Cone Build Manual Manutenção

8/16/2019 Cone Build Manual Manutenção

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Advanced Crushing Technology 1

Cone BuildManual




Remove the seal ring




Burn off the outer race




Turn the eccentric up side and heat up andsweat off the inner part of the bearing race.




Remove the oil flinger and turn the cone head upside down.Burn through the bearing carefully ensuring that you do not

burn into the casting




Construct a lifting devise to hook under the bearing to lift it out.The bearing will not come out until the bearing is fully cut

through.




Clean up the cone head from where the bearing has beenremoved.




Follow the relevant section for re-fitting the new bearing.




Contents page,

Description of Cone Crusher,

Tools required for build,

Parts list,

Heath and safety aspects,

Assembly procedure of Cone Crusher;

Checking bearing tolerances,

Shaft clean down and checking of tolerances,

Eccentric clean down and checking of tolerances,

Cone head clean down and checking of tolerances,

Mainframe clean down and checking of tolerances,

Counter shaft assembly,

Eccentric assembly;

Fitting of lifting plate,

Fitting of inner bearings,

Fitting of bevel gear,

Fitting of outer bearings,

Page No:




Fitting of the balance ring,

Fitting of the seal ring,

Cone head assembly;

Fitting mantle nut,

Fitting of bearings,

Fitting of mantle,

Mainframe assembly;

Welding of liner plate/fitting arm shields,

Fitting of shaft into mainframe,

Fitting of bearings to main shaft,

Fitting of the counter shaft assembly,

Fitting of eccentric assembly,Fitting of cone head assembly,

Testing procedure,

Fitting of anti rotation plate,

Fitting of dumpy jacks,

Fitting of wedge ring,

Upper frame assembly,

Fitting of upper frame,

Fitting of the hydraulic cylinders,




Description of a Automax

The Pegson Automax is a ‘cone’ type

rock crusher. The crushing action is

provided by an eccentric sleeve that is

mounted on heavy-duty roller bearings.

Stone is feed into the machine, and

crushed between two replaceable liners.

The inner liner is free to rotate above theeccentric.

The outer liner is held stationary by six

hydraulic cylinders working in

conjunction with a wedge ring assembly.These cylinders also act as a overload

release. The cone is lubricated by a

separate oil tank with a air blast oil cooler.




Tools required for build,




Parts list,




1000 Parts List




1300 Parts List




Mainframe Parts




Upper frame Parts




Hydraulic cylinder fixings Parts




Cone head Parts




Eccentric Parts




Countershaft Parts




1500 Parts List




Mainframe Parts,

REF Part Numbers Description QTY




Health and safety aspects,

Contents

Introduction

1 Application of the Regulations

2 Personal Protective Equipment

3 Contractors and Sub-Contractors

4 Customers, Suppliers & Visitors

5 Employees

5.1 Guidelines

5.2 Application of Safety Instruction

5.3 Minimum Recommended Requirements

5.3.1 Foot Protection5.3.2 Leg Protection

5.3.3 Thigh / Torso Protection

5.3.4 Whole Body Protection

5.3.5 Hand Protection

5.3.6 Eye Protection

5.3.7 Respiratory Protection

5.3.8 Hearing Protection

5.3.9 Head Protection

5.3.10 Fall Arrest Protection

5.3.11 Other Protective Equipment

5.4 Disciplinary Procedure

5.5 Requirement of control measures

6 Review




Introduction

This Safety Instruction (SI) is issued to assist Employees of BL PEGSON LTD to understand the requirements for the wearingof Personal Protective Equipment at Work

1/ Application of the Regulations

1.1 The Health and Safety at Work etc Act 1974 (HSWA) requires employers to ensure the health

safety and welfare of their employees and persons not in their employment who may be affected

by work activities.1.2 Regulation 3(1) of the Management of Health and Safety at Work Regulations 1999 requires

employers to identify and assess the risks to health and safety present in the workplace. This

general risk assessment should identify whether there is a risk of injury to persons from working

processes, procedures and practices. Where there is a risk identified, all practical measures shall be

taken to eliminate or reduce so far as is reasonably practicable exposure of the individual to those

risks. There is in effect a hierarchy of control measures and Personal Protective Equipment (PPE)

should always be regarded as the 'last resort'

1.3 The Personal Protective Equipment recommended for each group of people will be commensuratewith their experience and knowledge of the risks to which they are being exposed in any particular

working area.

1.4 This document details the ways in which BL PEGSON LTD discharges its duties and obligations

to its employees, contractors & sub-contractors, customers, suppliers and visitors under this

requirement.

2/ Personal Protective Equipment

'All equipment designed to be worn or held by a person at work to protect against one or more risks and any addition or

accessory designed to meet this objective'

2.1 Both protective equipment and clothing are within the scope of the definitions and therefore:




2.1.1 For the sake of this Safety Instruction 15/01/01 protective clothing such as overalls (when they

are Proban Treated or Pyrovatec) aprons, protective clothing for adverse weather conditions,

gloves, safety footwear, safety helmets, high visibility waistcoats etc; and 2.1.2 Protective equipment such as eye protectors, hearing protectors, respiratory protectors, face

protectors and safety harnesses

2.1.3 Overalls other than Proban Treated or Pyrovatec will not be regarded as PPE as they are for

welfare purposes and do not provide health and safety protection.

2.2 Selection of appropriate PPE will always be the factor that proves the item to be adequate or not

for example: when working with equipment i.e. hammer and chisel, that produces fragments and

splinters impact protection safety glasses with side protection or wrap-round. When operatingequipment that produces fine grit or offshoot i.e. grinder or cutting disc face mask with safety

glasses or box goggles. When working with hazardous substances or splashes invariably box

goggles should be selected.

2.3 With consideration given to the advice above anyone that feels they have insufficient knowledge

or experience in the selection of appropriate PPE they should consult their supervisor or Health

and Safety Officer for a risk assessment and necessary training.

3/ Contractors and Sub-ContractorsWhen contractors and sub-contractors are employed to carry out work that comes within the scope of this Safety

Instruction SI 15/01/01 they will be expected to comply in all factors as though they are direct employees of BL-Pegson Ltd.

(See section 5/ Personal Protective Equipment for employees)

4/ Personal protective Equipment for Customers, Suppliers and Visitors

4.1 When customers, suppliers and visitors to BL-Pegson are introduced to production areas theymust be equipped with adequate and appropriate Personal Protective Equipment (PPE).

It shall be the responsibility of the host responsible for the customer, supplier or visitor to ensure that PPE is

readily available prior to any entry to production areas.

4.2 The needs of paragraph 4.1 above may require the host to make pre-visit arrangements for some

customers, suppliers & visitors to provide their own PPE or provide sufficient information as may be necessary

to enable BL-Pegson ltd to obtain the appropriate clothing and or equipment.




4.3 Adequate and appropriate Personal Protective Equipment for all customers, suppliers and visitors

consists of;4.3.1 High visibility vest

4.3.2 Safety footwear with internal steel toe cap

4.3.3 Grade 2 impact eye protection

4.3.4 Hearing protection (all customers, suppliers and visitors will be advised to wear the hearing

protection, as, during production hours the background noise levels in production departments is

above the first action level of 85dB(a) whereby hearing protection must be provided.

4.4 Hosts escorting suppliers, customers and visitors to production areas who are not in compliance

with the above guidelines will be asked to leave the production area until appropriate remedial

action has been taken.

4.5 Persistent failure by an hosts to establish his customers, suppliers and visitors with the above

requirements will result in the instigation of the BL-Pegson Ltd progressive disciplinary procedures

against him/her.

5/ Personal Protective Equipment for Employees

5.1 Guidelines With due regard to the section 2.2 of this document, the following guidelines are set out

for PPE to be used by all BL-Pegson personnel when performing tasks in all production,

maintenance and testing areas.

5.1.1 When any employee is travelling through or working in a production, maintenance or test area (as

outlined in section 5.2 of this Safety Instruction), other than his/her normal working area, s/he will

be regarded as a visitor to the area. In these circumstances, as a visitor to an area s/he will be

required to adopt PPE (foot and eye protection) as a minimum basic requirement. Persistent failure

by any employee to conform with the designated requirements, for the use of personal protective

equipment within any production, maintenance or test area will result in the instigation of the BL-

Pegson Ltd progressive disciplinary procedures against him/her.




5.2 Application of S.I. For the purpose of this Safety Instruction a production, maintenance or testing

area, is anywhere on the Mammoth Street Site inside or outside of buildings, that;

5.2.1 machining, fitting, welding, burning attaching and/or removing, adjusting or testing of units or components to any item of equipment that goes to make up a crushing or pumping plant; or

5.2.2 any item of equipment used in the production, testing, adjustment or maintenance of crushing or

pumping plant; or

5.2.3 any location other than BL-Pegson Ltd Mammoth Street Site, where BL-Pegson personnel are

involved in the repairs, maintenance, adjusting or testing of any BL-Pegson manufactured plant and

or equipment.

5.3 Minimum/Recommended Requirements5.3.1 Foot Protection - Basic safety footwear protects the feet / lower leg of individuals, assessment has

indicated that the primary protection required at BL-Pegson ltd is Toe Protection (200 joule toecap

protection), Oil and Water Resistant with anti-slip soles with steel mid-sole (100 Newtons

penetration resistance) for protection against penetrating objects.

Safety shoes or Safety Boots shall be worn at all times inside production and maintenance areas.

5.3.2 Leg Protection -

Gaiters or knee-high boots shall be worn when pouring molten metals.

5.3.3 Thigh Protection -Leather apron should be worn when disc cutters and grinders are being operated at or below waist

level.

Nitrile coated or rubber apron should be worn when decanting or using hazardous liquids.

5.3.4 Whole Body Protection -

Proban overalls (flame retardant coating) should be worn when general welding and grinding

processes are carried out by an individual.Operators performing high intensity welding processes shall wear Pyrovatec overalls (heavy-duty

cotton with tight knit fabric and flame-retardant coating).




5.3.5 Hand Protection - Gloves giving a level of

Cut and puncture protection gloves should be worn when performing tasks employing sharp

bladed and pointed tools.

Cut and puncture protection gloves should be worn when performing lifting and handling tasks

on items of equipment or materials that may have rough edges or protruding wires etc.

Thermal protection gloves should be worn when processes require the

Handling of hot or cold items of equipment or materials, this is of particular significance in the

handling processes entailed in the use of liquid nitrogen.

Welding gauntlets should be worn when operating profile cutting / burning equipment and

welding.Rubber or Nitrile coating gauntlets / gloves should be used when working with hazardous

substances.

Nitrile or latex disposable gloves are recommended when working with other non-hazardous

fluids.

5.3.6 Eye Protection - The selection of correct eye protection is the primary consideration for an

individual when performing any task, poor selection is of no benefit to the individual and in somecases can make a situation worse. The reasoning behind this being that having made their

selection they believe themselves to be protected from any hazard. All eye protection PPE issued

at BL-Pegson Ltd is to EN166 Category 2.

Prescription lenses impact protection glasses all individuals that are required to wear

prescription spectacles will be issued with prescription safety glasses with grade 1 impact lenses

and side shields. There may be occasion where additional protection shall be required for

protection from splashes or dust particles in which case a box goggle shall be worn over the top

of the prescription lens safety glasses.




Impact Protection safety glasses shall be worn by operators at all times when working with the

following items of equipment;Machine tools (drilling / boring m/c's etc.) [May not be appropriate when reading drawings,

micrometers etc.]

Impact guns/wrenches (of any type), when working in teams, both/all team members shall wear

impact eye protection glasses

Drilling or tapping holes

Hammer of any size

Drift

Spreader

Chisels

Saws / hacksaws

Thread dies

Working in the vicinity of someone welding burning or grinding

Additional protection box goggle or visor shall be worn by operators at all times when using;

Hand held grinder 4" / 9" (angle grinders)

Die grinder Flap wheel

Bench / pedestal grinder

De-burring / fettling equipment

Air lines for swarf/debris removal

Oxy/acetylene equipment

Initial start-up of plant until such time as integrity of hydraulic system established.

Painting

Rust preventative

Pumps testing

Molten white metal

Decanting any hazardous substance




Tinted glass or Speedglass (electronic polarising action)

WeldingProfile cutter operation

Oxy acetylene burning

Any other situation, not included in this list whereby a potential for eye damage from a working process or procedure is present,

should be assessed by the section Team Leader and or the Health and Safety Manager. Appropriate protection commensurate with

the level of risk assessed should then be applied and this safety instruction amended.

5.3.7 Respiratory Protection - as with eye protection, respiratory safety hazards are extremely difficult

to protect against, as poor selection can lead to individuals feeling they are adequately protected and

yet not receiving any of the protection required for the situation. Dust, Gas and Vapour are specific

hazards and a filter protecting against mist and fume will not necessarily protect against dust

(particulate), similarly a particulate filter will not protect against gas and vapour.

Respiratory protection should only be selected as the last resort. All other sources of to control the

hazard should be considered first e.g. substitution, elimination, separation and engineering controls.

Respiratory Protection - when not in service all respiratory protective equipment must be kept in aclean dry environment where it can be protected from contaminants. Reusable equipment should be

wiped down with a mild solution of soap and water using a cloth or sponge, dried off and then

stored in a clean dry environment.

Powered air and Airfed Respirators and headtop should be worn when

High intensity welding processes (Particulate filter P(SL) filters must be fitted at the air intake. It isrecommended that in addition Organic gases and vapours with boiling point greater than 65oC;

inorganic gases and vapours and acid gases (A1B1E1) filters, should also be fitted at the air intake.

Paint spraying Plants etc. (Particulate filter P(SL) +Organic Vapour (OV) filters must be fitted at

the air intake.

Compressed Airline Feed Respirator and headtop must be worn when

Grit blasting.




Half mask respirators should be worn when

Stick welding (Particulate filter P(SL) It is recommended that in addition organic gases and

vapours with boiling point above 65oC; inorganic gases and vapours (A1B1) filters

should also be applied.

Paint spraying smaller items, short period, (Particulate filter P(SL) +Organic Vapour

Disposable particulate Respirators

Polishing surfaces with die grinder and flap wheels (Particulate filter P(SL))

De-burring / fettling equipment (Particulate filter P(SL))

Any other situation, not included in this list whereby a potential for respiratory damage from a

working process or procedure is present, should be assessed by the section Team Leader and or theHealth and Safety Manager. Appropriate protection commensurate with the level of risk assessed

should then be applied and this safety instruction amended.

5.3.8 Hearing Protection - The Noise at Work Regulations 1989 require hearing protection to be

provided where noise levels are between 85dB(A) and 90dB(A). Where noise levels are in excess

of 90dB(A) hearing protection becomes a mandatory requirement.

Noise level assessments have been carried out across the site and the results illustrate that when

production departments are in normal operation the background level of noise is in excess of

85dB(A). The company has made provision therefore for hearing protection to be available in all

production departments.

Fabrication Department, Quarry Plant Fitting Department and Quarry Plant Assembly

Departments results have indicated that the levels of exposure in these departments are in excess

of 90dB(A) in these departments therefore personal hearing protectors (Variphone) have been

offered to every employee. Being manufactured to suit an individual's ear canal these can be worn

for 8 hours per day with no discomfort and can be attenuated to match each individuals exposurelevels.

For those persons that have declined the offer of the above (Variphone) service a variety of styles

of hearing protection are available and the individuals selection must be worn every time they are

exposed to levels of noise in excess of 90dB(A)




Styles available:

Disposable foam Inserts - can be used alongside other PPE easy to use and provide levels of protection that can

exceed some earmuffs. Some come moulded for greater comfort. Must be disposed of after each wearing and new used each time. For effective operation the insert should be rolled between finger and thumb, the ear canal

should then be opened slightly by lifting the upper part of the ear, using the opposite hand the ear having the

insert applied to. The tightly rolled insert is then pushed into the ear canal and allowed to expand to create an

effective seal.

Corded inserts - a variety of types, foam, some with durable cleanable coatings for extended use, re-usable

moulded plastic. Any insert that is re-usable should be cleaned in a mild solution of soapy water at least eachday. This type of insert is fitted in the same way as described above.

Banded inserts - coated foam inserts and moulded plastic inserts, hang comfortably around the neck and ideal

for intermittent protection needs. To fit effectively the ear canal should be eased open slightly by lifting the

upper part of the ear using the opposite hand to which the ear protector is being applied. The plug or shaped

plastic pod should then be eased into the ear canal until a good seal is formed the ear should then be released.

Ear Muff - 3 basic styles Helmet Mounted, Overhead Band or NeckBand. For the muff to be effective a good

seal must be established between the soft outer part of the muff and the area of the head around the ear. Long

hair, beards and spectacles can impair the seal of the muff and thereby effect the physical performance of the protection. The earmuff should always be fitted in the vertical position as any other position will seriously

impaired as an effective seal will not be achieved.

When not in service all re-usable hearing protectors must be kept in a clean dry environment where they can be

protected from contaminants. Reusable equipment should be cleaned in a mild solution of soap and water, dried

off and then stored in a clean dry environment.

5.3.9 Head Protection - As a general rule head protection is not required in production or maintenanceareas at BL-Pegson. However when Plants are undergoing display or test programmes in the field

to the front of the site and stone or other material is being run through the machine Safety

Helmets must be worn by operators and onlookers.




Safety Helmets are a mandatory requirement for all BL-Pegson personnel when operating, testing, repairing or

adjusting Plant and Machinery at a quarry or demolition / recycling site.

Bump caps are available for all personnel and are recommended for use when working on Plants and Machines

in production and maintenance areas at the Mammoth Street Site.

5.3.10 Fall-arrest Protection - must be worn when working at heights where adequate provision for

guard-rails to prevent falls cannot be established.

Body Harness and attachment systems are available, that can be adjusted to fit the individual.

The attachment system must be connected to a reliable anchorage point. The vertical drop of theuser must be minimised to prevent collision with obstacles and the braking force injuring, tearing

or causing the operator to fall.

Inspections of the equipment must be carried out prior to use to check for wear and damage that

may cause the equipment to fail in operation.

The equipment should be examined every six months in accordance with the Lifting Operations

and Lifting Equipment Regulations 1998.

When not in service all fall arrest protection equipment and attachments must be kept in a clean dry environment

where they can be protected from contaminants. Reusable equipment should be cleaned in a mild solution of soap

and water, dried off and then stored in a clean dry environment.

5.3.11 Other Protective Equipment - Where BL-Pegson personnel are expected to attend quarrying or

other demolition / recycling sites mandatory requirements for Personal Protective Equipment are:

Hard hats / HelmetHearing Protectors

Eye Protection

Foot Protection

High Visibility coat or waistcoat

Respiratory Protection P(SL) strongly recommended




5.4 Disciplinary Procedure. Persistent failure by any employee to conform with the designated

requirements, for the use of personal protective equipment within any production, maintenance or

test area (as outlined in section 5.2 of this Safety Instruction), will result in the instigation of the

BL-Pegson Ltd progressive disciplinary procedures against him/her.

5.5 Requirement of Control Measures to keep all control measures in a clean condition. The

following is an extract from Regulation 9 of the Control of Substances Hazardous to Health

Regulations 2003.

(5) Every employer shall ensure that personal protective equipment, including protective clothing, is:

(a) properly stored in a well-defined place;

(b) checked at suitable intervals; and

(c) when discovered to be defective, repaired or replaced before further use.

(6) Personal protective equipment which may be contaminated by a substance hazardous to health

shall be removed on leaving the working area and kept apart from uncontaminated clothing and equipment.

(7) The employer shall ensure that the equipment referred to in paragraph (6) is subsequently

decontaminated and cleaned or, if necessary, destroyed.




Assembly procedure of Automax crusher,

Below is a table for checking

the bearing tolerances on the

three different sized machines,Machine Type

1000 1300 1500

Position Bore Dia O/dDia Bore Dia O/Dia Bore Dia O/Dia

Cone Head 160.00 290.00 200.00 360.00Radial 1-off 159.98 289.97 199.97 359.96

Cone Head 431.95 685.77 570.00 920.00

Tapper 1-off 431.90 685.70 569.95 919.90

Eccentric 160.00 290.00 200.00 360.00Radial 2-off 159.98 289.97 199.92 359.96

Eccentric 254.02 533.45 400.00 676.00

Tapper 1-off 254.00 533.40 399.96 675.93




Shaft clean down and checking of tolerances,

The first task is to wash all the preservative off the

main shaft with paraffin, then check that the

tolerances are within the limits shown on the check sheet below, you will require external micrometers.

Now fettle any burr that may be on the shaft.

Machine Type1000 1300 1500

Tolerance 160.04 - 160.07 200.03 - 200.00 220.03 - 220.00

199.97 - 199.99 300.75 - 300.72 310.03 - 310.00254.15 - 254.15 400.09 - 400.06 410.11 - 410.07

E t i l d d




Eccentric clean down and

checking of tolerances,

Wash the eccentric down with the use of paraffin to remove

all the preservatives from the casting. Check the tolerances

according to the table provided below. You will require

external micrometers and the use of a internal micrometer

for this. Now fettle any burrs that may be on the casting

1000 1300 1500 1000 1300 1500

Lower Inner 533.33 675.91 719.91 Lower Outer 289.93 570.01 660.23

Locating Bore 533.26 675.86 719.86 Locating Dia 289.99 570.04 660.15

Upper Inner 431.97 359.97 399.97 Upper Outer 160.03 200.03 220.03

Locating Bore 432.01 359.94 399.94 Locating Dia 160.05 200.01 220.01

Cone head clean down and




Cone head clean down and

checking of tolerances,

Wash all the preservative off the

cone head with the use of

paraffin and then check all thetolerances according to the check

sheet provided. You will require

a internal micrometer for this.

Now fettle off any burrs that may

be on the casting.

Machine Type

1000 1300 1500 1000 1300 1500

Lower Inner 685.61 919.90 969.90 Upper Inner 289.91 359.97 399.97

Locating Bore 685.53 919.84 969.85 Location Bore 289.96 359.94 399.94




Counter shaft assembly,

First clean the counter

shaft down with paraffin

and de-burr with the use of a file,

Fit the bearing

locking nut onto the

shaft making sure of

a good fit and so youcan lift the shaft as

shown to the right.

Bearing locking nut

Lift with the

use of a strap

Counter shaft

File the shaft down all over




Now the shaft has beencleaned and de-burred it

can be lowered into the

spur gear this should be a

slide fit now the ringfeder

can be put in place and

torque to a setting shown

in the table hex socket.

Tighten this ringfeder diametrically opposite

Drop the counter

shaft down into the

spur gear as shown

Machine Type Torque

1000 70 N/M

1300 125 N/M1500 125 N/M




Now the counter shafthousing can be cleaned

down, fettled, the

tolerances checked and

painted, ready for one half

of the bearings to be fitted.Ensure that all the holes and

tapped holes are free from any

contaminates by blowing outwith a air line.

Making sure that all the locating

faces are clean and de-burred




The bearing locating faces can now be checked with

the use of a internal micrometer. Then one half of the

bearing can be fitted into the counter shaft housing.

Check this tolerance

on both sides

Machine Type Tolerance1000 161.90 - 161.87

1300 212.70 - 212.68

1500 N/A

This is achieved with the use of I iti ll t i




This is achieved with the use of

a soft metal bar and hammer.

Making sure that it’s entering

into the housing square. Once in

place check that the bearing hasseated by running a feeler blade

between the bearing and the

housing.

First enter the bearing about

10mm into the housing making

sure that it’s square, then tap the

rest of the way in.

Initially tap in

about 10mm

Now turn over and tap the

bearing in the other side




Now the other half of the bearings can be heated up

and fitted to the counter

shaft. By means of a

induction heater or by

submersing in a oil bath

to a temperature of 110 to

140 degrees centigrade.Making sure that you are

wearing heat resistant

gloves. The first half you

must fit is the bearinglocating on the spur gear

as shown on the right.

Induction heater

Ensure that the bearing

is sitting down on the

spur gear

Lift the counter shaft housing




Lift the counter shaft housing

with the use of a pair of twolegged chains and a over head

crane. Then lower onto the shaft

assembly. Now the other half

bearing can be heated up and

lowered into place. Whilst the

bearings are still hot and not set,

screw down the bearing lockingnut with the use of a C-spanner

and tighten up to take the

clearance out of the bearing.

Leave to cool down then check the drag by turn the counter shaft

housing. If too free tighten more.

Lower the counter shaft housing

slowly on to the shaft assembly

Tighten up the bearing

locking nut clockwise




Now tighten the three grub screws around the

bearing lock nut using a 5mm hex socket and

torque wrench “7471 Activator and 245 thread

loctite” to a torque shown in the table below.

Bearing lock nutGrub screw

Machine Type Torque1000 35N/M

1300 35N/M

1500 35N/M




The oil guard can be

cleaned and any burrs

fettled off. The oil seal

can be tapped in with asoft mallet making sure

that its entering square.

Before fitting onto the

counter shaft assemblyrun a bead of flange

sealant loctite around

the locating face on the

oil guard as shown.

Oil seal inserted

in the oil guard.

Bead of flange sealant



Advanced Crushing Technology 77 Advanced Crusher Advanced Crusher Advanced Crusher

Insert the four HEX bolts along

with spring washers and tighten

with the aid of a spanner.

Oil guard sitting tightly down

on the counter shaft assembly

Eccentric Assembly, Insert two eye bolts

and suitable shackles




Fitting of lifting plate,

The lifting plate must

be fitted onto the top of

the eccentric and bolted to it using four cap

screws. You must now

turn the eccentric over

by the method shownopposite. This is now

ready for fitting the

internal bearings.

The eccentric is now

in position ready for

fitting the bearings

into the lifting plate

Lower onto a

block long with

a wooded packer

Lower onto the lifting plateand remove the eye bolts

Fit two eye bolts into

the face of the eccentricas shown here and lift

into position for fitting

the bearings






The eccentric must first be heated

up to above 110ºC with the use of

a propane heater. Once up to

temperature the two halves of the

parallel bearings can be lowered

into place. Insuring that the

bearing I.D. numbers are facingyou and that the bearings are

fully down. Care must be taken

as the eccentric will be very HOT

and there is a risk of burning. TheCirclip can now be but into place.

Using a pair of Circlip pliers.

Lower slowly into place ensuring

that the bearing is kept square

Use Circlip pliers

to fit the Circlip

into place



Insert eye




Once the bearings are in and are set the eccentric must be

turned over. The best way of

doing this is to insert two eye

bolts and two suitable shacklethen lift and lower as shown

here onto a piece of wood as

not to damage the eccentric.

Once down remove the eye

bolts and place them into the

lifting plate and lift on to a

block of wood so the eccentric

isn’t damaged. Ready for

lifting onto the bevel gear.

bolts here

Lower on to

wooded blocks

Fitting of bevel gear,




g g ,

First clean down the

bevel gear with

paraffin. Now fettleany burrs that may be

on the gear then blow

all tapped and oil

lubricant hole out.Ensuring that they are

free from any

contaminates.

Oil lubrication hole

Bevel gear

The keys can now be fitted intoCap screw down and




y

the eccentric and tried in the

bevel gear. You may have to

file these keys to fit. Once

fitted tighten down with a Capscrew to the required torque.

Ensure of a slide fit

into the bevel gear.

tightened into place.

File to size ensuring that

the key is kept square.

The eccentric can now be




lowered on to the bevel gear.This must be lowered on

square making sure there is

no dirt between the eccentric

and the bevel gear. Put in

place the 6 Cap screws

making sure to use thread

loctite. You will need a Hexsocket and torque wrench.

Once tightened down check

the clearance between the

eccentric and the bevel gear,this should be no greater than

*** mm.

Sitting fully down

Check around here

with feeler blades

Lower slowly into position

Fitting of outer bearing,




The taper roller bearing must

first be heated up with the use

of a induction heater, or by

submersing in a clean oil bathand then heating up. Lift the

bearing with the use of a over

head crane and three special

lifting hooks. If no liftinghooks are available use hooks

on the chains. The ideal

temperature for the bearing is

between 130 - 140 degreescentigrade. Ensure that the

bearing is fully down.

Induction heater

Special lifting

hooks




The small parallel bearing race

can now be heated up using a

induction heat or by

submersing into a clean oil bath and heating up. The ideal

temperature for this is between

120-140 degrees centigrade.

Make sure when fitting that

appropriate heat resistance

protection is being worn. Then

hold firmly down with a soft

metal bar until set.

Hold down on top of the bearing

until fully set with a soft metal bar.

Fitting of the balance ring,

Fi h b l i b k d




First the balance ring must be marked where the thickness of the ring is the

greatest, this is normal marked during

machining. You must also make a

mark on the eccentric were the balance ring will line up with.

Making sure that the eccentric is cool

before fitting the balance ring. Start

by lifting the balance ring with two

suitable eyebolts, two suitable

shackles and a overhead crane. Now

heat the balance ring up using a propane heat gun up to 110ºC. Once

up to temperature lower the balance

ring into position.

Thickest part highlighted

here by a black mark

Mark a line from

the low point to

the top. For

locating the

balance ring.

Line up

position.

Once fully set and cool the

b l i h




balance ring must have alocking pin inserted in

between the eccentric and the

balance ring. You will need to

drill in between the balance

ring and the eccentric. Then

insert the locking pin into the

hole. The locking pin must befully inserted.

Locking pin insert into

place and flush withthe balance ring.

Balance ring in place and fully

down against the eccentric.

Note: The 1000 cone

doesn’t have a balance ring.

The 1500 has a balance ring

and is fitted in the same

manner as described above.

Fitting of seal ring,

Fi t th l i t h fi




First the seal ring must have fivestuds inserted into the bottom of it.

for doing this you will require two

plain HEX nuts and a appropriate

spanner. The seal ring can now belifted using a set of four legged

lifting chains and a overhead crane.

one of the lifting chains will have to

be shortened by about 200mm, this

shorter chain must be fitted to the

side of the seal ring without the

balance ring on. Thus allowing aangled lift for easy of fitting. The

seal ring will only fit in one

location on the eccentric.

Insert the five studs

fully into the seal ring

As you can see

the seal ring

must be lifted at

this angle to fit

over the bearing

Locate downand turn into

position




This may require tapping

down slightly with the aid of a

mallet. Once the studs are

through the eccentric thehardened washers and plain

nuts can be fitted and used to

draw the seal ring down,

ensuring that the seal ring is

locating flush on the eccentric.

It can now be torqued.

Making sure there are no gapsunder the seal ring.

Machine Type Torque

1000 180 N/M

1300 350 N/M

1500

Once the seal ring is down

against the eccentric the




against the eccentric therelationship between the

eccentric and the seal ring must

be checked. With a straight

edge positioned on top of the

eccentric measure to the top of

the seal ring in four different

places. Once the checks have been done and noted the Tufnol

strips can be inserted. These

will require cutting to size.

Making sure that the smoothsurface is facing towards the

outer of the labyrinth groove.

473.7- 474.7

Tufnol strips inserted in

the labyrinth grooves.

Machine Type Tolerance

1000 362.10 - 363.10

1300 473.70 - 474.70

1500 N/A

Cone head assembly,

Fitting of the bearing




Before starting to fit the bearings

the cone head must be lifted off

the ground and onto some steel

packers as shown here. To fit the bearings the cone head must first

be free from any contamination

and then heated to above 100

degrees centigrade using a propane

heat gun. Once up to temperature

the parallel bearing can be lowered

into place taking care as thesurface of the cone head will be

extremely hot.

Lift the cone head on to the steel

packers with the using of a

overhead crane along with three

suitable eye bolts and shackles.

Heating the cone

head up with a

propane heater

Once the bearing is securely into

place and fully into position the




place and fully into position theCirclip can be fitted into place

with the use of Circlip pliers. The

large taper roller bearing must

now be lifted ready for installationwith the aid of two special lifting

arms, a spreader bar and lifted

with the aid of a overhead crane

with suitable shackles. Now heat

the cone head up again around

were the bearing locates to above

100 degrees centigrade. Thenlower the bearing slowly into

place, once located hold down

until set with a soft metal bar.Special lifting arms

Spreader bar

Circlip beinginserted with pliers

Before the oil flinger can

Tap into the cone head

in the places shown




Before the oil flinger can be fitted into the cone

head the O-ring must be

inserted into the groove.

Now the oil flinger can

be lowered into place,

this may require tapping

with a plastic mallet asthe O-ring will cause a

tight oil seal fit into the

cone head. Once down

the snap ring can be putinto place.

Insure that the oil flinger

is tapped in square

Snap ring

inserted here

Turning over of the

cone head assembly




cone head assembly

Once the oil flinger is in

the cone head the mantle

nut may be screwed on inthe manner shown. By

lifting the cone head with

three eye bolts and suitable

shackles. Remember thatthe nut is a left-hand

thread. You can now turn

over the cone head in the

manner shown here.

Insert two eye bolts

into the cone head

Ensure that the crane

and chains being used

are adequate for the job

Fitting of the mantle




Now that the bearings and oil

flinger are in place you must

smear Pegbak release agent

(2144-0002) around the conehead as shown here. You must

now check the mantle for any

burrs around or on the

locating taper, if there are any

then grind off using a grinder.

The mantle can now be

lowered onto the cone head slowly ensuring not to damage

the threads on the cone head.Smear the release agent

around here and remove any

that gets on the locating taper

Lift the mantle

with the aid of a

overhead crane

Lower slowly

into place

Now that the mantle is in

place and locating properly




place and locating properlyon the cone head the burning

ring can be but into place.

The threads on the cone head

must now have a light smear

of anti seize compound

applied. The mantle nut can

now be fitted and screwed down onto the burning ring

(remember that this is a left

hand thread). The mantle nut

plug can now be inserted thewrong way up into the mantle

nut as shown here.

Apply anti

seize compound

around the

threads here

Plug

inserted

here

The mantle nut must now be




The mantle nut must now betightened up using a sledding bar

and a sledge hammer (remember

that this is a left hand thread). Once

tightened you must then undo the

mantle nut and remove along with

the burning ring. The is so you can

pour in the Pegbak compound,which must be mixed firsts with

the activator. Once filled 1″ below

the top of the mantle the burning

ring and the mantle nut can befitted back on and tightened up.

Sledding bar inserted into

place ready for tightening

The Pegbak will require mixing with

hardening agent and then poured in

between the mantle and cone head.




Once the manganese has

been fitted to the cone head

the two lifting holes in the

bottom must be welded up.To do this you will require a

copper plate and a G-clamp.

Clamp the copper plate to the

inside of the cone head and

then weld the holes up.

These will require grinding

flush once fully welded up.

Weld these lifting

holes completely up.

Retaining clamp

Copper plate

Mainframe assembly

Welding of the liner plates




The liner plates must

now be welded into the

mainframe. Lift into place by hand and then

using a spreading bar

press the plate up against

the mainframe and thentack into place along

with the other two plates.

Once all are tacked in

place they can be

completely welded up.

First tack the

plates in place.

Plates full

welded in place

Insert a spreader

bar as shown here

to hold the plate

firmly against themainframe

Arm shield fitting

The three arm shields can now be fitted into place and




The three arm shields can now be fitted into place and

the counter shaft protecting shield put in place and the

anti movement key welded in place. These may

require tapping into place with the use of a steel bar.

Anti movement key

welded into place

onto the mainframe.

Arm shield in

place, located

down onto the arm

Fitting of the main shaft into the mainframe

Ensuring that the mainframe boresare clean and free from anyLower slowly down into the




gare clean and free from any

contamination. The main shaft can

be fitted, first the shaft must be

shrunk in a vat of liquid nitrogenand left to become the same

temperature as the nitrogen.

Which is -196 degrees centigrade.

You can also tell that thetemperature is the same when the

nitrogen stops boiling around the

shaft. The shaft diameters must be

checked when returned to normal

temperature as shown on the check

sheets.

When handling the liquid nitrogen you

must wear adequate safety equipment.

When handling the shaft take care as

bare skin will stick to it so thermal

protective gloves must be used.

mainframe and insure that the

shaft is fully located down.

Once the shaft has returned back

to normal temperature, the stub

Heating of the

shafts with a propane heat gun




pshaft can be inserted into the

main shaft. Now the two shafts

can heat up using a propane heat

gun to a temperature above 100

degrees centigrade. Then the two

shafts can be welded together

using dissimilar metal weldingrods. The shafts must then

quickly be covered with

heat/flame retarded cover, this is

done so that the shafts doesn’tcool down too fast as this would

crack the weld.Once welded in place the weld

must be cleaned of any splatter

p p g

Fitting of the bearing to the main shaft

Once the shaft has cooled down the




Once the shaft has cooled down the

main shaft spacer can be fitted into

place making sure that it is fully

down before fitting the bearings.Firstly fit the main taper roller

bearing, this must be heated up to

130-140 degrees centigrade with

the use of a bearing inductionheater. Then lower slowly into

place using a overhead crane and

three special lifting hooks. When in

place on the mainframe and main

shaft hold down with a soft metal

bar until set.

The two parallel bearings can

now be fitted to the main shaft.These bearings must be heated

Fit the two parallel

bearings one at a time

ensuring that they arelocated securely down




These bearings must be heated

up with the use of a induction

heater to a temperature of 130 -

140 degrees centigrade and thenlifted into place one at a time

using heat resistant gloves.

Once both bearings are in place

hold down with a soft metal bar

until the bearings set into place.

y

Hold the bearings in

place until they set

The bearing clamp

can now be fitted and held in place with 4

HEX bolts and 4

suitable tab washers.

Make sure that the counter shaft

bore is free from anycontamination prier to installing

Fitting the counter shaft

assembly,




contamination prier to installing

of the counter shaft assembly,

then apply a layer of anti seize

compound on the two locatingfaces within the mainframe. The

counter shaft housing assembly

can now be installed into the

mainframe. You must start bylowering the counter shaft onto

its side, taking care not to

damage any of the locating faces.

Now using either a chain or a

lifting sling, lift the counter shaft

assembly square as shown here.The lifting point is about

here for a square lift.

Apply the anti seize to these faces

Insure that the lubricationinlet is facing upwards

Once partly inserted the assembly

will need a new lifting point asshown here through the bolting




shown here through the bolting

holes. Then lift the assembly so

that it is square with the

mainframe, then insert two lengthsof threaded bar along with two

HEX plain nuts. These are used for

pulling the assembly into the

mainframe. Start to draw theassembly in slowly using a 36mm

spanner insure that it is entering

into the mainframe square. Take

the assembly in until the two

locating faces are about 40mm

away from each other.

Use two small lifting hooks for

this second lift

Always insure that the

assembly is entering

the mainframe square

Fitting of the dust seal,




The dust seal can now

be hammered into themainframe. Making sure

that the seal is tapped

firmly into the groove. If

the dust seal isn’t fully

into the mainframe the

upper frame will not be

able to fit down fully.

Use a hammer and

protective gloves when

handling the dust seal.

Dust seal fully

inserted into themainframe

As you can see from the

photograph the gear hast d i t iti




entered into position.

Before fitting the eccentric

assembly ensure that the

Tufnol strips are inserted in

the grooves on the

mainframe. Ensuring that

the shine face of the Tufnolstrips are facing outwards

of the groove walls. The

eccentric must be lifted

using the lifting plate alongwith the two eye bolts and

two suitable shackles.

Ensure that the correct lifting points on the plate are being used.

The gear has entered

into position.

Fitting of the eccentric assembly

The eccentric can now be lifted ontothe main shaft. The eccentric must be




lifted using the offset lifting holes on

the lifting plate. This is so that the

eccentric is lifted square. Whenlowering down you will need to look

down into the eccentric so you can

line the eccentric up properly and

turn slowly so that the gears start tomesh. Making sure that the stub shaft

remains in the centre when lowering

down. You will know the eccentric is

fully down when you can see the

location place for the oil flinger is in

line with the lifting plate.

Slowly lower the eccentric into

place, always looking down

into the eccentric to ensure that

the stub shaft remains in sight.

Make sure that the stub shaft oil

flinger location place is in line

with the top of the lifting plate

Fitting of the cone head assembly

Before the cone head can be lowered into

place the oil flinger and rubber O-ring must




be fitted onto the stub shaft. The cone head

must now be lifted with the correct lifting

plate attached, as this lifts the cone head up atthe correct angle for lowering onto the

eccentric. There will be a high side and a low

side to this lift, this is defined by the off

centre lifting plate. Mark on the manganesewhere the low side is. Now you must find the

low side of the eccentric, this is in the centre

of where the lead weight is inserted into the

seal ring. When lowering the cone head you

must line these two low points up with each

other, otherwise the cone head will not fit.

Have the low sidetowards the front

Low side

Mark the

low side

With the cone head in the air

connect the piston ring along withthe O-ring Now slowly lower the

Piston ring and

O-ring in place




the O-ring. Now slowly lower the

cone head down on to the

eccentric making sure that the

piston ring slots in between the

seal ring on the eccentric. You will

know when the cone head is fully

down because it will make athump sound. Another way of

testing if the cone head is down is

to hold the cone head and turn the

pulley the cone head shouldn’tturn around just wobble due to the

eccentric throw.

The low sides

are here.

Keep the low sidetogether until the

cone head is

completely down

Oil flinger

You can now fit the pulley onto

the counter shaft. First start byinserting the taper lock bush

Pulley in place

th h ft




inserting the taper lock bush

into the pulley along with the

four cap head bolts. Now insert

a wedge into the taper lock

bush. Insert the key into the

shaft. The pulley can now be

lifted with the aid of a crane.Slide the pulley onto the shaft

and position the taper lock bush

end so it is about flush with the

end of the shaft. The torquesettings for the bolts are in the

table opposite.

M achine Type Torque Setting

1000 CONE 190 N/M

1300 CONE 270 N/M

1500 CONE N/A

Make sure that the pulley

is flush as shown here.

on the shaft



Testing procedure,

Once the pulley has been fitted thecone must be tested this will

On this test rig the cone is

being run by a electric motor




involve mounting the cone onto a

test rig and connecting a lubrication

system to it. The pulley must also be connected to a motor with V-

belts. The test consists of a 5 hour

running test starting by lashing the

head down with a special antirotation plate along with shackles

and a rope for FOUR hours. Then a

ONE hour test unlashed. After the

test you must check around the

mainframe against the liner plates

for any signs of leaks.

The crusher is

then connected to this oil tank

The machine is

lowered onto

this live frame.

The dumpy jack cylindersand spacer can now be fitted

Dumpy jacks,




p

around the mainframe along

with the hydraulic pipes as

shown. Apart from betweenthe two cylinders at the rear

of the mainframe as these

have a T-piece inserted.

Connect all these pipes

loosely at first. Where the T-

piece is located at the rear of

the mainframe will require ahole burning through it

about 45mm ∅.

3/8 female T-piece

fitted in place.

This hole should be

about at the rear of

the mainframe

Wedge ring assembly and fitting,

The glue kit comprises of glue and activator. The glue is applied to the

d d h i i li d

Glue kit



Advanced Crushing Technology117

pads and the activator is applied to

the wedge ring. Before applying the

glue, dust the pads down. Beforeapplying the activator, make sure

that the wedge ring is free from

contamination. The wedge ring can

be placed into the hydraulic jig.Start from the cut out in the wedge

ring and slide the pads in between

the jig and the wedge ring and then

apply pressure with the jig. This

will take approximately 20 minutes

to cure.

Glue beingapplied

Activator being applied

Hydraulic jigwith wedge

ring in place

Once the pads have set onto the

wedge ring it can be screwed downonto the mainframe. Start by

d ti d th i f d




dusting down the mainframe and

the wedge ring, then apply a lay of

Molly Benton grease to the threadson the mainframe. lift the wedge

ring up using four suitable eye

bolts with suitable shackles, a set

of four legged chains and aoverhead crane. Then lower slowly

onto the mainframe turning slowly

clockwise. Always ensuring that

the threads don’t cross thread.

Screw down the wedge ring hard

onto the dumpy jack circuit.

Make sure that the wedge ring isfully down as shown here

Screw the wedge

ring down clockwise

The anti rotation post

Apply approximately a10mm fillet weld all

th d h





must now be welded

into place as in the picture here up

against the left hand

side. Using low

hydrogen weldingrods. The reason for

this is to stop the

wedge ring rotating.


is hard up against the

left side of the wedge

ring as shown here.

the way around here.

Apply approximately a

20mm fillet all the way

around the post.

Assembly of the upper frame,




The concave manganese must be

placed onto steel stools as shown

here approximately 400mmhigh. Now the anti rust

preservative must be removed

from the manganese with the aid

of a scrape. Check around the

locating face of the manganese

for any burrs, Remove if there

are any.

All this preservative must be

removed from the locating

face and all burrs removed.

The upper frame must now be

lifted up with the use of a 10

Lifting points




lifted up with the use of a 10

ton crane and three suitable

shackles. Then clean and fettle. Once clean you must

then smear release agent

around the upper frame as

shown in the picture to theright. Once the release agent

is applied the upper frame can

be slowly lowered down onto

the concave.

Smear release agent around this face on the mainframe.

Check this locating

face for any burrs

around here.

Once down past the lugs turn the upper

frame anticlockwise and then lower

fully down The wedges must now be




fully down. The wedges must now be

tried in place. If the wedges slide in

easily then the upper frame must belifted and rotated around until the wedge

covers the dowel hole once this is the

same for all the wedges they may be

tightened up using a T-bar and a sledgehammer. These must be a very tight fit.

Once all the wedges are tight the dowel

can be inserted, ensuring that the dowels

have anti rust compound on them. (This job will require two people).

Make sure that the wedge is

tight under the lug and the end

of the wedge is approximately

where the red line is on the

above photograph.




When locating the concave

make sure that there is a

even gap like this all the

way around.

Once the cylinder have been

fitted the anti rotation plate

can be assembled. Start by




can be assembled. Start by

inserting the pads into the

blocks using a counter sunk bolt and a suitable Allen

key. Now slide the blocks

into the anti rotation post

and tighten up using aspanner. The anti rotation

post can now be fitted onto

the mainframe then insert

the retaining bolts and tighten using two spanners.

Ensure that the anti rotation

post is free from any burrs.

This is one of the

pad assembles

Plate in position ready

for tightening

You must now smear MollyBenton grease all the way

around the wedge ring and




around the wedge ring and

around the dust seal on the

mainframe. The upper framecan now be slowly lowered

onto the mainframe making

sure that the anti rotation post

on the upper frame is located in between the anti rotation

bracket on the mainframe.

Also make sure that the upper

frame is locating onto the

wedge ring square.

Apply grease to thisslide faces here.

The upper frame should be

a slide fit into the bracket

Fitting of the hydraulic

cylinders,The bearings must be placed into

the mainframe with the use of a

soft hammer and loctite (bearing




soft hammer and loctite (bearing

fit). Make sure that the bearing has

the split in the side facing towardsthe out side and it is entered in

square. The hydraulic cylinders

must now have the locating pins

tried through the location holes.These holes may require slightly

buffing with emery cloth as these

pins must be a slide fit. Once the

pins have been tried in the top and

bottom of all the cylinder.

Make sure the pins are a

slide fit through the cylinder.

The cylinders can now be lifted

one at a time with the use of a




one at a time with the use of a

crane and strap. When fitting

make sure that the two washersare inserted between the

cylinder arms and the

mainframe. You must use a anti

seize compound on the pin. The

pin will require tapping in with

a soft hammer.

Insure that the two

washers are insert here

Smear anti seize compound

around the bearing and the pin.

Once the upper frame is

located down onto the

mainframe the crane can be

removed from the upper




pp

frame and the cylinders

piped up as shown here.Once piped up the cylinders

must be primed with the aid

of a hydraulic power unit to

prime the hydraulic pipes.This is done to remove air

from the system and check

for leaks. With a hydraulic

power unit connected move

the cylinders up and down

several times.Hydraulic

cylinder relief

The bearing can now be

inserted into the upper




inserted into the upper

frame. Clean the bearing

location holes and thensmear loctite bearing fit

around the bearings.

Making sure that the split

in the bearing is facingtowards you tap in using a

soft hammer until it

reaches the shoulder.Make sure thegrease nipples are

tightly in place.

Make sure that the

bearing is fully upto the shoulder.

The cylinders can now be connected

to the upper frame to do this thehydraulic power unit must be used.

Start by taking the cylinders down




Start by taking the cylinders down

and then take the cylinders up one at

a time. Now fit the locating pinsalong with the two washers in each

cylinder. Making sure that you use a

anti seize compound on the pins and

in the bearings. Always tap the pin in

from right to left. This is done so that

the bearing isn’t knocked out when

fitting the pins. Once all the cylindersare on fit the other washers and cotter

pins on all the pins.

The VRVT and mounting pot can

now be fitted. This will require

drilling and tapping one hole for

h i h f




the VRVT into the upper frame

and four holes into the

mainframe four the mounting

pot. To do this you will require a

Power drill, several drill piece,

taps and a tap wrench. On the1000 cone the rod will need to

have it fixing hole drilled into the

middle rib on the mainframe. On

the 1300 the fixing hole will need to be drilled into the bottom rib.

Here is the VRVT retaining bolt

secured to the upperframe

VRVT mounting pot in place

and fixed to the mainframe

Cone Build Manual Manutenção

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