Owner’s Manual > – For physical copy email: [email protected]
Outlining the preliminary essential steps for setup and initial operation:
Please review and follow all safety and maintenance procedures outlined in the user’s manual prior to operating any VYKIN machinery.
Prior to crushing any material:
1. Unloading:
1a. Please see next section below on how to unload your machine.
2. Fuel & Lubrication:
All tanks come bone dry, please ensure all tanks are filled appropriately:
2a. engine oil in reducer;
2b. grease all lubrication points on roller (Refer to the videos in the maintenance section below for specific locations and manual for grease type.)
3. Material Inspection:
3a. Please check the type of material and make sure it is a non-hazardous waste material.
3b. Ensure the material’s feed size is compatible with the crusher’s feed opening and selected conveyors / feeders.
4. Initial Operation:
4a. Position the crusher on a stable, level surface.
4b. Start the crusher and monitor its performance.
4c. Observe the material flow and adjust settings as needed to achieve optimal crushing efficiency.
4d. Pay attention to any unusual noises or vibrations, and stop the machine immediately if any problems occur.
4e. Check all belts, guards, and safety features are in place and functioning correctly.
5. Initial Break-In Period & Maintenance:
5a. During the first week of operation, check all bolts, lock nuts, pins, fittings, fasteners and connections every 3-4 hours. Then check and tighten all bolts and fasteners periodically, thereafter.
5b. Conduct frequent inspections of the teeth roller drum for wear and tear, and regularly clean to prevent material buildup ensuring efficient separation. Replace damaged drums promptly to maintain product quality and prevent downtime.
6. Feed Rate and Material Flow:
6a. Start with a slow and steady feed rate, gradually increasing it while monitoring the crusher’s performance and material flow.
6b. Avoid overloading the crusher, as this can lead to inefficiencies and potential damage.
6c. Choose the appropriate roller gap size based on your desired output product and feed material characteristics.
Important Notes:
Remember:
The VYKIN roll crusher is a powerful and efficient crushing machine. By following these simple steps and referring to the user’s manual, you can ensure safe and productive operation.
If you have any questions or concerns, don’t hesitate to contact VYKIN customer support for assistance.
Please be advised your crusher will be delivered either on a flatbed / box van (trailer type will be confirmed prior to delivery). To unload your machine from the truck — you can either (1) use a forklift, or (2) use a rollback / tow truck to help get the load off trailer:
The extra rollers will be placed on top of the machine, in the same crate.
Video Timestamps:
00:13 Check and Add Grease Before Starting Machine
01:49 How to Adjust the Roller Gap (please see below video for additional helpful instruction)
04:09 Daily Maintenance (please see below video for photo of roller disc bolts)
Roller Gap Adjustment:
1. At the back end of the machine, loosen the rear lock nut & then loosen the square (gap adjustment) bolt to loosen the spring and release pressure.
2. At the center of the machine, in the observation window you will find 1 adjustment screw rod (on both sides of the machine) — turn clockwise to tighten & push the moveable roller backwards (so that a gap is created enough to add/remove shim plates).
3. When the roller is pushed back, it will create a gap between the bearing chambers — here you can add or remove shims to adjust the gap between the rollers (adding shims increases gap; removing shims decreases gap). Please ensure both sides are made equal.
4. After gap adjustments are made, loosen the middle screw rods on both sides (NOTE: these middle screws should be completely loose) — and then tighten the two rear square bolts evenly (to compress the two springs evenly), secure the two locking nuts after tightening.
First image below is of the middle adjustment screw rod.
Second image after that is the stack of shim plates.
Page 57 in manual for filling hydraulic oil tank. After 50-hours, filter the hydraulic oil for any metal filings during break-in period.
Roller Disc Bolts on the Two Rollers:
VYKIN Double Roller Crusher Operation and Maintenance
1. Scope
This section outlines the technical use, maintenance, and equipment upkeep standards for VYKIN double roller crushers.
2. Reference Standard
This section refers to relevant parts of VYKIN’s equipment management guidelines.
3. Technical Operation Standards
3.1 Preparation and Inspection Before Operation
3.1.1 Before starting the roller crusher, check for the proper amount of lubricant in the bearings and reducer.
3.1.2 Inspect all spring bolts and other fastening bolts for tightness.
3.1.3 Coordinate with related processes (ventilation, sieving, conveying) and ensure the crushed material flow direction is correctly selected.
3.1.4 Adjust the vibrating feeder’s material feed rate according to production needs.
3.2 Precautions During Operation
3.2.1 Verify that the material’s physical and chemical properties and particle size meet the crusher’s requirements. Prevent oversized or unsuitable materials from entering the crusher.
3.2.2 Ensure uniform feeding and maintain a feed rate within the capacity of the belt conveyor and bucket elevator to prevent blockages.
3.2.3 Continuously monitor the motor and bearing temperatures, ensuring they do not exceed 70°C. The reducer and motor temperatures should also remain below 70°C.
3.2.4 Verify the correct feed direction and check for any blockages.
3.2.5 Pay attention to any abnormal sounds from the motor or mechanical components.
3.3 Inspection After Shutdown
3.3.1 Check the motor and bearings for excessive heat.
3.3.2 Inspect all fastening bolts for looseness.
3.3.3 Complete the production records.
3.3.4 Clean the equipment and maintain a tidy work environment.
4. Maintenance Standards
4.1 Lubrication System
Lubrication Point | Lubricant Type | Frequency |
Motor | Lubricating grease | During maintenance |
Reducer | 45# diesel engine oil | Check oil level regularly |
4.2 Maintenance Inspection
4.2.1 Ensure all anchor bolts and connecting bolts are tight.
4.2.2 Check the reducer’s oil level and quality.
4.2.3 Grease all lubrication points during production shifts.
4.2.4 Monitor motor and bearing temperatures, ensuring they remain within specified limits.
4.2.5 Inspect the reducer for unusual noises and ensure its temperature is normal.
4.2.6 Keep spring set screw nuts tightened.
4.2.7 Ensure the spring is free of debris. Stop and remove any debris immediately if found.
4.2.8 Inspect the rollers for wear.
4.2.9 After adjusting the gap between the rollers, securely fix the movable and fixed yokes.
4.3 Troubleshooting
Fault | Cause | Solution |
Material blockage | 1. Oversized raw materials | Adjust material feed rate and control the bulk density. |
Roller bearing heat | 1. Misalignment after roller gap adjustment | 1. Re-adjust alignment |
Motor trip | Foreign matter or oversized material | Remove obstruction |
Roller doesn’t turn | Severe reducer gear wear | Replace gears |
5. Inspection Standards
5.1 Inspection Cycle
Maintenance Type | Cycle | Time Required |
Minor repair | 3 months | 6 hours |
Medium repair | 1 year | 24 hours |
Major repair | 5 years | 40 hours |
5.2 Inspection Content
5.2.1 Minor Repair:
5.2.2 Medium Repair:
5.2.3 Major Repair:
5.3 Quality Standards
5.3.1 Horizontal and vertical dimensions of the rack should not exceed 0.2/1000.
5.3.2 Height difference in repaired roller skin welds should not exceed 3mm.
5.3.3 The gap between rollers should be 4-10mm (adjustable based on production).
5.3.4 Force on the roller spring should be uniform, screws should not be bent or damaged, and the H axis should be parallel.
5.3.5 Repair weld roller skin when surface wear exceeds 2mm. Replace when wear exceeds 5mm.
5.3.6 All sealing devices should prevent material leaks.
5.3.7 Transmission and reducer maintenance should align with general technical standards.
5.3.8 Refer to general standards for basic requirements.
5.3.9 Roller gap adjustment should ensure proper clearance, parallelism, and even spring compression.
5.4 Vulnerable Parts Replacement
Wear Part | Wear Limit | Minor Repair | Medium Repair | Major Repair |
Roller skin | Surface wear concave 5-10mm or more | Repair welding | Repair welding | Replace |
Bearing lining | Gap more than 0.5mm | Adjust | Replace | Replace |
5.5 Commissioning and Acceptance
5.5.1 Pre-Commissioning Checks:
5.5.2 No-Load Test (2 hours minimum):
5.5.3 Load Test (4 hours minimum):
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