BPB S ANGLAIS 1

STONE CRUSHER
TYPE
BPB 200 / 250
BPB-S-200/ 250
Year of manufacture:
CE Serial No.:
Manufacturer:
B. P. N° 2
47390 LAYRAC
Telephone: 0033+(0)5 53 87 00 02
Fax
: 0033+(0)5 53 87 10 02
Internet
: http://www.kirpy.com
Email
: [email protected]
MAINTENANCE MANUAL
CONTENTS
MAINTENANCE – USE
PAGE
CHAPTER
3
4
5
GENERAL
GUARANTIE CONDITIONS
CHARACTERISTICS
OPERATING CONDITIONS
6
OPERATING PRINCIPLE
7
OPERATING CONDITIONS
8
ADJUSTMENT
9 WARNINGS
SERVICING AND GREASING
10 HAMMERS
11 FREQUENCY OF SERVICING &
GREASING
12-13 GREASING POINTS
IMPORTANT
14 RECOMMENDATIONS
15 Operating of hydro pneumatic safety
device
SPARE PARTS
PAGE
CHAPTER
16
17-18
19
20
CONTENTS SPARE PARTS
DETAIL OF ROTOR BPB- BPB-S
DETAIL OF TOP TRANSMISSION
DETAIL OF ROTOR BEARING
TRANSMISSION of Machine
Tractor (WALTERSCHEID P500)
TRANSMISSION of Machine
Tractor (WALTERSCHEID P600)
DETACHABLE ANVIL
WEARING COUNTER-FLANGE
ELEMENTS DE GRAISSAGE DES
PALIERS
21
22
23
24
25
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26/04/2006
GENERAL INFORMATION ON THE OPERATING
CONDITIONS OF THE TYPE BPB- BPB-S CRUSHER
This crusher is characterised by a rotor with fixed hammers which operate by striking against an adjustable anvil whose distance from the rotor
is used as a basis for determining the desired granulometry.
The principle of the KIRPY fixed hammer rotor offers a number of advantages over the traditional range of crushers, particularly those listed
below:
-
Although the use of crushers is recommended in dry soil, the BPB crusher enables work to be carried out in good conditions in a slightly wet
soil. Nevertheless it must be remembered that the required power is higher in this case.
-
The BPB crusher has excellent crushing capacity and processes the raw excavation or quarry products according to the required granulometry.
-
Thanks to its inlet, which is 44 cm high, the BPB crusher operates down to a depth of 30/35 cm provided that the ground has been correctly
prepared.
-
The BPB crusher allows work to be carried out on thicker swaths, with more homogeneous crushing due to the adjustable anvil, and disperses
the crushed stones over a greater width by opening the rear hydraulic door to a greater or lesser degree.
The BPB crusher has a very robust structure and has been specially designed to work hard over a long period.
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GUARANTEE CONDITIONS
We guarantee the equipment sold against all material defects or design faults for a period of one year from the date of delivery.
This guarantee does not cover damage resulting from negligence, incorrect use of equipment subjected, for example, to abnormal stresses, or
due to the inexperience of the user.
It is invalidated if the operating or adjusting instructions supplied with the equipment are not followed.
It is limited to the pure and simple replacement of the defective part by ourselves, or to its repair at our convenience, in which case the parts
must be returned to our workshop without our contributing in any way to the labour costs incurred in disassembly and reassembly of the equipment.
By express agreement the guarantee is strictly limited to the replacement or repair of parts recognised to be defective, according to the above
conditions to the formal exclusion of all damages howsoever caused.
The following are excluded from the scope of the guarantee:
•
Parts which are not of the distributed brand, particularly mechanisms, devices and accessories bearing the brand name of their suppliers; the
latter bear the liability for their own products.
•
Equipment that has been transformed, modified, repaired or dismantled, even if only partially, outside the workshops of KIRPY, its dealer or
Agents of the latter.
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BPB- BPB-S TYPE STONE CRUSHER
CHARACTERISTICS
TYPE
BPB 200
BPB-S-200
BPB 250
BPB-S-250
A
B
C
E
F
G
H
No. of
Working Power
hammers length take-off
8
1825
1365
1350
65
825
550
12
2465
CLEARANCE
1.80 m
16
740
24
Rotor
speed
No. of
belts
2350 kg
1000 rpm
2.44 m
Weight
1120 rpm
Required
power
100/120 hp
2x6
3250 kg
130/140 hp
COUPLING
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HITCHING - OPERATING
3-POINT HITCH
Hitching STONE CRUSHERS on tractors is carried out in the same way as for any other 3-point hitch tool.
REQUIRED POWER:
For optimal working, tractor power required by the BPS150 is approximately between 120 and 130 cont. hp.
For optimal working, tractor power required by the BPS200 is approximately between 140 and 160 cont. hp.
For optimal working, tractor power required by the BPS250 is approximately between 160 and 200 cont. hp.
1 Excessive power associated with a forward working speed that is too high could cause crusher damage.
COUPLING THE DRIVE TO THE MACHINE
Before putting the drive into service, make sure the length of the sliding parts (male and female) is correct. In
maximum extension position (tool raised) the inserted part should not be less than 200 mm and in minimum
extension position (tool in working position) the sliding parts should not be hard against each other.
TO CHECK THAT LENGTHS ARE CORRECT PROCEED AS FOLLOWS:
Each final drive shaft is fixed to its appropriate splined end but the two drive shafts are not inserted into each other
(see diagram left). While holding the two final drive shafts side by side, vary the length as much as possible (max
and min extension), i.e.: in practice, top position - tool raised, and bottom position – tool working, with lateral play of
the tractor’s lower lift in both cases. You can then check that in minimum extension position the sliding parties will
not be hard against each other and in maximum position insertion length will be at least 200 mm.
When the two final drive shafts are mounted on the splined ends, you must make sure the universal drive head fastlocking lugs are well inserted into the circular grooves of the splined ends. Only use the hammer to insert the final
drive shafts onto the splined ends in exceptional cases. If it does become necessary, never strike directly on the crosspin bearing or on the clamp lugs but only on the base of the body (see diagram left).
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26/04/2006
N.B.: Final drive shaft at machine end is: 1” 3/4 (Ø44.45) 6-groove female spline.
Final drive shaft at tractor end is: 1” 3/8 (Ø34.92) 6-groove male.
WARNING:
When coupling the drive make sure joint angles are as slight as possible. The greater the angle, the greater the wear. Angles must not under
any circumstances exceed approximately 10°C to avoid the risk of vibration that could result in deterioration of tractor or machine mechanisms
(diagram below).
Perfect assembly
Acceptable assembly
Assembly to be eliminated
Optimal coupling:
The entire drive is parallel to the ground.
Splined ends are in the same axis.
No stress for drive components.
Acceptable coupling:
The drive coupling angle is 10°C or less
Drive unit stress increases with the angle in such a way that the service life of universal joints could be halved when the angle is
approximately 10°.
Coupling to be avoided:
The drive connection angle is too great.
Splined ends are too much out of line and are not parallel.
Dangerous for: the drive, the power take-off shaft and the machine’s angle transmission
Careful of vibrations.
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26/04/2006
OPERATING PRINCIPLE
Made up of disks and rectangular troughs in which the hammers are fixed and revolve at 1,000 rpm, is the heavy, extremely tough, horizontal
rotor.
The hammers of high circumferential speed pound any material (stone, wood, etc.) with great force to crumble it and to send it against an
anvil crushing it by impact.
The rear hydraulic door enables easy access to hammers (crusher at standstill and tractor engine stopped). When operating it can be left
slightly open to improve the spread of crushed material with the crusher’s run. The door must never be fully open during crushing under any
circumstances to prevent material being projected to great distances threatening people and objects in the vicinity.
Clearance between the hammers and anvil can be adjusted hydraulically to obtain the required size grading (between 15 and 40).
OPERATING CONDITIONS
To obtain the best results, the machine should be used on dry ground.
Forward working speeds are variable and take account of:
• the density of stones on the ground,
• their hardness,
• the power of the tractor being used,
• the required grading of crushed stones.
Generally speaking, the tractor’s forward working speed must not exceed 1 km/hr for surface working. A slower working speed (0.5 / 0.6
km/hr) should be used for depth working.
ADJUSTMENT
The BPS crusher requires no special preliminary adjustment. The working depth is adjusted by the tractor’s power lift.
It is recommended to work with the rear door lowered or slightly open to avoid rearward projection of stones.
Driver protection from stone projection is provided by a double chain curtain located in front of the crushers.
The hydraulic anvil is raised into maximum opening position. Closure, controlled directly from the tractor, enables finer grading.
The greater the working depth and the greater the degree of anvil closure, the greater is the power required by the tractor!
Before starting and during crusher work, the operator must make sure there is no-one nearby.
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WARNINGS
1
1
1
1
Before starting and during crusher work, the operator must make sure there is no-one
nearby.
Before any servicing or maintenance work, the crusher should be set on the ground
and the tractor engine stopped if the machine is hitched.
The rear door must be closed before the rotor is rotated and during crushing.
It is dangerous to walk around the machine when it is working or to stand
behind it, even several meters, because the accidental projection of stones
could cause serious injury.
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26/04/2006
HAMMERS
To gain access to the hammers, simply raise the breaker plate and the flap to the maximum.
Bodies with hammers are made of carbide steel. The carbide hammers cannot be built up. They must be changed when used.
For the built up bodies, regular building up is recommended rather than waiting too long and having a large thickness of build up to be
applied.
To change the carbide hammers:
- unscrew the carbide hammer holding body bolt
- on the body unscrew the two screws which hold the carbide hammer
- fit a new carbide hammer
- tighten the two screws which hold the new carbide hammer
- refit the holding body with hammer in its housing on the rotor
- tighten the carbide hammer holding body bolt.
Checking the tightness is recommended after half an hour of operation.
Make sure the hammer support housings are clean when reassembling.
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FREQUENCY OF SERVICING AND GREASING
Servicing of mechanical parts and regular greasing are indispensable to obtain maximum durability and serviceability from your crusher. Special care must
be taken with greasing, particularly by wiping the grease nipples, making sure they are clean before applying the grease pump, to prevent dust being
introduced into critical points of your machine.
Every day:
Check nuts and bolts.
Check hammer wear.
Grease the drive from the tractor to the machine.
Grease the top drive.
Clean the belt compartments and the angle transmission box supporting slides.
Every 4 hours:
Grease the rotor bearings and the top drive bearings.
Every 40 hours:
Check the oil level of the angle transmission box.
Grease the shafts of the rear door.
Check the belt tension springs.
On leaving the factory, the angle transmission gearbox oil level is made good with UNIL OPAL GEAR EP 85 W 140 .
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26/04/2006
GREASING POINTS:
1) Right and left bearing greasing nipples of the rotor with their flexible tube:
The rotor bearings should be greased every 4 hours with 3 or 4 strokes of the pump with a quality bearing grease.
2) Greasing nipples of bearings of tension device:
Greasing of bearings of tension devices is achieved in exactly the same way as for the rotor bearings.
3) Greasing nipples of the double joint or of the top drive depending on crusher model.
The two greasing nipples of the double joint and those of the top drive must be greased without fail every day.
4) Rear door shaft greasing nipple.
Rear door greasing nipples should be greased every 40 hours.
5) Angle transmission box:
Every 40 hours, check the oil level in the angle transmission box and top up to the level cap located under the driving shaft axis if necessary. On leaving the
factory, the angle transmission gearbox oil level is made good with UNIL OPAL GEAR EP 85 W 140 . At a certain temperature, a slight output of oil
emulsion from the filler cap breather can be expected. The quantity of oil required by the angle transmission box is : 2.3 liters for BPS 150
3.6 liters for BPS 200
5.7 liters for BPS 250
Reniflard
Bouchon de jauge
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26/04/2006
6) The drive from the tractor to the machine:
Grease the points shown on the diagram below every day.
PUTTING BACK INTO SERVICE
When equipment has been out of service, you must:
- Carry out a routine inspection.
- Carry out full greasing.
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26/04/2006
IMPORTANT RECOMMENDATIONS
REPLACEMENT OF WEIGHTS
The weights fixed to the rotor wear to varying degrees according to the density and percentage of silicon contained in the stone. Do not
forget to replace the weights when necessary to prevent wearing of the rotor.
LUBRICATION OF THE BEARINGS OF THE BPB TYPE STONE CRUSHERS
For lubricating the rotor and transmission bearings of the crusher we recommend the use of complex lithium greases, which have excellent
temperature resistance and are suitable for heavy loads and high speeds of rotation, of the type:
- UNIL OPAL THERMOPLEX 2 – FUCHS RENOLIT LXC2 – SKF LGEP2
(First line greases used).
- Or corresponding greases of another make.
IMPORTANT ! !
For some months we have been aware of intense advertising by the lubricant suppliers for molybdenum bisulphite and graphite greases.
We wish to inform all our customers, and more particularly users of stone crushers, that:
MOLYBDENUM BISULPHIDE GREASES ARE NOT SUITABLE FOR LUBRICATING BEARINGS ON OUR MACHINES AND
COULD RESULT IN THEIR DAMAGE (In this case damaged parts will not be replaced under the guarantee).
The products containing molybdenum bisulphide are products that are recommended for high loads but only for low speeds of rotation or
oscillations.
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26/04/2006
OPERATING OF HYDROPNEUMATIC SAFETY DEVICE
(IF USED)
Connect hydraulic hoses 1 and 2 to a double acting distributor of
the tractor.
Open the valve ref. 3 (handle into alignment of the pipes).
Adjust position of the anvil at work according to desired
granulometry.
After adjustment, close the hydraulic valve and raise the pressure to
40 bars on the gauge by actuating the distributor.
To modify adjustment of the anvil again, it will be necessary to
reopen the hydraulic valve.
1
3
2
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BPB & BPB-S SPARE PARTS
TABLE OF CONTENTS
SPARE PARTS
PAGE
16
17-18
19
20
21
22
23
24
25
CHAPTER
CONTENTS SPARE PARTS
DETAIL OF ROTOR BPB- BPB-S
DETAIL OF TOP TRANSMISSION
DETAIL OF ROTOR BEARING
TRANSMISSION of Machine Tractor
(WALTERSCHEID P500)
TRANSMISSION of Machine Tractor
(WALTERSCHEID P600)
DETACHABLE ANVIL
WEARING COUNTER-FLANGE
ELEMENTS DE GRAISSAGE DES PALIERS
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26/04/2006
ROTOR COMPLET DE BPB
01 093 071 MARTEAU CARBURE DE BPB
04 109 010
04 109 014
REP. REFERENCE
1
03 035 013
1
03 035 014
2
02 025 002
3
02 093 070
4
01 127 849
5
01 127 674
6
01 127 099
17
ROTOR CPLT BPB 200 MARTEAUX JETABLES
ROTOR CPLT BPB 250 MARTEAUX JETABLES
DESIGNATION
ROTOR NU DE BPB 200
ROTOR NU DE BPB 250
MASSE DE FIXATION MARTEAU BPB
Marteau mangano 80x60 de BPB
corps de boulon H-M 33x280 special BPB
ECROU HH 33 PAS 200 CL 10
VIS CHC 16 - 120 CL 12.9
1
1
NB. NB.
1
1
8
12
8
12
8
12
8
12
16 24
26/04/2006
ROTOR COMPLET DE BPB-S
02 093 063 MARTEAU CARBURE DE BPS
04 109 046
04 109 047
REP. REFERENCE
1
03 035 064
1
03 035 065
2
01 127 009
3
01 027 021
4
02 042 022
5
01 127 021
6
01 127 746
7
02 093 007
8
02 019 004
9
01 127 328
10
01 127 178
18
ROTOR CPLT BPB-S-200 MARTEAUX JETABLES
1
ROTOR CPLT BPB-S-250 MARTEAUX JETABLES
DESIGNATION
ROTOR NU DE BPB-S-200
ROTOR NU DE BPB-S-250
GOUJON M 18 LG 100 - 30 - 30 cl.12 filet roulé
PLAQUE DE CHOC LG 202 SUR BPBS
GLISSIERE LG 202 SUR ROTOR BPBS
Corps de boulon H M10x50
écrou frein M10
MARTEAU USINE DE BPB-S
BRIDE LG 202 SUR ROTOR BPBS
ECROU M 18 FREINE DIN 980/10 Classe 10 ZN
Vis HM 20x40 cl 8.8
1
NB. NB.
1
16
8
8
8
8
16
8
16
8
1
24
12
12
12
12
24
12
24
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26/04/2006
DETAIL TRANSMISSION SUPERIEURE BPB
05 109 017
05 109 018
REP. REFERENCE
04 100 003
1
04 100 003
2
01 126 451
3
01 127 077
4
01 126 060
5
01 127 751
02 035 015
6
02 035 016
7
01 127 752
8
01 101 005
9
01 095 005
10
01 112 005
11
01 121 009
ENSEMBLE TRANSMISSION COMPLET BPB 200
ENSEMBLE TRANSMISSION COMPLET BPB 250
DESIGNATION
BERCEAU TRANS SUP BPB 200
BERCEAU TRANS SUP BPB 200
RENVOI BDLI RA 2155
VIS FHC 90 16 X 30 CL 10.9
JOINT SIMPLE W 2600 1"3/4 Z6 Ø 45
CLAVETTE PARAL BOUT ROND 14X9X63
ARBRE TRANSMISSION SUPERIEUR BPB 200
ARBRE TRANSMISSION SUPERIEUR BPB 250
CLAVETTE PARAL BOUT ROND 14X9X100
PALIER APPLIQUE UKFS 311
MANCHON CONIQUE H 2311 X
BOUCHON DE POULIE 3535 Ø 50 LOCK
CORPS DE POULIE 6 SPB 280 3535 LOCK
1
1
NB. NB.
1
1
1
1
4
4
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
19
REP. REFERENCE DESIGNATION
12
01 127 247 rondelle plate M20
13
01 127 734 corps de boulon H M20x100
14
03 053 002 TENDEUR DE COURROIES DE BPB
15
01 127 815 écrou frein M20
16
02 008 005 RONDELLE BLOCAGE TRANS SUP BPB
17
01 127 179 VIS HM 20-50 CL 8.8
18
01 127 773 vis H M14x25
19
02 061 004 GRILLE DE PROTECTION SUR RENVOI BPB
20
01 127 722 VIS HM 16-35 CL 8.8
21
01 127 240 rondelle plate M16
22
01 127 819 vis H M10x16
23
01 127 606 rondelle plate M 10
24
02 096 057 BOL PROTECT 4 M 8 SUR Ø105
NB. NB.
5
5
8
8
4
4
4
4
4
4
4
4
2
2
1
1
4
4
4
4
4
4
4
4
1
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26/04/2006
DETAIL PALIER DE ROTOR BPB
REP REFERENCE DESIGNATION
1
03 109 016 PALIER DE ROTOR BPB (comprenant les pcs 2-3-4-5)
2
01 095 004
MANCHON CONIQUE H 2320 X
NB.
1
1
20
REP REFERENCE DESIGNATION
6
02 008 003 RONDELLE FIXATION PALIER ROTOR BPB
7
01 127 193 CORPS DE BOULON HM 20-60 CL 8.8
8
01 127 823 CLAVETTE PARALLELE BOUT ROND 25 X 14 X 90
9
01 121 010 CORPS DE POULIE 6 SPB 250 3535 LOCK
10
01 112 002 bouchon de poulie 3535 Ø90 lock
11
01 126 069 courroie H F X 2000 XPC
NB.
4
4
1
1
1
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26/04/2006
TRANSMISSION TRACTEUR MACHINE (WALTERSCHEID modèle P500)
Plan de
référence
BPB 200
BPB-S 200
01 109 051 Transmission tracteur machine 1’’3/8 Z6 Mdle P500
Coté tracteur
Rep.
Référence
1
2
3
4
5
6
7
01 126 088
01 084 076
01 064 067
n.r.
n.r.
n.r.
01 016 001
Coté machine
Désignation
½ trans. mâle 1’’3/8 Z6
Mâchoire ext. 1’’3/8 Z6 (36.10.00)
Croisillon Ø36 Lg=89 (36.00.03)
Mâchoire pour tube int.
Goupille
Tube intérieur
Verrou machine 1’’3/8 Z6 (33.91.07)
Rep.
Référence
Désignation
8
9
10
11
12
13
14
01 126 089
01 084 078
01 064 067
n.r.
n.r.
n.r.
01 016 002
½ trans. femelle 1’’3/4 Z6
Mâchoire ext. 1’’3/4 Z6 (36.18.00)
Croisillon Ø36 Lg=89 (36.00.03)
Mâchoire pour tube ext.
Goupille
Tube extérieur
Verrou machine 1’’3/4 Z6 (33.93.02)
NOTA : Il est interdit de monter le dispositif de sécurité coté tracteur
(décret 86-594 Art.5 du 14 mars 86).
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26/04/2006
TRANSMSISSION TRACTEUR MACHINE (WALTERSCHEID P 600)
Plan de
référence
BPB 250
BPB-S 250
01 109 053 Transmission tracteur machine 1’’3/8 Z6 Mdle P600
Coté tracteur
Rep.
Référence
1
2
3
4
5
6
7
01 126 092
01 084 091
01 064 010
n.r.
n.r.
n.r.
01 016 001
Désignation
Coté machine
Rep.
Référence
8
9
10
11
12
13
14
01 126 154
01 084 093
01 064 010
n.r.
n.r.
n.r.
01 016 002
½ trans. mâle 1’’3/8 Z6
Mâchoire ext. 1’’3/8 Z6 (26.10.00)
Croisillon Ø42 Lg=104 (26.00.03)
Mâchoire pour tube int.
Goupille
Tube intérieur
Verrou machine 1’’3/8 Z6 (33.91.07)
Désignation
½ trans. femelle 1’’3/4 Z 6
Mâchoire ext. 1’’3/4 Z 6 (26.84.104)
Croisillon Ø42 Lg=104 (26.00.03)
Mâchoire pour tube ext.
Goupille
Tube extérieur
Verrou machine 1’’3/4 Z 6 (33.93.02)
NOTA : Il est interdit de monter le dispositif de sécurité coté tracteur
(décret 86-594 Art.5 du 14 mars 86).
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26/04/2006
DETACHABLE ANVIL
REP. REFERENCE DESIGNATION
1
01 127 335 Corps de boulon HM 24x150 cl 8-8
2
02 027 012 ENCLUME AMOVIBLE DE BPB
04 126 489 ENCLUME DE BPB 200
3
04 126 490 ENCLUME DE BPB 250
23
NB. NB.
8 12
4
6
1
1
26/04/2006
WEARING COUNTER-FLANGE
REP. REFERENCE DESIGNATION
4
02 089 015 CONTREPATIN USURE BPB
5
01 127 748 écrou frein M16
6
01 127 082 VIS FHC 90 16 X 60 CL 10.9
DEFLECTEUR INTERIEUR
NB.
2
8
8
24
REP. REFERENCE DESIGNATION
NB.
5
01 127 748 écrou frein M16
8
6
01 127 082 VIS FHC 90 16 X 60 CL 10.9
8
7
02 104 009 DEFLECTEUR DROIT VISSE SUR MONTANT BPB
1
8
01 127 077 VIS FHC 90 16 X 30 CL 10.9
2
02 104 010 DEFLECTEUR GAUCHE VISSE SUR MONTANT BPB
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26/04/2006
ELEMENTS DE GRAISSAGE DES PALIERS
REP. REFERENCE DESIGNATION
1
01 126 031 Flexible de graissage 100 R7 3.16 lg 450
2
01 126 030 Flexible de graissage lg 300
3
01 127 587 graisseur hydraulique droit M8x125
4
02 018 118 vis H M14x25 usinée pour graissage
5
01 127 525 Ecrou H M14
25
NB.
2
2
4
4
4
26/04/2006
RC AGEN 026 320 028 00017
APE 293 D
BP N° 2 47390
LAYRAC
Tel: 0033+(0)5 53 87 00 02
Fax: 0033+(0)5 53 87 10 02
http://www.kirpy.com
[email protected]
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