INSTALLATION, OPERATION, LUBRICATION, AND MAINTENANCE OF NO. S B18 AND B24 SMOOTH ROLL CRUSHERS

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1 INSTALLATION, OPERATION, LUBRICATION, AND MAINTENANCE OF NO. S B18 AND B24 SMOOTH ROLL CRUSHERS I. INSTALLATION A. RIGID MOUNTING: Use two heavy WF or I-beams running parallel underneath at least eight (8) ft. of the 10 ft. length of the 8" WF-beam sills of the Crusher. Space these so that their inside edges coincide with the inside edges of the Crusher sills. BOLT (do not weld) Crusher sills to these supporting beams through holes provided. Use lockwashers to guard against vibration. B. SUSPENDED MOUNTING: Under certain conditions it may be advisable to suspend the Crusher by means of four (4) 7/8 min. dia. flexible steel cables from a relatively light overhead framework (see special drawing). In any event, two heavy crossmembers are required just below the sills of the Crusher for safety in the event of cable failure. C. CLAY FEED TO CRUSHER 1. It is preferable for the conveyor bringing clay to a Smooth Roll Crusher to run PARALLEL to the length of the sills of the Crusher. It does not matter from which end of the Crusher the conveyor approaches, but it is very important to have the flat sheet of clay coming off the conveyor drop directly between the rolls and across their full face width. 2. If this conveyor must unavoidably approach the Crusher at RIGHT ANGLES, the discharge end of the conveyor should be elevated so that a special chute can be provided with baffles designed to spread the clay evenly across the faces of the rolls. 3. Moveable bars or deflectors in the stream of clay are advisable no matter how the conveyor approaches, since occasional observation will indicate a need for re-direction of clay flow to compensate for uneven wear. D. CLAY REMOVAL FROM CRUSHER 1. It is some advantage for the conveyor that receives the discharge from the Crusher to be located IN LINE with the length of the Crusher sills, and it is also some advantage to have this conveyor proceed outward at the FAST ROLL end of the Crusher. When this conveyor must be located at RIGHT ANGLES to the length of the Crusher, the design and construction of a chute that will receive the discharge from the Crusher and turn it properly onto a conveyor becomes more complicated and clay is much more likely to adhere to the walls of the chute.

2 2. The recommended MINIMUM angle of the sides of all hoppers and chutes is 70 degrees with the horizontal. 3. Discharge from the Crusher will not be violent (approx ft./min.) and it is not usually considered necessary to discharge onto a separate, short, and easily replaceable conveyor belt. 4. Sticky or soft materials, especially those which have a tendency to adhere to metal, may require special chute-lining materials such as wood, teflon, or other substances designed to shed clay. Highly abrasive clays may require rubber chute linings. In any case, doors or removable panels in hoppers and chutes are a necessity for easy and frequent clean-outs. 5. When belt guards are required they should be mounted on the supporting structure rather than on the Crusher itself, since vibration and even movement will be present at all times. II. OPERATION A. BEFORE START-UP 1. SPACING BETWEEN THE ROLLS: CAUTION: Before attempting this procedure electrical power should be disconnected and locked out. a. These rolls are NOT designed to operate closer than 1 /16'1 (1, 5 mm), and under no circumstances must they touch. About 1/8" (3,0 mm) is considered "normal." For maximum crushing effect the rolls should be as close as is compatible with the quantity or volume of clay that must go through the Crusher. Depending on the nature and moisture content, as well as the crushing requirements of the clay, some experimentation may be required to arrive at a roll-spacing which will combine adequate tonnage with maximum crushing effect. b. To change the spacing between rolls, it will be necessary to change the position of the fast roll bearing housings (C-13). NOTE: Refer to drawing SK for reference. Page 2

3 To accomplish this, first adjust the fast roll scrapers to allow for movement of the fast roll (only necessary when decreasing gap). Next, decrease the belt tension of the fast roll by moving the motor on its adjustable base (only necessary when decreasing the gap between rolls). The next and very important step is to unlock the roll adjustment screws (20D). This is accomplished by first removing two locking set screws, located immediately above the dial rings (20C) in the retaining caps for adjusting end (C20). Once both set screws have been removed, you should then find two more set screws in the same holes. These set screws, which we will refer to as the adjustment screw locking set screws, should then be backed out until they are flush with the top of the threaded holes. Now, by using the roll adjustment nuts (20J), set the appropriate gap between the rolls. To decrease the gap, turn the adjusting nuts counterclockwise. To increase the gap, turn the nuts clockwise. Turn the adjusting nuts in an alternating sequence, so not to bind the bearing blocks on their slides. Once the appropriate gap has been established and is consistent from side to side, rotate the rolls by hand to insure that minimum clearance is maintained. At this time the adjustment screw locking set screws should be threaded back down until they engage again into one of the locking holes located at each indicating mark on the dial rings (20C). Next, replace the locking set screws and tighten until contact is made with the adjustment screw locking set screws. Now the appropriate belt tension should be reset. Replace all belt guards and covers, making sure to check for any foreign materials such as wrenches. The machine is now ready to be turned on and run without material. Finally, adjust scraper until it just touches the roll and then back off approximately 1/2 turn. The machine is now ready to put into service. NOTE: The roll adjustment assemblies and bearing blocks have grease fittings. To insure ease of roll adjustment, it is necessary to maintain the proper greasing schedule (once a month for one shift operation or every 160 hours of production should be adequate). c. The springs on the Slow Roll shaft are compressed to a length of 9.75" (from 10") at the factory, but this dimension is somewhat arbitrary. You should determine the MINIMUM compression which will enable the machine to meet your requirements. Tramp iron and other hard, foreign objects in the feed to the machine should be avoided at all costs. Page 3

4 2. Adjust the double-acting, constant-tension motor base for correct belt tension. (See instructions from manufacturer of this base - use minimum tension that will operate the Crusher but avoid belt slippage.) 3. Be sure that the two underneath Scraper Blades are very close to, but not touching the faces of the rolls. 4. Check oil levels in Bearing Housings (use SAE-20W-40 motor oil). B. START-UP 1. Be sure that there is no clay, no pieces of welding rod, or other foreign matter between the rolls of the Crusher. Anything there will make it very difficult, if not impossible, to start. 2. A motor with high starting-torque characteristics and either a manual or magnetic reduced-voltage starter are required for a Crusher because of inertia and slowness to get up speed. For these reasons a Smooth Roll Crusher should be stopped and restarted only at beginning and end of shifts or half-shifts, and in emergencies. 3. Let the rolls get up to full speed before introducing anything into the Crusher. 4. Be sure that tramp iron, tools, spikes, dipper teeth, welding rod pieces, and other hard objects do not go through a Smooth Roll Crusher. In order to be highly abrasion-resistant, the alloy of which the Roll Shells is cast must necessarily be hard and subject to breakage under some conditions. Manganese Steel Roll Shells are available where a multitude of hard objects, including hard rocks, are encountered. C. AFTER FIRST FORTY (40) HOURS OF OPERATION 1. Check oil level in bearings. 2. Retighten all bolts and cap screws. 3. Recheck V-Belt tension and sheave alignment. 4. Recheck spacing between two rolls, especially to see that rolls are parallel and space between is same all along width of rolls. 5. If any wear-pattern is discernible on face of rolls, it may be necessary to adjust clay conveyor or to baffle clay coming into Crusher to equalize wear. NOTE: It Page 4

5 probably will be necessary to wait until after at least hours of operation to detect any pattern of wear. 6. Readjust scrapers to be very close to (but not touching) faces of both rolls and all the way across. III. LUBRICATION A. Check oil level in bearing housings DAILY. Use SAE-20W-40 oil. B. Use light grease in holes or grease fittings in tubes of constant-tension motor base, at least ONCE A WEEK. C. Grease the two Zerk pressure fittings on each bearing housing (for slides) ONCE A MONTH. IV. MAINTENANCE A. We have discussed the importance of: 1. Maintaining an EVEN roll spacing all across faces of rolls. 2. Spreading of clay all across the faces of the rolls so as to equalize wear, and at times baffling or otherwise redirecting clay flow to equalize wear. 3. If it seems advisable, either or both Roll Shells can be REVERSED on its tapered Center Castings, thus realigning the roll faces to equalize wear. B. Although we have furnished roll grinding attachments, we do not feel that a permanent, built-on roll-grinder or surfacer is practicable because: 1. Unless it is very large and heavy, with a grinding wheel of 15 HP or more, grinding will proceed very slowly and will be costly. 2. Unless the device is fully automatic, that is to say, will feed back and forth automatically, too much labor will be involved. 3. If it is both of the above, it will necessarily be heavy and expensive, and hard to change back and forth from one roll to the other. If it must be a DOUBLE device - capable of grinding both rolls at once, or without moving it, then it will be prohibitively expensive. Page 5

6 C. We recommend the purchase or local fabrication of a spare shaft and one (18 ) pair or two (24 ) pairs of Roll Center Castings, mounted on two suitable roller or sheave bearings in some area of the maintenance shop so that it can be revolved slowly and the Roll Tires resurfaced with a large and efficient (at least 15 HP) grinder under the occasional supervision of the Maintenance Shop personnel. It will be necessary, of course, to purchase at least one (1) EXTRA Roll Tire to have ground off true and flat and ready for mounting in the Crusher at a moment s notice - no doubt two (2) such EXTRA Roll Shells would be more advantageous. NOTE: The Roll Shells (32 OD x 18 face for the 18B and two (2) 32" OD x 12" face for the 24B Crusher) are IDENTICAL with the Roll Shells used on the SLOW ROLL of the 6B18 and 6B24 Disintegrators, and the Bearings are likewise identical. D. No matter what arrangements are made for keeping the surfaces of the Roll Shells flat and true, it is a fact that, within reason, the MORE OFTEN Roll Shells are removed, replaced, and reground, the more efficient the whole operation, and certainly the more effective the crushing of the clay. E. As a MAINTENANCE AID, two (2) bearing way extensions are supplied with the machine. As the bearings are self-aligning, it is sometimes difficult to get the bearings to align with the bearing ways when replacing the rolls in the frame. Use of the way extension will facilitate this procedure. These parts are not attached to the machine between usages, and care should be taken to assure they are not lost or misplaced. V. CAUTIONS A. Take every precaution to prevent hard objects such as tools, rods, dipper teeth, track spikes, etc., from getting into the Crusher. B. If hard rocks are frequently encountered, it probably will be wise to procure manganese steel Roll Shells. Although they do not wear as well as our other alloys, they will not break and can be worn and reground until they are very thin with safety. C. DO NOT allow to wear or regrind our hard alloy Roll Shells down below about 30 OD (762 mm) because the necessary strength of the Roll Shell may not be present. (All Roll Shells are approximately 32 OD (812 mm) when new - they are ground initially to a point just below any imperfections or irregularities of casting, rather than to an exact OD.) October 2, 1989 Page 6

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