DIRECTORATE GENERAL BORDER ROADS
GENERAL MAINTENANCE INSTRUCTION NO: 215 ON
MARSHALL
PORTABLE STONE CRUSHER 6/10 TPH
INTORDUCTION
1. Marshall
portable Stone Crusher is a 16 x10 Jaw Crusher single Toggle Machine used for
crushing lime stone, granite and coal etc. This machine also can be converted
easily to a 16x6 granulator.
2. It
is powered with kirloshar RB-44, 4 Cylinder, 4 stroke water Cooled Diesel
Engine.
AIM
3. To
lay down the details of periodical maintenance and lubrication and hints for
safe operation and towing of Marshall Portable stone Crusher to achieve enhance
life.
ACTION BY
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a)
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USER UNIT
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To carry out regular/periodical maintenance
as laid down in this instruction and enter the tasks in log book.
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b)
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FIELD WORKSHOPS
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i)
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To check the maintenance and lubrication
actually carried out as per log book record during the inspection and repairs
of the equipment.
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ii)
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Advise user units in respect of any
discrepancy/short coming noticed.
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DETAILS
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a)
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Technical Specification Data
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Appx- ‘A’
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b)
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Periodical Service Schedule & recommended lubrication chart
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Appx -‘B’
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c)
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Hints for safe operation and towing
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Appx- ‘C’
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4. Please ack receipt.
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Sd/xxx
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(Rajendra Jee)
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EE (E&M)
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Offg Director (Tech)
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Date : 07 Mar 2002
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For Dir Gen Border Road
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Appx- ‘A’
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TECHNICAL SPECIFICATYION
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MODEL
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ENGINE
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Kirloskar RB-44 Diesel Engine
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No of Cylinders (Vertical in line)
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4
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Working Cycle
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4 Stroke Diesel
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Cooling System
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Water cooled
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Fan belt Tension
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8 to 10 mm
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Bore x Stroke
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110 x 116 mm
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Cubic Capacity
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4410 cc
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Firing Order (From F.W.end)
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1-3-4-2
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Direction of Rotation looking at F.W.end
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Anti clockwise
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Compression Ratio
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17:1
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B.M.E.P at 1500 rpm
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6.5 Kg/cm2
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Torque at 1500 rpm
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24.10 Kg/ cm2
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Fuel injection pressure
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200 Kg/ cm2
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Specification fuel
consumption at Full load and 1500 rpm +5% allowance
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230 Kg/Kwh
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Fuel Injection timing (By Spill cot off)
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34 ° ± 1°
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Lubrication System
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Force feed gear pump
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Lubrication Oil Pressure
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In idle run, min- 0.5 Kg/ cm2
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In normal working ( engine warm) Min-1.8 Kg/ cm2
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Valve Clearance (in cold)
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Inlet 0.25 mm
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Exhaust 0.3 mm
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Starting
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Electrical
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Max Operating Speed
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2000 rpm
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Min Operating Speed
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1200 rpm
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Idling Speed
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550-600 rpm
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CRUSHER
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Model
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1610 Marshall major crusher
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Size of machine
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400 mm x 250 mm
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Feed Size
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100 mm min-225 mm max
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Minimum jaw setting
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25 mm
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Screen size
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3048 mm (length) x 688 mm dia
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Punching (std) (on screen)
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22 mm dia. 45 mm dia. 55 mm dia.
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Power consumption
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60 HP (44.20 KW)
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APPROX CAPACITY
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Jaw setting
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20 mm, 25 mm, 38 mm, 50 mm & 63 mm (Granulator)
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Out put /Hour (Cu mtr)
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12-14, 12-14, 16-18, 20-22
& 25-28
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Shipping dimension
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7440 mm x1980 mm x 3000 mm (appx)
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Weight
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7000 Kgs (appx)
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Speed to be towed
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10Kmph (9 max) on plain roads.
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Type of wheels
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Pneumatic
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Appx- ‘B’
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PERIODICAL SERVICE
SCHEDULE AND RECOMMENDED LUBR
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1. PERIODICAL MAINTANENCE ON ENGINE
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DAILY
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(a) Check engine oil level
(This check should be made with the engine in horizontal position). If the
level only reaches to the lower mark of the dipstick, the oil should be
topped up with out delay.
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(b) Top up water in the
radiator.
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(c) Fill up the fuel tank
at the end of each working day. Never wait until the tank is empty. This
would necessitate rebuilding or the entire fuel system.
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(d) Clean the engine at
the day’s work.
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2. AFETR EVERY 50
HOURS (UNDER VERY DUSTY CONDITIONS)
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(a) Check and clean the
oil bath type air cleaner. Dismantle air cleaner and pour the dirty oil (In
case of normal working condition, this is to be followed after every 200
Hrs.)
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(b) Clean the dismantled
components with the help of Diesel fuel. Then filled up the bowl with fresh
engine oil up to the oil level mark and the unit then reassembled with
element in position.
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(c) It is also necessary
to check the unions and connection of the air intake manifold regularly.
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3. AFTER EVERY 200
HOURS
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a) Clean the lubrication oil
filter bowl and filter discs with the help of Diesel fuel.
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b) Greased the volute body of
water circuiting pump with the help of grease gun.
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c) Drain the fuel tank and
remove the sediments which accumulate at the bottom.
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d) Also check and clean the breather hole of
the tank if found blocked.
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e) Drain the fuel filter bowls to remove
sediments and water which accumulate at the bottom of bowls.
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f) Clean
the filter sleeve which has been fitted on the suction side of feed pump.
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g) Check electrolyte level in
each cell of battery with the help of electrolyte level tester/wooden stick.
In case of wood stick the level should wet the stick over a length of about
10 to 15 mm (0.4 inch to 0.6 inch). If the level found low then top up with
distilled water only.
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h) Check the cable
connections at the starter, battery and dynamo if found loose, tighten it
properly. Loose connections lead improper contact and damage to the
terminals.
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j) Check
the belt tension. It should be 8 to 10 mm. If found loose or more than adjust
tension.
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4. AFTER EVERY 400 HOURS
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a) Carry out oil change when the engine is
hot, flash out all old oil and fill in fresh oil in the sump up to top
dipstick mark.
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b) Check oil level in fuel injection pump
and Governor. If required, top up with engine oil through breather hole at
the top of Governor housing.
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c) If the engine is operating under very
dirty/ dusty condition, wash the air breather of the pump thoroughly in
petrol and blow dry with compressed air.
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d) It Spin-on type lub oil filter on the
engine. Change the filter.
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e) Drain the water from radiator/heat
exchanger and jacket of the cylinder block. Clean it with fresh water adding dissolving
compounds.
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f) Knock out shoot from exhaust silencer.
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g) Check and tighten up if necessary, the
following:-
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i) Fuel connection.
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ii) Oil Sump bolts.
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iii) All external nuts and bolts.
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iv) Engine and radiator counting
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v) Radiator hose connections.
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5. AFTER EVERY 500 HOURS
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(a) Clean the pre-filter bowls and replace
insert of fuel filter
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(b) Check the condition of sealing of
pre-filter and if required change it.
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NOTE: IMPROTANT
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Do not clean filter
inserts. Always destroy the filter
before throwing it away.
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6. AFTER EVERY 750 HOURS
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a) Change the Micro filter
insert of fuel filter.
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7. AFTER EVERY 800 HOURS
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a) Check and adjust valve
tappet clearance.
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b) Check the injector nozzle
spray. If required, cleaned and replace sealing washer and refit the nozzle,
connect the high pressure pipe.
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c) Check the brushes and
commutator of starting motor and dynamo Inject few drop of SAE 30 oil into
the hole at the center of commutator bracket of dynamo. Clean the contact
points of regulator.
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8. AFTER EVERY
1200HOURS/SIX M
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a) Clean the fuel tank
thoroughly with diesel. Do not use water for cleaning, it will lead to
rusting and scale formatting.
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9. AFTER EVERY 2500
HOURS
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a) Replace the oil in the
fuel injection pump or when the fuel injection pump is removed for some
attention. SAE30 oil should be used for refill.
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10. TOP OVERHAUL AND
MAJOR PERIODS
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a) After about 3000 working
hours engine will need top (min overhaul and after about 9000 working hours
engine will need major overhaul. This period are based provided the engine
properly maintained as per this GMI
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11. LUBRICATION OF BASIC
MACHINE
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a) Lubrication on basic machine should be
carried out as follows :-
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12. JAW STOCK BEARING
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Jaw stocks Stauffer are provided for lubricating Jaw stock bearing
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Servo Gem EP-2 of IOC Ltd or equivalent
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RECOMMENDED LUBRICANT FOR RB 44 FITTED WITH
THIS MACHINE
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Maintenance of Job
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Kind of Lub
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Ambient temperature
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Viscosity No.
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IOC Grade
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Periodicity
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Remarks
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MULTI GRADE
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Assy Kiloskar
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Engine Oil
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-20°C to+ 20°C
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SAE 10W30
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Ist change 50 working
hrs Thereafter Every 400 hrs
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SAE 15W40
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Servo Premium XHP 15W40 or Servo pride Super MG14W40
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-5°C to 45°C
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SAE 20W40
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Servo Premium 20W40
or Servo Pride 20W40
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MONO GRADE
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-15°C to -5°C
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SAE 10 W
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Servo Ultra 10 W
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- 5°C to +5°C
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SAE 20
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Servo Ultra 20 W
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+5°C to 25°C
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SAE 30
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Servo Ultra 30 or Servo Pride
30
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Above 25 °C
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SAE 40
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Servo Ultra 40 or Servo Pride
40
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LUBRICATION OF EQUIPMENT
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a)
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Lubricate Plumper blocks on the discharge chute and tail end Bracket
of the rotary screen, Bevel wheel at the tail end of the screen shaft and
bevel pinion tooth at every 8 working hours.
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Servo Gem EP-2 or IOC Ltd
Or equivalent.
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b)
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Lubricate turntable mounting pin & top plate and tow hook mounting
at every 500 working hours.
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-do-
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c)
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Lubricate wheel hub bearing of front axle and rear axle at every 1000
working hours.
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-do-
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IMPORTANT POINTS
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a) In order to ensure long
trouble free service it is most important that the crushing ratio of
reduction should not exceed 6 to 1. Therefore, a 25 mm setting the feed size
should not exceed 150 mm and at 38 mm feed size should be less than 225mm.
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b) Blow off the dust each day
and clean the Crusher thoroughly each week.
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c) Before closing down the
machine make sure that this crushing mouth is free from stone.
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d) If the crusher is clean if
all working parts are well lubricated, it will result in saving the power and
prolonging the life of the crusher.
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e) Before starting the crusher
each day make sure that the mouth of crusher is clean and that all bolts and
working parts are secured.
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f) Never start or stop the
crusher with stones between the jaws.
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Appx -‘C’
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HINTS FOR SAFE OPERATION AND TOWING
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a) Trolley should be properly
supported on all four supports to avoid excessive vibration during working of
the machine.
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b) Before towing, ensure the
following :-
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i)
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Removal of screen belt guard with belt and pinion assembly and
re-fitment on to the top of the chassis.
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ii)
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Re-fitment of the Adaptor at the near and cross member of the chassis
on to the top of the same.
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iii)
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Tail end bracket supporting the screen shaft to be fitted directly on
to the bottom of the rear end cross member of the chassis.
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c) During towing, maximum
speed of the machine shall not exceed 10 Km ph.
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d) Check for the tightness of
all fasteners on the machine after the machine has been towed to site. They
may have got work loosened during transportation.
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e) Also check once a week the
tightness of all nuts and bolts.
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f) Lubricate as per schedule
all the greasing points on the machine.
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| _________ |
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