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Pedestal Operation and Service

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1. the pedestal to keep dust out until the pedestal is installed back in the crusher INSTALL THE SHEAVE 1 Install the bushing key into the keyway in the shaft 2 Slide the bushing onto the shaft Align it with the mark or measurement you made during the COM PLETE PEDESTAL DISASSEMBLY Lock the bushing onto the shaft key with the set screw Lip 7 A F f p F A k S j L A en ki 4 Es 3 Place the sheave over the bushing Finger tighten the bolts which hold the sheave to the bushing Al chined lip with a wire brush and solvent Clean the bolts with solvent as well Air dry both the holes and the bolts r ia e Taig B a s al 1 a 7 p o L _ ey ds ro a A a pk Ti M i a 2 p p i Aa rs oe 4 i F 2 t i 7 Pa af i l p IN E 3 T E a 7 p iy P J J u ince ternately tighten the bolts in a pattern until they Clean holes in pedestal plate reach the torque specified in the table below Sheave Torque Table Size amp Ft Lbs Tapered Thread of To Apply With Bushing Cap Screw Torque Wrench No 10 42 1 4 20 5 16 3 8 1 2 9 16 5 8 3 4 78 Me E 7 1 1 4 7 Lift the rebuilt pedestal with a lifting eye and lower it into the crusher Be extremely careful Have a person help guide the sheave through the hole in the tub bottom Realign oil amp grease lines Lower rebuilt pedestal int
2. in the crusher A strap or chain arrangement should 73 PEDESTAL OVERHAUL a es be used as a Safety to catch the sheave and bushing 2 Clean out the oil and grease passages first with sol in the event they should unexpectedly slip off the shaft 1 Measure the bushing distance from the end of the pedestal shaft You will need this measurement when reinstalling the sheave bushing 2 Remove the sheave Refer to Sheave Replace ment section 3 Remove the sheave bushing 4 Tap the key out of the shaft keyway 5 Orient the pedestal assembly upside down in the work area for disassembly 6 Remove the lower seal plate cap screws and use lifting eyes if needed to remove the seal plate from the pedestal housing 7 Remove the lower oil seal and O ring from the seal plate 8 Inspect the seal plate and pedestal mating surfaces for damage 9 Remove the lower bearing shaft lock nuts and lockwasher Same procedure as 2 in Hub Removal 10 Orient the pedestal upside down in a hydraulic press and push the main shaft out of the hous ing Frequently the upper bearing will come out with the shaft If the bearing remains in the hous ing go ahead and remove the shaft and use a bearing block or heat to remove the bearing from the housing 11 Ifthe upper bearing is still attached to the shaft remove it using heat or a hydraulic press 12 The lower bearing should easily separate from the pedestal housing If i
3. where the plates meet 5 Inspect the shaft where the upper dust and grease seal and oil seal rubber gaskets make contact A groove in the shaft indicates lack of oil or grease If this groove is deeper than 004 the shaft needs to be repaired or replaced F y WEAR i GROOVES Grooves in shaft caused by seals PEDESTAL REMOVAL If the pedestal needs rebuilding it must be removed from the crusher now Otherwise follow the PEDES TAL ASSEMBLY procedure to install the upper seal plate with new seals 1 Clean or wash the pedestal sheave Remove ped estal shroud and remove material from the pedestal bottom Make sure the sheave bolt hole threads are clean 2 Remove the oil and grease lines from the pedestal underside Seal the loose hose ends to keep dirt out Oil and grease connections at pedestal 3 Remove the bolts which secure the pedestal to the crusher channel 4 Install a lifting eyebolt in the end of pedestal shaft and lift the assembly including the drive sheave out of the crusher 5 Wash the pedestal assembly to remove dirt and for eign material from the sides or seal plates 6 Bolt the pedestal assembly to a frame or table for further disassembly COMPLETE PEDESTAL DISASSEMBLY While all crusher drivetrains are unique in some cases the crusher may have a larger diameter sheave than the hole in the crusher Be extremely care ful when removing the sheave especially if the pedes tal is
4. 12 Taper d Shaft Sleeve over incl min max min max To find bearing bore mm on this chart take last two digits from the lower bearing part number and multiply them by 5 Example A Turbo 35 pedestal lower bearing is BRG 22314K 14x 5 70mm Nominal bearing bore mm for 70mm is between 65mm over and SOmm incl 76 a es n From this example the Radial Internal Clearance before mounting is 0037min 0047max Use along blade feeler gauge set to get the actual measurement of Radial Inter nal Clearance across both bearings Once the actual mea surement is recorded subtract the Reduction Radial In ternal Clearance min amp max to get a range of clear ance Example Actual measurement from feeler gauge is 0040mm 0040mm 00 16mm max 0024mm how loose 0040mm 0020mm max 0020mm how tight INSTALL UPPER SEAL S AND SEAL PLATE A grease seal and O ring are installed in the upper seal plate The grease seal provides a seal between the seal plate and shaft The O ring provides the seal between the seal plate and the pedestal housing Larger crush ers also have a dust seal which installs on top of the grease seal V DUST SEAL GREASE SEAL SHAFT TOP O RING SEAL Ny PLATE Large crusher top seal plate arrangement 1 Some recent model crushers have 2 set screws in the seal plate to separate it from the pedestal and facilitate removal If your crusher has these screws adjust them so th
5. PEDESTAL OVERHAUL INTRODUCTION A properly greased labyrinth seal will help prevent dust and water damage to the pedestal bearing oil supply and shaft seal area Properly greased and oiled pedestals rarely require an overhaul Oil seep ing out from the upper or lower seals or sideways shaft movement may be an indication that the ped estal needs a partial or complete overhaul b ae Sideways shaft movement If it is determined the pedestal needs a complete rebuild it should be removed from the crusher to a clean work area Refer to the parts manual for spe cific part identification Never replace only one bear ing and never reuse a seal or O ring Some assem bly steps require heating the bearings or pedestal housing to allow for part assembly with an interfer ence fit Heated parts need sufficient time to cool so they do not separate during subsequent assembly steps and before checking bearing tolerances RIC Seal plate removal can be done by hand on a small pedestal Use lifting eyes and a hoist to remove the seal plates on large pedestals Refer to the BELT MAINTENANCE AND RE PLACEMENT and SHEAVE REPLACEMENT sections where appropriate Some knowledge of bearing clearances is needed to properly diagnose and rebuild a pedestal Specifi cally the Radial Internal Clearance or RIC must be measured and compared to tabulated values The RIC and its measurements are standardized in the 041601 a a S S bearin
6. e ends do not stick out beyond the seal plate sur face 2 Orient the rubber lip so it will face downward when installed and press the grease seal into the seal plate If necessary gently tap the seal in place with a mallet and wood block SEMET PEDESTAL OVERHAUL S l _ Standard bottom seal plate arrangement 3 If your pedestal uses a dust seal orient the rubber lip upward when installed and press the dust seal into i the seal plate If necessary gently tap the seal in place aai aki GREASE SEAL with a mallet and wood block i i BOTTOM DUST SEAL 4 Smear a small amount of grease into the groove in SEAL PLATE the underside of the seal plate Press the large O ring into this groove The grease will hold it in place Bottom seal plate with a dust seal installed 5 Replace the O rings that fit over the alignment tubes l 1 Orient the rubber lip towards the lower bearing in the top of the pedestal housing and press the seal into the lower seal plate If 6 Lubricate the rubber lips on the seals with assembly necessary gently tap the seal in place with a grease Align the oil and grease openings in the mallet and wood block The Turbo 54 and Turbo seal plate over the alignment tubes in the pedestal 70 pedestals also have a dust seal which installs housing Some pedestal assemblies have a seal plate on top of the grease seal The installation of the alignment dowel pin Gently slide the seal plate with second s
7. ead one of the lower bearing shaft lock nuts with the flat side facing the bearing on the shaft This will prevent the bearing from slipping off the shaft At this point the entire pedestal assembly needs to cool down completely overnight would 2 Screw a lifting eyebolt into the top of the shaft Lower the shaft into the bearing Using some WD AO or other lubricant can help with inserting the haft may be best Once the pedestal has cooled tighten the A table with a hole in it works well for this proce nut and check the tapered bore bearing RIC As dure Allow the assembly to cool the nut is tightened the RIC decreases due to the 3 First heat the entire pedestal evenly then heat the ee pan On ORME a pedestal region which surrounds the upper bearing Do not overtighten If you exceed the bore until the inside diameter just exceeds the Maxi minimum RIC disassemble the pedestal and mum Upper Bore dimension given in the preced start over ene Vane 9 Install the lockwasher with the concave side away 4 Suspend the shaft and bearing above the upright from the pedestal housing The inner tooth slides pedestal Lubricate the outside of the bearing with in the slot machined into shaft threads WD 40 imilar lubricant DE a ee 10 Thread on the remaining large lock nut with the 5 Lower the shaft upper bearing assembly into the flat side away from the pedestal housing Manu bore Seat the bearing in the bore by tapping it ally tight
8. eal is similar to the Upper Seal Plate seals installed over the shaft Position it on top of seal installation the pedestal housing in line with the dowel pin 2 Smear grease into the groove in the underside of the seal plate Press the large O ring into this groove The grease will hold it in place F t EE h Xe 3 Replace the O rings that fit over the alignment rf Ts a u tubes in the bottom of the pedestal housing 1f A i Pi A N needed r Ae i hE ai B J 4 Lubricate the rubber lip on the seal with assem a D _ d bly grease and slide the seal plate with the seal installed over the shaft Avoid the keyway in 39 b the shaft which could cut the rubber seal Gen ama Cl a tly position the seal plat the pedestal hous gie Wee _ yp plate on the pedestal hous Fo te E ij Bi ing and align the mounting holes Pa O Aligned oil and grease openings and alignment dowel in the upper seal plate 8 Install the seal plate bolts Tighten the bolts in a cross wise pattern according to the torque guidelines INSTALL THE LOWER SEAL AND SEAL PLATE Installing the lower seal plate T PEDESTAL OVERHAUL l a es n Clean out the pedestal plate bolt holes and the ma 5 Install and torque the seal plate bolts Tighten the bolts in a cross like pattern according to the torque guidelines for machined parts in this manual 6 Plug the oil and grease holes in the underside of
9. en it with a hammer and punch or AN lightly with a brass or plastic mallet Allow the as socket sembly to cool slightly 5min so the upper bore can retain the bearing and shaft Tie 11 Bend a tab on the lockwasher into one of the four cutouts on the nut This locks the nuts in place A D J p M Fig iy F i 3 Lowering shaft bearing into pedestal 6 Orient the pedestal assembly upside down so the i i ible lower bearing bore is accessible Lockiutsiockwrashenbenttab T3 PEDESTAL OVERHAUL UPPER BEARING CLEARANCE 1 Leave the pedestal assembly in a horizontal position 2 Check the upper bearing Radial Internal Clear ance RIC by inserting a long feeler gauge be tween the rollers and the outer race With the shaft in the horizontal position the clearance must be measured over both rows of rollers Slide the feeler gauge in a saw like motion between the roller and the outer race The clearance should be within the specifications listed below Maximum 0072 inches Optimum 0055 inches Minimum 0038 inches 3 If the clearance is too loose the pedestal housing or shaft are out of tolerance and need to be re placed LOWER BEARING CLEARANCE Here are the clearance specifications for the lower bearings according to the crusher model you have Radial Internal Clearance Before Mounting Nominal bearing bore mm Reduction in Radial Internal Clearance Axial Displacement on a Solid Shaft 1
10. fits in the slot in the shaft threads Thread on the second locknut with the flat side up away from hub Tighten the lock nut with a blunt nose drift and a heavy hammer until it is firmly locked in place similar to the first lock nut 4 Bend a tab on the lockwasher into one of the four cutouts on the outer nut This locks the nuts in place 5 Use the pedestal grease zerk to fill labyrinth seal with grease If it is a new or rebuilt pedestal it may take up to 2 tubes of grease to fill it up 79 a 80
11. g industry Measurement procedures can be found in some bearing catalogs SPECIAL TOOLS Eyebolts for lifting Hydraulic press with a pressure gauge and blocks Table with a hole in it and a work stand to which the pedestal housing can be bolted A work stand that rotates along a horizontal axis is ideal AN NUT socket Long Feeler gauges for checking RIC Bearing Heater Some of the tools for a pedestal overhaul PEDESTAL y 4 PIVOT Pedestal work stand 71 PEDESTAL OVERHAUL REPLACEMENT PARTS Upper Dust Seal Upper and Lower Oil Seals Upper and Lower O Rings Alignment Tube O Rings Upper and Lower Bearings AN Lockwashers Replacement parts HUB REMOVAL 1 Remove SuperChipper or impeller table from the hub and set aside Wash the crusher and ped estal to remove dirt 2 Bend the lockwasher tab out of the slot in the upper lock nut and use a blunt nosed drift and a heavy hammer to remove the locknut then re move the lockwasher 3 Unthread the remaining locknut until it is even with the top of the shaft threads Leave the lock nut in this position to prevent the hub from com ing off the shaft or damaging the threads when it separates from the shaft 4 Insert three lifting eyes into the hub and use a lift or hoist to take the slack out of the chains and exert an upward force on the hub 5 If itis necessary place bottle jacks under the hub to help lift and remove hub from off of the pedes ta
12. l shaft Once the upward pressure is placed on 12 a es r the hub carefully heat the hub and strike the hub with an aluminum or brass block held against the hub Be careful not to damage the hub surface or lifting mechanism The hub should separate from the main shaft Relieve the lift pressure and re move the lock nut and hub a 4 NUT FLUSH WITH END Carefully strike a block held against the hub PRELIMINARY DISASSEMBLY AND DIAGNOSIS 1 Remove the six cap screws in the upper seal plate Use lifting eyes 1f equipped with them to raise the seal plate off the pedestal housing Note Recent model crushers have 2 set screws in the seal plate Tighten the set screws in equal increments to separate the seal plate from the pedestal housing To install the lifting eyes the set screws must be completely removed and the eyes are then threaded into the vacant holes Avoid scratching the seal surface Do not pry the seal plate off the pedestal hous ing a a S S PEDESTAL OVERHAUL Underside of the upper seal plate 2 Observe the underside of the seal plate Look for oil getting past the O ring Look for dirt in between the seals 3 Remove the upper dust and grease seal and the oil seal O ring from the seal plate Check the rubber on the seals and the O ring for damage 4 Inspect the mating surfaces between the upper seal plate and pedestal housing for dirt outside the oil seal O ring or any damage
13. o crusher NOTE The sheave diameter x circumference x RPM 12 ft minute D x x RPM 12 FPM Stock 3 Apply a locking compound to the bolts according to the manufacturers instructions CEMCO recommends Loctite 242 Anoeribic sheaves are given a static balance that is satisfac S Do not use red Loc tite or lock washers tory for rim speeds up to 6 500 feet per minute Sheaves with rim speeds above this limit must be Thread Locker and SAE flat washers i 4 Install the bolts which hold the pedestal housing to INSTALL THE PEDESTAL INTO THE the crusher Torque them according to the TORQUE CRUSHER SPECIFICATIONS guidelines 78 PEDESTAL OVERHAUL ue ay pply locking compound 5 Remove the covers from the oil and grease hoses Remove the plugs from the ports in the underside of the pedestal housing Inspect all the openings and remove any dirt or debris Carefully reinstall the fittings and the hoses onto the pedestal 6 Follow the BELT INSTALLATION and INITIAL CRUSHER START UP procedures outlined in this service manual INSTALL THE HUB 1 Install the hub key into the keyway in the shaft 2 Heat the hub to 50 F above the temperature of the shaft and slip over the tapered shaft end 3 Thread the first lock nut on flat side down against the hub Tighten the locknut with a blunt nose drift and a heavy hammer until it is firmly locked in place Install the lockwasher concave away from the hub The lock tab
14. t does not gently tap it out with a block of wood and a plastic or rub ber mallet CLEAN AND INSPECT THE PEDESTAL ASSEMBLY 1 Clean the shaft seal plates and pedestal housing with solvent or similar cleaner 74 vent and then with compressed air It is usually not necessary to remove any of the pipe plugs in the lower seal plate mounting surface If you do remove any plugs clean them thoroughly and replace them below the machined surface using pipe thread seal ant 3 Measure the upper and lower bearing bores in the pedestal housing and the shaft diameter at the upper bearing area They should meet the factory specifi cations listed in this manual 4 Inspect the shaft taper where the lower bearing fits It should be clean and smooth Measuring a bearing bore CRUSHER MODEL Upper Bore 35 54 70 80 96 ane a Lower Bore on it Shaft Diameter i mee Pedestal and Bearing Bore Specifications PEDESTAL ASSEMBLY 1 Heat the upper bearing to 50 F above the tempera ture of the shaft be careful not to overheat the bear ing SEMET PEDESTAL OVERHAUL 4 taper first over the shaft Tap the inside bearing r f AN DANGER race with a brass drift or punch securely seating it DO NOT NOT WELD REPAIR A against the tapered shaft section Orient the pedes tal sideways 7 Slide the tapered bore lower bearing large end of PEDESTAL MAIN SHAFT i jami mm a i ee 4 8 Thr

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