Raptor XL300&400 Rev 00 08-08

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  • Raptor XL300/XL400Instruction Manual

    August 2008ECT000-0337 Rev 00

  • ECT000-0337 - Rev. 00 - 08/08

    Section 1 Safety

    Section 2 General Crusher Information

    Section 3 General Installation Information

    Section 4 Main Frame Assembly

    Adjustment Ring Assembly

    Tramp Release Assembly

    Section 5 Countershaft Box Assembly

    Countershaft Assembly

    Sheave Assembly

    Section 6 Eccentric Assembly

    Section 7 Socket Assembly

    Section 8 Head Assembly

    Mantle Assembly

    Feed Plate Assembly

    Section 9 Bowl Assembly

    Bowl Liner Assembly

    Hopper Assembly

    Section 10 Bowl Adjustment Mechanism Assembly

    Section 11 Lubrication System

    Section 12 Hydraulic Systems

    Section 13 Operating Instructions

    XL300 Cross Section with Component Call Outs

    XL400 Cross Section with Component Call Outs

    Index

    XL300/XL400 Cone Crusher

  • ECT000-0337 - Rev. 00 - 08/08

  • ECT000-0337 - Rev. 00 - 08/08 1-1

    Section 1

    SafetySafetyThis section of the Instruction Manual provides only basic safety procedures and is in no way intended to replace safety codes, insurance requirements, federal, state and local laws, rules and regulations.

    Safety Begins and Ends With YouIt is the responsibility of each person to know and follow all the required safety procedures.

    Unfortunately, injury is often not just limited to those who do not follow required procedures. The safety of everyone relies on everyone.

    Safety and The Crusher Even the safest machine must be operated in accordance with the manufacturers recommendations. Review this Instruction Manual and become familiar with the hazards of the Crusher and associated equipment. Refer to the Operating Instructions Section of this Manual.

    Develop safety procedures in the operation and maintenance of the Crusher. Check for loose, damaged or worn parts and report unsafe situations immediately. Only use comparable type and quality replacement parts such as those supplied by Excel.

    Do not make any adjustmentsor repairs of any kind

    while the Crusher is operating!

    Always follow standard lockout procedures using warning tags before working on the Crusher. Each person working on the Crusher should have their own personal padlock, warning tag(s) and ONE key.

    Stay away from all moving parts of the Crusher. Loose clothing, watches and rings create a hazardous situation.

    Safety Glasses, Hard Hat and Safety Shoes are critical when around the Crusher and other machinery. Ear protection is suggested along with minimizing exposure time when the Crusher is in operation.

    Keeping the area around the Crusher and other machinery clean provides a safer working environment. Do not allow material to build-up around the Crusher.

  • ECT000-0337 - Rev. 00 - 08/08

  • ECT000-0337 - Rev. 00 - 08/08 2-1

    Section 2

    General Crusher InformationIntroductionThis manual provides information for properly installing, operating and maintaining the XL300/XL400 Crusher.

    It is recommended that this manual be read before installing and operating the machine.

    Initial InspectionA complete inspection is recommended as soon as possible following delivery of the Crusher. Look for any damage that might have occurred during transit. Also verify that all shipped loose items listed on the Bill of Lading, Freight Bill or Manifest are accounted for. Notify the carrier immediately of any damage or shortages.

    Information FurnishedThe following information for your XL300/XL400 Crusher is provided by the factory and includes:

    MountingandClearancedrawing.

    IndexforFieldConnectionsdrawing.

    OperationandmaintenanceinformationforequipmentnotmanufacturedbyExcel.

    CrusherPartsBook.

    Repair PartsExcel carries an extensive supply of replacement parts.To avoid delay and incorrect parts being furnished, the following information is required when ordering:

    1. Crusher size

    2. Crusher serial number

    3. Name of part, part number and the quantity of parts ordered

  • ECT000-0337 - Rev. 00 - 08/08

  • ECT000-0337 - Rev. 00 - 08/08 3-1

    Section 3

    General Installation Information

    Crusher Clearance Dimensions .................................................................................................................... 3-2

    Foundation ................................................................................................................................................... 3-2

    Weight of Complete Crusher and Assemblies Table 3-1 ......................................................................... 3-2

    Belt Types Figure 3-1 ...................................................................................................................................... 3-3

    Crusher and Subassembly Weights.............................................................................................................. 3-3

    Discharge Arrangement ................................................................................................................................. 3-3

    Feed Arrangement .......................................................................................................................................... 3-3

    V-Belt Drive ................................................................................................................................................... 3-3

    Crusher Motor .................................................................................................................................................. 3-4

    Hydraulic System Information ..................................................................................................................... 3-4

    Piping Information .......................................................................................................................................... 3-4

    General Assembly & Disassembly Information .......................................................................................... 3-5

    Special Tools Furnished with the Raptor Crusher Figure 3-2 ................................................................ 3-6

  • ECT000-0337 - Rev. 00 - 08/08

    Weight of Complete Crusher andWeight of Assemblies That Require Frequent Handling

    XL300 XL400 Pounds (Kilograms) Pounds (Kilograms)

    Complete Crusher 36,116 (16,382) 51,896 (23,540) Complete Crusher less Bowl, Hopper and Head Assembly 27,881 (12,647) 40,651 (18,439)

    Bowl Assembly, Bowl Liner and Hopper Assembly 7,376 (3,346) 10,171 (4,613) Main Frame Assembly 10,663 (4,837) 14,919 (6,767) Head Assembly, Feed Plate Assembly and Mantle 4,647 (2,108) 7,521 (3,411)

    Countershaft Box Assembly 893 (405) 1,230 (558)

    Eccentric Assembly 2,398 (1,088) 3,944 (1,789)

    Socket 120 (54) 183 (83)

    Socket Liner 100 (45) 140 (64)

    Mantel 1,815 (823) 2,845 (1,290)

    Bowl Liner 1,870 (848) 3,392 (1,539)

    Table 3-1

    3-2

    FoundationThe Mounting and Clearance Drawing, furnished by Excel, will provide you with mounting position of the foundation bolts, drive motor location and various clearances required to mount the Crusher onto the foundation. A durable, solid and level foundation is critical to the safe operation of the Crusher.

    ImportantInformation data sheets with Crusher foundation loads are available from Excel. The foundation must be designed to accept these loadings. The customer is responsible for the design of the foundation.

    Crusher Clearance DimensionsSuccess of the operation and maintenance of the Crusher relies on a well planned installation. Crusher clearances must be considered when designing the foundation. Clearance must be provided above the Crusher for the installation and removal of the Head and Bowl Assemblies. Clearance should also be provided for the feed equipment such as; chutes, feed hoppers, conveyors and other related equipment. Adequate area is also required in front of the foundation for the removal of the Countershaft Assembly. Another requirement is the room needed under the Crusher for a discharge conveyor and/or chute.

    Refer to the Mounting and Clearance drawing along with the Dimensional Data Sheets available from Excel to determine the clearances required in designing your foundation.

  • ECT000-0337 - Rev. 00 - 08/08

    It is recommended that a screen be placed ahead of the Crusher in the circuit to remove fine or sticky material. This will help avoid conditions such as bridging and ring bounce. Installation of a metal detector or magnet is recommended to remove any non-crushable items (called Tramp) before they get into the crushing cavity. Excessive amounts of tramp material passing through the Crusher can cause ring bounce, damage Crusher parts and possibly stall the Crusher drive motor.

    Discharge ArrangementThe construction recommendations shown on the Mounting and Clearance drawing should be followed. Replaceable wear material should be used to line the discharge compartment. Within the compartment, a shelf or ledge should be incorporated to make a dead bed for the Crusher discharge material to fall on. The dead bed is designed to absorb most of the energy of the falling material before cascading onto the conveying equipment.

    If a discharge chute is used, it must be positioned at an angle of 45 or greater from horizontal. If wet discharge material is present then the chute angle should be increased.

    As shown on the mounting and clearance drawing, adequate clearance is to be maintained between the discharge equipment and the Crusher. The proper amount of clearance will stop material from building up under the