FORM NO. 91126 Rev.

5/07

UNITED CONVEYOR CORPORATION

INSTALLATION, OPERATION & MAINTENANCE INSTRUCTIONS 33 x 30 EXCEN-CRUSHER SOLIDS REDUCER

2007 UNITED CONVEYOR CORPORATION ALL RIGHTS RESERVED

Table of Contents
Section Page I. SAFETY PRECAUTIONS....................1 1-1. Safety Precautions .........................1 1-2. Lockout Procedure .........................2 II. GENERAL INFORMATION .................3 2-1. Scope .............................................3 2-2. Equipment Description ...................3 A. Features ......................................3 B. Principle of Operation..................3 C. Specifications ..............................5 III. INSTALLATION...................................7 3-1. Inspection.......................................7 3-2. Wet Application Installation ............7 3-3. Dry Application Installation.............7 3-4. Electrical Connections....................8 3-5. Equipment Protection.....................8 IV. START UP ...........................................9 4-1. Pre-start Checkout .........................9 4-2. Operational Check .........................9 4-3. Operation .......................................9 A. Wet Application ...........................9 B. Dry Application ............................9 V. OPERATION AND CONTROLS ..........11 5-1. Operator Controls and Indicators ...11 5-2. Automatic Reversing & Crusher Failure Sensing .............................12 5-3. Operating Procedure......................13 A. Running the Crusher With an Automatic Control System...........13 B. Running the Crusher Manually (No Automatic Control System)...13 VI. MAINTENANCE AND SERVICE .........15 6-1. Regular Inspection and Service .....15 6-2. Lubrication......................................16 6-3. Troubleshooting .............................17 6-4. Replacement & Adjustment Procedure.......................................18 A. Roller Chain ................................18 B. Drive Sprocket.............................19 C. Bearing and Packing Assembly...20 D. Cam Assembly ............................22 E. Anvil Plate ...................................25 F. Combing Plate.............................26 Section Page G. Crusher Shaft & Cam Support .... 27 H. Drive Assembly ........................... 29 H-1. Electric Motor ........................ 29 H-2. Flexible Coupling................... 31 H-3. Gear Reducer........................ 32 VII. RECOMMENDED SPARE PARTS ..... 34 List of Illustrations Figure 1-1. 2-1. 5-1. 5-2. 6-1. 6-2. 6-3. 6-4. 6-5. 6-6. 6-7. 6-8. 6-9. 6-10. 6-11. 6-12. 6-13. 6-14. 6-15. 6-16. Page

Suggested Procedure for Blocking Isolation Door Close....................... 2 33" x 30" Crusher (Top View) .......... 4 Crusher Local Control Panel ........... 11 Automatic Reversing Controller....... 12 Lubrication Points............................ 16 Chain Tension ................................. 18 Sprocket Mounting Arrangement..... 19 Sprocket Alignment ......................... 20 Packing Orientation ......................... 21 Bearing and Packing Assembly....... 22 Installation of Wave Springs and Spacers .................................... 23 Front Drive Mounting Arrangement . 24 Rear Drive Mounting Arrangement.. 24 Cam and Cam Support.................... 25 Nuttal Drive...................................... 30 Link-Belt Drive ................................. 30 Proper Lifting Arrangement ............. 31 Flexible Coupling............................. 31 Flange Alignment ............................ 32 Drive Mounting Arrangement .......... 33 List of Tables

Table 2-1. 5-1. 6-1. 6-2. 6-3. 7-1.

Page

Crusher Specifications ...................... 5 Local Control Panel .......................... 11 Inspection and Service ..................... 15 Lubrication ........................................ 16 Troubleshooting ................................ 17 Recommended Spare Parts.............. 34

ii

SECTION I SAFETY PRECAUTIONS

1-1. Safety Precautions Personnel involved with this equipment must be familiar with plant safety and equipment operating procedures and must be alert for unsafe conditions or potential hazards at all times. The following precautions must be followed to avoid personal injury or equipment damage. Do not remove shipping skid until ready to place crusher into position. The electric motor, adaptor and reducer are very heavy. To prevent personal injury or damage to equipment, these components must be adequately supported before mounting bolts are loosened and removed. Equipment must be installed and operated according to drawings and instructions. Any changes must have the prior written approval of United Conveyor Corporation or UC Service Corporation. All electrical connections must comply with state and local codes. Verify that electrical power inputs conform to crusher voltage specifications before energizing unit. The gear reducer is shipped from the factory without oil. Before operating crusher, fill reducer with oil to proper level. (Ref. Section 4-1) Before attempting to remove, repair, visually inspect or do any work on the crusher: 1. The conveying system controller circuit breaker must be turned OFF and a safety lockout must be placed on the circuit breaker. Tag the breaker with a sign warning that the equipment is under repair and not to be operated. 2. Block closed any isolation doors between the storage vessel and the crusher and electrically isolate and tag the isolation door controls. (Ref. Section 1-2) 3. The power to the crusher control panel and the crusher motor must be turned OFF and a safety lockout must be placed on the circuit breaker. Tag the breaker with a sign warning that the equipment is under repair and not to be operated. Never operate crusher without chain guard. Do not overtighten the roller chain as this will cause rapid wear of parts. Exercise caution when removing electric motor from gear reducer, to avoid damaging flexible sleeve. When removing cams, combing plates, shaft, etc., use extreme caution to avoid dropping into the crusher body. See "Systems and Equipment Safety Instructions," UCC #721005 for further safety information. The above safety precautions must be followed in addition to precautions established by individual plant safety programs.

1-2. Lockout Procedure The following lockout procedure must be followed before installing, inspecting or repairing a crusher. 1. Shut down the conveying system. Turn off the circuit breaker that supplies power to the conveying system controls. Install a safety lockout on the circuit breaker and tag the breaker with a sign warning that the system is under repair and is not to be operated. 2. Turn off the circuit breaker that supplies power to the crusher. Install a safety lockout on the circuit breaker and tag the breaker with a sign warning that the equipment is under repair and is not to be operated.

3. Any isolation doors between the storage vessel and the crusher are to be mechanically blocked in the closed position and electrically isolated. The door controls are to be tagged with a sign warning that the equipment is not to be operated. Suggested Procedure for Blocking the Isolation Door Closed A pneumatically driven isolation door can be blocked closed by installing four isolation valves, as shown in Figure 1-1. During normal operation, valves 1 and 3 should be open and valves 2 and 4 should be closed. When electrically isolating the door, first close valves 1 and 3, then open valves 2 and 4.

Figure 1-1.

Suggested Procedure for Blocking the Isolation Door Closed

SECTION II GENERAL INFORMATION

2-1. Scope This manual describes the 33" x 30" EXCEN-CRUSHER (P/N 5-2103-124) solids reducer manufactured by United Conveyor Corporation, Waukegan, Illinois. Included are instructions for its installation, operation, lubrication, adjustment, troubleshooting, and repair within the scope of typical maintenance personnel. By following the guidelines and recommendations contained herein, you should receive many years of safe, dependable service from the crusher. Keep the manual in a convenient location for ready reference by operating and maintenance personnel. 2-2. Equipment Description 2-2-A. Features The 33" x 30" crusher incorporates a host of design features that provide efficient operation and minimize the need for maintenance. Some major features of the crusher are: Durable Cam Curved DURITE H Anvil Plate Anti-kickback Anvil Plate Corrosion-resistant Internal Components Two-Piece Bearing Housing Spring-loaded Shaft Seal Elastomer Seal Bolt-on Packing Follower Spring Loaded Grease Feeder Locked Shaft Design For additional information on the features and benefits of the crusher, refer to Product Information Marketing Bulletin: #93-10, "33" x 30" EXCEN-CRUSHER Unit From UCC." 2-2-B. Principle of Operation The 33" x 30" crusher (Figure 2-1) is designed to handle the broadest possible range of friable materials. As material is discharged from the hopper, the rotating cam teeth shear and split chunks of material against an anvil plate. The curved anvil plate acts to produce perpendicular forces at all angles of contact between the cams, material and plate. The crushed material then drops through the crusher into a receptacle or conveying line. As the cams rotate and mesh with the combing plate, crushed ash is efficiently cleared from the cams. Typical applications for the crusher include ash, concrete blocks or chunks, glass, hard clay, and many other friable materials. Crushing can be accomplished either wet or dry. A stainless steel body and shaft can be specified for use with highly corrosive slurries.

Figure 2-1.

33" x 30" Crusher (Top View)

2-3-C. Specifications Table 2-1 shows specification and performance characteristics of the 33" x 30" crusher. ITEM Rotor Construction SPECIFICATION 8 DURITE H cams (600-700 BHN) cast, mounted on a cam support, which is available in mild or stainless steel. Wet: Up to 200F Dry: Up to 800F Wet: DURITE H, Cast Dry: AR 500 DURITE H, Cast

Process Temperature: Anvil Plates Combing Plates,Side Wear Plates, & Bearing Housing Nosepiece Drive Assembly:

Operating Speed: Pressure: Material Input Size: Material Output Size: Vertical Headroom: Inlet Flange: Outlet Flange: Weight: Capacity Range:

10 hp, 230/460 or 575 volt, 3-phase, 60 Hz motor, flexible sleeve coupling and gear reducer unit. May be mounted directly to the crusher body or pedestal mounted. 16.2 rpm Wet: Up to 20 psi Dry: 1 psi 4" x 9" x 20" maximum 2" maximum 21-1/2" (Crusher body) 33" x 30" (Inside dimension) 18" x 30" (Inside dimension) Approximately 3,600 lbs Bottom Ash (from water impounded hopper): 10100tph Dry Sand: 85 tph House Bricks (8"x3"x2"): 10tph NOTE: Because capacity is greatly influenced by the size and characteristics of the material being crushed, this capacity range should be used with caution. Crusher Specifications

Table 2-1.

SECTION III INSTALLATION

3-1. Inspection The 33" x 30" crusher is shipped on two pallets; the crusher body on one and the drive assembly, chain, and sprockets on the second. These components must be assembled, aligned, and adjusted as described on the assembly drawing and Section 6 of this manual. The crusher should be thoroughly inspected and the mounting location checked before installation. 1. Visually inspect the crusher and immediately report any missing or damaged equipment to the carrier and to your United Conveyor Corporation Representative. Caution: Equipment must be left on skids until ready for installation. 2. Check for obstructions. interferences and 7. Install drive components. (See crusher assembly drawing and Section 6 of this manual for proper installation of crusher drive components.) 3-3. Dry Application Installation 3-2. Wet Application Installation 1. If required, install gate or valve on hopper as shown on contract drawing. 2. Carefully slide crusher into position under hopper and gate and support temporarily until all bolts are installed. 3. Apply a 1/4" bead of industrial sealant (UCC #45507-7) on each side of bolt holes and on top and bottom of inlet flange gasket. 1. If required, install gate or valve on hopper as shown on contract drawing. 2. Carefully slide crusher into position under hopper and gate and align flanges. Temporarily support crusher until all bolts are installed. 3. Install 3/8" spacers between crusher outlet flange and mating flange. With spacers positioned between flanges, install and snug bolts. Do not tighten bolts yet. 4. Install gasket on top flange of crusher and immediately install and tighten bolts. 5. Move sluice intake, adapter hopper, or receptacle into position under crusher and align flanges. Apply sealant to outlet flange gasket per Step 3. 6. Install gasket between crusher and mating flange, then immediately install and tighten bolts. Note: If crusher is used in a sluice system, the dilution spray pipe must be connected and properly aligned. Caution: The gear reducer is shipped from the factory without oil. Before operating crusher, fill reducer with oil to proper level. See Section 4-1.

3. Check that vertical clearance between flanges is adequate for mounting crusher.

4. Install 3/8" spacers between top flange on crusher and bottom flange on gate or hopper. Install and snug bolts. Do not tighten bolts yet. Note: The 3/8" spacers will hold the flanges open for installing NUVASEAL II cement (UCC #45557). 5. Refer to NUVASEAL II instruction #790933 for proper mixture. Install NUVASEAL II cement in joints between top and bottom flanges on crusher. 6. Remove the spacers as the NUVASEAL II starts to set up; then tighten bolts to maintain 1/4" joint. 7. Allow NUVASEAL II to set up, usually 6 - 24 hours, then tighten all bolts again and the gasket will be ready for use. 8. Install drive components. (See Section 6 of this manual for proper installation of crusher drive components.)

3-4. Electrical Connections Caution: All electrical connections must comply with state and local codes. 1. Check assembly and contract drawings for proper voltage, frequency, phase, and current to gearmotor. 2. Install conduit for easy servicing. When installing conduit, do not obstruct access to crusher for maintenance or service. 3-5. Equipment Protection It is common for the crusher to be installed while work is still in progress on the equipment above the crusher. If work is in progress, install a temporary cover made of heavy plywood or steel to protect the crusher and prevent debris and other objects from falling into the unit. Note: Ensure that all trash, wire, refractory, weld rods, and other debris is removed before attempting to operate the crusher.

SECTION IV START UP
4-1. Pre-start Checkout Caution: Verify that electrical power inputs conform to crusher voltage specifications before energizing unit. 1. Clean all trash, wire, and refractory from crusher. 2. Fill gear reducer with reducer manufacturers recommended lubricant. Remove oil fill plug (Figure 6-1) and oil level plug, and fill reducer with oil to level of hole. 3. Ensure that top and bottom flange connections are even to prevent leakage. Verify that flange bolts are tightened. 4. Check that packing glands have been filled. Grease with Shell Alvania #1 or equivalent, if necessary. Pump grease into the fitting until grease starts to come out of the pressure relief fitting on the bottom of packing gland. 5. Remove chain guard and check drive chain for proper tension as shown in Figure 6-2. Adjust chain tension, if required. 4-2. Operational Check 1. Start crusher and verify correct shaft rotation as indicated by arrow marker plate on housing. If required, reverse wiring to correct rotation. 2. In wet applications, inspect top and bottom flange joints for leakage. 3. Closely inspect chain and sprocket to ensure a smooth interaction with no excess noise. The chain should smoothly enter and exit the sprockets. If binding or noise is noted, realign sprockets. 4-3. Operation Refer to system operating instructions before feeding material into the crusher. On automatic systems, the crusher may stop and start with the timing cycle while the operating switch is on. 4-3-A. Wet Application If the crusher is used in a sluice system, make sure the crusher is operating and diluting spray water is on before opening the hopper gate or slag tank. Note: If required, refer to operating instructions for method of discharging ash from bottom ash hopper or slag tank. 4-3-B. Dry Application 1. If applicable, make sure that vacuum conveyor is operating. Note: Refer to operating instructions before starting vacuum conveyor. 2. Before starting crusher, ensure that ash intake under crusher is open (if used). Note: If crusher stalls and reverses, but does not operate in the forward direction, check for scrap iron or non-friable material in the crusher.

10

SECTION VII RECOMMENDED SPARE PARTS

Part No.
3-21996 4-21997 5-210169 3-21994-1 3-21994-3 3-21994-5 SK-210057 SK-46145 46366-750 405128-1 405098-2 210409-1 210409-2 40636-155 2103-106-5 2103-106-6 6246 6246-1 6247 6247-1 408914 408914-1 408915 408915-1 408931 408931-1 210172 210148-1 41037 * * * * *

Description
Combing Plate Anvil Plate (Wet Application) Anvil Plate (Dry Application) Cam (Wet Application) Cam (Dry Application) Cam (Dry Application) Side Wear Plate Bolt - Cam, 3/4" Nut, 3/4" Bearing - Flange Cartridge Block (Wet Application) Bearing - Flange Cartridge Block (Dry Application) Shaft (Mild Steel) Shaft (Stainless Steel) "O" Ring Packing Kit (Wet Application) Packing Kit (Dry Application) Gasket (Bottom Flange, Wet Application) Gasket (Bottom Flange,Dry Application) Gasket (Top Flange, Wet Application) Gasket (Top Flange, Dry Application) Gasket (Anvil Plate Holder, Wet Application) Gasket (Anvil Plate Holder, Dry Application) Gasket (Rear Access Door, Wet Application) Gasket (Rear Access Door, Dry Application) Gasket (Front Access Door, Wet Application) Gasket (Front Access Door, Dry Application) Bottom Wear Plate Nosepiece-Bearing Housing Gasket (Bearing Housing Nosepiece) Drive Sprocket Driven Sprocket Roller Chain Connecting Link Roller Chain Offset Line Roller Chain

Quantity
3 3 3 8 4 4 2 2 32 2 2 1 1 2 1 1 2 2 1 1 1 1 1 1 1 1 2 2 2 1 1 1 1 1

*See crusher assembly drawing for specific part number for your application. Table 7-1. Recommended Spare Parts

34

SECTION V OPERATION AND CONTROLS

5-1. Operator Indicators Controls and Crusher controls and indicators may vary in accordance with specific contract requirements.

The operation of the crusher is controlled by the Crusher Local Control Panel (Figure 5-1). This panel provides the controls for automatic reversing and crusher failure shutdown. This panel can be used by itself to control the crusher in a manual system, or it can be used in conjunction with an automatic control system. Table 5-1 explains the operator controls and indicators located on the local control panel. The push button, switch, and light numbers given in parentheses are found on the electrical assembly and schematic drawings. Note: These controls and indicators represent typical operator control arrangements.
Panel Label Crusher Failure (L3)
Forward (PB2/L1)

Figure 5-1. Crusher Local Control Panel

Reverse (PB3/L2)

Selector Switch Auto/Off/Manual(SW1)

Pull to Start/ Push to Stop (PB1)

Description This white light illuminates when the crusher fails to clear a jam after a set number of "Reverse - Forward" cycles in a one minute period. This button allows the operator to manually jog the crusher in the forward direction to help clear a jammed crusher. This push button is only operable when the selector switch (SW1) is in the MANUAL Position. This button allows the operator to manually jog the crusher in the reverse direction to help clear a jam. It is only operable when the selector switch (SW1) is in the MANUAL position. This switch must be placed in the AUTO position during system operation. Selecting the MANUAL position only allows the operator to jog the crusher in a forward or reverse direction. Selecting the OFF position disconnects the power to the crusher drive. This button disconnects the power to the crusher drive. In order for the crusher to run in either AUTO or MANUAL mode, the button has to be in the start position.

Table 5-1.

Local Control Panel - Controls and Indicators

11

5-2. Automatic Reversing and Crusher Failure Sensing The automatic reversing controller (located inside the Crusher Local Control Panel) measures the current flowing into the electric motor on the crusher drive. As the crusher stalls, the current flowing to the electric drive increases. The automatic reversing controller senses the increase in current and shuts the electric drive down. After a 5 second delay, the controller restarts the motor in the reverse direction for a period of 5 seconds. The electric drive stops again. After another 5 second delay, the controller restarts the crusher in the forward direction and operation resumes normally or the crusher stalls again.

The rotary switch on the front of the controller (Figure 5-2) allows the user to select a value from 0 to 5. This value stands for the number of consecutive stalls before the crusher is automatically shut down and the Crusher Failure alarm (L3) is triggered. A consecutive stall is any stall that occurs within 30 seconds of the previous stall. The standard setting is 3 consecutive stalls before shut down and alarm. If the Crusher Failure Light (L3) illuminates and the blockage cannot be cleared by jogging the crusher, the material has to be removed from the crusher manually.

Figure 5-2. Automatic Reversing Controller (Located Inside of Crusher Local Control Panel)

12

Caution: Before attempting to visually inspect or manually remove material from a crusher, observe the safety precautions listed in Section 1 of this instruction manual and also the precautions listed in Systems and Equipment Safety Instructions UCC #721005. The current flow trip point of the controller can be adjusted by turning the current adjustment screw. This screw is located either on the right side or the front face of the automatic reversing controller. By turning the screw in the negative (counterclockwise) direction, the trip point is lowered. By turning the screw in the positive (clockwise) direction, the trip point is raised. The trip point is factory set at approximately 5 amps. If repeated false stalls are alarmed, it may be necessary to raise the trip point. If, during a true crusher stall, the electric drive stays engaged for long periods of time before the controller senses the stall, the trip point should be lowered.

5-3. Operating Procedure 5-3-A. Running The Crusher With An Automatic Control System Crusher Local Control Panel should be set by pulling the Start/Stop Button (PB1) to the START position and setting the Selector Switch (SW1) to the AUTO position. The crusher will start and stop based on the sequencing of the main control system. 5-3-B. Running The Crusher Manually (No Automatic Control System) Follow the instructions for running the ash handling system. When the instructions call for the crusher to run, pull the Start/Stop Button (PB1) to the START position (Selector Switch (SW1) should be in the AUTO position). When crusher is to be shut down, push the Start/Stop Button to the STOP position.

13

14

SECTION VI MAINTENANCE AND SERVICE

6-1. Regular Inspection and Service Table 6-1 outlines regular service and inspection data. Item Drive Chain Condition Wear Frequency Monthly Action Adjust chain tension for minimum chain & Sprockets slack. Align drive sprocket with crusher shaft sprocket. Replace sprockets and/ or chain if chain rides up on sprocket teeth. Replace if worn or damaged. Remove old seal, then install new gasket or NUVASEAL II cement. Replace if worn or damaged. Add grease to grease fitting until it comes out pressure relief fitting on the bottom. Replace packing if leakage continues. Check Shaft for wear Replace flexible sleeve if worn or damaged.

Cams Flange Seals

Wear Leakage

Monthly Annually

Anvil Plate & Combing Plate Crusher Shaft Seals

Wear Leakage

Monthly Monthly

Flexible Coupling

Wear

Annually

Table 6-1.

Inspection and Service

15

6-2. Lubrication Table 6-2 details regular lubrication required by the crusher. Refer to Figure 6-1 for lubrication points on the crusher. Item Packing Gland Grease Fitting Frequency Every Other Day Lubricant Shell Alvania #1 or equivalent Application Gun: Fittings on top of packing gland. Fill until grease comes out of pressure relief on bottom of packing gland. Gun: Fittings on bearings. Fill bearings until grease seeps from the outer bearing seal. Fittings on motor. Fill reducer with oil to level of hole. See Figure 6-1. Brush: Chain guard must be removed. Spray: Through observation hole in chain guard during operation.

Shaft Bearings

Monthly

Shell Alvania #1 or equivalent Grease Gun: AGMA #4 Lubricant or equivalent SAE 30 Oil

Electric Motor Bearings Gear Reducer

Monthly Monthly

Roller Chain

Monthly

Table 6-2.

Lubrication

Figure 6-1. Lubrication Points

16

6-3. Troubleshooting Table 6-3 details areas in which specific conditions can occur, probable cause for these conditions, and corrective action to be taken. Condition
Excess noise from roller chain Wear on inside of roller chain links and on one side of sprocket teeth Output particles are too large

Probable Cause
Misaligned sprocket Too much or too little slack Inadequate lubrication Misaligned sprocket Too much or too little slack Inadequate lubrication

Corrective Action
Realign sprocket Adjust chain tension slack Lubricate properly Realign sprockets Adjust chain tension Lubricate properly

Drive assembly vibrates Crusher stalls and reverses but does not operate in forward direction Flange leakage

Worn or damaged cams or anvil plate Anvil plate needs to be shimmed Worn sleeve in flexible coupling Scrap iron or non-friable material in crusher Dilution spray pipe inoperative or misaligned Misaligned flanges Defective seal

Replace cams or anvil plate Add shim behind kickback anvil plate Replace sleeve Remove crusher material anti-

from

Inspect and realign dilution spray pipe Realign flanges Remove old seal and install new gasket or NUVASEAL II cement Lubricate properly Replace packing and bearing Replace shaft and install new packing Replace packing and/or bearing Inspect auto grease feeder. Add grease, if necessary. Replace packing and replace shaft if worn or damaged Add grease. Replace springs

Worn shaft bearings Material leakage past bearing/ packing assembly

Inadequate lubrication Seal leakage Worn shaft Worn packing and/or bearing Packing gland not properly lubricated Worn packing and/or damaged shaft Grease feeder reservoir empty Worn wave springs

Material discharge from drain hole in bearing/packing housing

Table 6-3.

Troubleshooting

17

6-4. Replacement Procedure 6-4-A. Roller Chain

and

Adjustment

4. Clean roller chain sprockets and inspect for wear or damage. Replace sprocket(s), if necessary. Note: If roller chain is worn out, it should be replaced by a complete new chain rather than replacing worn parts. Also, to ensure proper sag, the replacement chain must be the same length as the original. 5. Install new roller chain and assemble with connecting link. 6. Check chain tension. There should be approximately 1/2" to 1" of slack on lower side of chain as shown in Figure 6-2. 7. If excess slack is noted, place 1/4" shim(s) under base of reducer to properly tension chain.

The roller chain driving the crusher is subjected to wear and stretching in operation, so it must be adjusted periodically to maintain minimum slack. The chain must be replaced when worn or stretched excessively, to avoid causing abnormal sprocket wear due to overriding the sprocket teeth. Chain Replacement: 1. Stop equipment and place circuit breaker controlling crusher in OFF position. Install safety lockout on circuit breaker. 2. Remove chain guard to expose chain. 3. Locate chain connecting link and disassemble by removing cotter key from link pin. Remove chain.

16.2 RPM

Figure 6-2. Chain Tension

18

Caution: Do not over tighten chain as this will cause rapid wear of parts. 8. Reinstall chain guard before returning crusher to service. 6-4-B. Drive Sprocket If either drive sprocket is worn or damaged, it must be replaced. Sprocket Removal: 1. Stop equipment and place circuit breaker controlling crusher in OFF position. Install safety lockout on circuit breaker. 2. Remove chain guard; then remove roller chain. Note: Drive sprockets are mounted on keyed shafts with a split tapered bushing (see Figure 6-3). The sprocket is separated from the

bushing by using the mounting screws as jack screws. This loosens the grip of the bushing on the shaft. 3. Remove (3) cap screws (Figure 6-3) from sprocket hub and insert fully into adjacent threaded holes. Note: If sprocket does not separate, a sharp hammer blow sometimes helps, while the jack screws are heavily tightened. 4. Slide sprocket and bushing off shaft, taking care to save key for reuse. Sprocket Installation: Note: The crusher sprockets use standard mount and reverse mount split tapered bushings. Be sure to observe orientation shown in Figure 6-3 when mounting sprockets.

Figure 6-3.

Sprocket Mounting Arrangement

19

1. Insert (3) cap screws (Figure 6-3) into unthreaded holes in bushing and engage with threads in reducer shaft sprocket. Do not tighten cap screws yet. Slide sprocket and bushing onto gear reducer shaft and over key. 2. Position sprocket so that machined face is flush with end of shaft (1/8"). Tighten cap screws alternately and evenly to secure sprocket to shaft. Reducer shaft sprocket screws should be tightened to 30-35 ft/lbs. After tightening sprocket bolts to the proper torque, hammer on the sprocket using a hammer and block. Retighten bolts. Repeat until hammering does not cause bolts to lose tightening torque. 3. Install cam assembly shaft sprocket on shaft per Step 1. Do not tighten cap screws yet. Note: Sprockets must be properly aligned to provide distribution of loads across entire width of chain.

4. For sprocket alignment, lay a straightedge across the machined face of reducer sprocket and cam assembly shaft sprocket per Figure 6-4. 5. Align cam assembly shaft sprocket so that straightedge contacts all points of machined face on both sprockets. 6. With sprockets properly aligned, torque (3) cap screws in cam assembly shaft sprocket to 65-75 ftlbs. After tightening cap screws to the proper torque, hammer on the sprockets with a hammer and block. Retighten bolts. Repeat until hammering does not cause bolts to lose tightening torque. Note: Sprockets are subject to move when cap screws are tightened. Recheck sprocket alignment after tightening cap screws. Realign sprockets, if necessary. 7. Install chain and check for proper tension. Adjust chain, if necessary. 8. Install chain guard before returning crusher to service. 6-4-C. Bearing and Packing Assembly The 33" x 30" crusher incorporates autoadjust, spring-loaded packings, which automatically adjust during operation, providing a positive seal around the shaft with minimal use of force. The protection afforded by this design permits the use of close-mounted bearings. The bearings are contained in a two-piece, flangemounted housing. A drain hole has been cast in each bearing housing. The discharge of material from the hole indicates a worn or damaged packing that

Figure 6-4. Sprocket Alignment

20

must be replaced, or the packing needs to be greased. To Replace Packing: Caution: Before attempting to replace packing, observe the safety precautions listed in Section 1 of this Instruction Manual and in "System and Equipment Safety Instruction" UCC # 721005. 1. Remove chain guard and roller chain; then remove cam assembly shaft sprocket per Section 6-4-B . 2. Remove shaft guard (Figure 2-1) by removing hex nuts (4) from studs. 3. Loosen setscrew securing bearing collar to shaft, then remove collar from shaft. Note: When bearing is removed from shaft, shaft will drop 1/64" unless supported. 4. Remove hex nuts (4) securing bearing to housing. Separate bearing from housing and slide off shaft. 5. Remove screws (4) securing packing follower to the packing gland. Remove follower. 6. Remove wave springs, spacers, packings, and lantern ring from the bearing housing. Note: Be sure to observe orientation of components and removal sequence when disassembling packing assembly.

7. Disassemble opposite bearing and packing assembly using same procedure. 8. Inspect shaft, bearings, spacers, and springs. Replace if worn or damaged. Note: After the packing is installed, apply anti-seize compound (UCC P.N. 45532-1) to the shaft where the bearing slides on. This will aid in removal at a later date.

Figure 6-5. Packing Orientation 9. Reinstall components by reversing disassembly sequence and observing the following steps: Position packings in housing with splits staggered 180. Refer to Figure 6-6 for correct orientation of packing, spacers, and springs.

21

Figure 6-6.

Bearing and Packing Assembly (In Packing Gland) Note: The shaft must turn freely after flange mounted bearings have been reinstalled. 12. Reinstall sprocket and align per Sprocket Installation procedure in Section 6-4-B. 13. Reinstall roller chain. If required, adjust chain for proper tension as described in Section 6-4-A. 14. Reinstall chain guard and shaft guard before returning crusher to service. 6-4-D. Cam Assembly To ensure optimum performance, cams should be replaced if worn or damaged. Cams can be replaced individually by using the removable access door.

In order to make repacking easier, tape together (3) wave springs and (2) spacers as shown in Figure 6-7. The springs and spacer should be taped together with 3/4" wide electrical tape. Insert packing follower with lipped edge towards wave spring. 10. Install bearings. When tightening the nuts on the studs, make sure no clearance is detected between the housing and bearing flanges. 11. Using Shell Alvania #1 or equal. Pump grease into the grease fitting until it starts to come out of the pressure relief fitting on packing gland.

22

Caution: Before attempting to replace crusher cams, observe the safety precautions listed in Section 1 of this Instruction Manual and in "System and Equipment Safety Instruction" UCC # 721005.

removed. Remove nuts; then remove cam from support.

3. Clean support where new cams will be installed. Position (4) bolts in cam support keyholes (Figure 6-10). 4. Place replacement cam over bolts on cam support, ensuring that cam is correctly positioned as shown in Figure 6-10. Note: The cam teeth must rotate toward the anvil plate. 5. Apply Anti-seize (UCC#45532) to bolt threads; then install and tighten lock nuts alternately and evenly. Torque nuts to 260 to 310 ft-lbs. 6. After tightening nuts, tack weld the nuts and bolts with a stainless steel welding rod. 7. Repeat procedure for remaining cams to be replaced. 8. Reassemble crusher by reversing applicable disassembly procedure and observing the following steps. Apply sealant (UCC #45529) to all bolt threads securing access door to crusher housing. Replace access door gasket if worn or damaged

Figure 6-7. Installation of Wave Springs and Spacers 1. Access cams as follows: a. If crusher uses front drive mounting arrangement (Figure 6-8), remove access door and anvil plates as described in Section 6-4-E, Anvil Plate Removal procedure. b. If crusher uses rear drive mounting arrangement (Figure 6-9), remove access door and combing plates as described in Section 6-4-F, Step 3 under Combing Plate Removal. Caution: When removing cams, use extreme caution to ensure that cam is not accidentally dropped inside of crusher housing. 2. Using a pry bar, rotate cam assembly so that the (4) nuts securing worn or damaged cam to cam support can be

23

Access Door

Door Gasket

Combing Plate

Anvil Plate

Spacers

Holder Bar and Gasket

Drive Mounting Bracket

Cam Support

Cam

Door Gasket

Access Door

Figure 6-8. Front Drive Mounting Arrangement

Drive Mounting Bracket

Figure 6-9. Rear Drive Mounting Arrangement

24

6-4-E. Anvil Plate The crusher works by shearing and splitting input material against three anvil plates mounted in the crusher housing. If an anvil plate becomes worn or damaged, it must be replaced. Anvil Plate Removal: Caution: Before attempting to remove anvil plate from crusher, observe the safety precautions listed in Section 1 of this Instruction Manual and "System and Equipment Safety Instruction" UCC # 721005. 1. If crusher is equipped with rear drive mounting arrangement (Figure 6-9): a. Remove drive assembly described in Section 6-4-H. as

a. For wet applications - Loosen and remove (6) hex nuts and (6) jam nuts securing anvil plates to access door. For dry applications - Loosen and remove (6) screws securing anvil plates to access door. b. Remove (14) cap screws that secure access door to crusher body. Remove access door.
Prevailing Torque Locknut

Cam

Bolt

b. For wet applications - Loosen and remove (6) hex nuts and (6) jam nuts securing anvil plates to access door. For dry applications - Loosen and remove (6) screws securing anvil plates to access door. c. Remove (14) cap screws that secure access door and drive mounting bracket to crusher body. Remove access door. d. Proceed to Step 4. 2. If crusher is equipped with front drive mounting arrangement (Figure 6-8):
Cam Support

Figure 6-10. Cam and Cam Support 3. Remove (3) anvil plates and shims from crusher body. a. For dry applications - The shims must be removed before the anvil plates can be removed from the crusher. To remove shims, push on the tops of the anvil plates, forcing the plates to rotate towards the

25

cam support. Then remove the shims, followed by the anvil plates. 4. Install new anvil plates by reversing removal procedure. Reverse disassembly procedure to reassemble crusher. Note: Replace access door gasket if worn or damaged. Note: Apply sealant (UCC #45529) to bolt threads securing anvil plates to access door and to bolt threads that mount access door to crusher body. 6-4-F. Combing Plate The crusher uses three (3) combing plates to clear crushed material from the cams. To ensure optimum performance, worn or damaged combing plates must be replaced. Combing Plate Removal: Caution: Before attempting to remove combing plate from crusher, observe the safety precautions listed in Section 1 of this Instruction Manual and "System and Equipment Safety Instruction" UCC # 721005. Note: On some installations, combing plates can be replaced through the access door above the crusher, thereby eliminating the need to remove the crusher. 1. If crusher uses front drive mounting arrangement (Figure 6-8), the unit must be partially removed from under

hopper and gate to remove combing plates. To Remove Crusher: a. Disconnect electrical wiring and conduit. b. Disconnect dilution spray pipe, if required. c. Loosen and remove all upper and lower flange bolts. d. Carefully slide crusher from under gate and hopper so there is sufficient clearance to remove combing plates. e. Proceed to Step 3. 2. If crusher uses rear drive mounting arrangement (Figure 6-9), remove (16) hex nuts from studs on which access door is mounted. Remove access door. Caution: When removing combing plates, use extreme caution to avoid dropping plates inside of crusher body. 3. Remove (2) lock nuts and (2) washers from bolts securing worn or damaged combing plate to crusher body (see Figure 6-8 and 6-9). Remove plate from crusher body. 4. Reverse removal procedure to install new combing plate. Note: Apply sealant (UCC #45529) to bolt threads securing combing plate to crusher body.

26

5. Repeat replacement procedure for remaining worn or damaged combing plates. 6. Reverse applicable disassembly procedure to reassemble crusher. Note: Observe the following procedures during reassembly of crusher with rear drive mounting arrangement: Apply sealant (UCC #45529) to all bolt threads securing front access door to housing. Replace access door gasket if worn or damaged. Note: Observe the following procedures during reassembly of crusher with front drive mounting arrangement: Reinstall crusher under gate and hopper per Section 3-2 or 3-3, depending on crusher application (wet or dry). Connect dilution spray pipe, if required. Connect electrical wiring and conduit. Check crusher operation. 6-4-G. Crusher Shaft & Cam Support Removal of Shaft Caution: Before attempting to remove shaft from crusher, observe safety precautions listed in Section 1 of this Instruction Manual and also precautions listed in "System and Equipment Safety Instruction" UCC # 721005.

1. Remove chain guard and roller chain; then remove cam assembly shaft sprocket per Section 6-4-B. 2. Remove shaft guard (Figure 2-1) by removing hex nuts (4) from studs. 3. Loosen set screw securing bearing collar to shaft; then remove collar from shaft. Note: When bearing is removed from shaft, shaft will drop 1/64" unless supported. 4. Remove hex nuts (4) securing bearing to housing. Separate bearing from housing and slide off shaft. 5. Remove screws (4) securing packing follower to the packing gland. Remove follower. 6. Remove wave springs, spacers, packings, and lantern ring from the bearing housing. 7. Disassemble opposite bearing and packing assembly using the same procedure. 8. Loosen and remove the screws (8) holding each bearing housing to the crusher body. Remove the bearing housings. 9. Remove the set screw from the wedge. 10. Loosen and securing the support. remove the screws wedge to the cam

27

11. Thread a 3/8 screw into the tapped hole from which the set screw was removed. Note: The cam assembly must be supported with chain, cable, or sling before attempting to remove the wedges of the crusher shaft. 12. Use the screw as a jack bolt to break the wedge loose from the cam support and shaft. 13. Remove the wedge. 14. Repeat Steps 9 thru 13 for the wedge on the opposite end of the shaft. 10. Remove shaft by sliding the shaft out of the cam support and out the side of the crusher. Reinstallation of Shaft 1. Using a chain, cable, or sling, lower cam support into crusher body. The keyways in the cam support should be aligned vertically inside the crusher body. 2. Bolt the square and beveled keys to the shaft. Apply anti-seize compound to the area of the shaft that will be inside of the cam support. 3. Insert the shaft into the cam support with the beveled key facing up. 4. Center the cam support on the shaft by measuring from the vertical faces on the support to the steps on the shaft.

5. Support the cam support and shaft with the sling used for supporting the cam support only. Note: Do not sling up the shaft as the wedges cannot be properly tightened when the shaft and cam support are both individually supported. 6. Insert wedges. Apply thread locking compound to the 7/16-14 socket head capscrews and tighten the screws to 60-70 ft-lb. Check the gap between the vertical surfaces of the cam support and the wedge to assure that the wedges are drawn up evenly. Recheck the position of the cam support to make sure the support is still centered on the shaft. 7. After tightening the wedge bolts, hammer on the wedges using a hammer and block. Re-tighten bolts. Repeat until hammering does not cause the bolts to lose preload. 8. Apply silicone sealant (UCC P/N 45507-7) to completely fill all gaps at both ends of the cam support as well as wedge screw heads. 9. Reassemble the crusher by reversing disassembly procedure. See Section 6-4-C for reinstallation of packing and bearings.

28

6-4-H. Drive Assembly The 33" x 30" crusher can be equipped with either a Nuttall or Link-Belt drive assembly (Figure 6-11 & 6-12). Both consist of an electric motor mounted on a common base with the gear reducer. The electric motor and reducer are connected by a flexible sleeve coupling. Either type of drive unit can be removed as a complete unit (or as individual components) for repair or replacement. Although the following maintenance procedures apply to both drive assemblies, specific procedures for each drive must be observed to assure satisfactory operation. Caution: The electric motor, adapter, and reducer are very heavy. To prevent personal injury or damage, equipment must be adequately supported before mounting bolts are loosened and removed. Drive components should be lifted as shown in Figure 6-13 with a sling of ample strength. Make sure the load is properly secured and balanced to prevent shifting during suspension. 6-4-H-1. Electric Motor Electric Motor Removal:

a. Stop equipment and place circuit breaker controlling crusher in OFF position. Install safety lockout on circuit breaker. b. Disconnect electrical wiring and conduit. c. If Nuttall drive is used, remove safety screen from adapter (Figure 6-11). d. Loosen (2) setscrews securing flexible coupling flanges (Figure 614) to electric motor shaft; then slide flanges away from flexible sleeve. e. With motor properly supported, remove (4) mounting bolts securing motor to adapter; then remove motor. Caution: Exercise caution when removing electric motor from gear reducer, to avoid damaging flexible sleeve. f. Remove flexible coupling flange from electric motor shaft and save key for reuse. g. Install new or repaired electric motor by reversing removal sequence. Note: Refer to Flexible Coupling Replacement procedure for proper installation of flexible coupling.

29

Figure 6-11. Nuttall Drive

Figure 6-12. Link-Belt Drive

30

Figure 6-13. 6-4-H-2. Flexible Coupling

Proper Lifting Arrangement

b. Remove flexible coupling. The flexible coupling (Figure 6-14) protects the gearmotor from shock loads and vibration. Torque is transmitted between the shafts through an elastomeric sleeve with a saw tooth design. The sleeve is housed between two flanges. If the sleeve becomes worn or damaged, it must be replaced. Flexible Coupling Replacement: Nuttall Drive: a. Remove electric motor as described in electric motor removal procedure in this section of manual. 1. Slide flange onto reducer shaft (if removed) and install key. Do not tighten setscrews in flange yet. 2. Reinstall electric motor, flange, key, and sleeve by reversing electric motor removal sequence. Do not tighten setscrews in flange yet. 3. With electric motor and coupling installed, position coupling with an equal length of shaft extending into each flange (see Figure 6-15); then tighten setscrews to secure flanges on shafts. Figure 6-14. Flexible Coupling c. Before reinstalling electric motor, ensure that shafts on electric motor and reducer are clean. Remove any grease, burrs, etc. from shafts. d. To reinstall flexible coupling, observe procedure applicable to specific drive assembly used.

31

Caution: The electric motor, adapter, and reducer are very heavy and must be adequately supported, before mounting bolts are loosened and removed, to prevent personal injury or damage to equipment. Gear Reducer Removal: a. Stop equipment and place circuit breaker controlling crusher in OFF position. Install safety lockout on circuit breaker. b. Remove electric motor as described in Electric Motor Removal procedure in this section of manual. Note: In Step d, of Electric Motor Removal procedure, do not remove bolts securing electric motor to adapter; remove bolts securing adapter to reducer, leaving adapter attached to electric motor. c. Remove reducer shaft sprocket per Step b, Sprocket Removal procedure, in Section 6-4-B. d. With reducer properly supported (per Figure 6-13), remove (4) bolts securing reducer to mounting bracket (Figure 6-16); then remove reducer. Note: Gear reducer mounting hardware may include one or more shims to tension roller chain at assembly. Retain shims for use during reassembly.

Figure 6-15. Flange Alignment Link-Belt Drive: 1. Slide flange onto reducer shaft (if removed) and install key. Position flange flush with end of shaft as shown in Figure 6-15, then tighten setscrews. 2. Install flange and key on electric motor shaft. Position flange flush with end of shaft and tighten setscrews. 3. Insert new sleeve into flange on reducer. Carefully reinstall electric motor, ensuring that molded teeth along outside diameter of sleeve are completely seated in teeth on both flanges. 6-4-H-3. Gear Reducer

The gear reducer (Figure 6-14) provides transmission of power from the electric motor to the slower speed requirements for the crusher cam assembly. If the gear reducer is worn or damaged, it must be replaced.

32

e. Install new or repaired gear reducer by reversing removal procedure. Refer to flexible coupling replacement procedure for proper installation of coupling on shafts. f. Reinstall reducer shaft sprocket and align as per instructions in Section 6-4-B. g. Reinstall roller chain and check for proper tension. Adjust chain tension, if required. h. Reinstall chain guard before returning crusher to service.

Figure 6-16. Drive Mounting Arrangement

33