Ring-type Crusher Training

Program

August 28, 2017

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 Training Goals
This training program covers:

1. the components and technical specifications of the equipment;

2. the working principles of the equipment;

3. the launching and shut-off procedures of the equipment;

4. and matters needing attention and miscellaneous during the patrol

work.

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 Training Goals
Part I: Components and Technical Specifications of the Equipment
Part II: Working Principles
Part III: Launching and Shut-off Procedure
I. Non-loading Operations
II. Loading Operations
Part IV: Patrol Work and Matters Needing Attention
I. Patrol Work
II. Well-organized Manufacturing and Safety Management
III. Handling Method for Normal Breakdowns

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 Section I Equipment Component and Technical Specification
I. Components of the Equipment’s Structure

1. The equipment’s structure is composed of lower machine body, back cover, middle machine
body, front cover, rotor, synchronous regulator, sieve plate holder, shaft end cover and
hydraulic system for launching and shut-off.

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 Figure 2

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 2. The steel-welded machine body is composed of lower machine body, back cover, middle machine
body and front cover. The lower machine body is rigid and has seal groove on its bearing surface.
The middle machine body also has seal groove on its vertical flange and sealing joint strip inside.
The four parts will be connected with bolts and nuts. The front and back machine bodies will be
connected to the lower machine body with shaft for hinged lever to enable the rotation of launching
and shut-off. The machine body is equipped with a ZG50Mn2 anti-abrasion scale board inside. The
feeding inlet is above the middle machine body and has an air quantity regulating plate at its throat
to adjust the blast volume of rotor. Above the back cover is a hanging scroll support for the sieve
plate holder. Both the lower machine body and front cover have kick-out plates to remove foreign
matters. The machine has 8 inspection doors for maintenance, adjustment, overhauling and abrasion
testing. Rotors at both ends of the machine body are equipped with shaft end covers, which have
felt and gum sealing.
3. The principal shaft is equipped with 1 group of flat keys, 2 round plates, several cross rocker
arms and 2 spacer bushes, which have been fastened with jam nuts to prevent the motion block
from loosening.4 collared shafts are equipped with orderly-arranged ring gear and round-link
hammers, which have been limited with retaining bolts and spring washers. The two bearing bodies
are split type, whose bearing block has 2 ring grooves inside to orientate the maze and stifle. The
principal shaft has double-row self-aligning spherical roller bearings at both ends, which have been
fastened with round nuts and stop washers. Bearing outer rings at the output shaft are axially
fastened with stable rings, and the ones at other points can have axial play. The bearing radial will
have labyrinth seal. See details in Figure 4.
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 • 5. Please refer to Figure 1 and 5 for the synchronous regulator. The regulation between the sieve plate clearance is realized
through two eudipleural worm and gear reduction devices. Connect them with connecting shaft, sleeve and spring pin for
synchronous adjustment. While the endless screw is rotating, it pushes the screw, hinge head and shaft to move back and
forth, and the connecting rod can rotate around the shaft with shaft for hinged lever to adjust the relative position between
the sieve plate holder and rotor. The spacer shim is used for adjusting and bearing the impact force between sieve plates.

6. The hydraulic system for launching and shut-off is

composed of a hydraulic power unit, pipelines, control
elements (reversing valve) and actuating elements (oil
cylinder).The front and back covers each has two oil cylinders
to facilitate maintenance. However, it is forbidden to open the
front and back covers at the same time. It is required to take
measures to protect the quick coupling from dust while the
hydraulic system is off. The hydraulic power unit is composed
of motor, paul pawl coupling, gear pump, oil inlet and return
pipes, coarse and refined oil filters, relief valve, reversing
valve, throttle valve, filter, signal lamp, pressure gage and fuel
tank, etc. The refined oil filter is equipped with CMS-I. In
case the filter element is blocked and pressure pipelines’ oil
pressure difference reaches 0.35Mpa, the signal lamp will turn
on and it’s time to change the filter element.

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Figure 5
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 Figure 4

• 4. Refer to Figure 1 for sieve plate holder. The sieve plate holder’s frame is welded and hung
inside the back cover by shaft, which is connected to the synchronous regulator through the
shaft for hinged lever. There are 8 high manganese steels (4 type-I and 4 type-II) and 1 alloy-
steel sieve plate with tangential grating holes, which have been fastened with wedge bolts. The
sieve plate holder can rotate around the hanging shaft.

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 Section 2 Equipment Operation Principle
After the raw coal leaves the conveyor belt and enters the
crushing chamber of coal breaker, it will be chopped into
pieces by the ring hammer spinning at a high speed and then
rush into coal and sieve plates for further grinding.At the
same time, coal pieces will collide with each other and be
chopped, grinded and shred into the required particle size by
the ring hammer after they fell between the sieve plate and
ring hammer.Then they will be discharged from the sieve
plate with tangential grating holes.For materials hard to be
crushed such as steel and wood blocks, they will be thrown
into the deironing room by switch-plate and get removed on a
regular basis.
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 Section 3 Startup and Shutdown
One. Non-loading Operation
1. Close the front and back covers, shut off inspection doors and fasten them with wedges.
2. Check whether the connecting bolts, lining-plate bolts and anchor bolts have been
fastened.
3. Make sure there is no foreign matter in the machine body. Turn the machine 1 to 2 rounds
to check whether it can operate smoothly.
4. Fill each point of lubrication with lubricating oil as required.
5. Before inserting a hydraulic coupling into the motor, check whether its direction is in line
with that of coal breaker.
6. It is forbidden to change the rotating speed of rotor without approval.
7. Start the non-loading operation after completing the above inspection work.
8. The bearing temperature should not exceed 80℃ 4 hours after the non-loading operation.
9. Make sure that during the operation, there is no abnormal noise, the current value is
stable, the single amplitude of bearing support is within 0.06mm (rigid foundation). While
the elastic foundation depends on the nature of foundation, it should not exceed 0.35mm.

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Two. Loading Operation
1. Start the loading operation after completing the non-loading operation successfully. Gradually increase
the feedstock until it reaches the rated value. Evenly wrap the feeding inlet with cloth.
2. During the feedstock process, frequently check the current value, bearing temperature and the
amplitude of machine body and bearing support. Make sure that everything is ok and then start the
loading operation.
3. Except emergencies, it is not permitted to shut off the machine during the feedstock process.
4. Normal shut-off: turn off the feeder first, make sure that there is no substance left in the feeder (1 to 2
minutes after the crushing sound stops), and then shut off the machine.
5. Before the rotor stops still, it is forbidden to open the inspection door and carry out the maintenance
work.
6. During the loading operation, the vertical and horizontal single amplitude of bearing support should be
0.04～0.125mm. In case that the amplitude of a certain direction exceeds 0.25mm, shut off and inspect
the machine immediately; while the elastic foundation depends on the nature of foundation, once the
amplitude of a certain direction exceeds 0.50mm, stop the machine immediately, analyze the causes and
deal with them accordingly.
7. Under normal conditions, the working oil temperature of hydraulic coupling should not exceed 90℃.

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 Section 4 Patrol Inspection and Precautions
One. Patrol Work
1. Inspection before launching
1.1 Make sure that there is no staff near the coal breaker and mechanical parts;
1.2 Make sure that the electrical and control parts are in normal state, and the ground leads are intact
and fastened;
1.3 Make sure that the anchor bolts of motor and coal breaker are fastened;
1.4 Make sure that bearing supports and back plate screws are fastened;
1.5 Make sure that there is no foreign matter in the machine body that may cause blocking;
1.6 Make sure that the hammer head or ring is intact, and the sieve plate and hammer head are not
severely worn;
1.7 Check whether doors are fully closed;
1.8 Make sure that the hydraulic coupling is in normal oil level, and there is no oil leakage and no
blocking in fusible plug holes;
1.9 Frequent starting would cause the working oil to exceed rated temperature, so it is not permitted to
do so;

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 1.10 After the hydraulic coupling operates over 3000 hours, it is required to check the condition of
working oil and replace the aging and metamorphic with fresh one;
1.11 Before starting the hydraulic power unit, the oil level should be above the oil pointer. After
launching the unit, if the oil level is below the oil pointer, it is required to recharge the oil;
1.12 Make sure that all pipelines of the hydraulic system are well connected;
1.13 Get rid of the air in pumps and pipelines and fill the oil pumps with working oil;
1.14 It is forbidden to launch the coal break in loading state.

2. Matters Needing Attention During Operations

2.1 Make sure that the motor has no abnormal sound and the current is at the rated value;
2.2 Make sure that the anchor and fastening bolts are fixed;
2.3 During the operation, frequently check the temperature at both ends of the main shaft, and make
sure that the bearing temperature should not exceed 80℃ (alarming for 80℃, and shut-off for 90℃),
vertical amplitude: ≤0.25mm; horizontal displacement: ≤0.2mm;
2.4 Make sure that there is even coal supply and no abnormal sound;
2.5 The coal quantity in coal breaker should not exceed the design output. In case that the coal has large
water content, reduce the coal feeding quantity accordingly;

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 2.6 Pay attention to abnormal collision and friction sounds in the coal breaker,
and detect and report abnormal conditions immediately;
2.7 Frequently check if there is any blocking in the upper and lower coal
dropping pipes;
2.8 Check if there is any unqualified coal piece, and adjust the screw rod to
get them qualified;
2.9 During the operation, it is forbidden to open the deironing room to
remove steel blocks;
2.10 Make sure that the working oil temperature of hydraulic coupling is not
above 90℃;

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 III. Breakdowns and Troubleshooting Methods
No. Nature of Breakdowns Causes Troubleshooting Methods

Re-assemble it as stated in the instruction

Ring hammer breaks or severely wears and loses balance book and displace it with a new ring

hammer
Coal
Bearing damage or too much radial internal clearance Replace the bearing.

Conduct realignment as stated in the

1 Breaker The motor is not concentric with the hydraulic coupling.
instruction book.
Amplitude
Uneven feeding, which causes the uneven wearing of the ring Adjust the feeding devices and conduct the
Condition
hammer. feeding evenly along the rotor.

Fasten the screws.

Flexible bearing support or anchor screws

Too little or damaged bearing radical clearance. Replace 3G or 4G ample bearing to enlarge

The bearing temperature exceeds the clearance.

2
90℃. Inadequate lubricating oil. Add more lubricating oil.

Dirty lubricating oil. Replace the oil.

There are hard foreign matters inside. Shut off the machine and remove the

foreign matters.
Continuous knocking sounds inside
3 Flexible screws of coal breakers and sieve plates, etc., which
the coal breaker. Fasten the screw nuts.
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The ring hammer shaft got severely worn. Replace the ring hammer shaft.
 Significant increase in the Too much clearance between the sieve plate Readjust the clearance.

25mm and above particle and ring hammer. Replace the sieve plate.

size There is wreckage in the sieve plate hole. Replace the ring hammer.

4 The ring hammer is severely worn.

S i gn i f i c a n t r e d u c e i n Adjust the feeding units

production. Uneven feeding

5 Clean up the sieve plate holes and check

the water and dust content of coal.

The sieve plate hole is blocked.

Although the pump is The flood valve malfunctions. Dismantle the valve and repair it.

working, it fails to reach

the working pressure. No loading in the oil pressure loop. Check the channels for oil and load up.
6

System oil leakage. Check pipelines to stop the leakage.

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 Although there is pressure, It got foreign matters and has abnormal friction in the Conduct inspection and remove the foreign
the machine failures to sliding parts. matters.
discharge oil or volume Its suction tube is too thin or blocked. It is allowable to have mercury column with a

efficiency lowers. vacuum degree of 110mm.

7
The suction filter is blocked. Rinsing.

Suction filter does not have enough capacity. The capacity of filter should be twice of the available

capacity.

The suction tube or other parts has sucked air. Fill the suction tube with oil and detect the bad points.

Bubbles in the oil tank. Check the oil loop to prevent bubbles.

Low oil level Add oil until the oil level reaches the rated height.

There is not enough rigidity in the installation foundation of the Raise the rigidity of the installation foundation.

8 Too much noise pump.

The rotation speed and pressure exceed the rated value. Check the rotation speed, pressure and channels for

oil.

Poor volume efficiency and air in the pumps Get rid of the air to enhance the volume efficiency.

9 Overheated oil pumps.

Damaged bearing. Replace the bearing.

The oil is too sticky, not well lubricated or severely spoiled. Replace the oil.

O v e r h e a t e d h y d r a u l i c Reduce the oil loading. Add oil to the required quantity

10 coupling Overloading Reduce the loading

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 O i l l e a k a g e Damaged or flexible O-type seal
Replace the seal rings or fasten
d u r i n g t h e rings on the thermal protection or
the oil plugs
o p e r a t i o n o f oiling plugs

h y d r a u l i c Damaged O-type seal ring in the back room

11
coupling or the junction between the shell and pump Replace the seal ring.

pulley.

Flexible junction surface in the back room

Fasten the connecting bolts in these points.
or between the shell and pump pulley.

Oil leakage

12 during pulling The oil seal at the output shaft got damaged. Replace the oil seal

up.
Collision

sounds during
13 The elastic blocks are severely worn. Replace the elastic blocks.
the launching or

shut-off.

The motor got

burnt.

14 Too much oiling. Fill in oil as required.

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