2015.04.10, Manual of Hydraulic System

648
LARSEN & TOUBRO LIMITED

METALLURGICAL & MATERIAL HANDLING INDEPENDENT COMPANY
KANSBAHAL WORKS
OPERATION & MAINTENANCE MANUAL

FOR
IMPACTOR APSM 1313
CUSTOMER :: CHANDERPUR WORKS

A/C UNITED CEMENT
LOCATION :: CHANDERPUR WORKS

A/C UNITED CEMENT, NEPAL.
ORDER REF. :: CPW/U.CMT/4672/11.12

DATED: 29.02.2012
PROJECT NO. :: 101147
DOC.NO:900087 Larsen & Toubro Limited

Kansbahal Works Page 1 of 83
We have pleasure in enclosing Operating & Service Instructions

for the Impactor described in the following pages.
Strict observance of the Instructions is important for efficient

operation.
We would advise you to keep a stock of the spare parts for

future operation as per the spare parts drawing enclosed with
the manual.
To enable us to give prompt services, please do the following:
All orders should include the part number shown in the list of
spare parts plus a short description of the part required.
Please quote our Project Number on your order form or any

correspondence. Our Project Number is 101147.
Please note our Phone Numbers :: (06624)280241, 280101, 280123, 280145,

280551, 280552 & 280556
Fax Numbers :: 06624-280226,280238,280243 & 280055
E-mail addresses : Saurabh.Kant@larsentoubro.com
: vinod.choudhary@larsentoubro.com

WARNING!
DANGER TO LIFE!
THE INITIAL START - UP OF THE MACHINE MUST NOT BE

CARRIED OUT UNTIL ALL PROTECTIVE DEVICES (BELT
GUARD, SHAFT GUARD ETC.) HAVE BEEN FITTED.
<
MAKE SURE THAT ALL ERECTION AND SERVICE FLAPS,

INSPECTION DOORS AND HINGED SECTIONS ARE
ENCLOSED AND LOCKED.
DO NOT OPEN DOORS WHILE THE MACHINE IS

RUNNING.
DO NOT THRUST BARS OR SIMILAR TOOLS INTO THE

MACHINE.
SERVICING, REPAIR WORKS AND GAP SETTING ARE

ONLY TO BE CARRIED OUT WHEN THE MACHINE IS AT A
STAND STILL. THE SAME APPLIES TO ANY WORK ON OR
IN ANCILLARY EQUIPMENT.
MAKE SURE THAT THE MAIN SWITCH IS LOCKED.
PLEASE OBSERVE THE INSTRUCTIONS GIVEN IN THE

OPERATING & MAINTENANCE MANUAL SUPPLIED.
DO NOT MODIFY OR ADD EXTRA MASS BY WAY OF

WELDING OR HARD FACING, AS THIS MAY LEAD TO
CRACKS IN THE BODY AND SUBSEQUENT FAILURE OF
ROTOR

CONTENTS
SECTION DESCRIPTION
I GENERAL INFORMATION
II DESCRIPTION OF THE MACHINE
III DRIVE ARRANGEMENT AND V BELT
TENSIONING
IV GAP ADJUSTMENT & BLOW BAR EXCHANGE
V DESPATCH INSTRUCTIONS & INSTALLATION
VI LUBRICATION SCHEDULE
VII GENERAL OPERATING CONDITIONS AND
INTERLOCKS
VIII COMMISSIONING
IX ANTIFRICTION BEARINGS
X MAINTENANCE CHECKS
XI LOCKING ASSEMBLY
XII SPECIFICATION OF IMPORTANT ITEMS & TOOLS
XIII HYDRAULIC CYLINDERS
XIV HYDRAULIC POWER PACK MANUAL
XV HYDRAULIC SYSTEM FUNCTIONAL
WRITE-UP
XVI SPEED SENSOR
XVII LIST OF DRAWINGS & SPARES PART LIST
XVIII LIST OF SAFETY PRECAUTIONS AND

INSTRUCTIONS

SECTION I
GENERAL INFORMATION

I-1
GENERAL INFORMATION
CUSTOMER : CHANDERPUR WORKS

A/C UNITED CEMENT
CUSTOMER S ORDER NO. : CPW/U.CMT/4672/11.12
DATE: 29.02.2012
L & T PROJECT NO. : 101147
PLANT SITE WHERE
: CHANDERPUR WORKS
INSTALLED A/C UNITED CEMENT, NEPAL
EQUIPMENT TYPE & SIZE : SINGLE ROTOR IMPACTOR
EQUIPMENT SIZE : APSM-1313
YEAR OF MANUFACTURE : 2013
EQUIPMENT NO. : 010-1023
FEED MATERIAL : LIMESTONE
FEED SIZE : 500 mm. MAX.
PRODUCT SIZE : 85%(-)20 mm
150 TPH RATED
CAPACITY :
200 TPH DESIGN
MOTOR RATING : 179 KW, 1000 RPM
ROTOR RPM : 482
DRIVE ARRANGEMENT : Thru. V-Belt & pulley with Jack Shaft Arrgt.
TYPE OF BLOW BAR : S TYPE

SECTION II
DESCRIPTION OF MACHINE

II - 1
DESCRIPTION OF THE MACHINE
1. GENERAL
The Single Rotor Impactor, is designed to achieve maximum
reduction ratio in a single pass. Particular features of the machine
are its cubical product, largely free of tension and cracks and the
ease with which the servicing can be carried out.
2. DESIGN AND OPERATING PRINCIPLE

The housing of the Impactor is of welded plate construction
within which the rotor is installed on rigid bottom housing. The
cross sectional view shows the rotor working in conjunction with
Impact arms. The Impact arms are adjustable and they are
supported on the spindle, which allows them to retract when
uncrushable material enters the crusher. The easy adjustment of
Impact arms for constant product control and limitation of over
size, makes the impactor more user friendly. Over and under
feeding of the Impactor has only minimum effect on product.
3. MAIN COMPONENTS OF THE IMPACTOR

Following are the important components of the Impactor. These
are shown clearly in sketch enclosed.
HOUSING
Housing of the Impactor is of sturdy steel fabricated construction
and consists of two parts, bottom housing and top housing. The
rotor is housed in bottom housing and the top housing is bolted
on the top of it. The top housing can be lifted, after removing the
fixing bolts, by an overhead crane.

II 2
ROTOR
The rotor is fabricated one, which is secured to the shaft by
Locking Assemblies. These Locking Assemblies are carefully
clamped into position at the factory to the specified torque and
require no maintenance. The blow bars made of special alloy steel
are fixed on the rotor through high tensile fasteners.
The rotor is dynamically balanced to avoid any undue vibration &
stresses on the bearings during crushing.
BLOW BARS
Blow bars are made from high quality alloy steel. Following
certain period in operation the blow bars can be taken out of the
rotor and turned or exchange.
GRINDING PATH
The Impactor is fitted with a grinding path for fine grinding and
the production of an improved cubical product. The top of the
grinding path is hinged by a pin. At the bottom, the grinding path
is connected by two adjusting spindles. The bottom of the path is
fully adjustable.
The grinding path consists of a welded frame with many row of
holders for the grinding bars, these being placed on the holders,
starting from the bottom. They are sealed off and hold by a row of
impact plates (with one set compensating plates) which are tightly
and snugly bolted on to the construction.
The grinding bars are made of material highly resistant to wear
and must not be dropped or subjected to heavy blows.

II 3
WEAR PLATES
Housing is provided with wear resistance wear plates, which are
secured, in position by special fasteners, which can be changed as
and when required.
IMPACT ARMS
The Impactor is fitted with two Impact arms. The Impact arms are
fabricated units and they are fitted with Impact plates. These
Impact plates are subjected to heavy wear and must be replaced
from time to time.
The Impact arms are suspended in the housing upper part by
means of knockout spindles and they can be adjusted to the
desired gap setting from outside by means of adjusting spindles.

SECTION III
DRIVE ARRANGEMENT AND

V BELT TENSIONING

III 1
DRIVE ARRANGEMENT
Power to the machine is given through jackshaft arrangement. The

driven pulley is secured on the rotor shaft by a pair of locking
assembly.
The jackshaft assembly is supported on two bearing and coupled to

motor shaft through a coupling. The entire drive components with
drive motor, jackshaft assembly and bearing blocks are bolted to the
drive base frame, which is of rigid welded construction.
The drive base frame is mounted on the fabricated slide rail by means
of clamping pads. Adjusting bolts have been provided for tensioning
the V-belts. For details, refer drive arrangement drawing enclosed in the
manual.
The details of drive components are given below :
1) Motor : 179 kW, 1000 RPM
2) Pulleys : Drive Pulley - PCD 364 mm

Driven Pulley - PCD 755 mm
3) Belts : 8 Nos. V - BELT SPC 8000

III - 2
RECOMMENDATION FOR TENSIONING OF BELTS

As per the guide lines available for tensioning, all new belts during
installation should be tensioned to the HIGHER VALUE (refer
TENSIONING FORCES in the enclosed Installation & Maintenance
instructions of V-belts in this section) to allow for the normal drop in
tensioning during running in period. Use Belt tension indicator / tester
to check belt tension.
The tension of the belts to be very closely monitored and checked

within tension tester everyday for one week after installation and
running. This is to ensure satisfactory performance of the belts and
avoid twisting and jumping of belts. After one week of operation, the
belts should get stretched. However, if sagging is observed, proper
tensioning to be carried out immediately. At this stage, the tensioning
should be done towards the lower value. This has to be checked at least
twice a week regularly.
It may be emphasized that proper tensioning of belts will result in an

efficient drive system and better performance of the belts.
It is recommended that a drive which is to stand for a prolonged period

(say more than one week) before use should have the belt tension
relaxed to prevent the belt taking a permanent set on the pulleys. Before
a drive is started up, it is essential that the belt be re-tensioned.

III- 3

III-4

III-5

III-6

III-7

III-8

SECTION IV
GAP ADJUSTMENT AND

BLOW BAR EXCHANGE

IV - 1
GAP ADJUSTMENT
CAUTION ANY GAP ADJUSTMENT TO BE DONE IN

STATIONARY CONDITION ONLY.
IMPACT ARM ADJUSTMENT

Gap setting of impact arm must be altered according to the desired
degree of crushing. This must only be done when the rotor is stationary.
To reduce the gap, first turn up the top nuts of the adjusting device to
the required amount. Then lift the adjusting device with the help of a
crane. Turn up the bottom nut till it touches the plate. Lower the
adjusting device.
To increase the gap, first lift the adjusting device with the help of a
crane. Turn down the bottom side nuts to the required amount. Lower
the adjusting device. Then turn down the top side nuts till it touches the
plate.
WARNING: NO ADJUSTMENT SHOULD BE DONE WHILE THE

IMPACTOR IS RUNNING.
IMPORTANT
1) Tip circle diameter of the rotor will increase by approximately 23
mm while running. This should be considered while setting the
gap.
2) For getting the desired product granulometry, it is a must that
blow bars are in good condition.
3) Ensure uniform feeding to Impactor all along rotor length to
satisfy condition (2) above.

IV - 2
WEAR PLATES
Check the side wear plates from time to time. The space between the
rotor and these plates is to be kept as small as possible. In the upper
section, this is normally 5 mm. When this has worn to 15 - 20 mm
following a lengthy period of operation, the plates should be
interchanged as far as possible or replaced. Larger the gap between
rotor and side plates, the greater the wear on the edges of the rotor and
the wear plates. It is also important to check and retighten the screwing
bolts.
BLOW BAR EXCHANGE

The Impactor is supplied with S type blow bars. The shape of S type
blow bar is symmetrical and by turning them 1800, their useful life is
doubled. When edge of the blow bar has fully worn away, the blow bar
must be turned upside down and by rotating through 1800 the blow bar
can be reused. It is to be noted that the blow bar is to be turned or
replaced by a new one, once the distance from the top edge of the beam
to the top edge of blow bar is 25 mm. NEVER ALLOW THE BLOW
BAR TO WEAR SUCH THAT THE ABOVE DISTANCE IS LESS THAN
25 MM. OTHERWISE THE ROTOR BODY WILL BE EXPOSED TO
EXCESSIVE WEAR.
TO REMOVE BLOW BAR

Refer sketch below. Remove the locking plate holder. Take out locking
plate towards rear. Push out the blow bar, side ways. Before the blow
bars are turned or exchanged the locking plate on both ends of the
rotor, fitted to stop lateral movement of the blow bars, have to be taken
out of the blow bar groove and the rear beam.

IV - 3
CAUTION
BLOW BARS ARE MADE FROM HIGH ALLOY STEEL. THEY ARE
VERY HARD AND, THEREFORE, VERY SENSITIVE TO BLOWS. FOR
THIS REASON, THEY MUST NOT BE DROPPED OR SUBJECTED TO
HEAVY BLOWS.
PERMISSIBLE WEIGHT VARIATION FOR BLOW BARS

Care should be taken to ensure blow bars of approximately same
weights are placed diametrically opposite each other to maintain rotor
balance. For Impactor APSM-1313, the maximum permissible blow bar
weight variation is 40 gms.
The factory always supplies blow bars in pairs with a maximum weight
difference as indicated above.

IV - 4
ARRANGEMENT OF BLOW BAR K TYPE
RIGHT WRONG
X indicates weight difference between diametrically opposite blow bars.

IV - 5
COMBINATION OF BLOW BARS:
Example:
In a particular machine the following 6 nos. blow bars are supplied-

1) 564 kg 2) 563 kg 3) 563 kg 4) 562 kg 5) 564 kg 6) 562 kg
then the pairs can be chosen as given below:-
1st pair : 564 & 563 2nd pair: 563 & 562 3rd pair: 564 & 562.
The best combination arrangement is shown in figure on left side and

net permissible unbalance is shown in figure right side (given below)

SECTION V
DESPATCH INSTRUCTION
AND INSTALLATION

V-1
INSTALLATION
FOUNDATION
Foundation should be in accordance with the floor plan drawings
supplied by L&T. Construction details are not supplied and these are to
be taken from Civil Engineering Consultants of the Customer.
ERECTION (GA Drg. & Despatch Drg. available in Section - XIV).

- Place the steel packing and wooden packing on the concrete
foundation over foundation bolts. Maintain the required gap
shown in GA with drive drawing for final grouting by giving
suitable packing (I-Sections or Channels), below the steel plates.
Place the Impactor on wooden planks.
- Level the bottom housing by giving suitable packing (I-Section or
Channels).
- Checking of level to be done at bearing housing pad plate for
leveling the bottom housing. After proper leveling the primary
grouting of the housing may be done.
- After the curing period, the bottom housing should be finally
aligned and leveled and foundation bolts fully tightened.
- Place the rotor on the bottom housing, center them and tighten
them properly after adjusting the recommended distance from the
rear-housing hinge to the rotor. The clearance between the sides
of the rotor and wear plates of the housing should be almost
equal on both sides. Level of the rotor should be checked on
tender & drive side, any minor adjustment required might be
done before final grouting of the bottom housing. Please ensure
that the clearance of all labyrinth rings is uniform with the
respective bearing housing incase it is opened.
V-2
- Place the top housing and bolt it with the bottom housing.
- Fix the shaft seal of the rotor.
- Fix the blow bars in the rotors. Blow bar to be positioned such
that the total unbalance is within the limits specified in Section IV
of this manual. Care to be taken that while fixing the blow bars,
due to imbalance of the rotor, accident does not take place.
Locking arrangement should be used during blow bar change.
- Place top housing on the bottom housing and hinge it with the
bottom housing and clamp it.
- Fix the pulleys and complete the drive arrangement as per GA
with drive drawing given by L&T.

SECTION VI
LUBRICATION SCHEDULE

VI 1
LUBRICATION SCHEDULE
Lubricat Crusher Part Lubricant Frequency Amount

i-on
Point
No.
1 Rotor bearing SERVOGEM-3 Weekly 60 cm3
housing of IOC/Equiv.
2 Labyrinth seals SERVOGEM-3 Weekly 30 cm3
of IOC/Equiv.
3 Spindles SERVOGEM-3 As required -
of IOC/Equiv.
4 Cylinder SERVOGEM-3 Every three 10 cm3
bearings of IOC/Equiv. months
5 Hydraulic Power SERVOSYSTE See installation,
Pack M 68 OF IOC/ operation&
Eq. maintenance
instruction for
hydraulic system
of the Impactor.
* Operating 2 shifts, 12 hrs / day.
SERVOGEM - 3 SHOULD HAVE THE FOLLOWING PROPERTIES
Colour : Brown
Service Temp. in 0C : -30 to +100
(Continuous operation)
Penetration, 25 0C : 220 - 250 (MM/10)
Drop point 0C (min.) : 180
Permissible % of water : 0.1
contact (max.)
VI 2
NOTES:
Over filling / over greasing will cause unwanted temperature

rise, foaming & leakage.
Change greases every 1000 hrs. of operation or every six
months which ever is earlier.
If machine remains idle for long-time, old grease / lubricant to
be pumped out / flushed and fresh lubricant is to be refilled.
Bearing must be checked regularly and frequently. Proper
greasing and clearance must be ensured otherwise bearings
may run at very high-sustained temperature finally ceasing &
locking the rotor.

SECTION VII
GENERAL OPERATING
CONDITIONS & INTERLOCKS

VII-1
GENERAL OPERATING CONDITIONS
1.0 CHECKS BEFORE STARTING THE MACHINE
1.1 Gap Setting :

Before the first start - up and after a lengthy period of operation,
check the gap between the lower edge of impact arms and the
blow bars. Incase any other information not given; we
recommend a gap 120-125 mm for front impact arm, 45-50 mm for
rear impact arm, 55-60 for top grinding path & 18-23 for bottom
grinding path. These values are only indicative and by increasing
or decreasing these gap, the reduction ratio and cubicity is
regulated / controlled. The actual gap setting will be done at site
only to obtain the required granulometry.
1.2 Make sure that the rotor bearings are properly lubricated as
per lubrication plan. (Refer to Section VI).
1.3 Check that the V belts are properly tensioned (Refer

Section III).
1.4 Check that all bolts are properly tightened.

VII- 2
2.0 OPERATION INTERLOCKS
Following operational interlocks are recommended for personnel

and equipment safety.
2.1 Impactor drive motor should not be started when the

inspection doors are open.
2.2 Drive of Impactor and upstream feeding equipment cannot

be started unless the down stream belt conveyor is started.
2.3 Drive of upstream feeding equipment to be stopped

immediately in the event of stoppage of downstream belt
conveyor.
2.4 Upstream feeding equipment drive cannot be started unless

the Impactor is started.
2.5 Upstream feeding equipment drive to be stopped

immediately incase the Impactor rotor drops below the set
value or any possibility of jam inside the housing of
Impactor.
2.6 Drives of upstream feeding and Impactor to be stopped in

case the temperature of rotor bearings shoots up to
maximum permissible temperature.

SECTION VIII
COMMISSIONING

VIII - 1
COMMISSIONING
Complete the gap setting of Impact Arms with rotor blow bar tip circle
diameter as per the details given in Section VII.
Ensure that the lubrication of main bearing has been done.
Check proper tensioning of the belts. (Refer to Section III).
The rotor should be rotated manually to ensure that it is not fouling

anywhere and that there is no locking pin inserted in position.
After all the above checks and settings have been done, the motor can
be started and brought to the full speed.
Let the Impactor run for some time and check for the following:
A) Any noticeable vibration on crusher or drive arrangement.
B) Bearing temperature of rotor bearings.
C) Load on the drive motor.
Incase, running of the Impactor is normal, the no load trial can be

continued for a period of 6-8 hours and the bearing temperature should
be checked at regular intervals for undue rise in temperature.
After no-load run of 6-8 hours, check all the bolts once again for
tightness.
Check ancillary equipment like feeder and conveyors are operating

properly. Interlocking of the complete system should also be tried out.

VIII - 2
Start feeding material slowly and evenly and gradually bring the
crusher up to full load in 8-12 hours time. It is essential that material is
distributed evenly over the full width of the inlet otherwise blow bars
and impact plate will undergo uneven wear.
Check the motor load.
Check the temperature of the bearing to judge whether it has stabilized
or not.
Max. Permissible Temperature : 90 - 95 0C.
Normal Temperature : 70 - 80 0C.
When shutting down the Impactor, do not switch off the motor until the
material feed has stopped and nothing more is in the crusher.
OPERATIONAL SAFETY REGULATIONS

Do not open the inspection doors during running condition of the
Impactor.
Do not open inspection doors during running condition of Impactor.
ANY ADJUSTMENT CAN ONLY BE MADE WHILE THE IMPACTOR
IS IN STANDSTILL CONDITION.
No gap setting is to be done during running condition.
WARNING
Alloy steel impact plates as well as blow bars should not be built up
or cut with welding torch otherwise they are liable to fracture.
After stabilized operation, check the end product and if required, the
gap setting may be readjusted, after stopping the machine.

SECTION IX
ANTIFRICTION BEARINGS

IX - 1
ANTIFRICTION BEARINGS
The Impactor is fitted with self-alignment roller bearings. These are

secured to the roller shaft by adapter sleeves. The operating
temperature of the bearings should not exceed 90 - 95 0C. Usually it is
between 70 - 80 0C.
Use a grease gun to regrease the bearings via the two nipples on the
housing in accordance with lubrication instructions.
The bearing housing and cover has a pocket that allows surplus and
used grease to be expelled from the bearing housing.
LUBRICANTS
Use only unadulterated mineral lubricants. On no account, must the
lubricant contain uncombined mineral acids, free alkaline or metal -
corroding additives.
The correct lubricants are listed in Section VII.
STORAGE OF SPARE BEARINGS

Store the bearings in a dry place. Do not remove the makers original
packing material until shortly before fitting.
CHANGING BEARINGS
Before fitting a new bearing, clean the shaft and the surface of assembly
thoroughly. It is not necessary to wash out new bearings; nothing but
pure vaseline has been used as a protective against rust. If old bearings
are being fitted, these must be washed out. Use turpentine, petrol or
benzene.

IX - 2
Kerosene or paraffin must not be used. They often contain acids and
promote the formation of rust. After cleaning, regrease the bearings at
once.
Check the shaft for roundness.
It is also very important that adapter sleeves are tightened up

sufficiently and locked. The adapter sleeve nuts on self-aligning roller
bearing must only be tightened to the extent that the outer race can turn
and swivel out without hindrance. The table (enclosed) gives the
necessary clearance before and after mounting of bearing. Soak the felt
ring sealing in warm oil before fitting. Lubricate each bearing before
start-up. Even a short trial run without lubricating the bearing damages
it. Before making a trial run, check the bearings by turning lightly by
hand. After start-up and before coming upto full operating speed, check
that the bearings are running properly, once more. The noise of rough,
uneven running indicates that some fault is present (dirty bearings,
foreign bodies, faulty or insufficient lubrication, jamming etc.) .
DO NOT ATTEMPT TO MODIFY THE BEARINGS

Grooves, holes and beveling will release tension and cause the races to
become egg-shaped.
WARNING
WHEN CARRYING OUT WELDING ON THE IMPACTOR, ALWAYS
ENSURE THAT THE WELDING CURRENT DOES NOT PASS
THROUGH THE BEARINGS. IF THIS HAPPENS, THE ROLLERS MAY
BECOME COLD-WELDED TO THE RACES. IN THE ABSENCE OF
PROPER EARTHING SEVERE DAMAGE TO BEARINGS AND
LOCKING ASSEMBLIES COULD MAKE THEM UNUSABLE.

IX - 3
MOUNTING OF SPHERICAL ROLLER BEARING
Bearing No. 23140 CCK C3 / W33 23028 CCK C3 / W33
Radial internal Min. 0.220 mm Min. 0.160 mm

clearance of bearing as
Max. 0.290 mm Max. 0.200 mm
received from
manufacturer (C3)
Reduction in Radial Min. 0.090 mm Min. 0.065 mm

internal clearance
Max. 0.130 mm Max. 0.090 mm
Minimum permissible 0.100 mm. 0.080 mm.

clearance after
mounting bearing with
initial clearance C3.

IX-4
PROCEDURE FOR FITTING REMOVING

ANTIFRICTION BEARING HYDRAULICALLY:
FITTING:
Refer sketch (enclosed)
Slide the bearing housing onto the shaft (prior to this soak felt ring in
warm oil) on the adapter sleeve.
Push the bearing onto the adapter sleeve. First fit the inner distance ring
when installing the fixed bearing.
Put the pressure disc onto the adapter sleeve in front of the inner race of
the bearing. This will protect the inner race when the bearing is being
forced.
Screw the adapter sleeve collar nut onto the adapter sleeve until it
contacts the pressure disc.
Bolt the pressure bolts provided into the adapter sleeve collar nut.
Connect the hydraulic pump to the adapter sleeve by means of a 6 mm
pipe, 300 mm long having M6 threads at both ends. This pipe should be
screwed to the pump via a suitable reducer at one end and to the
adapter sleeve at the other end. Now force oil into the fitting groove in
the adapter sleeve and press the bearing onto the adapter sleeve with
the bolts. Measure the reduction in radial play at the same time. Refer
table enclosed.
After releasing the pressure created by oil the bearing must be kept
under the initial axial pressure for further 10 to 30 minutes. The oil can
escape completely.
Remove all components used to fit the bearing, such as hand pump,
bolts and pressure disc. The hand pump being under high pressure
( may be of the order of 1000 atmosphere) during operation, the pump
connections to the work piece may only be removed after pressure has
been released. For further details, kindly contact bearing manufacturers.
Tighten down adapter sleeve collar nut and secure with locking plate.
Fit bearing cover (fit front distance ring with fixed bearing).
Mount outer labyrinth ring.
SECTION X
MAINTENANCE CHECK

X- 1
ROUTINE CHECKS
CLIENT :
MACHINE :
YEAR OF MANUFACTURE :
CAPACITY :
SERVICE ENGINEER :
DATE OF INSPECTION :
CHECKS / INSPECTION FREQUEN OBSER- RECTIFICATI REMARKS

CY VATION ON CARRIED
OUT
A) LINERS
Condition of housing 15 days
liners
B) ROTOR
Condition of blow bars Weekly
Condition of hard faced Monthly
surfaces
Condition of locking of Weekly
the blow bars
Locking Assly. tightness Refer
section - XI
C) IMPACT ARM
Suspension arrangement Weekly
(suspension spindle, pins,
lock plates etc.)
Free movement of the Weekly
Impact arm

X-2
CHECKS / INSPECTION FREQUE OBSER- RECTIFICATI REMARKS
NCY VATION ON CARRIED
OUT
D) DRIVE
Tension of belts 15 days
Tightness of bolts of Monthly
slide rails
Condition of Coupling Monthly
Tightness of Locking Weekly
Assly.
E) GAP SETTING
Checking & resetting of As per
gap require
ment
F) LUBRICATION
Rotor bearings Weekly
Labyrinth sealing Daily
G) JACK SHAFT Monthly

BEARINGS
H) HINGES OF Monthly
HOUSING
I) FASTENERS Once in
CHECKING 3
months
J) ALL FOUNDATION Weekly

BOLTS
k) GRINDING PATH
Condition of grinding Weekly
bars.
Free movement of the Twice/
assembly week

X-3
HOUSING DUST SEAL
End covers and felt seals should be weekly checked and coal dust is to
be removed in order to avoid cutting on shaft (metal) at the housing
dust seal and end covers. If required, use new dust seal.
METAL UNCRUSHABLE ENTRY INTO IMPACTOR

With a view to ensuring a safe & trouble free operation and in order to
avoid major breakdown which results in expensive production loses,
we suggest the following:
a) Entry of uncrushable to the Impactor must be eliminated.
b) Crusher operating personnel should keep watch on heavy earth

moving machinery in order to stop shovel tooth getting dislodged
and enter the Impactor.
c) Regular maintenance checks on fasteners connecting liners /

grizzly bars on any fabricated items preceding Impactor.
In the event of accidental entry of such items, the rotor shaft,
bearings, locking assemblies, blow bars, housing liners and
fasteners should be thoroughly checked.

SECTION XI
LOCKING ASSEMBLY

XI - 1
LOCKING ASSEMBLIES
Locking assembly is a keyless shaft-hub connector providing

mechanically the same characteristics as a shrink fit. The torque is
transmitted by the contact pressure between the inner ring and shaft
and outer ring and hub.
In the Impactor, locking assemblies are used for the following:
A) For connecting the rotor to the rotor shaft.

B) For mounting drive pulley on the jackshaft.
Recommended tightening torque for various locking assemblies are

given below :
A) Size 190 x 250 RfN 7012 - for rotor : 190 Nm

B) Size 140 x 190 RfN 7012 - for Drive & Driven pulley : 125 Nm
INSTALLATION INSTRUCTIONS FOR LOCKING ASSEMBLIES

RfN 7012
The LOCKING ASSEMBLY is a keyless shaft hub connector providing

mechanically the same characteristics as a shrink fit. It is, however,
easily adjustable and removable thus facilitating assembly and dis-
assembly. Since torque is transmitted by contact pressure and friction
between functional surfaces, condition of contact surfaces and proper
tightening of the locking screws are of great importance.

XI - 2
IMPORTANT
To ensure satisfactory performance and easy installation, read first and

then follow all instructions carefully.
A) Clean and slightly oil shaft, hub bore and locking assembly. Make
sure to always oil thread and under the head of cap screws.
(NEVER USE MOLYBDENUM DISULPHIDE MOLYKOTE OR OTHER

SIMILAR LUBRICANTS).
B) Slip locking assembly and hub on to the shaft and bring them to
desired position.
C) Tighten locking screws evenly and in several stages following

radially opposite sequence as illustrated in Fig. 3.
Stage 1: Tighten by hand until a slight position contact is

established. Make final alignment and adjustment to
connection.
Stage 2: Tighten screws to approx. half the specified tightening

torque (MA) shown in table (Refer page XI-1) side. Do this
by extended key or a torque wrench.
Stage 3: Tighten screws to full tightening torque (MA) using a

torque wrench.
Stage 4: Check and make sure that no screws will turn any more by
applying specified torque (MA).

XI - 3
D) Allow assembly to stand for 1/2 to 1 hour.
F) Re-check tightening torque following the same sequence.

Assembly is completed when no screw can be turned any more by
the tightening torque.
NOTE
When dry installation is specified then the shaft, hub bore, inner and
outer ring of locking assembly are to be wiped dry by a clean rag
(normally, do not use any cleaning solution). However, still oil threads
and the bearing surface under the heads of cap screws.
REMOVAL
Locking Assemblies are not self-locking. The taper of the individual
rings are such that the inner and outer ring spring apart once the last
screw has been loosened.
The washer under the painted screw heads protects the auxiliary
(removal) thread against. These washers must be replaced after having
been used several times.
A) Loosen locking screws in several stages following diametrically

opposite sequence. Do not take out screws completely - it is not
necessary.
B) Removal hub and locking assembly from shaft either together or

individually.
Should the front thrust ring jam, remove the three cadmium-plated
screws to expose the pull out threads (dD) of the front thrust ring.
Screw in suitable bolts or threaded rod and lightly tap in outward
direction thus releasing the front thrust ring. The pullout threads have

XI - 4
only 3 to 5 effective threads; they are not suitable for high pulling
forces, and are to be used only for removal of the locking assembly.
TOOLS REQUIRED FOR ASSEMBLY
1) For locking assembly 190 x 250 Rfn 7012 (to be tightened 190 Nm)
REMOVAL
The pull-out bolts, or threaded rods with metric thread (dD) as given
below :
a) For locking assembly 190 x 250 RfN 7012, dD = M16

XI - 5
LOCKING ASSEMBLY TIGHTENING INTERVAL
To ensure satisfactory performance of locking assemblies, following

tightening interval is recommended.
a) After conducting no load trial run for 8 hours.

b) After conducting full load trial run for 8 hours.
c) Thereafter weekly for 3 weeks.
d) If no loosening of locking assembly occurs, check quarterly its
tightening.
LOCKING ASSEMBLY TIGHTENING SEQUENCE
a) Final tightening torque to be achieved in several stages by

increasing the torque step by step from lower value to final value.
b) The screw should be tightened in diametrically opposite sequence

as per sketch enclosed here under.
LOCKING ASSEMBLY SEQUENCE

SECTION XII
SPECIFICATION OF
IMPORTANT ITEMS & TOOLS

XII - 1
SPECIFICATION OF SOME IMPORTANT ITEMS
1) SPHERICAL ROLLER BEARINGS WITH ADAPTER SLEEVE :
For Rotor Assembly
Bearing : 23140 CCK C3 / W33
Adapter sleeve : H3140
For Jack Shaft Assembly
Bearing : 23028 CCK C3 / W33
Adapter sleeve : H3028
2) LOCKING ASSEMBLIES
For Rotor : 190 x 250 RfN 7012
For Drive & Driven Pulley : 140 x 190 RfN 7012
3) V - BELTS
For Rotor drive : 8 Nos. SPC 8000
4) PULLEYS
Drive Pulley : 364 PCD - 1 No.
Driven Pulley : 755 PCD - 1 No.
5) SPECIAL TOOLS
a) Torque wrench : (1/2 SQ. DRIVE).
Range 10-30 KGM.
b) Hex adapter : (1/2(F)XS=10MM(M)
Working torque= 13 KGM
c) Extension bar : (1/2SQ(F)X1/2SQ(M)
(MB 275 MEKASTER/EQUI.)

SECTION XIII
HYDRAULIC CYLINDERS

XIII - 1
1.0: GENERAL PRECAUTIONS:

Cylinders, which have been in storage for some time, should be
lubricated and cycled several times before they are installed on
machines and subjected to actual working loads. Excessive break-loose
and cycling pressures indicate the cylinder may have been damaged
during shipment or storage. Costly installation and removal time can be
eliminated by following this prodcedure. Cylinders should be stored in
a vertical position with the piston rod up.
SALZGITTER air or hydraulic cylinder is a precision piece of

equipment, and therefore, it is recommended that the cylinder be
removed from the machine and taken to a general repair area
where suitable tools, repair and testing facilities are available.
Dirt protector plugs should be kept in cylinder ports whenever the pipe
fittings are removed or while cylinder is in storage. This prevents dirt
and other foreign material from entering the cylinder and damaging
moving parts.
Be certain that the connecting pipes and fittings are clean before
connecting to the cylinder. All pipe ends should be deburred and the
inside of the pipe cleaned of scale, rust, dirt, and foreign matter.
Clean oil is essential for long and satisfactory operation of cylinders,

pumps, valves, etc. Keep oil tanks covered as even normal room dust
causes premature failure, sticking of parts, and needless repairs of
hydraulic systems. Provide an adequate oil filter, preferably a micro
filter.
AIR CYLINDER LUBRICATION AND INSTALLATION
Provide a lubricator and filter in the airline, and use light mineral oil as
a lubricant. Use a pressure regulator to conserve air and to provide a
smoother action. Save air and obtain a greater speed by installing the
valve as close to the cylinder port as possible.
CAUTION :
When cylinders require servicing, an additional set of seals should be

ordered and procured. The original seals may become damaged in
servicing, and this precaution will save time and eliminate costly
delays. Generally it is advisable to replace all seals unless the existing
XIII 2
seals are in excellent condition or this is not economical or possible due
to availability.
Any seal can be damaged if forced over threads or sharp metal parts.
All burrs and damaged areas should be corrected prior to removing
piston rod bushing and rod seal.
Accordingly, care in assembly should be exercised. In the case of a rod

seal, a simple shield of thin wrapping paper around the threads will permit
easy installation of the seals without damage.
DIRT WIPERS : To remove a dirt wiper without taking the rod bushing off, it
is necessary to use a pointed tool as the wiper is lodged firmly. It may be
necessary to take the wiper out in pieces Care should be exercised, so
that the piston rod will not be damaged on removal of the wiper A new
wiper will not be damaged. Whenever the dirt wiper has a tendency to be
blown out, it is an indication that the rod seal is leaking.
The following step-by-step outline will be a valuable aid to personnel
qualified to service precision equipment. By exercising only normal care,
which any good workman would accord to fine machinery, no undue
difficulty will be encountered.
1. Wipe all external surfaces clean. Drain excess oil from hydraulic cylinders.
Paint or draw a line on one side of the cylinder running from the cylinder cap
to the mounting end of the piston rod. This will serve as a reference line when
inspecting components and reassembling the cylinder.
2. VISUAL INSPECTION: Visually inspect all external surfaces for evidence of

damage and in particular, damage to the piston rod. Evidence of rod seal
leakage can usually be traced to nicks in the piston rod or misalignment. If a
slight nick is noticed in the piston rod, it can often be quickly removed by
using a No.400 grit emery cloth. The rod should then be wiped carefully for
removal of any matter.
UNDER NO CIRCUMSTANCES SHOULD COMPRESSED AIR BE USED TO

REMOVE FOREIGN MATTER, as this practice may tend to drive such particles
into close clearances. Misalignment can often be detected by observing the
condition of the piston rods for evidence of excessive wear, polishing, burning
or scoring on the side of the piston rod.
Check carefully the end of the piston rod and the area around the flats on the
end of the rod for burrs and nicks. If burrs and nicks are present, remove with
a file or emery cloth to avoid damage to the piston rod seal, rod wiper, and
bushing during removal.
3. LOOSENING THE TIE RODS (ONLY FOR CYLINDERS WITH TIE-ROD

CONSTRUCTION): Proceed to loosen the cylinder tie rods, noting if the tie rods
were tightened evenly. It may be necessary, in some cases, to grip the tie rod
with vice grips to prevent the tie rod from turning.

XIII 3
4. REMOVAL OF RETAINER PLATE: Remove retainer plate, (in some cases, this
may be a flange mounting plate) Model A,8 through 14 bores have a square
retainer holding the rod seal and bushing in place.
5. REMOVAL OF ROD SEAL: To remove rod seal, raise the cylinder head
approximately one inch and then lower it back into original position. This will
expose the rod seal for easy removal (BY NO MEANS USE A TOOL TO PRY OR
LIFT OUT THE ROD SEAL FROM THE CYLINDER HEAD).
6. REMOVAL OF PISTON ROD AND ASSEMBLY: Remove piston rod and piston
assembly from cylinder tubing(if tubing comes off from cap plate, merely slide
piston assembly off from cylinder tubing).
7. Remove tie rods from cylinder cap.
8. INSPECTION OF INTERNAL PARTS: Inspect all cylinder parts on internal

surfaces, noting particularly any evidence of foreign matter. (Retain all foreign
matter for future study, if necessary). Examine parts for evidence of
misalignment as evidenced by excessive or uneven wear on parts.
9. CONDITION OF PISTON, TUBING, PISTON ROD, etc: If piston, tubing, piston

rod/piston rod bushing is damaged, the part should be replaced, if available.
However, correct if necessary, by removing nicks, burrs and other forms of
damage. Do not remove more material so as to change the diameters, thus
affecting the clearance and fits.
10. REMOVAL OF PISTON ASSEMBLY: Piston assemblies are staked to prevent the
parts from coming loose in operation. If the piston assembly must be taken
apart first grind or drill out the stake marks to facilitate dismantling. When
removing the upset material caused due to staking, lightly touch the tool being
used to the stake area and remove only the upset material. To disassemble
single end cylinders you may insert two dowel pins in the spanner pin holes
and use a bar to remove the threaded follower, or in the case of double end
cylinders remove taper assembly. An alternate method is to clamp the piston
assembly by the faces of the followers in a vice and unscrewing (NEVER
CLAMP THE PISTON ON ITS OUTSIDE DIAMETER). The vice should be
equipped width bronze or brass jaw protectors, if clamping piston rod on
chrome plated area.
11. REFITTING OF PISTON ASSEMBLY: To assemble the piston cup assembly, first
assemble to the rod, the piston and followers only and tighten the piston
assembly tight (metal-to-metal). Scribe a diametral line, which is common to
both the piston rod and the threaded follower. Remove the threaded follower
and piston, and then place the piston cups into position. While tightening the
threaded follower, ensure that it is tightened to the scribed line on the rod or
slightly beyond. To restake a piston assembly, use a sharp center punch.
Stake marks must be in the thread area to be effective staking should be
accomplished at three points, which are different from the original stake
marks.
When installing the piston assembly into the cylinder tubing the piston
assembly should be inserted into the cylinder tube with the aid of a tapered
starting ring or with a piston ring compressor so as not to damage the lip of the
XIII 4
cup. If a tapered ring or compressor is not available, assemble the piston

assembly in the tubing as instructed below:
Install only the plain follower, one piston cup and the piston on the rod, and
insert that portion of the assembly into the cylinder tube keeping the piston
rod as parallel to the centerline of the tube as possible. Push the assembly to
the opposite end of the tube to within approximately from the end of the
tube, and install and second cup and the threaded follower. The piston
assembly is tightened and staked as indicated above. Assembling the piston
assembly in the tube eliminates the problem of starting the lip of the cup into
the tubing. Ample lubrication should be done when installing piston into tube.
Hydraulic cylinders equipped with followers have a small hole drilled through
the followers to the base of the cup seal. This hole permits pressure balancing
of the cup. Under no circumstances should the hole be closed.
12. INSTALLATION OF TUBING END SEAL (SHEF-SEAL): Prior to installing the

tube into the cylinder cap or head, install tubing end seal.
13. INSTALLATION OF WIPER INTO BUSHING: In cases of single wiper bushings,

it is convenient to install the wiper into the bushing before assembly of the
bushing on the piston rod. The wiper is not intended as a pressure seal but
only as a dirt wiper.
14. REASSEMBLY OF THE CYLINDER: After the cylinder has been assembled,
tighten tie rods snugly with hand wrench and light pressure, and accomplish
final tightening gradually working from one tie rod to the diagonally, opposite
tie rod to ensure evenness of tightening. DO NOT TIGHTEN ONE TIE ROD
COMPLETELY AND THEN THE OTHERS. THIS WILL RESULT IN IMPROPER
ALIGNMENT OF THE HEAD AND CAP.
15. REMOUNTING PROCEDURE: The ideal method of mounting a cylinder to the

machine is to have the point of mounting on the equipment machined to the
exact dimensions with proper alignment, so that bolting the cylinder in place
ensures perfect alignment. In many cases, this is not practical from a cost and
design stand point. Therefore alignment must be secured at the time of
installation.
Whenever the piston rod is fastened to the machine, which confines the
cylinder in one position, it is found that it frequently is best to bolt the
cylinder down as a last operation of assembly. Alignment can be secured in
other ways, but the following sequence of installation is quite effective:-
a) Assemble the piston rod to the machine. The piston rod must be fastened and
held securely, so its centerline is parallel to the guides (or parallel to the line of
movement in case of fixed mounted cylinders).
b) Insert mounting bolts but do not tighten them.
c) In the case of horizontally mounted cylinders, it is necessary to support the

weight of the cylinder body so as to eliminate strain on the piston rod.
d) Use feeler gauges under the mounting and insert shims at these points equal
to the thickness indicated by the feeler gauges.
XIII 5
e) Finally, tighten the mounting bolts.
f) If possible, the machine operation should be tested with lower pressure air to
ensure that cylinder and attached parts are operating freely. This should be
done without machine operating under load conditions.
NOTE :
A little extra care in aligning the cylinder properly will pay dividends in
terms of long, trouble-free service, and is well worth the additional time and
effort.
GENERAL:
Whenever possible, damaged parts especially seals, should be sent to

Salzgitter Hydraulics Private Limited along with a complete report, so that a
thorough analysis can be made. Your co-operation in this respect will help
us to help you overcome service difficulties encountered as a result of
adverse operating conditions or improper application.
CYLINDER INSTALLATION:
Proper installation of cylinder can be controlled to a considerable extent by

the Engineer at the time a machine layout is made. Drawing notes,
clarifying methods of installation, precautions to be observed, etc., are
helpful to installation personnel. Some points that manufacturing
engineers should consider in layout stage include.
1. If high shock loads are expected, the cylinder should be mounted, so that full
advantage is taken of the cylinder elasticity. Using the inherent elasticity of a
cylinder in shock situations can mean the difference between a successful
application and one that is always giving trouble. High shock conditions
usually require more rugged fastening provisions than are normally employed.
2. Fixed mounting cylinders should be held in place in keying or pinning, and

some provision should be made for this. Cylinders with integral key mounts
may be used where key-ways can be cut in a machine member. This type of
mounting takes up shear loads provides accurate alignment of the cylinder,
and simplifies installation and servicing.
3. The use of separate keys to take shear loads is relatively common. Shear keys
should be placed at the proper end of a cylinder at the rod end if major shock
loads are in thrust and at the blind end if major shock loads are in tension. In
a given installation, only one end of a cylinder should be keyed to the machine.
If both ends are keyed, the advantages of cylinder elasticity in absorbing
shocks will be lost. Temperature and pressure effects should also be
considered. A cylinder that is mounted at room temperature and zero pressure
may be subjected to working temperatures ranging from 120 to 140 F or
more, and pressures of 2000 or 3000 psi. Under those operating conditions, it
is obvious that the cylinder length will increase over its installed length and
the cylinder should never be mounted so that it is not free to expand and
contract. Even without the pressure of serious shock temperature and
pressure effects, use of shear keys at both ends of a cylinder is not advisable

XIII 6
because of the difficulty of manufacturing a cylinder to an exact overall length,

so that it will fit between keys located for another cylinder.
4. Locating pins may be used instead of shear keys to help take shear loads and
to obtain cylinder alignment. Cylinders should be pinned at either end (not
both ends). Occasionally a designer will carry over die design experience and
call for pinning across corners. This can result in severe warpping of a
cylinder when it is subjected to operating temperature and pressures.
5. Pivoted mounts should have the same type of pivots at the cylinder body and
the rod end. If a simple pivot pin mount is used, the pivot pin axes at each
end should be parallel. Trunnion mounts are generally designed to resist only
shear loads. Therefore, self-alignment mounts should not be used to support
the Trunnions, since bending forces can also be set-up.
1. Misalignment that can occur when a fixed mount cylinder is located so that its
centerline does not coincide with that of the actuated machine member is of
two types. While such a cylinder may tolerate misalignment that increases
with the stroke, it cannot tolerate misalignment that increases with the stroke,
it cannot tolerate misalignment, which remains constant throughout the
stroke. Section 6. 3. 2 of the Joint Industries Conference (JIC) Hydraulic
standards states the cylinders shall occur on piston rod or ram, unless other
suitable provisions are made to take such loads. The recommendation is a
good rule to follow in mounting a cylinder.
2. In attaching a cylinder rod to a machine member, the rod should not be

rotated unnecessarily, as there is always danger of scoring the cylinder body.
This is especially so, if there is misalignment when the rod is rotated.
3. To facilitate gland maintenance rod end knuckles, cam surfaces, and other
projections should not be welded or otherwise fastened, permanently to piston
rods during installation. Another point related to maintenance is that when
seals need replacement, the rod bearing probably should be replaced also.
Seal wear rates can be increased greatly when glands are oversize or worn.
4. Wherever possible, joints should be pulled-up tight against shoulders. This

will minimize bending at necked-down sections and decrease fatigue stresses
caused by reversal of forces in bending.
5. The effects of dirt and other foreign material should be considered at

installation of a cylinder. The installation group should be reminded to take
care that no paint or similar material is sprayed on an exposed cylinder rod
and that damage to exposed rods should be avoided.
---END---
C:\bas\MANUAL.doc

SECTION XIV
HYDRAULIC POWER PACK

MANUAL

XIV-1
INTRODUCTION
The Hydraulic Power Unit is a power transmission mechanism in

which hydraulic fluid is used as the power transmission medium. The
fluid generates pressure by the pump with a relief valve and in turn
delivered it to the Cylinder or hydraulic motor. Thus the pressure
energy is
converted to mechanical work. The hydraulic power pack unit supplied
for your equipment is to drive the machine; therefore it is essential that
the operation and maintenance personnel should be well conversant of
the system for trouble free operation.
Hydraulic Power Pack System Detail
Hydraulic circuit drg no- CS-1.3-05758

Motor capacity- 3.7 KW
Pump flow- 9 LPM
System working pressure- 150 KG/CM2
System test pressure- 225 KG/CM2
A brief description of the Hydraulic System
The system is basically consists of oil tank, pump, motor, control valve
and electrical control panel etc. The oil tank is of 30 litres capacity, fitted
with air breather, level indicator, return line filter, etc. Manhole cover is
provided for cleaning and maintenance purposes of the tank.
Description of Components
Pump
Vane Pump (1P3020, Dowty make) is a positive displacement pump.
The pump is coupled with electric motor (3 phase, 415V, 1450 RPM)
through
drive coupling with the help of bell housing. The pump delivers
approximately 9 lpm at 1450 r.p.m. The pump suction line is connected
with a suction strainer which prevents the foreign material to enter into
the system through the suction line of pump..

XIV-2
Manual Operated Directional Control Valve
This is 3 position 4 way manual operated directional control spool valve
(4DL06SGS, Polyhydron make) In neutral position for G spool valve
A&B port are closed. On actuation of the solenoid coil a or coil b the
pressure port gets connected to one of the cylinder port and other side
of the cylinder port gets connected to tank port.
Pressure Relief Valve

Pressure relief valve (DPRS 06T 315, Polyhydron make) is direct
operated pressure relief valve. It serves to limit pressure in the system.
The pressure is adjusted by means of screw. If pressure in the P-line
increased beyond the value set at spring, poppet opens against spring.
Oil now flows from P-line in T-line.
Settings:
Clockwise turning of the setscrew for increase and anticlockwise
turning for decrease of set pressure. In this case the set pressure is 150
Kg/cm2 (approx.)
Caution:
A higher setting of relief set pressure may cause damage to the
equipment. Any unauthorized person should not disturb the pressure
setting.
Return Line Filter

Return line filter (TIF2 06 25 ER, Hydroline make) is using the filter the
oil. It is intended for direct mounting on hydraulic tank. Filter element
of 25 micron should be change regularly. It is very essential for running
the equipment.
DESCRIPTION OF HYDRAULIC CIRCUIT
Refer to Hydraulic Circuit Diagram & Electrical Circuit Diagram

The Hydraulic Circuit of the Impactor is basically a open circuit and
employed for impact arm adjustment, grinding paths adjustment and
housing tilting. The hydraulic system is operated through the electrical
control panel. Switch on power supply through Q1. Press push button
S2 to star pump at no load. To start individual operation select position
of selector switch S5.Selector switch S4for selection of either forward or
reverse operation of cylinder.
XIV-3
Push button S2 for start operation of cylinder depending on selection of
S4 & S5.
1) Housing Opening:
Select the selector switch S5 to position 1 and the selector switch S4 to
either position Forward / Reverse selection. Press push button actuator
S3. The housing opening cylinder will gate actuated the Impactor
housing will start open/close. Change the portion of the selector switch
S4 for change position of cylinder. It is dangerous to operate Hydraulic
System operate while Impactor drive is on.
Installation, Commissioning And Maintenance

Installation
The following points should be noted while installing the power unit.
The highest degree of cleanliness must be followed because smallest
particles of dirt can cause serious damage to the hydraulic components
and actuators.
The entire pipes work end must be de rubbed after cutting and cleaned
internally prior to laying for connection to actuators. All the pipes shall
be pickled and flushed properly after welding. Good quality of pipes
and fitting must be used to avoid leaking.
Commissioning
Ensure the following checks before commissioning of Power Unit.
1) Ensure the cabling is of required size.
2) Check the oil level in the tank. The Oil sight glass and low level
switch is provided for this purpose in the tank.
3) All the fittings and joints are properly tightened. All the O-rings and
Gaskets should be in proper position and properly tightened.
4) Check the direction of rotation as per arrow mark shown on the
motor.
5) Start the electric motor with on / off, 2 / 3 times.
After the checking and starting of pump, follow the operation
mentioned earlier.
Maintenance
The basic maintenance of the Power Unit is to keep the oil clean to a
standard, which provides longer life of the components. For this
purpose, please check the cleanliness of filters every 15 days or 150 hrs
of a continuous working.

XIV-4
In case the filter is found choked or full of contamination, clean the
same or
replace with a new one. Please check the leakage, if any, found from
any where in Power Unit or Pipelines.
FAULT FINDING AND TROUBLE SHOOTING

SL. FAULT CAUSE REMEDY
No.
1 Pumps does not a. Insufficient oil in tank. Check & top up if req.
give flow
b. Incorrect direction of Check & rectify
rotation of motor.
c. Worn out pump Check & replace.
2 Pressure does not a. Insufficient oil in tank Check & top up if req.
develop
b. Worn out pumps Check and replace.
c. Damaged relief valves Check and replace if req.
d. Pressure relief valve set Adjust the relief valve Setting..
Too low.
e. Leakage in the system Find out and rectify it.
3 Pressure drop / a. Leaking the seals of Replace the seals.
retract cylinders
b. Pilot operated check Check, clean the valve
valve
c. Leakage in the system Find out and rectify
4 Cylinder a. Air in the system. Loosen the A&B port of the
movement erratic cylinder, remove the air and
tightened it again.
b. DC Valve is not found Check the DC valve, if Defective
valve not mounted in replace it.
working properly
5 Cylinder not a. Pilot operated check Mount the valve properly.
moving proper direction.

XIV-5

XIV-6

XIV-7

XIV-8

XIV-9

XIV-10

SECTION XV
HYDRAULIC SYSTEM
FUNCTIONAL WRITE-UP

XV-1
HYDRAULIC SYSTEM FUNCTIONAL WRITE UP
The hydraulic system for this Impactor is intended for opening of the
Rear Top Housing for maintenance activities.
The entire grinding path housing can also be retracted out of the
Impactor housing with the help of the power pack and two hydraulic
cylinders for maintenance / gap setting purpose.
Refer to the Hydraulic circuit drawing no. HE/HC/009 of

M/C.Hydrocraft Engineers enclosed in the manual.
The housing opening is performed by a pair of double acting hydraulic

cylinders. A gear pump suppliers pressurised oil to these cylinder
through a directional control value.
In addition to above, a counter balance valve has been provided for

each housing opening cylinder. This valve prevents sudden falling of
the Top housing during housing closing operation due to the housings
own weight. The counter balance valve is adjusted to maintain a
minimum of bar pressure against housing falling.
The system has been designed for a working pressure of 120 Bar.
Accordingly the pressure relief valve of the system can be set at site
suitably.

SECTION XVI
SPEED SWITCH

XVI-1
INSTRUCTION MANUAL FOR ELECTRONIC SPEED SWITCH
PRODUCT :: ELECTRONIC SPEED SWITCH

TYPE :: ESS-102
SUPPLY :: 110V/230V. 50 Hz (Selectable)
INPUT :: PULSES FROM SENSOR PROBE(M30, NPN,
NO' 5 mtr CABLE)
INITIAL BYPASS:: 1 TO 30 Sec (ADJUSTABLE)
OUTPUT :: PNP SWITCHING NO
CONTACT RATING:: 5 Amp AC, RES. AT 240V, 50HZ or AT 24V dc
SPEED RANGE :: 5-5000 PPM( lN 3RANGES: 5 -50,50-500,500-
5000 THRO 'DIP S/W)
ENCLOSURE :: CAST ALUMINIUM. POWDER COATED IP 65

GRADE.
ELECTRICAL CONNECTION:-

XVI-2
INSTRUCTIONS:-
Do the elect. Connections as per the electrical connection diagram
given in the unit
The unit senses speed in terms of ppm (pulses per min.) which is
given by : RPM X No. of actuations of sensor probe per rotation.
Adjust the IBPD (Initial By-Pass Delay) by means of IBPD not in
such a way, that drive is able to achieve its normal working
speed (PPM) during that period.
The relay in unit will remain pickred up during IBPD, irrespective
of actual speed.
When IBPD is over, the relay will remain picked up, Only if the
actual speed is more than set speed or it will drop out.
Select the appropriate speed range by means of range
dipswitch.
In the chosen range, adjust the correct speed by means of speed
pot.
For more details of input probe selection & its connection, Relay
logic selection (NO/NC). Speed selection, PCB component view &
mounting arrangement etc. see the attached drawings.

XVI-3

SECTION XVII
LIST OF DRAWINGS AND

SPARES PARTS LIST

XIV - 1
LIST OF DRAWINGS
Sl. No. Description Drawing No.

1 General Assembly of Impactor CS.1.1-08119B
2 General Arrangement of Impactor with CS.1.1-08168D
drive
3 Spare parts list CS.1.3-10388
4 Hydraulic circuit diagram CS.1.3-05758
NOTE :
Only reduced size prints have been enclosed with the manual for ready
reference. In case of any ambiguity, full size drawings may be referred,
which have been separately supplied to Client earlier.

SECTION XVII
LIST OF SAFETY PRECAUTIONS

AND INSTRUCTIONS

XVII - 1
SAFETY PRECAUTIONS & INSTRUCTIONS TO BE

FOLLOWED
A) Before making the repair / adjustments or performing routine

maintenance.
Cut of power supply to the equipment and let the machine come
to stand still.
B) During repair / adjustment or performing routine maintenance.
1) Never drop the blow bars and impact plates from a height
neither, try to rectify above by weld deposits / welding.
2) During welding operation, make sure that welding current

does not pass through the bearings, otherwise it will damage
the bearings. Ground the equipment accordingly prior to
welding.
3) Never attempt to modify the bearings.
4) Never attempt any welding on the rotor shaft.
5) While changing / reversing blow bars, ensure that blow bars

of approximately same weights are placed opposite to each
other. This is to maintain the rotor balance to avoid vibration.

XVII - 2
6) Replace blow bars in time as instructed in section IV to avoid

damage to the rotor.
7) While making gap adjustment, maintain parallel gap (i.e,

uniform gap along the rotor length).
C) After repair / adjustment or performing routine maintenance
1) Check tightness of all fasteners.
2) Check that lubrication has been done as per lubrication

schedule.
3) Check that tools, tackles etc. have not been left inside the
Impactor.
4) Check free rotation of rotor by rotating the driven pulley by

hand.
5) Check that all inspection doors are closed and locked.
6) Mount belt guards in position if dismounted for maintenance.
7) Connect power supply and check direction of rotation of

Impactor.


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648

LARSEN & TOUBRO LIMITED

OPERATION & MAINTENANCE MANUAL

CUSTOMER :: CHANDERPUR WORKS

LOCATION :: CHANDERPUR WORKS

ORDER REF. :: CPW/U.CMT/4672/11.12

PROJECT NO. :: 101147

DOC.NO:900087 Larsen & Toubro Limited

We have pleasure in enclosing Operating & Service Instructions

Strict observance of the Instructions is important for efficient

We would advise you to keep a stock of the spare parts for

To enable us to give prompt services, please do the following:

Please quote our Project Number on your order form or any

Please note our Phone Numbers :: (06624)280241, 280101, 280123, 280145,

DOC.NO:900087 Larsen & Toubro Limited

THE INITIAL START - UP OF THE MACHINE MUST NOT BE

MAKE SURE THAT ALL ERECTION AND SERVICE FLAPS,

DO NOT OPEN DOORS WHILE THE MACHINE IS

DO NOT THRUST BARS OR SIMILAR TOOLS INTO THE

SERVICING, REPAIR WORKS AND GAP SETTING ARE

MAKE SURE THAT THE MAIN SWITCH IS LOCKED.

PLEASE OBSERVE THE INSTRUCTIONS GIVEN IN THE

DO NOT MODIFY OR ADD EXTRA MASS BY WAY OF

DOC.NO:900087 Larsen & Toubro Limited

XVIII LIST OF SAFETY PRECAUTIONS AND

DOC.NO:900087 Larsen & Toubro Limited

DOC.NO:900087 Larsen & Toubro Limited

CUSTOMER : CHANDERPUR WORKS

DOC.NO:900087 Larsen & Toubro Limited

DOC.NO:900087 Larsen & Toubro Limited

DESCRIPTION OF THE MACHINE

2. DESIGN AND OPERATING PRINCIPLE

3. MAIN COMPONENTS OF THE IMPACTOR

DOC.NO:900087 Larsen & Toubro Limited

DOC.NO:900087 Larsen & Toubro Limited

DOC.NO:900087 Larsen & Toubro Limited

DRIVE ARRANGEMENT AND

DOC.NO:900087 Larsen & Toubro Limited

Power to the machine is given through jackshaft arrangement. The

The jackshaft assembly is supported on two bearing and coupled to

1) Motor : 179 kW, 1000 RPM

2) Pulleys : Drive Pulley - PCD 364 mm

3) Belts : 8 Nos. V - BELT SPC 8000

DOC.NO:900087 Larsen & Toubro Limited

RECOMMENDATION FOR TENSIONING OF BELTS

The tension of the belts to be very closely monitored and checked

It may be emphasized that proper tensioning of belts will result in an

It is recommended that a drive which is to stand for a prolonged period

DOC.NO:900087 Larsen & Toubro Limited

DOC.NO:900087 Larsen & Toubro Limited

DOC.NO:900087 Larsen & Toubro Limited

DOC.NO:900087 Larsen & Toubro Limited

DOC.NO:900087 Larsen & Toubro Limited

DOC.NO:900087 Larsen & Toubro Limited

DOC.NO:900087 Larsen & Toubro Limited

GAP ADJUSTMENT AND

DOC.NO:900087 Larsen & Toubro Limited

CAUTION ANY GAP ADJUSTMENT TO BE DONE IN

IMPACT ARM ADJUSTMENT

WARNING: NO ADJUSTMENT SHOULD BE DONE WHILE THE

DOC.NO:900087 Larsen & Toubro Limited

BLOW BAR EXCHANGE

TO REMOVE BLOW BAR

DOC.NO:900087 Larsen & Toubro Limited