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K-36 IMPACT CRUSHER OPERATION AND MAINTENANCE

MANUAL

EDITON: 2002/A

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1.0. IMPORTANT!

These Operating and Maintenance Instructions and Safety Regulations shall be

read and observed carefully prior to transport, installation, commissioning, maintenance
and servicing of the machine!

Authorized personnel only, who is familiar with the operating and maintenance
instructions and the appropriate instructions with regard to safety at work and accident
prevention, is allowed to use, maintain and repair the machine.

The manufacturer NA-CE MACHINERY Co. herewith declares, that the new
machine as described in the following is in compliance with the regulations of the
Machinery Safety 05/06/2002-official gazette : 24776 and thus complies also with the
Machinery Directive 98/37/EEC in its applicable version.

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1.1. Preamble

NA-CE Machinery Industry Co. thanks you for the confidence that you have
placed in NA-CE with the purchase of this equipment.

The information given to you with these operating and maintenance instructions
shall direct the user’s attention to design, construction and functioning of the IMPACT
CRUSHER K-36 and impart all knowledge necessary for a successful application, use, trouble-
free operation, expert maintenance and correct purchase of spare parts.

The present “Operating and Maintenance Instructions” shall not cancel the current
national laws and accident prevention regulations.

Impact crusher shall be used by expert and authorised personnel only and
exclusively for the purpose it had been designed and made for, which means the crushing of
materials specified.

Additionally, start-up, operating and maintenance conditions (in accordance with

the operating and maintenance instructions) as specified by the manufacturer of the crusher
shall be strictly observed.

Furthermore, foreseeable wrong behaviour of personnel and the directions of the

relevant local safety regulations and laws shall be well considered too.

The crusher shall be operated and maintained by authorised persons only, who
have been registered in the equipment check list and are therefore familiar with the crusher
and know the risks and hazards very well.

Any other use of the crusher shall not be covered by the above-mentioned
instructions. The manufacturer of the crusher shall neither be made liable for defects nor
consequential defects and damage resulting from such use, nor shall he take over any
liability with regard to the Product Liability Act.

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10 Commandments of Safety
1. Support all efforts to keep the place of work safe and healthy.

2. Act and do everything with responsibility and utmost care if your safety and the
safety of others is at stake.

3. Regularly check all protection devices and tools for completeness and safe
functioning.

4. Inform yourself and others about the risks involved with the job so that such
risks can be prevented in the most effective way.

5. To avoid injuries and mechanical defects inform yourself about hazards and
safety measures if you feel not having enough knowledge on this subject.

6. Always bear dangers of injuries and accidents in mind before you begin with a
new work. Prepare well thought out safety precautions to protect yourself and
others. Revise such measures regularly and introduce necessary improvements.

7. Warn others of possible risks and defects if you see that they are working in a
very dangerous way or are about to cause dangerous situations.

8. Pay attention to changes in working conditions and working processes and act
accordingly.

9. Hazardous and risky behaviour, dangerous conditions and processes, which

could have caused accidents, must be reported to the management without
delay. Do not assume that somebody else will do this. Do not take drugs, pills
etc. and never drink alcohol when operating or maintaining the machine, or
prohibit consumption of drugs and alcohol during working hours.

10. Keep your place of work/area of work tidy. Tools and auxiliary means must be
collected after use and kept in a place especially provided for this purpose.

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Additional Safety Regulations

Inform operating personnel of the emergency numbers. The emergency numbers
must be made clearly visible close to the telephone.

Let the operating personnel attend a First Aid Course if they do not have such
knowledge.

In case of injuries to a person call for a doctor or other ambulance personnel at

once and take care of the injured person without delay.

All accident must be reported at once to the management.

Take off rings, bracelets, wristwatches, necklaces etc. before you start working at
the crusher.

For lifting heavy loads (above 25 kg) always use appropriate lifting devices.

Lift loads only out of the legs with stretched back.

Never stand under lifted loads and check all load raising devices for damage and
sufficient load-bearing capacities before each use.

Protect hair with a hairnet and avoid loose clothing when working at the machine
to avoid getting caught by rotating parts.

Always wear helmets for your own safety.

Depending on the crushing material noise level may reach an extent that will force
you to use ear-plugs.

Crushing material and operating conditions may create dusty environments, which
necessitate the use of protection masks.

Protect your eyes with safety glasses to avoid injuries

caused by dust and flying particles.

Always USE safety work-shoes and gloves to avoid injuries.

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Avoid deposition of material on or under the machine.

Unauthorised stay of persons within dangerous areas of the machine is strictly

forbidden.

Do not change or remove installations that ensure safety and avoid accidents.
Always keep them in a safe-to-operate condition.

Prior to each start-up the crusher personnel must make sure that no unauthorised
persons are within the dangerous areas of the machine.

Visually verify that all personnel and objects are clear of

equipment prior to operation.

Service and maintenance work are only allowed - and that without any exception -
when the machine is switched off and protected against unintended start-up (lock main
switch).

In case of defects which reduce the crusher’s safety, stop the machine at once
resp. switch it off and inform the management.

Careful and detailed instruction and training of the operating,

maintenance and repair personnel only as well as observation
and keeping of the safety regulations and working prescriptions
of the operating instructions ensure high availability of the
equipment with regard to trouble-free operation and economical
application.
Supplement the safety regulations of this operating instruction with
internal operating instructions based on national prescriptions, local
and national environmental laws, national accident prevention
regulations etc.

In this connection reference is made to the EC-Directive (89/655/EEC).

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1.2. Machine-specific Safety Instructions

Feeding and Crushing
Expert and skilled persons only with adequate training, who are familiar with the
operating instructions and dispose of sufficient experiences to operate the crusher are
authorised to do so. Such persons must be registered with their names in the list of
operators of the crusher and confirmed by signature.

Prior to start the crushing operation the following must be considered:

Starting the crusher despite of visible defects or other damage is strictly forbidden.

All safety installations must be correctly mounted and be in a ready-to-operate

condition.

The crusher itself must be free from crushing material to ease starting the crusher
drive.

Check impact bars, impact plates for completeness, state of wear and tight seat.

For switching on the crusher wait until the material throughput shows no
obstructions and all operating personnel is well away from the plant.

Never start the crusher drive before all above-mentioned

conditions have been fulfilled.

Do not feed the material before the crusher’s driving motor has reached its
operating speed after start-up.

Within the working area of the feeding equipment (excavator,

loader) there is always an acute hazard due to falling material.

Any stay within this area of hazard during material loading by the feeding
equipment is strictly forbidden.

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Always wear suitable protection clothing (safety gloves, safety shoes etc.) to avoid
injuries. Make sure that iron pieces or other unbreakable material are not loaded into the
crusher.

Material only which is specified under application data shall be fed into the crusher
to enable the crusher to achieve the indicated throughput capacity.

Should it be the cases that oversize material pieces get stuck in the inlet itself use
a suitable lifting device to remove them, with stopped crusher drive.

Never try to:

• Push material pieces got stuck in the inlet into the crushing chamber by using
rods or similar.

• Blast material pieces got stuck in the inlet.

The crushing process must be permanently watched to avoid critical situations

even before they probably occur.

Permanent observation leads to a continuous flow of material, which favourably

influences the throughput capacity.

The maintenance doors shall only be opened during standstill of the machine.
Protection devices must not be opened

Do not pass beneath the machine.

Prior to stop the crusher, run it until all the material is broken and discharged from
the machine.

Dangers in case of material clogging and material flow irregularities

Elimination of irregularities in the material flow and in particular, removal of

clogged material will often lead to risky situations.

Having eliminated the malfunction re-mount all safety installations and check them
again for proper functioning and operation reliability.

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Electrical Equipment

NA-CE-authorised personnel only are allowed to perform repair work at

the electrical equipment.

Expert personnel of a licensed company only are allowed to work on the

electrical equipment of the machine.

The electrical equipment was made in accordance with the legal provisions.

Carefully check whether the crusher has been earthed in accordance

with the local provisions.

Welding repairs at the crusher without adequate safety precautions will damage
the electrical equipment.

Emergency-Off
The machine may only be operated with an emergency off device.

Determine the cause of the malfunction at once and initiate corrective actions.

In case of art EMERGENCY-OFF unbroken material may remain in the crusher,

which could block the crusher’s drive at a new start.

Make sure that such material is reliably removed from the crusher.

Never use the EMERGENCY-OFFS for a normal stop of the crusher. Check these
EMERGENCY-OFFS regularly for proper functioning.

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Maintenance and Servicing

lndicated lubrication and oil changing intervals must be kept.

Maintenance and servicing jobs at the crusher must only be carried out during
standstill of all drives.

Make sure to prevent unintended starting of the crusher (e.g. blocking the main
switch).

Never use any other lubricants than those recommended by NA-CE.

Never mix up lubricants based on different substances (e.g. lithium-soaped grease

with calcium-soaped grease) because otherwise this could considerably damage bearings and
scaling under certain circumstances.

After completion of maintenance and repair work re-mount all available safety
installation and check them again for proper functioning and operation reliability.

Hazardous Material Disposal

Waste oil, waste grease, cleansing liquids, remnants of paints etc. must be
disposed of in an expert way and in accordance with the relevant national environmental
laws that are generally applicable.

Welding repairs
Welding repairs on NA-CE - CRUSHER must only be done after consultation of NA-
CE MACHINERY Co.!!

1.3. Warning Paint, Lettering and Warning Signs

Nameplates and warning signs must never be removed or painted over.

Illegible and defective nameplates and warning signs must be replaced at once by
identical new ones. Nameplates may be obtained from NA-CE Machinery Industry/TURKIYE.

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[Link] DESCRIPTION
2.1. General
Type K36 impact Crushers reduce medium-hard, hard stones and slag with high
efficiency and better-controlled screen analysis. Crusher body was well designed and made
up of two convenient detachable parts which make operating and maintenance easier. These
two parts are; the lower body on which the rotor is placed and the upper body which can be
separated in order to reveal the rotor and inner parts.
The material, introduced through the feed mouth, is hit by the rotor hammers and
thrown against the breaker bars which are placed on upper body.
The rotor hammers can be replaced through the maintenance doors. The
hammers are interchangeable with the next one by just reversing. They can be used longer.

2.2. Housing
The housing is designed in robust welded construction and consists of the lower
and upper part of the machine.

Maintenance doors are provided at front side to enable a check of the state of
wear of wearing parts.

The housing lining and the breaker bars for the first crushing stage arranged
inside the crushing chamber are made of highly wear-resistant material.

2.3. Rotor
The rotor body is designed in extraordinarily rigid welded construction. The rotor
shaft is manufactured of forged and heat-treated high-quality steel. Clamping elements are
used as connection to the rotor body.

Drive journals are provided at both ends of the rotor shaft to enable vee belt
pulley mounting at each side. The free shaft end is protected with a cover. For the bearing of
the rotor rigid self-aligning roller bearings are used.

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[Link] AND INSTALLATION

[Link] of Machine
MAIN COMPONENTS WEIGHT
(Kg)(K36)
Complete Crusher 13.500
Rotor Assembly 3460
Hammer 85 x 6
Lower Body 2035
Upper Body 3115
Feeding Box 205
Motor 670
Liners 1415
Flywheel 655

Faulty Delivery:
For damage in transit and missing goods the responsibility will rest with the
forwarding agent. All dispatched items shall be examined exactly at arrival and be compared
with the enclosed packing list. Any deviation from the should-be condition (such as damage,
missing parts etc.) must be made known to the forwarding agent at once.

In case of complaints please always inform NA-CE Machinery Industry to allow

them to carry out subsequent checks, (if necessary).

Bearings and labyrinths are completely filled with grease.

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3.2. Installation of Machine

Weight of the crusher is approx. 13,5 tons. The frame must bear on a flat,
horizontal surface, which can support such heavy loads. Base plate of the crusher should be
placed on a flat surface and the crusher must be balanced.

The machine should be mounted on chassis by using bolts and lock nuts. NA-CE
Machinery Industry will give installation dimension of crusher.

Since crushed material will be fed into a screen or bin, a suitable chute should be
placed machine outlet.
It is recommended that the chute was lined and discharge chute is away from the
crusher.

All necessary free spaces, as are required for maintenance, servicing and repair
works, must be taken into consideration during installation of machine.

Take utmost care during handling of machine or machine parts to avoid damaging
of bearing surfaces and other machined surfaces. Put all parts onto adequate wooden
supports only, never place them directly on the ground.

Take care of that all supplied parts are immediately protected from wind and
weather. (Store them under roof).

The machine can be stored up to 30 days without any problems when it is

adequately protected from atmospheric conditions.

 During lifting of loads take care that there are no persons

staying under suspended loads!

Always use suitable and proofed lifting devices to raise the machine.

Crusher weights approx. ~13,5 tons.

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3.2.1. Installation of V-belt drive

[Link] all oil, grease or rust from the pulley grooves.

[Link] certain that the pulleys are correctly aligned and that the shafts are
parallel.

[Link] force belts onto pulleys. Always shorten the center distance until belts can
be slipped on easily.

To determine the minimum allowances for shortening or lengthening the center

distance between pulleys. See Table [Link] “V-belt take-up allowances”.

Minimum allowances mm (inches) below center distance for installation of belts

Min. allowance
above center
Belt Length* V-belt section
dist. For stretch
and wear
8V 8V banded belts SPC
mm inch mm-----inch mm---------inch mm----------inch mm---------inch
2000-2749 79-108 40 1½ 85 3 3/8 35 1 3/8 40 1½
2750-3499 108-138 40 1½ 85 3 3/8 35 1 3/8 45 1¾
3500-4499 138-177 40 1½ 85 3 3/8 35 1 3/8 55 2 1/8
4500-5499 177-216 45 1¾ 90 3½ 35 1 3/8 65 2½
5500-6499 216-256 45 1¾ 90 3½ 40 1½ 85 3 3/8
6500-7999 256-315 45 1¾ 90 3½ 40 1½ 95 3½
8000-9999 315-394 50 - 100 - 45 1¾ 110 4 3/8
10000-over 394-over 50 - 100 - 45 1¾ 140 5½
*In each group the range is to, but not including the second length.
Table [Link]. “V-belt take-up allowances”

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After calculating a center distance from a standard pitch length make provision
that the centers can be moved closer together by the amount shown in the following table to
facilitate installing the belts without deterioration. Also, the centers should be adjustable over
the calculated distance by an amount as shown in last column the table because of
manufacturing tolerance and possible stretch and wear of belt.

4. Always use a matched set of belts and use new belts of the same manufacturer.
Never mix worn- belts.
5. Place belts on pulleys and run the drive for a few minutes. Then tension the
drive until only a sag appears on the slack side of the belts when the drive is running. An
example of tight side is shown in Figure [Link] below. The slack side depends on motor
position and rotation direction.

Figure [Link]. Determining slack side

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[Link] the V-belt drive

Tensioning the drive is a term used when force is applied to the V-belt by some
method to provide the
Wedging action between the V-belt and the pulley. This wedging action provides
the ability for a V-belt to transmit power from motor pulley to the crusher pulley.

Various methods of tensioning V-belts have been established. Two simplified

method will be described in the following paragraphs. Tension-deflection and percent (%) of
elongation. Either of these two methods will provide satisfactory belt tension. Each has
certain advantages for a given type of belt.
For tensioning the drive using the TENSION-DEFLECTION method, proceed as
follows:

1. Place a straight edge across the top of both pulleys. See Figure [Link]
2. Measure the span length.
3. Using a spring scale at right angles to the center of the span length, apply a
force to the scale great enough to deflect one of the belts the equivalent of 0.016 times
millimeters of span length (0.016 times inches of span length).
4. The force should approximate the forces shown in Table [Link]. “Flexion
forces” for a properly tensioned drive.

Figure [Link]. Tension deflection method

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EXAMPLE
V-belt section = Standard 8V belt

Span length (center distance) 1575 mm (62”)

Deflection force (from table) = 15-22 Kg. (34-50 Lbs.)

Deflection = 1575 mm (62”) x 0.016 = 25 mm (1”)

Therefore, on a NEW installation with a standard 8V section belt and a span length
of 1575mm (62”), the belt should deflect 25 mm (1”) with a spring force of 15-22 Kg. (34-50
Lbs.) for a properly tensioned drive.
5. At the end of 2-4 hours of operation, the drive should be retensioned to
approximately the maximum force.
6. After 24-48 hours, it is well to check the drive to see if the force on the belts is
between the minimum and maximum force shown in table. Retension if necessary. Either
excessively low or high tension will affect the life and operation of a V-belt.


WHEN PROPERLY TENSIONED A NARROW V-BELT MAY NOT FEEL
AS TIGHT AS ONE MIGHT FROM THE TENSION THEY CARRY. THEREFORE, IT IS
AD VISABLE TO USE A SPRING SCALE TO CHECK BELT TENSION ON THESE BELTS.

STANDARD BELT BANDED BELT*

Minimum Tension Maximum Tension Minimum Tension Maximum Tension
Belt section
Kg Kg Kg Kg
(in Lbs.) (in Lbs.) (in Lbs.) (in Lbs.)

8V 15.4 (34) 22.7 (50) 18.1 (40) 272 (60)

SPC 10.4 (23) 15.4 (34) 11.8(26) 18.1 (40)

*Multiply these values by number of belts in band.

Table [Link]. “Flexion forces”

For tensioning the drive using the PERCENT (%) OF ELONGATION method,
proceed as follows. This particular method of tensioning V-belt drives was developed
primarily for tensioning banded belts.
1. Remove the slack from the belts.
2. Next, wrap a 15 meters (50 foot) steel tape around the outside circumference
of the belt and measure to nearest millimeter (1/16”). Record this length. See Figure [Link]
“Percent of elongation method”.

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Figure [Link]. Percent of elongation method

3. Multiply this recorded length by a percent of elongation factor which is shown in

table [Link]. “ Elongation factors” and add this amount to the initial measurement.

4. Elongate the belt to this new reading.

EXAMPLE
V-belt section = Standard 8V belt

Initial tape reading = 3 meters, 48 mm (120”)

Elongation factor (from table) = 0.009 (multiplier) which is 0.9% (percent)

New length reading = 3 meters, 48 mm (120”) initial reading x 0.009

elongation factor =

3 Meters, 48mm (120”) + 27mm (1-1/16”) or 3 meters, 75mm (121-1/16”).

Belt Multiplier Percent (%)

Section*

8V 0.009 0.9
*Standard or banded belts
Table [Link]. Elongation factors

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Therefore, on an installation with an 8V belt and an outside circumference

measurement of 3 meters, 48 mm (120”), the motor pulley should be moved away from the
crusher pulley until the steel tape reads 3 meters, 75 mm(121-1/ 16”) for a properly
tensioned drive.

5. Periodic belt tension checks must be made and if retensioning becomes

necessary, the tensioning process just described should be repeated.

It must be pointed out that the TENSION-DEFLECTION METHOD is the preferred

method of tensioning V-belts.

Usually the first sign that indicates retensioning is necessary is belt slippage. This
slippage will show up in loss of power and speed at the crusher pulley and in a high rate of
belt and pulley groove wear. These conditions are usually accompanied by belt “squeal” and
also a heating up of belts and pulleys. These conditions are readily apparent and can be
detected by simply looking, listening and feeling.

3.2.3.V-belt precaution

Some of the do’s and don’ts in connection with proper V-belt drive operation are
as follows:

DO DON’T
-Check belt tension
frequently during the first few days -Over tighten belts as
of run-in operation. When the belts too much tension shortens both
have had time to become seated in belt and bearing life. Maintain
the pulley groove, retension the uniform tension. Idle belts should
belts. New belts have a certain appear tight; in motion, they have
amount of initial stretch and will slight sag on the slack side.
require additional tensioning.

Keep drives well

ventilated as heat buildup over
600C (1400F) causes belt life to Allow any oil or grease to
become short. The sides of the belt come in contact with the belts as
guard must be designed to allow excessive oil causes them to swell
for adequate circulation of air. and the belts to fail prematurely.
Either perforated plate or expanded
metal is ideal for this type of
application.

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DO DON’T
Make V-belt drive
general inspections on a periodic
basis. The following points must be
checked at each inspection.

A. Loss of crusher
speed - check tension.

B. Unequal stretch -
check each belt.

C. Excessive
elongation - check for overload.

D. Belt softening or
swelling-check for oil or grease.

E. Belt hardening and

cracking - check for excessive heat.

DRIVE SAFETY GUARD

The drive guard protects the operator and the drive from accidental rock falls.
As the motor position is specific to each crusher installation: the guard is often
designed and produced specifically for each crushing station.

FOR THE SAFETY OF THE PERSONNEL THE DRIVE GUARD MUST BE

BUILDED IN COMPLIANCE WITH CURRENT SAFETY REGULATIONS FOR THE
SITE ON WHICH THE CRUSHER IS USED.

THE GUARD MUST BE IN POSITION WHEN THE CRUSHER IS OPERATING.

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LIST OF OPERATORS

Each operator of the crusher confirms by his signature that he has received, read
and understood these operating and maintenance instructions.
In case of non-observance the rights to claim under guarantee shall be lost and NA-
CE does not take over any liability with regard to the Product Liability Act.

NAME TAKEN OVER ON SIGNATURE

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

TYPE A B C D E F G H J K L M
K36 2370 535 200 - 2503 200 710 2400 1018 1226 1306 1823

N O P Q R S T U V W
1154 215 635 260 3510 346 1570 400 4455 250



    

 
(kw) (d/d.)     

K36 (Ø 1535x1000) 90 – 1500 320 – 390 – 490 75 – 100 100 – 130 8” – 200 13500

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4.0. OPERATING INSTRUCTION

4.1. Start-Up And Operation :

The electrical driving motor is to be a squirrel cage induction and started up with
star-delta (Y-) starters. Transition from star to delta connection takes approx. 25-30
seconds.

Rotation Direction: The crusher rotor must rotate in the direction shown in figure below.

Make sure that V-Belts for driving motor and rotor pulleys were tensioned
properly. (Chapter [Link] of machine)

Crusher has been designed to operate smoothly without vibration.

The rotor of the crusher is balanced before delivery and it is tested. If there is an
irregular wearing of hammers while crusher is working, the rotor will lose balance and
crusher starts vibrating. Open crusher body and control hammers whether there are
hammers excessively or differently worn out. If there are, then make hammers equal by
grinding in order to balance the rotor.

After the installation is completed, run the machine for approx. 30 min. without
feeding it. The purpose of this is to diffuse the grease to labyrinth seals efficiently.

There should be a 12 sc. period before the firstmaterial is fed to the crusher.

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After 1-2 hours of working, control and tighten the loose bolts on crusher body.
Repeat this procedure after three or four days of start-up operation. Then periodically (at
least once a month) control these bolts and nuts.

 Material-feeding mechanism must first be stopped, before

stopping the crusher.

When crusher rotor is speeding down, there will be noise. Do not worry, this is a
normal condition.

4.2. Changing Hammers:

Hammers are reversible top to bottom to give maximum life. They are keyed to
the hammer holders.

When rotor is accelerating, hammers lean against the rotor discs and remain just
in that position during the operation of crusher.

The hammer keys should be checked after the first run at the end of each hour,
later they all should be checked at the end of each day.

Reversing the hammer is as follows:

If one looks to the machine from the inspection door, the worn upper face of an
hammer at right-hand side is reversed to left-hand side bringing it’s upper face to down.
IMPORTANT: Never use the worn hammers without reversing. This leads to wear
of hammer holders.

The amount of wearing depends on:

a) The kind of material to be broken
b) The size of material
c) The rotor speed

Especially, if granite or basalt is being broken, the hammers must be checked two
times a week.

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4.3. Rotor Balance:

The unbalanced rotor causes vibration during running, overheating on bearing and
generally bad running. Therefore, the operator should look for following points when he
wants to replace to the worn out hammers.
a) Never replace or reverse one or few hammers. The hammers should be
changed (replaced or reversed) as a whole.
b) The weight of hammers differ from each other normally. Their weights should
be written on after weighing them.
c) These hammers should be distributed on the rotor accordingly to prevent
unbalanced forces.

4.4. Breaker Bars:

The middle breaker bars are interchangeable, reversible and easily renewable
where as upper and lower breaker bars are not.
The middle ones might be used one instead of the other.
The wear of the bars should be longitudinally equal. In such a case, the
distribution of the material along the feeding chute will be unequal.
If hard rock like “granite, basalt etc.” are being broken in the plant, the breaker
bars should be controlled two times per week.

4.5. Mounting The Breaker Bars:

The breaker bars can be lifted easily from 2 holes for different purposes. When it
is desired to change the bars special sealing materials should be settled between the bars.

4.6. Replacing The Rotor Discs:

Following steps should be followed to replace the discs.
a) Upper casing is removed and lifted.
b) The housing bolts are loosened.
c) The bolts on flywheel are loosened.
d) The rotor is lifted and placed on wooden blocks.
e) The disc is lifted and pulled with an axial force and dismounted.

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4.7. The Speed of Hammers:

The peripheral hammer speeds should be within certain limits. The number of
hammers passing the feed point each minute must be kept within certain limits. If the time
between each hammer passing is too great, the stone will fall into the rotor to give inefficient
breaking and excessive rotor wear. If the period is too short, the stone will not enter
sufficiently to receive a direct blow from the hammers.

4.8. The Feed Size and Feeding Rate:

It is not a good policy to attempt too large a ratio of reduction at one pass, but to
run at a moderate speed and return the oversize for re-breaking. This will effectively reduce
wear and percentage of fines. The crusher will accommodate occasional overloads but,
obviously the power consumption will increase. Best results are achieved by an even feed
rate, which gives efficient breaking and minimum wear.

4.9. Changing The Reduction Ratio:

The size of broken material might be changed by pieces settled between
lowermost breaker bars and lower casing. So, 10-50 mm output material can be obtained.

4.10. Replacing The Liners:

All liners are made from high-grade manganese steel. And are bolted to the casing
by hexagonal threads.
The liners must be checked once per month and the ones which are worn out
should be renewed.

4.11. The Main Reasons of Overheating In Bearings:

The bearings work in 32-55C and temperature increases to 94-95C in hot
seasons. The best way to take the working temperature under control is using a
thermometer. If you do not have a thermometer, do it as follows;
Pour a little amount of water onto the housing. If this water evaporates
immediately, this means temperature is greater than 100C. If the temperature is greater
than 100C, the plant should be stopped and the reasons of overheating must be examined.
The reasons might be:

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a) High amount of lubricating:

This is one of the main reasons of overheating especially in new machines. The
bearings throw the excess grease out after the first run, then the bearing gains its normal
working temperature.
b) Unequal feeding:
When the axis of rotor shaft is not parallel to the water level, overloading on the
bearing will occur, leading to overheating. So, the frame on which the breaker will be
mounted should be parallel to water-level.
c) Running the machine at a speed greater than recommended:
Running the machine at speeds higher than given in manual will decrease the
efficiency.

4.12. Renewing The Bearings:

The most important operation in maintenance is changing the bearing. So, this
should be performed by an expert operator.

4.13. The Important Factors

In Replacing The Bearings:
a) All pieces of housing and bearing should be isolated from dust.
b) Lubrication should be enough.
c) The V-belts on fly-pulley should be tightened.
d) Never feed the breaker for the first period after first run.

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4.14. Fault Finding:

Fault Cause Remedy

Crusher drive cannot be Crusher housing not Close crusher housing and
switched on again. completely closed. bolt.

Check limit switch at crusher

housing.

Crusher does not start or Electrical system or crusher Have electrical system or
stops. motor defective crusher motor checked by a
licensed electrician

Rotor blocked by material Remove material from

crushing chamber

Ferrous pieces have entered Remove ferrous parts from

the crusher crushing chamber

Abnormal noise at crusher Defective bearings Have bearing replaced by

expert personnel

Loose impact hammer(s) Fasten impact hammers

Loose wearing lining(s) Fasten wearing lining(s)

Vibrations at crusher Rotor clogged with material Clean rotor

Different impact bar weights Mount impact bars of the

same weight

Vee belt pulley clogged with Clean vee belt pulleys

material

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Fault Cause Remedy

Crusher bearings too hot Insufficient grease quantity Refill grease

Wrong grease quality Fill in correct grease quality

Bearings defective Have bearings replaced by

expert personnel

Too much grease Reduce grease quantity

Labyrinth rings have become Tighten labyrinth rings

loose

Vee belt rupture after short Mounting by force Belt installation without using
time of operation (belt force acc. to operating instr.
torn)
Foreign body effects Check protection device

Crusher drive is blocking Check reason and correct

Ruptures and cracks in belt Increased belt slip Re-tension drive

substructure
Chemical influences Check reason and correct

Strong vibration of vee Too less pre-tensioning Correct pre-tensioning

belts

Belts cannot be re- Incorrect belt length Use shorter belts

tensioned anymore

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5.0. MAINTENANCE
Lubrication: Proper lubrication is an important factor in extending service life of
the machine. Lubricant equipment and grease fitting must be kept clean of grit to assure the
longest possible bearing life. Always wipe fittings grease gun nozzle before adding lubricant.

Bearings should be lubricated with a little “Shell Alvania R3” grease every day. This
will be about two inches of grease from the gun nozzle. Work the gun handle to determine
the amount of stroke needed to extrude 2” of grease and use this as a reference for future
lubrication.

Recommended Lubricants:

a) Temperate & Tropical Climates (0C - 32C)

Shell : Alvania grease R3
Mobil Oil : Mobilplex 47
Castrol : Spheerol AP 3
b) Cold Climate (below 0C)
Shell : Alvania grease R2
Mobil Oil : Mobilplex 47
Castrol : Spheerol AP 2
c) Hot Climate (above 32C)
Shell : Alvania grease R3
Mobil Oil : Mobilplex 47
Castrol : Spheerol AP 3

CAUTION!
Do not over-lubricate. Too much lubricant will cause abnormally high
operating temperatures.

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K36-000-00 IMPACT CRUSHER

NO DRAWING NO PART NAME QUA.

1 K36-300-00 ROTOR COMPLETE
2 BOLT
3 NUT
4 WASHER
5 K36-200-01 LOWER BREAKER BAR
6 V-BELT
7 K36-600-00 COVER
8 MOTOR
9 K36-000-10 END PLATE
10 BOLT
11 K36-000-15 COLLAR
12 K36-200-02 MIDDLE BREAKER BAR
13 K36-200-00 UPPER BODY
14 K36-000-22 HOPPER
15 K36-200-06 UPPER BREAKER BAR
16 COTTER PIN
17 K35-000-34 PIN
18 K36-500-00 LOWER BODY
19 K36-900-00 CHASSIS
20 BOLT
21 NUT
22 WASHER
23 K35-400-00 LINERS
24 BOLT
25 NUT
26 WASHER

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K36-300-00 ROTOR COMPLETE

NO DRAWING NO PART NAME QUA.

1 TENSIONING NUT
2 K36-300-13 SIDE DISCS
3 K36-300-11 ROTOR SHAFT
4 K36-300-10 TENSIONING BOLT
5 K36-300-09 COLLAR
6 COTTER PIN
7 K35-300-08 KEY
8 K36-300-06 IMPACT HAMMER
9 K36-300-12 KEY
10 SEAL
11 K36-300-04 HOUSING
12 BOLT
13 BOLT
14 K36-300-02 END PLATE
15 K36-300-01 COVER
16 BEARING
17 BOLT
18 K36-300-15 SEAL HOUSING
19 K36-300-23 LOCKING WASHER
20 K36-300-22 LOCKING NUT
21 BOLT
22 K36-300-20 END PLATE
23 KEY
24 SEAL
25 K36-300-17 HOUSING COVER
26 K36-300-16 END COLLAR
27 K36-300-18 FLYWHEEL
28 K35-300-25 DUST SEAL

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K35-400-00 LINERS

NO DRAWING NO PART NAME QUA.

1 K35-400-01 LINER
2 K35-400-03 LINER
3 K35-400-05 LINER
4 K35-400-02 LINER
5 K35-400-08 LINER
6 K35-400-07 LINER
7 K35-400-06 LINER
8 K35-400-04 LINER
9 K36-600-08 LINER
10 K36-100-13 LINER
11 K36-100-07 LINER
12 K35-400-09 LINER

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SPARE PART ORDER FORM

Please use the form when giving orders for your machine.

SPARE PART ORDER FORM ORDER NO :

NAME OF FIRM : ORDER DATE :

ADDRESS : DELIVERY DATE :
CONTACT PERSON:
DRAWING NO PART NAME QUANTITY PRICE TOTAL PRICE

CUSTOMER APPROVAL NA-CE SPARE PART MANAGER DISTRIBUTE

FORM NO: FYD.01 12/02/1999-03 DISTRIBUTION : [Link] Purchasıng [Link] Inventory [Link] Back to spare parts manager
, [Link] Spare Parts Manager

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