Use the following procedure to install a Bowl Liner:
Note: A change in liner configuration may require a change in the Adapter Ring.
1. Remove all the paint from the seating surface on the Bowl Liner.
2. Place the Bowl Liner on wood blocking, making sure the blocking will allow the Bowl to fully seat on the Bowl Liner. Note: It is important to get the bowl liner as level as possible.
3. Place chalk marks at the apex of each of the helixes on the Bowl Liner. Refer to Figure 3-9
4. Clean the inside of the Bowl, and apply a coat of light oil to prevent the epoxy backing from adhering to the Bowl.
5. Lower the Bowl onto the Bowl Liner, making sure the chalk marks (step 2 above) line up with the wedge slots in the Adapter Ring of the Bowl.
6. With a 0.010” (.25mm) feeler gauge, check for clearance between the Bowl seat and the Bowl Liner seat. It should not be possible to get the feeler gauge FIG 3-10
1. Bolt Stop 2. Lock Plate 3. Cotter Pin 4. Square Head Bolt
5. Spherical Nut 6. Wedge
7. Wedge Retainer
Figure 3-8 Wedge Assembly
in for more than 20% of the circumference. If the gap between the Bowl seat and the Bowl Liner seat is excessive, the Bowl Liner may not be usable.
Note: Occasionally a bowl liner may be distorted after machining, and may no longer be suitable for use. Before replacing the liner, lift the bowl and rotate it 180 degrees and see if this makes a positive change.
7. Remove the bowl, place a 0.25” (6mm) bead of silicone sealant full circle at the bottom of the Bowl Liner seat, and replace the bowl, ensuring that the seating surfaces are properly aligned.
8. Take a measurement between the Bowl Liner flange and the inside of the Bowl at four places 90 degrees apart. This is to make sure the Bowl and the Bowl Liner are properly centered. If these measurements are not fairly equal (you are measuring from an “as cast” surface), lift the Bowl and reseat it on the Bowl Liner until they are. Note: A large pry bar will help. A cocked Bowl Liner can come loose during operation and cause serious damage to the Bowl seating surface. Refer to Figure 3-10
9. Thoroughly clean the threads on each wedge bolt, apply an anti-seize compound to the threads, and screw on the spherical nuts, making sure that the spherical side faces away from the head of the bolt.
Refer to Figure 3-11
Note: It is best to replace damaged or questionable wedge bolts.
10. Inspect the inclined surface on the nose of each wedge to make sure there are no gouges, heavy indentations, or proud surfaces. Dress as necessary with a high speed grinder to create a smooth upward, ramping surface. Place the wedges on the adapter ring between the stop blocks, and push the wedges forward until they contact the Bowl Liner.
Note: It is best to replace damaged or questionable wedges.
11. Each of the wedges should contact the helix of the Bowl Liner from about 35 to 50 per cent up the inclined surface of the wedge. Add or remove shims under the wedges to obtain the desired contact points on the helix. Once the proper wedge contact on the helix is established, tack weld the shims in place. Refer to Figure 3-11
12. Place a shim on top of the wedges to a height that is even with the top of the adapter ring. Then place and bolt the wedge retainers onto the adapter ring at each wedge location. The shims will keep the FIG 3-11
1. Bowl Liner
2. Chalk Mark Above High Point of Helix 3. High Point of Helix
Figure 3-9 Helix High Point Location
FIG 3-12
1. Bowl
2. Fiberglass Insulation 3. Bowl Liner
4. Epoxy Backing Material
5. 0.010” (0.25mm) 6. Feeler Gauge 7. Wood Block
Figure 3-10
Checking Bowl Liner Seating Surface
wedges from tipping when tightening and possibly coming loose during Crusher operations.
Note: Bowl Liners are castings, and occasionally there will be occurrences where the top of the wedge bolt will project above the top of the Adapter Ring. This will necessitate placing shims on the wedge retainer plates.
13. Place the square head bolts with spherical nuts (see Step 6) behind the wedges, making sure the bolt is horizontal and the heads are under the horizontal bolt retainers that are welded in the slots in the Bowl. The bolt retainers hold the heads of the bolts in place during tightening and prevent the bolts from sliding up during Crusher operations. If the bolts come up, the Bowl Liner will become loose.
Note: A change in liner profiles may require a change of Adapter Ring, and it will most likely be necessary to relocate the bolt retainers. Also, a change in Bowl Liner manufacturer may also result in a necessary change.
14. With a sledging wrench, alternately tighten each spherical nut in a crisscross pattern until all the wedges are tight in the Bowl Liner helix.
15. Check once again, the contact between the Bowl seat and the Bowl Liner seat at the bottom, using a 0.010” (0.25mm) feeler gauge. You should not be able to get the feeler gauge in for more than 20% of the seating surface. All openings caused by Bowl seating surface wear should be packed with caulking to prevent the backing material from leaking out when poured. Refer to Figure 3-10
16. Fill the entire space behind the Bowl Liner with the FLSmidth Excel epoxy backing compound recommended in the Parts Manual. Be sure to stop pouring before the backing compound reaches the level of the bottom of the Adapter Ring. Carefully follow the safety and mixing instructions supplied in each kit of epoxy backing compound.
Refer to Figure 3-10
17. After the epoxy has cured, repeat the tightening process for each wedge bolt. If time does not permit to wait for the epoxy to cure, still carry on with the repeat of the tightening process. The epoxy curing time is extremely temperature dependent. If the Bowl and Bowl Liner are cold, it will be necessary to heat up these pieces to approximately 70° to 80°F (21°
to 27°C). Normal curing time is about 8 hours at the above ambient temperature.
18. Place the lock plates over the spherical nuts and attach them to the wedges using cotter pins.
Refer to Figure 3-11
19. Using fiberglass insulation or other water resistant materials, cover the area above and around the wedge bolts, and completely fill the areas of the bowl. This will help prevent dirt and dust from accumulating around these parts while making it easier to remove them during the next Liner change.
Refer to Figure 3-10
20. Lift and place the Hopper into the Bowl, making sure the Hopper engages the slots in the top of the Bowl.
Apply silicone sealant to the horizontal surface of the bowl liner flange. When the Hopper is set into position, this will provide a seal between the bottom of the hopper and the top of the Bowl, and help in keeping rock fines from getting into the wedge bolt area.
FIG 3-13
1. Incline Midpoint 2. Wedge
3. Lock Plate 4. Bolt Stop Welded to Bowl
5. Square Head Bolt
6. Tack Weld Shim on this Figure 3-11 Bowl Liner Installation
21. Following the steps defined in the Bowl Installation Instructions detailed earlier: Lubricate the Bowl, Clamping Ring, and Adjustment Ring threads prior to installing the Bowl in the Crusher.
Note: If any of the Bowl threads have been refurbished (e.g. weld repaired and machined), it is important to apply to the threads the same break-in grease (anti-seize compound) used by the factory. This material is available from FLSmidth Excel, and significantly reduces wear and galling of new or rebuilt Bowl or Adjustment Ring threads. Use RXL000-0079.
22. Install the bowl back into the Crusher following the instructions in Section 1 as outlined in Installing the Bowl Assembly.