A Comprehensive Guide to Stone Crusher Installation

The correct installation of stone crusher is imperative for safe and efficient long-term operation. As key equipment in crushing applications, stone crusher equipment must be set up precisely according to engineering specifications.

This article provides a comprehensive guide to stone crusher installation procedures. It details pre-installation planning considerations and outlines each step - from site preparation to commissioning. Proper installation methods are explained to ensure crushers fulfill designed throughput capacities.

1. Pre-Installation Planning

Thorough planning aids smooth installation. Key factors include:

1. Crusher model selection - Choose to suit throughput needs and feed material type/size.
2. Foundation design - Factor crusher dimensions/weight into reinforced concrete slab sizing.
3. Lifting equipment - Onboard or mobile cranes rated adequately for crusher weight handling.
4. Commissioning schedule - Synchronize with civil works to avoid project delays.
5. Installation crew - Trained and competent with installation hardware/tools.
6. Spare parts - Have recommended spares readily available for unforeseen needs.
7. Installation drawings - Quality reference materials enabling systematic work.

Robust planning mitigates risks during crusher installation and commissioning phases.

2. Site Preparation

Preparing the installation site is crucial:

1. Clear area within 10m radius and level with compacted gravel/cement.
2. Excavate foundation pit to design depth, typically 0.5-1m deep.
3. Inspect pit bottom for irregularities, backfill if uneven.
4. Lay vibro-compacted gravel layers and level concrete formwork.
5. Pour and cure reinforced foundation slab to specified strength.
6. Check slab flatness with a spirit level, grind/polish imperfections.

A stable, flat foundation prevents crusher misalignment influencing operations.

3. Lifting and Positioning

Heavy-duty lifting equipment precisely transfers crushers:

1. Inspect cranes as per regulatory safety standards before use.
2. Attach slings to crusher using designated lifting lugs or eyes.
3. Slowly raise crusher and maintain stability in high winds if needed.
4. Direct it over foundation and lower carefully into position.
5. Chock wheels to prevent rolling until permanently secured.

Precise, properly rated lifting mitigates risks during this critical phase.

4. Leveling and Grouting

Leveling enables optimized crusher operation:

1. Level longitudinally using jack screws under rear beam.
2. Level laterally by measuring elevation at multiple points.
3. Check levelness using a spirit level on internal floor ring.
4. Grout beneath crusher by pouring non-shrink cementitious grout.
5. Screed excess grout level and finish surface before setting.

Perfect levelness is vital for consistent performance through the crusher.

5. Drivetrain Connection

The crusher drivetrain transmits torque to the crushing chamber:

1. Assemble gear reducer to the main shaft flange if not installed.
2. Bolt reducer base securely to crusher’s internal beams.
3. Connect motor to gear reducer via drive sheaves and a V-belt.
4. Adjust belt tension to manufacturer specifications.
5. Check shaft/bearing rotational alignment and lubrication levels.

Reliable power transmission depends on correct drivetrain assembly.

6. Hydraulic System Integration

Hydraulic circuits control operations:

1. Install hydraulic power units on custom skids or structures.
2. Route high-pressure hoses neatly to cylinders and manifold stations.
3. Connect hoses with fittings to mating hydraulic components.
4. Fill and bleed circuits, check for leaks at connections.
5. Perform function tests with hydraulic power cycling.

Hydraulic integrity ensures smooth remote control of crusher functions.

7. Electrical Installation

Control systems utilize electricity safely:

1. Connect motor leads to nearby main electrical panel.
2. Run power and control cabling in enclosed cable trays.
3. Terminate cables correctly in marshalling boxes and cabinets.
4. Ground all non-current carrying metalwork properly.
5. Install earthing grid and lightning protection as required.
6. Implement lock-out/tag-out safety protocols during installation.

Proper grounding/earthing guards personnel and equipment.

8. Commissioning

Commissioning validates correct installation:

1. Gradually commission drivetrain, hydraulic and control systems.
2. Start motor briefly and check for vibration or noise issues.
3. Run crusher without feed material at increasing motor speeds.
4. Introduce feed material in small batches to prove functionality.
5. Tune settings according to product specifications.
6. Conduct performance tests over 24-48 hours to validate capacity.

Thorough commissioning ensures smooth handover for operations.

Proper installation is critical for crusher longevity and operational safety. Following recommended procedures ensures optimal performance from day one of operation.