The provided document is a comprehensive operation and maintenance manual for the Saalasti Crush HF Series, a horizontal axis crusher designed for biomass processing. The manual is presented in both English and French, covering various aspects of the machine from its operational principles to detailed maintenance procedures and safety instructions.
Function Description:
The Saalasti Crush HF Series is a horizontal axis crusher that utilizes a high-speed rotating rotor to process untreated fuel. It is designed to handle various types of biomass, including round wood, bundles, pre-cut stumps, and full stumps. The machine integrates with a Saalasti Biomass Feeder, which supplies the untreated fuel to the crusher's infeed case. Within the infeed case, upper and lower feeding rolls guide the fuel towards the rotor at a predefined speed. The upper roll's vertical movement is controlled by hydraulic cylinders, with the force against the fuel automatically adjusted by a Distributed Control System (DCS). The speed of both upper and lower rolls can be varied based on the type of fuel being processed. The rotor crushes the fuel against an anvil plate and a grate, where the material achieves its final particle size. The rotor's cutting tools crush the fuel at high velocity and grind it in the gap between the anvil plate and the cutting tools, and subsequently between the grate and the cutting tools.
A key feature of the Saalasti Crush is its robust design, capable of handling small rocks and metal pieces, which are crushed and discharged with the processed fuel. For larger foreign objects, a safety system releases the anvil plate and grate, allowing the object to fall through without damaging the crusher. The anvil plate and grate are returned to their operational positions using hydraulics when the crusher is stopped. The hydraulic system also manages the upper rotor position adjustment and the opening of the upper case for maintenance.
Important Technical Specifications:
The manual provides some technical specifications for the hydraulic unit:
- Main dimensions (LxWxH): 1600 x 900 x 1500 mm
- Weight without oil: 350 kg
- Reservoir/drain tank volume: approximately 600 x 400 x 500 mm = 125 liters
- Hydraulic oil: ISO VG 46 (e.g., Mobil DTE 25)
- Hydraulic pump: Variable-displacement pump driven by a 7.5 kW electric motor.
- Pump flow: 0-26 l/min
- Pump pressure: 150 bar
- Pressure relief valve pressure: 220 bar
The machine is CE marked and complies with the mechanical equipment directive 2006/42/EC. It is also designed according to ATEX-directives 99/92/EC and 94/9/EC, with a separate ATEX-classification document available from the manufacturer.
Usage Features:
- Remote Control: The Saalasti Crush is remote-controlled, allowing the grab driver to select fuel type and load biomass into the feeder.
- Fuel Selection: Six predefined fuel selections (Round wood Ø < 400mm, Round wood Ø > 400mm, Bundles, Pre-cut stumps, Full stumps, Other material) influence feeding speed and upper roll vertical position.
- Feeding Control: The feeding (Biomass Feeder, upper and lower rolls) can be stopped or reversed via remote control during operation.
- Safety Systems:
- Rotation guards for the front roll and rotor stop feeding if no rotation is detected.
- A 0-speed guard prevents the rotor from starting unless it is completely stopped, and disables upper case opening hydraulics if the rotor is not standstill.
- Inductive switches monitor anvil plate and grate positions, interlocking feeding and discharge conveyors if they open.
- Close limit switches on returning cylinders interlock feeding if not properly closed.
- Hydraulic Control: The hydraulic unit, located near the crusher, has a manual hand directional valve panel for maintenance operations and automatic control for upper roll height adjustment.
Maintenance Features:
The manual emphasizes careful installation, regular checks, maintenance, and repairs, and strict compliance with operation instructions for reliable operation and long useful lifetime.
- Safety First: All maintenance work requires safety switches to be opened and locked with personal padlocks. The rotor must be fully stopped (run-down time is about 15 minutes). Discharge conveyors must be stopped and locked. The machine must be cleaned before maintenance, especially if welding is involved. Only properly trained personnel are allowed to perform maintenance.
- Rotor Cutting Tools Change:
- Cutting tools (chipper knives or cutter bars) reduce capacity and increase particle size when worn. They must be changed regularly to maintain efficiency.
- All cutting tools must be changed simultaneously to keep the rotor balanced.
- Damaged bolts must not be reused.
- New chipper knives must have similar wear (same length of available material) and weight to maintain rotor balance.
- Procedures involve loosening bolts (air gun recommended), lifting clamps, cleaning gaps with compressed air, installing new tools, and tightening bolts to a specified torque (900 N.m for chipper knives/cutter bars).
- Cutting tool holders are heavy and require a single girder crane for lifting; only one holder should be changed at a time to avoid unbalancing the rotor.
- Anvil Plate Cutter Inserts:
- Normal change interval is approximately 2 operational months.
- Inserts need replacement when wear reaches about 5 mm, or if feeding capacity is reduced/particle size increases.
- Procedure involves opening the anvil plate (using hydraulics), installing a service platform, opening fixing screws (bolt gun recommended), removing worn inserts, cleaning surfaces, lubricating bolt threads, and mounting new inserts with a 500 Nm torque.
- Anvil Plate Wear Plate:
- Normal change interval is approximately 6 operational months.
- Replacement is needed when maximum wear is about 15 mm.
- Procedure involves opening the discharge chute service hatch, installing a service platform, opening fixing screws, removing worn plates, cleaning surfaces, lubricating bolt threads, and mounting new plates.
- Anvil Plate and Grate Pins:
- Shear pins break to release the anvil plate/grate in case of large foreign objects, preventing damage.
- Hinge pins must be greased every 4 months to ensure easy opening.
- The use of hinge pins in shear pin positions is strictly forbidden as it can cause major damage.
- Changing Shear Pins:
- Both shear pins of the anvil plate or grate must always be replaced simultaneously.
- Hydraulic cylinders must be used to prevent movement of the anvil plate or grate before removing shear pins.
- Procedure involves removing securing screws and locking plates, using a shear pin removing tool, cleaning sleeves, greasing new pins, and installing them with a hammer.
- Grate Changing:
- Normal change interval is approximately 3-6 operational months.
- Replacement is needed when cutter edge wear reaches about 10 mm.
- Procedure involves opening the upper case, following safety instructions, opening grate cylinders (using hydraulics), removing shear pins, attaching the grate to a girder crane, removing hinge pins, lifting the grate, cleaning pin bushings, and installing the new grate in reverse order.
- Grate repair by welding worn parts is possible, following specific welding instructions and material characteristics (LAVA EA 600 SG or FILEUR 5-5 or Corodur 609 1.2mm wire).
- Frame Wear Plates:
- Normal repair interval is 2-3 operational years.
- All internal parts are covered with replaceable wear plates.
- Wear plates around lower rolls are bolted; others are plug welded.
- If wear plates beside the rotor are worn, the rotor must be lifted for replacement.
- V-belts (Main Drive and Upper Roll):
- First check after new belts: 50 operational hours.
- Normal check interval: 4 months.
- Normal change interval: 2 years.
- Procedure involves removing protections, loosening bolts to slide the motor, removing old belts, installing new ones, tightening belts, and measuring tension with a Sonic Tension Meter.
- Gear Boxes: Refer to the gear box manufacturer's manual for operation and maintenance.
- Lubrication:
- Many elements require regular lubrication: feeding rolls bearings, main rotor bearings, anvil plate lever axes, grate lever axes, upper roll pressure arm hinge, and all service cylinders swivel eyes.
- Critical points are often connected to an automatic lubrication unit (option).
- Manual lubrication intervals:
- Main rotor bearings (120g) and seals (30g): every two weeks.
- Feeding roll bearings (until housing is full) and upper roll pressure arm hinge (60g): monthly.
- Hinge pin and lever axes greasing nipples, hydraulic cylinder swivel eye greasing nipple: monthly.
- Chain transmission oil level must be checked regularly, and oil (ISO VG220) changed annually or after 5000 operating hours.
- Hydraulic Unit Maintenance:
- Hydraulic unit can be started locally for maintenance when the line is stopped and the rotor is not rotating.
- The hydraulic unit should only be used when needed, and turned off and secured after use.
- Pressure line manual valve must be opened before using manual valves and closed after maintenance.
- Hydraulic system must be pressure-free during maintenance. Accumulator valves should be shut off or pressure released if needed.
- Upper Case Opening:
- Ensure rotor is stopped, start hydraulic unit, open pressure line manual valve, drive upper case open with manual direction valve, lock with safety pins, and stop hydraulic unit. Safety pins must always be used when the upper case is open.
- Upper Roll Height Adjustment:
- For maintenance, the upper roll should be driven to the highest position and locked with safety pins.
- Working inside the crusher is prohibited unless the upper roll is secured with safety pins.
- Anvil Plate Opening and Closing:
- Opening is required for changing cutter inserts.
- Procedure involves starting hydraulic unit, opening pressure line manual valve, driving anvil plate cylinder cams against the frame, closing pressure line manual valve, turning off hydraulic unit, removing shear pins, turning on hydraulic unit, opening pressure line manual valve, and driving anvil plate cylinder close for gravity drop.
- Nobody is allowed inside the crusher when moving hydraulic cylinders. Working below the anvil plate is prohibited unless it is secured.
- Grate Opening and Closing:
- Both shear pins must be removed before the grate can move. Grate cylinders should be turned open before removing shear pins to prevent violent opening.
- After changing shear pins, close service cylinders before restarting the crusher.
- Regular Maintenance Schedule:
- Check leaks and oil level: weekly.
- Check filter clogging indicators: weekly.
- Check tightness of couplings and bolts: 1/2 year.
- Filter cartridge change interval: 1 year.
- Oil purity check interval: 1 year.
- Oil change interval: 2 years.
- Pump check / sealing change interval: 2 years.
- Tank cleaning interval: 2 years.
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