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Operation & Maintenance Instructions

21052 (3/97)

ATerex Company

VSI 1800/2100

Operation & Maintenance Manual

Form 21052

LJ1093200

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To the Owner & Operator:

Cedarapids, Inc. tries to provide information that gives our customers a clear understanding of equipmentconstruction, function, capabilities and requirements. This information is based on the knowledge and

experience of qualified people at our company and in our field organization. Proper use of this information

rewards users of Cedarapids equipment with high efficiency, maximum service life and low maintenance

costs. That is why we strongly recommend that anyone using our equipment be familiar with this manual.

This manual is not a bible. Information presented here should not be considered authoritative in every

situation. Users will, as a matter of course, encounter problems and circumstances that raise questions not

anticipated here. Such questions should be directed to Cedarapids, Inc.

Anyone who uses this equipment for any purpose other than that for which it was intended assumes sole

responsibility for dangers encountered and injuries sustained as a result of such misuse.

Respectfully,

Cedarapids Inc.

Danger - Federal, state and local safety regulations aim to protect both people and property from

accident, injury and harmful exposure. When complied with, such regulations are often effective.

Hazards to life, limb and property are further reduced when this equipment is used in accordance

with all operation and maintenance instructions. Generally:

1) Read and heed all danger, warning, caution and notice decals. Know what guards and protective

devices are included and see that each is installed and in operation condition. Additional guards and

protective devices may be required and must be installed by the user (owner) before operating.

2) Never attempt to maintain, lubricate or adjust this equipment while it is running. Lock out and tag out

all energy sources before doing maintenance, cleaning, adjusting or repairing this equipment. Make

it impossible for anyone to start this machine while others are working on it or in it.

3) Wear protective clothing such as hard hats and safety shoes, and use protective equipment such as ear

plugs and safety glasses when operating this equipment. Do not wear loose clothing or long hair.

4) Think safety and act safely. Stay alert at all times. Eliminate or neutralize potential hazards as soon

as you spot them. Never allow anyone to engage in horseplay when near this equipment.

Danger - Failure to take these precautions will result in death or severe personal injury.

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Introduction


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The following warning applies to Cedarapids equipment supplied with lead-acid batteries:

Warning: Battery posts, terminals and related accessories contain lead and lead compounds,

chemicals known to the State of California to cause cancer and reproductive harm.

Wash hands after handling.


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Section 1

Introduction and Contents

Experience shows it is to your advantage to have a

copy of this manual on site at the crusher where

operators can consult it as needed... and a copy onfile in your office so that shift leaders or supervisors

can conveniently refer to it.

This manual is printed on high quality paper and

bound in a tough, flexible three-hole binder so it can

be read and handled many times in the field. Feel free

to write notes or comments in it as needed. The

manual is for your use.

Additional copies can be ordered through your

Cedarapids/ElJay Distributor.

The Owner/Operator Manual may be bound with the

VSI Parts Book. The Owner/Operator Manual is not

intended as a source for ordering parts. Only your

VSI Parts Book, identified with your serial number,

can be relied on for accurate part numbers and part

descriptions for your machine.

Ongoing improvement of product design may result

in future changes to some parts. When ordering

replacement parts, please be as exact as possible in

describing the part.Use part numbers, model numbers, and serial number

to communicate with your Cedarapids Distributor.

When you have a question, please consult your

Cedarapids Distributor Representative.

About Cedarapids/ElJay

Cedarapids/ElJay is proud to manufacture the

superior VSI rock crusher for your use and profit.

We also take pride in the quality of our service and

replacement parts. We look forward to serving you.

About This Manual

This manual is for owners and operators of a Vertical

Shaft Impact rock crusher made by ElJay Division of

Cedarapids Inc. The VSI is a precisely engineered,

highly functional machine designed to provide years

of excellent service. We strongly recommend that

anyone involved with the operation or maintenance

of the crusher take the time to become familiar with

this manual.

Warning! This manual contains vital

information for the proper, safe operation of

this equipment. Read the whole manual

before beginning to operate the equipment.

Failure to follow instructions and warnings

contained in this manual could result in

severe personal injury or death! It could

also incur substantial property damage.

Attention! Sometimes, at customer’s request,

a VSI is shipped without certain features,

such as the sheave. When this happens,

Cedarapids/ElJay attaches a warning tag to

alert installers that the belt guard, a safety

feature, is missing. In such cases it is the

customer’s responsibility to properly guard

the machine while it is running.

Keep this manual for your future reference. It can

help you:

• safely operate your VSI

• understand how your crusher works

• get highest production efficiency

• perform regular maintenance and replace parts• get maximum life from your wear parts

• keep your downtime to a minimum.

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Table of Contents

Section 1

Introduction and Contents

About This Manual ........................................... 1.1

Section 2

Safety Precautions

Personal Safety Hints and Rules ....................... 2.1

Cedarapids/ElJay Recommends ....................... 2.1

Work Area Safety Hints ................................... 2.2

Equipment and Tools Safety Hints ................... 2.3

Section 3Installation and Start-up

Leveling on a Sturdy Foundation ..................... 3.1

Access ............................................................... 3.1

Transporting Your VSI ..................................... 3.1

Lock Down the Throw Device ......................... 3.2

Reinstall the Locking Bolts Before Travel ....... 3.2

Models .............................................................. 3.2

Types of Drive .................................................. 3.2Component Weights Chart ............................... 3.3

Electrical System .............................................. 3.4

Start-up Controls .............................................. 3.4

Automatic Shutdown ........................................ 3.4

Optional Pre-wired Panel.................................. 3.5

Setting Up the Lubrication System................... 3.5

Setting Up the Rock Material Feed .................. 3.5

Guards and Nearby Equipment......................... 3.5Check Rotation Direction Before Starting........ 3.5

Maximum RPM ................................................ 3.6

First Start-up Check List................................... 3.6

Storage .............................................................. 3.6

Installation Drawings

1800 VSI-GD.................................................... 3.7

1800 VSI-VBD ................................................. 3.9

2100 VSI-GD.................................................. 3.11

2100 VSI-VBD ............................................... 3.13

Section 4Daily Start-up and Check List

Daily Start-up Detail......................................... 4.1

VSI with CastRotor .......................................... 4.1

VSI Daily Start-up Inspection Form................. 4.3VSI with Table/Shoes ....................................... 4.5

Daily Start-up Detail- Continued...................... 4.5

Expected Flow Rates ........................................ 4.6

Cold Weather Start-up ...................................... 4.7

Hot Weather Start-up ........................................ 4.7

Section 5Changing Table/Shoe Wear Parts

Balanced Running Important ............................ 5.2

Tables: Various Types Available ..................... 5.2

Shoes, Shoe Pins, Shoe Bolts ........................... 5.2

Weight-Balanced Shoe Sets.............................. 5.3

When to Change Shoes ..................................... 5.3

How to Remove Shoes ..................................... 5.5

How to Replace Shoes ...................................... 5.5

Shoe Brackets and Liners ................................. 5.6

When to Change Shoe Bracket Liners .............. 5.6

Changing Table Liners ..................................... 5.6

Changing Feed Disc ......................................... 5.7

Changing Table Rim Liners ............................. 5.7

6-Shoe Closed-Top Table ............................... 5.10

Cover Plate ..................................................... 5.10

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Table of Contents

Section 6

Changing CastRotor Wear Parts

Maintain Balance with Matching Sets .............. 6.2

Epps and Wear Tips .......................................... 6.2

Changing Exit Port Protectors (Epps) .............. 6.2

Changing Wear Tips ......................................... 6.2

How to Change Primary and

Retaining Liners ............................................... 6.4

Changing Feed Disc ......................................... 6.5

CastRotor Tuning ............................................. 6.6

How to Change Trailing Angles ....................... 6.7

Changing the Feed Eye ..................................... 6.9

When to Change the Top Retaining Plates ....... 6.9

How to Change Top Retaining Plates .............. 6.9

How to Remove the CastRotor ....................... 6.10

Changing Rim Liners ..................................... 6.11

Changing Side Plates ...................................... 6.11

When to Change the Bottom Retaining Plate . 6.12

How to Change the Bottom Retaining Plate... 6.12

Installing Rotor Studs ..................................... 6.12

Section 7

Changing Stationary Wear Parts,Belts & Sheaves

The Feed Tube .................................................. 7.1

Removing and Reinstalling the Feed Tube....... 7.2

Adjusting the Feed Tube Height ....................... 7.2

Adjusting Feed Tube with an Open Table........ 7.3

Adjusting Feed Tube with a Closed Table ....... 7.3

Adjusting Feed Tube with a CastRotor ............ 7.4

Removing the Lid Assembly ............................ 7.4

Types of Impact Surfaces ................................. 7.5

Anvils ............................................................... 7.5

Rock Shelf ........................................................ 7.5

Monitoring the Anvil Ring ............................... 7.5

Replacing Lid Liners ........................................ 7.7

Replacing Tub Liner ......................................... 7.8

Replacing Flywheel Guard Wear Plates ........... 7.8

V-Belts .............................................................. 7.8

Installing New Belts ......................................... 7.8

Sheaves and Bushings ...................................... 7.9

Removing Sheaves and Bushings ..................... 7.9

Installing Sheaves and Bushings .................... 7.10

Check Alignment ............................................ 7.10

Section 8

Lubrication System

Lubricant Oil Specifications ............................. 8.1

Oil Properties at Operating Temperature.......... 8.1

Acceptable Lubricants ...................................... 8.1

Switching to Other Grades ............................... 8.1

Oil Analysis: When to Change Oil ................... 8.1

Taking Oil Samples .......................................... 8.2Checking Oil Level with the Dip Stick ............ 8.3

How to Change Oil & Filter Element ............... 8.3

Oil Flow Patterns .............................................. 8.4

Lubricating Oil Capacities ................................ 8.6

Oil Flow Monitoring System ............................ 8.6

Flow Meter/Switch Settings ............................. 8.7

Expected Oil Flow Rates .................................. 8.7

Section 9

Electrical System

Junction Box (J-Box)........................................ 9.1

Oil Pump........................................................... 9.1

Flow Switch and Warning Horn ....................... 9.1

Vibration Switch ............................................... 9.2

Start Delay ........................................................ 9.2

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Section 9 (con't)Electrical System

Monitor Delay and Simple Test ........................ 9.2

Automatic Shutdown ........................................ 9.2

Start-up Controls .............................................. 9.2

Wiring for Heater and Thermostat.................... 9.2

Wiring for Optional Pre-wired Panel................ 9.2

120 Volt Electrical Schematic

(For Units Without Optional Lid-Lifter) .......... 9.3

120 Volt Circuit Operation ............................... 9.4

220 Volt Electrical Schematic(For Units Without Optional Lid-Lifter) .......... 9.5

220 Volt Circuit Operation ............................... 9.6

220 Volt Electrical Schematic

(For Units With Optional Lid-Lifter) ............... 9.7

Section 10Applications

How It Works: VSI Crushing Action ............. 10.1

Characteristics of Rock................................... 10.1Hardness ......................................................... 10.1

Abrasion ......................................................... 10.1

Friability ......................................................... 10.1

Application ..................................................... 10.1

Every Particle Crushed ................................... 10.2

Variables You Control to

Meet Your Requirements................................ 10.3

Changing Speed .............................................. 10.3Varying Throw Devices.................................. 10.3

Balancing a Circuit ......................................... 10.3

Varying Feed Size .......................................... 10.3

Power, RPM, Feed Rates & Sizes Chart ........ 10.4

Controlling Wear ............................................ 10.5

Factors Affecting Gradation ........................... 10.6

Adjusting Trailing Angle Position.................. 10.7

Table Requires Anvil Ring ............................. 10.7

VSI-GD (Gear Driven) ................................... 10.7

Changing Throw Device Rpm........................ 10.7

Sheave and Rpm Combinations...................... 10.8

Section 11

Troubleshooting

Too Much Vibration ....................................... 11.1

High Operating Temperature .......................... 11.1

Too Much Noise ............................................. 11.2

Too Much Oil Consumption ........................... 11.2CastRotor Wear Tips Failing Too Soon ......... 11.2

Uneven Wear .................................................. 11.2

Rapid Wear ..................................................... 11.2

Bearing Failure ............................................... 11.3

Wear Part Breakage ........................................ 11.3

Low Production Tonnage ............................... 11.3

Plugging of Hopper ........................................ 11.3

Horn Sounds ................................................... 11.3V-Belts ............................................................ 11.4

Section 12Other Information

Temperature Conversion Chart ...................... 12.1

U.S. Standard Sieve Series ............................. 12.2

Bolt & Nut Torque Chart ................................ 12.3

U.S.- Metric Conversions ............................... 12.6

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Section 2

Safety Precautions

ATerex Company

Personal Safety Hints and Rules

Cedarapids/ElJay equipment is designed with the

safety of all personnel in mind. Do not attempt to

change, modify, or eliminate the accident prevention

devices installed at the factory. Make sure that all

personnel who regularly work or who might do work

in the area of the equipment are familiar with the

safety precautions. Owners and operators are

responsible for reading safety information and

following safe practices. Think safety! Act safely!

Guards, covers, and shields are installed around

moving parts at the factory whenever necessary to

prevent accidental injury to operators and others

working on or near the equipment. Do not remove

them.

Attention! Sometimes, at a customer’s

request, a VSI is shipped without certain

safety features, such as drive sheave guard

or belt guard. When this occurs Cedarapids/

ElJay attaches a warning decal to alert

installers that the safety feature is missing.

In such cases it is the cus tomer’s

responsibility to properly guard the machine

while running.

For your personal safety, this manual includes three

levels of hazard and injury alert notices: Danger,

Warning, and Caution. Each hazard alert notice is

accompanied by an international alert symbol to

help call your attention to dangerous or potentially

dangerous situations. Read all alert notices carefully

to prevent injury to yourself or others.

Danger! Whenever you see “DANGER!” inthis manual, it means that death or severe

personal bodily injury can immediately result

from improper procedures . Read al l

“Danger!” messages carefully to prevent

accidents. Take immediate action!

Warning: Whenever you see “Warning” in

this manual, it means that severe personal

bodily injury may result from improper procedures. Be on guard! Warning indicates

that a serious hazard is present and severe

injury is possible. Read all Warning messages

carefully to prevent someone being hurt.

Danger!, Warning: and Caution: messages are

accompanied by the international alert symbol to

help call your attention to situations where danger to

persons is present.

Caution! Whenever you see “Caution” in

this manual, it means that if proper

procedures are not followed, minor to

moderate injury (small cut, bruise, etc.) may

result. Do not neglect to care for even small

cuts. Avoid infection by cleansing and

covering wounds.

Cedarapids/ElJay recommends the following basic

safety practices

• Read all warning, caution, and instruction signs.

Warning! Lock out the power source to thiscrusher before attempting any maintenance.

Always establish a positive lockout of the

involved power source before performing

maintenance, cleaning, adjusting, or repair.

Secure the power source lockout to prevent

start-up by other persons.

• To help determine safe lifting conditions for

VSI components and units, see the Component

Weights Chart, pages 3.4 and 3.5.

• Save your back. If the load is more than 18 kg

(40 lbs), get help or use proper lifting

procedures. Use your leg muscles, not your

back, for lifting. Keep loads close to your

body. Avoid twis ting mo tions and

overextensions when moving loads.

• Do not remove any guards, covers, or shields

when equipment is running.

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Section 2

Safety Precautions

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• Replace any guards, covers, or shields after

adjustment or maintenance.

• Never lubricate moving or running equipment.

• Block parts as necessary to prevent unexpected

motion while performing maintenance,

adjustments, or repair.

• Do not attempt to remove jammed product or

other blockage from running equipment. Power

must be shut off and locked out while doing so.

Use adequate hearing protection devices

when noise level is above acceptable limits.

Wear an adequate protective breathing mask

whenever dust and fumes are above

acceptable limits.

Wear adequate eye protection goggles or

safety glasses with side shields to prevent

flying particles from entering eyes.

Hard hats are a good idea and are required at

most field work sites. Wear yours.

• Maintain safe work habits by dressing

appropriately for the job. Do not wear loosesleeves, flowing hair, long coat tails, wrist

watches or bracelets, or pockets full of tools,

which could get caught in moving machinery.

Thin-soled shoes without tread could cause

falls or foot injury. Wear safe shoes.

• Always look around equipment before start-

up to make sure no one is near moving parts,

making adjustments, or performing

maintenance. Keep alert to where your co-

workers are.

• Report defective machinery and unsafe

conditions to your supervisor.

• Know your equipment. Understand the

machine and the conditions under which it

operates. Do not limit playing it safe to only

these few general rules. Think and act safely

for your specific work environment and your

particular equipment.

Work Area Safety Hints

• Keep the work area as neat and as clean as

practical.

• Keep all warning and caution signs clear and

up to date.

Make certain that all electrical equipment is

properly grounded. Wet spots near electric

current are dangerous. Use ground-fault

interruptible circuits wherever a potential

shock hazard exists.

• Store hazardous materials in restricted access

areas and mark them clearly. United StatesEnvironmental Protection Agency federal

regulations require special labeling of certain

materials.

• Make certain enough ventilation is present to

safely run engines. Do not start an engine in an

enclosed space without properly vented

exhaust. Exhaust fumes from gasoline or diesel

can kill!

Do not smoke or allow smoking near

flammable fuels or solvents. Use

nonflammable solvents when possible for

cleaning parts and equipment.

Avoid electrical and static sparks and any

open flame while handling, storing, moving

or pouring fuels, electrolytes for batteries,

hydraulic fluids, or coolants.

Check for leaks in tanks or tubing with

flashlights or other proper equipment. Never

use an open flame to check for leaks.Know where fire extinguishers and other fire

suppression equipment are located. Learn

how to use them.

Be alert and wary around any pressurized

system: hydraulic or air. High pressure gases

and oils can be very dangerous. Know your

equipment and operate it properly.

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Section 2

Safety Precautions

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Equipment and Tools Safety Hints

• Clean and properly labeled tools are safer

tools. Keep your equipment and tools in order.

• Always use hoisting equipment for heavy loads.

Regularly check hooks, cables, shackles, and

chains for stretch and wear. Never overload

the lifting capacity of hoists, cranes, and lifting

devices.

• Keep V-belts and sheaves in good condition.

Frayed belts or cracked sheaves can be

dangerous and cause downtime.

• Keep your equipment clean and free of dirt andgrease so it can be checked for loose, cracked

or broken parts. Replace defective parts as

soon as they are discovered.

In addition, for your information, two other kinds of

alert messages are included in this manual.

Notice: Whenever you see “Notice” in this manual,

it means that failure to follow proper procedures

could lead to serious and expensive damage to your

machine.

Important: The “Important” messages in this

manual help you to choose procedures that add to

the efficiency and useful life of your machine.

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Section 3

Installation and Start-up

ATerex Company

Leveling on a Sturdy Foundation

To operate correctly all VSI's must be installed level

on a firm foundation. For stationary units, level the

base frame on a vibration-free foundation. Check

both east-west and north-south to be level. A solid,

well-drained concrete or stone foundation is ideal,

but compacted rock can work, too. If set up on

compacted rock, regularly test the foundation to

detect any movement or settling. Any supporting

steel structure must be heavy and sturdy enough to

support the total dynamic load of the operating

crusher, conveyors and other related equipment with

rock moving through it. Cross-bracing isrecommended.

For plant-mounted units: use a carpenter’s level to

check the plant frame. Use cribbing as needed to be

sure the plant is level and firm. Do not operate with

tires touching the ground.

Access

See appropriate installation drawing to help

determine needed clearances for your VSI and site.

Allow enough room all around for conveyors, loaders,maintenance cranes and other trucks. Allow enough

clearance below crusher for discharge conveyor.

Design safe overhead clearance, proper conduit for

electrical power and communication lines, safe

catwalks with handrails, and machine guards for

every moving machine part to prevent accidents.

VSI models are available in different drive systems,

types of throw device (also called impeller), sizes,

and impact surfaces. Each model performs

excellently in the right application, but must beinstalled correctly to get best results. The different

configurations require slightly different maintenance

and replacement steps. The ability to conveniently

service and maintain the VSI depends in part on how

its installed so that all major systems and components

are accessible. Eight major components or systems

work together to make the VSI an effective rock

crusher:

• Lid Assembly

• Throw Device (Impeller)

• Tub Assembly

• Vertical Housing and Shaft Assembly

• Drive Assembly

• Lubrication Oil System

• Electrical System

• Miscellaneous Components

On plant-mounted VSI's subcomponents of the

lubrication and electrical systems, such as the oil

pump and/or junction box, may be mounted on the plant’s frame. Since plant configurations vary, the

exact placement of these subcomponents and their

hose and line routings also vary. The installation

drawings shown in this section describe typical

locations for subcomponents.

Transporting Your VSI

A typical method for tying down the VSI for transport

is shown in Figure 3-1.

Note that the heavy timbers are placed under themounting pads and clearance below the mounting

pads helps avoid damage to the under-crusher

components. The cables are well-anchored and the

sheave is protected from accidental impact.

Figure 3-1Typical Tie-downs for Transporting the VSI

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Section 3


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Lock Down the Throw Device

The VSI is shipped from factory with locking bolts

in place to lock down throw device. The lock-down

process prevents the possibility of flywheel bouncing

up and down during transport, possibly damaging

bearings. A decal is mounted near inspection access

doors as a reminder (Figure 3-2)

1) Open the inspection doors.

2) Look for two or three bolts with yellow tags

attached (Figure 3-2). Some throw devices

have two, some have three locking bolts. Tables

with even numbers of shoes and CastRotorshave two. Tables with odd numbers of shoes

have three.

3) These locking bolts are installed vertically

between the top of the throw device and the lid

liners. The outer nuts are threaded out to apply

pressure down against throw device. The

second nut prevents the first nut from loosening.

4) Loosen the nuts and remove the bolts.

5) Store these bolts where you can use them

again the next time the VSI is to be transported.

Reinstall Locking Bolts Before Travel

Notice: Do not ship or transport VSI until throw

device is locked down to prevent bearing damage.

Bearing damage may not be easily seen or

immediately noticed, but it can cost valuable

downtime and repairs. Installing lock-down devices

before transport is easy and inexpensive.

1) Open the inspection doors.

2) Install the locking bolts shipped with your VSI

(Figure 3-2). If you need to use other bolts, use

new bolts at least 27 mm (1") diameter bolts

and paint them with a bright color or otherwise

mark them to be sure they are noticed and

removed at the end of the transport, before

operation. Choose bolts that are slightly shorter

than the distance from the top of the throw

device to the lid liners.

3) Use two nuts on each bolt. Place two or three

bolts to push evenly down on the throw device.4) Tighten these bolts firmly and evenly (but not

too tightly!) by threading the nuts outward.

5) Test the effectiveness of the locking bolts by

attempting to rotate the throw device by hand.

If you cannot dislodge the bolts by rocking the

throw device back and forth, then the bolts are

tight enough.

Notice: Do not overtighten these bolts. You could

crack the lid liners with too much pressure.

6) Use the second nut to lock the outer nut in

place.

Models

The VSI is available in 1800 and 2100 models. Each

size can be configured with table with shoes and

anvils, with rotor and rockshelf, or with rotor and

anvils, each driven by right angle gear (GD) or

vertical belt drive (VBD).

Types of Drive

The two types of drive system are right angle gear

drive (GD) and vertical belt drive (VBD). GD models

can be powered by diesel or electric motors while

VBDs are driven by one or two vertically mounted

electric motors.

THROW DEVICE MUSTBE LOCKED DOWNDURING TRANSPORTTO PROTECTCRUSHER BEARINGS.USE 2 BOLTS, ONOPPOSITE SIDES OFTHROW DEVICE.

Decal Part #01-871-372-0070

1" (27mm)bolts

Turn nut towedge bolt

in place

Lockingnut

Lid liner

Feed tube

Throw device(table or rotor)

NOTICE

Figure 3-2Lock Down the Throw Device Before Transport

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Section 3


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Weights in lbs (kg) 1800 GD 1800 VBD 2100 GD 2100 VBD

Total with rotor & anvils 14,400 (6545)

20,294 (9225) 2 mtr

26,000 (11818)

33,034 (15015) 2 mtr

15,972 (7260) 1 mtr 27,812 (12642) 1 mtr

Totals with rotor & rockshelf 13,250 (6022)19,144 (8702) 2 mtr

23,100 (10500)30,134 (13697) 2 mtr

14,822 (6737) 1 mtr 24,912 (11324) 1 mtr

Total with table, 4 shoes & anvils 14,180 (6727)20,074 (9124) 2 mtr

26,000 (11818)33,034 (15015) 2 mtr

15,752 (7160) 1 mtr 27,812 (12642) 1 mtr

Total with flywheel, no rotor,no anvils, no rockshelf

11,000 (4990)16,894 (7697) 2 mtr

21,580 (9789)26,614 (13006) 2 mtr

12,572 (5715) 1 mtr 23,392 (10633) 1 mtr

Lid Assembly 2,500 (1136) 2,500 (1136) 3,100 (1409) 3,100 (1409)

Anvils & Ring 2,100 (955) 2,100 (955) 2,900 (1318) 2,900 (1318)

Rockshelf (by itself) 950 (432) 950 (432) 1,080 (491) 1,080 (491)

Flywheel (by itself) 440 (200) 440 (200) 1,000 (455) 1,000 (455)

CastRotor 1,300 (591) 1,300 (591) 1,526 (694) 1,526 (694)

3-shoe Table 1,000 (455) 1,000 (455) 1,434 (652) 1,434 (652)

4-shoe Table 1,080 (491) 1,080 (491) 1,520 (691) 1,520 (691)

1 2

1 2

1 2

1 2

1 2

1 2

1 2

1 2

Weights in lbs (kg) 1800 GD 1800 VBD 2100 GD 2100 VBD

5-shoe Table 1,160 (527) 1,160 (527) 1,606 (730) 1,606 (730)

6-shoe Table 1,475 (670) 1,475 (670) 1,975 (898) 1,975 (898)

Uppter Tub with Rock 4,200 (1909) 4,200 (1909) 5,400 (2455) 5,400 (2455)

Lower Tub 1,370 (623) 1,370 (623) 1,700 (773) 1,700 (773)

Gear Box Drive Module 2,750 (1250) N/A 3,410 (1550) N/A

Housing Assembly VBD N/A 1,300 (591) N/A 1700 (773)

VBD Motor Mount with Bracket N/A 1,680 (764) N/A 1680 (764)

Feed Disc (flat) 86 (39) 86 (39) 129 (57) 129 (57)

Feed Disc (cone-shaped) N/A N/A 94 (43) 94 (43)Typical Anvil 60 (27) 60 (27) 86 (39) 86 (39)

Typical Shoe 57 (26) 57 (26) 82 (37) 82 (37)

Anvil Ring (by itself) 542 (246) 542 (246) 893 (406) 893 (406)

6-shoe Cover Plate 125 (57) 125 (57) 175 (80) 175 (80)

Hopper 460 (209) 460 (209) 630 (286) 630 (286)

Feed Tube Table 98 (45) 98 (45) 170 (77) 170 (77)

Feed Tube Rotor 98 (45) 98 (45) 130 (59) 130 (59)

1Weights assume 250 hp (187 kw) electric motor(s).2Weights assume 300 hp (224 kw) electric motor(s).

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Start-up Controls

A properly wired VSI assures that the drive cannot

be started unless the oil pump is running and the

proper amount of oil is flowing through the pump.

The horn sounds momentarily (1-2 seconds) then

turns off when you first start the oil pump. This

assures you that the horn and flow meter/switch are

working properly. Always be sure the oil pump

starts before the drive shaft turns.

On electrically powered models check the power

supply to be sure its voltage, frequency, and phasing

agree with that shown on the electric motor

nameplate(s).

Be certain that line voltage is within 10% of nameplate

value and that frequency is within 5% of nameplate

value. The combined variation of voltage and

frequency must not exceed 10%.

Wire the oil flow meter/switch to the warning horn

and main power source (Figure 9-4 & 9-4). This step

is a simple but very important protection for your

crusher. Your VSI must have full lubricant supply at

all times during running.Automatic Shutdown

If the oil flow rate is too low, the warning horn

sounds and the crusher shuts down. If this happens,

find out why the oil flow was too low before restarting

the VSI.

If the vibration detection switch trips, the crusher

drive shuts down, but the warning horn does not

sound. Momentum continues to keep the flywheel

rotating for awhile. After the flywheel and throw

device stop rotating, find out why the vibration

detection switch tripped. To restart the crusher, turn

the oil pump off, then back on. This resets the

vibration switch.

You can tell the difference between a shutdown

caused by the oil flow switch and one caused by the

vibration detection switch by whether or not the

horn sounds.

Electrical System

The electrical system for all VSI models includes a

vibration-sensitive shut-off switch, an electric oil

pump with timer, a flow meter/switch (also called

the flow monitor) connected to a warning horn, and

a thermostatically controlled oil heater.

See the Electrical Schematics in Section 9. Note

particularly the importance of the vibration switch

and the flow meter/switch.

Warning! The vibration switch must be

connected correctly and be in good working

order whenever the VSI is operating. Failureof the vibration switch to shut down the VSI

if high vibration develops during operation

could be very dangerous to operators or

other people nearby. Death or serious injury

could result!

Notice: Refer to the electrical schematic for proper

connection at the junction box. The flow meter/

switch must be tied into the warning horn, the

shutdown circuit and the feed device to prevent

serious machine damage in the event of lubrication failure.

Electrically ground the crusher mount or trailer

frame with standard grounding rod or earth/grounding

devices, according to local electrical code.

Warning! Failure to lock out the power

source before performing maintenance can

result in serious injury or death. Because of

the danger of accidental start-up of the VSI

while maintenance is being performed, you

must set up a system for positive lockout of the power source during cleaning,

maintenance, adjustment, or repair. Prevent

accidental start-up of the crusher by another

person. Make sure your lockout and tagout

system is well-known and respected by every

member of your work crew. See the safety

comments in Section 2 of this manual.

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Optional Pre-wired Panel

An optional pre-wired electrical panel is available

from your Cedarapids/ElJay Distributor. It contains

circuit breaker, fuses, step-down transformer, relays,

timers, lube pump start and stop switches, and

indicator lights for lube pump and heater.

Setting Up the Lubrication System

Important: If the oil supply fails during operation

for any reason, immediately shut down, determine

the cause and fix it before restarting.

Check the dip stick for adequate lubricant level.

If oil is old, dirty, or sticky, select a proper lubricant

and change the oil. Verify that the oil pump operates

continuously when the crusher drive is on.

Notice: Failure to run the oil pump at all times

while the crusher is running voids the warranty.

The external, electrically driven pump is the only

oil pump on the VSI.

See the Acceptable Lubricants Chart (Figure 8-2),

Lubricating Oil Capacities (Figure 8-10) and the Oil

Flow Charts (Figures 8-6 through 8-9 and 8-11).Setting Up the Rock Material Feed

Oversize feed material can cause serious damage to

the crushing chamber.

Notice: Damage to crusher chamber components

resulting from tramp iron passing through the

crushing chamber voids the warranty. The VSI

crusher has no built-in tramp iron protection.

Tramp material, especially heavier metal pieces,

entering the crushing chamber cause severe

damage to your crusher. If your crushing site or

feed system generates frequent tramp iron problems,

install metal detectors and/or removal devices (such

as a belt magnet) in the feed system well ahead of

the VSI in your production circuit. This reduces

the chance that tramp iron can enter the crusher.

Set up rock feed system so feed rate to VSI is even

and steady. Uneven feed rate can have a negative

effect on gradation and increase wear rate.

Center feed fall into crusher hopper. Off-center feed

can cause excessive wear, uneven wear, and

decreased production. To help center feed, rotatefeed box to angle needed to mate with feed conveyor.

Warning! The VSI generates high velocity

air flow through the discharge ports. Wear

dust masks or other breathing protection.

To reduce dust levels, ElJay Division advises dust

suppression devices, such as covered conveyors or

water injection at crusher discharge.

Guards and Nearby Equipment

Read all of Section 2 on safety and safe practices.

Caution! Read all warning, caution and

instruction signs. Know what guards and

protective devices are included with the

crusher and see that each is securely in

place. Operating without each of these guards

is a violation of federal safety codes and a

threat to the safety of operators and

observers. Do not remove these guards.

Warning! Do not operate until all guards,

protective devices and systems are in place

and operative.

Warning! Never stand on the VSI lid when

it is operating.

Warning! If any part of the throw device is

allowed to come loose during operation, a

serious accident could occur, endangering

operators and other people nearby! Do not

start the VSI with any loose parts on the

throw device. Especially check after transporting the VSI.

Check Rotation Before Starting

Notice: Serious damage to your crusher can result

if the shaft rotation direction is wrong. The oil

pump does not properly lubricate when the shaft

turns the wrong direction. Rock does not properly

strike the wear surfaces.

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1) Briefly engage the diesel engine or electric

motor(s) without the V-belts installed.

2) On GD models check that the pinion shaft

rotates in the direction of the rotation arrow

above the shaft. See Installation drawings for

GD models. On VBD models, be sure motors

and vertical shaft rotate counterclockwise

(viewed from top).

Maximum RPM

On diesel drive models the maximum recommended

diesel engine speed is 1800 rpm. Verify that the

governor is not allowing the diesel to operate beyondthis limit.

On electric drive models the maximum shaft rotation

speed is shown in charts in Section 10.

Check rpm specifications in Section 10.

Caution! Do not exceed the stated rpm for

the configuration of your crusher.

First Start-up Check List

1) Are all the components properly installed?

2) Is the Operation Manual present and available?

3) Has the operator reviewed the safety

precautions in the Owner/Operator Manual?

4) Is the equipment mounted level?

5) Is oil reservoir filled with the proper lubricant?

6) Are the automatic shutdown systems working?

7) Does the warning horn sound correctly?

8) Does the flow meter indicate proper oil flow?

9) Are all wear castings properly secured? Noloose parts?

10) Is the flywheel guard installed at the proper

height?

11) Is the feed tube adjusted to the proper height?

12) Have the locking bolts that prevent the throw

device from moving during transport been

removed?

13) Is the discharge area clear?

14) Are tramp iron (metal detection) removal

devices installed and in working condition?

15) Is the vertical shaft rotating in the proper

direction?

16) Is the crusher feed tied to the emergency

shutdown circuit?

17) Is the vibration detection switch working

properly?

Important: After the first hour at the initial start-

up, shut down the conveyors, the screen(s) and the

crusher to reinspect the VSI crusher chamber.

Varying crushing conditions and the great variety

of abrasive content in rock can significantly affect

the crushing capabilities of the VSI. At a new site

you can save time and money by an early check into

the wear characteristics your VSI is experiencing.

Also see the daily inspection form in Section 4.

Storage

Once a month during storage, or when running VSI

infrequently:

Notice: Do not immediately start the VSI or the oil

pump if the VSI has been idle for a month or more.

1) Check the dipstick.

2) After determining that oil can be properly

pumped, run the oil pump for 10 minutes to

pre-lubricate the bearings.

3) Turn the vertical shaft two complete revolutions

by hand to coat the bearings and/or gears with

lubricant.

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2032 mm(80")

1111 mm(433 / 4")

92 mm (33 / 4")

838 mm(33")

48 mm(17 / 8")

711 mm(28")

1321 mm (52")

1422 mm(56")

1702 mm (67")

1702 mm(67")

1321 mm(52")

1219 mm(48")

1175 mm (461 / 4")

1003 mm (391 / 2")

1

2

3

4

Figure 3-41800 VSI-GD Installation

Installation 1800 VSI-GD

Top and Bottom View this page.

Front and Side View opposite page.

Notes on callouts:

1) Clearance necessary to remove pinion shaft

assembly.

2) Inspection doors.

3) Keep this area clear for crusher lubrication

components.

4) Do not block discharge areas.

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1080 mm

(421 / 2")

356 mm(14")

692 mm (271 / 4")

762 mm (30")

724 mm(281 / 2")

2197 mm(861 / 2")

203 mm (8")

2140 mm(841 / 4")

1416 mm(553 / 4")

1010 mm(393 / 4")

537 mm(211 / 8")

1016 mm (40") 1219 mm (48")

1340 mm (523 / 4")

2356 mm (923 / 4")

359 mm(141 / 8")

57 mm (21 / 4")

5

6

7

8

3

910

9) Pinion shaft 88.9 mm (3-1/2") diameter with

22,2 mm (7/8") x 11.1 mm (7/16") keyway. Metric

conversions are approximate and are givenonly for convenience. Standard bore metric

sheaves do not fit the pinion shaft.

10) Standard sheave is 12 groove 8V 312 mm

(12.3") PD x 318 mm (12.5") O.D. (other

sheaves available).

5) Minimum heights required to gain access to

anvil ring.

6) Pinion rotation direction arrow.

7) Oil drain plugs.

8) Keep area above and around lid clear for

access to inspection doors.

Figure 3-41800 VSI-GD Installation Continued

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3181 mm(1251 / 4")

92 mm (33 / 4")

1054 mm

(411

/ 2")

1021 mm(403 / 16")

4331 mm (1701 / 2")

1320 mm (52")

1003 mm(391 / 2")

48 mm(17 / 8")

3352 mm ± 127 (132" ± 5)

1676 mm ± 64(66" ± 21 / 2)

762 mm(30")

1320 mm(52")

1190 mm(467 / 8")

2

3

4

5

1

Installation 1800 VSI-VBD

Top and Bottom View this page

Front and Side View opposite page

Notes on Callouts:

1) Motor rotation direction arrows.


3) Area used for crusher lubrication components.

Keep clear for access.

4) Oil drain plug.

Figure 3-51800 VSI-VBD Installation

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6) Minimum heights required to remove anvil

ring.

7) Not used if shipped in the single drive

configuration.



9) 1500 to 1700 mm (59 to 67") - dimension

depends on the motor used.

10) 1638 to 1842 mm (64-1/2 to 72-1/2")- dimension

depends on the motor used.

11) Clearance for sheave removal.

12) Clearance for belt removal.

6

3

87

9

10

11

1112

1054 mm(411 / 2")

721 mm

(283

/ 8") 368 mm(141 / 2")

546 mm(211 / 2")

57 mm(21 / 4")

997 mm(391 / 4")

1416 mm(553 / 4")

2032 mm (80")

762 mm (30")

2148 mm(849 / 16")

978 mm(381 / 2")

762 mm(30") 254 mm

(10")610 mm(24")

381 mm (15")

143 mm(55 / 8")

343 mm(131 / 2")

762 mm(30")

Figure 3-51800 VSI-VBD Installation Continued

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1067 mm(42")

1575 mm (62")

1575 mm(62")

762 mm(30")

787 mm(31")

190 mm (71 / 2")

48 mm (17 / 8")1187 mm (463 / 4")

213 mm (83 / 8")

213 mm (83 / 8")

318 mm (121 / 2")

171 mm (63 / 4")

94 mm (311 / 16")

2

1

3

5

4

6

Installation 2100 VSI-GD



Notes on callouts:

1) Inspection Doors.

2) Clearance necessary to remove pinion shaft

assembly.

3) Keep this area clear for crusher lubrication

components.


Figure 3-62100 VSI-GD Installation

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381 mm (15")

787 mm (31")

2057 mm (81")

1003 mm(391 / 2")

952 mm(371 / 2")

1143 mm(45")

1143 mm(45")

2705 mm (1061 / 2")

2832 mm(1111 / 2")

2517 mm(991 / 8")

1565 mm(615 / 8")

1254 mm(493 / 8")

492 mm(193 / 8")

314 mm (12 3 / 8")

432mm(17")

508 mm(20")

508 mm(20")

521 mm(201 / 2")

7

38

9

10

Figure 3-62100 VSI-GD Installation Continued

5) Oil drain plugs.

6) Pinion shaft 88.9 mm (3-1/2") diameter with

22.2 mm (7/8") x 11.1 mm (7/16") keyway.

Metric conversions are approximate and are

given only for convenience. Standard bore

metric sheaves do not fit the pinion shaft.

7) Minimum height required to gain access to

anvil ring.

8) Pinion rotation direction arrow.

9) Area around and above lid to be kept clear for


10) Standard sheave 12 groove 8V 452 mm (17.8")

PD x 457 mm (18") O.D. (other sheaves

available).

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3559 mm(1401 / 8")

1056 mm(419 / 16")

4832 mm (1901 / 4")

1575 mm (62")

1181 mm(461 / 2")

48 mm(17 / 8")

3861 mm ± 127 (152" ± 5)

1930 mm ± 64(76" ± 21 / 2)

762 mm(30")

1575 mm(62")

1422 mm(56")

171 mm (63 / 4")

1

2

2

3

45

Installation 2100 VSI-VBD



Notes on Callouts:

1) Motor rotation direction arrows.

2) Area used for crusher lubrication components.

Keep clear for access.


4) Oil drain plug.

Figure 3-72100 VSI-VBD Installation

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6) Minimum heights required to remove anvil

ring.

7) Not used if shipped in the single drive

configuration.



9) 1700 mm (67")- dimension depends on the

motor used.

10) 1842 mm (72-1/2")- dimension depends on the

motor used.

11) Clearance for sheave removal.

12) Clearance for belt removal.

Figure 3-72100 VSI-VBD Installation Continued

1054 mm(411 / 2")

953 mm

(37

1

/ 2

") 381 mm(15")

546 mm(211 / 2")

57 mm(21 / 4")

1254 mm(493 / 8")

1564 mm(619 / 16")

2286 mm (90")

1016 mm (40")

2572 mm(1011 / 4")

1276 mm(501 / 4")

762 mm(30") 254 mm

(10")610 mm(24")

508 mm (20")

143 mm(55 / 8")

343 mm(131 / 2")

762 mm(30")

6

87

9

10

11

1112

2

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Keep VSI operating properly with maximum

“uptime” in crushed rock production. Use the Daily

Inspection Form on page 4.3 to provide a routine anda record that helps monitor conditions and keep

crusher performing at its best. Photocopy the Daily

Inspection Form to help better maintain VSI.

The Daily Start-up Detail helps you decide when

parts have worn to the point they need changing and

provides more detailed information about the steps

in the Daily Inspection Form. See the Bolt and Nut

Torque chart in the Appendix.

Notice: Do not exceed recommended torque values

on the bolts holding cast wear parts. Cast wear

parts are more brittle than mild steel. A part that

breaks loose at high rpm inside the crushing

chamber can do serious damage to your VSI.

Daily Start-up Detail

Warning! Lock out the power source,

including power to the oil pump, before

attempting any maintenance.

Before starting any VSI for the workday or shift, do

the following pre-start checks:

1) Check oil level with dipstick at oil tank. Lift

dipstick and be sure oil is at proper level.

Check that oil drips from stick. If oil is too

thick to drip, it can damage oil pump and not

lubricate bearings. Be sure oil tank is full.

2) Check the discharge openings. Be sure they

are clear and unobstructed.

Notice: If your site has material such as sticks and

clay that can bridge and block the dischargeopenings, check the openings more often.

3) Check all visible oil fittings for leaks.

4) Check for loose bolts on the outside of the VSI.

5) Check that crusher V-belts are tight enough

and aligned. Check them for signs of wear.

6) Clean out all dust and dirt buildup on crusher

sheave and motor sheave. This buildup can

cause vibration and early wear.

7) Open the inspection doors to see the throw

device. Remove the locking pin from the door

locking wedge. Drive the wedge out with ahammer. Drive the locking bar out (Figures 4-

1, 4-2 and 4-3).

If you have a VSI with table/shoes, go to the

instructions on page 4.6.

VSI with CastRotor

8a) Inspect rotor assembly. Check all wear parts

and liners for excessive wear (Figure 4-4).

8b) Check all wear tip assemblies for damage and

excessive wear. Note especially the conditionof the primary wear tips.

Some CastRotors have primary carbide wear tips of

an earlier design that are 13 mm by 13 mm (1/2" by1/2") when new. Later designs of primary carbide

wear tips are 9.5 mm by 22.2 mm (3/8" by 7/8"). The

backup carbide wear tips are all 13 mm by 13 mm (1/

2" by 1-1/2").

If you are in doubt as to the extent of wear, check the

carbide tip with a straightedge (Figure 4-5).

A 140 mm (5-1/2") straight edge works well for the

1800 CastRotor. A 190 mm (7-3/8") straight edge

works for the 2100 model. Bridge the straight edge

vertically from an unworn portion at the top to an

unworn portion at the bottom of the carbide face

(Figure 4-5). Measure wear from the straight edge to

the deepest wear point of the carbide.

If you have primary wear tips that are 13 mm (1/2")

thick and Dimension A = 8 mm to 9.5 mm (5/16" to 3/

8"), immediately replace the wear tip.If you have primary wear tips that are 9.5 mm (3/8")

thick and Dimension A =17.5 mm to 19 mm (11/16 to3/4"), immediately replace the wear tip.

8c) Check the area of the tips in front (to the inside)

of the carbide for undermining of the wear tip

holder (Figure 6-7). Some undermining, up to

3 mm (1/8"), is expected and is not likely to

harm your VSI. 4.7 mm (3/16") or more is too

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Figure 4-1

To open the inspection doors in the lid,remove the locking pin

much undermining. If there is too much

undermining, consult local Cedarapids/ElJay

distributor before making any adjustments.After consulting your distributor, follow steps

for adjusting trailing angles in Section 6.

8d) Inspect anvils or rockshelf, as equipped, and

tub liner for wear. Check all wear parts for

excess wear. See steps for changing wear parts

in Sections 5, 6, or 7.

8e) Check for any loose fasteners on rotor and all

liners. Be sure bolts holding liners are snug.

Check the torque chart in the Appendix. Do

not overtighten the bolts. The liners are very

hard, high chrome parts and can crack if bolts

holding them are too tight, but, due to grit and

dirt getting under or behind the liners, they can

also sometimes loosen during operation.

Important: Liners and other rotor parts that are

too loose or too tight can damage or wear quickly.

Check for any loose bolts or other rotor parts.

8f) Check the position of feed tube to be certain it

is even with but not more than 13 mm (1

/2")above bottom of the feed eye (Figure 7-8).

Figure 4-2Remove locking wedge

Figure 4-3Drive the locking bar out

Figure 4-4Looking at the Rotor through the Inspection Doors

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VSI Daily Inspection Form

Before Start-up Inspect: ✔ Check Boxes Operator’s Initials

1. Undercrusher discharge area for blockage ❐❐❐❐❐ OK ❐❐❐❐❐ Cleaned

2. Oil ❐❐❐❐❐ proper level ❐❐❐❐❐ viscosity OK ❐❐❐❐❐ cleanliness OK ____Amount added

3. Visible oil fittings for leaks ❐❐❐❐❐ OK ❐❐❐❐❐ Replaced

4. Outside of VSI for loose bolts, wedges ❐❐❐❐❐ OK ❐❐❐❐❐ Tightened

5. Drive V-belts for wear, fraying, slipping ❐❐❐❐❐ OK ❐❐❐❐❐ Adjusted ❐❐❐❐❐ Replaced

6. Sheaves for material buildup ❐❐❐❐❐ OK ❐❐❐❐❐ Cleaned

7. Open the inspection doors to check throw device:

Table ✔ Hours or Tons run

Shoes ❐ OK

Shoe bracket liners ❐ OK

Shoe pins ❐ OK ❐ ReplacedFeed tube ❐ OK

Feed disc ❐ OK

Table liner ❐ OK

Rim liners ❐ OK

Anvils ❐ OK

Rotor ✔ Hours or Tons run

Feed tube ❐ OK

Tips ❐ OK

Epps ❐ OKPrimary liners ❐ OK

Retaining liners ❐ OK

Feed disc ❐ OK

Feed eye ❐ OK

Trailing angles ❐ OK

Side plates ❐ OK

Rim liners ❐ OK

Top wear plates ❐ OK

Bottom wear plates ❐ OK

Anvils or rockshelf ❐ OK

Warning: Lockout the power source,

including power to the oil pump before

inspecting the VSI.

Today’s date

Serial number

Machine ID number

Important: Do not replace one (1) part on table or CastRotor without also replacing similar parts in

similar positions. Maintain balanced weight condition at all times.

Notes on wear parts condition:

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Warning : Look carefully around before start-up! Sound the usual warning for your site. Be sure no

one is working on related equipment or might be injured by start-up!

Start-up time ______ ✔ Check Boxes Operator’s Initials

After start-up, running empty, inspect:

8. Low oil warning horn system ❐ OK ❐ Not working

9. Oil filter indicator for restricted flow

❐ Green ❐ White ❐ Red ❐ Replaced filter element

10. Flow meter: write down the reading ____ Liters per minute (gallons per minute) flow

11. Ammeter: write down the amperage ____ Motor 1 ____ Motor 2

12. Diesel motor rpm ____ RPM

After crushing begins, inspect:

13. Feed rate ❐ Choke fed ____ Tonnes (tons) per hour

14. Ammeter for amp draw under full load ____ Motor 1 ____ Motor 2

15. Flow meter reading after oil is warm ____ Liters per minute (gallons per minute) flow

16. Diesel rpm ____ RPM

Total crushing hours this date ________

Downtime this date ________

Total tonnes (tons) this date ________

Did you take an oil sample today? ❐ Yes ❐ No

Comments:

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134 2

1

Figure 4-5Measure Wear from a Straight Edge toDeepest Wear Point of the Carbide Tip

Figure 4-6Looking at Table through Inspection Doors

8g) Slowly rotate rotor and note clearance between

the feed tube and feed eye. Center feed tube as

much as possible for feed efficiency and to

avoid rotating parts contacting each other.

8h) Check the feed eye for wear paths. As the feed

eye wears out, paths wear in the eye and the

adjacent wear liners. To increase liner life, liftout the feed eye and rotate it 90°.

Go to Daily Start-up Detail- Continued, this page, to

complete the daily inspection of your VSI.

VSI with Table/Shoes

For a VSI model with table/shoe/anvil configuration:

8a) Inspect all shoes and shoe bracket liners for

wear. Inspect the shoe-holding pins. Be certain

they are in place and not bent (Figure 4-6).

8b) Inspect anvils, table liners, table rim liners, tubliner, and feed cone for wear. Refer for details

of wear minimums to Section 5.

8c) Check for loose fasteners on table and all wear

liners. Be sure wear liner bolts are snug. Do not

overtighten. Check the bolt and nut torque

chart at the end of this section.

Important: Liners and other rotor parts that are

too loose or too tight can damage or wear quickly.

Check that bolts are snug.

8d) Check the position of the feed tube. See that it

is even with the tops of the shoes. Readjust the

feed tube downwards when it has worn to 13

mm (1

/2") above the tops of the shoes.8e) Slowly rotate the table and note the clearance

between the feed tube and each shoe. Be sure

no shoes hit the feed tube.

Daily Start-up Detail - Continued

9) Close the inspection doors. Reinstall the locking

bar (Figure 4-7). Drive in the locking wedge

and install the locking pin.

10) Unlock the power source to the oil pump only

and tell fellow workers you are about to test thewarning horn before starting up.

11) Turn on the oil pump switch. It is normal for

the warning horn to sound for a few seconds

until the oil flow reaches a rate above the preset

warning level.

Sounding the warning horn serves two functions:

• It lets you know the warning system is working

to protect your VSI from low oil flow.

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14) Check screens and conveyors feeding the VSI

to be sure no tools or hardware have been left

on them.

Warning! Look carefully around; check

your radio; sound usual warning for your

site, or use other communications methods

to be sure no one is working on related

equipment or may be injured by starting up!

15) Unlock power source to crusher drive.

16) Turn on under-crusher conveyor.

Important: Never run VSI without under-crusher

conveyor also running.

17) For diesel driven crushers, start diesel and

warm it up according to diesel manufacturer’s

instructions. Bring diesel to about 1000 to

1100 rpm. Bump power takeoff (PTO) handle

several times to engage power takeoff

gradually.

Important: Do not move handle to full engagement

until VSI speed increases. If VSI is brought up to

full speed too quickly, it can damage your drive

belts, causing them to wear too quickly. New belts

need frequent tightening for several operating days

after being installed.

18) For electrically driven VSI's, engage drive

motor(s) and bring VSI to full rpm.

19) Monitor drive and VSI for any excessive

vibration. Normal conditions produce very

little vibration.

Important: If using a VSI with a rotor and have

cleaned rock buildup out of rotor, fill rotor and rockshelf with 30 to 60 seconds of 19 mm and

smaller ( 3¦4" minus) feed before feeding larger rock

into VSI. Without this buildup at start-up, large

rock can damage wear tips.

20) Start feeding material to the crusher.

• It lets workers in the surrounding area know

you are nearing start-up.

12) Check the flow meter. The oil flow rate varies

during the course of the day, depending on the

oil temperature. After the VSI has operated,

the oil warms and flows easier. The flow meter

shows this tendency. For approximate oil flow

rates, both cold and warm (Figure 4-8).

Important: To prevent damage to bearings, leavethe oil pump on at all times during crusher

operation. Do not shut off pump until crusher has

come to a complete stop.

13) Check to be sure all guards and protective

devices are securely in place.

Figure 4-7

Drive Locking Wedge In and Replace Locking Pin

Model Cold Warm

1800 VSI-GDliters/min 4.7 to 5.7 2.8 to 3.3

Gallons/min 1.25 to 1.5 .75 to .875

1800 VSI-VBDliters/min 2.8 to 3.8 1.4 to 1.9

Gallons/min .75 to 1 .625 to .5

2100 VSI-GDliters/min 5.7 to 6.6 3.3 to 4.3

Gallons/min 1.5 to 1.75 .875 to 1.125

2100 VSI-VBDliters/min 4.7 to 5.7 2.8 to 3.3

Gallons/min 1.25 to 1.5 .75 to .875

Figure 4-8Oil Flow Rates

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The VSI is equipped with an oil heater and thermostat

which is set to switch on at 15.5°C (60°F) oil

temperature and go off when oil is at 26.7°C (80°F).With oil pump continuously circulating oil, heater is

effective down to an ambient temperature of about -

9°C (15°F), but is not very effective when weather

conditions are below -9°C (15°F). For cold weather

operation, cover crusher at night and pre-warm it

with an external heater (propane, for example) before

morning start up.

Important: Do not start crusher if oil does not flow

freely. Oil must be free flowing to properly lubricate

bearings (and gears on gear drive models).

Hot Weather Start-up

Keep VSI oil temperature gauge reading below

115.5°C (240°F). If readings are nearing 115.5°C

(240°F), consult Acceptable Lubricants Chart to

select an oil designed for higher temperature

conditions.

Important: Maximum allowable oil temperature

under any conditions is 115.5°C (240°F) at

temperature gauge!

Important! Do not run CastRotor VSI's more than

15 minutes immediately after exit port protectors

or wear tips have been changed or serviced. Stopmachine and Open inspection door in lid. Inspect

rotor, carbide wear tips, and all wear points. Again

tighten exit port protector (epp) bolts to 190 n•m

(140 ft-lbs). Adjust trailing angles as needed to

control material buildup.

Any time rock material characteristics are changed

(such as size, rate of feed, rock material), it pays to

look carefully at crushing chamber for changes in

wear rates. Improperly adjusted trailing angles or

other VSI parts can be costly in creating unnecessarywear. It pays to check!

21) Start normal feed.

Cold Weather Start-up

Check dip stick to see that oil drips freely from stick.

If oil cannot drip from dip stick, it is too thick to

lubricate VSI.

Important: Do not start crusher if oil is too thick to

drip from dipstick.

Either warm crusher with a propane heater before

starting or change to a lighter oil.

See the Acceptable Lubricants Chart, page 8.1, for

proper oil specifications for your operating and

weather conditions.

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Section 5

Changing Table/Shoe Wear Parts

ATerex Company

The VSI’s structural members are protected from

abrasive wear. Some wear surfaces collect rock

material to protect structure. Some areas of crushingchamber, input and discharge areas include

replaceable, bolt-on wear parts. Highly wear-

resistant, each wear part armors VSI to protect it

from damage (Figure 5-1). Wear parts also efficiently

shape the flow of rock for crushing large volumes.

1. Shoe bracket

2. Flywheel bolt

3. Feed disc

4. Shoe pin

5. Shoe

6. Shoe bracket liner

7. Table liner

8. Special (Allen-head or shortened hex) table

liner bolt

9. Rim liner

10. Flywheel spacer ring

11. Table weldment (includes shoe brackets)

7

1

2

4

5

6

8

11

10

3

9

Warning! Lock out the power source to this

crusher before attempting any maintenance.

Turn off diesel power plant (if diesel is used.)

Notice Regarding Wear Part Fasteners: Except

where noted, most fasteners used to attach VSI

wear parts use anti-seize lubricant on the threads.

Cast wear parts are very abrasion-resistant, but are

more brittle than milder, softer steels. Standard

torque values of the recommended Grade 8 bolts

Figure 5-1Wear Parts Identified

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may be so high as to crack or break the cast part.

Except where a torque value is specifically noted,

always tighten wear part fasteners firmly to a“snug fit.” Except where noted in this manual, do

not tighten the bolts holding wear parts to their

full, standard, lubricated torque value.

Balanced Running Important

Balanced running is very important to the table and

shoes. Whenever you change wear parts, be sure to

replace them in matching, weight-balanced sets.

Tables: Various Types Available

The open-topped table is available with 3, 4, or 5-shoes. A 6-shoe table is available with a closed top.

You can refit your VSI with any one of the table

options. Find instructions for removing and

reinstalling tables later in this section.

Table options allow you to choose the best one to fit

your crushing needs. Generally, the more shoes, the

finer the crushed product and the more shoe life.

Figure 5-2 shows you the four table/shoe options.

Replacing the individual wear parts is essentiallythe same for each table type.

Under normal operating conditions, shoes are first

parts to need replacing due to wear. These and shoe

bracket liners can be changed while working through

access doors in lid. To change other table/shoe wear

parts best practice is to remove lid. See Removing

Lid Assembly in Section 7. Changing table rim

liners requires removing table from VSI. See

Changing Table Rim Liners, page 5-10 for

instructions on removing and replacing table.Shoes, Shoe Pins, Shoe Bolts

Shoes are easily removed and replaced. They are

attached to table’s shoe brackets with either shoe

pins or shoe bolts. Pins can be mounted either

vertically or diagonally, depending on type of shoe.

A pin stop is welded to each shoe bracket. This

determines which type of shoe and pin your table

requires. See Figure 5-3 for both types of pins.

3

4

1. 3-shoe, open top

2. 4-shoe, open top

3. 5-shoe, open top

4. 6-shoe, closed top

2

1

Figure 5-2Available Table Types

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Figure 5-4Weight Specifications for Shoes

Model 1800 2100

Typical Shoe 26 kg (57 lbs) 37 kg (82 lbs)

1. Diagonal Pin

2. Vertical Pin

Figure 5-3Two Types of Shoe Pins

Weight-Balanced Shoe Sets

Important: Balanced running is very important

with the VSI. Whenever you change wear shoes, be

sure to replace them in matching, weight-balanced

sets. Allow a maximum weight variation of only

0.45 kg (1.0 lb). Always replace shoes in matching,

weight-balanced sets all around the table. The

better balanced running you have, the longer bearing life you can expect. See the specifications

for weight-balanced sets (Figure 5-4).

Tables with even-numbered shoes (4 and 6-shoes)

can tolerate different weight shoes as long as they

balance 180° apart, across table. Tables with odd-numbers of shoes (3 and 5-shoes) require all shoes to

be more closely matched in weight (Figure 5-5).

A

A

A

Odd-number of

shoes on the

table

Even-number of

shoes on the

table

A

AA

A

A

A

AB

B

B

A

A

AB

B

B

A

Figure 5-5Even and Odd Shoe Balance Sets

When to Change Shoes

To inspect shoes, reach in through access door to

check inner edge of shoe. Feel inner edge of shoe to

be sure it has more than 6 mm (1/4") thickness

remaining (Figure 5-6).

A pocket worn by rock passage weakens shoe. If

pocketing has occurred, change when bottom of the

pocket is within 13 mm (1/2") of back side (Figure 5-

7). Change shoes when worn to within 6 mm (1/4") of

back side at discharge (outer) edge, or if cracked.

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Caution: Wear Safety glasses or goggles.

Brittle metals can shatter dangerously.

3) Rap on the face of the shoe with a hammer to

jar it slightly loose.

4) Use a pry bar to lift while pulling with locking

pliers to remove the pin. Figure 5-8 shows the

vertical-pin type shoe.

5) If the pin is solidly cemented by rock material,

you can use a torch to cut it loose, but carefully

avoid cutting into the shoe bracket!

6) If removing shoes of bolt-type, remove bolt

and backing plate. If shoe is solidly cemented by rock material, rap face of shoe with a

hammer to jar shoe loose (Figure 5-9).

How to Replace Shoes

1) Clean all surfaces where shoes have contact.

2) Inspect shoe bracket for weld integrity, cracks

or erosion (Figure 5-10). See also Shoe Brackets

and Liners.

Figure 5-8Removing Shoe Pin

Inner edge

6 mm (1/4") minimum

Figure 5-6Check the Inner Edges of the Shoes

inner edge

outer edge

6 mm (1/4")

minimum

13 mm (1/2")

minimum

Figure 5-7Pocketing Wear Shows It Is Time to Change Shoes

How to Remove Shoes

1) Clean away the rock material around the shoes,

shoe brackets, and pins or bolts.

2) Inspect the shoes for erosion.

Caution: Always replace shoe pins or bolts

when you replace shoes! A bent or worn shoe

pin or a poor condition bolt can be very

dangerous because it can fail at high rpm! A

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failed pin or bolt can also very rapidly cause

extensive damage to your VSI by letting a

shoe come loose during operation.

3) Place shoe against front of bracket with stob

through bracket.

4) Insert new pin through hole in shoe stob. A

properly fitting pin slips into place and does

not require driving into place.

Notice: Clearance must be no more than 1.6 mm

(1/16") (Figure 5-11). If shoe pin has worn a low

spot in back of shoe bracket, gap between pin and

bracket is too large. Pin can bend and cause shoe

stob to crack and break out. Serious damage to

crusher chamber may occur.If table has an even number of shoes and pin seems

too tight, try trading shoe directly opposite across

table. Sometimes minor variations in shoe fit can

occur. Be sure to keep weight balanced. Allow a

maximum weight variation of only 0.45 kg (1.0 lbs).

Important: ElJay/Cedarapids factory-original shoe

pins are stress-proof. Use no substitutes.

Bolt Backing plate

Figure 5-9Removing Bolt-type Shoe

Shoe bracket

erosion

Figure 5-10Look for Shoe Bracket Erosion

shoe bracket wear from the pin

Figure 5-11Pin Wear in the Shoe Bracket

5) Check to be sure pin is fully seated against the

pin stop. Use only correct length pin. When

fully and correctly seated, pin is even with top

of shoe.

6) For bolt-type shoes, check backing plate. Reuse

a backing plate that is not bent or badly worn.

7) Install shoe bolts dry, without any lubrication.

8) Tighten the bolt to 203 N•m (150 ft-lbs).

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Important: Do not use an impact (pneumatic)

wrench to tighten the shoe bolts.

9) Turn the table by hand to check for any

clearance problems.

Shoe Brackets and Liners

The portion of the table weldment called the shoe

bracket is not itself a wear part, but can erode where

the shoe pins contact the bracket and at the side

members (Figure 5-10).

If the shoe bracket is worn in the area of the pin, fill

the worn area with mild steel weld and grind it flush

(Figure 5-11).

Side members of bracket can also show wear.

Important: Heavy welding activity can distort the

roundness of the table and unbalance it. Always

rebalance the table after major maintenance.

Important: When wear has advanced enough that

bracket might bend, replace table itself. Always

maintain shoe brackets in like-new condition.

When to Change Shoe Bracket Liners

Change shoe bracket liners when worn to 5 to 6 mm

(3/16" to 1/4") thick, or if cracked. Both high chrome

and heat treated shoe bracket liners are available.

See your Cedarapids distributor.

1) Remove bolts holding liner. Remove old liner.

2) Clean rock material from liner seat area. Check

liner’s mating surface area for proper fit.

3) Set new liner in place (Figure 5-12).

4) Use anti-seize lubricant on bolt threads. Attach

liner with bolts. Tighten to 67.8 N•m (50 ft-lbs) lubed. Do not overtighten.

Changing Table Liners

1) Remove the shoes.

2) Remove the appropriate table liner bolts

(Figure 5-13). Some table liners have Allen-

head bolts acting as guide pins under the

shoes. You do not need to remove these bolts

that are threaded into the table unless they are

damaged or worn. Other table liners use short-

head bolts under the shoes. These hex-head

bolts, part number 02-382-510-0030, have

shorter heads so the shoe seats properly over

the table liner. The heads of these bolts are

machined to 9.5 mm (0.375") high. Some

types of table liners have 3 bolt holes; some

have 4. As long as you keep the table weight-

balanced, you can interchange the table liners

types as they are available.

3) Lift off the old liners.

4) Thoroughly clean flat areas of table, clean bolt

holes and threads, and blow out holes with air.

5) Set liners in position.

6) Apply anti-seize lubricant to bolt threads.

7) Install bolts with shortened heads (as needed)

in shoe area and standard bolts in open area

(Figure 5-13). If bolts supplied with liners are

lost, replace them with Grade 5 or higher.

8) Hand tighten bolts in shoe area.

9) Hand tighten bolts in open area.

10) Tighten all table liner bolts to 135.6 N•m

(100 ft-lb). Do not overtighten.

Figure 5-12Install Shoe Bracket Liner

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Important: Centrifugal force during operation locks

the liners into place. If you overtighten the bolts,

they can be nearly impossible to remove. Also, if acasting is just slightly warped, overtightening can

crack it. A cracked casting could become dangerous

if it were to fly apart during operation.

Changing Feed Disc

Change the feed disc when hole first appears in

surface, or if cracked. If you allow feed disc wear to

go on, costly damage can occur to table, flywheel

and the vertical shaft.

When the disc is worn, the outer edge in front of shoe becomes rounded off (Figure 5-14). Rotate feed disc

so worn sections are under shoes and sharp edges of

d

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