December 2002
Here’s a guide to the new standards manufacturers must meet
By Cristina Ruiz
Before purchasing a new machine, the buyer researches a variety of issues from its performance abilities to its engine. But the buyer is not the only entity checking out mining and construction equipment. Every diesel engine-powered machine marketed in the United States, whether on-road or off, must meet strict emissions standards established by the Environmental Protection Agency (EPA). Because these standards can, at times, affect the buyer, it is important to understand their significance.
Setting the Standard
The 1988 Clean Air Act gave birth to the emissions standards tests. EPA defines emissions as the level of noxious gases that are released during the engine combustion process and through an engine’s tailpipe, said Joe Unseth, environmental compliance manager for Deutz Corp., Norcross, Ga.
As part of the Clean Air Act, the California Air Resources Board, working with the EPA, is the only state organization legally allowed to set guidelines. The Engine Manufacturers Association (EMA) is also in constant communication with these regulatory authorities. Many times, individual engine manufacturers will also stay in contact with EPA in regard to these standards, said Roe East, product strategist for Cummins, Columbus, Ind. EPA welcomes this communication, he said. EPA officials request feedback to know what is truly feasible for engine manufacturers to accomplish. Yet, it is ultimately EPA’s decision what the standards will be and when they will go into effect.
Since EPA first enacted the levels, or tiers, of standards, many changes have occurred. The original Tier I requirements were some of the first emissions standards for the industry. Tier I standards are also what most machines today are in compliance with. Currently, many engine manufacturers are gearing up to finish Tier II requirements, while at the same time starting work for Tier III deadlines.
There is not simply one deadline for all of the tier requirements. Deadlines are set by horsepower range, not by product or manufacturer, Unseth said. Engines within defined horsepower ranges must meet specific EPA emissions standards by their given deadlines. At the start of 2003, for example, engine manufacturers must meet specific emission standards within the 100- to 175- horsepower range. There is a different deadline in 2003 for 175- to 300-horsepower engines. Each of these categories have different compliance standards that indicate the allowable level of emissions, Unseth said.
Meeting the Standards
“The goal is to provide clean diesel engines without increasing fuel consumption or maintenance,” said Carl Volz, spokesman for Caterpillar, Peoria, Ill.
Unseth and Volz agreed that this is not always an easy combination to reach. Cummins, Deutz, and Caterpillar said that engine manufacturers will fight any overly strict or unattainable standard and also will try to negotiate with the EPA. “In some cases there’s negotiation, but in others it’s a very strict, straight line situation with the EPA,” Volz said.
But once the standard is set, engine manufacturers have no other alternative than to meet them. “If they do not (meet standards) there are some very strict fines and penalties pressed upon the manufacturer,” said Volz.
With such strict standards, it is important that engine manufacturers start research early to develop compliant products. East said that Cummins started research for Tier III requirements in the 1990s. “In general, our work for emissions (reduction) is ongoing.”
Some engine manufacturers try to kill two birds with one stone by looking beyond Tier II requirements. Caterpillar and Cummins are two companies that have developed advanced technology that would make their engines comply with Tier II and Tier III standards.
Caterpillar introduced its Advanced Combustion Emissions Reduction Technology (ACERT). Volz explained that ACERT is a systems approach to solving emissions problems and has four major parts to it. “ACERT takes our proprietary technology in electronics, fuel injection, system combustion, and aftertreatment to deal with emission control,” he said.
Emissions are getting harder to measure, Volz said, because they are being reduced to such low levels, thus a system approach seemed the most reasonable.
Caterpillar has reduced emissions from its on-highway truck engines by 90 percent since 1988, and it is estimated that the level will drop another 90 percent by 2007, according to Volz.
ACERT technology can control fuel injection rates — and therefore to an extent the combustion process — to the nanosecond, Volz said. Caterpillar’s on-highway truck engines, incorporating some elements of ACERT, recently were certified by the EPA. The company expects engines with full ACERT technology to be commercially available beginning in early 2003.
Cummins takes a different approach to emission-compliant products with its “Right Technology.” John Wall, Cummins president and chief technical officer, explained that this technology will allow machine manufacturers to minimize engineering and product development costs by using existing engine platforms with electronic fuel systems. The new technology would eliminate the need for aftertreatment devices, which are susceptible to degradation from high-sulfur fuels.
Detroit Diesel Corporation (DDC) eliminated the need for aftertreatment devices by equipping its on-highway engines with Exhaust Gas Recirculation (EGR). The company announced in October that it received EPA certification for its 12.7- and 14.0-liter Series 60. DDC offset the increased weight of the EGR system with a new low-profile gear train and other lighter-weight components. Without changes to maintenance procedures or recommended oil changes, the company claimed that the EGR-equipped Series 60 has proven to have reduced piston ring and cylinder liner wear compared to previous engines without EGR.
But not all engine manufacturers are introducing new technology to deal with emission regulations. Deutz Corp.’s Unseth said that many manufacturers will install intercooled engines. “I don’t expect any major changes beyond intercooling,” he said.
Intercooling works with an air cooler between the turbo charger and the engine air intake, Unseth explained. The turbo charger compresses the air. The intercooler cools it off, and makes the air more dense. “That gives you more flexibility,” he said. “When it cools off the combustion, lower NOx (oxides of nitrogen) surge and it improves your power density.” Unseth estimated that 90 percent of engines manufactured will require some sort of intercooling.
While Unseth does not envision any external changes beyond this, some say intercooled engines can impact machine performance. This stems from the idea that smaller engines may have to be reconfigured to fit the intercooling system, making the entire unit bigger.
Keeping the Standard
Manufacturers agree that equipment owners will not have to update or participate in any special procedure to remain in compliance with EPA regulations. However, each noted that the buyer should always take the step to make sure they are in compliance with EPA standards. According to Unseth, inspectors are checking if engines carry the correct EPA-certified tag. If a machine does not have the proper certification, the owner could encounter a series of penalties and fines. EPA also can impound the machine. Unseth admitted that situations like these are rare, but owners should al-
ways make sure their machines are certified.
Finding an uncertified machine is not common, but be careful when buying imported machinery. “EPA and U.S. Customs found that foreign engine companies sometimes import uncertified engines,” Unseth said. Because he has known some foreign companies to try to make counterfeit EPA labels, he suggested that if buyers are ever suspicious about an engine they should contact EPA or an engine manufacturer. “But EPA and U.S. Customs work closely together in monitoring imported non-road engines,” Unseth said.
East also warned that while it is legal to operate older machines that don’t meet the latest emission standards, some stipulations may come along with using them. “Nothing prevents local officials from forcing contractors to use newer, cleaner equipment on government-funded projects,” said East. Normally, as long as the machine is in compliance with emission regulations of the year it was manufactured, everything should be fine, he said.
But a permit may be necessary for stationary equipment in non-attainment areas, such as Los Angeles, New York, and Atlanta. To help bring air quality within national standards, local governments sometimes take special actions in nonattainment areas, including regulating stationary emission sources such as power generation equipment. According to East, mobile equipment cannot be regulated by local authorities.
Equipment owners should keep another point in mind when upgrading an engine with a newer model. The upgraded engine must meet the compliance standards of the year it was manufactured. However, owners exchanging engines for the same model do not have to worry about newer compliance standards.
| Engine Design Strategies
A factsheet from the Diesel Technology Forum (www.dieselforum.org) lists the following strategies being used to develop cleaner diesel engines:
|
Cristina Ruiz is assistant editor for AggMan.
Quarry Dreams
Opening their first quarry, partners research options and make non-traditional equipment choices
By John Watson
Big Creek Quarry President and Co-owner Scott Hiebert stands beside the JCI 400-hp remote-adjust cone.
Iwanted a quarry forever,” said Scott Hiebert, president and co-owner of Big Creek Quarry. The quarry is a new endeavor in Moscow Mills, Mo., about 30 miles northwest of St. Louis. It opened for business in March 2001.
“Several years ago, I had a concrete paving business with a portable ready-mix plant,” said Hiebert. “I learned early on that the paving guys who also own quarries get the best jobs.” Hiebert sold his paving company to Goldstar Paving in 1995 and entered the sewer construction business, but he kept his dream of owning a quarry.
“I wanted to supply my sewer business with aggregate and also figured I could get four or five other main customers in the same business,” he said. “But instead, only a few months after we opened for business, I have more than 60 customers, and only two of them are sewer construction companies.”
Big Creek is a new limestone quarry. When Hiebert purchased it in January 2000, it was licensed and permitted, but at that point had only carried out test blasts. He and his partner, Todd Barklage, spent a year trying to get a larger portion of the property permitted. They also started — without the benefit of prior experience — a search for the best plant configuration and equipment to meet their production goals. The research led them to make some non-traditional equipment choices.
Hiebert and Barklage weighed their options, talking to local equipment dealers and manufacturers and looking at operations around the country. The partners were aware that most operations in their area used impactors for secondary crushing. But after talking with several quarry owners, they were leaning toward purchasing a primary jaw and a secondary cone crusher.
Their rationale was that a cone would produce more clean rock, without the fines manufactured by an impact crusher. In addition, the partners weighed maintenance and cost per ton between the two crusher types. “You can’t just look at equipment cost and tons per hour,” Hiebert said. “You have to include cost per ton and downtime.”
Hiebert said he and Barklage researched equipment for a year as they worked on permits for the quarry. Ultimately they chose to purchase a Pioneer 3350 jaw and a 400-hp remote-adjust JCI cone. Both are Astec companies represented in the St. Louis, Mo., area by Cummings McGowan & West. The quarry also has two JCI 6- x 20-ft. horizontal screens.
“Originally, we were going to make only 1-in. clean and 1-in.-minus product for the sewer accounts,” Hiebert said. “Other operators we knew in the area laughed about that, and it turns out they were right.”
Big Creek’s products now include 1-in. clean (the company’s primary product), 2-in. clean, 1-in. minus, 2-in. minus and 4- to 8-in. clean. Recently, Big Creek began selling screenings, boulders, shot rock and rip rap, as well.
“We are reading up on what we can do with fines,” Hiebert noted. “But we still are not making a lot of fines as it is. This is one of our competitive advantages; while much of the industry struggles with an excess of fines, our equipment purchases have helped us to minimize that.”
Scott Hiebert and Todd Barklage, co-owners of Big Creek Quarry, purchased a Pioneer 3350 jaw primary crusher. A front-end loader feeds the jaw through a 50-in. x 20-ft. vibrating grizzly feeder.
Solving Problems
It has been their customers who have driven the decision to expand products. “We see a lot of established quarries that don’t take care of their customers very well,” said Hiebert. “We work to convince our customers we will take care of them. So, for example, we hired an ex-truck driver to load trucks for us because he understands how truck drivers want to be loaded and turned. It’s attention to details like this that helps our business. We work just as hard to make the ‘little guys’ as happy as the ‘big guys,’” he added.
Hiebert said that having been in the paving and sewer construction business, he already knows most of the customers in the area. His experience from this side of the business helps him to stay aware of the problems his customers may encounter. “Even though we have only been in business since March 2001, we are still operating from the standpoint of solving problems for our customers,” he said.
As for the equipment, Hiebert said he and Barklage are still learning six months into their endeavor. “We noticed after several weeks that we were getting some wear on the liners and there was excess rock going across the top of the screens. We realized we had too much rock going through, so we adjusted.”
Big Creek Quarry’s primary products include 1-in. clean and 2-in. clean stone. The company also produces 1-in. minus, 2-in. minus and 4- to 8-in. clean. In recent months, Big Creek has begun to sell screenings, boulders, shot rock, and rip rap.
Learning Curves
The 3350 jaw, from Pioneer’s Vanguard Series, features a hydraulic dual-wedge adjustment for changing the closed-side setting (CSS). Heavy-duty 63-in. flywheels optimize stored energy, reducing peak horsepower requirements, according to the manufacturer.
As vice president, and the partner in charge of running Big Creek Quarry’s day-to-day operations, Barklage has had the opportunity to become more familiar with the equipment. He said he likes the jaw’s stroke and toggle adjustment. “The hydraulic wedge adjustment is something we had to learn by trial and error,” Barklage said. “We tried a range of 4 to 8 in. and decided it needs to be set at 5 1/2 in.”
Production rates of 400 to 450 tons per hour are possible with the 3350 jaw, according to Barklage, provided material is fed consistently to the crusher. “That is usually dependent on loader distance from the crusher,” he said. “For the most part, the loader is able to keep the jaw fed.”
The JCI 400-hp, remote-adjust cone is a roller bearing design. Internal counterweights located out of the rock stream eliminate wear and maintain the machine’s precision balance throughout the life of the machine, according to the manufacturer.
Hiebert said the only problem Big Creek Quarry has had with the cone happened when it was started after days of not running. “Early on, we broke the anti-spin cone brake. We called JCI, and they installed their new cone brake design — and we haven’t had any problems with it since.”
Barklage said that he has chosen not to use the crusher’s capability to change the CSS under load. “The remote-adjust feature allows us to tweak the CSS to pick up production on our 1-in. clean product. And that is what we use it for primarily.”
The JCI three-shaft, horizontal “oval motion” screen features slip-on gears, keyless shafts with a tapered locking system, double-roll spherical roller bearings, and the ability to quickly change the oval stroke length and angle, according to the manufacturer. A variable-pitch sheave allows quick changes as screening applications change.
“We were pleased that the screens had a smaller learning curve,” Barklage said. “We did learn last winter that they needed thinner oil; we had a problem starting them up in the cold, but we took care of that easily.”
“We are happy so far with the choices we have made in all of this,” said Hiebert. “We like that we are able to take care of our customers and see something at the end of the day. That’s where we see our success.”
Crushed material from the Pioneer 3350 Jaw goes to a JCI 6- x 20-ft., three-deck horizontal screen. Plus 1-in. material goes to the JCI cone. After the second crushing, the material is sent in closed circuit to the second JCI 6- x 20-ft. three-deck screen.
the bottom line...
Solving problems for customers and paying attention to details — including choosing equipment not typical for area operations — has quickly expanded business for these first-time quarry owners.
To submit a suggestion for a Success in the Field or for more information about any of these stories, contact AggMan at (330) 433-9463, Fax: (330) 433-9463 or email at bob@aggman.com
Information for this article was provided by Kolberg-Pioneer and JCI.
Automation Leadership
Feltes Sand & Gravel shows that reaping benefits from technology
depends more on attitude than company size
By Gail Stolzenburg
After the initial morning check in, 90 percent of the truck traffic can be handled automatically. This allows the weigh-master to spend time contacting customers.
Despite being talked about for the past 30 years, automation is fairly new to the stone, sand, and gravel industry. Because the industry doesn’t accept change easily, most automation of aggregates operations has happened in just the last 10 years.
Automation is a continual process that when done right is very rewarding. When it’s not, it can be disastrous. In the automation process, there are always a few leaders who are willing to take a risk before others, who envision a better way to do things. Feltes Sand & Gravel Company is one of those leaders. It is not among the top 10 largest aggregate companies — maybe not even in the top 50 — but it is years ahead of most companies when it comes to automation. Feltes has proved that a smaller company can implement innovative technology just as easy, and sometimes a lot faster, than the large companies.
Feltes Sand & Gravel Company is located in Elburn, Ill., about 40 miles west of Chicago, in the middle of an area with continuous residential and commercial development. Rick and Tim Feltes, third generation owners, take an active role in their business and industry. They have been active in the National Stone, Sand & Gravel Association, gaining valuable insights for their own company while leading the way for other producers to benefit from the association. It’s a formula that works well for the company.
Together, Rick and Tim Feltes formulate the sales, operating, and financial plans for their company. Once the objectives are set, their team of experienced, dedicated employees is charged with implementing the plans and achieving the goals.
Nevertheless, automation didn’t happen overnight at Feltes. Like many companies, they started with a computer in the office for billing and accounting. Then, they put a computer in the plant to print scale tickets. That worked fine for a while, but with the office separated from the plant by 20 miles, it was hard to stay in touch with what was happening.
About six years ago, they saw the benefits of automated identification and installed one of the first bar code systems in the country. At the same time they put in remote ticketing using a thermal transfer printer, which saved an enormous amount of the weigh-master’s time.
Feltes was able to double its sales and still operate the scale house with just one person. Then the company did something few others have done — eliminated the scale house. They moved the office from North Aurora to the Elburn Plant, installed video controls to see everything that was going on, and put traffic lights on the scales so they could be operated unmanned.
The company set up one scale for check-in (tare weight) in one direction and for a back-up weigh-out in the other direction. At the same time they automated the plant so products could be produced faster, easier, and at less cost.
Recently, Feltes Sand & Gravel implemented one of the most innovative identification and weighing systems in the country using radio frequency identification (RFID). Each truck has a small RF tag installed in the windshield. Feltes doesn’t own its own trucks. They rely on outside haulers, who need a reason to come to the Feltes plant. The reason haulers come to the Elburn Plant is that they are able to get through faster and with less hassle. This can result in the trucker getting an extra load every day, which translates into more take-home pay.
Feltes installed a state-of-the-art computer system coupled with the RFID. After the initial morning check-in, 90 percent of the traffic can be handled unmanned. There are two lanes for incoming traffic — one with a scale for tare weight and one for express traffic, the trucks that are delivering additional loads to the same job. The system allows for orders to be set up in advance so that trucks can be checked in, loaded, and weighed before the weigh-master gets to the office. With the automated system and RFID, the weigh-master is able to spend her time doing customer contact work as an inside sales person.
Feltes Sand & Gravel is preparing for the next step — e-commerce. The groundwork has already been done. Information is available in its database so that when high-speed internet access is available, Feltes Sand & Gravel’s customers will be able to access information about their jobs. They will see every load that has gone to each of their jobs, including total quantities and dollars, without having to make a phone call to the plant.
Other options include getting quotes, sending orders, seeing accounts receivable, and analyses of purchases. In addition, Feltes Sand & Gravel’s staff will be able to access information from anywhere. Salesmen will be able to use a PDA to check customer information before meeting with them.
Feltes Sand & Gravel operates two lanes for incoming truck traffic — one with a scale for tare weight and one for express traffic (trucks delivering additional loads to the same job). The incoming scale can also be used for outgoing traffic if needed.
the bottom line...
Feltes Sand & Gravel’s state-of-the-art radio frequency identification (RFID) system for customers’ trucks allowed the company to double sales and essentially eliminate its scale house. The company’s next step is e-commerce.
To submit a suggestion for a Success in the Field or for more information about any of these stories, contact AggMan at (330) 433-9463, Fax: (330) 433-9463 or email at bob@aggman.com
Gail Stolzenburg is the chief executive officer of Snead Management Systems, Inc., a consulting firm specializing in automated systems and e-commerce for the aggregates industry. He is past-chairman of the NSSGA Manufacturers and Services Division, a Trustee of ROCKPAC, a founding member of the Automation Committee, a frequent speaker at aggregate industry functions and author of numerous articles for industry magazines.
Basic Specs for Rigid-Frame Haul Trucks
By Cristina Ruiz and Bob Drake
Compared to the fleets of 300-ton-plus haul trucks working at many metal mines, those used in the aggregates industry look like toys. Most aggregate operations use haul trucks rated to carry 100 tons or less, although a few large quarries have opted for 150-ton trucks.
Nevertheless, what the aggregates industry lacks in machine size, it makes up in numbers. According to the U.S. Geological Survey, in 2000, the 115 metal mines in the United States handled about 2.2 billion metric tons of material, including crude ore and waste. By comparison — like industrious ants — the 11,072 U.S. crushed stone and construction sand and gravel operations handled more than 2.7 billion metric tons.
The large number of aggregates operations and construction companies provides manufacturers a relatively large market for small- to medium-sized (35- to about 100-ton) rigid-frame haul trucks. It also provides users a broad range of machines from which to choose. Almost two dozen models from five manufacturers are available in this size range.
The basic specifications in the table below only begin to indicate the capabilities of each model. A few miles-per-hour difference in maximum speed or a couple seconds faster in body raise time are only meaningful to overall productivity if your operation is already efficient: smooth, well-maintained, properly sloped haul roads; properly matched loading tools and primary crushers; and well-trained operators.
With minor variations, all manufacturers today equip haul trucks with a long list of standard features, such as ROPS/FOPS cab, adjustable operator’s seat, trainer’s seat, air conditioning, radio, cup holders, automatic transmission, electronic monitoring and troubleshooting systems, integral torque converters with lock-up in all gears, hydraulic retarders, and oil-cooled rear wet-disk brakes (except 35-ton trucks, which typically have air drum brakes).
Optional features, likewise, are similar among manufacturers, including rear view television monitors, automatic lubrication systems, fire supression systems, on-board weighing systems, body liners, and different tires. Caterpillar is the only company that offers optional body designs for most of its trucks — V-shaped floor with rear ducktail or flat forward-sloping floor.
Listed specifications are for models with standard equipment. Blanks indicate that information was not readily available at press time. All manufacturers provide the disclaimer that specifications are subject to change without notice.
| Rated Payload |
Volume (SAE) Heaped 2:1 |
Manufacturer and Model |
Maximum GVW (lb) |
Horsepower Gross/Net |
Engine/ Transmission |
| 35.0 tons | 25.0 cu yd | Terex TR35 | 122,300 | 400/369 | Cummins/Allsion |
| 35.9 tons | 27.5 cu yd | Hitachi EH600 | 125,467 | 398/383 | Volvo/Allsion |
| 40.0 tons | 31.7 cu yd | Cat 769D | 150,000 | 510/487 | Cat/Cat |
| 40.0 tons | 30.7 cu yd | Hitachi EH 650 | 137,919 | 496/491 | Volvo/Allsion |
| 41.9 tons | 31.2 cu yd | Hitachi EH 700 | 154,000 | 525/486 | Cummins/Allison |
| 42.5 tons | 36.3 cu yd | Hitachi EH 750 | 163,139 | 525/486 | Cummins/Allsion |
| 44.0 tons | 31.4 cu yd | Komatsu HD 325-6 | 159,020 | 508/488 | Komatsu/Komatsu |
| 45.0 tons | 36.0 cu yd | Cat 771D | 166,500 | 518/487 | Cat/Cat |
| 45.0 tons | 34.0 cu yd | Terex TR45 | 171,870 | 525/ | |
| 55.0 tons | 41.8 cu yd | Payhauler 350C | 172,800 | 635/607 625/597 |
Cummins/ Cat/ |
| 60.0 tons | 46.4 cu yd | Cat 773E | 219,000 | 710/671 | Cat/Cat |
| 60.0 tons | 46.0 cu yd | Terex TR60 | 210,940 | 650/613 | Cummins/Allison |
| 61.0 tons | 44.7 cu yd | Komatsu HD 465-7 | 217,820 | 739/715 | Komatsu/Komatsu |
| 66.0 tons | 47.0 cu yd | Hitachi EH1000 | 224,000 | 700/648 | Cummins/Allison |
| 67.0 tons | 52.3 cu yd | Komatsu HD605-7 | 240,740 | 739/715 | Komatsu/Komatsu |
| 70.0 tons | 54.3 cu yd | Cat 775E | 239,000 | 760/730 | Cat/Cat |
| 72.0 tons | 54.3 cu yd | Terex TR70 | 248,330 | 760/700 | Detroit Diesel/Allison |
| 72.3 tons | 51.0 cu yd | Hitachi EH1 100 | 239,000 | 760/725 | Detroit Diesel/Allison |
| 98.9 tons | 74.6 cu yd | Hitachi EH1 600 | 354,086 | 1,050/982 | Cummins/Allison |
| 100.0 tons | 78.6 cu yd | Cat 777D | 355,000 | 1,000/938 | Cat/Cat |
| 100.0 tons | 78.7 cu yd | Komatsu HD785-5 | 367,000 | 1,082/1,042 | Komatsu/Komatsu |
| 100.0 tons | 74.5 cu yd | Terex TR100 | 347,715 | 1,050/ | |
| 108.4 tons | 78.8 cu yd | Hitachi EH1700 | 375,000 | 1,200/1,121 | Cummins/Allison |
| Body Raise Time (sec) |
Maximum Speed (mph) |
Standard Tire Size |
Max. Steer Angle |
Body Type |
Info Express |
Notes |
| 14.0 | 34.2 | 18.00 R25 | 42° | V | 700 | |
| 12.0 | 35.4 | 18.00 25 | 40° | Flat | 701 | |
| 48.3 | 18.00 R33 | * | Flat/V | 703 | *Turning circle = 65 ft. | |
| 12.0 | 39.1 | 18.00 33 | 40° | Flat | 702 | |
| 11.2 | 42.5 | 18.00 R33 | 42° | Flat | 704 | |
| 11.2 | 42.5 | 18.00 R33 | 42° | Flat | 705 | |
| 10.0 | 43.5 | 18.00 R33 | * | V | 706 | *Min. turning radius = 23 ft. 7 in. |
| 7.5 | 35.6 | 18.00 R33 | * | Flat | 707 | *Turning circle = 65 ft. |
| 21.00 R35 | 708 | |||||
| 17.0 | 18.00 R25 | Flat | 709 | All-wheel drive; dual front & rear tires | ||
| 9.5 | 41.1 | 24.00 R35 | * | Flat/V | 710 | *Turning circle = 78 ft. 9 in. |
| 16.0 | 35.7 | 24.00 R35 | 39° | V | 711 | |
| 11.5 | 43.5 | 24.00-35-36PR | 39° | V | 712 | |
| 10.0 | 38.1 | 24.00 R35 | 39° | Flat | 713 | |
| 11.5 | 43.5 | 24.00 R35 | * | V | 714 | *Min. turning radius = 27 ft. 11 in. |
| 9.5 | 41.1 | 24.00 R35 | * | Flat/V | 715 | *Turning circle = 78 ft. 9 in. |
| 13.0 | 35.5 | 24.00 R35 | 42° | V | 716 | |
| 11.1 | 38.1 | 24.00 R35 | 39° | Flat | 717 | |
| 12.8 | 36.4 | 27.00 R49 | 38° | Flat | 718 | |
| 15.0 | 39.9 | 27.00 R49 | * | Flat/V | 719 | *Turning circle = 93 ft. 2 in. |
| 12.0 | 40.2 | 27.00 R49 | 45° | V | 720 | |
| 12.8 | 38.3 | 31/80 R49 | 38° | Flat | 721 |
Cristina Ruiz is assistant editor for AggMan.
Bob Drake is editor for AggMan.
A Checklist for Safe and Profitable HSI Operation
Regular maintenance is crucial to keep a horizontal shaft impactor (HSI) running in peak condition. Like all machinery, an HSI must be maintained properly and operated in the correct application to achieve its potential. Misapplication or abuse leads to underperformance and potential costly consequences. A little time spent each day on preventive maintenance minimizes the risk of spending a lot of time on a big headache in the future.
Set up for success
Proper setup lays the ground work for smooth operations. Check the following:
- Stability and levelness of the ground.
- Proper drainage/runoff to handle normal rainfall.
- Ample room around the machine for access to inspection doors so the unit can be opened for rotor inspection.
- Equipment is on the downside of the prevailing wind direction.
- HSI is properly cribbed and has landing devices secured. Make sure cribbing is in proper condition.
Preoperational checks
Before starting up the HSI, perform proper preoperational checks, including the following:
- Power unit is set as recommended.
- Rotor speed settings are correct.
- Blow bar retaining assemblies are secured properly.
- Blow bar wear is adequate (more than 0.75 in. above the rotor surface).
- Proper clearance exists between the rotor and aprons.
- Inspection doors are secured.
- Crushing chamber is free of materials.
- Safety guards are in place and secure.
- Operation and maintenance personnel understand machine operation and safety.
Adjustments
When making adjustments, keep the following factors in mind:
- Never adjust aprons closer than minimum settings.
- Always shim both sides of aprons equally.
- Secure inspection doors when finished with adjustments.
- Never make adjustments until machine motion has stopped and it is locked out.
Routine maintenance
The following recommendations are made for HSIs running in “normal” conditions. If you are running in extreme conditions, maintenance may need to be performed more often. Keeping a log is a way to ensure that proper maintenance is being performed.
Daily: Do an entire walk-around of the machine. Items to perform include the following:
- Inspect the unit for loose bolts, nuts, and screws.
- Ensure adequate lubrication.
- Check for fluid leaks and repair, if necessary.
- Make sure all guards are in place and functional.
- Inspect safety of handrails, ladders, and walkways.
- Clear away built up dirt and debris.
- Turn/replace blow bars before they are worn lower than 0.75 inch above the rotor.
Every 50 hours: Perform a detailed inspection of your HSI. In addition to the daily tasks, perform the following:
- Check for wear on impact plates and side liners. Be sure to replace plates before they are worn through.
- Verify that impact plates and side liners are secured to the machine.
- Check hydraulic fluid levels and inspect the apron retention system.
In addition to operating and maintenance manuals, detailed posters from HSI manufacturers can help operators and maintenance personnel understand machine operation and safety, and can highlight important areas for routine and special maintenance.
If questions arise about maintenance or operations, contact your authorized dealer or the HSI manufacturer.
| Lock Out! No matter which level of maintenance is being performed, don’t make any repairs or adjustments until all motion has stopped and the machine has been locked out. |
Information for this article was provided by Kolberg Pioneer, Inc.