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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.
16885 (3/99)
Introduction
Operation & Maintenance Manual
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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.
Operation & Maintenance Manual
ATerex Company
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21052 (3/97) Page 1.1 LJ1093200
Operation & Maintenance Manual
ATerex Company
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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Operation & Maintenance Manual
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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• 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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ATerex Company
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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ATerex Company
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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ATerex Company
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.
2) Inspection doors.
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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5) Do not block discharge areas.
6) Minimum heights required to remove anvil
ring.
7) Not used if shipped in the single drive
configuration.
8) Keep area above and around lid clear for
access to inspection doors.
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
Top and Bottom View this page
Front and Side View opposite page
Notes on callouts:
1) Inspection Doors.
2) Clearance necessary to remove pinion shaft
assembly.
3) Keep this area clear for crusher lubrication
components.
4) Do not block discharge areas.
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
access to inspection doors.
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
Top and Bottom View this page
Front and Side View opposite page
Notes on Callouts:
1) Motor rotation direction arrows.
2) Area used for crusher lubrication components.
Keep clear for access.
3) Inspection doors.
4) Oil drain plug.
Figure 3-72100 VSI-VBD Installation
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5) Do not block discharge areas.
6) Minimum heights required to remove anvil
ring.
7) Not used if shipped in the single drive
configuration.
8) Keep area above and around lid clear for
access to inspection doors.
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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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