UNITEDCONVEYORCORPORATION

INSTALLATION, OPERATION & MAINTENANCE INSTRUCTIONS

33” x 30” EXCEN-CRUSHER® SOLIDS REDUCER

FORM NO. 91126 Rev. 5/07

©2007 UNITED CONVEYOR CORPORATION ALL RIGHTS RESERVED

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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 Page 1-1. Suggested Procedure for Blocking

Isolation Door Close....................... 2 2-1. 33" x 30" Crusher (Top View).......... 4 5-1. Crusher Local Control Panel ........... 11 5-2. Automatic Reversing Controller....... 12 6-1. Lubrication Points............................ 16 6-2. Chain Tension ................................. 18 6-3. Sprocket Mounting Arrangement..... 19 6-4. Sprocket Alignment ......................... 20 6-5. Packing Orientation ......................... 21 6-6. Bearing and Packing Assembly....... 22 6-7. Installation of Wave Springs and Spacers .................................... 23 6-8. Front Drive Mounting Arrangement .24 6-9. Rear Drive Mounting Arrangement.. 24 6-10. Cam and Cam Support.................... 25 6-11. Nuttal Drive...................................... 30 6-12. Link-Belt Drive ................................. 30 6-13. Proper Lifting Arrangement ............. 31 6-14. Flexible Coupling............................. 31 6-15. Flange Alignment ............................ 32 6-16. Drive Mounting Arrangement .......... 33

List of Tables Table Page 2-1. Crusher Specifications...................... 5 5-1. Local Control Panel .......................... 11 6-1. Inspection and Service ..................... 15 6-2. Lubrication ........................................ 16 6-3. Troubleshooting ................................ 17 7-1. Recommended Spare Parts.............. 34

Table of Contents

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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.

SECTION ISAFETY PRECAUTIONS

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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

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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.

SECTION IIGENERAL INFORMATION

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Figure 2-1. 33" x 30" Crusher (Top View)

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2-3-C. Specifications Table 2-1 shows specification and performance characteristics of the 33" x 30" crusher.

ITEM SPECIFICATION Rotor Construction 8 DURITE® H cams (600-700 BHN) cast, mounted

on a cam support, which is available in mild or stainless steel.

Process Temperature: Wet: Up to 200°F Dry: Up to 800°F

Anvil Plates Wet: DURITE H, Cast Dry: AR 500

Combing Plates,Side Wear Plates, & Bearing Housing Nosepiece

DURITE H, Cast

Drive Assembly: 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.

Operating Speed: 16.2 rpm Pressure: Wet: Up to 20 psi

Dry: ± 1 psi Material Input Size: 4" x 9" x 20" maximum Material Output Size: 2" maximum Vertical Headroom: 21-1/2" (Crusher body) Inlet Flange: 33" x 30" (Inside dimension) Outlet Flange: 18" x 30" (Inside dimension) Weight: Approximately 3,600 lbs Capacity Range: Bottom Ash (from water impounded hopper): 10-

100tph 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.

Table 2-1. Crusher Specifications

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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 interferences and

obstructions. 3. Check that vertical clearance between

flanges is adequate for mounting crusher.

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.

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.

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 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.

SECTION IIIINSTALLATION

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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.

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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

manufacturer’s 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.

SECTION IVSTART UP

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Part No. Description Quantity 3-21996 Combing Plate 3 4-21997 Anvil Plate (Wet Application) 3

5-210169 Anvil Plate (Dry Application) 3 3-21994-1 Cam (Wet Application) 8 3-21994-3 Cam (Dry Application) 4 3-21994-5 Cam (Dry Application) 4 SK-210057 Side Wear Plate 2 SK-46145 Bolt - Cam, 3/4" 2 46366-750 Nut, 3/4" 32 405128-1 Bearing - Flange Cartridge

Block (Wet Application) 2

405098-2 Bearing - Flange Cartridge Block (Dry Application)

2

210409-1 Shaft (Mild Steel) 1 210409-2 Shaft (Stainless Steel) 1 40636-155 "O" Ring 2 2103-106-5 Packing Kit (Wet Application) 1 2103-106-6 Packing Kit (Dry Application) 1

6246 Gasket (Bottom Flange, Wet Application) 2 6246-1 Gasket (Bottom Flange,Dry Application) 2 6247 Gasket (Top Flange, Wet Application) 1

6247-1 Gasket (Top Flange, Dry Application) 1 408914 Gasket (Anvil Plate Holder, Wet Application) 1

408914-1 Gasket (Anvil Plate Holder, Dry Application) 1 408915 Gasket (Rear Access Door, Wet Application) 1

408915-1 Gasket (Rear Access Door, Dry Application) 1 408931 Gasket (Front Access Door, Wet Application) 1

408931-1 Gasket (Front Access Door, Dry Application) 1 210172 Bottom Wear Plate 2

210148-1 Nosepiece-Bearing Housing 2 41037 Gasket (Bearing Housing Nosepiece) 2

* Drive Sprocket 1 * Driven Sprocket 1 * Roller Chain Connecting Link 1 * Roller Chain Offset Line 1 * Roller Chain 1

*See crusher assembly drawing for specific part number for your application.

Table 7-1. Recommended Spare Parts

SECTION VIIRECOMMENDED SPARE PARTS

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5-1. Operator Controls and Indicators

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.

Crusher controls and indicators may vary in accordance with specific contract requirements.

Figure 5-1. Crusher Local Control Panel

Panel Label Description Crusher Failure (L3) 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. Forward (PB2/L1) 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.

Reverse (PB3/L2) 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.

Selector Switch Auto/Off/Manual(SW1)

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.

Pull to Start/ Push to Stop (PB1)

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

SECTION VOPERATION AND CONTROLS

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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)

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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.

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6-1. Regular Inspection and Service Table 6-1 outlines regular service and inspection data.

Item Condition Frequency Action Drive Chain Wear Monthly 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.

Cams Wear Monthly Replace if worn or damaged. Flange Seals Leakage Annually Remove old seal, then install

new gasket or NUVASEAL II cement.

Anvil Plate & Combing Plate

Wear Monthly Replace if worn or damaged.

Crusher Shaft Seals

Leakage Monthly Add grease to grease fitting until it comes out pressure relief fitting on the bottom. Replace packing if leakage continues. Check Shaft for wear

Flexible Coupling

Wear Annually Replace flexible sleeve if worn or damaged.

Table 6-1. Inspection and Service

SECTION VIMAINTENANCE AND SERVICE

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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 Frequency Lubricant Application Packing Gland Grease Fitting

Every Other Day

Shell Alvania #1 or equivalent

Gun: Fittings on top of packing gland. Fill until grease comes out of pressure relief on bottom of packing gland.

Shaft Bearings Monthly Shell Alvania #1 or equivalent

Gun: Fittings on bearings. Fill bearings until grease seeps from the outer bearing seal.

Electric Motor Bearings

Monthly Grease Gun: Fittings on motor.

Gear Reducer Monthly AGMA #4 Lubricant or equivalent

Fill reducer with oil to level of hole. See Figure 6-1.

Roller Chain Monthly SAE 30 Oil Brush: Chain guard must be removed.

Spray: Through observation hole in chain guard during operation.

Table 6-2. Lubrication

Figure 6-1. Lubrication Points

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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 Probable Cause Corrective Action Excess noise from roller chain

• Misaligned sprocket • Too much or too little slack • Inadequate lubrication

• Realign sprocket • Adjust chain tension slack • Lubricate properly

Wear on inside of roller chain links and on one side of sprocket teeth

• Misaligned sprocket • Too much or too little slack • Inadequate lubrication

• Realign sprockets • Adjust chain tension • Lubricate properly

Output particles are too large

• Worn or damaged cams or anvil plate

• Anvil plate needs to be shimmed

• Replace cams or anvil plate • Add shim behind anti-

kickback anvil plate Drive assembly vibrates

• Worn sleeve in flexible coupling

• Replace sleeve

Crusher stalls and reverses but does not operate in forward direction

• Scrap iron or non-friable material in crusher

• Dilution spray pipe inoperative or misaligned

• Remove material from crusher

• Inspect and realign dilution

spray pipe Flange leakage • Misaligned flanges

• Defective seal • Realign flanges • Remove old seal and install

new gasket or NUVASEAL II cement

Worn shaft bearings

• Inadequate lubrication • Seal leakage

• Lubricate properly • Replace packing and bearing

Material leakage past bearing/ packing assembly

• Worn shaft • Worn packing and/or

bearing • Packing gland not properly

lubricated

• Replace shaft and install new packing

• Replace packing and/or bearing

• Inspect auto grease feeder. Add grease, if necessary.

Material discharge from drain hole in bearing/packing housing

• Worn packing and/or damaged shaft

• Grease feeder reservoir empty

• Worn wave springs

• Replace packing and replace shaft if worn or damaged

• Add grease. • Replace springs

Table 6-3. Troubleshooting

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6-4. Replacement and Adjustment Procedure

6-4-A. Roller 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.

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.

Figure 6-2. Chain Tension

16.2 RPM

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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

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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.

Figure 6-4. Sprocket Alignment

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 ft-lbs. 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 auto-adjust, 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, flange-mounted 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

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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.

22

Figure 6-6. Bearing and Packing Assembly (In Packing Gland) • 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.

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.

23

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 Instruc-tion" UCC # 721005.

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

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

24

Figure 6-8. Front Drive Mounting Arrangement

Figure 6-9. Rear Drive Mounting Arrangement

Access Door

Door Gasket

Combing Plate

Anvil Plate

Spacers

Holder Bar and Gasket

Access Door Door

Gasket Cam Drive Mounting

Bracket Cam Support

Drive Mounting Bracket

25

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 as described in Section 6-4-H.

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):

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.

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

Prevailing Torque Locknut

Bolt

Cam Support

Cam

26

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.

27

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 remove the screws

securing the wedge to the cam support.

28

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. Re-check 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.

29

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 6-14) 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.

30

Figure 6-11. Nuttall Drive

Figure 6-12. Link-Belt Drive

31

Figure 6-13. Proper Lifting Arrangement 6-4-H-2. 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:

a. Remove electric motor as described in electric motor removal procedure in this section of manual.

Figure 6-14. Flexible Coupling

b. Remove 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.

Nuttall Drive: 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.

32

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.

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.

33

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