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The horizontal shaft impactor crushers on the market are built to last and provide high capacity in demanding applications.

Kolberg-Pioneer
Maximum-performance rotor

The Pioneer Horizontal Shaft Impact Crushers from Kolberg-Pioneer, Inc. (KPI) — the 4233, 4240, 4250, and 5260 models — provide adaptability, reliability, accessibility, and versatility in primary, secondary, tertiary, and recycling operations, according to the company. The units feature a maximum-performance rotor with access characteristics of a segmented rotor in two-, three-, and four-bar configurations. A sequentially welded, fabricated base provides maximum strength for extended base life, and heavy-duty crusher shaft and bearing assembly and rotor retention system allow the crushers to withstand the day-to-day harsh environment and severe impact applications, the manufacturer says.

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Lippmann
Produces cubical aggregate

Lippmann’s 4800 Series Impact Crushing Plants features a large crusher feed opening that the company says is able to devour concrete full of rebar and ripped asphalt, as well as many other tough materials filled with debris. The self-contained unit contains the company’s 4248LP Impactor with a 34-inch feed height and has a 48-inch rear-discharge conveyor, 20-inch wide return conveyor, and two 20-inch wide cross conveyors. The unit’s 425-horsepower diesel motor, 100-kilowatt generator, and the heavy-duty rotor of the system’s crusher provide the portable plant with the power to offer a greater reduction ratio and to produce a high-quality, uniform cubical product, including Superpave aggregate, according to the manufacturer. Other features include an abrasion-resistant hopper, hydraulic legs, a 62-inch by 10-foot double-deck screen with an underscreen hopper, a 48- by 72-inch pan feeder under the impactor, the company’s 4716 feeder with 4-foot grizzly, and an optional 36-inch permanent magnet.

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Grasan
Automatic hydraulic cylinder system

The newest track-mounted primary crushing plants from Grasan are custom designed and built to meet customers’ needs and specifications to high-production aggregate applications. A Hazemag 1515 APPH primary horizontal shaft impact crusher with a fully automatic hydraulic cylinder system is used in the customized plant pictured here. It features a 46- by 60-inch crusher inlet opening with a 32-inch cube maximum recommended feed size and is capable of crushing up to 700 tons her hour of shot limestone. The crusher inlet hood is fabricated of extra heavy-duty steel plate with dual chain curtains. The crusher’s power is supplied by two 200-horsepower electric motors, and its chassis and hopper are made of heavy steel plate.

The plant is mounted on 500-mm wide, three-bar grouser tracks, and four independent, hydraulic legs stabilize the plant for operation. Some other components include a 62- by 18-inch vibrating grizzly feeder with a 60-horsepower motor; a 5- by 6-foot single-deck scalping screen; a 54- inch by 40-foot discharge conveyor; a 36-inch by 28-foot grizzly reject conveyor; an 18- by 17-1/3- foot feed hopper with skirt liners; and remote pendant or radio controls for the crusher itself, its tracks, and all other components.

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Terex | Pegson
Reversible steel blow bars

The 1412 Trakpactor plant from Terex | Pegson features a horizontal primary crusher with hydraulic controls, which the company says produces more uniform products, as well as the most recent PLC CAN BUS control system to automatically regulate the feed to the crusher, based on the engine load. This plant, which is suitable for crushing concrete, asphalt rubble, brick, and medium-to-hard limestone, uses a hydraulic apron-locking mechanism with overload protection and automatic reset. According to the company, it provides consistent product size with less oversize than conventional spring-loaded impact crushers and with added protection against tramp metal, according to the manufacturer. Additionally, the crusher also opens and adjusts hydraulically and is fitted with a hydraulic tilting feed plate to improve blockage clearance.

The crusher feed opening is 32 by 54 inches, with a 48- by 53-inch rotor size that has four reversible steel blow bars held with a simple clamping system. Maximum feed size is 24 by 20 by 20 inches cube or 48 by 40 by 20 inches slab. The crusher is also outfitted with a modular 48-inch-wide dual-drive discharge conveyor that raises and lowers hydraulically for maintenance and transportation purposes. The unit also has a two-way dirt chute. 

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Telsmith
Massive solid-type rotor

The Telsmith PA6060 Andreas style primary impact crusher is built with a 59-inch solid-type sculptured rotor in two- and four-bar arrangements that combine high inertia for performance crushing and the durability needed to handle up to 40-inch feed, the company says. The unit uses double-row spherical bearings that are 220 mm wide and has hydraulic apron adjustments with automatic positions reset, a hydraulic tilting feed plate that eliminates bridging, and momo-block aprons that are reversible and interchangeable to extend service life. The 61,000-pound crusher has a recommended motor of 400 to 500 horsepower and a rate capacity of 350 to 600 short tons per hour. Only two shapes of frame liners are used, allowing interchangeability and reducing inventory needs, according to the manufacturer. Push buttons control all functions, including frame open/close, feed plate raise/lower, and upper and lower apron adjustment.

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Universal Engineering
Hydraulically adjustable feed plate

Universal Engineering Corp.’s MaxCap Series of horizontal shaft primary impact crushers offer the capacity of a New Holland Style Crusher with the ease of operation and maintenance of an Andreas style machine, the company says. The series of crushers features a hydraulically adjustable feed plate, interchangeable back and top wall castings, a hydraulically adjustable breaker plate that automatically maintains its position, and a heavy-duty disc style rotor with quick-change hammers.

The crusher series, which are available in a variety of dimensions with capacities up to 1,400 tons per hour, have a heavy-duty fabricated steel construction with an upper section of the housing that retracts hydraulically for easy access to the interior of the impactor. Other features of the HSIs in this series include the following: a hydraulically adjustable feed plate, hydraulically adjustable breaker plate with automatic positioning; fabricated disc-rotor assembly with quick-release hammer locks; and a rotor lock pinned from the crusher housing into the rotor body; top-loading, reversible hammers with protruding leading edges; interchangeable abrasion-resistant alloy steel liners to protect the interior walls of the crushing chamber; and large access doors on the side and back of the crusher.

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Metso Minerals
Meets demanding applications

The new LT1315 and LT1415 new generation Lokotrack mobile horizontal shaft impact crushers from Metso Minerals combine high crushing capacity, a broad range of process options, and operator friendliness with the latest dust- and noise-reduction options, according to the company.

The LT1315 has a low transport height, and when equipped with the optional overband magnetic separator and pan feeder below the crusher, recyclable materials containing rebar may be processed without any problems, the manufacturer says. The LT1415 features a capacity range of up to 1,000 short tons per hour. Both primary crushers are built around the company’s Nordberg NP Series impact crushers, have Tier 3-approved engines, and can be equipped with a pan feeder/scalper or a roller grizzly. They also can be equipped with a two-deck screen and product conveyors. The LT1315 and LT1415 have a quarrying setting range of 60 to 150 mm and 60 to 200 mm, respectively. Both have rotor speeds of 450 to 560 rpm and have feed hoppers 8-cubic-meters in volume and 108 inches in width. An optional rubber lining is available for reduced wear and noise level, and optional feed hopper extensions enable loading by a wheel loader. The standard hopper is suitable for excavator loading.

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Eagle Crusher
Industry’s heaviest solid-steel rotor

The UM 1600-69 HSI crushing and recycling plant from Eagle Crusher is portable and self-contained with a 69-inch feed opening. The crusher features a sculptured three-bar rotor made of solid-steel and contains a 61,000-pound impactor with a 68-inch by 20-foot vibrating grizzly feeder. With its 13-ton sculptured solid-steel rotor, the heaviest in the industry, according to the manufacturer, the shock of huge, slabby, concrete, and asphalt is easily absorbed.

The plant weights 77,800 pounds in transport mode and 170,000 pounds when it’s complete. Travel width is 11-feet, 11 inches, and travel height is 13 feet, 5 inches. Feed hopper capacity is 27 cubic yards, and the discharge system is 54 inches by 40 feet. A road-portable discharge conveyor is optional. The standard on-plant power supply is 500 horsepower electric with an optional 800 horsepower electric or 521 horsepower diesel engine.

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Terex | Finlay
Large-reduction ratio

The new I-1312 impact crusher plant from Terex | Finlay is a multiple-speed impactor, which is designed for primary and secondary crushing of concrete/asphalt rubble and limestone. It features high throughput, a large reduction ratio, and quick set-up, according to the company. The plant’s crusher has a large discharge opening and has a standard three-bar or optional four-bar configuration. The hopper capacity is 11.7 cubic yards, with hydraulically folding sides, 5/8-inch hardox sidewalls, and tapered grizzly apertures. The system features an advanced compliant control system with large display screen, a detachable doglead control for tracking or optional full-function radio remote, and five operating modes — track, manual, automatic, configuration, and language — with a menu-driven graphic user interface. Other options on the crusher include a bypass conveyor, overband magnet, belt weigher, extra dust cover for discharge conveyor, hydraulic water pump, re-circulation conveyor, tracked or wheeled undercarriage, and a Caterpillar Tier 3 engine.

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Construction Equipment Co.
Two plants work in tandem

Construction Equipment Company’s Crush-It-Screen-It Combination Unit combines two plants that work in tandem. The Crush-It is able to handle recycle concrete, recycle asphalt, limestone, decomposed granite, shale, basalt, and other materials, while the Screen-It provides the means to deliver spec product. The combination unit works together as a closed circuit, total product package, according to the manufacturer, but each plant also can work separately to screen or crush when needed. The unit can deliver 125-300 tons per hour, depending on the material. The Crush-It plant is driven by a Caterpillar engine package that features a push-button, self-adjusting, hydraulically actuated clutch that will not start when the engine speed exceeds 800 rpm.

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Stedman
Reduces metal replacement

Stedman’s Grand Slam series of HSIs is composed of 11 high-production models with capacities ranging from 5 to 1,200 tons per hour for applications such as limestone, gravel, and asphalt materials. High-chrome metallurgy is used to reduce wear life, and the crushers’ impactor design incorporates both primary and secondary aprons for maximum product control and eliminates the need for high-maintenance grate bars and discharge screens that can clog often, according to the company. The series features a full-length rotor shaft with two, double-row spherical-type bearing assemblies with a taper lock design. The rotor itself features a two-, three-, or four-row breaker bar design, depending on machine and model size. A wedge-locking design secures the breaker bars in place and simplifies servicing needed on the breaker bars, according to the manufacturer. Additionally, the rotor lock table, which is a Stedman exclusive, the company says, facilitates breaker bar rotation and replacement.

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Terex | Cedarapids
High-production tonnages

The horizontal shaft impact crushers from Terex | Cedarapids have an extra-large feed opening accepts feed sizes from 6 inches to a maximum 22 inches to process most types of material including gravel, shot rock, and recycle feed. They come in two sizes with two crushing chamber configurations and offer high-production tonnages, improved particle shape, and reduced wear costs, according to the manufacturer. Three- or four-bar rotors are available for either 4- or 5-inch thick, four-turn blow bars, made from chrome or tool steel with optional ceramic inlays. The 50-inch open rotor design with 5-1/4-inch thick backer bars results in a high-rotor inertia, allowing it to operate at large reduction ratios for higher capacity.

The primary apron is configured as either a one-piece cast manganese configuration that can be turned to increase wear life or a high-strength fabrication with bolt-on 3-inch thick cast chrome liners. The crushers also feature large, spherical roller bearings with taconite-type labyrinth seals, large inspection access doors, and hydraulically opening body halves, which results in quicker blow bar and liner changes, according to the company.

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Sandvik 
Unique hammer and rotor designs

The Impactmaster horizontal shaft impact crushers from Sandvik Mining and Construction — the Impactmaster P & S Series high-performance crushers — features are distinguishable from other HSIs by their unique hammer and rotor designs, modular concept, operator-friendly maintenance, and safe operation, according to the manufacturer. Both crushers in the series offer operators a range of aggregate and recycling applications. The units, which may be used for primary and secondary applications, are each fitted with a common rotor, covering the full crusher range with three rotor sizes — 45, 51, and 67 inches in diameter. A single type of hammer, which is available in two lengths, covers all combinations on the rotors on all primary and secondary models.

The all-welded rotors also have heavy, rigid hammer backing bars, and hammer locking is accomplished by means of locking wedges. Options for the crushers including a motor-driven hydraulic power pack for curtain setting assistance and crusher topshell opening; manganese, chrome steel, and/or chrome iron for hammers and liners (depending on the application); a jib crane for removing and replacing hammers; and a re-circulating chute, which enables a P series crusher to operate in a closed circuit.

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Reprinted from Aggregates Manager Magazine
December 2006