on the Main Shaft, extra effort will be required to remove the Eccentric Assembly. Consult the factory for suggested instructions. To remove an Eccentric Bushing that has seized on the Main Shaft, do the following:

1. Located on the inside of the Bushing is a longitudinal oil groove that is centered on the large oil hole. The oil hole is visible from the outside of the Bushing and is vertically centered on the Bushing.

2. Using a heavy duty circular saw and metal cutting blade, cut around the Bushing wall at the longitudinal oil groove location. Set the depth of the cut at 0.75” (20mm). Do not exceed 1” (25mm) depth. It is critical not to damage the Main Shaft. Scoring of the Shaft can result in required replacement.

3. Using a pry bar, spring the Bushing open and off the Main Shaft.

Eccentric Bushing InstallationThe Eccentric Bushing is designed to have a loose fit in the Eccentric bore. To install an Eccentric Bushing do the following:

Note: A tight fit is the result of a pulled in or out-of-round Eccentric bore. Improperly storing or shipping the Bushing can result in a out-of-round Bushing.

1. Clean, inspect and measure the Bushing. Remove any scratches and burrs.

2. Thoroughly clean the pockets in the Eccentric of any epoxy locking compound. Inspect the Eccentric bore for scratches, nicks and gouges. Smooth out any upsets found.

3. Cool the Bushing to create the proper minimum temperature difference between the Bushing and Eccentric.

Temperature Difference between Eccentric / Bushing XL300 40°F (22°C) XL400 35°F (19°C)

4. Mark lines on both sides and top of the Bushing adjacent to the oil hole locations. Refer to Figure 6-9 Do the same for the two holes in the Eccentric

Figure 6-9 Eccentric Bushing Alignment

1. Mark lines along side and top of Bushing above the oil holes 2. Small Oil Hole 3. Oil Holes 4. Eccentric Bushing 5. Large Oil Hole

1. Ring Bolts and Washers Will Hold Bushing 2. Bushing Lock 3. Eccentric Bushing 4. Eccentric

Figure 6-10 Eccentric Bushing Alignment

ECT000-0337 - Rev. 00 - 08/08 6-9

bore. Make sure to extend the lines up to the top surfaces. These lines will be used to align the oil holes in the Bushing and Eccentric.

5. Using the lifting rings supplied with the tools assembly in the top of the Bushing, lift and center the Bushing above the Eccentric. With the oil hole lines and locking pockets aligned, quickly lower the Bushing into the Eccentric making sure the top of the Bushing is flush with the top of the Eccentric.

It is very important that the oil passage holes in the bushing are aligned with the mating holes in the Eccentric. Due to casting variations, this may not provide exact alignment of the locking pockets. However, it is critical that the oil holes in the bushing match-up with the oil holes in the Eccentric.

6. Ensure that the Eccentric and Eccentric Bushing have warmed to ambient (60° to 80°F (16° to 27°C) is desired). Mix the Locking Compound per the manufacturer’s instructions and fill each locking pocket to the top.

7. After the epoxy has fully cured, remove any excess locking compound by grinding flush with the top of the Bushing and Eccentric.

Whenever a new Eccentric Bushing is installed, it is important to follow Item D of the Check List for Starting a New Crusher defined in Section 13, Operating Instructions.

Adjusting the Gear Backlash for WearTo adjust the root clearance and backlash follow the instructions in Eccentric Assembly Installation and Checking Backlash Between the Gear and Pinion as outlined earlier in this section.

Gear ReplacementThe bevel gear mounted on the underside of the Eccentric should be inspected whenever the Eccentric Assembly is removed from the Crusher or if there is a concern regarding excessively worn or broken gear teeth. Excessive gear wear is indicated by a step worn in the profile of the teeth or pitting and galling of the profile. This can be caused by the following conditions:

• Incorrectamountofshimsunder theLowerThrustBearing resulting in the wrong backlash setting.

• Operating theCrusher in anoverload condition forextensive periods of time.

• Operatingwithexcessivelydirtylubricationoil.

If it’s determined that the Gear has worn to the point requiring replacement, follow the instructions outlined in Removal of the Gear and Counterweight.

Removal of the Gear and CounterweightRemove the Eccentric as instructed in Eccentric Assembly Removal found earlier in this section. To remove the Gear and Counterweight do the following:

1. Place the Eccentric Assembly on wood blocking. Make sure the blocking is positioned under the Gear and not under the Counterweight.


2. There are capscrews that run through the Counterweight and Eccentric flange into tapped holes in the Gear that must be removed. These capscrews are factory installed with Loctite and will require heating to remove.

3. Remove the capscrews that hold the Counterweight Guard to the Counterweight. Refer to Figure 6-11

4. Install the ring bolts supplied in the tool box in the tapped holes on the top of the Counterweight where the capscrews were removed in Step 3.

5. Using the proper equipment, lift the Counterweight off the Eccentric.

6. Remove the capscrews running through the Eccentric flange into tapped holes in the Gear. These capscrews were also installed with Loctite requiring heat to be removed.

7. There is a slight interference fit between the Eccentric flange and a counter bore in the top of the Gear. Install ring bolts from the tool box into the Eccentric Assembly lifting ring.

8. Attach proper equipment to the Eccentric ring bolts and lift the Eccentric 1.5” (38mm) above the wood blocks. With a torch, evenly heat the Gear all around until the Gear expands enough to fall off the Eccentric onto the wood blocking.

ECT000-0337 - Rev. 00 - 08/086-10

9. If the Upper Thrust Bearing is to be removed, place the Eccentric on its side on wood blocks to protect the machined surfaces and go to Step 10. If the Upper Thrust Bearing is not to be removed, place the Eccentric on wood blocks to protect the machined surface of the Upper Thrust Bearing.

10. To remove the Upper Thrust Bearing from the Eccentric, first remove the socket head capscrews that hold the thrust bearing to the Eccentric. Then remove the thrust bearing.

Assembling the Gear and CounterweightTo assemble the Gear and Counterweight as part of the Eccentric Assembly, do the following:

1. If the Upper Thrust Bearing was removed, turn the Eccentric upside down and place on wood blocks. If the thrust bearing was not removed, go to Step 4.

2. Place the Thrust Bearing on the bottom of the Eccentric with its mounting holes aligned with the tapped holes in the Eccentric. Install the socket head capscrews with new spring washers and tighten.

3. Turn the Eccentric right side up and place it on wood blocks to protect the machined surface of the Thrust Bearing.

4. Place the Gear on wood blocks with the teeth down. Clean all the tapped holes in the Gear with an oil free solvent such as alcohol or acetone. Loctite will be applied to these holes later. Refer to Figure 6-11

5. With the Eccentric lifting ring and lifting ring bolts attached to the top of the Eccentric, lift the Eccentric until it is safely suspended above the Gear approximately 12” (305mm) while centered over the Gear counter bore.

6. Measure the Eccentric flange diameter and the Gear counter bore for use later.

7. Using a torch, evenly heat the Gear all around the counter bore area to the temperature listed.

Refer to Table 6-4

It is critical that the gear be evenly heated and that the supply of heat is not concentrated in one spot or area. Heating in one spot or area could destroy the heat treatment of the gear. A chemical marking device designed to melt at a specifi ed temperature can be used to make sure over heating doesn’t occur. An infared pyrometer or digital contact thermometer can also be used.

8. M easure the Gear counter bore while it is being heated. Once the counter bore has expanded to a diameter slightly larger than the Eccentric flange, quickly lower the Eccentric into the counter bore in the Gear while making sure to align the Eccentric mounting holes with the tapped holes in the Gear. Refer to Figure 6-12

1. Counterweight Cover to Counterweight Capscrew 2. Counterweight 3. Eccentric 4. Eccentric Bushing 5. Eccentric to Gear Capscrew

6. Wooden Timber 7. Upper Thrust Bearing 8. Gear 9. Alignment Dowel 10. Eccentric Lifting Ring

Figure 6-11Lifting Counterweight and Eccentric

ECT000-0337 - Rev. 00 - 08/08 6-11

9. Clean the threads on the Eccentric to Gear capscrews with an oil free solvent such as acetone or alcohol. Apply Loctite 271 to the capscrew threads and install them in the tapped holes in the Gear at the locations. Refer to Figure 6-12

Note: If the bolts required heating to remove, they must be replaced.

10. Assemble the capscrews and hardened washers into the holes and tighten them using a crisscross pattern to the torque specified in Table 6-4.

Capscrew Torque and Gear Heating

Crusher Size XL300 XL400

Eccentric toGear CapscrewSize & Length M16 x 70 M20 x 100

Counterweight toGear CapscrewSize & Length M16 x 90 M20 x 120

Capscrew Torque 202 ft/lbs 396 ft/lbs (274 N-m) (537 N-m)

Minimum TempertureDifference 85°F (47° C) 63°F (35° C)(as compared to Eccentric)

1. Gear Mounting Holes 2. Counterweight Locating Dowel 3. Eccentric Flange

Figure 6-12 Gear Mounting Holes

Warning: An impact gun may break the Loctite and allow the bolts to back out.

11. If a new Gear was installed, check and adjust the backlash as detailed in Checking Backlash Between the Gear and Pinion outlined earlier in this section.

12. Install the ring bolts from the tools assembly into the Counterweight hole locations.


13. Lift and lower the Counterweight onto the Eccentric flange making sure to line-up the dowel in the Eccentric with the matching hole in the Counterweight.

14. Clean the threads on the Counterweight to Gear capscrews with an oil free solvent such as acetone or alcohol. Apply Loctite 271 to the capscrew threads and install them in the tapped holes in the Gear.

15. Assemble the capscrews and hardened washers into the Eccentric flange holes and tighten them using a crisscross pattern to the torque specified.

Refer to Table 6-4

16. Rotate the Countershaft to check the Pinion teeth for damage or wear before installing the Eccentric back into the Crusher.

17. Install the Eccentric and check the gear backlash, following the instructions detailed in the Eccentric Assembly Installation procedure outlined earlier in this section.

Note: Excel recommends checking the torque with a torque wrench on all the capscrews that hold the Gear to the Eccentric during each liner change.

Table 6-4

ECT000-0337 - Rev. 00 - 08/086-12

ECT000-0337 - Rev. 00 - 08/08 7-1

Section 7

Socket Assembly

Socket and Socket Liner Installation ............................................................................................................. 7-2

Socket Installation Heating Temperature and Socket Capscrew Torque Requirements Socket Assembly Figure 7-1 ................................................................................... 7-2

Socket Installation Figure 7-2 ........................................................................................................................ 7-2

Checking Socket Contact Figure 7-3 ............................................................................................................. 7-3

Measuring Socket Liner Oil Groove Depth Figure 7-4 ................................................................................ 7-3

Socket Liner Removal and Replacement ...................................................................................................... 7-3

Socket Liner Figure 7-6 .................................................................................................................................... 7-4

Socket Liner Installation Figure 7-5 .............................................................................................................. 7-4

Socket Removal ................................................................................................................................................. 7-4

Socket Removal Figure 7-7 ............................................................................................................................. 7-5

ECT000-0337 - Rev. 00 - 08/087-2

5. With the Socket suspended above the line-up studs, quickly lower it onto the Main Shaft making sure it is firmly seated. Use a feeler gauge to check that the web of the Socket has seated flat on the Main Shaft. Refer to Figure 7-3 There should be no clearance.

6. Remove the line-up studs and install the cap screws with lock washers down through the Socket and secure to the Main Shaft. Alternately tighten the cap screws in small increments until the torque value specified is achieved. Refer to Table 7-1

Recheck the torque after the Socket has cooled for one hour.

1. Capscrew 2. Lockwasher 3. Ring Bolt

Figure 7-2 Socket Installation

4. Main Shaft 5. Alignment Studs 6. Socket

Socket Installation Heating Temperature and Socket Capscrew Torque Requirements

Table 7-1

Temperature Difference Socket Capscrew (between Socket & Mainshaft)

Crusher Fahrenheit Centigrade Size & Length Torque Size Ft/Lbs (N/M)

XL300 190° 105° M16x90 192 (260)

XL400 128° 71° M20x100 345 (470)

Description Refer to Figure 7-1This section covers the Socket Assembly, which consists of the Socket and Socket Liner. These parts are mounted on the top of the Main Shaft and support the Head Assembly. They transfer the crushing force to the Main Frame. The Socket is held in place on the Main Shaft by a press fit along with a series of bolts. The Socket Liner, which is mounted in a counter bore of the Socket and doweled, provides a bearing surface for the Head Ball. Pressurized lubricating oil is supplied to the grooves located in the spherical surface of the Socket Liner to provide lubrication between the Socket Liner and Head Ball.

Socket and Socket Liner InstallationTo install the Socket and Socket Liner in the Crusher, do the following:

1. Install the Eccentric Assembly as instructed in Section 6.

2. Install the alignment studs from the tools assembly in the top of the Main Shaft. Refer to Figure 7-2

3. Insert the ring bolts in the Socket which are provided in the tools assembly. Refer to Figure 7-2

4. Evenly heat the lower flange of the Socket all around, to the temperature specified. Refer to Table 7-1 Use a chemical marker, which melts at a specified temperature, to help determine when the Socket has reached the proper temperature from the table.

1. Straight Pin 2. Socket Flange 3. Main Shaft

Figure 7-1 Socket Assembly

4. Capscrew with Lock Washer 5. Socket Liner

ECT000-0337 - Rev. 00 - 08/08 7-3

7. Install the ring bolts provided in the tools assembly into the tapped holes located around the outside diameter of the Socket Liner. Refer to Figure 7-5

8. Cool the Socket Liner to achieve a temperature difference of as compared to the Socket.

Temperature Difference Between Socket & Socket Liner XL300 97°F (54°C) XL400 86°F (48°C)

9. Lower the Socket Liner over the locating dowels in the Socket making sure the Liner has firmly seated on the web of the Socket and remove the ring bolts.

Socket Liner Removal and ReplacementThe Socket Liner is typically removed from the Socket for one of two reasons:

• Replacementduetooilgroovewear• To be able to remove the Eccentric Assembly

(includes removal of the Socket)

If the Socket Liner is being replaced due to wear, start with Step 1. If the Socket Liner and Socket are being removed to pull the Eccentric Assembly, start with Step 2.

1. Use the depth of the oil grooves in the spherical surface of the Socket Liner to determine if the Liner needs to be replaced. Measure the depth.

Refer to Figure 7-4

Changing liners provides a good opportunity to check the Socket Liner groove depth.

2. Install the ring bolts located in the tools assembly, in the tapped holes located around the outside diameter of the Socket Liner. Refer to Figure 7-5

3. Lubricate the jack screws and install them into the Socket Liner until they bottom out on the Socket. Refer to Figure 7-6

4. Alternately tighten each jackscrew in small increments, so as to not cock the Socket Liner in the Socket during the removal. A little amount of heat applied to the upper portion of the Socket may be required to aid in removing the Liner.

5. Lift the Socket Liner out of the Crusher using the ring bolts around the sides of the Liner.

6. To install a new or existing Socket Liner, follow Steps 7 thru 9 located in Socket and Socket Liner Installation found earlier in this section.

1. Socket 2. Tight

Figure 7-3 Checking Socket Contact

3. Main Shaft 4. Feeler Gauge

1. Original Contour of Socket Liner 2. XL300 Minimum Groove Depth = 0.082” (2.1mm) XL400 Minimum Groove Depth = 0.098” (2.5mm) 3. Socket Liner 4. Oil Groove 5. Socket Liner Wear 6. Depth Gauge

Figure 7-4Measuring Socket Liner Oil Groove Depth

ECT000-0337 - Rev. 00 - 08/087-4

Socket RemovalTo remove the Socket, do the following:

1. Remove the cap screws and washers that attach the Socket to the Main Shaft.

2. Using the jack screws located in the tools assembly, apply anti-seize and insert them in the Socket until they bottom out on the top of the Main Shaft.

Refer to Figure 7-7

3. Thread the ring bolts into the Socket. Refer to Figure 7-7

4. Heat the lower flange of the Socket evenly to achieve the required temperature difference. Alternately tighten each jackscrew in small increments. If the jackscrews start to push the Socket off the Main Shaft, keep the heat on the Socket and keep alternately tightening the jackscrews in small increments until the Socket is free of the Main Shaft. It is important that the jackscrews be tightened in small increments so the Socket will not cock and jam on the Main Shaft. If after heating the Socket lower flange to the required temperature difference the jackscrews will not move the Socket, then increase the temperature difference and try again. Continue increasing the applied heat until the Socket is able to be removed from the Main Shaft.

5. With the Socket lifting rings attached, quickly lift the Socket off the Main Shaft.

6. To install the Socket, follow the instructions defined in Steps 1 thru 9 of Socket and Socket Liner Installation located earlier in this section.

1. Socket Liner 2. Ring Bolt 3. Main Shaft 4. Capscrew and Lockwasher

Figure 7-5 Socket Liner Installation

5. Socket 6. Web of Socket 7. Straight Pin

1. Socket Liner 2. Jackscrew 3. Heat Upper Portion of Socket if Necessary 4. Main Shaft 5. Socket

Figure 7-6 Socket Liner

ECT000-0337 - Rev. 00 - 08/08 7-5

1. Jackscrews 2. Socket 3. Main Shaft

Figure 7-7 Socket Removal

4. Heat Lower Portion of Socket to Aid in Removal 5. Socket Lifting Ring Bolts

ECT000-0337 - Rev. 00 - 08/087-6

ECT000-0337 - Rev. 00 - 08/08 8-1

Section 8

Head, Mantle and Feed Plate Assemblies

Head Mantle and Feed Plate Assembly Figure 8-1 ..................................................................................... 8-2

Head Removal .................................................................................................................................................... 8-2

Cutting the Torch Ring Figure 8-4 ................................................................................................................. 8-3

Installing and Removing Head Assembly Figure 8-2 ................................................................................. 8-3

Mantle Replacement Figure 8-3 ..................................................................................................................... 8-3

Mantle Replacement ......................................................................................................................................... 8-3

Locking Bolt Wrench Figure 8-5 ..................................................................................................................... 8-4

Mantle Lifting Figure 8-6 ................................................................................................................................. 8-4

Installing the Mantle Figure 8-9 ..................................................................................................................... 8-5

Lifting Lug Figure 8-7 ....................................................................................................................................... 8-5

Seating the Mantle Figure 8-8 ........................................................................................................................ 8-5

Head Ball Replacement .................................................................................................................................... 8-6

Installing Head Ball Figure 8-11 ...................................................................................................................... 8-6

Removing Head Ball Figure 8-10 .................................................................................................................... 8-6

Handling the Head Figure 8-12 A-E ............................................................................................................... 8-7

Handling the Head ............................................................................................................................................. 8-7

Replacing the Lower Head Bushing ............................................................................................................... 8-7

Lower Head Bore Inspection ........................................................................................................................... 8-8

Lower Head Bushing Installation ................................................................................................................... 8-8

Sawing Bushing Flange Figure 8-13 .............................................................................................................. 8-8

Sawing Head Bushing Wall Figure 8-14 ........................................................................................................ 8-8

Head Bushing Installation Figure 8-15 .......................................................................................................... 8-9

Replacing the Upper Head Bushing ............................................................................................................... 8-9

Upper Head Bore Inspection ......................................................................................................................... 8-10

Upper Head Bushing Installation .................................................................................................................. 8-10

“T” Seal Replacement ...................................................................................................................................... 8-10

Head Assembly Installation ........................................................................................................................... 8-11

Replacing the “T” Seal Figure 8-16 ............................................................................................................... 8-11

ECT000-0337 - Rev. 00 - 08/088-2

Description Refer to Figure 8-1This section covers descriptions of the Head, Mantle and Feed Plate Assemblies along with installation and removal instructions. The Head along with the Mantle in combination with the Bowl and Bowl Liner make up the major components of the crushing chamber.

Mounted on the top surface of the Mantle is a torch ring. Both the Mantle and torch ring are held in place by the Locking Bolt. Mounted on top of the Locking Bolt is the feed plate. The feed plate protects the Locking Bolt from wear and helps distribute material around the crushing cavity.

A Head Ball is secured in the Head with an interference fit and sits in the Socket Liner mounted on top of the Main Shaft.

There are two Bushings contained in the Head. An Upper and Lower Head Bushing. The flanged Lower provides the bearing surface with the Eccentric. The Upper provides bearing support for the top of the Head during no-load (non-crushing) operation.

A molded polyurethane “T” shaped seal is adhered to a groove in the Head. This T-seal runs parallel with a similar “U” shaped seal mounted in the adjoining Counterweight. Together they form a labyrinth seal that protects the internals of the Crusher from dust infiltration and prevents excessive oil leakage.

Head RemovalTo remove the Head Assembly from the Crusher, do the following:

1. Remove the Feed Plate from the Locking Bolt.

2. Secure the ring bolt (supplied in the tools assembly) in the off-centered 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. Refer to Figure 8-2

1. Feed Plate 2. Locking Bolt 3. Upper Head Bushing

Figure 8-1 Head Mantle and Feed Plate Assembly

4. Head 5. Lower T-Seal 6. Head Ball

7. Lower Head Bushing 8. Mantle 9. Strap

10. Head Skirt 11. Torch Ring

ECT000-0337 - Rev. 00 - 08/08 8-3

3. Making sure the ring bolt in the Head Lifting Plate is positioned toward the closed side of the crushing cavity and that the lifting equipment is relatively centered over the Head, slowly lift the Head Assembly straight up and out of the Crusher. The off-center position of the ring bolt slightly tilts the Head into a position that will not damage the Lower Head Bushing when removing the Head. If the ring bolt is not correctly positioned, Lower Head Bushing damage will occur.

4. Place the Head on suitable cribbing. If the Head Assembly includes a Head Skirt, DO NOT support the Head using the Skirt. It will not handle the weight of the Head Assembly.

Mantle ReplacementRefer to Figure 8-3To replace a worn Mantle, do the following:

1. Crushing forces create a self-tightening action that keeps the Locking Bolt tight against the Torch Ring and Mantle. The recommend procedure for removing the Mantle from the Head is to grind all of the stitch welds between the Mantle, Torch Ring and Locking Bolt. Next, cut through the Torch Ring. Refer to Figure 8-4 Care should be taken not to damage the Locking Bolt and Head. Once the Torch Ring is cut through, the preload is off the Locking Bolt and it should easily turn out of the Head by hand. If there

is damage to the threads of the Locking Bolt or Head and the bolt cannot be turned by hand, then go to Step 2. If the Locking Bolt is easily removed, go to Step 3.

2. If the Locking Bolt is still hard to turn after cutting through the Torch Ring, obtain the Locking Bolt wrench from the tools assembly and mount it on the Locking Bolt with the wrench pins engaging the holes in the Locking Bolt. Use the capscrew, also from the tools assembly, to hold the wrench in place on the Locking Bolt. Refer to Figure 8-5

Figure 8-2Installing and Removing Head Assembly

1. Head Lifting Plate 2. Thick Side of Eccentric

Figure 8-3 Mantle Replacement

1. Feed Plate 2. Capscrew 3. Fill with Silastic

4. Mantle 5. Torch Ring 6. Locking Bolt

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

Figure 8-4 Cutting the Torch Ring

ECT000-0337 - Rev. 00 - 08/088-4

With the wrench firmly attached, strike the side of the wrench with a sledge hammer or suspended weight so the Locking Bolt turns in a counterclockwise direction. Continue this until the Locking Bolt can be turned by hand.

3. The Mantle is now free to be removed from the Head. Lift the Mantle off the Head using the two equally spaced and welded lifting lugs on the Mantle.

Refer to Figure 8-6

WarningIf lifting lugs are used to lift the Mantle, be sure they are strong enough to handle the weight and the proper weld rod is used to weld the steel lugs to the manganese Mantle. Make two lifting lugs. Refer to Figure 8-7

4. Chip off all backing material left on the Head after removing the Mantle.

5. Clean the Locking Bolt threads along with the mating threads in the Head. Inspect both sets of threads and remove any nicks or burrs found. Inspect the Locking Bolt where the torch ring seats and remove upsets to insure proper contact is achieved. Then coat the threads with a moly based anti-seize grease.

6. Inspect the Mantle seating surface on the Head and grind any ridges to provide a smooth surface. If the seating surface of the Head has worn to the point that it is flush with the wear indication groove, the Head should be refurbished. Contact Excel for instructions.

7. Wipe a light coating of grease or oil on the Head to prevent the backing material from adhering.

8. A loose or improperly seated (cocked) Mantle will damage the Head seating surface. To correctly seat the Mantle, do the following:

a) Lower the Mantle onto the Head using one of the methods described in Step 3.

b) Place the Torch Ring on the Mantle.

c) Turn the Locking Bolt down until it is close to the Torch Ring. Refer to Figure 8-8 The distance between the Torch Ring and Locking Bolt should be the same all around to ensure that the Mantle is centered on the Head. This will also ensure that it will seat properly on the Head when the Locking Bolt is tightened. If the distance is not even, do not try to even it out by tightening the Locking Bolt. Even the distance out by either bumping the top of the Mantle to reposition it on the Head or by lifting the bottom of the Mantle on the low side. (Keep in mind that the Mantle must also seat properly on the Head seating surface. See Step 11 Once an even distance has been achieved, tighten the Locking Bolt down snug on the Torch Ring.

9. Mount the Locking Bolt wrench to the Locking Bolt as outlined in Step 2.

10. 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 Bolt in a clockwise direction. Keep ramming the wrench until only .06” (1mm) of Locking Bolt turn per blow is achieved.

1. Mantle 2. Locking Bolt 3. Locking Bolt Wrench

Figure 8-5 Locking Bolt Wrench

4. Torch Ring 5. Head

1. Lifting Cables 2. Mantle

Figure 8-6 Mantle Lifting

3. Lifting Lugs Welded to Mantle

ECT000-0337 - Rev. 00 - 08/08 8-5

11. Use a 0.010” (0.25mm) feeler gauge at least 80% of the way around the bottom of the Mantle to check that it’s seated tightly against the Head. If there are openings, due to head seat wear, fill these areas with caulking to keep the backing material from leaking out when poured. Refer to Figure 8-9

12. Scribe a vertical line down through the lower flange of the Locking Bolt, Torch Ring and upper section of the Mantle. Heat the outside of the Mantle in the seating surface area to 130°F (55°C). Sledge the Wrench again until the Locking Bolt has moved an additional 1” (25mm).

13. Weld the Locking Bolt to the Torch Ring and the Torch Ring to the Mantle with four 3.5” (90mm) long welds equally spaced around the perimeter of the parts.

14. Fill the space between the Head and Mantle to the top of the pouring holes in the Mantle with high performance epoxy. Refer to Figure 8-9 Carefully follow the epoxy backing manufacturers mixing, pouring and safety instructions. 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.

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. (15.6° 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.

15. Install the Head Assembly in the Crusher as outlined in Head Assembly Installation as outlined later in this section. Cure time for the epoxy backing material is normally about 8 hours. However, this cure time can be up to 24 hours if the ambient temperature is low in the 60° F (15.6° C) range.

Figure 8-7 Lifting Lug

1. 4” (100mm) 2. 2” (50mm) 3. 2” (50mm)

4. R 2” (50mm) 5. 2” (50mm)

Note: Make Lifting Lug from .38”(10mm) Thick ASTM A36Steel Plate Figure 8-8 Seating the Mantle

1. Locking Bolt 2. Equal Distance All Around 3. Head

4. Mantle 5. Torch Ring

Figure 8-9 Installing the Mantle

1. Mantle 2. Head 3. Feeler Gauge

4. 0.010” (0.25mm) Maximum Clearance Allowed 5. Pouring Trough 6. Epoxy Backing Material

ECT000-0337 - Rev. 00 - 08/088-6

Head Ball ReplacementNormal Crusher operation should not involve a lot of wear between the Head Ball and the mating surface of the Socket Liner. However, if the lube oil is excessively dirty or if there is a loss of oil supply and the Head Ball is worn to the point of replacement, do the following:

1. Remove the capscrew that secures the strap in the Head Ball. This capscrew is factory installed with Loctite and will require heat to be removed.

Refer to Figure 8-1

2. The Head Ball has an interference fit in the Head. Therefore, to drive the Ball out of the Head, do the following:

a) Place wood blocking under the Head Ball. Refer to Figure 8-10 The blocking should be high enough to allow the Head Ball to just clear the bore in the Head when it drops. Allowing the Head Ball to drop through the Lower Head Bushing risks damage to the Bushing.

b) Place a steel round bar down through the Head and onto the Head Ball. Sledge the round bar on one side and then on the other to drive the Head Ball out of the Head. If the Head Ball will not move during sledging, heat the Head to a maximum of 300°F (149°C) in the area and keep

sledging. Care should be taken not to damage the threads in the inside top of the Head used with the Locking Bolt. Refer to Figure 8-10

3. With the worn Head Ball removed, turn the Head upside down using the handling instructions outlined further on in this section.

4. Cool the replacement Head Ball to achieve the proper temperature difference compared to the Head.

Temperature Difference Between Head & Head Ball XL300 125°F (69°C) XL400 120°F (67°F) This will shrink it enough to be set in the Head. It’s

suggested that the bore in the Head and the Head Ball diameter are measured to make sure enough shrinkage has occurred before installing the Ball in the Head.

5. With the Head Ball sufficiently cooled, attach a ring bolt to the Head Ball and position it above the Head making sure to line-up the dowels. Then quickly lower it into the Head engaging the dowels and making sure the Head Ball has fully bottomed in the bore of the Head. Refer to Figure 8-11

6. Using Loctite, install the capscrew into the Head. Refer to Figure 8-1

7. Using the handling instruction below, turn the Head back upright.

1. Head Ball 2. Ring Bolt

1. Steel Round Bar 2. Heat this area if necessary 3. Clearance

Figure 8-10 Removing Head Ball

4. Head Ball 5. Blocking 6. Upper Head Bushing

Figure 8-11 Installing Head Ball

3. Steel Ring 4. Steel Frame

ECT000-0337 - Rev. 00 - 08/08 8-7

Handling the HeadThe following instructions are to be used to turn the Head upside down for Ball, Bushing, or seal replacement:

1. If the Mantle is on the Head, install the Head lifting plate as outlined in Step 4 under Head Assembly Installation found later in this section. If the Mantle is not on the Head, make sure the Locking Bolt is securely screwed into the Head and the Head lifting plate is bolted to the Locking Bolt.

2. Place the Head on suitable cribbing. If the Head Assembly includes a Head Skirt, DO NOT support the Head using the Skirt. It will not handle the weight of the Head Assembly. Refer to Figure 8-12A

3. Attach a second lifting cable using the hoist ring supplied by Excel attached to a tapped hole in the underside of the Head. Refer to Figure 8-12B

4. Lift the Head off the blocking while slowly and carefully turning the Head. Set it down. Place blocking on both sides of the Head so it will not roll when the lifting equipment is removed.

Refer to Figure 8-12C

Note: Leave the Head in this position for removing either the Upper or Lower Head Bushings.

5. Connect lifting cables to the hoist rings under the Head. Refer to Figure 8-12D

6. Carefully lift and turn the Head until it is upside down. With the Head upside down, place it on a customer supplied steel frame. The Head is to be in this position for installing the Head Ball and Head Bushings. Refer to Figure 8-12E

Replacing the Lower Head BushingThe Lower Head Bushing is secured in the Head using an interference fit and capscrews. To remove the Lower Head Bushing do the following:

1. First turn the Head on its side as instructed under Handling the Head, outlined earlier in this section.

2. Remove the capscrews and lock washers that secure the flange area of the Bushing to the Head. The capscrews were factory installed with Loctite so heat will likely be required to remove.

Figure 8-12 A-E Handling the Head

3. With a heavy duty circular saw equipped with a metal cutting blade, make two cuts on bushing flange. Set the saw blade depth to slightly less than the thickness of the Bushing, so the saw blade does not contact the Head. The Lower Head Bushing is made from leaded bronze. It is important to wear a dust respirator whenever cutting or grinding leaded bronze bushings. Refer to Figure 8-13

A

B

C

D

E

ECT000-0337 - Rev. 00 - 08/088-8

4. Place the saw inside the Bushing and lined up with one of the cuts from Step 3. The saw blade depth should be set so the blade just clears the Head bore while sawing the Bushing. Make a sample cut to make sure the saw blade is correctly set and adjust if necessary. Refer to Figure 8-14

5. Saw cut the full length of the Bushing at both saw cuts in the flange.

6. Place a steel rod against the Bushing flange between the two saw cuts and hit it with a hammer. This will peel that portion of the Bushing out from between the saw cuts allowing the Bushing to collapse. The Bushing can now be easily lifted out of the Head bore.

Lower Head Bore InspectionWith the Lower Head Bushing removed, inspect the bore for any rough areas or scoring and smooth them out. Also measure the bore to determine if it has shrunk undersize due to an overheating condition or has worn undersize.

Measure the bore at the top, center and bottom at 90° apart at each location. Contact Excel to verify that the measurements are within factory specifications. If they are not, Excel will provide further instructions.

1. Circular Saw 2. Flange Saw Cuts (see Figure 8-13)

1. Saw Cuts 2. Lower Head Bushing Flange 3. Head 4. Lower Head Bushing Flange Thickness XL300 .841” (21.3mm) XL400 .768” (19.5mm) 5. .50” (12mm) to .75” (20mm) Between Saw Cuts

Figure 8-13 Sawing Bushing Flange

Lower Head Bushing InstallationTo install a new Lower Head Bushing, do the following:

1. Using a wire brush, clean the outside diameter of the Bushing and Head bore.

2. Cool the Bushing to establish the proper temperature difference with the Head bore.

Temperature Difference Between Head & Lower Head Bushing XL300 53°F (29°C) XL400 44°F (25°F)

Important: Do not try to install a bushing in a bore that is undersize or pulled in due to a high heat event (burnt bushing, weld repairs).

3. After the temperature difference has been achieved, measure the Head bore and the Bushing outside diameter to verify that the Bushing has shrunk enough to be inserted in the Head bore.

4. Install the ring bolts supplied with the tools assembly in the Bushing flange.

Figure 8-14 Sawing Head Bushing Wall

3. Lower Head Bushing 4. Blade Depth

ECT000-0337 - Rev. 00 - 08/08 8-9

5. With the Bushing positioned above the Head bore, use customer supplied threaded aligning bolts to quickly lower it into the Head until the Bushing flange bottoms on the Head. Make sure the countersunk holes in the Bushing flange are lined up with the mating tapped holes in the Head.


6. Once the Bushing has returned to ambient temperature, use Loctite (available from Excel) to install the eight capscrews and lock washers in the Head. Torque the capscrews to the proper tightness.

Lower Head Bushing Capscrew Torque Requirements XL300 44 Ft-lbs (60 N-m) XL400 44 Ft-lbs (60 N-m)

7. With the Lower Head Bushing installed, turn the Head right side up following the Head handling procedures outlined in this section.

Replacing the Upper Head BushingThe Upper Head Bushing is secured in the Head using an interference fit along with keys. To remove the Upper Head Bushing do the following:

XL3001. First turn the head on its side as instructed under

Handling the Head, outlined earlier in this section.

2. Remove all of the Hex Head Capscrews from the Lower Head Bushing. (Bolts that have been heated should be replaced.) Heat may be required as the capscrews were factory installed using Loctite 277.

3. Remove the Lower Head Bushing with a procedure similar to the Counter Shaft Bushing Removal by jacking in Section 5. Refer to Figure 5-14

If the head bushing can not be removed by jacking, the Lower Head Bushing must be removed with the procedure outlined earlier in this section Replacing the Lower Head Bushing.

4. Remove the four keys used to hold the Upper Head Bushing by unbending the tabs on the Lock Plates, loosening and removing the cap screws. (Bolts that have been heated should be replaced.) Heat may be required as the cap screws were factory installed using Loctite 277.

5. Extract the Upper Head Bushing from the Head bore by use of a small Porta Power positioned between the Head Ball and the underside of the Upper Head Bushing using a small piece of rubber to protect the Head Ball surface. Jack out the Upper Head Bushing by moving the Porta Power evenly around the bushing.

If a Porta Power is not available, a similar procedure to the Countershaft Bushing Removal in Section 5 can be used to extract the Upper Head Bushing.


XL4001. First turn the Head on its side as instructed under

Handling the Head, outlined earlier in this section.

2. Remove the four keys used to hold the Upper Head Bushing by unbending the tabs on the Lock Plates, loosening and removing the cap screws. (Bolts that

Figure 8-15 Head Bushing Installation1. Lower Head Bushing

1. Lower Head Bushing 2. Head

3. Steel Ring 4. Steel Frame

ECT000-0337 - Rev. 00 - 08/088-10

have been heated should be replaced.) Heat may be required as the cap screws were factory installed using Loctite 277.

3. Extract the Upper Head Bushing from the Head bore by use of a small Porta Power position between the head ball and the underside of the Upper Head Bushing using a small piece of rubber to protect the Head Ball surface. Jack out the Upper Head Bushing by moving the Porta Power evenly around the bushing.

If a Porta Power is not available, a similar procedure to Countershaft Bushing Removal in Section 5 can be used to extract the Upper Head Bushing.


Note: It may be possible to remove the Upper Head Bushing by hand if it has been damaged as a result of a high heat event due to a lack of proper lubrication.

Upper Head Bore InspectionWith the Upper Head Bushing removed, inspect the bore for any rough areas or scoring and smooth them out. Also measure the bore to determine if it has shrunk undersize due to an overheating condition or has worn oversize.

Measure the bore at the top and bottom at 60° apart at each location. Contact Excel to verify that the measurements are within factory specifications. If they are not, Excel will provide further instructions.

Upper Head Bushing InstallationTo install a new Upper Head Bushing, do the following:

1. Using a wire brush, clean the outside diameter of the Bushing and Head bore.

2. Cool the Bushing to establish the proper temperature difference with the Head bore.

Temperature Difference Between Head & Lower Head Bushing XL300 53°F (29°C) XL400 44°F (25°C)

Important: Do not try to install a bushing in a bore that is undersize or pulled in.

3. After the temperature difference has been achieved, measure the Head bore and the Bushing outside

diameter to verify that the Bushing has shrunk enough to be inserted in the Head bore.

4. Install the ring bolts, supplied with the Tools Assembly, in the Upper Head Bushing. Ensure the ring bolt eyes are not perpendicular to the Upper Head Bushing. The perpendicular ring bolts will not allow the Upper Head Bushing to be lowered into the Head Assembly. Washers may be added to correctly orientate the ring bolts.

5. With the Upper Head Bushing positioned above the head. Align the bushing key slots with the Key Retainers in the Head. Quickly lower the Upper Head Bushing into the Head until the Lower Head Bushing seats firmly into the Head.

6. To assist in the Key assembly, slightly bend the long tab and slightly bend the short tab in the opposite direction. Using Loctite 277 (available from Excel), install the Hex Head Cap screws and Locking Plates in the Keys. After firmly securing the Hex Head Cap screws, install the Lock Plates by bending the long tab down around the Key and the short tab up around the flat side of the Hex Head Cap screws.

7. If working on the XL300 install the Lower Head Bushing using the Lower Head Bushing Installation procedure earlier in this section.

8. With the Upper Head Bushing installed, turn the Head right side up following Handling the Head procedures outlined in this section.

“T” Seal ReplacementThe “T” Seal located in a groove on the underside of the Head will typically see very little wear. It is important to check it every time the Head Assembly is removed from the Crusher and reattach or replace it if the seal is ever loose or damaged. The seal prevents dust from infiltrating the inside of the Crusher. To replace the “T” Seal, do the following:

1. Turn the Head upside down following the Handling the Head Procedure outlined earlier in this section.

2. Remove the seal and scrape out any old glue residue left in the seal groove. Refer to Figure 8-16


4. If the new seal is coated with a shiny mold release agent, use coarse sand paper to remove just enough

ECT000-0337 - Rev. 00 - 08/08 8-11

off the sides of the seal that will be contacting the Head to completely remove the shine. It is important that the release agent be completely removed so the adhesive used to hold the seal in the Head groove will adhere to the seal.

The seal could become loose and work itself out of the groove during Crusher operation if the release agent is not completely removed.

5. Apply a very thin coat of activator to the Head contact sides of the seal. Too much activator will result in a partial cure that may not provide complete bond of the adhesive.

6. Apply a thin coat of adhesive to the groove in the Head. Then apply just enough adhesive to the contact sides of the seal to obtain a minimal squeeze out when pressure is applied in Step 7.

7. After the adhesive has been applied, quickly place the seal into the groove in the Head. Apply a steady force to the seal. A satisfactory handling bond will occur in approximately three minutes.

8. Turn the Head right-side-up following the Handling the Head Instructions detailed earlier in this section.

Head Assembly InstallationTo install the Head Assembly in the Crusher, proceed as follows:

1. With the Head assembled and the Mantle mounted per the instructions shown earlier in this section, install the Head Lifting Plate to the Locking Bolt. Refer to Figure 8-2

2. Properly clean the Eccentric, Socket Liner, Head Bushing bores and Head ball. Also make sure all oil passages have been cleaned as well. Any scratches or nicks in the Upper and Lower Head Bushings should be smoothed out with fine emery paper.

3. 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.

4. Making sure the ring bolt in the Head Lifting Plate is positioned toward the thick portion of the Eccentric and centered the Head Assembly over the crusher. Slowly lower the Head Assembly down into the crusher. The off-center position of the ring bolt 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, the Lower Head Bushing damage will occur.

5. After seating the Head Assembly on the Socket Liner, lift the Head Assembly up approximately 1” (25 mm) and suspend the Head Assembly in the crusher and run the lube pump for 10 minutes. This operation will wash away any contamination and lubricated the critical bearing surfaces in the crusher.

6. Lower the Head Assembly on to the Socket Assembly.

7. Remove the Head Lifting Plate and mount the Feed Plate onto the Locking Bolt. Refer to Figure 8-3

8. After securing the Feed Plate mounting bolt, fill the area around the bolt with Silastic. This operation will prevent dust and water packing around the bolt making removal of the bolt easier at the next removal. Refer to Figure 8-3

1. Head 2. “T” Seal 3. Clean bottom of seal using coarse sand paper to remove surface shine before applying activator and adhesive to bottom of groove in head.

Figure 8-16 Replacing the “T” Seal

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ECT000-0337 - Rev. 00 - 08/08 9-1

Section 9

Bowl, Bowl Liner and Hopper AssembliesBowl Assembly Installation ............................................................................................................................. 9-2

Bowl, Bowl Liner & Hopper Figure 9-1 .......................................................................................................... 9-2

Bowl Removal .................................................................................................................................................... 9-3

Lifting the Bowl Figure 9-2 ............................................................................................................................. 9-3

Bowl Wedge and Liner Parts Figure 9-3 ....................................................................................................... 9-3

Bowl Liner Removal .......................................................................................................................................... 9-4

Wedge Assembly Figure 9-4 ........................................................................................................................... 9-4

Bowl Liner Installation ...................................................................................................................................... 9-5

Helix High Point Location Figure 9-5 ............................................................................................................ 9-5

Installation of Bowl Liner Figure 9-6 ............................................................................................................. 9-5

Checking Bowl Liner Seating Surface Figure 9-7 ........................................................................................ 9-6

Bowl Adapter Ring Figure 9-8 ........................................................................................................................ 9-7

Bowl, Bowl Liner Seating Surface .................................................................................................................. 9-7

Changing Bowl Hopper Height Figure 9-9 ................................................................................................... 9-7

Changing the Bowl Adaptor Ring ................................................................................................................... 9-7

Determining Bowl Thread Wear ..................................................................................................................... 9-7

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Description Refer to Figure 9-1This section covers descriptions of the Bowl, Bowl Liner and Hopper Assemblies along with installation and removal instructions. The outside diameter of the Bowl consists of greased heavy-duty right-hand threads that mate with corresponding threads in the Clamping and Adjustment Rings and provide vertical adjustment of the Bowl position in the Crusher. The Bowl is rotated in the counter-clockwise direction to open the close side setting of the crushing cavity and rotated clockwise to close it.

The Adjustment Cap is mounted to the top of the Bowl and contacts a rubber seal on the Dust Shell (which is bolted to the Adjustment Ring). The seal, Adjustment Cap and Dust Shell protect the greased threads from dust contamination. When pressurized, Clamping Cylinders (spaced around the top of the Adjustment Ring) provide a locking mechanism for holding the Bowl in position during crushing. The Bowl Assembly is turned by an electric or hydraulic motor adjusting mechanism mounted on the Adjustment Ring.

The upper and lower sections of the Feed Hopper are designed to direct feed into the crushing cavity. The flat bottom of the Hopper provides a shelf for the incoming feed to collect and form a dead bed that contributes to wear protection of the Hopper.

The Bowl Liner is secured in the Bowl using Wedges, Wedge Bolts and an Adapter Ring designed to accommodate various Liner configurations.

Bowl Assembly InstallationTo install the Bowl and Hopper Assemblies in the Crusher, proceed as follows:

1. Thoroughly clean the Bowl, Adjustment Ring and Clamping Ring threads. Note: Assemblies shipped to customers that are not factory installed in the Crusher (e.g. spare or replacement assemblies) will have a protective coating material such as cosmoline applied to the threads that must be removed.

2. Liberally apply a coat of FLSmidth Excel supplied 3% moly grease to the Bowl, Adjustment Ring and Clamping Ring threads.

3. Lift the Bowl Assembly with the Hopper installed, using the lifting ears on the Adjustment Cap. Slowly set the Bowl Assembly in the Crusher on the Clamping Ring threads, being sure to match the thread starts of both components. Refer to Figure 9-2

4. With the threads of the Bowl Assembly resting on the threads of the Clamping Ring, turn the Bowl Assembly clockwise into the Crusher as follows:

1. Bowl Liner 2. Adjustment Cap 3. Bowl

Figure 9-1 Bowl, Bowl Liner & Hopper Assemblies

4. Adaptor Ring 5. Wedge Bolt 6. Wedge

7. Upper Hopper 8. Lower Hopper

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a) Turn the selector switch labeled “Local / Remote” located on the Remote Mounted Hydraulic Power Unit Control Panel to the “Local” position.

b) Turn the selector switch labeled “High / Low” located on the Remote Mounted Hydraulic Power Unit Control Panel to the “High” position.

c) Open the Clamping Circuit pressure dump valve before installing or removing the Bowl Assembly. This is to insure that the Bowl or Adjustment Ring threads are not damage during minimal thread engagement and automatic pressurization of the Clamping Circuit in a minimum thread engagement condition.

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.

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

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

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

Bowl RemovalTo remove the Bowl Assembly from the Crusher during inspection or a Liner change, do the following:

1. Turn the “Local / Remote” selector switch located on the Remote Mounted Hydraulic Power Unit Control Panel to the “Local” position.

2. Turn the “High / Low” selector switch located on the Remote Mounted Hydraulic Power Unit Control Panel to the “High” position.

3. Open the Clamping Circuit pressure dump valve before installing or removing the Bowl Assembly. This is to insure that the Bowl or Adjustment Ring threads are not damage during minimal thread engagement and automatic pressurization of the Clamping Circuit.

Figure 9-2 Lifting the Bowl

1. Feed Hopper 2. Lifting Cable 3. Anchor Shackle 4. Adjustment Cap Lifting Lug

5. Adjustment Cap 6. Bowl Liner 7. Bowl

1. Bolt Stop 2. Loosen Nut .25” (20mm) 3. Cotter Pin 4. Wedge 5. Bowl Liner 6. Epoxy Backing

Figure 9-3 Bowl Wedge and Liner Parts

7. Spherical Nut 8. Square Head Bolt 9. Bowl 10. Lock Plate 11. Wood Blocking

ECT000-0337 - Rev. 00 - 08/089-4

4. Turn and hold the “Open / Close” selector switch located on the Remote Mounted Hydraulic Power Unit Control Panel to the “Open” position. There will be a brief delay as the Hydraulic Power Unit depressurizes the clamping circuit pressure. The Bowl will then begin to turn counter-clockwise 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, 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 top thread of the Clamping Ring, the Bowl will drop the 2” (100mm) height of one full thread and could cause thread damage.

5. Attach suitable lifting equipment to the lifting ears located on the top of the Adjustment Cap and lift the Bowl Assembly out of the Crusher and onto wood blocking. Refer to Figure 9-3

Bowl Liner RemovalTo remove the Bowl Liner from the Bowl, proceed as follows:

1. Support the Bowl Assembly with the bottom of the Bowl Liner resting on wooden blocking. This will support the Bowl Liner when removing the Bowl. Refer to Figure 9-3

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.

3. Attach suitable lifting equipment to the two lifting holes spaced 180° at the top of the Hopper and lift it out of the Bowl. This will provide access to the wedges that hold the Bowl Liner in place.

4. Remove the cotter pins and lock plates from each of the wedges. Refer to Figure 9-4

5. Unscrew the spherical nuts (used to hold the wedges tight against the Liner) approximately 0.5” (12 mm).

6. If any of the wedges do not loosen when the spherical nut is backed off, strike the wedge with a hammer and blunt chisel.

7. With all the wedges loose, unscrew all the spherical nuts far enough to allow for removal of the square head bolts and wedges.

WarningIt is important to follow the wedge removalprocedure as outlined above. If not, the wedges could propel outward and cause bodily damage when they break loose.

8. With all the Liner retention hardware removed, lift the Bowl off the Bowl Liner. Note: Factory 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. If someone other than FLSmidth Excel should improperly install the Bowl Liner, and some of the backing material remains attached to the Bowl, it may be necessary to use a heavy object to remove the backing material from the Bowl Liner. After removing the Bowl free of the Liner, set the Bowl on wood blocking.

9. Inspect the seating surface of the Bowl for ridges or steps caused by the removed Bowl Liner. Grind any discontinuities 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.

1. Lockplate 2. Bolt Stop 3. Square Head Bolt

Figure 9-4 Wedge Assembly

4. “Special” Spherical Nut 5. Wedge 6. Cotter Pin

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Warning:Improper seating of the Bowl Liner in the Bowl can cause ridges or steps in the seating surface of the Bowl. This condition can cause the Bowl Liner to come loose in the Bowl and create additional seating surface damage.

Bowl Liner InstallationTo install a Bowl Liner, do the following:

Note: If the Bowl Liner configuration is being changed (e.g. Standard to Short Head), the Adapter Ring may require changing as well.

1. Place the Bowl Liner on wood blocking making sure the blocking will allow the Bowl to fully seat on the Bowl and remove all the paint from the seating surface.

2. Place chalk marks at the high points of the helix on the Bowl Liner. Refer to Figure 9-5

3. Apply a light coat of oil or grease on the inside of the Bowl to prevent the epoxy backing from adhering to the Bowl.

4. Lower the Bowl onto the Bowl Liner making sure the chalk marks on the Bowl Liner from Step 2 are centered between the stop blocks on the adapter ring.

5. Take a measurement between the Bowl Liner flange and the inside of the Bowl at four places 90° apart. This is to make sure the Bowl Liner is properly centered in the Bowl. If these measurements are not fairly equal, lift the Bowl and reseat it on the Bowl

Liner until they are. Refer to Figure 9-7 A cocked Bowl Liner can come loose during operation and cause damage to the Bowl seating surface.

6. After applying anti-seize compound to the thread of the square head bolts, screw on the spherical nuts, making sure that the spherical side faces away from the head of the bolt. Refer to Figure 9-6

7. Inspect the inclined surface on the nose of each wedge to make sure there are no gouges. Any gouges should be smoothed out to eliminate possible contact problems between the Bowl Liner helix and the wedge. Place the wedges on the adapter ring between the stop blocks and push the wedges forward until they contact the Bowl Liner.

Refer to Figure 9-6

Figure 9-5 Helix High Point Location

1. Bowl Liner 2. Chalk Mark Above High Point of Helix 3. High Point of Helix

1. Lock Plate 2. View Showing Lockplate 3. Bolt Stop Welded to Bowl 4. Lock Plate 5. Wedge 6. Inclined Midpoint 7. Bowl Adapter Ring 8. Must Have Clearance 9. Bowl Liner 10. Bowl 11. Tack Weld Shim on this surface, if required 12. Square Head Bolt

Figure 9-6 Installation of Bowl Liner

ECT000-0337 - Rev. 00 - 08/089-6

8. Each of the wedges should contact the helix of the Bowl Liner midway up the inclined surface of the wedge. Add or remove shims under the wedges to obtain the desired contact points on the helix not to exceed .50” (13mm) shim height. Once the proper wedge contact on the helix is established, tack weld the shims in place. Refer to Figure 9-6

9. Place the square head bolts with the screwed on spherical nuts (see Step 6) behind the wedges making sure the bolt heads are under the bolt stops welded in the Bowl slots. The bolt stops hold the heads of the bolts in place. If the bolts slide up, the Bowl Liner will come loose. Note: If the Liner confi guration is changed causing a change of adapter ring part numbers, the bolt stops may need to be relocated. Refer to Figure 9-6

10. With a sledging wrench, alternately tighten each spherical nut in a crisscross pattern until all the wedges are tight in the Bowl Liner helixes.

11. Use a 0.010” (0.25 mm) feeler gauge around the bottom of the Bowl Liner to check that the Bowl Liner is seated tightly against the Bowl. Any 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 9-7

12. Fill the entire space behind the Bowl Liner with high performance epoxy up to the level. Carefully follow the epoxy backing manufacturers mixing, pouring and safety instructions. Refer to Figure 9-7

13. After the epoxy has cured, recheck each of the spherical nuts to make sure they are all tight.

14. Place the lock plates over the spherical nuts and attach them to the wedges using cotter pins. The lock plates prevent the spherical nuts from loosening which in turn prevents the Bowl Liner from coming loose. Refer to Figure 9-6

15. Using fiberglass insulation cover the entire area above the wedge bolt assemblies all the way around. This will prevent dirt and dust from accumulating around these parts while making it easier to remove them during the next Liner change.

Refer to Figure 9-7

16. Lift and place the Hopper into the Bowl making sure the Hopper engages the dowels in the top of the Bowl. Apply silicone to the seam between the vertical face of the Bowl Liner and the underside of the Hopper to prevent material from getting under the Hopper. Note: If a change is made to the type of Liner (e.g. Short Head changed to a Standard), it may be necessary to change the height of the Hopper. To change the Hopper height, remove the two angles located on the inside of the Hopper that join the upper and lower Hopper, slide the upper hopper up or down to accommodate the change in height and re-weld the angles. Refer to Figure 9-9

17. Following the steps defined in the Bowl Assembly Instructions detailed earlier in this section, lubricate the Bowl, Clamping Ring and Adjustment Ring threads prior to installing the Bowl in the Crusher.

Note: If any of the threads have been refurbished (e.g.

weld repaired), it is important to apply the same break-in grease used by the factory to the threads. This material is available from FLSmidth Excel and has a signifi cant affect on the wear of new or rebuilt threads.

1. Bowl 2. Fiberglass Insulation 3. Bowl Liner 4. Epoxy Backing Material

Figure 9-7Checking Bowl Liner Seating Surface

5. Blocking 6. Feeler Gauge 7. .010” (.025mm) Maximum Clearance

ECT000-0337 - Rev. 00 - 08/08 9-7

Changing the Bowl Adaptor RingIf a change is made to the type of Liner (e.g. Short Head Medium changed to a Standard Fine), a change to the adapter ring located in the Bowl may also be required. To change the adapter ring, do the following:

1. Remove the socket head capscrews and lock washers holding the adapter ring in the Bowl.

Refer to Figure 9-8

2. Lift the existing adapter ring out of the Bowl and replace it with the new one.

3. Reinstall the socket head capscrews and lock washers.

Bowl, Bowl Liner Seating SurfaceExtended periods of crushing operation will eventually cause wear of the Bowl seating surface requiring weld repair and machining. Contact FLSmidth Excel for reconditioning instructions.

Determining Bowl Thread WearDuring every Liner change, the threads on the Bowl, Adjustment Ring and Clamping Ring should be checked for excessive wear. Follow the instructions outlined in Section 4, Determining Adjustment and Clamping Ring Thread Wear to do a similar check of the Bowl threads.

1. Bowl Adapter Ring 2. Stop Blocks (Part of Adaptor Ring) 3. Socket Head Capscrew & Lockwasher 4. Bowl

Figure 9-8 Bowl Adapter Ring

1. Upper Hopper2. Support Angle3. Lower Hopper

Figure 9-9Changing Bowl Hopper Height

ECT000-0337 - Rev. 00 - 08/089-8

ECT000-0337 - Rev. 00 - 08/08 10-1

Section 10

Bowl Adjustment Mechanism AssemblyElectric Adjustment Mechanism Assembly Figure 10-1A ........................................................................ 10-2

Adjustment Mechanism Installation ............................................................................................................ 10-2

Hydraulic Adjustment Mechanism Assembly Figure 10-1B .................................................................... 10-3

Hydraulic Adjust Drive Oil Specifications .................................................................................................... 10-3

Drive Ring Support System ............................................................................................................................ 10-3

Drive Assembly ................................................................................................................................................. 10-3

Drive Ring Support Figure 10-2 .................................................................................................................... 10-4

Lower Support Bracket Figure 10-3 ............................................................................................................ 10-4

Tooth Replacement Figure 10-4 ................................................................................................................... 10-4

Jacking Bolts Figure 10-5 .............................................................................................................................. 10-4

ECT000-0337 - Rev. 00 - 08/0810-2

Description Refer to Figure 10-1A & 10-1BThis section covers the description of the adjustment mechanism along with installation and removal instructions.

The XL300/XL400 Crusher is equipped with an adjustment mechanism consisting of an electric or hydraulic drive assembly, drive ring and drive ring support brackets. Refer to Figure 10-1A or Figure 10-1B. These parts provide the necessary turning of the Bowl for close side setting adjustment and Bowl removal/installation during Liner changes. To turn the Bowl, the clamping circuit is depressurized to release the holding of the Bowl. After a brief delay to ensure the clamping circuit pressure is completely released, the electric or hydraulic drive motor mounted on the Adjustment Ring turns a pinion that is mounted on the drive assembly. The teeth of the pinion engage teeth in the drive ring. Mounted to the top of the drive ring are turning brackets that match with lugs welded to the outside of the Adjustment Cap that is bolted to the Bowl. The drive turns the Bowl in either direction to open or close the close side setting of the Crusher. Mounted to the cover that protects the pinion are two proximity sensors used by the control system to count the pinion teeth. The count is used to monitor the changes in setting along with liner life. Refer to the Automated Control System instruction manual for more information regarding setting change capabilities.

Adjustment MechanismInstallationTo install the adjustment mechanisms, do the following:

1. Bolt the electric drive assembly to the mounting adapter. Refer to Figure 10-1A or Figure 10-1B

2. Lift and place the drive assembly and mounting adapter onto the mounting weldment, which is part of the Adjustment Ring. and bolt in place. Do not completely tighten the bolts at this time.

3. Lift and set the Bowl Assembly, as instructed in Section 9 on the Clamping Ring threads making sure the square vertical bars welded to the outside diameter of the Adjustment Cap engage in the three turning brackets bolted to the top of the drive ring.

4. Remove the cover shield protecting the drive pinion.

5. Supply power to the electric adjust motor or connect the hydraulic lines to the hydraulic adjust motor and brake. See the adjustment mechanism hose assembly in the customer parts book.

6. Carefully turn both the pinion and drive ring to position the teeth of the pinion relative to the teeth

1. Drive Ring 2. Electric Drive Assembly 3. Mounting Adaptor 4. Electric Motor

Figure 10-1A Electric Adjustment Mechanism Assembly

5. Pinion 6. Mounting Weldment 7. Drive Ring Retainer and Support 8. Turning Bracket

9. Lower Drive Support 10. Cover Shield 11. Proximity Switches

ECT000-0337 - Rev. 00 - 08/08 10-3

in the drive ring. Refer to Figure 10-4 Turn the jacking bolts mounted on the mounting adapter to achieve the required root clearance. Tighten the locking bolts along with the bolts that secure the mounting adapter to the mounting weldment.


7. Rotate the Drive Ring 360° in both directions to make sure the pinion and Drive Ring teeth do not bind or slip. If binding or slippage occurs while turning the Bowl Assembly, adjust the pinion to drive ring root clearance to eliminate the problem. Adjust the bolts in the turning brackets and pinion to drive Ring root clearance using the jacking screws.


Directions for turning the Bowl Assembly into the Adjustment Ring can be found in Section 9, Bowl Assembly, Steps 1 thru 4.

Directions for turning the Bowl Assembly out of the Adjustment Ring can be found in Section 9, Bowl Removal, Steps 1 thru 3.

8. Re-install the cover shield to protect the pinion and drive ring teeth.

7

9

10

11

1. Drive Ring 2. Hydraulic Drive Assembly 3. Mounting Adapter 4. Hydraulic Motor

Figure 10-1B Hydraulic Adjustment Mechanism Assembly

5. Pinion 6. Mounting Weldment 7. Drive Ring Retainer & Support 8. Turning Bracket

9. Cover Shield 10. Proximity Switches 11. Brake

Drive AssemblyThe drive assembly consists of an electric or hydraulic motor, drive housing and pinion. Refer to the customer parts book for replacement component part numbers.

Hydraulic Adjust Drive Oil Specifications The hydraulic adjust drive lubricant level should be checked every 1,000 hours of Crusher operation.

Gear Box LubricantLubricant Type Grade GL-5 EP 80/90Quantity 2.5 Pints (1.2 Liters)

Brake LubricantLubricant Type ATF-Type FQuantity 2 FL. OZ (0.06 Liter)

Drive Ring Support SystemAs the Drive Ring rotates; it is kept in the same plane as the Adjustment Mechanism pinion by three Drive Ring Retainers, with two replaceable (top and bottom) urethane Support Pads. Refer to Figure 10-2

ECT000-0337 - Rev. 00 - 08/0810-4

Figure 10-5 Jacking Bolts

1. Jacking Bolts 2. Locking Bolts

Figure 10-2 Drive Ring Support

1. Drive Ring Support 2. Drive Ring Retainer 3. Turning Bracket 4. Adjustment Ring

5. Drive Ring 6. Drive Ring Support Pads 7. Centering Bolts

Figure 10-3 Lower Support Bracket(Electric Drive Only)

1. Drive Ring 2. Drive Pinion

Figure 10-4 Tooth Replacement

3. .25” (6mm) 4. Pinion

ECT000-0337 - Rev. 00 - 08/08 11-1

Section 11

Lubrication SystemLubrication System (Water Cooled) Figure 11-1 ....................................................................................... 11-2

Lubricating Oil Specifications ........................................................................................................................ 11-3

Lubrication System (Air Cooled) Figure 11-2 ............................................................................................. 11-3

Air Oil Cooler Figure 11-3 ............................................................................................................................... 11-4

Crusher Operating Oil Temperature ............................................................................................................. 11-4

Drain Oil Temperature .................................................................................................................................... 11-4

Reservoir Oil Temperature ............................................................................................................................. 11-4

Supply Oil Temperature .................................................................................................................................. 11-4

Air Cooled .......................................................................................................................................................... 11-5

Lube System Placement and Installation ................................................................................................... 11-5

Air Cooler System ............................................................................................................................................ 11-5

Skid Mounted Lube System ........................................................................................................................... 11-5

Oil Supply Regulation ...................................................................................................................................... 11-5

Oil to Water Cooling ........................................................................................................................................ 11-5

Tank Location Figure 11-4 ............................................................................................................................. 11-5

Crusher Air Breather Figure 11-5 ................................................................................................................. 11-6

Crusher Air Breather ....................................................................................................................................... 11-6

Oil Tank Breather ............................................................................................................................................. 11-6

Piping Information .......................................................................................................................................... 11-6

Oil Contamination Guidelines Table 11-1 .................................................................................................... 11-7

Oil Contamination ............................................................................................................................................ 11-7

Oil Coolers ......................................................................................................................................................... 11-7

Oil Filtration ..................................................................................................................................................... 11-7

Air Cooler .......................................................................................................................................................... 11-8

Water Cooler .................................................................................................................................................... 11-8

Water Control Valve Troubleshooting ......................................................................................................... 11-8

Water Cooled Lube System Components ................................................................................................... 11-8

Water Strainer Cleaning ................................................................................................................................. 11-8

Low Oil Level ..................................................................................................................................................... 11-9

Oil Heater ........................................................................................................................................................... 11-9

Oil Pressure Sensor .......................................................................................................................................... 11-9

ECT000-0337 - Rev. 00 - 08/0811-2

Description Refer to Figure 11-1This section covers the description of the Lubrication System and its related components along with installation and removal of those components.

There are two lubrication packages available. Selection depends on the oil cooling requirement. Figure 11-1 shows the parts of a water cooled lube system. Figure 11-2 shows the parts of an air cooled lubrication package. Both systems are designed to operate at a maximum pressure of 125 psi (8.6 Bars).

The Package Lubrication Systems are skid mounted and consists of the following:

• Reservoir with a oil level sensor, temperature sensor and a thermowell mounted oil heater

• Submerged oil pump attached to a vertically positioned electric drive motor, which is mounted to the top of the oil reservoir

• Main system relief valve set at 125 psi (8.6 bars)• 20 micron fi lter system with 50 psi (.34 bars) internal

bypass two separate filter differential pressure switches

• 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

• A crusher relief valve (mounted near the Countershaft Box Assembly) set a 35 psi. This function is to protect the crusher from excess pressures and hydraulically lifting the Head Assembly during no load operations.

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 a vertical

1. Oil Reservoir 2. Oil Reservoir Clean Out Cover 3. Heat Exchanger (Oil to Water) 4. Water Control Valve 5. Water Strainer 6. Check Valves 7. Oil Filter 8. Oil Heater 9. Inspection Screen

Figure 11-1 Lubrication System (Water Cooled)

10. Oil Pump 11. Oil Pump Motor 12. Oil Reservoir Breather 13. Oil Reservoir Temperature Transducer 14. Oil Supply Temperature Transducer 15. Drain Oil Temperature Transducer 16. Oil Level Sight Gauge 17. Pressure Relief Valve

18. Oil Level Sensor 19. Cooler By-Pass Relief Valve 20. Water Inlet Connection 21. Water Outlet Connection 22. Drain Oil Connection 23. Supply Oil Connection 24. Crusher Pressure Relief Valve Return Connection

ECT000-0337 - Rev. 00 - 08/08 11-3

gallery at the center of the Main Shaft, where it lubricates the Head Ball, Socket Liner, and (during no load operations) the Upper Head Bushing. There is an intersecting cross gallery in the Main Shaft that carries 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.

There is a “T” in the 2 inch lube oil supply line, located near the crusher, that supplies oil to lubricate the Countershaft Box bushings. The correct oil flow to the Countershaft Box is determined by the size of the flexible 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 SpecificationsUse high grade paraffin (not naphthalene) based ISO EP 150 gear oil that meets the following requirements:

1. High film strength

2. High adhesiveness to metal surfaces

3. Stable physical and chemical properties

4. 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.

5. High viscosity index

6. Rapid water separation

7. Resist foaming

8. Provides rust and corrosion protection

9. Includes anti-wear additives

Figure 11-2 Lubrication System (Air Cooled)

1. Oil Reservoir 2. Oil Reservoir Clean Out Cover 3. Pressure Relief Valve 4. Oil Heater 5. Oil Filter 6. Oil Pump Motor

7. Oil Pump 8. Oil Reservoir Breather 9. Oil Level Sight Gauge 10. Oil Reservoir Temperature Transducer 11. Check Valve 12. Drain Oil Temperature Transducer

13. Oil Level Sensor 14. Inspection Screen 15. Drain Oil Connection 16. Supply Oil Connection 17. Crusher Pressure Relief Valve Return Connection

LECECRUSHER

ECT000-0337 - Rev. 00 - 08/08Rev. B - 03-0811-4

International Standards Organization Grade 150Viscosity: 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 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 Excel’s customer service for assistance.

Crusher Operating OilTemperatureThe 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 Figure 11-1 for the lube system transducer locations.

If the Crusher oil is cooled by an air to oil cooler, the fan motor is controlled by the drain line temperature sensor located in the lube package. There is a supply oil temperature transducer mounted on the cooler assembly in the outlet piping. Refer to Figure 11-3 for the transducer location on the air cooler.

Reservoir Oil TemperatureA 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 Heater and to monitor the “start permissible” for the Lube Oil Pump.

Drain Oil TemperatureA temperature probe mounted in the Crusher drain line connection on the side of the reservoir is connected to the Return Temperature transducer and 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 TemperatureThe 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:

1. Air to Oil Cooler 2. Fan Motor

Figure 11-3 Air Oil Cooler

3. Supply Oil Temperature Transducer 4. Pressure Relief Valve

ECT000-0337 - Rev. 00 - 08/08

Oil to Water CoolingThe Supply Oil Temperature probe is mounted adjacent to the 2” NPT 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 CooledThe Supply Oil Temperature sensor is mounted in the outlet piping of the Air Cooler Assembly and wired to the Automated Control System (ACS). Refer to the ACS manual for operational information and instructions. Refer to Figure 11-3

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

Normal supply oil flow to the Crusher is XL300 30-35 GPM (114-132 LPM) XL400 50-55 GPM (189-208 LPM)

Normal supply oil pressure at the Crusher should be: XL300 20-40 psi (1.4-2.8 Bars) XL400 20-40 psi (1.4-2.8 Bars)

The amount of oil to fill the lubrication system reservoir: XL300 80 U.S. Gallons (302 Liters) XL400 120 U.S. Gallons (454 Liters)

Lube SystemPlacement & Installation

Skid Mounted Lube SystemLocate the lube system below and as near the Crusher as possible. To obtain the proper fl ow 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. Make sure that the Package Lube Skid is level before attaching to the foundation, using shims if necessary. Refer to Figure 11-4

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.

Air Cooler SystemCrushers 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 already piped in place. Refer to Figure 11-3 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) can be mounted by overhead suspension or 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 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, start the motor and check its rotation. It should rotate the fan so air

11-5

1. Crusher 2. Minimum 4’ (1.3 Meters) plus 1” (25mm) for every 1’ (0.3 Meters) tank is away from the crusher horizontally 3. Oil Tank

Figure 11-4 Tank Location

ECT000-0337 - Rev. 00 - 08/08

is forced through the radiator from the motor side. Refer to Figure 11-3 for air flow direction. If the motor is rotating the fan in the wrong direction, change the fan motor wiringand re-check the direction of air flow.

Piping InformationThe 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 inch (25mm) of vertical change for every 12 inches (305mm) of horizontal change. Refer to Figure 11-4 for minimum vertical distance between the Lube Tank and Crusher.

2. The piping should be as direct and short as possible with a minimum amount of turns, dead pockets and similar obstructions.

3. Install flexible couplings or short hoses between the piping from the Lube Package and the Crusher to accommodate Crusher movement.

4. Install unions or bolted, flanged joints to aid at various locations 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 cause 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 feet (1220 mm) long, contact Excel’s customer service department for instructions for installing and maintaining a drain line trap.

ImportantThe 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.

Crusher Air BreatherA Breather is connected by hose to the Countershaft Box to provide atmospheric pressure inside the Crusher. This is required to allow the lube oil to drain freely from the Crusher. Locate the Breather away from the Crusher in a relatively dust free area. Refer to Figure 11-5

To verify that the Crusher is breathing properly, remove the hose from the breather and place a piece of light paper at the opening. The paper should be pulled slightly inward. If not, it could be that the cored passage that runs the length of the Countershaft Box is plugged with dirt. This can usually be corrected by blowing pressurized air into the Countershaft Box at the hose connection to blow out the dirt. This method does not require the removal of the Countershaft Box Assembly from the Crusher. The more common problem is a dirty or plugged Breather element. These paper elements are not considered cleanable and should be changed out as needed.

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. Refer to Figures 11-1 and 11-2

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.

11-6

1. Countershaft Box 2. Hose (15 feet long) 3. Air Breather

Figure 11-5 Crusher Air Breather

ECT000-0337 - Rev. 00 - 08/08

Oil FiltrationThe Package Lube System includes a full flow oil filter with integral pressure relief, a replaceable 20 micron filter element and two pressure switches used to indicate dirty and plugged filter element conditions. These signals are sent to and processed by the Automated Control System (ACS). To replace the filter element, disconnect the electrical connector and unscrew the top cover of the filter. The element includes a handle for ease of removal. Refer to Figure 11-6

Under the oil tank cover is removable/cleanable strainer basket designed to catch large particle contamination as the drain oil falls back into the tank.

Oil ContaminationUse 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 listed in Table 11-1, 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 CoolersThe lubrication system includes an oil cooler designed to maintain the drain oil temperature of the Crusher between 100°F (38) 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).

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

11-7

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 11-1

1. Cover 2. Element 3. Filter Housing

Figure 11-6 Lubrication Filter

Oil Contamination Guidelines

Rev. B - 02/07

ECT000-0337 - Rev. 00 - 08/08

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.

Air CoolerThe 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. Refer to Figure 11-3

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

Water CoolerThe 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). Refer to Figure 11-1

Contact Excel customer service for operation and maintenance instructions for the water heat exchanger.

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 inch 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. Refer to Figure 11-1

Water Cooled Lube SystemComponentsThe 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 a thermowell on 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.

If for some reason, the valve needs adjusting, contact 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

11-8

through its inlet and outlet. 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.

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

1. Check the water strainer located on the water inlet side of the cooler for any debris.


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 will 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. Chattering of the water control valve may indicate loose parts within or near the valve.

Water Strainer CleaningDepending upon the quality of the cooling water, it may be necessary to clean the strainer weekly. Refer to Figure 11-1 for its location. 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.

ECT000-0337 - Rev. 00 - 08/08

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

Oil HeaterThe Lube System includes an oil heater mounted in a thermowell used to maintain oil temperature in cold operating conditions. Equipment required for heater operation such as magnetic contactor and fuse protection is to be furnished by the customer and must meet local electrical code requirements.

Oil Pressure SensorAn 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.

11-9

ECT000-0337 - Rev. 00 - 08/0811-10

ECT000-0337 - Rev. 00 - 08/08 12-1

Section 12

Hydraulic Systems

Hydraulic Power Unit Installation ................................................................................................................ 12-2

Tramp Release and Clamping Cylinders Figure 12-1 ................................................................................ 12-2

Crusher to Power Unit Hose Connections ................................................................................................. 12-3

Hydraulic Power Figure 12-2 ........................................................................................................................ 12-3

Hydraulic Power Unit Hose Connections Figure 12-3 .............................................................................. 12-3

Release and Clearing System Hose Connections Figure 12-4 ................................................................ 12-4

Hydraulic Adjust Drive Hose Connections Figure 12-4A .......................................................................... 12-4

Remote Mounted Pushbutton Control Panel Installation ..................................................................... 12-4

Cold Weather Oil Specifications .................................................................................................................... 12-5

Hydraulic Oil Specifications ........................................................................................................................... 12-4

Hydraulic System Pre-Start Tramp Release System ................................................................................ 12-5

Accumulator Valve Figure 12-5 .................................................................................................................... 12-5

Charging and Gauging Assembly Figure 12-6 ........................................................................................... 12-6

Clamping Circuit System ................................................................................................................................ 12-7

Hydraulic Power Unit Controls ..................................................................................................................... 12-7

Push Button Pendent Figure 12-7 ............................................................................................................... 12-7

Power Unit Service Switches Figure 12-8 .................................................................................................. 12-8

Remote Push Button Panel Indicator Lights .............................................................................................. 12-8

Service Box Switches ...................................................................................................................................... 12-8

Hydraulic Power Unit Start-up and Operation .......................................................................................... 12-9

Bleeding and Pressure Testing the Tramp Release and Clamping Systems ........................................ 12-9

Bleeding the Tramp Release System ........................................................................................................... 12-9

Bleeding the Clamping System ................................................................................................................... 12-10

Power Unit Oil Filter Figure 12-9 ................................................................................................................ 12-11

Changing the Oil Filter .................................................................................................................................. 12-11

Hydraulic Oil Changing ................................................................................................................................. 12-11

Cleaning the Hydraulic System ................................................................................................................... 12-11

ECT000-0337 - Rev. 00 - 08/0812-2

DescriptionThis section covers the description of the hydraulic circuits and related components along with installation and removal of those components. All XL300/XL400 Crushers are furnished with hydraulic tramp release, cavity clearing and clamping circuits. They also have the ability to run a hydraulic Bowl adjust drive system when additional components are supplied.

Hydraulic Tramp Release Cylinders hold the Adjustment Ring firmly to the Main Frame. The top of each Cylinder is attached to the Adjustment Ring by a hex nut. The bottom of each Cylinder is secured to the Main Frame by a pin. 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 Tramp Release Cylinders and force oil from the rod side of the cylinders 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 accomplished by depressurizing the rod side of all the Tramp Release Cylinders and pressurizing the piston side. This extends the Cylinders and lifts the Adjustment Ring and Bowl Assembly off the Main Frame.

The clamping system consists of a set of Clamping Cylinders installed in the Clamping Ring which is mounted on top of the Adjustment Ring. Refer to Figure 12-1 When the Clamping Cylinders are pressurized, the Clamping Ring raises slightly and locks the Bowl threads in the Adjustment Ring 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 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 foot (9 meter) long cable. Refer to Figure 12-2 The Hydraulic Power Unit can be controlled locally at the push button pendent or at the Automated Control System (ACS) touch screen.

Figure 12-1Tramp Release and Clamping Cylinders

1. Clamping Ring 2. Clamping Cylinder 3. Adjustment Ring 4. Tramp Release Cylinder

Hydraulic Power Unit InstallationThe Hydraulic Power Unit should be carefully placed in an area that is protected from falling rock and no more than 50’ (15 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 clearing or while turning the Bowl (setting adjustment).

There are three 50 foot (15 meter) long hydraulic hoses that connect the Crusher to the hydraulic power unit. Two are .75” (20mm) in diameter and the other is .50” (12mm) in diameter. If a hydraulic drive is used rather than electric, three additional hoses are supplied; one 0.50” (13mm) in diameter and two 0.75” (19mm) in diameter. These hoses are shipped loose for field installation. The hoses include reusable couplings on one end providing the customer with the ability to change the length of the hoses to fit the installation.

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

ECT000-0337 - Rev. 00 - 08/08

Figure 12-3Hydraulic Power Unit Hose Connections

1. Clearing Circuit Hose Connection 2. Tramp Release Circuit Hose Connection 3. Clamping Circuit Hose Connection

Crusher to Power Unit Hose Connections

1. Connect the .50” (12mm) diameter hose to the clamping circuit connection on the power unit. Refer to Figure 12-3 for the clamping system power unit connection location. Connect the other end of this hose to the clamping system connection on the Adjustment Ring. Refer to Figure 4-15 in Section 4 Main Frame, Adjustment Ring and Tramp Release Assemblies.

2. Connect one of the two .75” (20mm) diameter hoses to the release system connection on the power unit. Refer to Figure 12-3 Connect the other end to the lower connection on the tramp release cylinder located just to the right of the accumulator on the Main Frame. Refer to Figure 12-4.

3. Connect the other .75” (20mm) diameter hose to the clearing system connection on the power unit. Refer to Figure 12-3 Connect the other end of this hose to the upper connection on the release cylinder located just to the right of the accumulator on the Main Frame. Refer to Figure 12-4

12-3

WARNING

1. Oil Reservoir 2. Oil Reservoir Clean Out Cover 3. Oil Level Sight Gauge 4. Oil Filters 5. Junction Box 6. Reservoir Oil Fill Cap 7. Service Switch Box 8. Reservoir Breather

Figure 12-2 Hydraulic Power

9. Accumulator 10. Oil Level Switch 11. Electric Motor 12. Clamping System Manifold and Valves 13. Tramp Release System Manifold and Valves

14. Clamp Circuit Pressure Transducer 15. Tramp Release Circuit Pressure Transducer 16. Reservoir Drain Plug 17. Manual Dump Valve (Clamp) 18. Manual Dump Valve (Tramp)

ECT000-0337 - Rev. 00 - 08/08

Note: If a hydraulic adjustment mechanism is used, connect the following additional hose’s.

4. Connect the 0.50” (13mm) diameter hose to the “Brake” port connection at the Hydraulic Power Unit. Connect the other end of this hose to Brake on the hydraulic adjust drive. Refer to Figure 12-4a

5. Connect the two 0.75” (19mm) diameter hoses to the “Open” and “Close” port connections at the Hydraulic Power Unit. Connect the other ends of these hoses to the corresponding open and close ports on the hydraulic motor. Refer to Figure 12-4a

Remote Mounted Pushbutton Control Panel Installation The remote mounted pushbutton panel includes a 30 foot (9 meter) 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 SpecificationsThoroughly 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.

International Standards Organization Grade 32Viscosity: 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

12-4

Figure 12-4 Release and Clearing System Hose Connections

1. Tramp Release Hose to Power Unit 2. Clearing Hose to Power Unit

3. Adjustment Ring 4. Clamping Hose to Power Unit

1. Gearbox Fill Plug 2. Brake Port 3. Port B Open

Figure 12-4A Hydraulic Adjust DriveHose Connections

4. Port A Closed 5. Gearbox Drain Plug

ECT000-0337 - Rev. 00 - 08/08

Fire resistant hydraulic oil should not be used. This type 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.

The reservoir is to be filled to the top of the oil level gauge. Approximately 50 US gallons (189 Liters) will be required. An additional 10 gallons (38 liters) of oil will be required to initially fill and bleed the clamping, release and clearing systems.

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

Cold Weather Oil SpecificationsCold 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.

International Standards Organization Grade 1010 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-StartTramp Release System (Checking Pre-Charge and Charging the Accumulator)

The 5-gallon 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. 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 and pressurize (pre-charge) the tramp release system accumulator, do the following:

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

2. At the power unit, open the service door. Turn the Operation-Service selector switch to the Service position. Refer to Figure 12-2 and 12-8 for the Operation-Service selector switch location.

3. Eliminate all the tramp release circuit pressure using the tramp release pressure dump valve located on the backside of the tramp circuit manifold block. Make sure the pressure on the tramp release circuit pressure transducer reads zero before going any further. Refer to Figure 12-2 for the dump valve and release system pressure transducer locations.

4. Push the power button down 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. Refer to Figure 12-5

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. Refer to Figure 12-6

12-5

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

Figure 12-5 Accumulator Valve

4. Valve Guard 5. Washer

ECT000-0337 - Rev. 00 - 08/08

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 bars) +/-

50 psi (3 bars). 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.

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.

12-6

1. Accumulator 2. Screw 3. Bleeder Valve 4. Swivel Connector 5. Gas Charging Valve 6. Pressure Gauge 7. T-Handle 8. Air Chuck

Figure 12-6 Charging and Gauging Assembly

9. Swivel 10. Gas Valve Stem 11. Hose Assembly 12. Coupling 13. Gland 14. Gland Nut 15. Pressure Regulator Valve 16. Nitrogen Bottle

ECT000-0337 - Rev. 00 - 08/08

18. Lift up on 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, then install the cover back onto the hydraulic power unit.

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 1-gallon accumulator is located inside the hydraulic power unit. Follow the same procedure used to check and charge the 5-gallon tramp release accumulator on the 1 gallon clamping circuit accumulator. The only difference is that the pre-charge pressure must be 1000 psi (69 bars) +/- 50 psi (3 bars).

Hydraulic Power Unit Controls Refer to Figure 12-7

Do not operate the hydraulic power unit until after reading the following information.

WarningPressing 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 LightsPush to Stop - Twist or Pull to StartTo 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-RemoteThis 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).

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 - ClearTurning this selector switch to the “Clear” position and holding it there will raise the Adjustment Ring and Bowl Assemblies off the Main Frame and clear the crushing cavity of material. When clearing, the tramp release circuit pressure is automatically dropped to zero. Refer to Section 13 (Clearing the Crusher) for instructions on how to properly clear the Crusher.

12-7

Figure 12-7 Push Button Pendent

ECT000-0337 - Rev. 00 - 08/08

When clearing of the Crusher is complete, be sure that any Safety Blocks are removed if they were inserted during clearing and turn the switch to the Tramp Pressure Reset position. This action will pressurize the tramp release circuit.

Hi Speed - Low SpeedThis switch controls the speed of the electric Bowl adjust motor. The High speed position is used primarily for installation and removal of the Bowl. (The high speed adjust feature is only available with electric adjust drives.) The Low speed position is typically used for adjusting the closed side setting. It is not recommended to use the High speed setting for adjusting the Crusher.

Open-CloseTurning 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.

Remote Push Button Panel Indicator LightsPower OnThis 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.

RemoteThis 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 PressureThis red light will illuminate when the clamping circuit pressure falls below 2200 psi (152 bars).

Note: Automatic pressurization of the clamping circuit occurs at 2400 psi (165 bars).

Low Tramp PressureThis red light will illuminate when the tramp release circuit pressure falls below 1800 psi (124 bars).

Note: Automatic pressurization of the tramp release circuit occurs at 2000 psi (138 bars).

Service ModeThis 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 SwitchesThere 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 Figure12-2 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 Figure 12-8

The following is a description of the switches and their functions:

Operation - ServiceDuring 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.

12-8

Figure 12-8Power Unit Service Switches

ECT000-0337 - Rev. 00 - 08/08

Tramp Press - Clamp PressThis 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.

Hydraulic Power Unit Start-up and OperationThe 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. Refer to Figure 12-7 For the Hydraulic 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 Hydraulic 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 Hydraulic 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 andClamping SystemsDuring initial Crusher start-up and whenever the tramp release or clamping circuit components have been disconnected, it is necessary to bleed the hydraulic hoses to remove any air that may be trapped.

WarningNo 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.

If the tramp release and clamping circuits are being pressurized for the first, 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 of the bladder.

Bleeding the Tramp Release SystemTo 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 Figure 12-2 and 12-8 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 Figure 12-2 for the release system dump valve location.

12-9

ECT000-0337 - Rev. 00 - 08/0812-10

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 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 bars). 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 bars) of pressure is maintained as indicated on the tramp release system pressure transducer located on the circuit manifold block. Refer to Figure 12-2 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 of 2400 psi (165 bars) 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 SystemTo 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 Figure 12-2 and 12-8 for location of the switch.

4. Open the clamping system pressure dump valve all the way open. Refer to Figure 12-2 for the clamping system dump 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 bars). 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 bars) of pressure is maintained as indicated on the clamp system pressure transducer located on the circuit manifold block. Refer to Figure 12-2 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.

ECT000-0337 - Rev. 00 - 08/08 12-11

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 Clamp Press position until the normal operating pressure of 2800 psi (193 bars) 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 FilterLocated inside the Hydraulic Power Unit are two high pressure oil filters. Refer to Figure 12-2 for the filter locations. 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.

7. Install the canister and tighten it to 30-35 foot pounds (41-47 N/m) of torque.

Hydraulic Oil ChangingAt 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.

Cleaning the Hydraulic SystemAfter 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.

1. Hex 2. Canister 3. Base 4. Condition Indicator Button

Figure 12-9 Power Unit Oil Filter

ECT000-0337 - Rev. 00 - 08/0812-12

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 Figure 12-2 for the location of the oil drain plug.

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.

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

Rev. A - 09/06 13-1

Section 13

Operating Instructions

Check List for Starting New Crusher (Part 1) ............................................................................................ 13-2

Check List for Starting New Crusher (Part 2) ............................................................................................ 13-3

Pre Start-Up Procedures ................................................................................................................................ 13-4

Countershaft Rotation ................................................................................................................................... 13-4

Hydraulic Power Unit Operation .................................................................................................................. 13-4

Initial Start-Up and Break-In Instructions ................................................................................................... 13-4

Daily Start-Up Instructions ............................................................................................................................ 13-4

Checking the Setting ...................................................................................................................................... 13-5

Daily Shut-Down Instructions ....................................................................................................................... 13-5

Normal Operating Recommendations ........................................................................................................ 13-5

Setting the Crusher Figure 13-1 ................................................................................................................... 13-5

Setting the Crusher ......................................................................................................................................... 13-5

Adjustment Ring Movement ......................................................................................................................... 13-6

Determining Liner Wear ................................................................................................................................. 13-6

Grease Fittings Figure 13-3 ........................................................................................................................... 13-6

Number of Driver Ring Teeth and Bowl Travel Information Table 13-3 ............................................... 13-6

Position of Adjustment Cap With Worn Liners Figure 13-2 .................................................................... 13-6

Bowl Thread Engagement With Adjustment Ring Figure 13-4 .............................................................. 13-7

Clearing the Crusher ....................................................................................................................................... 13-7

Difficulty Turning the Bowl ........................................................................................................................... 13-7

Thread Lubrication .......................................................................................................................................... 13-7

Safety Blocking Figure 13-5 .......................................................................................................................... 13-8

Inspection Periods ........................................................................................................................................... 13-9

Lubrication Maintenance Chart Table 13-4 ................................................................................................. 13-9

Daily Checks and Maintenance ................................................................................................................... 13-10

Monthly Checks and Maintenance ............................................................................................................. 13-11

Weekly Checks and Maintenance ............................................................................................................... 13-11

Annual Checks and Maintenance ............................................................................................................... 13-12

Liner Change Checks and Maintenance .................................................................................................... 13-12

Rev. B - 03/08

Rev. A - 09/0613-2

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 Accumulator has been charged to specified pressure. 1500 psi

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 12 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 1000 psi 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.

Check List for Starting New Crusher

Rev. B - 03/08

Rev. A - 09/06

B. Start the Oil Pump SATISFACTORY UNSATISFACTORY

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 has been given to the customer. 6. Verify that the drive belts have been re-tensioned per the belt manufacturers instructions.

F. Portable Plants 1. Check for properly installed cribbing. Comments

Check List for Starting New Crusher

13-3Rev. B - 03/08

Rev. A - 09/06

Initial Start-Up and Break-In InstructionsAlthough the Crusher was run no-load at the factory, Excel recommends a field run in as part of initial start-up or after new bearings have been installed. Refer to Item D, Start the Crusher for step-by-step instructions related to power draw. Drain oil temperature should be closely watched during this time. Refer to Oil Temperature in Section 11.

Daily Start-Up InstructionsFollowing the proper break-in period, Excel recommends the following daily start-up procedures:

1. Turn on the lube system to provide adequate lubrication to the Crusher before starting. The start-up drain line temperature must be at least 60°F (16°C). The Automated Control System will energize the tank heater automatically to maintain the temperature. In extremely cold conditions, it may be necessary the constantly run the heater and lube system to maintain the required start-up oil temperature during long periods of down time.

2. Once the lube system is started, the control system begins a timing sequence of one minute of oil circulation before the Crusher can be started. Access the inspection cover on the lube tank to verify flow of lube oil. The drain oil pipe should be approximately half full. If there’s only a small stream of oil or no flow at all, do not start the Crusher. Insufficient or no oil flow can be a result of an obstruction in the piping, failed oil pump, relief valve or incorrect relief valve setting. Operating the Crusher in this situation will cause extreme Crusher bearing failure.

3. Start-up the Crusher and run it empty (no-load) for 5 minutes.

4. Slowly start the feed of material to the Crusher and gradually increase the feed rate. See Section D in Check List for Starting New Crusher. Due to design characteristics, the Crusher should never be continuously operated below 50% drive motor full load amps.

Pre Start-Up ProceduresFollowing proper start up and inspection habits will provide years of successful operation. Regular start up procedures will help eliminate possible expensive down time while increasing Crusher life. Before starting the Crusher, perform the following:

1. Go through the check list at the start of this section, line by line.

2. Make sure the correct lube oil is being used. Refer to Section 11, Lubricating System.

3. Check the end float. The Countershaft should be free to move in and out 0.061” (1.6mm) to 0.031” (0.8mm). Refer to Section 5, Countershaft, Countershaft Box and Sheave Assemblies for adjusting the end float.

4. Bump the lube oil pump and hydraulic power unit motors to make sure that they are rotating in the correct direction. Decals on the top of the motors indicate correct direction of rotation.

5. Check both the lube and hydraulic systems for any leaks.

6. Make sure all fasteners are tight.

7. Bump the Crusher drive motor. If the Mantle is hitting the Bowl Liner, refer to the Setting the Crusher instructions as outlined further on in this section.

8. When all the above items have been checked, proceed with starting the Crusher as outlined in the Initial Start-up and Break-In Instructions located further on in this section.

Countershaft RotationThe Crusher is designed to run Counter-Clockwise as viewed from the front of the Countershaft. Under no circumstances should the Crusher be rotated any differently.

Hydraulic Power Unit OperationRefer to Section 12, Hydraulic Systems for the hydraulic power unit and its related systems operating instructions.

13-4 Rev. B - 03/08

Rev. A - 09/06 13-5

1. Bowl Liner 2. Adjustment Ring 3. Bowl

Figure 13-1 Setting the Crusher

4. Parallel Zone 5. Mantle 6. Head

Daily Shut-Down Instructions1. Shut the feed off to the Crusher and allow the

Crusher to run empty for 5 minutes.

2. Turn the power off to the Crusher drive motor and monitor the time it takes for the Crusher Sheave to coast to a stop. Coast down time should be 60 to 90 seconds.

3. Under normal operating oil temperatures, allow the lube system to run at least 5 minutes before shutting down. In extremely cold conditions refer to Step 1 in Daily Start-Up Instructions above.

Setting the CrusherSize of the crushed product is controlled by the close side setting. The close side setting should be slightly less than the maximum product size required.

Setting the Crusher is done by turning the Bowl either clockwise (closed) to reduce the close side setting or counter clockwise (open) to increase the close side setting.

Refer to the Automated Control System Instruction Manual for the descriptions of available automatic setting controls.

Checking the SettingOne of the methods available to check the close side setting is called “slugging” the Crusher. This is accomplished by attaching a piece of lead to wire and lowering it all the way down through the parallel zone of the Crusher with the head not spinning. Refer to Figure 13-1

With the Crusher running empty (no-load), the Head will spin in a clockwise direction. As rock is introduced into the crushing cavity, the Head will stop spinning clockwise and start turning slowly in the counter clockwise direction. To accurately check the close side setting of the Crusher, there must be no rock in the crushing cavity and the Head cannot be spinning. This is best accomplished by slugging the Crusher during start-up or immediately following the completion of feed through the crushing cavity and before spinning of the Head begins.

Contact Excel customer service to discuss the method best suited for your installation and personnel.

Normal Operating RecommendationsProper operation of the Crusher is critical in maximizing the life of the Crusher. Excel recommends operating as close to full power as possible without exceeding power draw peaks of 110%. Running at a lower average power draw may be necessary to avoid this condition.

Under no circumstances should the Crusher ever be continuously operated at or below 50% power. Although far less critical, it is suggested to try and minimize starting and stopping of the feed to maximize production. 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.

Rev. A - 09/06

Adjustment Ring MovementUnder no circumstances should the adjustment ring be allowed to lift during crushing except to pass tramp material.

Lifting of the Adjustment Ring (ring bounce) is caused by exceeding the force limit of the Crusher. One or more of the following conditions can cause ring bounce. Running the Crusher with too tight of a close side setting, incorrect Liner configuration, wet feed, segregation of feed and/or inadequate screening.

Determining Liner WearThe following information is intended to help determine when the Liners have worn to the point of needing to be replaced.

1. With a new set of Liners installed set to the desired close side setting, measure and record the distance from the bottom of the Adjustment Cap to the bottom

of the Dust Shell. This measurement should be taken after the installation and setting of each new set of Liners as Liner thicknesses will vary somewhat from set to set. Refer to Figure 13-2

2. Take the same measurement at the end of the life of the Liners (when production drops below 10%).

3. 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.

13-6

1. Adjustment Cap 2. Bowl 3. Position of Adjustment Cap with New Liners 4. Dimension “A” Refer to Table 13-3 5. Adjustment Ring 6. Drive Ring 7. Dust Shell

Figure 13-2Position of Adjustment Cap With Worn Liners

1. Grease Fitting 2. Adjustment Ring 3. Main Frame

Figure 13-3 Grease Fittings

Number of Driver Ring Teethand Bowl Travel Information

Crusher Size XL300 XL400

Number of Driver Ring Teeth Available 156 176In One Complete Revolution of Bowl

Vertical Travel of Bowl per .013” .011”Driver Ring Tooth (.33mm) (.29mm)

Change in Crusher Setting .009” .008”per Driver Ring Tooth in. (mm)* (.23mm) (.20mm) “A” Approximate Minimum Height 2.0” 1.12”of Adjustment Cap (50mm) 29mm)w/Worn Liners in. (mm)

Table 13-3 *Contact ECT Engineering with specific liners (STD/SH) for exact change in setting per tooth.

Rev. A - 09/06

Thread LubricationIt 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 13-3 The relationship of the Bowl, Adjustment Ring and Clamping Ring threads in both the crushing and adjusting positions is illustrated. Refer to Figure 13-4 Excel recommends using lithium based grease like NLGI No. 1 containing 5-10% 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.

Difficulty Turning the BowlDifficulty 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. Using grease not recommended by Excel.

2. Lack of or improper thread lubrication.

3. Damaged or worn Dust Shell allowing dust and other contaminates to get into the grease.

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

Whenever the Bowl has been removed from the Crusher, clean the threads and re-coat them with the proper grease. Also check the condition of the Dust Shell Seal and replace if necessary.

If the Bowl will not move using the electric adjust motor, contact Excel customer service to discuss doing the following:

1. With the Crusher running and the Bowl unclamped, feed a small amount of rock into the Crusher.

2. Pour penetrating oil or antifreeze around the threads and through the grease fittings. Let the Crusher sit for a few hours to allow the solution to soak in before attempting to turn the Bowl.

Note: These processes may need to be repeated a few times to free the Bowl.

Clearing the CrusherIf the Crusher stops while crushing (under load), no attempt should be made to restart it with the crushing cavity full of material. Trying to restart the Crusher in this condition will severally damage the machine and drive motor.

This condition can occur for a number of reasons. The most common are when the Crusher drive motor stops as a result of a power outage, the discharge conveyor stops causing discharge material to backup under the Crusher or tramp iron becoming stuck in the crushing cavity.

To clear the crushing cavity, do the following:

1. Go to the hydraulic power unit remote push button panel and turn the selector switch labeled Local / Remote to the Local position and turn and hold the Tramp Pressure Reset / Clear selector switch in the Clear position. This will depressurize the tramp release cylinders and pressurize the clearing circuit which will raise the Adjustment Ring and Bowl Assemblies.

Usually with the Bowl and Adjustment Ring raised and the crushing cavity enlarged, any material in the Crusher will slide out. If the cavity does not clear in Step 1, proceed to Step 5.

13-7

1. Adjustment Ring 2. Bowl

Figure 13-4Bowl Thread Engagement

With Adjustment Ring

3. Crushing Position 4. Released or Turning Position

Rev. A - 09/06

2. If the cavity completely clears in Step 1, release the Tramp Pressure Reset / Clear selector switch. The Adjustment Ring and Bowl will lower back onto the frame.

3. Momentarily turn the Tramp Pressure Reset / Clear selector switch to Tramp Pressure Reset position. This will signal the control system that is alright to pressurize the tramp release circuit.

4. Turn the Local / Remote selector switch to the Remote position and resume normal operation.

5. It is possible that some of the material in the crushing cavity is too large to slide out the Crusher. If this happens, raise the Adjustment Ring and Bowl as defined in Step 1. With the raised assemblies (holding the Tramp Pressure Reset / Clear selector switch in the Clear position), place safety blocks between the Adjustment Ring and Main Frame at the Main Frame Pin locations. Refer to Figure 13-5

6. Release the Tramp Pressure Reset / Clear selector

switch. This will allow the Adjustment Ring and Bowl Assemblies to lower onto the safety blocks.

WarningWhile 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 from the “Clear” position at any time during the clearing cycle, the Adjustment Ring and Bowl will lower.

WarningDo not try to remove any material from the crushing cavity unless the safety blocks have been placed between the Main Frame and Adjustment Ring to hold the ring in a raised position. This will protect hands and arms from being caught between the crushing members.

Never place feet or hands between the Main Frame and Adjustment Ring. Even when the safety blocks are positioned between the Main Frame and Adjustment Ring holding the Adjustment Ring in a raised position.

13-8

WarningDO NOT PRESSURIZE THE TRAMP RELEASE CIRCUIT WITH SAFETy BLOCkS IN PLACE BETWEEN THE ADJUSTMENT RING AND MAIN FRAME. This will put abnormal stresses on the tramp release system components, main frame and adjustment ring causing bending and/or parts failure.

7. With the Adjustment Ring and Bowl Assemblies resting securely on the safety blocks, remove any material that was too large to pass through the cavity.

8. With all the material removed from the crushing cavity, follow the instructions in Step 1. This will raise the Adjustment Ring and Bowl to the maximum height and allow the safety blocks to be removed.

Figure 13-5 Safety Blocking

1. Bowl 2. Adjustment Ring 3. Safety Block (Do not set block on Main Frame Bushing) 4. Main Frame 5. Main Frame Bushing

Rev. A - 09/06

After removing the safety blocks, release the Tramp Pressure Reset / Clear selector switch to allow the Adjustment Ring and Bowl to lower back onto the Main Frame.

9. Visually verify that the Adjustment Ring and Bowl have properly seated back onto the Main Frame. If they have not, re-clear and lower. Never pressurize the tramp release cylinders if the Adjustment Ring is not sitting level on the Main Frame. This will damage the tramp release cylinders.

13-9

10. With the Adjustment Ring and Bowl Assemblies properly seated on the Main Frame, pressurize the tramp release cylinders as instructed in Step 3 and resume operation per Step 4.

Inspection PeriodsTo keep the Crusher in a good operating condition, 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.

Lubrication Maintenance Chart Location Lubrication Interval Method

Oil Change every1 Crusher Circulating Oil ISO 150 (630-770 SUS @ 100° F) 2000 hours Circulation (With E.P. Additives) (if required)

Hydraulic Power Unit (not Oil: Change every2 shown), Tramp Release ISO 32 (135-165 SUS @ 100° F) 2000 Hours Circulation Cylinders, Clamping Cylinders (if required)

Bowl and Head Surfaces Only Oil: Every liner3 Do Not Oil Mantle or Bowl Liner ISO 150 (630-770 SUS @ 100° F) change Manual, brush (contacting the epoxy backing)

Bowl, Clamping Ring and Grease: 40 hours: Grease fittings4 Adjustment Ring Threads Lithium Base NLGI No. 1 with 3% every liner Manual, brush (unclamp bowl before greasing) Molybdenum Disulfide (by wieght) change

Grease: Every liner5 Locking Bolt Threads Lithium Base NLGI No. 1 with 3% change Manual, brush Molybdenum Disulfide (by wieght)

Main Frame and Adjustment Grease:6 Ring Seating Surface Lithium Base NLGI No. 1 with 3% 2000 hours Manual, brush Molybdenum Disulfide (by wieght)

7 Countershaft Box Wear Strip Grease During Manual, brush assembly

Grease8 Mechanical Overload Clutch Grade 1 to 1.5 Lithium Base 2000 hours Grease fitting Non-EP

Oil: Change every9 Electric Bowl Adjust 220 EP Gear Oil 1000 hours Pour (if required)

Table 13-4

Rev. B - 03/08

Rev. A - 09/0613-10

Daily Checks and Maintenance Check Normal Condition

1 Check oil tank level

2 Check lube oil pressure at the Crusher 20-40 psi (1.4-2.8 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 2400 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 1500 psi

22 Check Sheaves (Crusher and Motor) for build-up of material

Rev. A - 09/06

Weekly Checks and Maintenance Check Normal Condition

1 Check the condition of the Countershaft Box breather (RXL405-0008)

2 Check the condition of the lube and hydraulic power unit tank breathers (RXL419-0016)

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

13-11

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 See Oil Contamination Chart in Section 11

4 Check the Countershaft end float 0.061” - 0.031” (1.6mm - 0.8mm)

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 1000 psi

Rev. B - 03/08

Rev. A - 09/0613-12

Annual Checks and Maintenance Check Normal Condition

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.

Liner Change Checks and Maintenance Check Normal Condition

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

ECT000-0337 - Rev. 00 - 08/08

IndexAccumulator Depressurization Figure 4-18 ............................................................................................... 4-18Accumulator Mounting Figure 4-19 ............................................................................................................ 4-19Accumulator Valve Figure 12-5 ..................................................................................................................... 12-5Adjusting the Gear Backlash for Wear ............................................................................................................ 6-9Adjustment Mechanism Installation ............................................................................................................ 10-2Adjustment Ring Assembly Removal ........................................................................................................... 4-14Adjustment Ring Movement ......................................................................................................................... 13-6Adjustment Ring Placement Figure 4-15 ................................................................................................... 4-15Air Cooled ......................................................................................................................................................... 11-5Air Cooler ......................................................................................................................................................... 11-8Air Cooler System ............................................................................................................................................ 11-5Air Oil Cooler Figure 11-3 ............................................................................................................................... 11-4Annual Checks and Maintenance ................................................................................................................ 13-12Assembling the Gear and Counterweight ................................................................................................... 6-10Backlash and Root Clearance Figure 6-3 ...................................................................................................... 6-3Backlash and Root Clearances Table 6-1 ....................................................................................................... 6-4Belt Types Figure 3-1 ........................................................................................................................................ 3-3Bleeding and Pressure Testing the Tramp Release and Clamping Systems ......................................... 12-9Bleeding the Clamping System ................................................................................................................... 12-10Bleeding the Tramp Release System ............................................................................................................ 12-9Bowl Adapter Ring Figure 9-8 ......................................................................................................................... 9-7Bowl Assembly Installation .............................................................................................................................. 9-2Bowl Liner Installation ...................................................................................................................................... 9-5Bowl Liner Removal ........................................................................................................................................... 9-4Bowl Removal ..................................................................................................................................................... 9-3Bowl Thread Engagement With Adjustment Ring Figure 13-4 .............................................................. 13-7Bowl Wedge and Liner Parts Figure 9-3 ........................................................................................................ 9-3Bowl, Bowl Liner & Hopper Figure 9-1 .......................................................................................................... 9-2Bowl, Bowl Liner Seating Surface ................................................................................................................... 9-7Bushing Lock Removal Figure 6-7 .................................................................................................................. 6-6Bushing Removal Plate Figure 5-12 ............................................................................................................. 5-10Capscrew Torque and Gear Heating Table 6-4 ........................................................................................... 6-11Changing Bowl Hopper Height Figure 9-9 ................................................................................................... 9-7Changing the Bowl Adaptor Ring ................................................................................................................... 9-7Changing the Oil Filter .................................................................................................................................. 12-11Charging and Gauging Assembly Figure 12-6 ............................................................................................ 12-6Check List for Starting New Crusher (Part 1) ............................................................................................. 13-2Check List for Starting New Crusher (Part 2) ............................................................................................. 13-3Checking Backlash Between the Gear and Pinion ....................................................................................... 6-3Checking Bowl Liner Seating Surface Figure 9-7 ........................................................................................ 9-6Checking for Thread Wear Figure 4-21........................................................................................................ 4-20Checking Socket Contact Figure 7-3 ............................................................................................................. 7-3Checking the Setting ...................................................................................................................................... 13-5Clamp Cylinder Travel Figure 4-20 ............................................................................................................... 4-20Clamp Ring Spacers and Capscrews Figure 4-16 ....................................................................................... 4-16Clamping Circuit System ................................................................................................................................ 12-7

ECT000-0337 - Rev. 00 - 08/08

Cleaning the Hydraulic System ................................................................................................................... 12-11Clearing the Crusher ....................................................................................................................................... 13-7Cold Weather Oil Specifications .................................................................................................................... 12-5Countershaft Assembly Figure 5-1 ................................................................................................................ 5-2Countershaft Assembly Installation (Method-A) Figure 5-4 ..................................................................... 5-4Countershaft Assembly Installation (Method-B) Figure 5-5 ..................................................................... 5-4Countershaft Box Assembly Removal ............................................................................................................ 5-6Countershaft Box Installation ......................................................................................................................... 5-2Countershaft Box Pinion and Seal Figure 5-19 .......................................................................................... 5-14Countershaft Box Removal Figure 5-8 .......................................................................................................... 5-6Countershaft Box Seal Figure 5-3 .................................................................................................................. 5-3Countershaft Box Temperature Sensor Installation ................................................................................... 5-5Countershaft Bushing Figure 5-15 .............................................................................................................. 5-11Countershaft Bushing by Jacking Figure 5-14 ........................................................................................... 5-11Countershaft Bushing Installation ............................................................................................................... 5-11Countershaft Bushing Removal .................................................................................................................... 5-10Countershaft End Float Figure 5-2 ................................................................................................................ 5-3Countershaft Installation ................................................................................................................................. 5-8Countershaft Removal ...................................................................................................................................... 5-8Countershaft Rotation .................................................................................................................................... 13-4Counterweight Assembly Figure 6-1 ............................................................................................................ 6-2Crusher Air Breather ....................................................................................................................................... 11-6Crusher Air Breather Figure 11-5 ................................................................................................................. 11-6Crusher and Subassembly Weights ................................................................................................................ 3-3Crusher Clearance Dimensions ...................................................................................................................... 3-2Crusher Grouting Figure 4-2 ........................................................................................................................... 4-4Crusher Installation on a Concrete Foundation .......................................................................................... 4-4Crusher Installation on a Steel Structure ...................................................................................................... 4-5Crusher Motor .................................................................................................................................................... 3-4Crusher Operating Oil Temperature ............................................................................................................. 11-4Crusher Sheave Assembly Figure 5-9 ............................................................................................................ 5-7Crusher Sheave Installation ............................................................................................................................. 5-7Crusher Sheave Removal .................................................................................................................................. 5-7Crusher to Power Unit Hose Connections ................................................................................................. 12-3Cutting the Torch Ring Figure 8-4 ................................................................................................................. 8-3Daily Checks and Maintenance .................................................................................................................... 13-10Daily Shut-Down Instructions ........................................................................................................................ 13-5Daily Start-Up Instructions ............................................................................................................................. 13-4Determining Adjustment and Clamping Ring Thread Wear .................................................................... 4-20Determining Adjustment Ring Wear ............................................................................................................ 4-13Determining Bowl Thread Wear ...................................................................................................................... 9-7Determining Liner Wear.................................................................................................................................. 13-6Determining Main Frame Seat Liner Wear................................................................................................... 4-12Determining Seat Liner Wear Figure 4-12................................................................................................... 4-13Difficulty Turning the Bowl ............................................................................................................................ 13-7Discharge Arrangement ................................................................................................................................... 3-3

Index

ECT000-0337 - Rev. 00 - 08/08

Drain Oil Temperature ..................................................................................................................................... 11-4Drive Assembly ................................................................................................................................................. 10-3Drive Motor Positioned Below Motor Sheave Figure 5-18 ...................................................................... 5-13Drive Ring Support Figure 10-2 .................................................................................................................... 10-4Drive Ring Support System ............................................................................................................................ 10-3Eccentric Assembly Installation ...................................................................................................................... 6-2Eccentric Assembly Removal ........................................................................................................................... 6-4Eccentric Bore Inspection ................................................................................................................................ 6-7Eccentric Bushing .............................................................................................................................................. 6-6Eccentric Bushing Alignment Figure 6-10 .................................................................................................... 6-8Eccentric Bushing Alignment Figure 6-9 ...................................................................................................... 6-8Eccentric Bushing Installation ......................................................................................................................... 6-8Eccentric Bushing Removal Figure 6-8 ......................................................................................................... 6-7Electric Adjustment Mechanism Assembly Figure 10-1A ........................................................................ 10-2Epoxy Grouting Requirements Table 4-1 ...................................................................................................... 4-5Feed Arrangement ............................................................................................................................................ 3-3Forcing Countershaft Box into Main Frame Figure 5-6 ............................................................................. 5-5Foundation ......................................................................................................................................................... 3-2Gear Mounting Holes Figure 6-12 ................................................................................................................ 6-11Gear Replacement ............................................................................................................................................. 6-9General Assembly & Disassembly Information ............................................................................................. 3-5Grease Fittings Figure 13-3 ........................................................................................................................... 13-6Groove Depth Table 6-3 .................................................................................................................................... 6-5Handling the Head ............................................................................................................................................. 8-7Handling the Head Figure 8-12 A-E ................................................................................................................ 8-7Head Assembly Installation ............................................................................................................................ 8-11Head Ball Replacement ..................................................................................................................................... 8-6Head Bushing Installation Figure 8-15 .......................................................................................................... 8-9Head Mantle and Feed Plate Assembly Figure 8-1 ...................................................................................... 8-2Head Removal ..................................................................................................................................................... 8-2Helix High Point Location Figure 9-5 ............................................................................................................. 9-5Holding the Countershaft Figure 5-10 .......................................................................................................... 5-8Hydraulic Adjust Drive Hose Connections Figure 12-4A .......................................................................... 12-4Hydraulic Adjust Drive Oil Specifications ..................................................................................................... 10-3 Hydraulic Adjustment Mechanism Assembly Figure 10-1B ..................................................................... 10-3Hydraulic Oil Changing .................................................................................................................................. 12-11Hydraulic Oil Specifications ............................................................................................................................ 12-4Hydraulic Power Figure 12-2 ......................................................................................................................... 12-3Hydraulic Power Unit Controls ...................................................................................................................... 12-7Hydraulic Power Unit Hose Connections Figure 12-3 .............................................................................. 12-3Hydraulic Power Unit Installation ................................................................................................................. 12-2Hydraulic Power Unit Operation ................................................................................................................... 13-4Hydraulic Power Unit Start-up and Operation ........................................................................................... 12-9Hydraulic System Information ........................................................................................................................ 3-4Hydraulic System Pre-Start Tramp Release System .................................................................................. 12-5Initial Start-Up and Break-In Instructions .................................................................................................... 13-4

Index

ECT000-0337 - Rev. 00 - 08/08

“Inner” Countershaft Bushing Oil Groove Location Figure 5-16 ............................................................ 5-12Inspection Periods ........................................................................................................................................... 13-9Installation of Bowl Liner Figure 9-6 ............................................................................................................. 9-5Installing and Removing Head Assembly Figure 8-2 .................................................................................. 8-3Installing Head Ball Figure 8-11 ...................................................................................................................... 8-6Installing the Adjustment Ring Assembly ................................................................................................... 4-16Installing the Clamping Ring ......................................................................................................................... 4-19Installing the Main Frame Seat Liner and Fulcrum Bar ............................................................................. 4-14Installing the Mantle Figure 8-9 ..................................................................................................................... 8-5Installing the Tramp Release Cylinder .......................................................................................................... 4-17Lifting Counterweight and Eccentric Figure 6-11 .................................................................................... 6-10Lifting Eccentric Assembly Figure 6-2 ........................................................................................................... 6-3Lifting Lug Figure 8-7 ....................................................................................................................................... 8-5Lifting of the Crusher Figure 4-3 ................................................................................................................... 4-5Lifting the Bowl Figure 9-2 .............................................................................................................................. 9-3Liner Change Checks and Maintenance ..................................................................................................... 13-12Locking Bolt Wrench Figure 8-5 ..................................................................................................................... 8-4Low Oil Level ..................................................................................................................................................... 11-9Lower Head Bore Inspection ........................................................................................................................... 8-8Lower Head Bushing Installation .................................................................................................................... 8-8Lower Support Bracket Figure 10-3 ............................................................................................................. 10-4Lower Thrust Bearing and Shims Figure 4-7 ................................................................................................ 4-8Lube System Placement and Installation .................................................................................................... 11-5Lubricating Oil Specifications ........................................................................................................................ 11-3Lubrication Maintenance Chart Table 13-4 .................................................................................................. 13-9Lubrication System (Air Cooled) Figure 11-2 ............................................................................................. 11-3Lubrication System (Water Cooled) Figure 11-1 ........................................................................................ 11-2Main Frame Arm Guard Figure 4-5 ................................................................................................................. 4-7Main Frame Assembly Figure 4-1 ................................................................................................................... 4-3Main Frame Flange Spacers Figure 4-4 ......................................................................................................... 4-6Main Frame Liner Figure 4-6 ........................................................................................................................... 4-7Main Frame Liners and Arm Guards ................................................................................................................ 4-6Main Frame Pin Bushing Replacement XL300 ............................................................................................. 4-10Main Frame Pin Bushing Replacement XL400 ............................................................................................. 4-11Main Frame Pin Replacement XL300 ............................................................................................................... 4-9Main Frame Pin Replacement XL400 ............................................................................................................. 4-10Main Frame Pin XL300 Figure 4-9a .................................................................................................................. 4-9Main Frame Pin XL400 Figure 4-9b ................................................................................................................ 4-10Main Frame Ring Figure 4-10 ........................................................................................................................ 4-11Main Frame Seat Liner and Fulcrum Bar ...................................................................................................... 4-12Main Frame Seat Liner and Fulcrum Bar Figure 4-13 ............................................................................... 4-14Main Frame Seat Liner and Fulcrum Bar Frame 4-11 ................................................................................ 4-12Main Shaft Inspection ....................................................................................................................................... 6-7Mantle Lifting Figure 8-6 ................................................................................................................................. 8-4Mantle Replacement ......................................................................................................................................... 8-3Mantle Replacement Figure 8-3 ..................................................................................................................... 8-3

Index

ECT000-0337 - Rev. 00 - 08/08

IndexMaximum Vertical Seat Liner Wear Table 4-2 .............................................................................................. 4-13Measuring Socket Liner Oil Groove Depth Figure 7-4 ................................................................................ 7-3Monthly Checks and Maintenance .............................................................................................................. 13-11Normal Operating Recommendations ......................................................................................................... 13-5Number of Driver Ring Teeth and Bowl Travel Information Table 13-3 ................................................. 13-6Oil Contamination ............................................................................................................................................ 11-7Oil Contamination Guidelines Table 11-1 .................................................................................................... 11-7Oil Coolers ......................................................................................................................................................... 11-7Oil Filtration ..................................................................................................................................................... 11-7Oil Heater ......................................................................................................................................................... 11-9Oil Leakage Out of the Drive End of the Countershaft ............................................................................. 5-13Oil Leakage Out of the Pinion End of the Countershaft Box ................................................................... 5-14Oil Pressure Sensor .......................................................................................................................................... 11-9Oil Supply Regulation ...................................................................................................................................... 11-5Oil Tank Breather .............................................................................................................................................. 11-6Oil to Water Cooling ........................................................................................................................................ 11-5“Outer” Countershaft Bushing Oil Groove Positions Figure 5-17 .......................................................... 5-12Pinion Location Figure 5-11 .......................................................................................................................... 5-10Pinion Replacement .......................................................................................................................................... 5-9Piping Information ............................................................................................................................................ 3-4Piping Information .......................................................................................................................................... 11-6Position of Adjustment Cap With Worn Liners Figure 13-2 ..................................................................... 13-6Power Unit Oil Filter Figure 12-9 ................................................................................................................ 12-11Power Unit Service Switches Figure 12-8 ................................................................................................... 12-8Pre Start-Up Procedures ................................................................................................................................ 13-4Push Button Pendent Figure 12-7 ............................................................................................................... 12-7Release and Clearing System Hose Connections Figure 12-4 ................................................................. 12-4Remote Mounted Pushbutton Control Panel Installation ...................................................................... 12-4Remote Push Button Panel Indicator Lights .............................................................................................. 12-8Removal of the Gear and Counterweight ..................................................................................................... 6-9Removing Head Ball Figure 8-10 .................................................................................................................... 8-6Removing the Clamping Ring ........................................................................................................................ 4-19Removing the Countershaft Bushing by Ramming Figure 5-13 ............................................................ 5-11Removing the Eccentric Bushing ................................................................................................................... 6-7Removing the Tramp Release Cylinder ........................................................................................................ 4-16Replacing the “T” Seal Figure 8-16 ............................................................................................................... 8-11Replacing the Accumulator ........................................................................................................................... 4-18Replacing the Counterweight Guard ............................................................................................................. 6-4Replacing the Lower Head Bushing ............................................................................................................... 8-7Replacing the Lower Thrust Bearing and Shims .......................................................................................... 4-7Replacing the Main Frame Ring .................................................................................................................... 4-11Replacing the Main Shaft .................................................................................................................................. 4-7Replacing the Upper Head Bushing ............................................................................................................... 8-9Reservoir Oil Temperature ............................................................................................................................. 11-4Safety Blocking Figure 13-5 ........................................................................................................................... 13-8Sawing Bushing Flange Figure 8-13 .............................................................................................................. 8-8

ECT000-0337 - Rev. 00 - 08/08

IndexSawing Head Bushing Wall Figure 8-14 ......................................................................................................... 8-8Seating the Mantle Figure 8-8 ........................................................................................................................ 8-5Service Box Switches ....................................................................................................................................... 12-8Setting the Crusher ......................................................................................................................................... 13-5Setting the Crusher Figure 13-1 ................................................................................................................... 13-5Shim Thickness Table 6-2 ................................................................................................................................. 6-4Skid Mounted Lube System ............................................................................................................................ 11-5Socket and Socket Liner Installation .............................................................................................................. 7-2Socket Assembly Figure 7-1 ............................................................................................................................ 7-2Socket Installation Figure 7-2 ......................................................................................................................... 7-2Socket Installation Heating Temperature and Socket Capscrew Torque Requirements Table 7-1 .... 7-2Socket Liner Figure 7-6 .................................................................................................................................... 7-4Socket Liner Installation Figure 7-5 ............................................................................................................... 7-4Socket Liner Removal and Replacement ....................................................................................................... 7-3Socket Removal .................................................................................................................................................. 7-4Socket Removal Figure 7-7 .............................................................................................................................. 7-5Special Tools Furnished with the Raptor Crusher Figure 3-2 ................................................................... 3-6Supply Oil Temperature .................................................................................................................................. 11-4“T” and “U” Seal Replacement Figure 6-6 ..................................................................................................... 6-6“T” and “U” Seal Replacement .......................................................................................................................... 6-6“T” Seal Replacement ...................................................................................................................................... 8-10Tank Location Figure 11-4 .............................................................................................................................. 11-5Temperature Probe Figure 5-7 ....................................................................................................................... 5-5Thread Lubrication .......................................................................................................................................... 13-7Tooth Replacement Figure 10-4 ................................................................................................................... 10-4Tramp Release and Clamping Cylinders Figure 12-1 ................................................................................ 12-2Tramp Release Cylinder Assembly Figure 4-17 .......................................................................................... 4-17Tramp Release Cylinder Strap Figure 4-14 ................................................................................................. 4-15“U” Seal Replacement ........................................................................................................................................ 4-8“U” Seal Replacement Figure 4-8 .................................................................................................................. 4-8Upper Head Bore Inspection ......................................................................................................................... 8-10Upper Head Bushing Installation .................................................................................................................. 8-10Upper Thrust Bearing ........................................................................................................................................ 6-4Upper Thrust Bearing Figure 6-5 ................................................................................................................... 6-5Upper Thrust Bearing Wear Figure 6-4 ......................................................................................................... 6-5V-Belt Drive ......................................................................................................................................................... 3-3Water Control Valve Troubleshooting .......................................................................................................... 11-8Water Cooled Lube System Components.................................................................................................... 11-8Water Cooler .................................................................................................................................................... 11-8Water Strainer Cleaning .................................................................................................................................. 11-8Wedge Assembly Figure 9-4 ............................................................................................................................ 9-4Weekly Checks and Maintenance ................................................................................................................ 13-11Weight of Complete Crusher and Assemblies Table 3-1 ........................................................................... 3-2

raptor xl300&400 rev 00 08-08

Documents

xl300xl400 crusher

required safety procedures

safety shoes

safety codes

safety glasses

basic safety procedures

operating instructions

socket assemblysection