TBK 80 (Ø850) Rock-On-Rock Vsi Crusher Operation and Maintenance Manual

TBK 80(Ø850) ROCK-ON-ROCK VSI CRUSHER
OPERATION AND MAINTENANCE MANUAL
EDITION: 2006/A
TBK80 ROCK-ON-ROCK Date : 24/11/2006
Rev. : 0
VSI CRUSHER Page No : 2/45
1.0. IMPORTANT !
These Operating and Maintenance Instructions and Safety Regulations shall be

read and observed carefully prior to transport, installation, commissioning, maintenance
and servicing of the machine!
Authorised personnel only, who is familiar with the operating and maintenance
instructions and the appropriate instructions with regard to safety at work and accident
prevention, is allowed to use, maintain and repair the machine.
The manufacturer MTM MACHINERY Co. herewith declares, that the machine
as described in the following is in compliance with the regulations of the Machinery
Directive 98/37/EEC in its applicable version and other directives and standards given in
the manufacturer’s declaration of conformity for jaw crushers (FGN.30).
NOTE: MTM has all rights on the above specifications without any notifications.
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1.1. PREAMBLE
MTM Machinery Industry Co. thanks you for the confidence that you have
placed in MTM with the purchase of this equipment.
The information given to you with these operating and maintenance instructions
shall direct the user’s attention to design, construction and functioning of the CRUSHER and
impart all knowledge necessary for a successful application, use, trouble-free operation,
expert maintenance and correct purchase of spare parts.
The present “Operating and Maintenance Instructions” shall not cancel the
current national laws and accident prevention regulations.
Jaw crusher shall be used by expert and authorised personnel only and
exclusively for the purpose it had been designed, made for and explained in the declaration
of conformity.
Additionally, start-up, operating and maintenance conditions (in accordance with

the operating and maintenance instructions) as specified by the manufacturer of the
crusher shall be strictly observed.
Furthermore, foreseeable wrong behaviour of personnel and the directions of the

relevant local safety regulations and laws shall be well considered too.
The crusher shall be operated and maintained by authorised persons only, who
have been registered in the equipment check list and are therefore familiar with the crusher
and know the risks and hazards very well.
There are special conditions for underground working. If the customers do not
particularly specify this condition, manufacturer does not accept any liability for the damage
resulting from using the standard jaw crushers for underground works.
Any other use of the crusher shall not be covered by the above-mentioned
instructions. The manufacturer of the crusher shall neither be made liable for defects nor
consequential defects and damage resulting from such use, nor shall he take over any
liability with regard to the Product Liability Act.
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1.2. COMMANDMENTS OF SAFETY

1. Support all efforts to keep the place of work safe and healthy.
2. Act and do everything with responsibility and utmost care for your safety and
the safety of others.
3. Regularly check all protection devices and tools for completeness and safe
functioning.
4. Inform yourself and others about the risks involved with the job so that such
risks can be prevented in the most effective way.
5. To avoid injuries and mechanical defects inform yourself about hazards and
safety measures if you feel not having enough knowledge on this subject.
6. Always bear dangers of injuries and accidents in mind before you begin with a
new work. Prepare well thought out safety precautions to protect yourself and
others. Revise such measures regularly and introduce necessary
improvements.
7. Warn others of possible risks and defects if you see that they are working in a
very dangerous way or are about to cause dangerous situations.
8. Pay attention to changes in working conditions and working processes and act
accordingly.
9. Hazardous and risky behaviour, dangerous conditions and processes, which

could have caused accidents, must be reported to the management without
delay. Do not assume that somebody else will do this. Do not take drugs, pills
etc. and never drink alcohol when operating or maintaining the machine, or
prohibit consumption of drugs and alcohol during working hours.
10. Keep your place of work/area of work tidy. Tools and auxiliary means must
be collected after use and kept in a place especially provided for this purpose.
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1.3. ADDITIONAL SAFETY REGULATIONS

Inform operating personnel of the emergency numbers. The emergency numbers
must be made clearly visible close to the telephone.
Let the operating personnel attend a First Aid Course if they do not have such
knowledge.
Always follow the rules and take care all the warnings given in labels on the
machine.
In case of injuries to a person call for a doctor or other ambulance personnel at

once and take care of the injured person without delay.
All accident must be reported at once to the management.
Take off rings, bracelets, wristwatches, necklaces etc. before you start working
at the crusher.
For lifting heavy loads (above 25 kg) always use appropriate lifting devices.
Lift loads only out of the legs with stretched back.
Never stand under lifted loads and check all load raising devices for damage and
sufficient load-bearing capacities before each use.
Protect hair with a hairnet and avoid loose clothing when working at the machine
to avoid getting caught by rotating parts.
Always wear helmets (hard hats) for your own safety.
Depending on the crushing material noise level may reach an extent that will
force you to use earplugs.
Crushing material and operating conditions may create dusty environments,
which necessitate the use of protection masks.
Protect your eyes with safety glasses to avoid injuries

caused by dust and flying particles.
Always USE safety work-shoes and gloves to avoid injuries.
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At night works, supply sufficient illumination for the

machine (~350-400 W). Avoid deposition of material on or
under the machine.
Unauthorised stay of persons within dangerous

areas of the machine is strictly forbidden. (Feed Points,
discharging area and at least 1- meter peripherals of the
machine).
Stand clear of material discharge and fed areas at all times. Material can be
ejected or ricochet unexpectedly from feed and discharge openings.
Do not change or remove installations that ensure safety and avoid accidents.
Always keep them in a safe-to-operate condition.
Prior to each start-up the crusher personnel must make sure that no
unauthorised persons are within the dangerous areas of the machine.
IF MTM makes installation works for the machine,
There will be a sound-alarm system for the plant and machine.
Do not cancel or change the alarm system.
Visually verify that all personnel and objects are clear of
equipment prior to operation.
Service and maintenance work are only allowed - and that without any exception
- when the machine is switched off and protected against unintended start-up (lock main
switch).
In case of defects, which reduce the crusher’s safety, stop the machine at once,
switch it off and inform the management.
Careful and detailed instruction and training of the operating,

maintenance and repair personnel only as well as observation
and keeping of the safety regulations and working prescriptions
of the operating instructions ensure high availability of the
equipment with regard to trouble-free operation and economical
application.
Supplement the safety regulations of this operating instruction with
internal operating instructions based on national prescriptions, local
and national environmental laws, national accident prevention
regulations etc.
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1.4. ELECTRICAL EQUIPMENT
MTM-authorised personnel only are allowed to perform repair work at

the electrical equipment.
Expert personnel of a licensed company only are allowed to work on

the electrical equipment of the machine.
Carefully check whether the crusher has been earthed in accordance

with the local provisions.
Welding repairs at the crusher without adequate safety precautions will damage
the electrical equipment.
1.5. EMERGENCY-OFF
The machine shall only be operated with an emergency off device.
Determine the cause of the malfunction at once and initiate corrective actions.
In case of art EMERGENCY-OFF unbroken material may remain in the crusher,

which could block the crusher’s drive at a new start.
Make sure that such material is reliably removed from the crusher.
Never use the EMERGENCY-OFFS for a normal stop of the crusher. Check these
EMERGENCY-OFFS regularly for proper functioning.
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1.6. MAINTENANCE AND SERVICING

Indicated lubrication and oil changing intervals must be kept.
Maintenance and servicing jobs at the crusher must only be carried out during
standstill of all drives.
Make sure to prevent unintended starting of the crusher (e.g. blocking or locking
the main switch).
Never use any other lubricants than those recommended by MTM.
Never mix up lubricants based on different substances (e.g. lithium-soaped

grease with calcium-soaped grease) because otherwise this could considerably damage
bearings and scaling under certain circumstances.
After completion of maintenance and repair work re-mount all available safety
installation and check them again for proper functioning and operation reliability.
1.7. HAZARDOUS MATERIAL DISPOSAL

Waste oil, waste grease, cleansing liquids, remnants of paints etc. must be
disposed of in an expert way and in accordance with the relevant national environmental
laws that are generally applicable.
1.8. WELDING REPAIRS

Welding repairs on MTM - CRUSHER must only be done after consultation of
MTM MACHINERY Co.!!
When welding mild steel lifting loops to manganese steel, the international
standards are to be followed. In particular:
Use stainless 310 rod, 5/32 inch ( 3.97 mm ) in diameter.
Make a number of passes rather than one large pass
No preheating or after-welding heating
Follow all safety precautions when lifting.
Special ventilation or a respirator may also be required when welding in confined spaces.
Contact your welding consumables supplier.
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1.9. HYDRAULIC EQUIPMENTS IN GENERAL

Do not dismount any connection when hydraulic equipment is under pressure.
Do not handle or repair hydraulic equipment with dirty or oily hands.
Always take care of clean conditions when repairing the hydraulic equipment.
Close all openings immediately with plugs.
Refill new hydraulic oil through undamaged filter only.
Damaged pipes, filters, hoses and so on must be replaced at once.
1.10.WARNING PAINT,LETTERING AND WARNING SIGNS

Nameplates and warning signs must never be removed or painted over.
Illegible or defective nameplates and warning signs shall be replaced by identical

new ones. Nameplates may be obtained from MTM Machinery Industry/TURKEY.
Be careful! Crushing and cutting injury may occur
Lift from this side
Emergency Stop
Dust Hazard Wear Mask
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Careful Impact may occur
Wear eye and ear protection
No Pacemakers
Be Careful trained personnel only
Be Careful, Hard Hats must be worn
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GENERAL DIMENSIONS OF THE CRUSHER

MODEL A B C D E F G H I J K L M N O P
TBK80 6300 5017 2900 3150 1748 2092 930 3022 1995 3046 1120 512 1260 210 2990 1390
TECHNICAL SPECIFICATIONS
MODEL TBK80
MOTOR RPM RANGE 2 x 110 Kw / 1500 rpm
MAX.FEED SIZE 50
MAX. CAPACITY 50-125
TOTAL WEIGHT 14000 kg
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2.GENERAL INFORMATION:
TBK 80 rock-on-rock crusher uses a field proven rock lined rotor that acts as a high
velocity dry stone pump hurling a continuous rock stream into a stone lined crushing
chamber.
Material fed into the top of the machine is accelerated in the rock lined rotor, is thrown
to the crushing chamber with high speed.
Rotor range is 1500-2500 rpm and rotor diameter is 790 mm.

If the speed of the rotor is wanted to accelerate, greater motor pulley can be used, so
that we can get high capacity.
Start Up Procedure
This section describes the start-up procedure, including the initial commissioning start-
up.
2.1 BEFORE START-UP
1. Have all electrical connections checked, including the operation of the vibration
switch.
2. Check pulley alignment and V belt tensions.
3. Check rotor rotation-it must be counter-clockwise when we viewed from above.
Severe damage to the rotor will result if the rotation is incorrect.
4. Make sure all bolts in the rotor, crusher and main support frame are tightened to the
correct torque.
5. Check all wear parts are correctly fitted in the rotor.
6. Remove all tools from on or within the crusher.
7. Ensure that all guards, doors, hatches and safety pins are in place.
2.2 INITIAL START-UP

1. Confirm ammeter is operating.
2. Run without load for 30 minutes. Grease bearing cartridge until grease flows from
the grease discharge chute while the machine is running.
3. After 30 minutes running, stop the crusher, remove belt guards and check
bearing cartridge temperature (Use magnetic thermometer). The temperature
shouldn’t exceed 70C. If the temperature exceeds this, continue to run with no
load for a further 30 minutes and check again. If high temperatures continue
your MTM service centre for advice. If temperature is within normal range replace
the guards.
4. Inspect rotor and cascade assembly. Ensure that all rotor parts are in place.
Ensure that the feed tube is still centralised in the feed eye ring.
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2.3 INITIAL FEEDING OF CRUSHER
1. The machine can now be run with a load. Feed material should be no larger than
the maximum allowable feed size for the MTM model being commissioned.
2. Feed a small sized chip or all-in product, preferably 5mm for the half minute or
so. A few cubic metres of material is enough. This allows an even build-up of
stone in the rotor and promotes good balance.
3. If coarse feed must be used at the start, some vibration can be expected for
several hours until fines are able to work their way through the voids in the
initial rotor build-up and bring the density of each rotor build-up into equilibrium.
4. When first feeding the rotor there will usually be an out of balance stage for
about 30-60seconds.Do not stop the feed to the rotor at this point but feed it as
much as possible until the vibration settles down.
In normal operation there is intermittent detectable vibration about30% of time.

This can be felt when standing on the machine and is most noticeable with largest feed
sizes. This is due to stone lodging by one rotor tip, causing a build-up.
And then being worn away. The condition is normal and no concern provided the
machine returns to normal running after a few seconds.
AFTER 10 MINUTES
1. Centre the spreader plate under conveyor discharge so feed falls in an even curtain
around the spreader. The feed should fall squarely through the control plate feed
opening. This stabilises rotor feed.
2. Check motor power draw. If motor(s) are overloaded , reduce feed volume or adjust
cascade control until ammeter reading is corrected. If dual drive motors are running at
different amps see belt tensioning.
AFTER 30 MINUTES
1. Stop machine and check build-up in rotor.
2. Check crushing chamber build-up.
3. Make sure feed tube is in correct position in rotor, i.e. central in rotor feed hole and
extending into rotor.
4. Check that rotor tip assemblies are intact and tight.
5. Check feed eye ring has not turned or lifted.
6. Check belt tensions.
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AFTER 4 HOURS
1. Check build-up in rotor, crushing chamber and base.
2. Check bearing temperatures.
3. Check belt tensions.
4. Grease at the end of the shift, and perform daily inspections as listed.
Normal Bearing Temperature

The normal operating temperature for the bearing cartridges: 40C.A short duration
temperature rise of approximately 10C can be experienced when bearings are lubricated.
2.4 OPERATION
During operation it is important that the operator pays attention to the following:
1. AMMETER READING
High amps: could indicate high feed rates, extreme build-up in the chamber or the
base, blocked discharge chutes ,incorrect cascade adjustment ,mechanical and electrical
problems.
Low amps: could indicate low feed rates, incorrect cascade adjustment, V-belt
slippage, electrical problems.
Unbalanced amps: in a dual drive unit could indicate incorrectly tensioned, V- belts,
electrical or mechanical problems.
2. NOISE LEVELS
An increase in noise level could indicate bearing failure ,V belt slippage ,scouring of
build up in crushing chamber ,feed tube rubbing on feed eye ring.
3. VIBRATION
An increase in vibration could indicate uneven wear on wear parts or rotor, unbalanced
rotor due to uneven build-up in rotor, failure of anti-vibration pads, loose or pulley taper
lock.
4. FLOW OF MATERIAL
Changes in feed conditions could require adjustment of the feed plate and control
choke in the feed hopper. Increases in moisture content may increase build-up in the
rotor, crushing chamber and base.
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2.5 SHUT DOWN PROCEDURE
Extended periods of running out the circuit with low feed rates to the crushing chamber
and rotor body. If the crushing circuit and weather conditions permit, stop all conveyors
before the crusher fully loaded. At the very least be aware of the excessive wear that
takes place and minimise the run-out time.
SHUT DOWN
 Shut down feed device (conveyor or feeder) before the TBK.

 Observe ammeter unload prior to disconnecting power from the TBK.
 Time run-down time of rotor and record in Daily Log Book. If you cannot locate this
contact your MTM Service Engineer.
Inspection and Servicing:

The TBK 80 is a rugged machine which is a mechanically simple and extremely easy to
maintain. The machine does however require routine and regular inspections and
attention.
The machine should not be ignored for lengthy periods, during which potentially serious
damage to wear parts may remain undetected.
Important note: TBK rotor wear parts are designed to protect the rotor body from
wear. They are not involved in the crushing action of the machine. Consequently it is not
possible to determine the state of wear of these parts from the product discharging from
the crusher.
To ensure trouble free operation TBK it is necessary to inspect the condition of the
rotor wear parts and the rock build-up within the machine on a regular basis.
Any wear parts that are unable to complete another shift should be replaced.
MTM recommended that you should carry out the following every 8 to 10 hours of
operation:
 GREASE BEARING CARTRIDGE

 INSPECT EXTERIOR OF RUSHER
 INSPECT INTERIOR OF CRUSHER
 INSPECT ROTOR
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3. LUBRICATION
BEARING CARTRIDGE
The bearing cartridge must be greased every 8 to 10 hours of operation.
OPERATION
The best practise is to grease the bearings when the bearing cartridge is at operating
temperature while the machine is running at the end of each production shift.
RECOMMENDED GREASES
SHELL ALVANIA EP2, CASTROL SPHEEROL EPl2 OR EQUIVALENT
Bearing grease must have extreme pressure properties, such as provided by molybdenum
or lithium additive, with aluminium complex or similar base. Use a grease that conforms to
N.L.G.J. No: 2 with a minimum drop point L88°C.
OPERATING TEMPERATURE
Normal operating temperature for the bearing cartridge is: 40° to 60°C. A short
duration temperature rise of approximately 10°C can be experienced when bearings ere
lubricated.
HIGH TEMPERATURE BEARING CARTRIDGE

When using HT Bearing Cartridges for high temperature applications, it is
recommended to use a high temperature bearing grease such as Mobil SHC 100 or
equivalent. The high temperature bearing cartridge can operate at temperatures up to a
maximum of 150°C.
GREASE DISCHARGE
Ensure that the grease discharge is away from the V-belts and grease hoses ere
undamaged.
It is also a good practice to perform a weekly inspection of the grease discharge to
ensure that it is not blocked, which may lead to pressure build-up inside the cartridge;
breakdown of grease inside, etc.
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4. ROTOR SERVICING
The rotor assembly is the main wearing component of the TBK, and regular and
timely inspection of wear parts will extend the life of the rotor. If wear parts are not
replaced when required, severe damage or even total destruction of the rotor body may
result.
While wear patterns and wear rates can be observed with the rotor in place, it may be
necessary or desirable to remove the rotor from the crusher to replace any worn wear
parts.
In this manual we have assumed that the parts are being replaced with the rotor in the
machine. The major problem with this can be the removal of the build-up of material in the
rotor around the wear parts.
4.1 CLEANING OUT ROTOR
The most successful method of removing the build-up is by using water. If a hosepipe
is available at the crusher it is quite in order to "wash out" the build-up by inserting the
hose pipe into the hopper, directing the water into the rotor while the crusher is running.
CAUTION : Do not insert the hose pipe into the rotor, direct the water flow only into the
rotor. The use of water into the rotor may scour out the build-up in the crushing chamber.
This in itself is not a problem but if the feed size is at the maximum, chamber gusset wear
will result until the build-up in the crushing chamber is replaced on start-up.
If a hosepipe is not available near the crusher it may be possible to remove build-up
with a podger bar. If this is not possible or too time consuming, then it will be necessary to
remove the rotor from the crusher for the removal of the upper and lower wear plat,es.
Distributor plate and feed eye ring.
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4.2 ROTOR TIPS
Rotor tips must be checked to determine the amount of wear on the inserts. Tips need to
be replaced once 95% of the insert has been removed at the centre of the wear. The back-
up tip assembly will protect the rotor body from damage therefore a tip in this condition
could be run for another shift. Experience will help the operator understand the wear
performance of the tip.
Ensure that the rotor tips are tightly held and not broken, cracked or badly chipped.
Normal Wear
The rotor tips are wearing normally. Replace when less than 3mm.
Cracked or Chipped Inserts

Tramp iron in feed. Remove tramp iron. Oversize feed material. Investigate cause of
oversize. Reduce maximum feed size.
Off Centre Wear
The rotor tips are wearing at the top or bottom not in the centre. Trail plate angle may
require altering
4.3 TIP CARRIER WEAR PLATES
Initially, the tip carrier wear plates may wear quickly until they reach o certain profile
governed by the application. This is quite normal and should not cause concern.
Tip carrier wear plates must be inspected for wear and be replaced when there is doubt
they will last another shift, or as soon as wear appears on the top of the bolt head. Replace
tip carrier wear plates which have crocked. Check that tip carrier wear plates are not loose.
Normal Wear
The tip carrier wear plates are wearing normally. Replace when wear just starts to
show on bolt head
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Cracked Tip Carrier Wear Plates

Caused by tromp iron, oversize feed, excess build-up with damp/sticky material uneven
mating surface. Remove tromp iron. Reduce feed size. Ensure that mating surfaces are fiat,
i.e. there is no spatter or grit between tip carrier wear plate and bock-up tip.
Uneven Wear
Tip carrier wear plates are wearing at the top or bottom not in the centre. Adjust trail
plate angle.
Uneven wear can also be caused by excessive crushing chamber build-up.
Premature top wear can be indicative of' o worn cavity ring and/or cascade wear skirt .
Premature bottom wear can be indicative of excessive build-up in the base.
4.4 BACK-UP TIPS
In normal operation the back-up tip should be unused and in many eases is not visible
(depending on rotor tip and tip carrier wear plate style used).
The back-up tip is only exposed to wear when the rotor tip has failed or worn out. In
the event of emergency use of the back-up tips, they should be replaced once there is only
3-5 mm of insert remaining at the centre of the wear path.
Back-up tips should also be replaced if the insert is cracked or badly chipped
Irregular Wear
Rotor tips being left in place too long and wearing out.
Back- up lips Breaking

Rotor tip failed, exposing back-up tip, usually caused by tramp iron or oversize feed or
having been worn too thin.
REMOVAL/INSTALLATION
Removal
Remove taper bolts. Tap rotor tip inward to break away build-up that will hold tip and
back-up tip in place.1t may be necessary to use o bar to chisel away very tightly compacted
build-up. If this condition persists it is advisable to wash out build-up with water.
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Installation
Ensure that all mating surfaces on rotor tip, tip carrier wear plates and back up tips are
free of any high spots (dirt, weld spatter, burrs).
Position back up tip, rotor tip and tip carrier wear plate in rotor port. Insert taper boltsı
ensure that copper washer is in place, and tighten. (Applying anti-lock compound to thread
will make removal easier). Ensure that tip assembly is pulled up tight and that there is no
movement in the parts.
NOTE: ROTOR TIPS, TIP CARRIER WEAR PLATES AND BACK-UP TIPS MUST BE CHANGED
AS SETS. DO NOT REPLACE SINGLE PARTS OR A ROTOR OUT-OFBALANCE CONDITION
MAY RESULT
4.5 UPPER AND LOWER WEAR PLATES
Replace upper and lower wear plates when it is obvious that they will not last another
shift. Replace once there is less than 3-5 mm of plate remaining at the centre of the wear
path at the discharge edge or inside edge
Upper Wear Plate

Rapid upper wear plate wear is an indication that the feed tube and feed eye ring are
worn. Replace worn parts.
Upper wear plate wear accompanied by rotor tiptop end wear is an indication that the
trail plates are incorrectly shaped. Adjust trail plates as described in rotor tuning.
Lower Wear Plate
Lower wear plate wear accompanied by rotor tip bottom end wear is an indication that
the trail plates are incorrectly shaped. Adjust trail plates as described in rotor tuning.
Other Influences
As the feed eye ring wears the leading edge of the upper wear plate is progressively
exposed to wear.
As the distributor plate wears on the lower wear plate will deepen.
UPPER AND LOWER WEAR PLATES
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REMOVAL / INSTALLATION
It is possible to remove and install the upper and lower wear plates while the rotor is in
place however it is necessary to dean out the build-up thoroughly. This can be done by
using water as described in rotor servicing.
Removal
Upper Wear Plates
1.Remove hopper ı crusher top and cascade assembly in one lift.

2.Remove rotor tips and tip carrier wear plates.
3.Remove feed eye ring.
4.Tap the wear plate towards the centre of the rotor to release it from the keepers.
5.Withdraw the plate through the feedhole.
6.Thoroughly scrub out the remaining build up with o wire brush or hosepipe.
INSTALLATION
Lower Wear Plates
1.Remove rotor tips and tip carrier wear plates.
2.Remove the distributor plate.
3.Tap the wear plate towards the centre of the rotor to release it from the keepers.
4.Withdraw the plate through the feed hale.
1.Ensure mating surfaces are clean and free of snags.

2.Insert new wear plate through the feed opening and slide into place.
3.Ensure the new plates are wedged under the keepers.
4.6 DISTRIBUTOR PLATE
The distributor plate wears in three places, opposite each rotor port.
Turn the distributor 1/6 th of a turn when partly worn to ensure maximum usage.
Replace distributor plate once the bolt head starts to wear once there is only 3-5 mm of
casting left at the thinnest point.
PREMATURE WEAR
Generally caused by oversize feed or material dropping from a conveyor or screen
chute directly onto the distributor plate.
Reduce feed size. Install or centralise spreader plate are available. Please contact your
dealer for more information.
Removal
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1.Remove hopper, crusher top and cascade assembly in one lift.

2.Remove feed eye ring.
3.Remove stones and protective rag from distributor bolt hole.
4.Remove distributor plate bolt.
5.Distributor plate lifts out
Refitting
1 . Clean off centre of rotor.
2.Place distributor plate in centre of rotor.
3.Insert distributor plate bolt and tighten.
The use of large impact wrenches should be avoided when tightening bolt.
Reassembly is a straight reversal of removal.
4.7 PROTECTIVE PLATE
Wear on the protective plate is largely determined by the material flow from the feed
tube. Thus as the feed tube wears the protective plate will be exposed to more wear.
To minimise the wear of the protective plate it is essential to maintain the feed tube in
the correct position.
Replace the protective plate when the upper wear plate is worn to a thickness of 3-5
mm at the inside edge.
Removal
1. Remove hopper, crusher top and cascade assembly in one lift.
2. With o hammer hit the top of the rotor (not the feed eye ring) above the wear
plates to loosen the build-up.
3. Turn the feed eye ring counter-clockwise until the locking tabs line up with the
slots in the rotor top. If material build-up stops the worn feed eye ring from
turning use o soft blow hammer to tap the feed eye ring counter-clockwise.
4. Lift the feed eye ring out.
Installation
1. Ensure mating surfaces are clean and free of snags. lf refitting upper and lower
wear plates ensure these are in position.
2. Position feed eye ring so locking tabs and slots line up.
3. Lower feed eye ring and turn clockwise to lock in place.
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4.8 FEED TUBE (collector)
Replace feed tube just before the bottom lip is exposed above the protective plate.
The feed tube should wear evenly up the casting.
Maintaining the correct position of the feed tube in the rotor will result in increased life
for the feed eye ring and upper wear plates.
Uneven Wear
Feed tube wearing on one side - feed tube not centralised.
Check feed tube and cascade assembly.
Cracking and Breakage

Feed tube crocking on bottom edge - excessive rotor build-up is rubbing on feed tube
and causing overheating.
Adjust trail plates to reduce build-up.
Feed tube breaks - can be caused by excessive build-up in rotor, stones wedging
between feed tube and feed eye ring, feed eye ring coming loose or the feed tube coming
loose (check clamp sleeve).
Removal
1.Remove the hopper from the crushing chamber assembly.

2.Clear stones from around feed tube, clamp sleeve and retaining wedge.
3.Remove retaining wedge and knock the clamp sleeve clockwise to release.
4.Lift clamp sleeve out.
5.Lift feed tube out.
Installation
1.Ensure feed tube holder is free from stones, etc.

2.Lower feed tube into place.
3.Ensure it is centralised and level.
4.Refit clamp sleeve.
5.Turn clamp sleeve into locked position and insert retaining wedge.
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4.9 ROTOR TUNING
The success of the TBK is centred around its rotor. lf the rock build-up within the rotor
is ideal, then wear on the upper and lower wear plates will be even, the rotor tips fully
utilised, and the lowest consumables cost per tonne of product will be achieved.
Unfortunately, the build-up characteristics are never the same for any two materials,
indeed the nature of the build-up will vary with rotor speeds, rotor sizes, feed rates, feed
sizes, and feed moisture.
The main purpose of tuning is to ensure that the build-up within the rotor extends from
the trail plate to the inserts in the rotor tip, and that the wear is centralised across the rotor
tips.
Insufficient build-up will result in tip exposure. This will lead to early failure of the rotor
tips through the chipping of the inserts by direct contact with the larger stones in the feed.
Insufficient build-up of material will expose the supporting metal of the rotor tips. This will
also lead to premature failure of the inserts by direct abrasion from the stone flow through
the rotor. This can also result in the rotor tips wearing in front of the inserts which will
eventually lead to their falling out of the carrier plate.
5. CRUSHER SERVICING
5.1 BEARING CARTRIDGE
The bearing cartridge is a grease filled, sealed bearing assembly which can be removed
in one piece (shaft, bearings, seals and housing) for overhaul and inspection.
When the new bearing cartridge has run between 100 and 150 hours, begin a series of
routine checks on the run down time of the rotor (time from power being cut to rotor stops
turning).
A significant decrease in the run down time over a period will indicate that the bearings
(crusher or motor) are deteriorating. Once the time falls below two minutes the bearings
should be checked at the next routine service time.
Operators should become familiar with the sound of the bearings running. If this noise
changes, especially if it begins rumbling, this will also indicate that the bearings are
deteriorating.
Rev. : 0
If, when standing on top of the rotor during servicing, the shaft can be rocked from
side to side with excessive float, then the radial bearings are worn.
If no-load current begins to increase slowly over a period of time, this is an indication
that the crusher bearings are worn.
Upper seals should be replaced and labyrinth repacked with grease at yearly intervals.
REMOVAL
1.Remove hopper, crusher top and cascade assembly in one lift.

2.Remove the rotor.
3.Loosen off belt tension and remove V-belts.
4. Remove the pulley. In larger models, use o threaded rod (in the threaded hole in
shaft) and support to assist in lowering pulley.
5.Remove grease hoses.
6.Release the bottom taper ring by removing the taper ringbolts.
7.Screw half of these back into the top of the tapped holes to force the taper ring off.
8.Remove the bottom inner taper ring.
9.Remove half of the top taper ringbolts and loosen the other half.
10.Place o strut under these remaining bolts in tl1rn and unscrew to force the taper
ring up.
11.Insert lifting eyebolt into the top of the shaft.
12.Lift out bearing cartridge.
REFITTING
1.Ensure all mating surfaces are clean.
2.Lower bearing cartridge into the bearing cartridge housing.
3.Check grease points line up with grease hoses.
4.Replace top taper ring and loosely bolt down.
5.Replace bottom inner taper ring. Replace bottom taper ring and loosely bolt up.
6.Tighten the top taper ringbolts in series to a maximum torque.
7.Tighten the bottom taper ringbolts in series to a maximum torque.
8.Refit grease hoses making sure they are not twisted or blocked. Ensure that grease
hoses are not able to fall onto V-belts during operation.
9.Refit pulley and drive belts.
10.Refit rotor.
Rev. : 0
6.BELT TENSIONING
Correct belt tensioning is the most important factor necessary for long, satisfactory
V-belt operation. Too little tension will result in slippage, causing rapid belt and sheave
wear, and poor efficiency. Too much tension results in excessive strain on belts,
bearings (especially motor bearings), and shafts.
6.1 NEW BELTS (This includes the initial commissioning of the crusher).
New belts will take a little time to settle into the grooves, and will naturally stretch in
the first days of operation. To accommodate this settling in process, it is recommended that
the V-belts are tensioned some 20% above the optimum. Refer to the Belt Tension/
Deflection Chart under Initial Installation Tension column for the recommended tension for
the standard deflection for new belts.
Belt tension should be monitored regularly (at least weekly), but does not need
adjustment unless it falls outside the range indicated in the Normal Running Tension
column
RUNNING IN NEW BELTS (This includes the initial commissioning of the

crusher).
After 30 Minutes
After thirty minutes running it is recommended that the tension should be checked and
retensioned to the Initial Installation Tension values.
After 4 Hours
Re-tension to the Initial Installation Tension values.
Next 5 Days
Check tension at least once daily and you should observe a settling, requiring minimum
adjustment to maintain the tension as per the Normal Running Tension.
Rev. : 0
6.2. INSTALLATION OF V-BELT DRIVE:

1.Clean all oil, grease or rust from the pulley grooves.
2.Make certain that the pulleys are correctly aligned and that the shafts are
parallel.
3.Never force belts onto pulleys. Always shorten the centre distance until belts
can be slipped on easily.
To determine the minimum allowances for shortening or lengthening the centre

distance between pulleys. See Table 6.2.1. “V-belt take-up allowances”.
Minimum allowances mm (inches) below centre distance for installation of belts

Min. allowance
above centre
Belt Length* V-belt section
dist. For stretch
and wear
8V 8V banded belts SPC
mm inch mm-----inch mm---------inch mm----------inch mm---------inch
2000-2749 79-108 40 1½ 85 3 3/8 35 1 3/8 40 1½
2750-3499 108-138 40 1½ 85 3 3/8 35 1 3/8 45 1¾
3500-4499 138-177 40 1½ 85 3 3/8 35 1 3/8 55 2 1/8
4500-5499 177-216 45 1¾ 90 3½ 35 1 3/8 65 2½
5500-6499 216-256 45 1¾ 90 3½ 40 1½ 85 3 3/8
6500-7999 256-315 45 1¾ 90 3½ 40 1½ 95 3½
8000-9999 315-394 50 - 100 - 45 1¾ 110 4 3/8
10000-over 394-over 50 - 100 - 45 1¾ 140 5½
*In each group the range is to, but not including the second length.
Table 6.2.1. “V-belt take-up allowances”
Rev. : 0
After calculating a centre distance from a standard pitch length make provision
that the centres can be moved closer together by the amount shown in the following table
to facilitate installing the belts without deterioration. Also, the centres should be adjustable
over the calculated distance by an amount as shown in last column the table because of
manufacturing tolerance and possible stretch and wear of belt.
4. Always use a matched set of belts and use new belts of the same
manufacturer. Never mix worn- belts.
5. Place belts on pulleys and run the drive for a few minutes. Then tension the
drive until only a sag appears on the slack side of the belts when the drive is running. An
example of tight side is shown in Figure 5.14.1.2 below. The slack side depends on motor
position and rotation direction.
Figure 6.2.2. Determining slack side
6.3. TENSIONING THE V-BELT DRIVE:

Tensioning the drive is a term used when force is applied to the V-belt by some
method to provide the
Wedging action between the V-belt and the pulley. This wedging action provides
the ability for a V-belt to transmit power from motor pulley to the crusher pulley.
Various methods of tensioning V-belts have been established. Two simplified

method will be described in the following paragraphs. Tension-deflection and percent (%)
of elongation. Either of these two methods will provide satisfactory belt tension. Each has
certain advantages for a given type of belt.
Rev. : 0
For tensioning the drive using the TENSION-DEFLECTION method, proceed as

follows:
1. Place a straight edge across the top of both pulleys. See Figure 6.3.1.
2. Measure the span length.
3. Using a spring scale at right angles to the centre of the span length, apply a
force to the scale great enough to deflect one of the belts the equivalent of 0.016 times
millimetres of span length (0.016 times inches of span length).
4. The force should approximate the forces shown in Table 6.3.2. “Flexion
forces” for a properly tensioned drive.
Figure 6.3.1. Tension deflection method
EXAMPLE
V-belt section = Standard 8V belt
Span length (centre distance) 1575 mm (62”)
Deflection force (from table) = 15-22 Kg. (34-50 Lbs.)
Deflection = 1575 mm (62”) x 0.016 = 25 mm (1”)
Therefore, on a NEW installation with a standard 8V section belt and a span

length of 1575mm (62”), the belt should deflect 25 mm (1”) with a spring force of 15-22
Kg. (34-50 Lbs.) for a properly tensioned drive.
5. At the end of 2-4 hours of operation, the drive should be retensioned to
approximately the maximum force.
6. After 24-48 hours, it is well to check the drive to see if the force on the belts is
between the minimum and maximum force shown in table. Retension if necessary. Either
excessively low or high tension will affect the life and operation of a V-belt.
Rev. : 0

WHEN PROPERLY TENSIONED A NARROW V-BELT MAY NOT FEEL
AS TIGHT AS ONE MIGHT FROM THE TENSION THEY CARRY. THEREFORE, IT IS
AD VISABLE TO USE A SPRING SCALE TO CHECK BELT TENSION ON THESE
BELTS.
STANDARD BELT BANDED BELT*

Minimum Tension Maximum Tension Minimum Tension Maximum Tension
Belt section
Kg Kg Kg Kg
(in Lbs.) (in Lbs.) (in Lbs.) (in Lbs.)
8V 15.4 (34) 22.7 (50) 18.1 (40) 272 (60)
SPC 10.4 (23) 15.4 (34) 11.8(26) 18.1 (40)
*Multiply these values by number of belts in band.
Table 6.3.2. “Flexion forces”
For tensioning the drive using the PERCENT (%) OF ELONGATION method,
proceed as follows. This particular method of tensioning V-belt drives was developed
primarily for tensioning banded belts.
1. Remove the slack from the belts.
2. Next, wrap a 15 meters (50 foot) steel tape around the outside circumference
of the belt and measure to nearest millimetre (1/16”). Record this length. See Figure 6.3.3.
“Percent of elongation method”.
Figure 6.3.3. Percent of elongation method
Rev. : 0
3. Multiply this recorded length by a percent of elongation factor which is shown

in table 6.3.4. “ Elongation factors” and add this amount to the initial measurement.
4. Elongate the belt to this new reading.
EXAMPLE
V-belt section = Standard 8V belt
Initial tape reading = 3 meters, 48 mm (120”)
Elongation factor (from table) = 0.009 (multiplier) which is 0.9% (percent)
New length reading = 3 meters, 48 mm (120”) initial reading x 0.009

elongation factor =
3 meters, 48mm (120”) + 27mm (1-1/16”) or 3 meters, 75mm (121-

1/16”).
Belt Multiplier Percent (%)

Section*
8V 0.009 0.9
*Standard or banded belts
Table 6.3.4. Elongation factors
Therefore, on an installation with an 8V belt and an outside circumference

measurement of 3 meters, 48 mm (120”), the motor pulley should be moved away from the
crusher pulley until the steel tape reads 3 meters, 75 mm(121-1/ 16”) for a properly
tensioned drive.
5. Periodic belt tension checks must be made and if retensioning becomes

necessary, the tensioning process just described should be repeated.
It must be pointed out that the TENSION-DEFLECTION METHOD is the preferred

method of tensioning V-belts.
Usually the first sign that indicates retensioning is necessary is belt slippage. This
slippage will show up in loss of power and speed at the crusher pulley and in a high rate of
belt and pulley groove wear. These conditions are usually accompanied by belt “squeal” and
also a heating up of belts and pulleys. These conditions are readily apparent and can be
detected by simply looking, listening and feeling.
7.SPARE PARTS (TBK80-00-00-00.B)
Rev. : 0
MAIN ASSEMBLY
Rev. : 0
Ø850 TBK80-00-00-00.B
NO DRAWING NO PART NAME QUA.

1 TBK80-01-00-00.D HOUSING COMPLETE 1
2 TBK80-02-00-00 ROTOR COMPLETE 1
3 TBK80-03-00-00 CASCAD FEEDING GROUP 1
4 TBK80-04-00-00 MAIN FRAME COMPLETE 1
5 TBK80-05-00-00.A BOTTOM FRAME COMPLETE 1
6 TBK80-06-00-00 UPPER FRAME 1
7 TBK80-07-00-00 MOTOR CARRYING GROUP 2
8 TBK80-08-00-00 CRUSHER CHASSIS 1
9 TBK80-09-00-00 DISCHARGE CHUTE 1
10 TBK80-10-00-00 PLATFORM COMPLETE 1
11 TE4-1240-000-11 RUBBER BLOCK 4
12 SPC22x4750 V-BELT 12
13 HEXAGON BOLT 32
14 HEXAGON NUT 32
15 WASHER 64
16 HEXAGON BOLT 48
17 HEXAGON NUT 48
18 WASHER 48
19 SPRING WASHER 48
Rev. : 0
HOUSING COMPLETE (TBK80-01-00-00.B)
Rev. : 0
TBK80-01-00-00.B

1 TBK80-01-01-00-00.D SHAFT 1
2 TBK80-01-02-00-00.A OIL PAN 1
3 TBK80-01-03-00-00.A LABYRINTH-A 1
4 TBK80-01-04-00-00.A LABYRINTH-B 1
5 TBK80-01-05-00.A LABYRINTH-C 1
6 TBK80-01-06-00.A LABYRINTH-D 1
7 TBK80-01-07-00.A LABYRINTH-E 1
8 TBK80-01-08-00.A BEARING BARREL 1
9 TBK80-01-09-00.A TEFLON DISC 1
10 TBK80-01-10-00-00 LOCKING MEMBER 1
11 TBK80-01-11-00-00 PROTECTIVE OUTER BARREL 1
12 TBK80-01-12-00-00 OUTER DISTANCE RING 2
13 TBK80-01-13-00-00 INNER DISTANCE RING 1
14 TBK80-01-14-00-00 LOCKING RING 1
15 TBK80-01-15-00-00 SPECIAL LOCKING RING 1
16 TBK80-07-01-00-00.A PULLEY 1
17 TBK80-07-02-00-00.A CLAMPING CORE 1
18 TBK80-07-05-00-00.A WASHER 1
19 LOCKING NUT 1
20 LOCKING WASHER 1
21 BEARING 2
22 BEARING 1
23 V-RING 1
24 V-RING 1
25 V-RING 1
26 O-RING 1
27 O-RING 1
28 CYLINDIRICAL PIN 1
29 WEDGE 1
30 WEDGE 1
31 WEDGE 1
32 RECORD 3
33 CYLINDIRICAL SCREW 1
35 HEXAGON BOLT 16
36 HEXAGON BOLT 15
37 HEXAGON BOLT 1
38 HEXAGON BOLT 16
39 HEXAGON BOLT 16
40 SPRING WASHER 31
41 WASHER 32
Rev. : 0
ROTOR COMPLETE (TBK80-02-00-00)
Rev. : 0
TBK80-02-00-00
1 TBK80-02-01-00 ROTOR FRAME 1
2 TBK80-02-02-00 FEED TUBE RING 1
3 TBK80-02-03-00 UPPER PLATE 3
4 TBK80-02-04-00 BOTTOM PLATE 3
5 TBK80-02-05-00 DISTRIBUTING DISC 1
6 TBK70-08-03-00 CONNECTING FLANGE 1
7 TBK70-08-04-00 CLAMPING CORE 1
8 TBK70-08-05-00 FLANGE 1
9 TBK70-08-07-00 PLATE CONNECTING MEMBER 6
10 TBK70-08-08-00 IMPACT PLATE 3
11 TBK70-08-09-00 SUPPORT 3
12 HEXAGON BOLT 12
13 HEXAGON BOLT 8
14 HEXAGON BOLT 1
15 WASHER 1
17 HEXAGON NUT 12
18 WASHER 6
19 HEXAGON BOLT 6
20 HEXAGON NUT 6
21 WASHER 6
Rev. : 0
CASCADE FEEDING GROUP (TBK80-03-00-00)
TBK80-03-00-00
1 CARRYING SUPPORT 3
2 CHUTE 1
3 CHUTE 1
4 LOCKING PLATE 1
5 TBK80-03-02-00 FEED TUBE HOLDER 1
6 TBK80-03-01-00 FEED TUBE 1
7 LOCKING KEY 1
8 CHAIN 1
9 HEXAGON BOLT 3
10 TBK80-03-03-00 PROTECTIVE CIRCLE 1
Rev. : 0
MAIN FRAME COMPLETE (TBK80-04-00-00)
TBK80-04-00-00
1 COVER HOLDER 12
2 CLOSURE 1
3 TBK80-04-01-00 COVER 1
Rev. : 0
BOTTOM FRAME COMPLETE (TBK80-05-00-00.A)
TBK80-05-00-00.A

1 TBK70-03-01-00 ABRASION PARTICLE 4
2 TBK80-05-01-00 COVER 2
3 HEXAGON BOLT 4
4 HEXAGON NUT 4
5 SPRING WASHER 4
6 HEXAGON BOLT 4
Rev. : 0
UPPER FRAME
(TBK80-06-00-00)
Rev. : 0
TBK80-06-00-00

1 CIRCLE 1
2 DISC 1
3 SUPPORT 2
4 COVER CYLINDER 1
5 ADJUSTMENT PLATE 1+1+1
6 HEXAGON BOLT 2
7 HEXAGON NUT 2
8 SPRING WASHER 2
9 HEXAGON BOLT 3
10 HEXAGON NUT 3
11 WASHER 3
12 HEXAGON BOLT 10
13 HEXAGON NUT 10
14 SPRING WASHER 10
Rev. : 0
MOTOR CARRYING GROUP (TBK80-07-00-00)
TBK80-07-00-00
1 TBK80-07-01-00 PULLEY 1
2 TBK80-07-02-00 CLAMPING CORE 1
3 TBK80-07-03-00 MOTOR GUARD 1
4 TBK80-07-04-00 MOTOR CHASSIS 1
5 TBK80-07-05-00 WASHER 1
6 TBK70-04-01-00 MOTOR ADJUSTMENT SYSTEM 2
7 MOTOR 1
8 CHAIN 2
9 COVER 2
10 HEXAGON BOLT 8
11 HEXAGON NUT 8
12 WASHER 8
13 HEXAGON BOLT 8
14 WASHER 8
15 HEXAGON BOLT 8
16 PIN 2
17 CYLINDER HEAD BOLT 3
Rev. : 0
DISCHARGE CHUTE (TBK80-09-00-00)
TBK80-09-00-00

1 HEXAGON BOLT 12
2 HEXAGON NUT 12
3 WASHER 12
4 SPRING WASHER 12
5 COUNTERSUNK SLOTTED BOLT 48
6 HEXAGON BOLT 16
7 HEXAGON NUT 64
8 HEXAGON BOLT 16

TBK 80 (Ø850) Rock-On-Rock Vsi Crusher Operation and Maintenance Manual

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TBK 80(Ø850) ROCK-ON-ROCK VSI CRUSHER

OPERATION AND MAINTENANCE MANUAL

These Operating and Maintenance Instructions and Safety Regulations shall be

Additionally, start-up, operating and maintenance conditions (in accordance with

Furthermore, foreseeable wrong behaviour of personnel and the directions of the

1.2. COMMANDMENTS OF SAFETY

9. Hazardous and risky behaviour, dangerous conditions and processes, which

1.3. ADDITIONAL SAFETY REGULATIONS

In case of injuries to a person call for a doctor or other ambulance personnel at

All accident must be reported at once to the management.

Lift loads only out of the legs with stretched back.

Protect your eyes with safety glasses to avoid injuries

Always USE safety work-shoes and gloves to avoid injuries.

At night works, supply sufficient illumination for the

Unauthorised stay of persons within dangerous

Careful and detailed instruction and training of the operating,

1.4. ELECTRICAL EQUIPMENT

MTM-authorised personnel only are allowed to perform repair work at

Expert personnel of a licensed company only are allowed to work on

Carefully check whether the crusher has been earthed in accordance

In case of art EMERGENCY-OFF unbroken material may remain in the crusher,

1.6. MAINTENANCE AND SERVICING

Never use any other lubricants than those recommended by MTM.

Never mix up lubricants based on different substances (e.g. lithium-soaped

1.7. HAZARDOUS MATERIAL DISPOSAL

1.8. WELDING REPAIRS

1.9. HYDRAULIC EQUIPMENTS IN GENERAL

Do not handle or repair hydraulic equipment with dirty or oily hands.

Refill new hydraulic oil through undamaged filter only.

Damaged pipes, filters, hoses and so on must be replaced at once.

1.10.WARNING PAINT,LETTERING AND WARNING SIGNS

Illegible or defective nameplates and warning signs shall be replaced by identical

Be careful! Crushing and cutting injury may occur

Lift from this side

Dust Hazard Wear Mask

Careful Impact may occur

Wear eye and ear protection

Be Careful trained personnel only

Be Careful, Hard Hats must be worn

GENERAL DIMENSIONS OF THE CRUSHER

MOTOR RPM RANGE 2 x 110 Kw / 1500 rpm

MAX. CAPACITY 50-125

TOTAL WEIGHT 14000 kg

Rotor range is 1500-2500 rpm and rotor diameter is 790 mm.

2.1 BEFORE START-UP

2.2 INITIAL START-UP

2.3 INITIAL FEEDING OF CRUSHER

In normal operation there is intermittent detectable vibration about30% of time.

Normal Bearing Temperature

2.5 SHUT DOWN PROCEDURE

 Shut down feed device (conveyor or feeder) before the TBK.

Inspection and Servicing:

 GREASE BEARING CARTRIDGE

HIGH TEMPERATURE BEARING CARTRIDGE

4.1 CLEANING OUT ROTOR

4.2 ROTOR TIPS

Cracked or Chipped Inserts

Off Centre Wear

4.3 TIP CARRIER WEAR PLATES