Training

Hammer Crushers

Double-Shaft Hammer Crushers Type HDS

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Hammer Crushers

Machine Type/Designation

HDS 2000 x 2200

Hammer crusher 2200 mm inner length

Double-shaft 2000 mm Rotor tip circle

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Method of Operation

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Method of Operation
The material dropping down from the supplying
conveyor enters the range of action of the hammers.
Maximum comminution takes place above the centre
of the rotating hammers by:
percussion effect of the freely swinging hammers
stabilized by rotation against the dropping-down
raw material,
mutual effect of the material accelerated by the
hammers to a high relative velocity
After having reached a minimum grain size, the
material is passing the anvil, on this way it is
reduced due to shear and friction.
Further more, the material is equally distributed on
both crushing grate halves. By crushing the
material through the gap of the grates, the material
is getting the final size.
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Method of Operation
You can look inside jaw, cone and gyratory crusher while they are
operating. The mechanical construction conforms to the method by which
they work. These crushers operate by overcoming the inherent strength of
the materials being processed. This is a static process in which the
resulting products are almost entirely independent of the speed of
crushing.
This is different with the hammer crusher. The hammer crusher operates
dynamically. The hammers which rotate at high speed approach the feed
material from below in an oblique position and crush the feed as it is falling
in free air.
This process cannot be observed in an operating crusher. The crushing
action takes place much too quickly to be seen at normal operating speed.
With the help of high speed cameras the crushing process has been
filmed. This clearly shows the special process involved in crushing.

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Method of Operation

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Setting of tasks feed

The feed should have a medium to low hardness like limestone, chalk, gypsum and clay.
The moisture of the feed should not exceed 12 - 15 %.
If the material is too sticky, the grates are going to be clogged.

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Design - Housing

inspection door for gap gap adjustment

adjustment (grate support)
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Design - main components

apron feeder wear plates

support
inspection door

grates with grate

bars

anvil
rotors
hammers

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The HDS rotor is a disc-type rotor, the rotor discs being removable attached to the
shaft and fixed in axial direction. The outer discs are pulled together by tension rods.
Depending on the crusher size there are 4, 5 or 6 hammer axis. The hammers are
mounted free swinging on the hammer axis. The weight of the hammers are from 60
kg up to 175 kg.
main shaft

rotor disc

hammer

hammer axis

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tension rod screw nut

(super bolt)

holes for rotor

fixation
(maintenance)

hexagonal shaft

bearings with
clamping discs clamping sleeves
for axial fixation of
spring-type-straight pins the rotor package
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spring-type- tension rod

straight pins
screw nut
(super bolt)

holes for rotor

fixation
(maintenance)
Sealing ring

Clamping
discs for axial
fixation

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super bolt for axial

tensioning of the
single discs

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Design - Rotor
The rotor disc is a welding design. Against wear, the discs are hard faced at the outer
face.

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Design - Grate basket with grate and grate bars

The grate (with grate bars) is built in the grate basket. This assembled unit gives the
built in grate bars the necessary mechanical stability and simultaneously fix the grate
bar width which is required to generate a specific product size. A wear resistant hard
facing protects the grate retaining plates against premature abrasion.
grate bars
grate

grate
basket
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Design - Grate grate disassembling

The grate basket is pulled in and out by two hydraulic cylinders. After fixing the grate basket
with both bolts, these cylinders turns the grate basket in upper position, where it is adjusted
and fixed with the grate support.
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Design - Grate grate installation

The grate basket is pulled in and out by two hydraulic cylinders. After fixing the grate basket
with both bolts, these cylinders turns the grate basket in upper position, where it is adjusted
and fixed with the grate support.
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Design - Grate grate installation

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Design - Grate grate installation

grate

grate support

Shim plates

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Design - Anvil and wear plates

Anvil: Suited to its duty the anvil is made of special cast steel and has to perform a
multiple function in the crusher.
It participates in the comminution process, distributes the material flow onto both
crushing grates and mechanically protects the first grate bars from violent destruction.
To ensure protection against wear, the sidewalls of the housing top section are
equipped with replaceable (screwed) wear plates. Moreover, the free space between
the end discs of rotor and housing walls is covered by segments to avoid penetration
of fines.

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Special HAZEMAG features

All hammer crushers are fitted with a key-transfer-

system, which prevents unauthorised opening of
the housing during operation and prevents motor
start-up whilst work is being carried out on the
open crusher.

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Maintenance

A comprehensive maintenance and

inspection checklist is described in the
Operating instructions.
We will take the opportunity to give
some essential tips for good
maintenance.

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Maintenance
Portable operating panel

By using hydraulic cylinders, different types of necessary

maintenance works can be supported.
The wished function can be set on the delivered Portable
operating panel.

Selector switch
1. Spare function
2. Shifting of grate carriage
3. Hammer bolt pulling device
deploy
4. Rotor turning device 1
5. Rotor turning device 2
6. Spare function
retract
7. Spare function

Hydraulic Stop

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Maintenance
Hammers

The material and the shape of the hammer guarantee mechanical

stability and effective support of the rotors by rotational energy.
The hammers are of symmetrical shape, by turning them, a new
face is brought into operation, thus permitting optimum utilization.

New hammer First face worn Second face worn

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Design Rotor turning device and bearing

With the aid of an hydraulic worm gear, the rotor can be turned for hammer changing
and maintenance. The rotor bearings are robust pillow block frames with grease
lubricated self-aligning spherical roller bearings and clamping sleeves. Labyrinth seals
with additional built in felt packing guarantee an effective protection against penetration
of dust.

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Worm gear with hydraulic

drive and break

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Maintenance

Rotor
turning
device

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Maintenance
Procedure for controlled rotor turning

In order to enable the use of the rotor turning gear, the following must apply:
- The slewing-motion actuator is connected to the hydraulic unit via supply lines.
- The front hood on the rotor turning gear is removed.
- Activation of the slewing-motion actuator until half the bores on the slewing-motion
actuator line up with half the bores in the rotor shaft.
- Insert the existing carrier plate into the bores and secure with a hexagon head bolt
Remove the locking pin of the rotor
catch, before rotating the rotor using
the rotor turning gear.

Remove the carrier plate and mount

all safety devices before the
hammer crusher is started again.

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Maintenance
Procedure for hammer changing
Unlock Trapped key interlock system of the housing doors
Opening of housing doors in the upper housing.
Lock the rotor in position wit the rotor turning device and unscrew
the covers of the hammer bolts from the upper housing and the
outer rotor disc.
During each turning or replacing of the hammers, the rotor must be
locked using the rotor turning device, in order to prevent the rotor
from turning unintentionally when the hammers are removed.
Accident risk!

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Maintenance
Procedure for hammer changing
Removing the hammers
-rotor is at standstill
-open the maintenance doors
-move the rotor with the rotor turning device
-secure the rotor in the desired position
-demount the cover of the hammer axis
-fix the hammer axis pulling device to the machine
-connect the pull rod to the hammer axis
-fix the hammers in the hammer changing device
-pull out the hammer axis, until the fixed hammer is released
-the hammers are then either turned or replaced as necessary
(see Operating Instructions Fitting the hammers)
-using the rotor turning device, select the next rotor position
-repeat the hammer changing operation as above.
-this process is continued as often as necessary.

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crane
Maintenance
maintenance door

feeder hood

inlet hood

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Maintenance
Procedure for hammer changing
hammer changing
device
hammer axis
pulling device

rotor turning device

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Maintenance hammer changing

Procedure for hammer changing device

rotor turning
device

hammer axis
pulling device

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Maintenance
hammer axes pulling device directly connected with the outer rotor disc.
No forces are treating the bearing in axial direction.

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Maintenance hammer changing device

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Maintenance hammer changing device

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Maintenance hammer changing device

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Maintenance hammer changing device

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Maintenance hammer changing device

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Maintenance hammer changing device

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Maintenance
Procedure for rotor changing

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Action in case of malfunction

Irrespective of the following instructions, the operation of the machine is governed

by local safety regulations.

Safety switch-off

A lockable local safety switch is to be provided to prevent unintentional switch-on

of the machine during repair or corrective work. Moreover, the applicable accident
prevention instructions must be followed.

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Troubleshooting
Fault indication Cause Corrective measures
Machine vibrates - rotor unbalance - check hammers,
severely change if necessary,
re-weigh and mount
uniformly acc. to
maintenance instructions
Bearing temperature too -inadequate or excessive -check lubrication
high lubricant

-erection error -check assembly of

bearing(s)

-excessive vee-belt -check vee-belt pre-

tension tension

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Troubleshooting
Fault indication Cause Corrective measures
Smell of rubber -vee-belt slip -check belt tension
(lack of tension)

-rotor blocked -free chamber of feed

material
Throwing of the vee- -lack of tension -check tension
belts
-worn belts -replace belts

-foreign matter in the -remove foreign matter

grooves

-pulleys misaligned -realign

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Troubleshooting
Fault indication Cause Corrective measures
Unusual noises inside -foreign matter in the - shut down Crusher,
the crusher Crusher remove foreign matter
Motor cannot turn rotor -material in the Crusher -remove material from
the Crusher

-thermal tripping of the -check the fusible plugs

coupling and replace as
necessary.
Top up with oil

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