OPERATION & MAINTENANCE MANUAL

Vertical Shaft Impact Crusher

Model 2500 Ultra Spec

700 West 21st Street

Yankton, SD 57078 IB-0227 2/00
page
Record your 2500 Ultra Spec serial number and order number in the space
below. Please include these numbers when requesting service or ordering
replacement parts.

KOLBERG-PIONEER, INC.
JOB ORDER

MODEL S/N

MANUFACTURED BY KOLBERG-PIONEER, Inc. YANKTON, SD, U.S.A.

CALIFORNIA
Proposition 65 Warning

Diesel engine exhaust and some of its constituents are known

to the state of California to cause cancer, birth defects, and
other reproductive harm.

Copyright KOLBERG-PIONEER, INC.

2000
page
 INTRODUCTION

This bulletin contains operating instructions and lubrication-maintenance information. Application of this information
should maximize the performance and life of your equipment and minimize down time.

Safe and efficient operation requires that you and anyone else who will be operating or maintaining this equipment
read and understand the safety, operation, maintenance and troubleshooting information contained in the
operator's manual.

Continuing improvement and advancement of KOLBERG-PIONEER Products may cause changes to your
equipment which may not be reflected in this publication.

KOLBERG-PIONEER, Inc. reserves the right to make changes or add improvements to its products at any time,
without incurring any obligation to make such changes on previously manufactured equipment.

Although care has been taken to assure the accuracy of this publication, KOLBERG-PIONEER, Inc. does not
assume any liability for errors or omissions.

page
CONTENTS

Safety
Safety Symbol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Sign-Off Form. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safety Decals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7

Operating Principles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Machine Parts Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-12

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Application Information
Feed Rate & Gradation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Output Gradation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Screening. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Feed Size/Impeller Table Speed/Rotation. . . . . . . . . . . . . . . . . . . . . 15
Impeller Table Speed/Wear Relationship . . . . . . . . . . . . . . . . . . . . . 15
Impeller Table Speed/Tonnage Relationship. . . . . . . . . . . . . . . . . . .15
Tonnage Thru-put/Casting Wear Relationship . . . . . . . . . . . . . . . . .15
Tramp Material. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Air Flow At Discharge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Lubrication System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-18

Lubrication Electrical Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-22

Preoperation Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-25

Start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Wear Parts
Hydra-Arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Feed Tubes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Lid Liners. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Inspection Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Impeller Shoes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Feed Disc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Flat Table Liners. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31-33
Anvils. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Skirt Cone. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

page
 CONTENTS

Maintenance
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Maintenance Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Daily. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38-40
50 Hours. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41-42
200 Hours. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43-44
500 Hours. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Maintenance Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46-47

Trouble Shooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

page
SAFETY SYMBOL
BE ALERT ! YOUR SAFETY IS INV
ALERT
INVOLVED
This symbol is used to bring attention
to safety precautions and instructions.
When you see this symbol, be alert and pay
attention to all instructions.
YOUR PERSONAL SAFETY IS INVOLVED.
Most accidents are caused by failure to
observe basic safety rules or precautions. An
accident can often be avoided by recognizing
potentially hazardous situations before an
accident occurs.
Improper operation is dangerous and could
result in injury or death
CAUTION: Read and understand
all safety precautions and
warnings before operating this
equipment.
Basic safety precautions are outlined in the
“SAFETY PRECAUTIONS” portion of this
bulletin and in the description of operations
where hazards exist.
Warning decals have also been placed on the
equipment to provide instructions and to
identify specific hazards which, if not heeded
could cause bodily injury or death to you or
other persons.
KOLBERG-PIONEER, Inc. cannot anticipate
every possible circumstance that might involve
a potential hazard. The warnings in this
publication and on the equipment are therefore
not all inclusive.
page 1
OL
OLVED
If an operation is not performed as specifically
recommended by KOLBERG-PIONEER, Inc.
you must satisfy yourself that it is safe for you
and others. You should also ensure that the
equipment will not be damaged or made
unsafe by the method of operation you choose.
The following signal words may be used in
this manual to designate a degree or level of
hazard and are defined as follows.
DANGER
Imminently hazardous situation which, if not
avoided, will result in death or hazardous
injury.
WARNING
A potentially hazardous situation which, if not
avoided, could result in death or serious injury.
CAUTION
CAUTION
A potentially hazardous situation which, if not
avoided, may result in minor or moderate
injury. It may also be used to alert against
unsafe practices.
IMPORTANT
IMPORT
Specific practices that are critical to the
operation or maintenance of the equipment.

The safe operation and maintenance of the
impactor is the responsibility of the owner/
employer and the operator/employee.
The owner/employer must ensure that anyone
who operates, maintains, services, transports
or works around the impactor is familiar with
operation, maintenance and safety procedures
and information outlined in this manual.
Owner/Employer's Responsibility
It is the owner/operator's responsibility to
insure everyone operating the equipment is
familiar with safe operation and maintenance
of the impactor. Do not risk injury or death by
ignoring safety practices or failing to instruct.
It is the owner's responsibility to give the
operator or employee instruction before
allowing them to operate, service, transport
or work around the impactor. This instruction
should be reviewed at least annually.
Operator/Employee's Responsibility
It is the operator's responsibility to read,
understand and follow all operation, service
and safety information presented in this
manual and on the impactor.
Untrained operators and maintenance
personnel are a hazard to themselves and
others and are not qualified to operate or
service the impactor.
Never modify the impactor in any way.
Unauthorized modifications can affect the
function and/or safe operation and life of the
impactor.
page 2
SAFETY
The following section presents material on
specific safety items. Although specific safety
guidelines are given, each situation can have
its own peculiarities which can not always be
covered by specific rules.
General Safety
1. Read and understand the Operator's
Manual before operating, servicing or
working around this machine.
2. Have a first aid kit available and know
how to use it.
3. Have a fire extinguisher available and
know how to use it.
4. Wear necessary protective gear,
including but not limited to:
a. Hard hat
b. Protective shoes with slip resistant
soles
c. Eye protection
d. Protective gloves
e. Hearing protection
f. Respirator or filter mask
5. Check and secure all guards before
operating. Repair or replace any
damaged or missing guards or
guarding devices.
6. Repair or replace any damaged
handrails, ladders or walkways.
7. Place all controls in neutral, stop
engine, remove ignition key, follow lock
out/tagout procedure and wait for all
motion to stop before lubricating,
adjusting or servicing.
8. Clear area of people before starting
the impactor.
9. Review safety practices annually.
SAFETY
Assembly Safety
1. Assemble in an area with sufficient
space to handle the largest component
and access to all sides of the machine.
2. Use only cranes, jacks and tools with
sufficient capacity.
3. Do not allow spectators in the assembly
area.
Operating Safety
1. Read and understand the Operator's
Manual before operating, servicing or
working around this machine.
2. Keep hands, feet, hair and clothing
away from moving parts.
3. Place all controls in neutral, stop
engine, remove ignition key, follow lock
out/tagout procedure and wait for all
motion to stop before lubricating,
adjusting or servicing.
4. Clear the area of people before starting
the impactor. Keep people away
from the impactor and loading
hopper area while operating.
5. Never operate the impactor if it
has been damaged.
6. Review safety practices annually.
page 3
Operating Safety Area
1. Keep away from loading area.
2. Keep away from discharge end.
3. Always be aware of the location of
other personnel and keep them away
from hazard areas.
Maintenance Safety
1. It is the owner/operator's responsibility
to provide a safe method of access to
service areas.
2. Read and understand the Operator's
Manual before lubricating, servicing or
working around this machine.
3. Place all controls in neutral, stop
engine, remove ignition key, follow lock
out/tagout procedure and wait for all
motion to stop before lubricating,
adjusting or servicing.
4. Follow good shop practices.
5. Make sure all guards are in place and
properly secured when maintenance
work is completed.
6. Never wear poor fitting, baggy or frayed
clothing when working around or on
any of the drive system components.
7. Keep hands, feet, hair and clothing
away from moving or rotating parts.
8. Clear the area of bystanders when
carrying out any maintenance or
adjusting.

Transport Safety
1. Make sure you are in compliance with
all local regulations regarding
transporting equipment on public roads
and highways.
2. Make sure that all the lights and
reflectors that are required by the local
highway and transportation authorities
are in place, are clean and can be
seen clearly by all overtaking and
oncoming traffic.
page 4
SAFETY
3. Do not allow anyone to ride on the
impactor during transport.
4. Do not exceed 45 mph when
transporting the machine. Reduce
speed on rough roads and surfaces.
5. Install lighting bar when transporting.
6. The machine is not grounded.
Electrocution can occur without direct
contact. Stay away from overhead
power lines.
SIGN-OFF FORM

Anyone who will be operating and/or
maintaining the 2500 Ultra Spec must read
and clearly understand all safety, operating
and maintenance information presented in
this manual.
Do not operate or allow anyone else to operate
this equipment until this manual has been
read and clearly understood.
A sign-off sheet has been provided for your
record keeping to show that all personnel who
will be working with this equipment have read
and understand the information in this manual
and that they have been instructed in the
operation of this equipment.
This manual should be reviewed at least
annually.

The following personnel have reviewed and have been trained in the proper operation and
maintenance of the 2500 Ultra Spec.

Date of review and

training completion Trainee Signature Trainer Signature

page 5
 SAFETY DECALS

CAUTION: Safety decals are The following illustrations are shown to

provided for your personal safety. help identify decals to be replaced. Make
If they should become damaged, sure machine surface is clean and free from
they must be replaced. grease and oil before applying decal.

Decal, Lock-out Power

Decal, Secure Doors
Part No. 46-60118
Part No. 46-60091

Decal, Lid Warning

Part No. 46-60082

Decal, Loading Area

Part No. BB-64826 Decal, Nip Points
Part No. BB-64827

page 6
SAFETY DECALS

Decal, Lube Pump

Decal, Heat 20W Oil Part No. 46-60097
Part No. 46-60082

Decal, Horn Will Sound

Part No. 46-60098

page 7

The Pioneer line of secondary and tertiary
vertical shaft impact crushers represents the
HARD ROCK breakthrough for impact
reduction technology. This design is
differentiated from other types of impactors in
how it works, crushing chamber design, wear
parts metallurgy, crushing characteristics and
broad application range. Hence, the crusher
has proven a viable and economical impact
solution for crushing highly siliceous rock, as
well as a variety of other materials.
Feed Tube
Stationary Impeller
Anvil Shoe
fig. 1
Material is directed by the feed tube to the
center of the rotating impeller assembly, plus
exactly spaced and angled impeller shoes,
accelerate the feed particles outward and
forward, throwing them at true right angles
against the stationary anvils.
page 8
OPERATING PRINCIPLES
Free Body
Impacting
Material
Discharge
fig. 2
The anvils are positioned a sufficient distance
from the rotating table to allow for free body
impacting. The resulting fragmented cubical
product is then gravity discharged. Output
gradation, within limits, is controlled by impeller
table speed, configuration (number of impeller
shoes) and feed material characteristics.
Typically, the crusher is operated in closed
circuit with a vibrating screen.
The design incorporates "Free Body Impact
Sizing", a simplified crushing chamber, cast
iron chrome-iron alloy wear parts that eliminate
hard surfacing, a variable reduction ratio of
8:1 to 3:1 accomplished with relatively
inexpensive options and simplified structural
and mechanical components.
Resulting benefits are superior product yield,
cubical particle shape, application flexibility, a
crusher virtually immune to plugging and a
new meaning to maintenance simplicity.
MACHINE PARTS DESCRIPTION

The following is a brief description of the Feed Tube

vertical shaft impact crusher's basic parts and
their function.
Feed Box
The feed box collects feed material and
directs it down the feed tube. The feed box
is designed with a rock shelf to provide rock
on rock wear protection.
The feed tube assembly in the center of the
lid assembly plays a vital role in the overall
performance of the crusher. The feed tube
directs the feed material directly over the
feed disc. It is important that the feed tube
be directly over the feed disk to provide even
distribution of the feed material to the anvil
ring assembly,

Feed Box Hydra-Arm

Feed Tube

Lid Assembly

Table
Assembly
Anvil

Feed Disk

Tub

Rock Shelf

Shaft
Assembly
Base

Drive
Sheave

fig. 3

page 9

Lid Assembly
The lid assembly consists of the feed box,
feed tubes, lid liners and inspection doors.
The lid contains the crushing action and
provides a feed entry point. For access to
the complete crushing chamber, the entire
lid may be lifted after removing the hold-
down wedges. On models using the Hydra-
Arm, the lid can be raised and rotated
hydraulically. The lid is equipped with bolt-
in alloy liners.
Anvils
The anvils are arranged in a circular pattern
around the table assembly and provide the
main striking surface for the material
propelled from the table assembly. Anvil
changes require lid removal.
Tub
The tub includes the cluster ring and tub
liners. The tub supports the lid assembly,
cluster ring and contains the crushing action.
Shaft and Drive Assembly
The shaft assembly supports and rotates the
table assembly at a high speed.
Table Assembly
The table assembly consists of a center feed
disc, impeller shoes, flat table liners and
outer table liner(s). The table assembly
rotates and propels the feed material
outward toward the anvils.
page 10
MACHINE PARTS DESCRIPTION
Feed Disc
As the material drops through the feed tube,
it lands on the rotating feed disc located at
the center of the impeller table. The feed
disc distributes the feed material to the
impeller shoes. The feed disc also provides
wear protection for the table and shaft
assembly.
Impeller Table
Table configuration of three, four and five
shoes are available. Table rotation is
counterclockwise. The impeller table is
bolted to the flywheel that is keyed and lock-
nutted to the pedestal shaft. Access to the
table bolts is obtained by removing the
impeller shoes and the center feed disc
thereby exposing the bolts for removal.
The Impeller Table Assembly as originally
installed consists of a center feed disc,
impeller shoe and pins, flat table liners and
outer table liner(s).
The impeller table, without the attached
liners, consists of a steel blank and the
appropriate number of steel impeller shoe
brackets. In manufacturing, the steel blank
is machined to specified tolerances, liner
holes drilled and tapped, impeller shoe
brackets welded in place, the table is
balanced and the entire assembly is stress
relieved. In the event that damage occurs
to the table or the impeller shoe bracket -
the table must be replaced.
Properly maintained, the impeller table has
a long and useful life. The outer and inner
portion of the shoe bracket is vertically hard-
surfaced.
MACHINE PARTS DESCRIPTION
The feed disc affects:
1. Distribution of material across the
shoe face.
2. Trajectory of material to the anvils.
3. Rate of wear of top table liners.
4. Overall crusher performance.
Rock Shelf
The rock shelf supports fractured material
from the anvils. This material acts as a
cushion to protect the upper tub area from
wear. It also provides rock-on-rock
fracturing.
Base
The base supports the tub and the lid
assembly, provides anchoring for the
pedestal assembly and motor and provides
the discharge area for the crushed material.
Flat Table Liner(s)
The flat table liner is designed to protect the
top of the impeller table area in front of the
impeller shoe. Flat table liners are
segmented for the table configuration. This
liner is secured with bolts and should be
replaced when it is worn to one-half its
original thickness. Flat table liners require
matched weights placed opposite on the
impeller table for balance.
Flat table liner wear is accelerated from lack
of maintenance to the feed disc.
When replacing this edge liner ring, be sure
to center it around the table and secure it
with wooden wedges (the gap will fill with
dust and hold the liner in place). If this liner
is not centered, excessive wear will occur
on one side.
page 11
Outer Table Liner
This liner configuration requires individual
casting to be bolted to the bottom of the
table. These liners require table removal
and should be replaced when worn to
approximately one-half their original
thickness. Note that liners of equal weight
must be placed opposite of each other to
maintain table balance.
Lid Liners
The lid liners are arranged in circular pattern
in order to cover the entire under side of the
lid from wear. The inner liners and outer lid
liners bolt to the lid with hex head bolts.
Anvils/Cluster Ring
The feed material is accelerated by revolving
impeller table. Crushing takes place when
the feed material impacts on the anvil
assembly. You will note the geometry of
the anvils, provide for a right angle impact.
Each crusher is supplied with anvils
designed for optimum performance and
metal utilization. The anvils are made of
the same high chrome iron alloy as the
impeller shoes. The anvils are positioned by
a cluster ring. The anvils incorporate a
dovetail corresponding to the cluster ring
brackets. The cluster ring assembly rests
on a multiple step-bracket or a shim-pac
suspension device.
To optimize anvil life, the cluster ring may
be adjusted vertically.

Impeller Shoes/Shoe Pins
For each crusher, different styles of impeller
shoes are available. The crusher is originally
equipped with an impeller shoe designed
for optimum performance.
The impeller shoe are a cast chrome iron
alloy material and must be replaced prior to
wearing through to the steel support
brackets. The impeller shoe is held secured
to the bracket with a shoe pin.
Pedestal
Refers to the main rotor assembly of shaft,
bearings, housing and seals. The shaft is
keyed to a massive flywheel to which the
impeller table is bolted. The driven speed
of the pedestal shaft (or gearbox output
speed) determines the speed of the impeller
table. An independent lubrication system
with external pumps, filtering and alarm
system insures proper bearing lubrication.
Diesel Gearbox/V-Belt
The gearbox converts horizontal shaft input
power (diesel engine) to vertical shaft output
(pedestal) through a modified right-angle
gearbox that is v-belt connected to the
pedestal shaft. The gear box provides the
reduction ratio necessary to limit the pedestal
shaft for maximum speed, at 2100 RPM on
the engine. Additional table speed is
available by changing the sheave ratio and/
or the engine speed.
page 12
MACHINE PARTS DESCRIPTION
Lubrication Panel/Reservoir/Greasing
A lubrication panel is provided with all
necessary lubrication fitting and gauges, plus
a temperature and flow monitoring system
with an alarm system. Each component of
the system is labeled with its name and
service instruction to clearly illustrate proper
maintenance schedules required. The
pedestal and gearbox assembly have
independent lubrication pumps, oil reservoirs
and monitoring panels.
All grease fittings for pedestal and gearbox
are located on the lubrication panel, with
name and frequency of service instruction.
Grease is used to purge the pedestal and
gearbox seals.
Heat Exchangers - Air to Oil Cooler
To provide cooling of the gearbox/pedestal
lubricants, heat exchangers are used. The
gearbox heat exchanger is designed for
mounting on the radiator of the diesel engine.
The pedestal heat exchanger is normally
mounted integral with the pedestal lubrication
tank and uses and electric motor for
operation.
Oil Heaters (Optional)
Available as option.
Hydra-Arm (Optional)
Hydra-arm lifts the lid for a full 360o access
for safe and efficient maintenance
procedures.
SPECIFICATIONS

A
F
E

B B

fig. 4

A - 7'-0" (213 cm) D - 6'-11 1/2" (212 cm)

B - 1'-11 1/2" (60 cm) E - 11 3/8" (30 cm)

C - 5'-2" (157 cm) F - 3'-0" x 3'-0" (7.6 cm x 7.6 cm)

Standard
Minimum Capacity (3) Impeller
Maximum (2) Recommended Feed Tube Effective Crushing Table Speed
Feed Size Closed Diameter Range Range
Inch (MM) Circuit Inch TPH (MTPH) RPM
2 (50) 4M 8.5 75-125 67-112 720-2000

Approximate
Recommended Table/Anvil Explosion Chamber Weight
Horsepower Clearance Volume WK2 EV-Models (Electric Shown)
Electric H.P. Inch (MM) CU Inch Lbs-Ft.2 Lbs (Kgs)
75-150 10.4 (260) 46351100 13,200 (6,000)

page 13

The 2500 Ultra spec is cost effective,
crushing material with up to 80% hard parts
(which includes Sio2, Fe203 and AL 203).
Typical construction applications are asphalt
plant mix, concrete stone, chips/popcorn/
topping rock, pea gravel reduction,
manufactured sand, blend sand,
beneficiation, soft stone elimination, cubing
recycling concrete/asphalt and fracture
count.
Typical mining applications include ore
beneficiation, pilot plant operation, secondary
and tertiary crushing.
Vertical Shaft Impactor
fig. 5
The performance of the crusher and its
contribution to the crushing circuit is directly
related to the extent the owner/operator/
service personnel work with the machine and
adapt the Ultra Spec's operating variables
to the material's crushability and other
specific conditions of the job.
The following information is offered with that
intent.
page 14
APPLICATION INFORMATION
Feed Rate and Gradation
Optimum performance from a 2500 Ultra
Spec occurs when it is continuously and
uniformly fed properly sized material. Surges
in the feed rate may have pronounced effect
on the rate of production, output gradations
and wear rate.
Output Gradation
The 2500 Ultra Spec is normally operated
in closed circuit with a vibrating screen.
Recirculating some or all of the oversized
material, as production requires, will result
in optimum crusher performance. The feed
should be free of undersize material, and
tonnage must be consistent with the
crusher's capacity and horsepower.
Feeds predominantly large, small or
erratically graded, will affect crusher
production performance.
Screening
Properly applied, the Ultra Spec is capable
of producing relatively high volumes of
material, but excessive recirculation of
already sized product (screen override) will
adversely affect the wear rate of the crushing
chamber, reduce capacity, increase
horsepower required, and effect product
gradation. Consequently, carefully reviewing
the plant's screening capabilities to assure
the proper balance with crusher capacity will
help achieve optimum crusher/system
performance.
APPLICATION INFORMATION
Feed Size/Impeller Table Speed/Rotation
When operating the impeller table at or near
maximum RPM, reduce maximum allowable
feed size by 1/2" (12mm).
3 inch (76mm) and not weigh more than
1.3 lb (0.59 kg) per particle 1400 max. RPM
- CCW.
Producing Maximum Fines
3/4" X 0 (18mm X 0)
Asphalt plant mix
Minus 5/8" (16mm)
1/2" (13mm)
3/8" (9mm)
Manufactured sand supplement. Normally
80-100% of maximum impeller speed. Four
or five shoe table configuration.
Producing Minimum Fines
Concrete Aggregate
Chips
Railroad Ballast
1 1/2" X 0 (38 mm X 0)
Normally 60-80% of maximum impeller
speed. Three or four shoe table
configuration.
Note: Higher operating speeds generally
produce better fragmentation, thus greater
production of fine material, as required for
asphalt materials and sand supplement. For
applications requiring maximum production
of smaller fractions and fines, higher speed
on the impeller table, along with the use of
the five shoe table will result in optimum
production.
page 15
For applications requiring a minimum of fines
generation, the two/three/four shoe impeller
tables and slower impeller speeds are
recommended.
Do not operate the impeller table at speeds
above factory recommended maximum.
Impeller Table Speed/Wear Relationship
Adapting the table configuration and
optimum speed to the material's crushability
allows the operator a wide range of
production flexibility. Yet higher impeller
speeds usually result in faster wear rates.
Consequently, the speed/wear relationship
must be observed to determine the optimum
balance between the crusher production
characteristics and the optimum casting wear
rate.
Impeller Table Speed/Tonnage Relationship
Contrary to some types of crushers, the
tonnage capacity of the Ultra Spec
throughput is not significantly affected by
reducing impeller speed. Crusher throughput
ratings published in our general literature
are applicable at virtually all impeller speeds
and impeller table configuration.
Tonnage Thru-Put/Casting Wear
Relationship
As quantity of feed increases, the wear rate
increases.

Tramp Material
Centrifugal impact crushers have no internal
tramp metal protection. Do not allow tramp
material such as drill bits, bucket teeth, etc. to
enter the crusher - as severe damage to
internal castings and machine components
may result. Interior casting or component
damage resulting from tramp material voids
the warranty.
If tramp material is a persistent problem,
contact your dealer for information concerning
external protective devices available at
additional cost to the user.
page 16
APPLICATION INFORMATION
Air Flow At Discharge Point/Dust
Suppression
The design of a centrifugal impactor is such
that an enormous amount of air is blown
through the discharge point. Discharge chutes
should be constructed according to factory
recommendations and dust covers installed
on the conveyors for minimum of 15 feet.
Conveyors on all crushers built portable
chassis are covered to discharge point unless
otherwise specified.
Water may be introduced at the feed opening
of the crusher to reduce dust, but doing so can
adversely affect casting wear. If water must
be introduced, do so at the discharge point of
the crusher. The factory can suggest optional
dust suppression equipment suppliers.
LUBRICATION SYSTEM OPERATION
The VSI lubrication system consists of a
lubrication oil pump and motor assembly,
pressure and temperature gauges,
temperature and flow switches, pressure
bypass valve, oil filter, oil cooler and a 16.7
gallon oil storage tank. These components
make up the standard VSI lubrication panel
that supply the lubrication oil to the crusher
pedestal bearing.
Warning Horn
Motor & Oil Pump
Oil Tank
fig. 6
Oil from the tank is pumped to the lubrication
panel containing the manifold with the gauges,
switches, filter, and by-pass valve. The
temperature of the oil will determine the
direction of flow at this point.
When the oil is cold, the resistance of the by-
pass valve is less than the resistance of the oil
cooler lines and the oil cooler. The oil
pressure will be sufficient to open the valve
and the oil will flow directly to the filter, through
the flow switch and on to the pedestal, by
passing the oil cooler.
page 17
As the oil temperature rises, the resistance of
the oil cooler lines and the oil cooler decreases,
allowing the oil to begin to pass through the
cooler. When the oil reaches a sufficient
temperature the resistance of the by-pass
valve will be greater than the resistance of the
oil cooler lines an the cooler allowing of the oil
to pass through the cooler. The system is self-
balancing and works well to maintain the
proper oil temperature. Oil from the cooler
flows through the filter and flow switch and on
to the pedestal.
The oil enters the pedestal through the bottom
and passes through a port in the pedestal
housing to the top where it is discharged and
allowed to flow through the top bearing.
At this point, it drains down through the upper
bearing to the bottom of the pedestal, through
the bottom bearing and flows back to the tank
through a 1-1/4” gravity return line. The tank
is situated lower than the bottom of the pedestal
to facilitate proper gravitational flow.
The normal operating pressure of the system
will depend on the temperature of the oil.
Normal operating pressure is generally +1
PSI to +100 PSI. Oil pressure is not significant
in this system. The main function of the
pressure gauge is to determine proper pump
direction at start-up or when the crusher has
been moved or reconnected to line power.
This lubrication system is designed to be flow-
sensitive and will sound the warning horn
should the flow drop below the factory set
point of 1 GPM refer to Cold Start-Up.
Procedure on the next page.
 LUBRICATION SYSTEM COLD START-UP
The lubrication system is designed to reliably
pump oil at +15oF with either SAE 20W-20
engine oil or AGMA (American Gear
Manufacturer’s Association) 2EP oil (similar
viscosity, “winter oils). If the oil temperature is
below +15oF, the oil must be heated to +15oF.
Failure to do this may result in premature
pedestal bearing failure.
The flow switch incorporated in the lubrication
system will warn you if the oil flow drops below
1 GPM (2 GPM is the normal flow). However,
the flow switch is calibrated with warm oil.
With cold, thick oil, the flow switch will indicate
adequate flow when there may actually be
very little flow. It still functions reliably as a
flow/no-flow indicator, but it is not accurate
enough to detect low oil flow with very cold oil.
page 18
In addition, the oil pump used does not give
any obvious indication when the oil gets too
cold or thick; it just pumps less. Our testing
shows that at 0oF the pump is only pumping
about one-half gallon per minute; but there is
no cavitation or unusual noise.
This is why it is very important to heat the oil
when it is below +15oF. Otherwise, the oil flow
may be inadequate, the lubrication warning
horn will not sound, and there is no easy way
to see that the oil system is not working.
If the crusher still has a “summer” oil in it,
SAE30 or AGMA 3EP, the minimum start-up
oil temperature is +32oF (freezing).
IMPORTANT
Heat “winter” oil to +15oF before starting
the crusher.
LUBRICATION ELECTRICAL REQUIREMENTS
All crushers use externally mounted lube
pumps for the pedestal and gearbox lubrication
systems. These systems are independent of
each other and require separate pumps. The
pump motors are typically 1 to 2 HP, 22-/440/
3 phase and are factory wired for 440V
operation.
Power to the lube pump motors must be
connected so the pumps will be energized
before the crusher is started. The pump
motors must be wired independently of each
other and to circuits dedicated for their own
use only. Connecting pump motors across an
existing circuit such as a conveyor drive motor
may causes a bearing failure should the circuit
be disabled during crusher operation.
If power to the lube pumps and the lube
warning system is supplied by an auxiliary
generator, the crusher must never be operated
while the generator is off. Both the lubrication
pump and the 120V lubrication warning system
(on the electric motor powered crushers only)
would be inoperative and serious damage to
the pedestal and gear box would result. When
the crusher and lube pumps are off and the
generator is on, the lube warning horn will
sound (if properly wired). You may wish to
leave the lube pumps running to prevent the
horn from sounding until the generator is shut
down.
IMPORTANT
Never operate the crusher while the
lubrication pump is off. Always leave
the lubrication pump on while the
crusher is coasting to a stop.
page 19
All models use fan cooled heat exchangers
for pedestal oil cooling. The fan motor for the
heat exchanger is typically 1/4 HP, 220/440V/
3 phase and is factory wired for 440V operation.
The motor should be wired to its own circuit,
properly protected and wired in accordance
with local codes. The unit is typically for warm
weather operation any may be left off during
cold weather.
The lube failure warning system operates on
one of two voltages depending on crusher
drive power type.
1. 120VAC for electric motor powered
crushers
2. 24 VDC for models (DGV, DCV,DV)
The system components may vary slightly but
the operating principal will remain the same.
The warning system consists of temperature
sensing switches, temperature and pressure
gauges, flow sensing switches, control relay
and a warning horn. All switches are wired in
series.
1. The 120VAC system uses a 120VAC
control relay and 120VAC horn.
2. The 24 VDC system uses a 24 VDC
control relay and a 24VDC horn
Factory advises that the supply power for the
lube warning system come from the crusher
drive motor power supply (on full voltage start
motors only). Never wire the lube failure
warning system across an already claimed
circuit. If the warning system is to be wired to
its own individual circuit, it should be ahead of
the lube pump motor and behind the crusher
drive motor. The sequence of start would be:
1. Lube pump motor
2. Lube failure warning system
3. Crusher drive motor
LUBRICATION - ELECTRICAL REQUIREMENTS

fig. 7

page 20
LUBRICATION - ELECTRICAL REQUIREMENTS

fig. 8

page 21
 LUBRICATION ELECTRICAL REQUIREMENTS
The 120VAC lube failure warning system is
completely wired at the factory.
The 24VDC system utilizes the crusher drive
engine 24V battery system for power. When
the diesel engine is installed by the factory,
the lube warning system is completely wired
and ready for operation. When the customer
installs the engine, the power to the warning
system will have to be installed by the customer
also. Contact factory for details and refer to
the warning system electrical schematic found
in this section of the Service Manual.
On diesel powered crushers, the lube warning
system is activated by a “whisker” type limit
switch controlled by movement of the clutch
handle. When the clutch is engaged, the
warning system is activated. When the clutch
is disengaged, the system is deactivated.
IMPORTANT
Never shut off the lube pump while the
crusher is coasting to a stop.
Never operate the crusher while the
lube warning system is off.
The lube pump should be started before the
lube failure warning system is activated.
However, in order to test the warning system
for proper operation, follow these instructions:
1. Apply power to the warning system
first and the horn will sound.
2. Start the lube pump and when the
pressure or flow is normalized, the
horn will silence.
page 22
Operation of Events
- Power to the warning system is turned
on.
- The horn will sound. If the horn sounds, the
system is working properly.
- The flow switch contact are normally open.
- The temperature switch contacts are normally
closed.
- The lubrication pump is started and oil flow
is brought to normal.
- The temperature switch contact will remain
closed.
- The flow switch contact will close.,
- Current will pass through both switches to
energize the control relay coil.
- The relay (normally closed) contacts will
open and stop current flow to the horn.
- The relay (normally open) contact will close
and allow the drive motor interlock to start the
drive motor (if so wired).
- If the crusher oil temperature rises above the
set point or the oil flow fall below the set point,
the sensing switches will open and break the
current flow to the relay coil. This will close the
relay contact (normally closed) and sound the
horn.
PREOPERATION CHECK
PREOPERATION
Check each component of the impactor to
insure that it is in operational condition. This
check should include, but not be limited to
the following.
PRE-OPERATIONAL CHECKS OK
1. Sheet Metal/Appearance/Paint
2. Lubrication
Circulating Oil System:
a. Oil Reservoir Level
b. Oil Filters
e. Hoses & Fittings
f. Oil Breathers
3. V-Belts
4. Grease Lube Points
5. Inspection Doors Closed
6. Lid Hold-down Wedges
7. General
a. Operator's Manual on Unit
b. Decals in Place & Readable
c. Safety Guards in Place
page 23
IMPORTANT
This preoperational check should be
performed any time the impactor is
moved to a new site, or after not
being operated for an extended
period.
Adjust OPERATIONAL CHECKS OK Adjust
1. Unit Vibration
2. Table Rotation (counter clockwise)
3. Alarm System Functions Correctly
4. Oil Pressure
Pedestal - +1 lb to +100 lb
Gearbox - 15 lb to 25 lb
5. Oil Temperature (180 deg. max.)
6. Oil Fittings for Leaks
IMPORTANT
Oil pressures mamayy run higher at
star t-up because of cold oil.
start-up

Use the following procedure to start the
impactor in operation.
The impactor should be run empty initially to
insure everything is operating properly and
there are no misaligned or binding parts.
Operate a new impactor empty for two hours.
After this run-in period, check bearing
temperatures and relubricate as required.
1. On electric models, ground chassis
with standard grounding rod driven at
least six feet into the ground.
2. Block crusher chassis or skid mounting
solid and level in both directions. If the
machine is not level, you will experience
uneven wear on the feed tube, feed
disc and anvil ring.
3. Set the crusher feed conveyor or chute
so the rock will flow to the center of the
feed tube. Use a bang board or
deflection chute if necessary. If the
crusher feed is concentrated to one
side of the feed tube, the result will be
uneven wear on the feed tube, anvil
ring and other stationary wear parts.
CAUTION: Before starting the
impactor, be sure all tools and
foreign objects have been removed
and everyone is clear.
page 24
OPERATION
OPERATION
IMPORTANT
Do not operate pedestal lubrication
pump counterclockwise as severe
damage will result. The pump
should turn clockwise facing the
shaft.
WARNING: Do not under any
condition, remove crusher lid or
open inspection door while the
crusher is running or in shutdown
procedure. Never run the crusher
when the lid or inspection door is
not in place and properly secured.
Never stand on top of crusher
while crusher is operating.
4. Inspect crushing chamber.
a. Check position of shoe pins.
b. Check for loose bolts on liners,
table, tub and lid liners.
c. Check location of feed tube. It
should be approximately 1/2” to 1”
above the impeller shoes. Adjust
the feed tube down as necessary.
5. Inspect the top of the crusher.
a. Close inspection door and secure
with the bar and wedge.
b. Check to see that the feed box
bolts are secure.
c. Check to see that all lid hold down
wedges are in place and tight.
OPERATION
6. Inspect lubrication system:
a. Electric or diesel v-belt drives.
1. Check oil level in pedestal oil tank.
Level should be within 1/2” of top of
sight glass.
2. Grease crusher grease points
b. Diesel gearbox drives.
1. Check crusher lubrication as listed
above in item a.
2. Check oil level in gearbox oil
reservoir. Level should be at the
center on the sight glass.
3. Grease “U” joints in drive line and
engine PTO bearings.
4. Check oil and water levels in diesel
engine where applicable.
7. Check rotation of oil pump and start oil
pump if rotation is correct.
8. Inspect main drive belts for proper belt
tension or check drive line to see if it is
secure, clear of obstructions and that all
drive guards are in place.
9. Check rotation of the crusher. (Table
should rotate counter clockwise).
page 25
10.
10.For diesel driven crusher, warm engine
3-5 minutes at 700 rpm, then engage
clutch. Increase speed slowly to
recommended range.
11.
11.Immediately after start-up, check the
following:
a. Check to see that the alarm system
functions correctly during start-up.
b. Check for correct oil pressure.
-Pedestal: +1lb to +100lb
-Gearbox: 15lb to 25lb
c. Check to see that oil temperature
stabilize after several hours of running
time. Temperature alarm system are
set to react at 180oF. Air to oil coolers
are supplies with all crushers. Keep
maintained properly.
d. Check all oil fitting for leaks
e. EV - Model crushers, in operations
3,300 feet above sea level or higher do
not exceed full load nameplate
amperage, as at higher elevation the
motor cooling is affected.

The following procedure should be followed
when starting the crusher.
1. Inspect the rotor for loose bolts.
Bolts
Rotor
fig. 9
2. Pour 2-3 buckets of dry sand into rotor at
start-up to seat parts and to fill voids for
later maintenance. This will make wear
part removal easier.
3. Assure that everything is operational, start
crusher discharge and feed conveyors.
4. After two hours, shut down the crusher
and related equipment. With power locked
out, inspect crushing chamber in
accordance with instruction manual.
page 26
START-UP
5. Inspect rotor daily for wear, particularly
the carbide tips. It is very important to
keep all tramp iron out of the crusher
circuit. Tramp iron can cause chipped or
broken carbides and will result in
accelerated outer cap wear.
6. Observe rock shelf edge wear. Accelerated
wear will be apparent if the rock shelf
is set to high. A straight line from the
bottom of the rotor should pass just above
the top of the leading edge of the rock
shelf.
7. Feed tube clearance to top of rotor is the
same as for the table, 1/2 in. to 1 in. Be
sure the feed tube does not touch the
rotor. If gap is more than 1 in. accelerated
wear will occur on top of the rotor.
8. Feed size for the rotor is 2 in. maximum
when using the rock shelf (autogenous)
and 3 in. maximum when using the anvil
ring (semi-autogenous).
IMPORTANT
The pedestal lube pump should be
allowed to run until the crusher has
stopped.
WEAR PARTS

WARNING: Never attempt to Hydra-Arm

service or adjust this machine until
all motion has stopped and power
has been disconnected and locked
out or the engine control key has
been removed and the control
panel has been locked.
To Remove the Lid with Hydra-Arm
The following adjustment have been made at
the factory.
Unclamp lid and remove wedge locks and
start hydra-arm pump. Activate lever, the lid
will raise, make sure to lift lid for proper
clearance.

1. Drive the wedges back out of lug slots.

Lever

Wedge Locks

Lug Slots
Pump
fig. 10

2. To remove lid from Hydr-Arm in the
down position, remove two 3/4” x 3”
bolts from inner end of the lid rim and
two 3/4” x 2-1/2” bolts that fasten the lid
to the arm. Raise Hydra-Arm swing to
one side and the lid may then be
removed.
fig. 11
Rotate lid by lifting stop and manual rotating
lid. Replace stop to secure lid. Follow the
same procedure to rotate lid back top operating
position.

3. Lift lid and remove, by use of yard Stop

crane. Be careful to block-up the lid to
prevent damage to the feed tube.

fig. 12

page 27

Before positioning and securing the lid, check
the inside of the machine completely to insure
that tools or any other foreign materials are
not left inside the crusher.
fig. 13
When positioning and securing the lid:
1. Align slots with lugs and lower into
place.
2. To secure, drive lid wedges through
the slot in the lugs.
3. Always drive wedges in the direction of
the table rotation (counter-clockwise).
page 28
WEAR PARTS
Feed Tubes
The feed tube assembly consists of two
identical feed tubes. The feed tube is designed
to direct feed material to the center of the
impeller table. To replace or adjust for wear,
the feed box must be removed. Feed tube
height can be adjusted by rearranging the
rubber spacers above and below. The distance
between the bottom of the feed tube and the
top of shoes should be 5/8”. This adjustment
should be made after the lid is in place.
Externally
Feed Tube Adjustable
Feed Tube
fig. 14
WEAR PARTS

Lid Liners Inspection Doors

The lid liners are bolted in circular pattern to
protrct the entire under side of the lid from
wear. Replace liners when they wear
1/2 their original thickness or as experience
dictates. Two types of wear resistant alloys
are available.
The lid is equipped with inspection doors to
facilitate easy internal inspection and allows
for certain table wear pars replacement or -
use Hydra-Arm to lift and rotate lid to expose
crushing chamber.

Lid Liners

Inspection Doors
fig. 15

To Change Lid Liners: fig. 16

1. Remove lid liner bolts and worn lid
liners. IMPORTANT
Wear parts should not be forced into
IMPORTANT place.
When replacing lid liners it is often
easier to cut the bolts on the top
side of the lid.

2. Install new lid liners using new

factory lid liner bolts.

3. Note steel spacers required for

inspection door liners.

page 29

Impeller Shoes
Several impeller shoe types are available
A. To remove worn shoes:
1. Pin on styles shoes.
a. Strike the face of the shoe
sharply with a hammer to
loosen, then pull out securing
pin and remove shoe.
b. If shoes are stubborn and
cannot removed by step No.1,
then cut the pins off the shoe
with a torch. (be careful not to
cut the brackets).
IMPORTANT
Once the pin has been cut from a
shoe, under no circumstances may
that particular shoe be reused. Wear
alloys are extremely heat sensitive
and cracking is usually a result of ap-
plied heat.
2. Bolt on style shoes.
a. remove the 1-1/2 inch diameter
bolts and then remove shoe
from bracket.
B. To replace impeller shoes
1. Clean out shoe opening in bracket.
2. Before installing new shoes -
inspect all other table liners and
surfaces.
3. When installing new shoes, be sure
matching weights are opposite to
insure balance of impeller table.
Shoe weight are marked on the
back side of the shoe with yellow
marking paint in pounds and
ounces.
page 30
WEAR PARTS
On four shoe tables, keep balanced
shoe pairs opposite as with table
liners. Three and five shoe tables
use all the same weight. Vibration
due to improper table balance may
cause premature pedestal bearing
failure.
4. Insert shoe into bracket.
5. Pin on style shoes
Insert stress-proof steel securing
pins. Do not hammer into place, if
interference occurs, check as to
what might be the problem.
IMPORTANT
Use only factory pins, as they are
specifically designed to support the
shoes (USE NO SUBSTITUTES)
Bolt on style shoes
Install two 1-1/2” diameter x 3”
long grade 8 bolts, torque to
approx. 800 ft.lb.
6. Inspect the ID and OD of the
shoe brackets for wear.
Feed Disc
With the shoes removed, rotating or change
feed disc as required to maintain proper feed
entry trajectory. The feed disc is easily
removed by prying under the outer edge and
lifting. No fasteners are used because the
impeller shoes hold the disc in position.
WEAR PARTS

Flat Table Liners

Impeller table liners should be replaced before

they wear through to the impeller table.
Replace flat table liners in matching pairs.

Feed Disc

fig. 17
The feed disc should never be allowed to
wear completely through as serious damage
can be caused to the impeller table, main
pedestal shaft, and flywheel.
To replace liners:
Feed disc wear is evidenced by a rounding
off of its outer edge immediately in front of
the impeller shoe. While wear is normal,
rotating the feed disc approximately 30o
clockwise will present a fresh corner at the
impeller shoe as required. Properly
maintained, the feed disc allows for optimum
feed distribution to the impeller shoes and
optimum material trajectory to the anvils.
Improperly maintained, a worn feed disc can
result in:
1. “Slotting” of the impeller shoes.
2. Accelerated wear on flat table liners
and/or outer table liners.
3. A poor anvil wear pattern.
4. Overall reduced crushing efficiency.
When replacing a feed disc make sure it is
centered on the impeller table. You will note
the bevel on the impeller shoes helps
accomplish this, however, casting tolerances
prevents a close tolerance fit, and serious
impeller table vibration can occur if the feed
disc is not centered.
page 31
Flat Table Liner
fig. 18
1. Impeller shoe must be removed.
2. Loosen and remove table liner
bolts. If bolts are stubborn, it is
often helpful to strike the liner
sharply with a hammer near the
bolt head and at the same time turn
the wrench.
3. Remove the liner. If at any time the
table liners or shoes are removed
and are intended for reinstallation,
they must be tagged as to opposing
pairs so that an imbalance does not
occur due to improper positioning.
4. Insert the new liner. Be sure
matching weights are opposite to
insure balance of the impeller table.
5. Bolt the liner into place. Do not
over-tighten the liner bolts (snug
only). The heat-treating process
way causes a slight warp in the
liners. Overtightening may cause
them to break.

Replacing Outer Table Liners - Segmented
Castings
To remove liner:
1. Remove lid assembly for access.
2. Remove impeller shoes, feed disc
and flat table liners.
3. Remove table from flywheel, turn
table upside down.
4. Remove bolts from segmented
liners and remove liners. If broken
liners are being replaced, the
broken liner and the liner on the
opposite side must be replaced to
maintain proper table balance.
If liners are being removed and
installed on another table, be sure
they are placed on the new table in
the same position to maintain proper
balance. If table balance is not
maintained, a vibration will result
causing premature pedestal
bearing failure.
5. When installing liners, start the
bolts, tap the liner to the outside,
and snug the bolts. The heat-
treating process may cause a slight
warp in the liners and over
tightening the bolts may cause them
to break.
6. Install table on flywheel; torque
bolts.
7. Install flat table liners, feed disc
and impeller shoes.
page 32
WEAR PARTS
Replacing Optional One Piece Rolled
Outer Table Liner
To remove liner:
1. Remove lid assembly for access.
2. Remove impeller shoes, feed disc
and flat table liners.
3. Lift worn outer liner straight up and
remove
4. At this point, check the condition of
the rolled ring support. (the steel
ring bolted to the bottom of the
impeller table).
5. Replace rolled section and
reassemble table liners.
Removing the Impeller Table - Power
Locked Out/Lid Off
The impeller table is the flat plate to which all
the moving wear parts are attached. To
remove the impeller table, first remove the
shoes/feed disc and flat table liners. Then six
(6) hex head capscrews must be removed.
The table can then be lifted out. When
replacing the table, make sure the top of the
flywheel is clean, also bolt holes and threads.
A bolt lubricant such as graphite, or white lead
may be used, if desired.
Impeller Shoe/Bracket Fit Tolerance -
Maximum Allowed Plug 1/8” (pin on style)
The centrifugal force exerted on the shoe and
the constant hammering by material will
eventually wear on the face of the shoe bracket
and the back of the bracket where the pin is
located.
WEAR PARTS

These two critical areas, if left unchecked may
cause trouble. It will allow the shoe to be
thrust outwardly and leave a gap between the
shoe and the shoe bracket. This will fill with
material and a wedging action may occur
causing excessive stress on the shoe pin and
promote failure of the shoe stob.
Shoe Bracket Tolerance Maintenance (pin
on style)
Hardfacing Requirements - Requires
removing the table from crushing chamber
Here at the factory, the ID & OD of the shoe
brackets are hardfaced with Stoody #133
wire. This surface must be maintained or
serious table damage will result. Stoody wire
#31 or #35 stick rod may be used to repair
surfaces on the shoe bracket where the
hardfacing has worn off. Many good hadfacing
rods are available, with a cross-reference.

Rectify fit by placing shims between the shoe

and the shoe bracket with the pin installed.
For example, if the tolerance between the
shoe and the bracket is in excess of 1/8”,
insert two pieces of 10 gauge material 1” wide
by appropriate length on the vertical faces of
the shoe brackets. Tack weld shims in place
and grind flat. Replace the shoe. The pin
should slip in easily; if not, use a thinner shim.
This shimming will renew necessary fit
tolerance and help to prevent failure of the
shoe holding mechanism.
Cluster Ring/Anvil Assembly - Adjustment
To achieve additional anvil life, it is possible to
vertically adjust the ring, allowing the anvil to
“pocket” in the lower half first and the top half
secondly. When feed size is at or near
maximum allowed, this adjustment is not
recommended. The crusher incorporate a
1/2” “stepped adjustment” cluster ring support
bracket. “No fasteners” lift ring and rotate
clockwise to lower.

Many times when the pin is cut to remove the

shoe, that area of the bracket, right behind the
pin is cut into. This area of the bracket should
be cleaned and welded up to its original Retaining Bracket
thickness. Doing this with stainless steel
welding rod is advantageous. It is very difficult
to cut stainless steel with a torch, thus saving
the bracket from future cuts. Where the pin
makes contact with the top of the bracket it will
“wear in” and allow more distance between
the shoe and the bracket. A small amount of
weld metal applied in the indentation will
tighten up the fit. Make very sure that the weld
metal does not extend beyond the original
fig. 19
thickness of the shoe bracket.

page 33

Replacing Anvils
Before attaching lifting device to the cluster
ring, check the condition of “lifting eyes”.
Over a period of time, they can become
damaged and require maintenance.
Anvils
fig. 20
With appropriate lifting equipment, remove
the entire ring to a safe working area.
Reconnect the lifting device and turn the
assembly upside down on blocking, allowing
the anvil to fall free from the ring. May have to
strick with sledge hammer before releasing
Return ring to upright position and load new
anvils into the ring.
IMPORTANT
The anvil/cluster ring assembly is
designed to form a “material or
material shelf” above the assembly
and thereby protect the upper tub
area.
page 34
WEAR PARTS
IMPORTANT
Prior to new anvils being inserted,
check the condition of the mild steel
bracket(s) and ring. In the event of
bracket damage, a new bracket can be
purchased and welded into place after
first removing the damaged one(s).
Alternative Anvil Change Method
Having moved the cluster ring assembly to
the ground and safely supported, the worn
anvils may be individually removed and new
anvils inserted.
Before replacing cluster ring assembly to its
proper tub location, check the following:
Skirt Ring Assembly
The skirt ring sets below the impeller table
and protects the flywheel and pedestal. The
skirt ring is faced with cast alloy skirt liners
held in place by hex head bolts. Liners can
be replaced individually or as a set. For
extended life, rotate skirt liners 180o as they
typically wear more in the top half.
Skirt Liner
fig. 21
WEAR PARTS
Pedestal Skirt Cone - Polyurethane
Located behind the skirt ring assembly, the
skirt cone protects the pedestal and related
parts. The conical shaped guard is made of
an abrasion resistance polyurethane
compound. It is removed and installed from
the top of the pedestal with the impeller table
and flywheel removed. Replace when worn
thin or if a hole appears.
Pedestal
fig.22
page 35
Cluster Ring/Anvil Change
(Lock out power source before attempting
this maintenance). The entire set of anvils
is normally replaced. To accomplish this, the
lid assembly must be removed or rotated
away by the Hydra-Arm. When removing
the lid, take care to block sufficiently under
the lid to avoid damage to the feed tube. A
spare cluster ring is advantageous where
frequent anvil changes are required in very
abrasive applications.
To remove or install the cluster ring, it must
be lifted on or off its positioning brackets.
No fasteners are employed. On crushers
using stepped adjustment, the cluster ring
positioning brackets must be aligned before
lowering into final position.
 MAINTENANCE

The following section contains instructions for The type of lubricants specified are industry
maintaining and lubricating the impactor. specifications.

Maintenance intervals shown are for normal
operating conditions. If the impactor is
operated under severe or adverse conditions
maintenance may need to be performed more
often.
Record service performed in the Maintenance
Record section of this manual.
Failure to perform regular maintenance may
result in impactor failure or damage.
See lubrication specifications for complete
descriptions.
NOTE
Quantities of grease have been
specified by the term “pumps”, this
refers to one pump from a standard 13
oz. grease gun delivering 20-25 pumps
per oz.

WARNING: Never attempt to

service or adjust this machine
until the engine control key has
been removed and the control
panel has been locked.

WARNING: Never attempt to open

inspection doors whle crusher is
in operation.

page 36
MAINTENANCE

MAINTENANCE CHART

5
4

fig. 23
Ref.
Interval No. Item Notes
DAILY - Pedestal Dust Seal Grease
- Gearbox Shaft Seal Grease
- Rotor Check for wear
- Belt Tension Check tension
- Guages Check oil level

50 HRS 1 Feed Tube Check for wear

2 Hydra-Arm Greaase Bearing
3 Table Assembly Check for wear
4 Feed disk Check for wear
- Oil Filters Replace

200 HRS 5 Lid Liners Check for wear

6 Anvils Check for wear
7 Tub Liners Check for wear
- Pedestal Skirt Ring Check for wear

500 HRS - Pedestal Oil Tank Drain, flush & refill

page 37
 MAINTENANCE - DAIL
DAILY
AILY

Pedestal Dust Seal

Pedestal dust seal should be greased once a

shift (every 9 hours of operation) while the
crusher is running or coasting to a stop (10 to
15 pumps required.)

Pedestal Dust Seal

fig. 24

Gearbox Input Shaft Seal

Gearbox input shaft seal should be greased

ounce a shift (every 8 hours of operation).
One to two pumps of grease is required for
proper seal protection.
Gearbox seal

fig. 25

page 38
MAINTENANCE - DAIL
DAILY
AILY

Rotor

Inspect rotor daily for wear. Especially the

carbide tips. It is very important to keep all
tramp iron out of the crusher circuit. Tramp
iron can cause chipped/broken carbides and
will result in accelerated outer cap wear.

Rotor

fig. 26

Broken pocket
(caused by tramp iron
or over size feed

fig. 27

page 39
 MAINTENANCE - DAIL
DAILY
AILY

Belt Tension

Check all belts for proper tension

Gauges

Keep oil level in upper half of sight gauge.

V-Belt Drives

Crushers w/Electric or diesel with v-belt drives.

Check the following:
a. Check the sheaves for dust build-up.
b. Check for loose bushings in the
sheaves.
c. Check for loose or missing bolts in the
electric motor or diesel engine mouning

Gearbox Drives

Crushers w/diesel and right angle gearbox

drives. Check the following:
a. Inspect engine PTO for possible
outboard bearing failure.
b. Inspect driveline for the following items.
1. Worn or loose “U” joints.
2. Missing bolts in the driveline
couplings.
3. Missing balance weights on
drivelines.
4. Possibility of a bent driveline.
c. Inspect the right angle gear box for the
following items:
1. Check for loose or missing bolts in
the gearbox mouning.
2. Check input and output shafts of
the gearbox for possible bearing
failure.
d. Inspect engine mounting for loose or
missing mounting bolts.
page 40
MAINTENANCE - 50 HOURS

Feed Tube

Make sure there is proper distance between

the bottom of the feed tube and the top of Externally
Feed Tube Adjustable
shoes
Feed Tube

fig. 41

Impeller Shoes

Inspect impeller shoes for wear every 50

hours. Change worn shoes and anvils before
they break or wear through their holding
brackets. Replace shoes in matching pairs
only.

IMPORTANT
Expect to change a complete set of
anvils for every four to twelve sets of Impeller shoe
impeller shoe replacement.

fig. 42

Shoe Brackets

Check shoe brackets for excessive wear and

sloppy shoe fit.

page 41
 MAINTENANCE - 50 HOURS

Feed Disc

Check fee disc for excessive wear. Turn feed

disc about 30 Deg. clockwise every time shoes
are changed.

Feed Disc

fig. 43

Hydra-Arm

Turn table bearing has (4) points grease

fittings. Fitting should be greased every 50
hours.
Turn Table Bearing

fig. 44

Oil Filters

All oil filters should be changed after the first

50 hours of operation. After that, change
filters on a 250 hour operation intervals or
sooner if conditions dictate. Do not use an
automotive type filter,

page 42
MAINTENANCE - 200 HOURS

Lid Liners

Inspect liners for excessive wear.

To change lid liners:

1. remove lid from crusher.
2. remove lid liner bolts.
Note: when replacing lid liners it is
often easier to cut the bolts on the
top side of the lid. Lid Liners
3. drop used lid liners.
4. install new lid liners using new factory
lid liner bolts. fig. 32

Tub Liners

Inspect tub liners for excessive wear. Liners

should be inspected every 200 hours of Tub Liners
operation.

fig.33

page 43
 MAINTENANCE - 200 HOURS

Anvils

Check for excessive wear and replace anvils

as needed.

Anvils

fig. 34

Pedestal Skirt Ring

Check pedestal skirt ring mounting brackets

for wear or loose bolts. And inspect pedestal
skirt ring for excessive wear or broken liners.
Brackets

Liners

fig. 35

page 44
MAINTENANCE - 500 HOURS

Pedestal Oil Tank

Change oil and filter in pedestal oil tank after

500 hours of operation or as condition dictate.

Pedestal Oil Tank

fig. 36

page 45
 MAINTENANCE RECORD

Maintenance - 50 Hours

Hydra-Arm Bearings
Hours
Date
Hours
Date

Oil Filters
Hours
Date
Hours
Date

Maintenance - 200 Hours

Lid Liners
Hours
Date
Hours
Date

Anvils
Hours
Date
Hours
Date

page 46
MAINTENANCE RECORD

Maintenance - 50 Hours

Tub Liners
Hours
Date
Hours
Date

Maintenance - 500 Hours

Pedestal Oil Tank

Hours
Date
Hours
Date

page 47
 TROUBLE SHOOTING

Properly operated and maintained, the crusher is extremely quiet and free of vibration. In the
event you notice vibration investigate immediately. One method of isolating or locating the
source of vibration is to run the crusher up top operating speed, release the clutch and shut off
the diesel engine. This will allow the crusher to run without the noise and vibratino of the engine
whih may help determine where the vibration is coming from

SYMPTOM PROBLEM REMEDY

Excessive vibration 1. Crusher is not level 1. Make sure blocking is

adequate and that it is
solid
2. Inspect impeller table for rock 2. Remove rock or tramp
wedge between the impeller iron
shoes or loged on the feed disc. 3. Make sure feed disc is
centered

Oil Leak 1. Loss of bottom oil seal or a 1. Replace seal or bearing.

bearing in the pedestal.

Hydra-Arm 1. Check pressure guages 1. Pressure guages

3000 PSI
2. Check relief settings 2. Relief setting @2500 PSI

page 48
LUBRICATION SPECIFICATIONS
Motor Oils
Designated by SAE viscosity number:
10w
20w
30w
40W
10w30
Use an oil meeting or exceeding API
service SG, SF or CC performance ratings
with viscosity as indicated.
Mild EP Lube Oils
Designated by AGMA viscosity number:
2EP
4EP
5EP
6EP
8EP
Use a premium quality, heavy duty
industrial gear lubricant intended for
enclosed gear sets. Use lubricants
formulated with rust, corrosion, oxidation and
foam inhibitors.
These lubricants should also be fortified
with sulfur-phosphorus extreme pressure
additives.
Gear Oil
Designated by ISO viscosity grade
number:
220
A heavy bodied rust and oxidation
inhibited lubricating oil manufactured of
highly refined paraffinic and residual base
stocks for use in multifunctional applications.
Note: Gear oils with EP additives should not
be used in gear reducers used in conveyor
drives. These additives will cause the backstop
function to fail.
page 49
Semi-Fluid Grease
Designated by NLGI grade number:
00
A semifluid grease that provides good
resistance to oxidation, rusting and corrosion.
General Purpose High Temperature
Grease
Designated by NLGI grade number:
NLGI 0
NLGI 1
NLGI 2
An EP series lithium-based grease which
is oxidation resistant. Should protect against
rusting and water washout.
This grease should have a minimum
dropping point of 340 degrees F.
Open Gear Lubricant
Designated by initials:
OGL
An unleaded, diluent-type heavy-bodied
adhesive lubricant designed to lubricate open
gears. It contains a nonflammable, high flash
point, volatile solvent that ensures fluidity
during application.
Once applied, the diluent evaporates and
the lubricant takes on a flexible, adhesive,
high-strength consistency.
Hydraulic Oil
Designated by ISO viscosity grade
number:
32
This hydraulic oil should be comprised
of a high-quality base stock, premium anti-
wear agents, stabilizers and rust & oxidation
inhibitors.
Kolberg-Pioneer installs Conoco
Superdraulic 5W20 or equivalent which
meets the specifications listed above.
page
 West 21st Street
Yankton, SD 57078
page