Vsi 1800-2100 O&m

Operation & Maintenance Instructions
VSI 1800/2100
Operation & Maintenance Manual
Form 21052
LJ1093200
A Terex Company
21052 (3/97)
A Terex Company
Introduction
To the Owner & Operator:

Cedarapids, Inc. tries to provide information that gives our customers a clear understanding of equipment
construction, function, capabilities and requirements. This information is based on the knowledge and
experience of qualified people at our company and in our field organization. Proper use of this information
rewards users of Cedarapids equipment with high efficiency, maximum service life and low maintenance
costs. That is why we strongly recommend that anyone using our equipment be familiar with this manual.
This manual is not a bible. Information presented here should not be considered authoritative in every
situation. Users will, as a matter of course, encounter problems and circumstances that raise questions not
anticipated here. Such questions should be directed to Cedarapids, Inc.
Anyone who uses this equipment for any purpose other than that for which it was intended assumes sole
responsibility for dangers encountered and injuries sustained as a result of such misuse.
Respectfully,
Cedarapids Inc.
Danger - Federal, state and local safety regulations aim to protect both people and property from
accident, injury and harmful exposure. When complied with, such regulations are often effective.
Hazards to life, limb and property are further reduced when this equipment is used in accordance
with all operation and maintenance instructions. Generally:
1) Read and heed all danger, warning, caution and notice decals. Know what guards and protective
devices are included and see that each is installed and in operation condition. Additional guards and
protective devices may be required and must be installed by the user (owner) before operating.
2) Never attempt to maintain, lubricate or adjust this equipment while it is running. Lock out and tag out
all energy sources before doing maintenance, cleaning, adjusting or repairing this equipment. Make
it impossible for anyone to start this machine while others are working on it or in it.
3) Wear protective clothing such as hard hats and safety shoes, and use protective equipment such as ear
plugs and safety glasses when operating this equipment. Do not wear loose clothing or long hair.
4) Think safety and act safely. Stay alert at all times. Eliminate or neutralize potential hazards as soon
as you spot them. Never allow anyone to engage in horseplay when near this equipment.
Danger - Failure to take these precautions will result in death or severe personal injury.
16885 (3/99)
A Terex Company
The following warning applies to Cedarapids equipment supplied with lead-acid batteries:
Warning: Battery posts, terminals and related accessories contain lead and lead compounds,
chemicals known to the State of California to cause cancer and reproductive harm.
Wash hands after handling.
22388 (6/00)
A Terex Company
22388 (6/00)
A Terex Company
Section 1
Introduction and Contents
About This Manual
This manual is for owners and operators of a Vertical
Shaft Impact rock crusher made by ElJay Division of
Cedarapids Inc. The VSI is a precisely engineered,
highly functional machine designed to provide years
of excellent service. We strongly recommend that
anyone involved with the operation or maintenance
of the crusher take the time to become familiar with
this manual.
Warning! This manual contains vital
information for the proper, safe operation of
this equipment. Read the whole manual
before beginning to operate the equipment.
Failure to follow instructions and warnings
contained in this manual could result in
severe personal injury or death! It could
also incur substantial property damage.
Attention! Sometimes, at customers request,
a VSI is shipped without certain features,
such as the sheave. When this happens,
Cedarapids/ElJay attaches a warning tag to
alert installers that the belt guard, a safety
feature, is missing. In such cases it is the
customers responsibility to properly guard
the machine while it is running.
Keep this manual for your future reference. It can
help you:
Experience shows it is to your advantage to have a

copy of this manual on site at the crusher where
operators can consult it as needed... and a copy on
file in your office so that shift leaders or supervisors
can conveniently refer to it.
This manual is printed on high quality paper and
bound in a tough, flexible three-hole binder so it can
be read and handled many times in the field. Feel free
to write notes or comments in it as needed. The
manual is for your use.
Additional copies can be ordered through your
Cedarapids/ElJay Distributor.
The Owner/Operator Manual may be bound with the
VSI Parts Book. The Owner/Operator Manual is not
intended as a source for ordering parts. Only your
VSI Parts Book, identified with your serial number,
can be relied on for accurate part numbers and part
descriptions for your machine.
Ongoing improvement of product design may result
in future changes to some parts. When ordering
replacement parts, please be as exact as possible in
describing the part.
Use part numbers, model numbers, and serial number
to communicate with your Cedarapids Distributor.
When you have a question, please consult your
Cedarapids Distributor Representative.
About Cedarapids/ElJay
safely operate your VSI

understand how your crusher works
get highest production efficiency
perform regular maintenance and replace parts
Cedarapids/ElJay is proud to manufacture the

superior VSI rock crusher for your use and profit.
We also take pride in the quality of our service and
replacement parts. We look forward to serving you.
get maximum life from your wear parts

keep your downtime to a minimum.
21052 (3/97)
Page 1.1
LJ1093200
A Terex Company
Table of Contents
Section 1
Introduction and Contents
Installation Drawings
1800 VSI-GD .................................................... 3.7
About This Manual ........................................... 1.1
1800 VSI-VBD ................................................. 3.9

2100 VSI-GD .................................................. 3.11
Section 2
Safety Precautions
2100 VSI-VBD ............................................... 3.13
Personal Safety Hints and Rules ....................... 2.1

Cedarapids/ElJay Recommends ....................... 2.1
Work Area Safety Hints ................................... 2.2
Equipment and Tools Safety Hints ................... 2.3
Section 4
Daily Start-up and Check List
Daily Start-up Detail ......................................... 4.1
VSI with CastRotor .......................................... 4.1
Section 3
Installation and Start-up
VSI Daily Start-up Inspection Form ................. 4.3
Leveling on a Sturdy Foundation ..................... 3.1
Daily Start-up Detail- Continued ...................... 4.5
Access ............................................................... 3.1
Expected Flow Rates ........................................ 4.6
Transporting Your VSI ..................................... 3.1
Cold Weather Start-up ...................................... 4.7
Lock Down the Throw Device ......................... 3.2
Hot Weather Start-up ........................................ 4.7
VSI with Table/Shoes ....................................... 4.5
Reinstall the Locking Bolts Before Travel ....... 3.2

Models .............................................................. 3.2
Types of Drive .................................................. 3.2
Component Weights Chart ............................... 3.3
Electrical System .............................................. 3.4
Start-up Controls .............................................. 3.4
Automatic Shutdown ........................................ 3.4
Optional Pre-wired Panel.................................. 3.5
Setting Up the Lubrication System ................... 3.5
Setting Up the Rock Material Feed .................. 3.5
Guards and Nearby Equipment......................... 3.5
Check Rotation Direction Before Starting........ 3.5
Maximum RPM ................................................ 3.6
First Start-up Check List................................... 3.6
Storage .............................................................. 3.6
Section 5
Changing Table/Shoe Wear Parts
Balanced Running Important ............................ 5.2
Tables: Various Types Available ..................... 5.2
Shoes, Shoe Pins, Shoe Bolts ........................... 5.2
Weight-Balanced Shoe Sets.............................. 5.3
When to Change Shoes ..................................... 5.3
How to Remove Shoes ..................................... 5.5
How to Replace Shoes ...................................... 5.5
Shoe Brackets and Liners ................................. 5.6
When to Change Shoe Bracket Liners .............. 5.6
Changing Table Liners ..................................... 5.6
Changing Feed Disc ......................................... 5.7
Changing Table Rim Liners ............................. 5.7
6-Shoe Closed-Top Table ............................... 5.10
Cover Plate ..................................................... 5.10
21052 (3/97)
Page 1.2
LJ1093200
A Terex Company
Table of Contents
Section 6
Changing CastRotor Wear Parts
Monitoring the Anvil Ring ............................... 7.5

Replacing Lid Liners ........................................ 7.7
Maintain Balance with Matching Sets .............. 6.2

Epps and Wear Tips .......................................... 6.2
Changing Exit Port Protectors (Epps) .............. 6.2
Changing Wear Tips ......................................... 6.2
How to Change Primary and
Retaining Liners ............................................... 6.4
Changing Feed Disc ......................................... 6.5
CastRotor Tuning ............................................. 6.6
How to Change Trailing Angles ....................... 6.7
Changing the Feed Eye ..................................... 6.9
Replacing Tub Liner ......................................... 7.8

Replacing Flywheel Guard Wear Plates ........... 7.8
V-Belts .............................................................. 7.8
Installing New Belts ......................................... 7.8
Sheaves and Bushings ...................................... 7.9
Removing Sheaves and Bushings ..................... 7.9
Installing Sheaves and Bushings .................... 7.10
Check Alignment ............................................ 7.10
When to Change the Top Retaining Plates ....... 6.9
Section 8
Lubrication System
How to Change Top Retaining Plates .............. 6.9
Lubricant Oil Specifications ............................. 8.1
How to Remove the CastRotor ....................... 6.10
Oil Properties at Operating Temperature.......... 8.1
Changing Rim Liners ..................................... 6.11
Acceptable Lubricants ...................................... 8.1
Changing Side Plates ...................................... 6.11
Switching to Other Grades ............................... 8.1
When to Change the Bottom Retaining Plate . 6.12
Oil Analysis: When to Change Oil ................... 8.1
How to Change the Bottom Retaining Plate... 6.12
Taking Oil Samples .......................................... 8.2
Installing Rotor Studs ..................................... 6.12
Checking Oil Level with the Dip Stick ............ 8.3

How to Change Oil & Filter Element ............... 8.3
Section 7
Changing Stationary Wear Parts,
Belts & Sheaves
Oil Flow Patterns .............................................. 8.4
The Feed Tube .................................................. 7.1
Oil Flow Monitoring System ............................ 8.6
Removing and Reinstalling the Feed Tube....... 7.2
Flow Meter/Switch Settings ............................. 8.7
Adjusting the Feed Tube Height ....................... 7.2
Expected Oil Flow Rates .................................. 8.7
Adjusting Feed Tube with an Open Table ........ 7.3

Adjusting Feed Tube with a Closed Table ....... 7.3
Section 9
Electrical System
Adjusting Feed Tube with a CastRotor ............ 7.4
Junction Box (J-Box) ........................................ 9.1
Removing the Lid Assembly ............................ 7.4
Oil Pump ........................................................... 9.1
Types of Impact Surfaces ................................. 7.5
Flow Switch and Warning Horn ....................... 9.1
Anvils ............................................................... 7.5
Vibration Switch ............................................... 9.2
Rock Shelf ........................................................ 7.5
Start Delay ........................................................ 9.2
21052 (3/97)
Lubricating Oil Capacities ................................ 8.6
Page 1.3
LJ1093200
A Terex Company
Table of Contents
Section 9 (con't)
Electrical System
Table Requires Anvil Ring ............................. 10.7

VSI-GD (Gear Driven) ................................... 10.7
Monitor Delay and Simple Test........................ 9.2

Automatic Shutdown ........................................ 9.2
Changing Throw Device Rpm ........................ 10.7

Sheave and Rpm Combinations ...................... 10.8
Start-up Controls .............................................. 9.2

Wiring for Heater and Thermostat.................... 9.2
Wiring for Optional Pre-wired Panel................ 9.2
120 Volt Electrical Schematic
(For Units Without Optional Lid-Lifter) .......... 9.3
Section 11
Troubleshooting
Too Much Vibration ....................................... 11.1
High Operating Temperature .......................... 11.1
120 Volt Circuit Operation ............................... 9.4
Too Much Noise ............................................. 11.2

(For Units Without Optional Lid-Lifter) .......... 9.5
Too Much Oil Consumption ........................... 11.2
220 Volt Circuit Operation ............................... 9.6
Uneven Wear .................................................. 11.2

(For Units With Optional Lid-Lifter) ............... 9.7
Rapid Wear ..................................................... 11.2
Section 10
Applications
Wear Part Breakage ........................................ 11.3
How It Works: VSI Crushing Action ............. 10.1
Plugging of Hopper ........................................ 11.3
Characteristics of Rock ................................... 10.1
Horn Sounds ................................................... 11.3
Hardness ......................................................... 10.1
V-Belts ............................................................ 11.4
CastRotor Wear Tips Failing Too Soon ......... 11.2
Bearing Failure ............................................... 11.3

Low Production Tonnage ............................... 11.3
Abrasion ......................................................... 10.1

Friability ......................................................... 10.1
Section 12
Other Information
Application ..................................................... 10.1
Temperature Conversion Chart ...................... 12.1
Every Particle Crushed ................................... 10.2
U.S. Standard Sieve Series ............................. 12.2
Variables You Control to

Meet Your Requirements................................ 10.3
Bolt & Nut Torque Chart ................................ 12.3

U.S.- Metric Conversions ............................... 12.6
Changing Speed .............................................. 10.3

Varying Throw Devices.................................. 10.3
Balancing a Circuit ......................................... 10.3
Varying Feed Size .......................................... 10.3
Power, RPM, Feed Rates & Sizes Chart ........ 10.4
Controlling Wear ............................................ 10.5
Factors Affecting Gradation ........................... 10.6
Adjusting Trailing Angle Position .................. 10.7
21052 (3/97)
Page 1.4
LJ1093200
A Terex Company
Section 2
Safety Precautions
Personal Safety Hints and Rules
Cedarapids/ElJay equipment is designed with the
safety of all personnel in mind. Do not attempt to
change, modify, or eliminate the accident prevention
devices installed at the factory. Make sure that all
personnel who regularly work or who might do work
in the area of the equipment are familiar with the
safety precautions. Owners and operators are
responsible for reading safety information and
following safe practices. Think safety! Act safely!
Guards, covers, and shields are installed around
moving parts at the factory whenever necessary to
prevent accidental injury to operators and others
working on or near the equipment. Do not remove
them.
Attention! Sometimes, at a customers
request, a VSI is shipped without certain
safety features, such as drive sheave guard
or belt guard. When this occurs Cedarapids/
ElJay attaches a warning decal to alert
installers that the safety feature is missing.
In such cases it is the customers
responsibility to properly guard the machine
while running.
Warning: Whenever you see Warning in

this manual, it means that severe personal
bodily injury may result from improper
procedures. Be on guard! Warning indicates
that a serious hazard is present and severe
injury is possible. Read all Warning messages
carefully to prevent someone being hurt.
Danger!, Warning: and Caution: messages are
accompanied by the international alert symbol to
help call your attention to situations where danger to
persons is present.
Caution! Whenever you see Caution in
this manual, it means that if proper
procedures are not followed, minor to
moderate injury (small cut, bruise, etc.) may
result. Do not neglect to care for even small
cuts. Avoid infection by cleansing and
covering wounds.
Cedarapids/ElJay recommends the following basic
safety practices
For your personal safety, this manual includes three

levels of hazard and injury alert notices: Danger,
Warning, and Caution. Each hazard alert notice is
accompanied by an international alert symbol to
help call your attention to dangerous or potentially
dangerous situations. Read all alert notices carefully
to prevent injury to yourself or others.
Danger! Whenever you see DANGER! in
this manual, it means that death or severe
personal bodily injury can immediately result
from improper procedures. Read all
Danger! messages carefully to prevent
accidents. Take immediate action!
Read all warning, caution, and instruction signs.

Warning! Lock out the power source to this
crusher before attempting any maintenance.
Always establish a positive lockout of the
involved power source before performing
maintenance, cleaning, adjusting, or repair.
Secure the power source lockout to prevent
start-up by other persons.
To help determine safe lifting conditions for
VSI components and units, see the Component
Weights Chart, pages 3.4 and 3.5.
Save your back. If the load is more than 18 kg
(40 lbs), get help or use proper lifting
procedures. Use your leg muscles, not your
back, for lifting. Keep loads close to your
body. Avoid twisting motions and
overextensions when moving loads.
Do not remove any guards, covers, or shields
when equipment is running.
21052 (3/97)
Page 2.1
LJ1093200
A Terex Company
Section 2
Safety Precautions
Replace any guards, covers, or shields after
adjustment or maintenance.
Work Area Safety Hints
Never lubricate moving or running equipment.

Block parts as necessary to prevent unexpected
motion while performing maintenance,
adjustments, or repair.
Do not attempt to remove jammed product or
other blockage from running equipment. Power
must be shut off and locked out while doing so.
Use adequate hearing protection devices
when noise level is above acceptable limits.
Wear an adequate protective breathing mask
whenever dust and fumes are above
acceptable limits.
Wear adequate eye protection goggles or
safety glasses with side shields to prevent
flying particles from entering eyes.
Hard hats are a good idea and are required at
most field work sites. Wear yours.
Maintain safe work habits by dressing
appropriately for the job. Do not wear loose
sleeves, flowing hair, long coat tails, wrist
watches or bracelets, or pockets full of tools,
which could get caught in moving machinery.
Thin-soled shoes without tread could cause
falls or foot injury. Wear safe shoes.
Always look around equipment before startup to make sure no one is near moving parts,
making adjustments, or performing
maintenance. Keep alert to where your coworkers are.
Report defective machinery and unsafe
conditions to your supervisor.
Know your equipment. Understand the
machine and the conditions under which it
operates. Do not limit playing it safe to only
these few general rules. Think and act safely
for your specific work environment and your
particular equipment.
21052 (3/97)
Page 2.2
Keep the work area as neat and as clean as

practical.
Keep all warning and caution signs clear and
up to date.
Make certain that all electrical equipment is
properly grounded. Wet spots near electric
current are dangerous. Use ground-fault
interruptible circuits wherever a potential
shock hazard exists.
Store hazardous materials in restricted access
areas and mark them clearly. United States
Environmental Protection Agency federal
regulations require special labeling of certain
materials.
Make certain enough ventilation is present to
safely run engines. Do not start an engine in an
enclosed space without properly vented
exhaust. Exhaust fumes from gasoline or diesel
can kill!
Do not smoke or allow smoking near
flammable fuels or solvents. Use
nonflammable solvents when possible for
cleaning parts and equipment.
Avoid electrical and static sparks and any
open flame while handling, storing, moving
or pouring fuels, electrolytes for batteries,
hydraulic fluids, or coolants.
Check for leaks in tanks or tubing with
flashlights or other proper equipment. Never
use an open flame to check for leaks.
Know where fire extinguishers and other fire
suppression equipment are located. Learn
how to use them.
Be alert and wary around any pressurized
system: hydraulic or air. High pressure gases
and oils can be very dangerous. Know your
equipment and operate it properly.
LJ1093200
A Terex Company
Section 2
Safety Precautions
Equipment and Tools Safety Hints
Clean and properly labeled tools are safer
tools. Keep your equipment and tools in order.
Always use hoisting equipment for heavy loads.
Regularly check hooks, cables, shackles, and
chains for stretch and wear. Never overload
the lifting capacity of hoists, cranes, and lifting
devices.
Keep V-belts and sheaves in good condition.
Frayed belts or cracked sheaves can be
dangerous and cause downtime.
In addition, for your information, two other kinds of

alert messages are included in this manual.
Notice: Whenever you see Notice in this manual,
it means that failure to follow proper procedures
could lead to serious and expensive damage to your
machine.
Important: The Important messages in this
manual help you to choose procedures that add to
the efficiency and useful life of your machine.
Keep your equipment clean and free of dirt and

grease so it can be checked for loose, cracked
or broken parts. Replace defective parts as
soon as they are discovered.
21052 (3/97)
Page 2.3
LJ1093200
A Terex Company
Section 2
Safety Precautions
21052 (3/97)
Page 2.4
LJ1093200
A Terex Company
Section 3
Leveling on a Sturdy Foundation
Lid Assembly
To operate correctly all VSI's must be installed level

on a firm foundation. For stationary units, level the
base frame on a vibration-free foundation. Check
both east-west and north-south to be level. A solid,
well-drained concrete or stone foundation is ideal,
but compacted rock can work, too. If set up on
compacted rock, regularly test the foundation to
detect any movement or settling. Any supporting
steel structure must be heavy and sturdy enough to
support the total dynamic load of the operating
crusher, conveyors and other related equipment with
rock moving through it. Cross-bracing is
recommended.
Throw Device (Impeller)

Tub Assembly
Vertical Housing and Shaft Assembly
Drive Assembly
Lubrication Oil System
Electrical System
Miscellaneous Components
For plant-mounted units: use a carpenters level to

check the plant frame. Use cribbing as needed to be
sure the plant is level and firm. Do not operate with
tires touching the ground.
On plant-mounted VSI's subcomponents of the

lubrication and electrical systems, such as the oil
pump and/or junction box, may be mounted on the
plants frame. Since plant configurations vary, the
exact placement of these subcomponents and their
hose and line routings also vary. The installation
drawings shown in this section describe typical
locations for subcomponents.
Access
Transporting Your VSI
See appropriate installation drawing to help

determine needed clearances for your VSI and site.
Allow enough room all around for conveyors, loaders,
maintenance cranes and other trucks. Allow enough
clearance below crusher for discharge conveyor.
Design safe overhead clearance, proper conduit for
electrical power and communication lines, safe
catwalks with handrails, and machine guards for
every moving machine part to prevent accidents.
A typical method for tying down the VSI for transport

is shown in Figure 3-1.
Note that the heavy timbers are placed under the
mounting pads and clearance below the mounting
pads helps avoid damage to the under-crusher
components. The cables are well-anchored and the
sheave is protected from accidental impact.
VSI models are available in different drive systems,

types of throw device (also called impeller), sizes,
and impact surfaces. Each model performs
excellently in the right application, but must be
installed correctly to get best results. The different
configurations require slightly different maintenance
and replacement steps. The ability to conveniently
service and maintain the VSI depends in part on how
its installed so that all major systems and components
are accessible. Eight major components or systems
work together to make the VSI an effective rock
crusher:
21052 (3/97)
Page 3.1
Figure 3-1
Typical Tie-downs for Transporting the VSI
LJ1093200
A Terex Company
Section 3
Lock Down the Throw Device
Lid liner
1" (27mm)
bolts
Throw device
(table or rotor)
1) Open the inspection doors.
NOTICE
Feed tube
The VSI is shipped from factory with locking bolts

in place to lock down throw device. The lock-down
process prevents the possibility of flywheel bouncing
up and down during transport, possibly damaging
bearings. A decal is mounted near inspection access
doors as a reminder (Figure 3-2)
Turn nut to
wedge bolt
in place
Locking
nut
THROW DEVICE MUST

BE LOCKED DOWN
DURING TRANSPORT
TO PROTECT
CRUSHER BEARINGS.
USE 2 BOLTS, ON
OPPOSITE SIDES OF
THROW DEVICE.
Decal Part #01-871-372-0070
Figure 3-2
Lock Down the Throw Device Before Transport
2) Look for two or three bolts with yellow tags

attached (Figure 3-2). Some throw devices
have two, some have three locking bolts. Tables
with even numbers of shoes and CastRotors
have two. Tables with odd numbers of shoes
have three.
3) Use two nuts on each bolt. Place two or three

bolts to push evenly down on the throw device.
3) These locking bolts are installed vertically

between the top of the throw device and the lid
liners. The outer nuts are threaded out to apply
pressure down against throw device. The
second nut prevents the first nut from loosening.
5) Test the effectiveness of the locking bolts by

attempting to rotate the throw device by hand.
If you cannot dislodge the bolts by rocking the
throw device back and forth, then the bolts are
tight enough.
4) Loosen the nuts and remove the bolts.

5) Store these bolts where you can use them
again the next time the VSI is to be transported.
4) Tighten these bolts firmly and evenly (but not

too tightly!) by threading the nuts outward.
Notice: Do not overtighten these bolts. You could

crack the lid liners with too much pressure.
6) Use the second nut to lock the outer nut in
place.
Reinstall Locking Bolts Before Travel

Notice: Do not ship or transport VSI until throw
device is locked down to prevent bearing damage.
Bearing damage may not be easily seen or
immediately noticed, but it can cost valuable
downtime and repairs. Installing lock-down devices
before transport is easy and inexpensive.
Models
The VSI is available in 1800 and 2100 models. Each
size can be configured with table with shoes and
anvils, with rotor and rockshelf, or with rotor and
anvils, each driven by right angle gear (GD) or
vertical belt drive (VBD).
1) Open the inspection doors.
Types of Drive
2) Install the locking bolts shipped with your VSI

(Figure 3-2). If you need to use other bolts, use
new bolts at least 27 mm (1") diameter bolts
and paint them with a bright color or otherwise
mark them to be sure they are noticed and
removed at the end of the transport, before
operation. Choose bolts that are slightly shorter
than the distance from the top of the throw
device to the lid liners.
The two types of drive system are right angle gear

drive (GD) and vertical belt drive (VBD). GD models
can be powered by diesel or electric motors while
VBDs are driven by one or two vertically mounted
electric motors.
21052 (3/97)
Page 3.2
LJ1093200
A Terex Company
Section 3
Weights in lbs (kg)
1800 GD
1800 VBD
20,294 (9225) 2 mtr
Total with rotor & anvils
14,400 (6545)
Totals with rotor & rockshelf
13,250 (6022)
15,972 (7260) 1 mtr
2100 GD
1
1
19,144 (8702) 2 mtr 1

14,822 (6737) 1 mtr
2100 VBD
33,034 (15015) 2 mtr 2
26,000 (11818)
23,100 (10500)
27,812 (12642) 1 mtr
30,134 (13697) 2 mtr 2

24,912 (11324) 1 mtr
20,074 (9124) 2 mtr 1

14,180 (6727)
Total with flywheel, no rotor,

no anvils, no rockshelf
11,000 (4990)
Lid Assembly
2,500 (1136)
2,500 (1136)
3,100 (1409)
3,100 (1409)
Anvils & Ring
2,100 (955)
2,100 (955)
2,900 (1318)
2,900 (1318)
Rockshelf (by itself)
950 (432)
950 (432)
1,080 (491)
1,080 (491)
Flywheel (by itself)
440 (200)
440 (200)
1,000 (455)
1,000 (455)
CastRotor
1,300 (591)
1,300 (591)
1,526 (694)
1,526 (694)
3-shoe Table
1,000 (455)
1,000 (455)
1,434 (652)
1,434 (652)
4-shoe Table
1,080 (491)
1,080 (491)
1,520 (691)
1,520 (691)
1
2
16,894 (7697) 2 mtr 1

12,572 (5715) 1 mtr
33,034 (15015) 2 mtr 2
Total with table, 4 shoes & anvils
15,752 (7160) 1 mtr
26,000 (11818)
21,580 (9789)
27,812 (12642) 1 mtr
26,614 (13006) 2 mtr 2

23,392 (10633) 1 mtr
Weights assume 250 hp (187 kw) electric motor(s).

Weights assume 300 hp (224 kw) electric motor(s).
Weights in lbs (kg)
1800 GD
1800 VBD
2100 GD
2100 VBD
5-shoe Table
1,160 (527)
1,160 (527)
1,606 (730)
1,606 (730)
6-shoe Table
1,475 (670)
1,475 (670)
1,975 (898)
1,975 (898)
Uppter Tub with Rock
4,200 (1909)
4,200 (1909)
5,400 (2455)
5,400 (2455)
Lower Tub
1,370 (623)
1,370 (623)
1,700 (773)
1,700 (773)
Gear Box Drive Module
2,750 (1250)
N/A
3,410 (1550)
N/A
Housing Assembly VBD
N/A
1,300 (591)
N/A
1700 (773)
VBD Motor Mount with Bracket
N/A
1,680 (764)
N/A
1680 (764)
Feed Disc (flat)
86 (39)
86 (39)
129 (57)
129 (57)
Feed Disc (cone-shaped)
N/A
N/A
94 (43)
94 (43)
Typical Anvil
60 (27)
60 (27)
86 (39)
86 (39)
Typical Shoe
57 (26)
57 (26)
82 (37)
82 (37)
Anvil Ring (by itself)
542 (246)
542 (246)
893 (406)
893 (406)
6-shoe Cover Plate
125 (57)
125 (57)
175 (80)
175 (80)
Hopper
460 (209)
460 (209)
630 (286)
630 (286)
Feed Tube Table
98 (45)
98 (45)
170 (77)
170 (77)
Feed Tube Rotor
98 (45)
98 (45)
130 (59)
130 (59)
21052 (3/97)
Page 3.3
LJ1093200
A Terex Company
Section 3
Electrical System
Start-up Controls
The electrical system for all VSI models includes a

vibration-sensitive shut-off switch, an electric oil
pump with timer, a flow meter/switch (also called
the flow monitor) connected to a warning horn, and
a thermostatically controlled oil heater.
A properly wired VSI assures that the drive cannot

be started unless the oil pump is running and the
proper amount of oil is flowing through the pump.
The horn sounds momentarily (1-2 seconds) then
turns off when you first start the oil pump. This
assures you that the horn and flow meter/switch are
working properly. Always be sure the oil pump
starts before the drive shaft turns.
See the Electrical Schematics in Section 9. Note

particularly the importance of the vibration switch
and the flow meter/switch.
Warning! The vibration switch must be
connected correctly and be in good working
order whenever the VSI is operating. Failure
of the vibration switch to shut down the VSI
if high vibration develops during operation
could be very dangerous to operators or
other people nearby. Death or serious injury
could result!
On electrically powered models check the power

supply to be sure its voltage, frequency, and phasing
agree with that shown on the electric motor
nameplate(s).
Notice: Refer to the electrical schematic for proper

connection at the junction box. The flow meter/
switch must be tied into the warning horn, the
shutdown circuit and the feed device to prevent
serious machine damage in the event of lubrication
failure.
Wire the oil flow meter/switch to the warning horn

and main power source (Figure 9-4 & 9-4). This step
is a simple but very important protection for your
crusher. Your VSI must have full lubricant supply at
all times during running.
Electrically ground the crusher mount or trailer

frame with standard grounding rod or earth/grounding
devices, according to local electrical code.
If the oil flow rate is too low, the warning horn

sounds and the crusher shuts down. If this happens,
find out why the oil flow was too low before restarting
the VSI.
Warning! Failure to lock out the power

source before performing maintenance can
result in serious injury or death. Because of
the danger of accidental start-up of the VSI
while maintenance is being performed, you
must set up a system for positive lockout of
the power source during cleaning,
maintenance, adjustment, or repair. Prevent
accidental start-up of the crusher by another
person. Make sure your lockout and tagout
system is well-known and respected by every
member of your work crew. See the safety
comments in Section 2 of this manual.
21052 (3/97)
Be certain that line voltage is within 10% of nameplate

value and that frequency is within 5% of nameplate
value. The combined variation of voltage and
frequency must not exceed 10%.
Automatic Shutdown
If the vibration detection switch trips, the crusher

drive shuts down, but the warning horn does not
sound. Momentum continues to keep the flywheel
rotating for awhile. After the flywheel and throw
device stop rotating, find out why the vibration
detection switch tripped. To restart the crusher, turn
the oil pump off, then back on. This resets the
vibration switch.
You can tell the difference between a shutdown
caused by the oil flow switch and one caused by the
vibration detection switch by whether or not the
horn sounds.
Page 3.4
LJ1093200
A Terex Company
Section 3
Optional Pre-wired Panel
An optional pre-wired electrical panel is available
from your Cedarapids/ElJay Distributor. It contains
circuit breaker, fuses, step-down transformer, relays,
timers, lube pump start and stop switches, and
indicator lights for lube pump and heater.
Center feed fall into crusher hopper. Off-center feed

can cause excessive wear, uneven wear, and
decreased production. To help center feed, rotate
feed box to angle needed to mate with feed conveyor.
Warning! The VSI generates high velocity
air flow through the discharge ports. Wear
dust masks or other breathing protection.
Setting Up the Lubrication System

Important: If the oil supply fails during operation
for any reason, immediately shut down, determine
the cause and fix it before restarting.
To reduce dust levels, ElJay Division advises dust

suppression devices, such as covered conveyors or
water injection at crusher discharge.
Check the dip stick for adequate lubricant level.
Guards and Nearby Equipment
If oil is old, dirty, or sticky, select a proper lubricant

and change the oil. Verify that the oil pump operates
continuously when the crusher drive is on.
Read all of Section 2 on safety and safe practices.

Caution! Read all warning, caution and
instruction signs. Know what guards and
protective devices are included with the
crusher and see that each is securely in
place. Operating without each of these guards
is a violation of federal safety codes and a
threat to the safety of operators and
observers. Do not remove these guards.
Notice: Failure to run the oil pump at all times

while the crusher is running voids the warranty.
The external, electrically driven pump is the only
oil pump on the VSI.
See the Acceptable Lubricants Chart (Figure 8-2),
Lubricating Oil Capacities (Figure 8-10) and the Oil
Flow Charts (Figures 8-6 through 8-9 and 8-11).
Warning! Do not operate until all guards,

protective devices and systems are in place
and operative.
Setting Up the Rock Material Feed

Oversize feed material can cause serious damage to
the crushing chamber.
Notice: Damage to crusher chamber components
resulting from tramp iron passing through the
crushing chamber voids the warranty. The VSI
crusher has no built-in tramp iron protection.
Tramp material, especially heavier metal pieces,
entering the crushing chamber cause severe
damage to your crusher. If your crushing site or
feed system generates frequent tramp iron problems,
install metal detectors and/or removal devices (such
as a belt magnet) in the feed system well ahead of
the VSI in your production circuit. This reduces
the chance that tramp iron can enter the crusher.
Set up rock feed system so feed rate to VSI is even
and steady. Uneven feed rate can have a negative
effect on gradation and increase wear rate.
21052 (3/97)
Warning! Never stand on the VSI lid when

it is operating.
Warning! If any part of the throw device is
allowed to come loose during operation, a
serious accident could occur, endangering
operators and other people nearby! Do not
start the VSI with any loose parts on the
throw device. Especially check after
transporting the VSI.
Check Rotation Before Starting
Notice: Serious damage to your crusher can result
if the shaft rotation direction is wrong. The oil
pump does not properly lubricate when the shaft
turns the wrong direction. Rock does not properly
strike the wear surfaces.
Page 3.5
LJ1093200
A Terex Company
Section 3
1) Briefly engage the diesel engine or electric
motor(s) without the V-belts installed.
2) On GD models check that the pinion shaft
rotates in the direction of the rotation arrow
above the shaft. See Installation drawings for
GD models. On VBD models, be sure motors
and vertical shaft rotate counterclockwise
(viewed from top).
Maximum RPM
On diesel drive models the maximum recommended
diesel engine speed is 1800 rpm. Verify that the
governor is not allowing the diesel to operate beyond
this limit.
On electric drive models the maximum shaft rotation
speed is shown in charts in Section 10.
Check rpm specifications in Section 10.
Caution! Do not exceed the stated rpm for
the configuration of your crusher.
13) Is the discharge area clear?

14) Are tramp iron (metal detection) removal
devices installed and in working condition?
15) Is the vertical shaft rotating in the proper
direction?
16) Is the crusher feed tied to the emergency
shutdown circuit?
17) Is the vibration detection switch working
properly?
Important: After the first hour at the initial startup, shut down the conveyors, the screen(s) and the
crusher to reinspect the VSI crusher chamber.
Varying crushing conditions and the great variety
of abrasive content in rock can significantly affect
the crushing capabilities of the VSI. At a new site
you can save time and money by an early check into
the wear characteristics your VSI is experiencing.
Also see the daily inspection form in Section 4.
Storage
First Start-up Check List

2) Is the Operation Manual present and available?
Once a month during storage, or when running VSI

infrequently:
3) Has the operator reviewed the safety

precautions in the Owner/Operator Manual?
Notice: Do not immediately start the VSI or the oil

pump if the VSI has been idle for a month or more.
1) Are all the components properly installed?
4) Is the equipment mounted level?
1) Check the dipstick.
5) Is oil reservoir filled with the proper lubricant?
2) After determining that oil can be properly

pumped, run the oil pump for 10 minutes to
pre-lubricate the bearings.
6) Are the automatic shutdown systems working?

7) Does the warning horn sound correctly?
8) Does the flow meter indicate proper oil flow?
9) Are all wear castings properly secured? No
loose parts?
3) Turn the vertical shaft two complete revolutions

by hand to coat the bearings and/or gears with
lubricant.
10) Is the flywheel guard installed at the proper

height?
11) Is the feed tube adjusted to the proper height?
12) Have the locking bolts that prevent the throw
device from moving during transport been
removed?
21052 (3/97)
Page 3.6
LJ1093200
A Terex Company
Section 3
Installation 1800 VSI-GD
Notes on callouts:
Top and Bottom View this page.
1) Clearance necessary to remove pinion shaft

assembly.
Front and Side View opposite page.
2) Inspection doors.
3) Keep this area clear for crusher lubrication
components.
4) Do not block discharge areas.
838 mm
(33")
2032 mm
(80")
1111 mm
(433/4")
92 mm (33/4")
1702 mm (67")
1321 mm (52")
4
1321 mm
(52")
711 mm
(28")
1219 mm
(48")
1422 mm
(56")
1702 mm
(67")
1003 mm (391/2")
1175 mm (461/4 ")
48 mm
(17/ 8")
Figure 3-4
1800 VSI-GD Installation
21052 (3/97)
Page 3.7
LJ1093200
A Terex Company
Section 3
9) Pinion shaft 88.9 mm (3-1/2") diameter with
22,2 mm (7/8") x 11.1 mm (7/16") keyway. Metric
conversions are approximate and are given
only for convenience. Standard bore metric
sheaves do not fit the pinion shaft.
5) Minimum heights required to gain access to

anvil ring.
6) Pinion rotation direction arrow.
7) Oil drain plugs.
8) Keep area above and around lid clear for
access to inspection doors.
10) Standard sheave is 12 groove 8V 312 mm

(12.3") PD x 318 mm (12.5") O.D. (other
sheaves available).
1080 mm
(421/2 ")
356 mm
(14")
7
692 mm (271/4 ")
762 mm (30")
724 mm
(281/2")
2140 mm
(841/4 ")
2197 mm
(861/2")
1416 mm
(55 3/4 ")
203 mm (8")
1010 mm
(39 3/4 ")
537 mm
(211/8 ")
10
359 mm
(141/8")
1016 mm (40")
1219 mm (48")
57 mm (21/4 ")
1340 mm (52 3/4 ")

2356 mm (92 3/4 ")
Figure 3-4
1800 VSI-GD Installation Continued
21052 (3/97)
Page 3.8
LJ1093200
A Terex Company
Section 3
Installation 1800 VSI-VBD
Notes on Callouts:
Top and Bottom View this page
1) Motor rotation direction arrows.
Front and Side View opposite page
3) Area used for crusher lubrication components.
Keep clear for access.
4) Oil drain plug.
3181 mm
(1251/4")
2
1
1021 mm
(40 3/16")
92 mm (33/4")
1054 mm
(411/2")
3
4331 mm (1701/2")
48 mm
(17/ 8")
1320 mm (52")
1003 mm
(391/2")
1320 mm
(52")
762 mm
(30")
1190 mm
(467/8")
1676 mm 64
(66" 21/2)
3352 mm 127 (132" 5)
Figure 3-5
1800 VSI-VBD Installation
21052 (3/97)
Page 3.9
LJ1093200
A Terex Company
Section 3
6) Minimum heights required to remove anvil
ring.
7) Not used if shipped in the single drive
configuration.
9) 1500 to 1700 mm (59 to 67") - dimension

depends on the motor used.
10) 1638 to 1842 mm (64-1/2 to 72-1/2")- dimension
depends on the motor used.
11) Clearance for sheave removal.
12) Clearance for belt removal.
1054 mm
(411/2")
721 mm
(28 3/8")
368 mm
(141/2")
1416 mm
(553/4")
997 mm
(391/4")
546 mm
(211/2")
57 mm
(21/4")
2032 mm (80")
762 mm (30")
381 mm (15")
2148 mm
(849/16")
343 mm
(131/ 2")
9
10
978 mm
(381/2")
762 mm
(30")
143 mm
(5 5/ 8")
11
610 mm
(24")
762 mm
(30")
254 mm
(10")
12
11
Figure 3-5
1800 VSI-VBD Installation Continued
21052 (3/97)
Page 3.10
LJ1093200
A Terex Company
Section 3
Installation 2100 VSI-GD
Notes on callouts:
1) Inspection Doors.
2) Clearance necessary to remove pinion shaft

assembly.
3) Keep this area clear for crusher lubrication
components.
2
1067 mm
(42")
171 mm (63/ 4")
3
1575 mm (62")
94 mm (311/16 ")
762 mm
(30")
318 mm (121/ 2")

1575 mm
(62")
190 mm (7 1/2")
787 mm
(31")
6
213 mm (83/ 8")
213 mm (83/ 8")

1187 mm (463/ 4")
48 mm (17/ 8")
Figure 3-6
2100 VSI-GD Installation
21052 (3/97)
Page 3.11
LJ1093200
A Terex Company
Section 3
5) Oil drain plugs.
6) Pinion shaft 88.9 mm (3-1/2") diameter with
22.2 mm (7/8") x 11.1 mm (7/16") keyway.
Metric conversions are approximate and are
given only for convenience. Standard bore
metric sheaves do not fit the pinion shaft.
7) Minimum height required to gain access to

anvil ring.
8) Pinion rotation direction arrow.
9) Area around and above lid to be kept clear for
10) Standard sheave 12 groove 8V 452 mm (17.8")
PD x 457 mm (18") O.D. (other sheaves
available).
1003 mm
(391/ 2")
952 mm
(371/ 2")
381 mm (15")
8
3
787 mm (31")
2057 mm (81")
2705 mm (1061/2 ")
1143 mm
1143 mm
(45")
(45")
508 mm 508 mm
(20")
(20")
9
2517 mm
(991/8")
2832 mm
(1111/2 ")
1565 mm
(615/8")
521 mm
(201/2 ")
1254 mm
(493/8")
432mm
(17")
10
492 mm
(193/8")
314 mm (12 3/8 ")
Figure 3-6
2100 VSI-GD Installation Continued
21052 (3/97)
Page 3.12
LJ1093200
A Terex Company
Section 3
Installation 2100 VSI-VBD
Notes on Callouts:
1) Motor rotation direction arrows.
2) Area used for crusher lubrication components.

Keep clear for access.
4) Oil drain plug.
171 mm (63/4")
3559 mm
(1401/8")
2
1
1056 mm
(419/16")
3
1
4832 mm (190 /4")

1575 mm (62")
48 mm
(17/ 8")
1181 mm
(461/2")
1575 mm
(62")
762 mm
(30")
1422 mm
(56")
1930 mm 64
(76" 21/2)
3861 mm 127 (152" 5)
Figure 3-7
2100 VSI-VBD Installation
21052 (3/97)
Page 3.13
LJ1093200
A Terex Company
Section 3
6) Minimum heights required to remove anvil
ring.
7) Not used if shipped in the single drive
configuration.
9) 1700 mm (67")- dimension depends on the

motor used.
10) 1842 mm (72-1/2")- dimension depends on the
motor used.
11) Clearance for sheave removal.
12) Clearance for belt removal.
1054 mm
(411/2")
953 mm
(371/2")
381 mm
(15")
2
6
546 mm
(211/2")
1564 mm
(619/16")
1254 mm
(493/8")
57 mm
(21/4")
2286 mm (90")
1016 mm (40")
508 mm (20")
2572 mm
(1011/4")
343 mm
(131/ 2")
9
10
1276 mm
(501/4")
762 mm
(30")
143 mm
(5 5/ 8")
762 mm
(30")
11
610 mm
(24")
254 mm
(10")
12
11
Figure 3-7
2100 VSI-VBD Installation Continued
21052 (3/97)
Page 3.14
LJ1093200
A Terex Company
Section 4
Keep VSI operating properly with maximum
uptime in crushed rock production. Use the Daily
Inspection Form on page 4.3 to provide a routine and
a record that helps monitor conditions and keep
crusher performing at its best. Photocopy the Daily
Inspection Form to help better maintain VSI.
The Daily Start-up Detail helps you decide when
parts have worn to the point they need changing and
provides more detailed information about the steps
in the Daily Inspection Form. See the Bolt and Nut
Torque chart in the Appendix.
Notice: Do not exceed recommended torque values
on the bolts holding cast wear parts. Cast wear
parts are more brittle than mild steel. A part that
breaks loose at high rpm inside the crushing
chamber can do serious damage to your VSI.
Daily Start-up Detail
Warning! Lock out the power source,
including power to the oil pump, before
attempting any maintenance.
Before starting any VSI for the workday or shift, do
the following pre-start checks:
1) Check oil level with dipstick at oil tank. Lift
dipstick and be sure oil is at proper level.
Check that oil drips from stick. If oil is too
thick to drip, it can damage oil pump and not
lubricate bearings. Be sure oil tank is full.
2) Check the discharge openings. Be sure they
are clear and unobstructed.
Notice: If your site has material such as sticks and
clay that can bridge and block the discharge
openings, check the openings more often.
3) Check all visible oil fittings for leaks.
4) Check for loose bolts on the outside of the VSI.
5) Check that crusher V-belts are tight enough
and aligned. Check them for signs of wear.
6) Clean out all dust and dirt buildup on crusher
sheave and motor sheave. This buildup can
cause vibration and early wear.
21052 (3/97)
7) Open the inspection doors to see the throw

device. Remove the locking pin from the door
locking wedge. Drive the wedge out with a
hammer. Drive the locking bar out (Figures 41, 4-2 and 4-3).
If you have a VSI with table/shoes, go to the
instructions on page 4.6.
VSI with CastRotor
8a) Inspect rotor assembly. Check all wear parts
and liners for excessive wear (Figure 4-4).
8b) Check all wear tip assemblies for damage and
excessive wear. Note especially the condition
of the primary wear tips.
Some CastRotors have primary carbide wear tips of
an earlier design that are 13 mm by 13 mm (1/2" by
1
/2") when new. Later designs of primary carbide
wear tips are 9.5 mm by 22.2 mm (3/8" by 7/8"). The
backup carbide wear tips are all 13 mm by 13 mm (1/
1
2" by 1- /2").
If you are in doubt as to the extent of wear, check the
carbide tip with a straightedge (Figure 4-5).
A 140 mm (5-1/2") straight edge works well for the
1800 CastRotor. A 190 mm (7-3/8") straight edge
works for the 2100 model. Bridge the straight edge
vertically from an unworn portion at the top to an
unworn portion at the bottom of the carbide face
(Figure 4-5). Measure wear from the straight edge to
the deepest wear point of the carbide.
If you have primary wear tips that are 13 mm (1/2")
thick and Dimension A = 8 mm to 9.5 mm (5/16" to 3/
8"), immediately replace the wear tip.
If you have primary wear tips that are 9.5 mm (3/8")
thick and Dimension A =17.5 mm to 19 mm (11/16 to
3
/4"), immediately replace the wear tip.
8c) Check the area of the tips in front (to the inside)
of the carbide for undermining of the wear tip
holder (Figure 6-7). Some undermining, up to
3 mm (1/8"), is expected and is not likely to
harm your VSI. 4.7 mm (3/16") or more is too
Page 4.1
LJ1093200
A Terex Company
Section 4
much undermining. If there is too much
undermining, consult local Cedarapids/ElJay
distributor before making any adjustments.
After consulting your distributor, follow steps
for adjusting trailing angles in Section 6.
8d) Inspect anvils or rockshelf, as equipped, and
tub liner for wear. Check all wear parts for
excess wear. See steps for changing wear parts
in Sections 5, 6, or 7.
Figure 4-1
To open the inspection doors in the lid,
remove the locking pin
8e) Check for any loose fasteners on rotor and all

liners. Be sure bolts holding liners are snug.
Check the torque chart in the Appendix. Do
not overtighten the bolts. The liners are very
hard, high chrome parts and can crack if bolts
holding them are too tight, but, due to grit and
dirt getting under or behind the liners, they can
also sometimes loosen during operation.
Important: Liners and other rotor parts that are
too loose or too tight can damage or wear quickly.
Check for any loose bolts or other rotor parts.
8f) Check the position of feed tube to be certain it
is even with but not more than 13 mm (1/2")
above bottom of the feed eye (Figure 7-8).
Figure 4-2
Remove locking wedge
Figure 4-3
Drive the locking bar out
21052 (3/97)
Figure 4-4
Looking at the Rotor through the Inspection Doors
Page 4.2
LJ1093200
A Terex Company
Section 4
VSI Daily Inspection Form

Warning: Lockout the power source,
including power to the oil pump before
inspecting the VSI.
Todays date
Serial number
Machine ID number
Before Start-up Inspect:
Check Boxes
1. Undercrusher discharge area for blockage

proper level
viscosity OK
2. Oil
3. Visible oil fittings for leaks
4. Outside of VSI for loose bolts, wedges
5. Drive V-belts for wear, fraying, slipping
6. Sheaves for material buildup
OK
Cleaned
cleanliness OK
____Amount added
OK
Replaced
OK
Tightened
OK
Adjusted
Replaced
OK
Cleaned
Operators Initials
7. Open the inspection doors to check throw device:

Table
Shoes
Shoe bracket liners
Shoe pins
Feed tube
Feed disc
Table liner
Rim liners
Anvils
OK
OK
OK
OK
OK
OK
OK
OK
Hours or Tons run
Replaced
Rotor
Feed tube
Tips
Epps
Primary liners
Retaining liners
Feed disc
Feed eye
Trailing angles
Side plates
Rim liners
Top wear plates
Bottom wear plates
Anvils or rockshelf
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
Hours or Tons run
Important: Do not replace one (1) part on table or CastRotor without also replacing similar parts in
similar positions. Maintain balanced weight condition at all times.
Notes on wear parts condition:
21052 (3/97)
Page 4.3
LJ1093200
A Terex Company
Section 4
Warning: Look carefully around before start-up! Sound the usual warning for your site. Be sure no
one is working on related equipment or might be injured by start-up!
Check Boxes
Start-up time ______
Operators Initials
After start-up, running empty, inspect:

8. Low oil warning horn system
9. Oil filter indicator for restricted flow
Green
White
10. Flow meter: write down the reading
11. Ammeter: write down the amperage
12. Diesel motor rpm
OK
Not working
Red
Replaced filter element
____ Liters per minute (gallons per minute) flow
____ Motor 1 ____ Motor 2
____ RPM
After crushing begins, inspect:

13. Feed rate
14. Ammeter for amp draw under full load
15. Flow meter reading after oil is warm
16. Diesel rpm
Choke fed ____ Tonnes (tons) per hour

____ Motor 1 ____ Motor 2
____ Liters per minute (gallons per minute) flow
____ RPM
Total crushing hours this date

Downtime this date
Total tonnes (tons) this date
________
________
________
Did you take an oil sample today?
Yes
No
Comments:
21052 (3/97)
Page 4.4
LJ1093200
A Terex Company
Section 4
Figure 4-5
Measure Wear from a Straight Edge to
Deepest Wear Point of the Carbide Tip
Figure 4-6
Looking at Table through Inspection Doors
8g) Slowly rotate rotor and note clearance between

the feed tube and feed eye. Center feed tube as
much as possible for feed efficiency and to
avoid rotating parts contacting each other.
Important: Liners and other rotor parts that are

too loose or too tight can damage or wear quickly.
Check that bolts are snug.
8h) Check the feed eye for wear paths. As the feed
eye wears out, paths wear in the eye and the
adjacent wear liners. To increase liner life, lift
out the feed eye and rotate it 90.
8d) Check the position of the feed tube. See that it

is even with the tops of the shoes. Readjust the
feed tube downwards when it has worn to 13
mm (1/2") above the tops of the shoes.
Go to Daily Start-up Detail- Continued, this page, to

complete the daily inspection of your VSI.
8e) Slowly rotate the table and note the clearance

between the feed tube and each shoe. Be sure
no shoes hit the feed tube.
VSI with Table/Shoes
Daily Start-up Detail - Continued
For a VSI model with table/shoe/anvil configuration:

8a) Inspect all shoes and shoe bracket liners for
wear. Inspect the shoe-holding pins. Be certain
they are in place and not bent (Figure 4-6).
8b) Inspect anvils, table liners, table rim liners, tub
liner, and feed cone for wear. Refer for details
of wear minimums to Section 5.
8c) Check for loose fasteners on table and all wear
liners. Be sure wear liner bolts are snug. Do not
overtighten. Check the bolt and nut torque
chart at the end of this section.
9) Close the inspection doors. Reinstall the locking

bar (Figure 4-7). Drive in the locking wedge
and install the locking pin.
10) Unlock the power source to the oil pump only
and tell fellow workers you are about to test the
warning horn before starting up.
11) Turn on the oil pump switch. It is normal for
the warning horn to sound for a few seconds
until the oil flow reaches a rate above the preset
warning level.
Sounding the warning horn serves two functions:
It lets you know the warning system is working
to protect your VSI from low oil flow.
21052 (3/97)
Page 4.5
LJ1093200
A Terex Company
Section 4
14) Check screens and conveyors feeding the VSI
to be sure no tools or hardware have been left
on them.
Warning! Look carefully around; check
your radio; sound usual warning for your
site, or use other communications methods
to be sure no one is working on related
equipment or may be injured by starting up!
15) Unlock power source to crusher drive.
16) Turn on under-crusher conveyor.
Figure 4-7
Drive Locking Wedge In and Replace Locking Pin
It lets workers in the surrounding area know

you are nearing start-up.
12) Check the flow meter. The oil flow rate varies
during the course of the day, depending on the
oil temperature. After the VSI has operated,
the oil warms and flows easier. The flow meter
shows this tendency. For approximate oil flow
rates, both cold and warm (Figure 4-8).
Important: To prevent damage to bearings, leave
the oil pump on at all times during crusher
operation. Do not shut off pump until crusher has
come to a complete stop.
13) Check to be sure all guards and protective
devices are securely in place.
Model
Warm
liters/min
4.7 to 5.7
2.8 to 3.3
Gallons/min
1.25 to 1.5
.75 to .875
liters/min
2.8 to 3.8
1.4 to 1.9
Gallons/min
.75 to 1
.625 to .5
liters/min
5.7 to 6.6
3.3 to 4.3
Gallons/min
1.5 to 1.75
.875 to 1.125
liters/min
4.7 to 5.7
2.8 to 3.3
Gallons/min
1.25 to 1.5
.75 to .875
1800 VSI-VBD
2100 VSI-GD
2100 VSI-VBD
17) For diesel driven crushers, start diesel and

warm it up according to diesel manufacturers
instructions. Bring diesel to about 1000 to
1100 rpm. Bump power takeoff (PTO) handle
several times to engage power takeoff
gradually.
Important: Do not move handle to full engagement
until VSI speed increases. If VSI is brought up to
full speed too quickly, it can damage your drive
belts, causing them to wear too quickly. New belts
need frequent tightening for several operating days
after being installed.
18) For electrically driven VSI's, engage drive
motor(s) and bring VSI to full rpm.
19) Monitor drive and VSI for any excessive
vibration. Normal conditions produce very
little vibration.
Cold
1800 VSI-GD
Important: Never run VSI without under-crusher

conveyor also running.
Important: If using a VSI with a rotor and have

cleaned rock buildup out of rotor, fill rotor and
rockshelf with 30 to 60 seconds of 19 mm and
smaller (34" minus) feed before feeding larger rock
into VSI. Without this buildup at start-up, large
rock can damage wear tips.
20) Start feeding material to the crusher.
Figure 4-8
Oil Flow Rates
21052 (3/97)
Page 4.6
LJ1093200
A Terex Company
Section 4
Important! Do not run CastRotor VSI's more than
15 minutes immediately after exit port protectors
or wear tips have been changed or serviced. Stop
machine and Open inspection door in lid. Inspect
rotor, carbide wear tips, and all wear points. Again
tighten exit port protector (epp) bolts to 190 nm
(140 ft-lbs). Adjust trailing angles as needed to
control material buildup.
Any time rock material characteristics are changed
(such as size, rate of feed, rock material), it pays to
look carefully at crushing chamber for changes in
wear rates. Improperly adjusted trailing angles or
other VSI parts can be costly in creating unnecessary
wear. It pays to check!
21) Start normal feed.
Cold Weather Start-up
Check dip stick to see that oil drips freely from stick.
If oil cannot drip from dip stick, it is too thick to
lubricate VSI.
Important: Do not start crusher if oil is too thick to
drip from dipstick.
Either warm crusher with a propane heater before
starting or change to a lighter oil.
The VSI is equipped with an oil heater and thermostat

which is set to switch on at 15.5C (60F) oil
temperature and go off when oil is at 26.7C (80F).
With oil pump continuously circulating oil, heater is
effective down to an ambient temperature of about 9C (15F), but is not very effective when weather
conditions are below -9C (15F). For cold weather
operation, cover crusher at night and pre-warm it
with an external heater (propane, for example) before
morning start up.
Important: Do not start crusher if oil does not flow
freely. Oil must be free flowing to properly lubricate
bearings (and gears on gear drive models).
Hot Weather Start-up
Keep VSI oil temperature gauge reading below
115.5C (240F). If readings are nearing 115.5C
(240F), consult Acceptable Lubricants Chart to
select an oil designed for higher temperature
conditions.
Important: Maximum allowable oil temperature
under any conditions is 115.5C (240F) at
temperature gauge!
See the Acceptable Lubricants Chart, page 8.1, for

proper oil specifications for your operating and
weather conditions.
21052 (3/97)
Page 4.7
LJ1093200
A Terex Company
Section 4
21052 (3/97)
Page 4.8
LJ1093200
A Terex Company
Section 5
The VSIs structural members are protected from
abrasive wear. Some wear surfaces collect rock
material to protect structure. Some areas of crushing
chamber, input and discharge areas include
replaceable, bolt-on wear parts. Highly wearresistant, each wear part armors VSI to protect it
from damage (Figure 5-1). Wear parts also efficiently
shape the flow of rock for crushing large volumes.

Turn off diesel power plant (if diesel is used.)
Notice Regarding Wear Part Fasteners: Except
where noted, most fasteners used to attach VSI
wear parts use anti-seize lubricant on the threads.
Cast wear parts are very abrasion-resistant, but are
more brittle than milder, softer steels. Standard
torque values of the recommended Grade 8 bolts
4
5
3
11
10
1. Shoe bracket
2. Flywheel bolt
3. Feed disc
4. Shoe pin
5. Shoe
6. Shoe bracket liner
7. Table liner
8. Special (Allen-head or shortened hex) table
liner bolt
9. Rim liner
10. Flywheel spacer ring
11. Table weldment (includes shoe brackets)
Figure 5-1
Wear Parts Identified
21052 (3/97)
Page 5.1
LJ1093200
A Terex Company
Section 5
may be so high as to crack or break the cast part.
Except where a torque value is specifically noted,
always tighten wear part fasteners firmly to a
snug fit. Except where noted in this manual, do
not tighten the bolts holding wear parts to their
full, standard, lubricated torque value.
Balanced Running Important

Balanced running is very important to the table and
shoes. Whenever you change wear parts, be sure to
replace them in matching, weight-balanced sets.
Tables: Various Types Available
The open-topped table is available with 3, 4, or 5shoes. A 6-shoe table is available with a closed top.
You can refit your VSI with any one of the table
options. Find instructions for removing and
reinstalling tables later in this section.
Table options allow you to choose the best one to fit
your crushing needs. Generally, the more shoes, the
finer the crushed product and the more shoe life.
Figure 5-2 shows you the four table/shoe options.

Replacing the individual wear parts is essentially
the same for each table type.
Under normal operating conditions, shoes are first
parts to need replacing due to wear. These and shoe
bracket liners can be changed while working through
access doors in lid. To change other table/shoe wear
parts best practice is to remove lid. See Removing
Lid Assembly in Section 7. Changing table rim
liners requires removing table from VSI. See
Changing Table Rim Liners, page 5-10 for
instructions on removing and replacing table.
Shoes, Shoe Pins, Shoe Bolts

Shoes are easily removed and replaced. They are
attached to tables shoe brackets with either shoe
pins or shoe bolts. Pins can be mounted either
vertically or diagonally, depending on type of shoe.
A pin stop is welded to each shoe bracket. This
determines which type of shoe and pin your table
requires. See Figure 5-3 for both types of pins.
21052 (3/97)
Page 5.2
1. 3-shoe, open top

2. 4-shoe, open top
3. 5-shoe, open top
4. 6-shoe, closed top
Figure 5-2
Available Table Types
LJ1093200
A Terex Company
Section 5
Tables with even-numbered shoes (4 and 6-shoes)
can tolerate different weight shoes as long as they
balance 180 apart, across table. Tables with oddnumbers of shoes (3 and 5-shoes) require all shoes to
be more closely matched in weight (Figure 5-5).
Even-number of
shoes on the
table
Odd-number of
shoes on the
table
1. Diagonal Pin
2. Vertical Pin
B
A
B
A
Figure 5-3
Two Types of Shoe Pins
Weight-Balanced Shoe Sets

Important: Balanced running is very important
with the VSI. Whenever you change wear shoes, be
sure to replace them in matching, weight-balanced
sets. Allow a maximum weight variation of only
0.45 kg (1.0 lb). Always replace shoes in matching,
weight-balanced sets all around the table. The
better balanced running you have, the longer
bearing life you can expect. See the specifications
for weight-balanced sets (Figure 5-4).
Model
1800
2100
Typical Shoe
26 kg (57 lbs)
37 kg (82 lbs)
Figure 5-5
Even and Odd Shoe Balance Sets
When to Change Shoes

To inspect shoes, reach in through access door to
check inner edge of shoe. Feel inner edge of shoe to
be sure it has more than 6 mm (1/4") thickness
remaining (Figure 5-6).
A pocket worn by rock passage weakens shoe. If
pocketing has occurred, change when bottom of the
pocket is within 13 mm (1/2") of back side (Figure 57). Change shoes when worn to within 6 mm (1/4") of
back side at discharge (outer) edge, or if cracked.
Figure 5-4
Weight Specifications for Shoes
21052 (3/97)
Page 5.3
LJ1093200
A Terex Company
Section 5
Caution: Wear Safety glasses or goggles.
Brittle metals can shatter dangerously.
6 mm (1/4") minimum
3) Rap on the face of the shoe with a hammer to

jar it slightly loose.
4) Use a pry bar to lift while pulling with locking
pliers to remove the pin. Figure 5-8 shows the
vertical-pin type shoe.
5) If the pin is solidly cemented by rock material,
you can use a torch to cut it loose, but carefully
avoid cutting into the shoe bracket!
6) If removing shoes of bolt-type, remove bolt
and backing plate. If shoe is solidly cemented
by rock material, rap face of shoe with a
hammer to jar shoe loose (Figure 5-9).
Inner edge
Figure 5-6
Check the Inner Edges of the Shoes
How to Replace Shoes

1) Clean all surfaces where shoes have contact.
inner edge
2) Inspect shoe bracket for weld integrity, cracks

or erosion (Figure 5-10). See also Shoe Brackets
and Liners.
13 mm (1/2")
minimum
6 mm (1/4")
minimum
outer edge
Figure 5-7
Pocketing Wear Shows It Is Time to Change Shoes
Figure 5-8
Removing Shoe Pin
How to Remove Shoes

1) Clean away the rock material around the shoes,
shoe brackets, and pins or bolts.
2) Inspect the shoes for erosion.
21052 (3/97)
Page 5.4
Caution: Always replace shoe pins or bolts

when you replace shoes! A bent or worn shoe
pin or a poor condition bolt can be very
dangerous because it can fail at high rpm! A
LJ1093200
A Terex Company
Section 5
Bolt
Backing plate
Shoe bracket
erosion
Figure 5-10
Look for Shoe Bracket Erosion
Figure 5-9
Removing Bolt-type Shoe
shoe bracket wear from the pin
failed pin or bolt can also very rapidly cause

extensive damage to your VSI by letting a
shoe come loose during operation.
3) Place shoe against front of bracket with stob
through bracket.
4) Insert new pin through hole in shoe stob. A
properly fitting pin slips into place and does
not require driving into place.
Notice: Clearance must be no more than 1.6 mm
(1/16") (Figure 5-11). If shoe pin has worn a low
spot in back of shoe bracket, gap between pin and
bracket is too large. Pin can bend and cause shoe
stob to crack and break out. Serious damage to
crusher chamber may occur.
If table has an even number of shoes and pin seems
too tight, try trading shoe directly opposite across
table. Sometimes minor variations in shoe fit can
occur. Be sure to keep weight balanced. Allow a
maximum weight variation of only 0.45 kg (1.0 lbs).
Important: ElJay/Cedarapids factory-original shoe
pins are stress-proof. Use no substitutes.
Figure 5-11
Pin Wear in the Shoe Bracket
5) Check to be sure pin is fully seated against the

pin stop. Use only correct length pin. When
fully and correctly seated, pin is even with top
of shoe.
6) For bolt-type shoes, check backing plate. Reuse
a backing plate that is not bent or badly worn.
7) Install shoe bolts dry, without any lubrication.
8) Tighten the bolt to 203 Nm (150 ft-lbs).
21052 (3/97)
Page 5.5
LJ1093200
A Terex Company
Section 5
Important: Do not use an impact (pneumatic)
wrench to tighten the shoe bolts.
9) Turn the table by hand to check for any
clearance problems.
Shoe Brackets and Liners
The portion of the table weldment called the shoe
bracket is not itself a wear part, but can erode where
the shoe pins contact the bracket and at the side
members (Figure 5-10).
If the shoe bracket is worn in the area of the pin, fill
the worn area with mild steel weld and grind it flush
(Figure 5-11).
Figure 5-12
Install Shoe Bracket Liner
Side members of bracket can also show wear.
that are threaded into the table unless they are

damaged or worn. Other table liners use shorthead bolts under the shoes. These hex-head
bolts, part number 02-382-510-0030, have
shorter heads so the shoe seats properly over
the table liner. The heads of these bolts are
machined to 9.5 mm (0.375") high. Some
types of table liners have 3 bolt holes; some
have 4. As long as you keep the table weightbalanced, you can interchange the table liners
types as they are available.
Important: Heavy welding activity can distort the

roundness of the table and unbalance it. Always
rebalance the table after major maintenance.
Important: When wear has advanced enough that
bracket might bend, replace table itself. Always
maintain shoe brackets in like-new condition.
When to Change Shoe Bracket Liners
Change shoe bracket liners when worn to 5 to 6 mm
(3/16" to 1/4") thick, or if cracked. Both high chrome
and heat treated shoe bracket liners are available.
See your Cedarapids distributor.
3) Lift off the old liners.
1) Remove bolts holding liner. Remove old liner.
4) Thoroughly clean flat areas of table, clean bolt

holes and threads, and blow out holes with air.
2) Clean rock material from liner seat area. Check

liners mating surface area for proper fit.
5) Set liners in position.

6) Apply anti-seize lubricant to bolt threads.
3) Set new liner in place (Figure 5-12).
7) Install bolts with shortened heads (as needed)

in shoe area and standard bolts in open area
(Figure 5-13). If bolts supplied with liners are
lost, replace them with Grade 5 or higher.
4) Use anti-seize lubricant on bolt threads. Attach

liner with bolts. Tighten to 67.8 Nm (50 ftlbs) lubed. Do not overtighten.
Changing Table Liners
8) Hand tighten bolts in shoe area.
1) Remove the shoes.
9) Hand tighten bolts in open area.
2) Remove the appropriate table liner bolts

(Figure 5-13). Some table liners have Allenhead bolts acting as guide pins under the
shoes. You do not need to remove these bolts
21052 (3/97)
10) Tighten all table liner bolts to 135.6 Nm

(100 ft-lb). Do not overtighten.
Page 5.6
LJ1093200
A Terex Company
Section 5
3) Clean off the feed disc seat area.
Important: Centrifugal force during operation locks

the liners into place. If you overtighten the bolts,
they can be nearly impossible to remove. Also, if a
casting is just slightly warped, overtightening can
crack it. A cracked casting could become dangerous
if it were to fly apart during operation.
4) Center the feed disc in the counter-bore in the

table. Casting tolerances permit from 1.5 to 3
mm (1/16 to 1/4") total clearance between the
feed disc and the hole in the table, so it is
possible in rare cases for the feed disc to be off
center by up to 3 mm (1/4"). If you notice
vibration after installing a new feed disc, stop
the crusher and check for centering by
measuring from the inside edges of the shoe
brackets. If disc is off center, pry into centered
position. Fill space around feed disc with fine
rock material to hold the position until it seats.
Changing Feed Disc

Change the feed disc when hole first appears in
surface, or if cracked. If you allow feed disc wear to
go on, costly damage can occur to table, flywheel
and the vertical shaft.
When the disc is worn, the outer edge in front of shoe
becomes rounded off (Figure 5-14). Rotate feed disc
so worn sections are under shoes and sharp edges of
disc are in front of shoes. Rotate the feed disc a small
amount each time you change shoes to get even wear
of feed disc and to promote even shoe wear.
Changing Table Rim Liners
1) Remove the shoes.
Change the table rim liners when they are worn to 9

mm (3/8") thick , or when top surface wears to within
6 mm (1/4") of top of table, or if any are cracked
(Figure 5-16).
2) Pry under the outer edge of the disc and lift

(Figure 5-15).
To change the rim liners, first remove the lid

assembly. See section 7 for instructions.
1. Standard length bolts.

2. Shortened bolts for use under shoes (some
table liners use Allen-head bolts. See
Figure 5-1).
Figure 5-13
Table Liners with Bolts
21052 (3/97)
Page 5.7
LJ1093200
A Terex Company
Section 5
4
3
Typical table wear patterns
1. Shoe wear
2. Feed disc wear
3. Rim liner wear
4. Table liner wear
5
1. Do not remove large flywheel locknut.
2. Top of shaft
3. Flywheel bolts
4. 6 mm (1/4") minimum to top of table
5. 9 mm (3/8") minimum thick
Figure 5-14
Feed Disc and Table Rim Liner Wear
Figure 5-16
Table Rim Liner Wear
Figure 5-15
Pry Up on Feed Disc
21052 (3/97)
Figure 5-17
Lift Table from Flywheel
Page 5.8
LJ1093200
A Terex Company
Section 5
Figure 5-20
Clean the Underside of the Table
3) Attach lifting device through shoe brackets

(Figure 5-17).
4) See the Component Weights Chart in Section
3. Remove table from flywheel. Place table so
chains can be repositioned to lift the table from
the center (Figure 5-18).
Figure 5-18
Turn the Table Upside Down
5) Turn table upside down (Figure 5-19).

6) Remove the bolts from each liner.
7) When you have removed the rim liners, clean
the flat underside of the table. Clean the bolt
holes and threads (Figure 5-20).
8) Obtain a weight-balanced set of table rim
liners. Not more than 0.227 kg (0.5 lbs) weight
variance is allowed. Set the replacement liners
in place (Figure 5-21).
9) Apply anti-seize lubricant to bolts. Install the
bolts in each liner.
10) Hand tighten bolts. Hand-tightening helps
assure proper alignment of the cast parts.
Figure 5-19
Remove Table Rim Liner Bolts
1) Remove the shoes and feed disc.

2) Remove the bolts holding table to flywheel,
but do not remove the large flywheel locknut.
21052 (3/97)
11) Tighten bolts on 1800 VSI's with 3, 4, or 5 shoe

tables to 190 Nm (140 ft-lbs). On 6-shoe
1800s and all 2100 VSIs tighten bolts to 298
Nm (220 ft-lbs). Do not overtighten
(Figure 5-22).
Page 5.9
LJ1093200
A Terex Company
Section 5
Figure 5-23
Tighten Table to Flywheel Bolts
Figure 5-21
Rim Liners Carefully Weighed
and Placed to Balance Load
14) Tighten table bolts to 540-680 Nm (400-500

ft-lb) (Figure 5-23).
15) Install feed disc and shoes.
16) Reinstall the lid assembly.
17) Rotate the table to check clearances.
6-Shoe Closed-Top Table
Most maintenance tasks are the same on the 6-shoe
table as on other, open-topped tables, such as the 5shoe and 4-shoe tables. The main difference is in the
cover plate and its retainers and bolts.
Cover Plate
To replace or maintain cover plate, remove lid
assembly. See Section 7 for removing lid assembly.
Figure 5-22
Tighten Rim Liner Bolts
Caution! Use eye protection!
Important: Centrifugal force during operation locks

liners into place. If bolts are overtightened, they
can be nearly impossible to remove. If a casting is
just slightly warped, overtightening can crack it. A
cracked casting could become dangerous if it were
to fly apart during operation
12) Place table on flywheel.
13) Use anti-seize lubricant on table bolt threads.
If original bolts become lost, replace with
Grade 8 or higher.
21052 (3/97)
1) Protect eyes from flying particles. Blow dust

out of cover plate bolt retainers (Figure 5-24).
2) Use a 1-1/8" socket wrench to remove 3/4"
diameter bolt from each retainer. Retainers
protect bolt heads from abrasive wear during
operation.
3) Shoes can be changed without removing cover
plate if using shoes that have vertical shoe pins
or bolt in place. However, it may be more
convenient to remove cover plate.
Page 5.10
LJ1093200
A Terex Company
Section 5
1
Bosses
Figure 5-25
Detail of the Bosses
1. Cover plate
2. Cover plate retainer
3. Cover plate bolts
Figure 5-24
Six-Shoe, Closed -Top Table
4) Remove all six bolts and retainers. The retainers

can be reused if they are not worn too much.
Caution! Plate is very heavy! A new plate
weighs 50-55 kg (110-120 lbs). Do not strain
your back! Get help or use a mechanical lift
to handle the cover plate.
5) Lift off the cover plate. You can turn the cover
plate upside down and rotate it to extend its use
if it is not too worn. The plate can be safely
reused if 1/3 or less of the original thickness of
the plate has been eroded away. A new plate is
38 mm (1-1/2") thick.
21052 (3/97)
6) Check bosses at top of each shoe holder to see

that they are flat, in good condition, and all
same height. If wear has occurred to bosses,
add hard-facing weld to protect them. Avoid
distorting or damaging threads (Figure 5-25).
7) Replace the cover plate. You can also rotate it
to a new position.
8) Replace the bolt retainers. Rotate each retainer
so the thickest portion faces the tables direction
of rotation. If you are in doubt about whether
to reuse worn retainers, replace them.
9) Tighten cover plate bolts to 136 Nm
(100 ft-lbs).
10) Reinstall the lid assembly.
Page 5.11
LJ1093200
A Terex Company
Section 5
21052 (3/97)
Page 5.12
LJ1093200
A Terex Company
Section 6
The CastRotors structural members are protected
from abrasive wear with replaceable, bolt-on wear
parts. Some wear surfaces collect rock material to
protect the structure. Highly wear-resistant, each
wear part armors the rotor to protect it from damage.


Turn off diesel power plant (if diesel is used.)
Notice Regarding Wear Part Fasteners: Except
Direction of rotation
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
Exit path of
rock material
10
Backup wear tip

Primary wear tip
Exit port protector
Exit port rim liner
Feed tube
Feed disc
Rim liner
Side plate
Bottom retaining liner
Bottom primary liner
Trailing angle
Feed eye
Top retaining plate
Metal shim
Top primary liner
Top retaining liner
Rubber shim
Bottom retaining plate
1
11
2
3
4
12
5
13
14
15, 16
8
9, 10
17
7
18
Figure 6-1
Wear Parts of the CastRotor
21052 (3/97)
Page 6.1
LJ1093200
A Terex Company
Section 6
Maintain Balance with Matching Sets
Lid assembly
Exit port
Lid liner
Balanced running is very important to the throw

devices. Whenever you change wear parts, be sure to
replace them in matching, weight-balanced sets.
Epps and Wear Tips
At the outer edge of the CastRotor replaceable
carbide wear tips at each exit port protect the throw
point from excessive erosion. Under normal operating
conditions the epps (exit port protectors) and the
wear tip assemblies are the first parts to need replacing
due to wear. These parts can be changed through the
access doors in the lid.
After the first 4 hours of rotor operation with new
parts, check the wear tips and the buildup, the exit
port protectors, the primary liners, the feed eye and
feed tube (Figure 6-2). After that check once every
shift (or 8 hours of operation).
Exit port protector (epp)
Anvils
Figure 6-2
Check the Rotor Often
Changing Exit Port Protectors (Epps)

Change epps when they are damaged or when they
are worn too thin (Figure 6-3). Look at the epp
retaining nuts. Replace the epps when epp material
has worn so much that 25% (1/4) of the retaining nut
has worn away. Always replace bolts, nuts, and
lockwashers when replacing epps.
Nuts
Caution! If any part of the CastRotor is

allowed to come loose during operation, a
serious accident could occur, endangering
operators and other people nearby! Do not
start the VSI with any loose parts on the
throw device.
Notice: If the retaining nuts get worn too thin, they
could allow epps to fly off the rotor assembly. This
could cause serious damage to your crusher.
1) With the VSI at a complete stop, and after
locking out the power, open the access doors in
the lid.
2) Remove nuts from the epps (Figure 6-3).
3) Remove the worn epps (Figure 6-4).
21052 (3/97)
Figure 6-3
Nuts Holding the Epps
Changing Wear Tips

For typical recommended feed sizes, change wear
tips when worn to 3 mm (1/8") thick minimum.
Larger feeds often require changing them sooner.
New wear tip carbide is 22 mm (7/8") thick on
primary carbide tips and 13 mm (1/2") thick on
backup tips. Check the tips on both sides for
undermining of the holder. If you find undermining,
adjust the trailing angles according to instructions in
Page 6.2
LJ1093200
A Terex Company
Section 6
Figure 6-4
Removing an Epp
How to Change Trailing Angles. Check carbides

carefully for cracks. If hairline cracks are found, run
crusher but check them often. Cracked carbides may
indicate other problems to watch for. See
Troubleshooting, item 5.
Primary wear tip
Backup wear tip
Figure 6-5
Remove the Primary Wear Tip
1) After removing the epps, remove the primary

wear tip (Figure 6-5).
2) Drive the bolts out (Figure 6-6). If you are
changing your primary carbide tips at proper
intervals and controlling feed to avoid oversized
feed material, you may not need to change
backup tips at this time. Whether or not you
change backup tips, drive the bolts out and
change them every time you replace the primary
carbide tips. Never reuse the epp bolts or nuts!
3) Check the wear tip condition (Figure 6-7).
Look for undermining in the holder and cracks
in the carbides. If any tip has more than 3 mm
(1/8") of carbide is exposed (undermined), see
CastRotor Tuning, How to Change Trailing
Angles, and Troubleshooting, Item 5. Check
carefully any tip where more than 50% of
carbide is exposed by undermining. Determine
and fix the cause. Then frequently monitor the
carbide condition. You may soon need to
change these tips. Replace any wear tips that
have more than hairline cracks.
21052 (3/97)
Page 6.3
Figure 6-6
Drive the Epp Bolts Out
4) Clean the seating area for both backup and

primary tips.
Caution! Use only Grade 8 fasteners. Never
reuse an epp bolt.
5) Install the backup tip, then the bolts, then the
primary tip (Figure 6-8). Replace the epps only
as a set of three. When replacing the epps, be
sure all parts are fully seated.
6) Torque the epp nuts to 190 Nm (140 ft-lbs.)
7) Close and secure the access doors. Clear the
immediate area for start-up.
LJ1093200
A Terex Company
Section 6
1. Good wear. No more than
3 mm (1/8") of carbide
exposed.
1
3 mm (1/8")
Backup Wear Tip
Surface 1 slips in back of surface 2
2. Too much undercuttingmore than 50% of carbide

exposed (x/y).
3. Too much backdooring,
where support for the
carbide tip is worn away.
Figure 6-8
Backup Tip Comes Out Last, Goes In First
Top primary liner
Top retaining liner
x y
Figure 6-7
Check Carbide Wear Tips Carefully
8) Follow safe start-up procedures and bring VSI

up to operating speed.
9) After reaching full operating speed for five
minutes, shut down the VSI again briefly to
recheck bolt torques.
Warning! Always lock out and tag out
power source.
10) Re-torque the epp nuts to 190 Nm (140 ft-lbs).
21052 (3/97)
Bottom Primary Liner
Bottom Retaining Liner
Figure 6-9
Primary and Retaining Liners
11) The first material fed to the VSI after cleaning

and replacing parts should be 19 mm and
smaller (3/4 minus) to provide initial protection
to the wear tips and to fill the rotor.
12) Again start and operate as usual, being alert to
possible vibration imbalance in the first few
minutes of crushing.
Page 6.4
LJ1093200
A Terex Company
Section 6
Change Primary and Retaining Liners
The CastRotor has top and bottom primary liners at
each exit port (Figure 6-9). Primary liners are each
held in place by secondary, or retaining, liners. Bolts
hold top and bottom retaining liners in place. Always
change primary and retaining liners in matched,
weight-balanced sets.
Feed
disc
clip
1) Remove lid assembly.

2) Dig out and remove rock material as needed to
remove retaining liner bolts.
3) Remove retaining liners.
4) Remove primary liners.
Worn feed disc
5) Clean up seating area for all liner sets

(Figure 6-10).
Wear pattern in
feed disc
Figure 6-11
Feed Disc and Clips
Changing Feed Disc

Change feed disc when a hole first appears in surface,
or if it cracks. If feed disc wear is allowed to
continue, costly damage can occur to rotor, flywheel
or vertical shaft.
Seating
areas
When disc is worn, outer edge becomes rounded off

(Figure 6-11).
Rotate feed disc so worn segments are in a different
position relative to exit ports. Rotate feed disc a
small amount each time change epps are changed to
promote even wear of disc.
Figure 6-10
Clean Seating Area for Liner Sets
1) Loosen and remove bolts holding feed disc

clips. Remove clips.
6) Install primary liners.
2) Pry under outer edge of disc and lift. A new

feed disc weighs about 45 kg (100 lbs).
7) Install retaining liners.

8) Pull or tap liners outward to assure a lock fit.
9) Install bolts and tighten to 136 Nm
(100 ft-lbs).
10) Reinstall lid assembly.
21052 (3/97)
Page 6.5
3) Clean off feed disc seat area.

4) Center new feed disc. If there is vibration after
installing a new feed disc, stop crusher and
check for centering by measuring from inside
edges of primary liners.
LJ1093200
A Terex Company
Section 6
5) If disc is off center, pry into centered position.
Fill space around feed disc with fine rock
material to hold position until it seats.
Direction of rotation
6) Replace feed disc clips and tighten bolts to

67.8 Nm (50 ft-lb.)
CastRotor Tuning
Trailing angle positions and conditions are very
important in maintaining efficient crushing and
crushed material specifications (Figures 6-12 and 613). Inside CastRotor each trailing angle controls
rock material buildup in rotor segment traveling
ahead of angle. The angle trails (or follows) wear tip
in same rotor segment.
C
A
B
During crushing, material collects at leading face of

trailing angles and builds out to carbide tips at three
exit ports. This material buildup at each rotor segment
prevents or slows wear and affects finished material
specifications. Buildup is controlled by position,
length and shape of trailing angle irons.
Trailing angle
A = Buildup just right
B = Buildup too big
C = Buildup too small
Figure 6-13
Three Types of Buildup
Buildup also varies with material type, moisture

content, and revolutions per minute (rpm) of rotor.
Figure 6-13 shows three different buildup conditions
illustrated in one rotor. In actual practice buildup
would result in rotor imbalance and very poor
operation. For best conditions, position all three
trailing angles equally and adjust them so that buildup
between each wear tip and its trailing angle are as
shown in the A portion of figure. Both too much and
too little buildup prevent good VSI performance.
Replace or modify trailing angles when:
buildup can not be controlled by trailing angle
position
2
1. Leading Face
2. Trailing Face
trimming or increased depth of trailing angle

is needed
hardfacing must be renewed on angle toe.

Figure 6-12
Trailing Angle Controls Buildup
21052 (3/97)
Page 6.6
LJ1093200
A Terex Company
Section 6
1
Toe of the
angle
Note the dimensions of 1 and 2 to within

1.6 mm (1/16").
Figure 6-15
Measuring Trailing Angle Position
Figure 6-14
Trailing Angle Modification to Control Buildup
Check to see that trailing angles are hard-faced at toe

(Figure 6-14). Check both inside and outside carbide
tips for undermining of wear tip holder. Too little
buildup can undermine wear tips and/or break them
by allowing material to stream past trailing angles.
Important: Small changes in trailing angle position

and shape can make big changes in VSI
performance and in wear rates. Do not change
trailing angle position or profile without reading
the whole section on CastRotor Tuning.
Some undermining, up to 3 mm (1/8"), is expected

and is not likely to harm VSI. 5 mm (3/16") or more
undermining is too much.
If there is too much undermining, consult your local
Cedarapids/ElJay distributor before making any
adjustments.
How to Change Trailing Angles
1) Showing a typical trailing angle position
(Figure 6-15). First, measure carefully position
and angle of each trailing angle before
loosening bolts holding them. Note their
positions to within 1.6 mm (1/16"). Write
dimensions down for later use. This helps
correctly position replacement parts.
21052 (3/97)
Page 6.7
2) Dig out rock material packed around trailing

angles.
3) After measuring and recording position of
trailing angles, loosen and remove the bolts
that hold trailing angles. Remove feed disc
retaining clips.
4) Remove trailing angles.
5) Replace trailing angles as a set. Make sure
parts are fully seated.
6) Adjust trailing angles to their previous position
unless a different buildup performance is
desired (Figure 6-16).
If you want to change performance, read all of
this section before choosing a new position for
trailing angles.
LJ1093200
A Terex Company
Section 6
Figure 6-16
Adjust Angles to their Proper Position
Place all three trailing angles in matching

positions so rock material buildup is even and
balanced.
Wear patterns in epps are another indicator to
suggest adjustments to trailing angles. Figure
6-17 shows three typical trailing angle positions
and associated wear pattern in epps. The shaded
area represents the wear in epp. The top image
indicates trailing angles need to be adjusted
because epp is wearing too fast at top.
The bottom image shows a good wear pattern
in epp. This wear pattern provides longest
wear life for epp.
7) Tighten trailing angle bolts.
8) Replace feed disc retaining clips and tap them
down firmly against feed disc.
9) Tighten trailing angle bolts to 67.8 Nm
(50ft-lbs).
Caution! Do not overtighten bolts on cast
wear parts. Cast parts are more brittle than
mild steel. They can crack and break under
too much stress from the bolt torque. If a
large piece breaks and flies loose during
operation, it can be dangerous.
21052 (3/97)
Page 6.8
Epp wear patterns
Trailing angle
positions
Figure 6-17
Epp Wear Related to Trailing Angle Position
LJ1093200
A Terex Company
Section 6
Changing the Feed Eye
Change Top Retaining Plates
As feed eye wears out, wear paths occur in eye and

adjacent wear liners. Regularly inspect feed eye to
note progress of wear paths. To increase liner life,
lift out feed eye and rotate it 90.
Change top retaining plates if they are (Figure 6-19):

worn to 4 or 5 mm (3/16") thick, or 1/4 the
original thickness of 19 mm (3/4").
cracked or chipped
1) To remove feed eye, first remove lid assembly.
worn to minimum dimension of 102 mm (4")

shown in Figure 6-19. Note this dimension on
new top wear plates is 108 mm (4-1/4")
2) Remove four socket-head screws and lift out

feed eye (Figure 6-18).
3) To extend feed eyes wear life, rotate it 90 so
an unworn portion of eye lines up with each
exit port.
4) Make sure feed eye is completely seated in
rotor.
5) Replace four bolts and tighten to 81 Nm (60
ft-lbs).
6) After replacing lid assembly or hopper and
feed tube, inspect rotor for clearance by turning
the rotor by hand with lid on and access doors
open. See Adjusting Feed Tube Height in
Section 7.
Important: Do not allow top wear plates to wear so

much that holes can be seen or studs in the rim
liners. If you can see these holes or studs, you have
let wear plates go too far. Replace immediately to
avoid costly damage to VSI.
How to Change Top Retaining Plates
The top retainer plates help armor top side of rotor,
but also help retain rim liners around upper rim
(Figure 6-20).
Feed eye bolts
2) Lift old plates out. Replace plates in balanced

sets around rotor.
102 mm
(4")
Feed eye
Figure 6-19
Minimum Dimension for Wear
of Top Retaining Plates
Figure 6-18
Worn Feed Eye and Bolts
21052 (3/97)
1) To change top wear plates, remove two sockethead bolts holding each plate in place.
Page 6.9
LJ1093200
A Terex Company
Section 6
3) Be sure each part is fully seated. Replace bolts
as needed. Do not reuse worn or damaged
bolts. Apply a thread-locking agent, such a
Loctite 242, to bolt threads. Tighten bolts t
136 Nm (100 ft-lb).
How to Remove the CastRotor
Changing many CastRotor wear parts requires that
rotor be removed from the flywheel and set outside
VSI. Working on upper liners inside rotor and on
those on bottom of rotor requires rotor be turned
upside down. The job can be done in mud and water,
but is more likely to be done correctly in good
conditions. A good idea is to prepare a clean, dry
work area near VSI or prepare to move rotor to a
work area with good conditions.
1) Remove lid and set it aside.
2) Dig rock material out from around feed disc.
Also dig out feed eye.
6) Remove six bolts holding rotor to flywheel.

7) With all liners installed, 1800 model CastRotor
weighs about 591 kgs (1300 lbs), 2100 model
CastRotor weighs about 694 kgs (1526 lbs).
Use appropriate lifting device to lift rotor and
set it in a clean, dry work area.
The following instructions on changing rotor wear
parts all assume you have removed rotor from VSI.
Changing Rim Liners
The rim liners protect outer rim of rotor at both top
and bottom edges (Figure 6-21). The same rim liners
fit both upper and lower positions. Each rim liner fits
over studs and is retained by one or more plates that
are bolted in place. A metal shim fits between top
retaining plates and upper rim liners. A rubber shim
fits between lower set of rim liners and bottom
retaining plate. The top retaining plates are not
interchangeable with bottom retaining plate. The
3) Remove bolts holding feed eye and lift clear.

4) Dig out and remove three angle clips that hold
feed disc. These clips keep the feed disc in
place when rotor is running empty at start-up.
5) Pry up the edge of feed disc and lift out of rotor.
Feed disc weighs about 45 kg (100 lbs).
B
Change rim liner when
B = 8 mm (5/16") or less
Figure 6-20
Changing Top Retaining Plates
21052 (3/97)
Figure 6-21
When to Change Rim Liners
Page 6.10
LJ1093200
A Terex Company
Section 6
rim liners above and below exit ports are longer and
fit over more studs than rim liners between exit
ports. To change lower rim liners, turn rotor upside
down. Usually, upper rim liners wear faster than
lower. Change rim liners when dimension B is 8 mm
(5/16") or less.
Any time a rim liner is removed, look carefully at
studs that rim liners fit over. Immediately replace
any that are bent, loose, chipped, dented, or damaged
in any way.
1) To change rim liners, remove the bolts holding
retaining plates.
2) Carefully remove shim between retaining plates
and rim liners. If replacing upper rim liners,
shim is metal. Lift out and set aside. If replacing
lower rim liners, shim is rubber. Peal off rubber
shim without damaging it, if possible.
3) Examine studs for looseness and wear. If loose
or worn, replace studs. See Installing Rotor
Studs.
4) Replace liners in balanced sets around rotor.
Be sure each rim liner is fully seated and that
metal shim fits cleanly onto upper rim liners.
Replace rubber shim on lower rim liners if the
rubber is brittle or torn. Replace metal shim if
it is worn, bent or broken.
5) Replace retaining plates and torque bolts to
136 Nm (100 ft-lb).
Changing Side Plates
Side plates can often be used until a hole is worn
through. Wear near top or bottom of side plate is
more common than wear in middle.
1) Remove top retaining plates.
Caution! Wear goggles and dust mask. Fine

airborne abrasive particles can be
hazardous.
5) Blow out all dust.
Side plates can be turned upside down or have their
order changed to increase wear life. If worn side
plates are kept in service, position new ones behind
epps, so new plates follow exit ports as rotor rotates.
Always replace side plates in sets of three to maintain
weight balancing. If changes are made to one
segment, it must be done to all. Weight range among
side plates must not vary more than 57 grams (2 oz.).
6) Replace side plates.
7) Before replacing rim liners or top retaining
plates check alignment studs. Be sure they are
sound. If not, replace them. See Installing
Rotor Studs.
8) Replace rim liners.
9) Replace metal shim.
10) Replace top retaining plates and tighten bolts
to 136 Nm (100 ft-lb).
When to Change
Bottom Retaining Plate
Look through gap between lower rim liners and the
flywheel guard liners (Figure 6-22). Note how usage
and wear have caused lower edge of bottom retaining
plate to recede. If bottom retaining plate appears to
have been extensively worn, remove CastRotor from
VSI and measure diameter of wear plate (Figure 623). If diameter is less than 762 mm (30"), change
retaining plate. This can only be seen clearly with
rotor removed and turned upside down.
2) Remove metal shim.

3) Remove upper rim liners.
4) Remove worn (or cracked) side plates.
21052 (3/97)
Page 6.11
LJ1093200
A Terex Company
Section 6
How to Change Bottom Retaining Plate
1) To change bottom retaining plate, turn rotor
upside down (Figure 6-23). Remove bolts
holding bottom retaining plates.
Gap Between Lower

Rim Liners and
Flywheel Guard
Liners
2) Replace rubber shim if rubber is brittle or torn.

3) Replace plate (Figure 6-24).
Bottom retaining plate
Flywheel Guard
Bottom
Retaining Plate
Rubber shim
Figure 6-22
Gap Between Lower Rim Liners
and Flywheel Guard Liners
762 mm (30") minimum
Rotor shown upside down.

Figure 6-24
Replacing Bottom Retaining Plate
Rotor shown upside down.

Figure 6-23
Measure Diameter of Bottom Retaining Plate
21052 (3/97)
4) Be sure rim liners and retaining plate are fully

seated. Replace bolts as needed. Tighten to
136 Nm (100ft-lb).
Page 6.12
LJ1093200
A Terex Company
Section 6
Installing Rotor Studs
CastRotor studs are not actually a wear part, but are
included here because they are important in properly
holding rim liners and side plates.
The fourth stud in each of these groupings is behind

a portion of rotor weldment called epp mounting
plate and is harder to see, but must be checked
carefully (Figure 6-26).
The rotor requires 72 Grade 8 studs, p/n 02-382-7190000, 3/4 -10. 36 studs are at top of rotor; 36 are at
bottom (Figure 6-25).
Stud
Rotor
1
1. Exit port rim liners
2. Epp
3. Fourth stud ends hidden
4. Visible stud ends
Grind flush any portion of stud that

extends through the rotor.
Figure 6-25
CastRotor Studs
Before mounting studs, check condition of both

male and female threads. If female threads in rotor
weldment are damaged, consult factory for proper
repairs. Reject studs that are damaged and use only
studs in good condition. Apply Loctite 271 or similar
thread-locking agent. Tighten each stud to full extent
of threads, but do not distort slotted head of stud.
Figure 6-26
Fourth Stud behind Epp Mounting Plate
After tightening fully, be sure that studs are flush

with surface inside rotor weldment. Do not allow
stud to project into epp area. If any studs project
inside surface, from above or below epp, grind them
flush before attempting to mount tip brackets.
Note that special attention must be paid to studs

above and below three epps.
At each epp (exit port protector), four studs are at top
and four are at bottom. These eight studs must be
checked closely after being tightened fully. Of these
eight, three at top and three at bottom are fully
visible from outside of rotor.
21052 (3/97)
Page 6.13
LJ1093200
A Terex Company
Section 6
21052 (3/97)
Page 6.14
LJ1093200
A Terex Company
Section 7 - Changing Stationary Wear

Parts, Belts, Bushings & Sheaves
Maintaining condition of stationary (non-rotating)
wear parts in VSI is just as important as with moving
wear parts. From hopper, through feed tube, past
flywheel guard plates and on through discharge
openings, every surface that is impacted or abraded
by rock material must be maintained and protected
in order to keep whole machine functioning well.
torque values of recommended Grade 8 bolts may

be so high as to crack or break cast part. Except
where a torque value is specifically noted, always
tighten wear part fasteners firmly to a snug fit.
Except where noted in this manual, do not tighten
bolts holding wear parts to full, standard, lubricated
torque value.
This section also helps maintain other moving parts

involved in driving VSI.
The Feed Tube
Notice Regarding Wear Parts Fasteners: Except

wear parts use anti-seize lubricant on threads. Cast
wear parts are very abrasion-resistant, but are
1. Tub liner
2. Anvil
3. Wedges
4. Lid liners
5. Lid
6. Hopper
The feed tube works same for both table/shoe and

CastRotor options (Figure 7-2). It is made to adjust
downward as wear occurs by removing adjusting
rings until all rings have been removed. Feed tubes
are installed at factory in pairs, one tube pointing
down and one up. When one pointing down wears to
7. Feed tube
8. Ring shims
9. Rotor option
10. Table option
11. Flywheel guard
12. Upper tub assembly
6
7
8
4
10
11
12
Figure 7-1
Stationary Wear Parts
21052 (3/97)
Page 7.1
LJ1093200
A Terex Company

8) Fit feed tube with ring shims at desired height
into lid assembly. See Adjusting Feed Tube
Height.
point that no further downward adjustment is

possible, turn pair over so worn tube is on top and
new one faces down. A new wear surface is then
ready for use.
9) After you have adjusted tube to proper height,

lift lid assembly and replace it. Bolt hopper
back onto lid. Tighten locking wedges in
opposite direction of throw device rotation.
Removing and Reinstalling Feed Tube

1) Unbolt feed hopper and attach appropriate
lifting device (Figure 7-3). Also see Component
Weights Chart. Note that component weights
are stated without rock material in VSI. Actual
weights can be heavier, depending on how
much material is trapped on component.
2) Lift hopper clear. Feed tube remains in lid.
Rock material usually jams feed tube tightly in
place. Set hopper down on ground.
3) Knock lid-locking wedges free (Figure 7-4).
4) Attach appropriate lifting device (Figure 7-5).
Lift lid with feed tubes still in place.
Warning! Stand clear when swinging lid
assembly free of VSI and to the side!
5) Set lid down with a heavy enough action to
loosen feed tube.
6) With feed tube un-jammed from lid, re-remove
feed tube.
Adjusting Feed Tube Height

Warning! Lock out power source before
opening access doors. Use a positive lockout
system.
The feed tube has four rings for height adjustment.
Three are 13 mm (1/2") thick; one is 19 mm (3/4")
thick (Figures 7-2 and 7-7 through 7-10). Select
rings needed to match feed tube height you need and
put them on ledge of lid. To adjust feed tube
downwards, remove one or more rings. If removing
all rings does not bring feed tube down within 13 mm
(1/2") of feed eye or shoes, turn tube over to unused
half and replace all rings. If both ends of tube are
worn, replace it.
7) Clean out lid so seating surfaces of feed tube

mate and tube can sit level in lid.
Figure 7-2
Feed Tube and Ring Shims
21052 (3/97)
Figure 7-3
Removing Hopper
Page 7.2
LJ1093200
A Terex Company

Figure 7-4
Remove Lid Wedges.
Figure 7-7
Feed Tube Too High Above Table
Figure 7-5
Adjusting Feed Tube with Open Table

Figure 7-8
Feed Tube Just Right Above Open Table
1) Open access doors in lid to check tube height.

2) With an open table, measure from top of shoe
to lowest point of feed tube. Keep this
dimension at 13 mm (1/2") or less. The best
position is when bottom of tube is flush with
top of shoes. If you find more than 13 mm (1/
2") gap, adjust feed tube down until gap is less
than 13 mm (1/2") (Figures 7-7 and 7-8).
5) Close and secure the access doors.

Adjusting Feed Tube with Closed Table
3) Keep feed tube centered over throw device. If

feed tube is worn on one side or you see a wear
pattern in shape of a scallop in tube, check to
be sure tube is centered above throw device.

2) With a closed table, measure from bottom of
cover plate to lowest point of feed tube. Keep
this dimension at 13 mm (1/2") or less. The best
position for bottom of tube is flush with top of
shoes. If you find more than 13 mm (1/2") gap,
adjust feed tube down until the gap is less than
13 mm (1/2") (Figure 7-9).
4) Rotate throw device by hand to check clearance

all around feed tube.
21052 (3/97)
Page 7.3
LJ1093200
A Terex Company

Adjusting Feed Tube with CastRotor
2) With rotor, reach through exit port to feel
lower edges of feed eye and feed tube (Figure
7-10). The feed tube must not be lower than
feed eye. If feed tube is worn more than 13 mm
(1/2") higher than feed eye, lower feed tube.
feed tube is worn on one side or you see
scalloping in tube, check to be sure tube is
centered above throw device.
Figure 7-9
Feed Tube Just Right Above Closed Table
5) Close and secure access doors.

Removing the Lid Assembly
Several checks can be done through access doors in
lid assembly. For other procedures, entire lid
assembly must be removed. It can be removed with
feed hopper in place or remove hopper first. See
Component Weights Chart. To remove lid assembly
with hopper in place, chains or cables are needed that
are about 3 meters (8 to 9 feet) long. Cedarapids
recommends a three point lifting device to remove
lid (Figure 7-11).
Warning! Lock out the power source before
removing the lid assembly. Use a positive
lockout system.
Figure 7-10
Feed Tube Just Right Above Rotor

feed tube is worn on one side or you see
scalloping in tube, check to be sure tube is
centered above throw device.
1) Remove locking pins from wedges. Drive

wedges from wedge brackets.
2) Attach lifting device at three equally spaced
points on lid (Figure 7-11).

3) Lift lid high enough to clear wedge brackets

and bottom of feed tube.
5) Close and secure the access doors.
4) Carefully swing lid away from crusher and

place it on blocks on ground. Interior wear
parts of the VSI are now accessible.
21052 (3/97)
Page 7.4
LJ1093200
A Terex Company

Monitoring the Anvil Ring
A set of anvils generally shows greatest wear at a
point not quite opposite end of feed conveyor. To
even out wear and extend wear life of anvils, rotate
anvil ring 180 halfway through anvil wear life.
If anvil wear pattern is not centered vertically on
anvil faces, adjust height of anvil ring as needed.
Warning! Lock out power source before
beginning maintenance!
Change anvils when worn to within 6 mm (1/4") of
back side. This is often about every 4 to 8 shoe
changes. Wear pattern should be a cup shape,
surrounded on 3 sides by face of anvil (Figure 7-12).
Do not allow wear to break through far side of anvil
face. Change if cracked.
Figure 7-11
Removing Lid Assembly
Types of Impact Surfaces

The impact-resistant, stationary surfaces mounted
around inner surface of upper tub also are available
in two separate options.
Anvils
The anvil ring option contains a set of replaceable,
white iron, high-chromium alloy castings, called
anvils or anvil blocks. These fit into holding brackets
around inside of upper tub. With proper lifting
equipment anvil ring can be lifted as a unit out of VSI
and tipped upside down for quick change of anvils.
Rock Shelf
To change anvils:
The rock shelf option is a simple, reinforced steel

ring mounted inside upper tub where rock
accumulates. After shelf area of ring fills with first
few hundred pounds or kilograms of rock through
crusher, following rock flung by rotary action hits
accumulated rock mass held on shelf area, creating
a rock-on-rock crushing effect.
21052 (3/97)
Figure 7-12
Worn Anvil
1) Remove bolts holding hopper.

2) Remove hopper from lid and place on ground
using appropriate cables or changing.
Note: If cables are 3 meters (8-9 ft), you don't need
to remove feed hopper before lifting lid.
Page 7.5
3) Remove wedges from lid wedge brackets by

driving out with a hammer.
LJ1093200
A Terex Company

4) Attach cables or chains with lifting hooks
though holes in lid gussets at three points.
5) Raise lid high enough to clear wedge brackets
and feed tub.
6) Swing lid away from crusher and place on
ground.
7) Remove wedges from upper tub wedge brackets
by driving out with a hammer.
8) Attach lifting hooks at three points through
wedge brackets on upper tub.
9) Raise upper tub high enough to clear wedge
brackets.
Figure 7-13
Place Anvils in Brackets
10) Swing upper tub away from crusher.

11) Tip upper tub assembly upside down on ground.
Caution! Wear eye protection!
12) Tap anvils lightly with hammer until anvils
fall to ground.
13) Turn upper tub with empty anvil ring right side
up on ground.
14) Place anvils into anvil brackets. Place the
narrow end of dovetail on back of anvil toward
bottom (Figure 7-13).
Note: Keeping a spare ring with anvils in stock can
make for quick changes, keeping downtime to a
minimum (Figure 7-14). Anvil ring removed from
crusher can be refitted with anvils in shop while
crusher continues to run.
Figure 7-14
Spare or Replacement Anvil Ring
15) Set upper tub in place with slots over wedge

brackets. Lower into position. Upper tub must
be kept level to avoid hanging up on wedge
brackets.
16) Drive in wedges securely (Figure 7-15). Install
locking pins.
Warning! Drive wedges in clockwise
direction to prevent loosening.
21052 (3/97)
Page 7.6
Figure 7-15
Drive Wedges Clockwise
LJ1093200
A Terex Company

Replacing Lid Liners
Warning! Stand Clear! Lid assembly can
drop quickly when turning upside-down!
To remove liners:
1) Remove the hopper and then lid. See Removing
and Reinstalling the Feed Tube.
2) Swing lid away from crusher and place on
blocks on ground to prevent damage to feed
tube.
3) Remove lid liner bolts.
4) Drive bolts through with drive punch.
5) Allow old liners to fall to ground.
To install new liners:
1) Turn lid upside down and place on support
stands strong enough to support weight of lid
assembly (Figure 7-16).
2) Set new liners in place (Figure 7-17). Begin
with liners furthest from inspection doors,
crowding liners at first to give extra space for
manipulating liners near doors.
Figure 7-16
Note: Different manufacturers of lid liners put the

mounting bolts in different places and you may not
be able to mix brands within a concentric ring of
liners (inner ring, middle ring, and outer ring). Fit
up all liners before tightening bolts.
3) On inspection doors a 13 mm (1/2") spacer is
required between door and liner.
4) Install new bolts. Do not tighten bolts until all
liners are in place to permit small adjustment
of liners.
5) Tighten bolts. Snug only- do not overtighten.
6) Turn lid right side up.
7) Reinstall lid and hopper.
21052 (3/97)
4
1. Outer ring liner
2. Middle ring liner
3. Inner ring liner
4. Door spacer- 13 mm (1/2") thick
Figure 7-17
Replacing Lid Liners
Page 7.7
LJ1093200
A Terex Company

Replacing Tub Liner
Replacing Flywheel Guard Wear Plates
When to change:
Change before worn through, or if cracked. If tub
liner wears completely through, deformation of
broken-out area may make liner difficult to remove.
If tub liner is worn only on one side, it can be rotated
180 to even out wear. If tub liner is worn only on
top, it can be inverted.
Warning! Lock out the power source before

beginning maintenance!
Change flywheel guard wear plates before worn
through, or if cracked. Wear plates do not need to be
changed as a set.
1) See Section 5 for steps in removing table from
flywheel or Section 6 on removing CastRotor.
To remove tub liner:
2) Remove two bolts from each liner.
1) Remove lid, anvil ring, and upper tub assembly.

See Monitoring the Anvil Ring.
3) Set replacement liner in place.
2) Remove channel rubber from top edge of tub.

Remove silicone sealant between tub and tub
liner.
5) Install two bolts in each liner. Tighten bolts to

81 Nm (60 ft-lbs).
3) Attach appropriate cables or chains with lifting

hooks to three lifting eyes on tub liner. If lifting
eyes are worn off or unusable, replace with
new ones.
Caution! Welds to AR plate are brittle. Use
caution when lifting liner.
4) Raise high enough to clear tub wedge brackets.
Swing liner clear of crusher and set on ground.
To install new liner:
1) Attach cables or chains with lifting hooks to 3
lifting eyes on new tub liner.
2) Lift liner, position over tub, and set in place.
3) Fill any large gaps (greater than 6 mm (1/4"))
between tub and liner with pieces of
polyurethane foam or similar material. Seal all
around space between tub and liner with
silicone caulking. Caulking prevents dust from
building up in space between tub and liner.
Liner can be installed without it, but will may
become cemented in place by packed dust.
4) Apply anti-seize lubricant to bolts.
V-Belts
Danger! Stand clear of running belt drive.
Warning! Shut down and lock out the power
source before beginning maintenance!
Attention: Sometimes, at customer request, a VSI
is shipped without certain features, such as drive
sheave. When this happens, Cedarapids/ElJay
attaches a warning tag to alert installers that belt
guard, an important safety feature that must be
fitted to sheave size, is missing. In such cases it is
customers responsibility to properly guard machine
while it is running.
Installing New Belts
Important: Do not use belt dressing of any kind. Do
not pry belts. Always use a matched set of belts.
Never mix belts from different manufacturers,
worn and new belts, or belts of the same
manufacturer that are from different lots.
4) Set upper tub in place, drive in wedges, install

pins. Set lid in place, drive in wedges, install
pins.
21052 (3/97)
Page 7.8
1) Check sheaves carefully for worn grooves or

other damage. Worn grooves can shorten belt
life by as much as 50%. See Sheaves and
Bushings, next page.
LJ1093200
A Terex Company

2) Remove all grease, rust and dirt from grooves
in sheaves.
3) Be sure sheaves are aligned and shafts are

parallel. See Sheaves and Bushings.
4) If belts do not slip easily onto sheaves, shorten
distance between sheaves (center distance or
span) until they go on easily. Do not pry belts
onto sheaves.
1. Belt touches bottom of sheave
2. Worn belt or sheave
3. Proper fit
5) Place belts on sheaves.

6) With belts still loose, rotate the drive so all
slack is on one side.
Figure 7-18
Belt Fit
7) Tighten belts with threaded adjustments at

motor mount. General guidelines for getting
and maintaining proper belt tension:
Warning! Standard iron sheave rim speed

must not exceed 1981 meters per minute
(6500 feet per minute, fpm). Standard iron
sheaves can explode when run at excessive
speeds! If rim speed exceeds 1981 meters per
minute (6500 fpm), ductile iron or steel
sheaves are required.
The best tension is lowest at which the belts

will not slip under highest load. Too much
tension shortens belt and bearing life!
Check tension often in first day operating
with new belts
Check belt tension on a regular schedule
Keep belts and sheaves free of material that
may cause slippage (oils, grease, silicone, etc.)
Removing Sheaves and Bushings

1) Loosen and remove three hub bolts from
sheave.
If a V-belt slips, tighten it!
2) Insert the three bolts in threaded jackscrew

holes in sheave hub.
8) New belts stretch after installation. Check

tension periodically and readjust as necessary.
3) Start with bolt farthest from busing saw slot.

Tighten all jack screw bolts in small equal
amounts, progressing around the circle, until
tapered hub and sheave disengage.
Sheaves and Bushings

Check sheaves carefully for worn grooves or other
damage. Worn grooves can shorten belt life by as
much as 50% (Figure 7-18).
Caution! To check by feel, protect fingers
from cuts by using gloves or a rag. Replace
sheave if grooves are dished out.
Important: Sheaves are cast iron and fragile.

Excessive or unequal pressure on jack screws can
break bushing flange, making removal difficult
without destroying sheave. Use care when handling.
To check by gauge, use sheave groove gauge. Replace

sheave if sidewall wear exceeds 0,635 mm (0.025").
21052 (3/97)
Page 7.9
4) Remove sheave and bushing. If bushing does

not slip off shaft, wedge screwdriver in saw cut
to loosen, being careful not to damage shaft or
bushings.
LJ1093200
A Terex Company

Installing Sheaves and Bushings
1) Consult dealer when using sheaves other than
those listed in Section 10.
2) Make sure tapered outer surface of bushing
and bore of sheave are clean.
3) Place key on shaft. Slide bushing into place
with flange toward crusher.
4) Line up unthreaded holes in sheave with
threaded holes in bushing. Position threaded
jack screw holes as far from busing saw slot as
possible to lessen chance of bushing breakage
at next removal.
5) Insert bolts and lock washers through sheave
into busing, engaging only two or three threads.
Notice: Sheave manufacturers do not recommend
use of anti-seize bolt lubricant on bolts or mating
surfaces. It can cause sheave breakage.
8) Tighten set screw in bushing flange to hold key

securely during operation.
9) Check to see that drive and driven shafts are
parallel. Check by measuring distance between
shafts at three or more points. If distances are
equal, shafts are parallel.
10) Check alignment between the two sheaves.
Check Alignment
by placing straight edge across face of both
sheaves. Sheaves are aligned if straight edge
touches sheaves at two points on each sheave
Or by tying a piece of string to one shaft, then
stretching it across the faces of both sheaves.
Check alignment at minimum of two positions:
across tops of sheaves and across bottoms of sheaves.
Rotate sheaves 90 and check again.
Adjust alignment if needed.
6) Position sheave and bushing assembly for

good belt alignment.
7) Carefully tighten bolts in small equal amounts,
progressing around the circle just until the
tapers are seated. Torque bolts to 136 Nm
(100 ft-lb) dry. This normally leaves a gap
between bushing flange and sheave.
Notice: Overtightening can cause sheave and/or
bushing breakage.
21052 (3/97)
Page 7.10
LJ1093200
A Terex Company
Section 8
Lubrication
Lubricant Oil Specifications
VSIs run at high rpm to effectively crush rock. They
are sensitive to oil temperature changes near upper
end of oil performance range. Take frequent oil
samples and base an oil and filter change schedule
on data from those samples. This is most reliable
way to assure long bearing, shaft, and/or gear life for
a VSI. This practice is efficient and cost effective
over time and can greatly extend life of VSI.
Above 66C (150F) ISO 68 thins out below

minimum viscosity of 100 SUS. At this point replace
it with heavier oil. However, even lighter weight oils
may require heaters for cold weather start-up. Before
starting the crusher in cold climates, be sure the oil
in the sump and external lines is fluid.
The oils shown can be used as long as specifications
are met (Figure 8-2).
VSIs are filled with ISO 150 oil at factory when

tested. This oil protects gears and bearings to a
maximum operating temperature of 115.5C (240F).
This oil minimizes cold weather start-up problems
and still supplies adequate viscosity for bearing
lubrication.
Use only extreme pressure (EP) rated oils.
Oil Properties (at Operating Temperatures)
Minimum Viscosity
(Saybolt Universal Seconds)
Centistrokes
100 SUS
55 lb
Minimum Viscosity Index
90
Amoco
Amogear EP 150
Chevron
Ultra Gear ISO 150
Exxon
Spartan EP 150
Gulf
Gulf EP HD 150
Mobil
Mobilgear 629
Shell
Omala 150
Texaco
Meropa 150
Switching to Other Oil Grades

Notice: Maximum allowable oil temperature under
any condition is 116C (240F) at gauge!
Figure 8-1
Notice: Using a lubricant that does not meet these

specifications voids warranty.
Cedarapids has found, for conditions above -18C
(0F) with no wind chill, internal bearing temperature
is independent of outside (ambient) temperature and
can reach 82C (180F) in any size VSI (Figure 8-1).
In cold weather operation with ISO 150 grade oil an
oil heater may be needed to keep oil fluid and
prevent damage to lubrication pump. Continuous
operation in very cold temperatures may allow use
of lighter oils. For example, ISO 68 oil may be used
to maintain lubricant liquidity in climates where
temperatures are commonly well below freezing, as
long as oil temperature does not exceed 66C (150F).
21052 (3/97)
Brand Name/Grade
Figure 8-2
Acceptable Lubricants
20.58
Minimum Timken OK Load
Oil Company
If oil temperature reading for crusher exceeds 104C

(220F) with ISO 150 grade oil, Cedarapids
recommends installation of ISO 220 or equivalent.
This does not make crusher run any cooler, but oil is
able to maintain an adequate oil film thickness at
higher operating temperatures.
If VSI is run at 80-100% of maximum recommended
speed, changing to a heavier oil is likely to raise
operating oil temperature.
Oil Analysis: When to Change Oil
Cedarapids/ElJay recommends that oil be
periodically sampled and analyzed in a qualified lab.
The data from a proper analysis indicate:
Page 8.1
condition of oil
what contaminants are in oil
when it should be changed
LJ1093200
A Terex Company
Section 8
Lubrication
VSIs built in 1989 and after have an oil sampling
valve fitted conveniently near filter. Usually, oil
should be changed every 1000 operating hours. You
may get longer service from your oil. The best
indicator of oil condition is Total Acid Number, the
TAN. It is a measurement of how much the oil has
degraded. The TAN rises as oil degrades. Generally,
a 100% increase in TAN indicates that you should
change lubricating oil. As TAN continues to increase,
oil carries more contaminants and viscosity increases,
decreasing lubricant effectiveness.
Keep a record of lab reports to develop a history of

oil consumption, metal concentrations and other
useful data for preventative maintenance. If oil sample
analysis is not available, or if no machine history
data exists on which to schedule preventive
maintenance, use following schedule for oil changes.
A good lab analysis shows concentrations of wear

metal elements in parts-per-million. Typical
concentrations and limits are shown (Figure 8-3).
Notice: Dirty oil can damage bearings.
1) Change oil after first 500 hours of operation,

then every 1000 hours or every 6 months. In
very dirty conditions, change the oil more
often. See oil sampling program recommended
in Taking Oil Samples.
2) Change oil at end of shift when oil is warm.
3) Change oil filter element at same time as the
oil change. Do not run clean oil through a dirty
filter.
Aluminum
Typical
Concentration
0-10
Copper
0-15
50
Taking Oil Samples
Nickel
0-5
10
Chrome
0-5
10
Lead
0-20
50
The oil sampling valve allows you to take oil samples

for lab testing while still crushing (Figures 8-4 and
8-5).
Iron
30-50
150
Silicon (dirt)
10-30
75
Wear Metal
Upper Limit
1) Unscrew the protective cap.

2) Lightly push on the sampler needle assembly.
Allow a small amount of oil to escape into a
spare container to avoid possible contamination
from dirt near the sampling valve.
Figure 8-3
Metal Concentration Upper Limits
A good oil sample report shows a viscosity number,

expressed in centistokes, Saybolt Universal Seconds,
or Minimum Viscosity Index.
3) Holding the open tube end in a sampling bottle,

fill the sample bottle and cap it tightly.
If you are using an oil with a rating of 140 SUS at

40C (104F) for SAE 80W-90 when it is clean and
fresh, a report might show 168 SUS at 40C (104F)
for SAE 80W-90. 168 SUS is an increase of 20% in
the oils base viscosity level at same temperature
and SAE rating. In this case, report tells you it is time
to change oil.
To protect your VSI from damage caused by
inadequate lubrication is to continue taking periodic
oil samples, sending them for analysis, and depending
on that analysis to assess effectiveness of your oil.
21052 (3/97)
Page 8.2
Figure 8-4
Oil Sampling Valve
LJ1093200
A Terex Company
Section 8
Lubrication
4) Replace the protective cap.
5) Label oil sample. Write date, machine ID

number, oil type, number of hours run, and
other useful data on label. Make a copy to keep
with your records. Send sample and data to
your analysis lab.
2
3
Checking Oil Level with Dipstick
1. Oil sampling valve

2. Indicator
3. Housing
4. Cannister
5. Nut
To be sure your VSI has enough oil, check dipstick

every day. See Figures 8-6 through 8-9 for the
dipstick location on your machine.
1) Clean top of oil filler cap (which is welded to
dipstick) and clean surrounding area before
unscrewing cap.
2) Unscrew dipstick/oil filler cap and remove it.
Look at oil on stick. Note oil characteristics. If
oil is too thick to drip, it can damage oil pump
and not properly lubricate bearings.
Figure 8-5
Oil Filter
Change filter element:

After first 500 hours of operation, then every
1000 hours or every 6 months. Samples may
indicate need for more frequent filter changes
3) Wipe dipstick on a clean cloth.
At each oil change
4) Place dipstick/oil cap on top of filler pipe

(without threading it down).
When oil flow is slowed by blockage of filter.

Change element when indicator shows a change
is needed
5) Lift dipstick a second time and read oil level.

6) Add clean oil as needed and replace dipstick/
oil filler cap tightly.
When samples show a particulate count that is

too high
How to Change Oil and Filter Element

To ensure only clean oil flows over bearings, each
VSI is equipped with an external oil filter (Figure 85). The filter is designed to have high dirt-holding
capacity and to filter harmful particles out of
lubricating oil.
Notice: Use of filter element with particle removal

rating coarser than 25 microns absolute voids
warranty.
1) Before draining oil, make sure it is warmed to
operating temperature.
2) Take an oil sample from sampling valve.
The filter has a replaceable element. It is important

to use proper replacement element in filter. An
element that is too fine plugs quickly and one that is
too coarse allows too many particles to pass.
3) Remove drain plug(s). Each model has a

different configuration and location of oil drain
plugs. All plugs are magnetic with 25.4 mm
(1'') square heads.
Check filter element indicator every shift.
1800 GD: Two oil drain plugs, both on drive-shaft

face of base below drive sheave. Removing upper
plug drains outer tank and removing lower plug
drains inner tank (Figure 8-6).
21052 (3/97)
Page 8.3
LJ1093200
A Terex Company
Section 8
Lubrication
1. From external oil system
2. Dipstick (not shown)
3. In-line oil filter
4. Pinion bearing spray nozzle
5. Suction strainer
6. To external oil system
7. Outer tank drain plug
8. Inner tank drain plug
1
2
3
Figure 8-6
Oil Flow Pattern 1800 VSI-GD
1. Dipstick
3. Oil level
4. Oil tank
5. Drain Plug
3
4
5
Figure 8-7
Lubrication Flow Pattern 1800 VSI-VBD
21052 (3/97)
Page 8.4
LJ1093200
A Terex Company
Section 8
Lubrication
2
1

2. Pinion bearing spray nozzle
3. Dipstick
4. Lower tank drain plug
6. Belly pan access cover
7. Inner tank drain plug
4
7
6
5
Figure 8-8
Oil Flow Pattern 2100 VSI-GD

3. Dipstick
4. Cover plate
5. Oil drain Plug
1
2
Figure 8-9
Lubrication Flow Pattern 2100 VSI-VBD
21052 (3/97)
Page 8.5
LJ1093200
A Terex Company
Section 8
Lubrication
1800 VBD: Plug in bottom of oil tank (Figure 8-7).
Lubricating Oil Capacities
2100 GD: Two plugs. Remove belly pan access

cover (14 bolts). Remove plug from inner tank.
Remove lower tank plug (Figure 8-8).
Notice: Oil capacities shown in accompanying

chart are guidelines only, based on averages. Actual
capacity of VSI may differ from that stated in chart.
2100 VBD: One plug. Remove cover plate from

lower (secondary) motor mount. Slide a collecting
bucket up between belts. Remove plug from bottom
of oil tank (Figure 8-9).
4) Drain oil from reservoir(s). Replace drain plugs.
5) Remove filter cannister with an open end, box,
or socket wrench. Filter housing remains fixed.
Crusher Model
Liters
U.S. Gallons
1800 GD
45
12
1800 VBD
26
2100 GD
49
13
2100 VBD
28
7.5
Figure 8-10
Approximate Lubricating Oil Capacities
6) Take out white indicator ring and set aside.

7) Drain old oil from cannister and remove
element. Dispose properly.
15) Check dipstick to be sure of correct oil level

before restarting VSI.
8) Clean cannister.
Notice: Take precautions to prevent water from

getting in oil. Store oil barrels where rain and
condensation cannot get in.
9) Replace seal that fits inside lip of filter housing.

10) Install a new element.
Oil Flow Monitoring System
11) Replace indicator ring.
Oil flow monitoring system includes:
12) Fill cannister with new, approved lubricant.
a flow meter
13) Reinstall cannister.
a flow switch
14) See Lubricating Oil Capacities, Figure 8-10.

Add clean oil, about half volume required for
total system, through oil filler pipe. Start pump
to fill oil sump (gearbox on gear-driven VSIs)
and circulate oil through system. Add
remaining half of total required oil while pump
continues to run.
Important: Protect the filter housing from
contamination. Dirt particles in oil can damage
bearings.
a warning horn
If a breakdown in oil flow occurs, flow monitoring
system can alert operator that a malfunction needs to
be corrected. It is recommended to have flow monitor
switch shut down feed to crusher if oil flow is
interrupted (Figure 8-11).
Notice: Continued operation of crusher with
insufficient oil flow severely damages bearings.
Use flow monitoring system to prevent costly repairs
and downtime resulting from insufficient oil flow.
Failure to properly interlock flow monitoring system
to protect crusher voids warranty!
Figures 8-6, 8-7, 8-8, and 8-9 show the internal oil
flow in the various VSI models.
21052 (3/97)
Page 8.6
LJ1093200
A Terex Company
Section 8
Lubrication
Expected Oil Flow Rates
1
Flow in liters per minute (lpm) and U.S. gallons per

minute (gpm).
Model
Cold
Warm
liters/min
4.7 to 5.7
2.8 to 3.3
Gallons/min
1.25 to 1.5
.75 to .875
liters/min
2.8 to 3.8
1.4 to 1.9
Gallons/min
.75 to 1
.625 to .5
liters/min
5.7 to 6.6
3.3 to 4.3
Gallons/min
1.5 to 1.75
.875 to 1.125
liters/min
4.7 to 5.7
2.8 to 3.3
Gallons/min
1.25 to 1.5
.75 to .875
1800 VSI-GD
5
1800 VSI-VBD
2100 VSI-GD
2100 VSI-VBD
Figure 8-12
Oil Flow Rates
For other lubrication questions, call your Cedarapids/

ElJay Distributor, or call Cedarapids at (319) 3633511 for location of your nearest distributor.
1. Warning horn
2. Temperature gauge
3. Oil sampling valve
4. Filter
5. To crusher
6. From crusher
7. Pump
8. Flow meter/switch
Figure 8-11
External Oil Flow
Flow Meter/Switch Settings

Flow meters are set at factory to activate warning
horn when oil flow rate descends to:
1.9 liters per minute (0.50 U.S. gpm) on models
1800 GD and 2100 VBD
1.4 liters per minute (0.375 U.S. gpm) on
model 1800 VBD
2.8 liters per minute (0.75 U.S. gpm) on model
2100 GD
21052 (3/97)
Page 8.7
LJ1093200
A Terex Company
Section 8
Lubrication
21052 (3/97)
Page 8.8
LJ1093200
A Terex Company
Section 9
Electrical System
The electrical system for all VSI models includes an
electric oil pump, a flow switch activated by flow
meter and electrically connected to a warning horn,
a vibration switch, transformer, and a thermostatically
controlled oil heater. Wiring for each of these
electrical components is routed to a junction box
(sometimes called the j-box).
See appropriate, suggested wiring diagram for your
operating voltage, Figures 9-3 or 9-4.
The oil pump circulates oil from the sump through
the filtering system and to the bearings.
Oil Pump
The electric oil pump of VSI is its only source of
lubrication. The VSI has no mechanical oil pump, so
it is very important that electric pump be wellmaintained and always in working condition.
The 1800 and 2100 VSI pumps have different sized
outlet ports. The 1800 model has a 9.5 mm (0.375")
port with an output of 1.9 lpm (0.5 U.S. gpm). The
2100 model has a 12.7 mm (0.5") port with an output
of 2.84 lpm (0.75 U.S. gpm).
Flow Switch and Warning Horn
The flow switch protects crusher bearings by

sounding warning horn, cutting off power to crusher
and feed conveyor at any time oil flow rate drops
below preset value.
Cedarapids recommends that flow switch also be

wired to feed source, so that if bearing lubrication is
inadequate, load is immediately taken off bearings.
See suggested wiring diagram.
The warning horn sounds to alert operators that oil

flow to bearings has become too low.
The switch point (oil flow rate at which an internal

cam in flow meter throws a switch, activating warning
horn and cutting off power to crusher and feed
conveyor) is preset at factory.
The vibration switch protects crusher and nearby

people by shutting down power to crusher whenever
too much vibration occurs.
The transformer converts incoming voltage to
appropriate levels for electrical components.
Note: Attempting to reset switch point voids

warranty.
Switch point settings for 60Hz systems:
The thermostatically controlled heater warms oil in

sump to help assure proper oil flow to bearings.
lpm = liters per minute, gpm= U.S. gallons per

minute.
Junction Box (J-Box)
1800 GD is set at 1.9 lpm (0.5 gpm).
Inside each junction box Cedarapids attaches a wiring

schematic to help users set up and maintain proper
wiring for their VSI (Figures 9-3 or 9-4).
1800 VBD is set at 1.1 lpm (0.3 gpm)

2100 GD model is set at 2.8 lpm (0.75 gpm)
2100 VBD model is set at 1.9 lpm (0.5 gpm)
List of components terminating in J-box:
Switch point settings for 50Hz systems:
Oil pump
1800 GD is set at 1.5 lpm (0.4 gpm).
Flow switch
1800 VBD is set at 0.83 lpm (0.22 gpm)
Warning horn
2100 GD model is set at 2.3 lpm (0.6 gpm)
Vibration switch
2100 VBD model is set at 1.5 lpm (0.4 gpm)
Transformer
Heater and thermostat
An electrical outlet is located at J-box, wired at
factory to match voltage requirements of region.
21052 (3/97)
Page 9.1
LJ1093200
A Terex Company
Section 9
Electrical System
Automatic Shutdown
If oil flow rate is too low, warning horn sounds and
crusher shuts down. If this happens, find out why oil
flow was too low before restarting VSI.
If vibration detection switch trips, crusher drive
shuts down, but warning horn does not sound.
Momentum continues to keep flywheel rotating for
awhile. After flywheel and throw device stop rotating,
find out why vibration detection switch tripped. To
restart crusher, turn oil pump off, then back on. This
resets vibration switch.
Figure 9-1
Vibration Switch
Vibration Switch
The factory normally ships VSI with 220 or 120 volt
50/60 Hertz (Hz) circuitry with vibration switch set
at 4.5 (4.5) gravities. Other voltage packages must
be stated at time machine is ordered.
A transformer is supplied for vibration switch to step
voltage down from 220 to 120 volts.
Start Delay
When you first start VSI after power has been shut
off, a 30 second delay circuit prevents vibration
switch from reacting to any vibrations during that
period.
Monitor Delay and Simple Test
After 30 seconds of operation monitor circuit is
activated. It also has a delay of 5 seconds. This is to
prevent unnecessary shutdowns for brief,
intermittent, mild vibrations, but allows quick
shutdown for any violent or long-duration vibrations.
A simple test of monitor-delay circuit is to hit base
frame mounting bolt with a 1 kg (2 lb) hammer. Then
listen for vibration switch to trip first relay. If system
is working correctly, the physical/electrical contacts
open, starting timer. After 5 seconds you can hear
them close. If you hit mounting bolt continually to
make vibration last longer than 5 seconds, VSI
should shut down.
21052 (3/97)
The difference between a shutdown caused by oil

flow switch and one caused by vibration detection
switch is whether or not warning horn sounds.
Start-up Controls
A properly wired VSI assures that drive cannot be
started unless oil pump is running and proper amount
of oil is flowing through pump. The horn sounds
momentarily (1-2 seconds) then turns off when first
starting oil pump. This assures that horn and flow
meter/switch are working properly. Always be sure
oil pump starts before drive shaft turns.
Wiring for Heater and Thermostat
1800 models have a cast heater with radiating vanes.
2100 models have a tube-type heater. Both have
built-in thermostats.
Wiring for Optional Pre-wired Panel
An optional pre-wired electrical panel is available
containing circuit breaker, fuses, step-down
transformers, relays, timers, lube pump start/stop
switches, and indicator lights for lube pump and
heater.
Page 9.2
LJ1093200
A Terex Company
Section 9
Electrical System
L1 L2
L3
Main
Breaker
70 A
Circuit
Breaker
20 A
5 KVA
Transformer
X1
40 A
M1
480 V
X2
F4
F2
F3
20 A
7A
20 A
F1
120 V 60Hz
20
120 V Outlet
20
X2
(12 Ga)
R2
14
(12 Ga)
14
14
Red
14
M2
Lube Pump 1 HP
120 V
M1
15 HP
U/C Conveyor
X2
R2
Green
Flow Switch
18 N.O. 21
18
22
F5
(Fast)
KTK 1.5 A
21
R2
22
V.S.
23
X2
23
CR1
X2
Sup
18
Flow Switch
N.C.
R4
15
(12 GA)
16
X2
16
16
R4
16
Horn
19
19
0X
0X
U/C Conveyor
Crusher junction box

terminations.
R4
R2
Vibraswitch Power Supply
V.S.
Items in gray boxes are standard

equipment on VSIs.
X2
Start
Stop
1
X2
Amber
17
17
Lube
Pump
Heater 600 W
51
50
O.L.
Items shown as black lines are

supplied on plants ordered with
the electrical package.
M1
M1
EQUIPMENT FEEDING VSI CRUSHER
Feed
Stop
CR1
1
26
Feed
Start
Items shown as dotted lines are

not supplied by Cedarapids.
O.L.
26
Feed
Feed
ELECTRIC DRIVE
Crusher
Stop
CR1
1
27
1.5 mm2 (16 gauge) wire used

except where noted.
Crusher
Start
O.L.
27
C
C
X1
X2
Figure 9-2
VSI Electrical Schematic - 120 Volt
(For Units without Optional Lid-Lifter)
21052 (3/97)
Page 9.3
LJ1093200
A Terex Company
Section 9
Electrical System
120 Volt Circuit Operation
Heater Fuse Chart
The lube pump switch energizes Relay R2 and

vibraswitch power supply (VS). Relay R2 contacts
energize lube pump motors starter (M2) and flow
switch circuit. The horn blows momentarily until
Normally Closed (N.C.) flow switch contact opens.
The Normally Open (N.O.) flow switch contacts
close, energizing CR1. When CR1 is energized, you
can start electric drive (or engage PTO of a running
diesel) and start feed equipment.
The G-force of vibration switch is preset. Continuous

G-forces greater than this setting for more than five
(5) seconds opens vibration switchs Normally
Closed contact (VS), de-energizing CR1, This stops
crusher drive (diesel or electric) and equipment
feeding VSI, It does not sound warning horn. Reset
vibration switch by momentarily interrupting power
to lube pump or by installing a reset button on
Vibraswitch terminal strip locations #3 and #4.
2000 W
F2
10 amp
20 amp
14
4
25
17
16
27
26
19
18
X2
X2
21
20
X2
X2
23
22
24
GND GND
GND GND
120 V
VSI Crusher J-Box Terminal Strips
120 V
X2
120 V
22
23
Reset
Vibraswitch Terminal Strip
Cummins Clutch Limit

Diesel Battery Supply
From Fuel
Solenoid
+24 VDC
To Fuel
Solenoid
CR1
24
24
25
25
LS1
24
24
25
25
Clutch Limit
Opens Circuit When Clutch is Engaged
Caterpiller Clutch Limit

From Fuel
Solenoid
The clutch limit switch, LS1, lets you warm up

diesel without VSI lube pump running. It stops
diesel if Power Take Off (PTO) is engaged without
oil flow and/or if vibration switch is tripped.
21052 (3/97)
600 W
In case of loss of oil flow when using an electric

drive, flow switchs Normally Open contacts open,
de-energizing CR1. This stops drive motor and the
equipment feeding crusher. The Normally Closed
flow switch contacts also close, sounding horn to
alert operator.
In case of loss of oil flow when using a diesel drive,
flow switchs Normally Open contacts open, deenergizing CR1. This shuts off diesel fuel solenoid,
stopping diesel engine and equipment feeding
crusher. The Normally Closed flow switch contacts
also close, sounding horn to alert operator.
Fuse
Page 9.4
+24 VDC
24
24
To Fuel
Solenoid
LS1
28
CR1
25
25
Clutch Limit
Closes Circuit When Clutch is Engaged
LJ1093200
A Terex Company
Section 9
Electrical System
L1 L2
L3
Main
Breaker
70 A
40 A
15 A
380/416 V 50 Hz
5 KVA
Transformer
M1
M2
220 V 50-60 Hz
X2
X1
20
20
(12 Ga)
M1
M2
15 HP
U/C Conveyor
1 HP
Lube Pump
Amber
T2 T3
F6
5A
F5
F4
15 A
F3
F2
5A
15 A
F1
T1
220 V
Outlet
R4
15
(12 Ga)
16
Heater
16
R4
1
17
17
R4
50 VA Transformer
220 V 50-60 Hz
1
2
X1A
120 V
50-60 Hz
0.5 A
On Transformer
X2A
X2A
Vibraswitch Power Supply

22
X2A
V.S.
Green
X1A
X2A
23
Lube
Pump
0X
V.S.
22
22
23
X2A
CR1
Sup
Crusher junction box

terminations.
Red
Lube
Pump
0X
M2
U/C Conveyor
51
50
Items shown in gray boxes are

standard equipment on VSI
crushers.
Lube Pump- 3 Phase
Start
Stop
1
O.L.
14
O.L.
M1
M1
EQUIPMENT FEEDING VSI CRUSHER
Start
Stop
CR1
26
26
Items shown as black lines are

supplied on plants ordered with
the electrical package.
O.L.
CR2
Feed
Crusher
Starter
Interlock
Feed
Electric Drive
Diesel Drive
ELECTRIC DRIVE
M2
18
Flow Switch
N.O.
18
21
21
Stop
CR1
27
O.L.
27
Aux
C
C
Flow Switch
N.C.
Items shown as dotted lines are

not supplied by Cedarapids.
Start
Crusher Motor
Horn
19
19
1.5 mm2 (16 gauge) wire used

except where noted.
Figure 9-4
VSI Electrical Schematic - 220 Volt
(For Unit Without Optional Lid-Lifter)
21052 (3/97)
Page 9.5
LJ1093200
A Terex Company
Section 9
Electrical System
220 Volt Circuit Operation
For both electric and diesel drives, lube pump switch
energizes Vibraswitch power supply (VS), CR1 and
lube pump motor starter M2.
The clutch limit switch, LS1, warms up the diesel

without VSI lube pump running. It stops diesel if
Power Take Off (PTO) is engaged without oil flow
and/or if vibration switch is tripped.
Heater Fuse Chart
Contact C is optional as shipped from factory.

Cedarapids recommends installing Contact C as
appropriate to prevent feeding any rock to VSI if loss
of oil flow or overload conditions occur. For VSIs
with diesel drive use CR2 contacts to stop feed.
Fuse
600 W
2000 W
F2
5 amp
10 amp
F5
5 amp
10 amp
For VSIs with electric drive, horn blows momentarily

until Normally Closed (N.C.) flow switch contact
opens. If CR1 contacts are closed, Normally Open
(N.O.) flow switch contacts close, enabling (usersupplied) Relay C and Contact C to start electric
drive and feed equipment. If vibration switch is
tripped, CR1 does not close.
X1A
X2A
X2A
For VSIs with diesel drive, oil flow switch operates

same as with electric drive except that CR1 contact
energizes CR2 relay, which controls operation of
diesels fuel solenoid.
In a loss of oil flow condition with an electric drive,
flow switchs Normally Open contacts open, deenergizing (user-supplied) Relay C. This stops drive
motor. The flow switchs Normally Closed contacts
close, sounding warning horn.
In a loss of oil flow condition with a diesel drive,
flow switchs Normally Open contacts open, deenergizing CR2. This shuts off diesel fuel solenoid,
stopping diesel. The flow switchs Normally Closed
contacts close, sounding horn.
G-force of vibration switch is preset. Continuous Gforces greater than setting for more than five seconds
open vibration switchs Normally Closed contact
(VS), de-energizing CR1 (CR2 for diesel), This
stops crusher drive (diesel or electric) and equipment
feeding VSI, It does not sound horn. Reset vibration
switch by momentarily interrupting power to lube
pump or by installing a reset button on Vibraswitch
terminal strip locations #3 and #4.
16
18
21
17
19
23
25
27
22
24
GND GND
GND GND
1
26
20
T1
T3
T2
220 V
22
X2A
22
23
120 V
Reset

Diesel Drive
1
M2
18
18
Flow Switch
N.O.
CR1
21
27
CR2
27
Aux
Flow Switch
N.C.
Horn
19
19

From Fuel
Solenoid
+24 VDC
To Fuel
Solenoid
CR2
24
24
LS1
24
24
25
25
25
25
Clutch Limit
Opens Circuit When Clutch is Engaged
Caterpiller Clutch Limit

From Fuel
Solenoid
+24 VDC
24
24
To Fuel
Solenoid
LS1
28
CR2
25
25
Clutch Limit
Closes Circuit When Clutch is Engaged
21052 (3/97)
Page 9.6
LJ1093200
A Terex Company
Section 9
Electrical System
L1 L2
L3
Main
Breaker
70 A
Circuit
Breaker
20 A
5 KVA
Transformer
X1
15 A
40 A
M1
480 V
X2
7A
F4
20 A
F2
F1
120 V 60Hz
20
20
(12 Ga)
120 V Outlet
R4
15
Heater
16
M1
M2
2 HP
Lube Pump
15 HP
U/C Conveyor
Amber
Red
Start
Stop
2
M1
M1
VS
51
50
M2
U/C Conveyor
Feed to Impact
Stop
CR1
Vibration Switch
U/C Start
Stop
Lube Pump
Feed
26
Thermostat
R4
17
Off On
Lid Lifter
Up
Up
M1
OX
14
33
32
Down
Down
31
Green
XO
21
18
F5
1.5 A
22
V.S.
23
Suppressor
27
#22
#23
Reset

X2

XO
19
Horn
24
2
120 V
From Fuel
Solenoid
X2
1
CR1
Sup
Stop
#4
25
1 4 14 16 17 18 19 20 21 22 23 24 25
To Diesel
Fuel Solenoid
Clutch Limit
Switch
26 27 31 32 X2 X2 X2 X2 GND GND GND T1 T2 T3

24
CR1
25
120 V
Figure 9-4
Electrical Diagram for Units Equipped with Optional Lid-Lifter. Refer to Lid-Lifter Addendum
21052 (3/97)
Page 9.7
LJ1093200
A Terex Company
Section 9
Electrical System
21052 (3/97)
Page 9.8
LJ1093200
A Terex Company
Section 10
Applications
How It Works: VSI Crushing Action
Abrasion
The VSI is a machine for volume production of

cubically fractured crushed rock. The drive system
rotates vertical shaft and rotating throw device (rotor
or table with shoes) at top of vertical shaft.
Tests for chemicals with known abrasive compounds

can determine abrasion characteristics of specific
rocks. Silica dioxide (SiO2), iron oxide (FeO) and
aluminum oxide (Al2O3) are commonabrasive
compounds in rock. Magnesium carbonate (MgCO3)
and calcium carbonate (CaCO2) are also associated
with abrasive effects. Abrasiveness and toughness
are different. Some basalts are tough materials,
performing very well in soundness tests, but are
moderate on an abrasion scale.
Rock is continuously fed through a hopper into

crushing chamber, where its caught by high speed
rotating throw device and thrown outwards, striking
and rebounding from impact-resistant, stationary
surfaces mounted inside upper portion of tub.
Rock pieces shatter in crushing chamber, then fall
through discharge area. A significant percent of rock
is cubically fractured by high speed impacting inside
crushing chamber.
Abrasion and friability test data are needed when

considering impact crushing. A high abrasive content
causes more liner wear.
Characteristics of Rock
Friability
In any rock crushing operation physical

characteristics of raw material affect output product
achieved. The characteristics of rock of most interest
in the industry are hardness, abrasion, friability,
toughness, and specific gravity. Cedarapids testing
facility is equipped to test samples using several
tests to quantify or compare rocks on basis of these
characteristics. Tests follow American Standards
Testing Methods (ASTM) standard procedures.
Friability indicates how well rock shatters or crumbles

when impacted. Friability can be contrasted with
toughness of rock. The Burbank Paddle Test used on
a rock sample shows where sample lies on a
continuum from a high degree of toughness to high
degree of friability, as compared with other samples
of the same rock type.
Hardness
Some practical testing of hardness that can be done
in the field is based on Mohs Scale of Hardness. Talc
has a hardness value of one, diamond value of ten.
talc = 1
gypsum = 2
alcite = 3
fluorite = 4
apatite = 5
orthoclase = 6
quartz = 7
topaz = 8
corundum = 9
diamond = 10.
With this scale a rock that can be scratched with:

fingernail = about 2
copper coin = about 3
pocket knife = over 5
window glass = 5-1/2
steel file = 6-1/2
21052 (3/97)
For more extensive information about types and

characteristics of rock, consult a Cedarapids Dealer
and Cedarapids Pocket Reference Guide.
Application
VSI's suit a variety of applications. For a particular
application judge how VSI suits need by considering
overall operating costs and production capability of
VSIs specific configuration. Here are some
guidelines to help make the appropriate adjustments
to VSI to adapt to varying friability, hardness, and
abrasion conditions.
Good VSI applications include producing:
Page 10.1
Base materials
Asphalt rock with a high percentage of fines
Chips (also called topping rock or chippings)
Winter sanding material (applied when roads
are icy or snow-covered)
LJ1093200
A Terex Company
Section 10
Applications
VSIs are also good at:
Getting more minus 4.75 mm (#4) mesh product
Preparing a ballmill feed
Beneficiating to remove softer stone from
harder stone
With a VSI even these smaller particles are fractured.

Regardless of size,each rock particle passes through
the throw device to be thrown against impact surface
(anvil ring or rock shelf). Every particle of rock is
likely to be crushed during its path through crusher.
Use VSI to:
Increasing asphalt stability by adding fractured

faces to smaller gravel sizes
Cleaning up a particle shape problem by:
improving results of ASTM C-131 test
(sometimes known as Los Angeles Abrasion
or LA Rattler test)
improving the ability of particles to pass skid
resistance tests
improving concrete pumpability by reducing
chance of blockage in pump
improving screening efficiency with more
cubical particle shape
Balancing a circuit where a compression-type
crusher is struggling to crush material that is
already nearly sized to crushers setting. The
VSI can stabilize recirculating load, preventing
tendency to increase, and maintain screening
efficiency
Since more friable materials crush easier in VSI, you
may be able to slow speed of throw device (also
called impeller) and still get a satisfactory gradation.
This also can help wear rate.
Relieve near-size problems in a compression

crushing circuit that can cause bumping
Put fractured faces on smaller material that is
already near to your product size
Reduce material beyond the efficient closed
size settings of compression crushers
Because aggregates crush differently in a VSI than
in compression crushers, VSI may be useful in
material with high compressive strength. Rocks
with high compressive strength may also be brittle
(friable) and crush more efficiently in a VSI. Particles
that are flat or long and narrow usually break across
their shorter, thinner dimensions when impacted,
providing a more cubical product. Some materials
tend to break to a natural grain size when impacted,
giving reduction ratios very different from (and in
some cases improved beyond) compression methods.
Use this tool to:
If there is tough rock mixed with friable rock, use a

slower throw device speed and a rock shelf to help
remove some of the softer stone.
Every Particle Crushed
Many producers find VSIs helpful in solving
troublesome production problems occurring with
compression crushers because impacting is a
dramatically different method of crushing. With a
cone or roll crusher, particles that enter crushing
chamber at or near the desired product size or slightly
smaller than closed side setting can pass through
without being broken.
21052 (3/97)
Page 10.2
Get more fines when a compression circuit is

showing deficiencies
Improve the percentage of harder, more durable
materials by crushing softer undesirable
materials to fines and screening them out
Improve the typical particle shape for superior
asphalt stability, better concrete pumping, and
better skid resistance of aggregates
LJ1093200
A Terex Company
Section 10
Applications
Controling Variables to Meet User
Requirements
Changing Speed
VSI offers many variables that you can use to match
machine capabilities to changing needs. Changing
rotation speed is the most commonly used variable.
Use throw device (impeller) speeds 50-80% of
maximum for making coarse-graded products (such
as chips, with few fines) and for improving physical
properties of output product. Use slower speeds for
putting fractured faces on particles of gravel while
minimizing fines production. Use higher speeds
(80-100% of maximum) for greatest reduction when
producing dense graded products with lots of fines,
like base mix, asphalt mix, and when supplementing
sand production. See charts showing sheave and
engine/motor speed combinations to get desired
throw device speeds and maximum speeds for each
model. Remember: Higher speeds cause faster wear.
Notice: When running near maximum rpm,
Cedarapids suggests reducing the maximum size
of feed material by 13 mm (1/2").
Varying Throw Devices
VSI can be equipped with either a 3, 4, 5, or 6-shoe
table, or a rotor (Figure 10-1).
Field studies show that fewer shoes on a table give
a coarser output gradation when run at same speed.
More shoes gives a finer gradation. Using rotor may
be desirable to reduce wear cost in very abrasive
materials, because rotor uses a rock-on-rock strategy
for reducing wear costs.
The rotor usually gives a coarser gradation, so be
sure trade-off is justifiable. Use throw device most
efficient and effective for site.
Aggregate producers often use a table with more
shoes to extend life of each set of shoes. If a 4-shoe
table gives reduction of aggregate that is desired,
replacing it with a 5-shoe table and slowing speed
down can usually match crushing action and give
wear savings of a slower speed.
21052 (3/97)
If using a rotor in VSI, there is the option of using a

rock shelf for autogenous crushing (obtained by
crushing a rock with a rock) or an anvil ring assembly.
Depending on needs, rock shelf may be a costeffective option. Crushing against an anvil ring
assembly usually results in better reduction and a
finer gradation. If reduction offered by rotor and
rock shelf is acceptable, or if trying to shape material
with less reduction, this offers the added feature of
reduced wear cost.
Balancing a Circuit
VSIs are high production machines, well suited to
finishing, or final sizing applications. As compression
crusher closed side settings are pinched down,
throughputs diminish. VSI's, when properly powered,
retains their throughput rating even with smaller
product sizes. A three-stage circuit having extra
capacity at primary and secondary stages but which
is limited at tertiary stage by capacity may benefit
from high throughput capability of a VSI. Balancing
a circuit in this way gives producer better return on
money invested in entire crushing plant.
Varying Feed Size
Cedarapids establishes maximum sizes of feed
material for all VSI models. These are published as
maximum cubed size, the size square opening in
screen cloth that feed to crusher must fit through.
Feeds that are graded from maximum size down to
closed circuit size result in an output gradation that
are more evenly distributed along gradation curve
(Figure 10-2).
If wanting to produce a narrow band of sizes, for
example, 13 mm by 4.75 mm (1/2" x 4M), an optimum
feed size is slightly larger than product band, for
example 25 by 13 mm (1 x 1/2").
Slowing throw device and/or using a table with
fewer shoes, or a rotor, can concentrate more product
in a narrower coarse-product band, rather than
distributing product evenly throughout gradation.
Page 10.3
LJ1093200
A Terex Company
Section 10
Applications
Model
1800 3-4-5
Shoe Table
1800 6-Shoe
Table
1800
Rotor
2100 3-4-5
Shoe Table
2100 6-Shoe
Table
2100
Rotor
Feed Rate
Tonnes per hour
(Tons per hour)
136-181
(150-200)
136-181
(150-200)
136-181
(150-200)
227-318
(250-350)
227-318
(250-350)
181-227
(200-250)
Maximum
Feed Size
57 mm
(2-1/4")
57 mm
(2-1/4")
51 mm
(2")
76 mm
(3")
76 mm
(3")
63.5 mm
(2-1/2")
1535
1426
1920
1316
1206
1700
1400
1300
1750
1200
1100
1550
813 mm
(32")
889 mm
(35")
864 mm
(34")
940 mm
(37")
1041 mm
(41")
864 mm
(34")
Tip Speed at Maximum RPM

meters/minute (feet/minute)
3575
(11,729)
3631
(11,912)
4748
(15,577)
3543
(11,624)
3599
(11,807)
4205
(13,797)
Suggested
Nominal Power
224 kW
(300 hp)
224 kW
(300 hp)
298 kW
(400 hp)
298 kW
(400 hp)
298 kW
(400 hp)
373 kW
(500 hp)
Maximum
Pinion RPM
Maximum
Throw Device RPM
Diameter of
Throw Device
4, 5
Diesel Power Range
Electric Motor
Power Range
149-373 kW
(250-500 hp)
224-448 kW
(300-600 hp)
75, 112, 149 or 187 kW Twin

(100, 150, 200 or 250 hp Twin)
112, 149, 187 or 224 kW Twin

(150, 200, 250 or 300 hp Twin)
Notes
7) De-rated for altitude.
1) High-output version is available on some

models. Consult ElJay for information.
2) When operating near maximum RPM ElJay
suggests reducing the maximum feed size of
material by 13 mm (1/2").
Warning! Do not attempt to observe throw

device's operating rpm directly through
access doors. Any small particle of rock can
be ejected at any moment, causing serious
injury or death!
3) VSI-GD models only.

4) Warning! Do not allow cast iron sheave
rim speed to exceed 1981 meters/minute
(6500 fpm). Exceeding this rim speed requires
ductile iron sheave.
Point of exit
5) Same as VBD crusher sheave rpm.

6) Table and rotor outside dimensions refer to
actual throw diameter at point of exit where
rock is thrown from table or rotor.
Figure 10-1
Power, Rpm, Feed Rates & Sizes
21052 (3/97)
Page 10.4
LJ1093200
A Terex Company
Section 10
Applications
100%
1
3
Percent
passing
0%
Larger product size
Smaller product size

Critical Product Band
1. Feed size just larger than the critical product
band
2. Larger percent of crusher output in the
critical product band
3. Feed size up to maximum

4. Smaller percent of crusher output in the
critical product band
Figure 10-2
Output at Slow Throw Device Speed
Controlling Wear
Following adjustments can help control wear cost:
Annual cost for high chrome iron wear parts in a VSI

is higher than manganese cost in a cone crusher. But,
considering low initial investment cost of a VSI
coupled with high production rate, VSI can actually
improve overall plant cost per ton. This is of most
importance in situations where labor costs are high.
Depending on amount of rock being processed and
on hardness, silica content, moisture, and other
factors, wear parts need periodic replacement. Section
6 explains how often wear parts must be changed.
The strategy for controlling wear is to reduce chances
for abrasive action and increase chances of breaking
rock on impact.
21052 (3/97)
Page 10.5
Use appropriate throw device and impact

surface configuration for your application.
Use an efficient vibrating screen ahead of
crusher to scalp out excessively slabby material
and oversize rock, and to prevent as much
abrasive sand and fines as possible from
entering crushing chamber.
Reduce or eliminate water with feed. More
water usually means more wear. Water
increases wear to parts such as shoes, liners,
and anvils. Water causes fine particles to cling
to coarse particles, making coarse particles
more abrasive and increasing scouring effect
on surfaces contacted by moving rock.
LJ1093200
A Terex Company
Section 10
Applications
Feed crusher more than 50% of maximum feed
rate. Light tonnage rates (below 50%) can
aggravate wear on lower parts of table shoes.
A symptom of this condition is slotting in
shoes (Figure 10-3). If allowed to continue,
slotting increases operating costs by
prematurely wearing out shoes.
Shape and size of feed is a factor. Large, round

uncrushed rock is generally less abrasive than
rock with broken edges. Small, crushed rock is
generally more abrasive. Recirculating alreadysized rock or oversize rock which has been
partially fractured can increase wear.
Table or rotor speed is important. Higher rotor
or table rpms, create greater wear on cast liner
parts, shoes, anvils, or exit port protectors. A
moderate change in rpm can have little effect
on gradation, yet increase wear rate.
On table/shoes/anvils VSIs, number of shoes

affects wear life. Generally, more shoes on the
table means longer wear life of each shoe.
The rock shelf is used with CastRotor only.
Adjust rock shelf to height where rock strikes
the buildup in shelf as low as possible without
damaging shelf. Adjust not higher than 13-25
mm (1/2"-1") below exit port of rotor.
Too little buildup can undermine wear tips

and/or break them by allowing material to
stream past trailing plates. Field-cut trailing
plates to desired depth and then hardface as
detailed in Section 6.
1. Minimum 1/2"
2. Slot
Figure 10-3
Factors Affecting Gradation
Keep feed tube properly adjusted. Letting feed

tube wear too high can cause scuffing on
forward edge of top of shoes, poor gradation,
and possibly cause lid liner breakage.
Feed to center of feed tube. Feeding to side of
feed tube can cause uneven wear around anvil
ring. Anvil ring can be turned to compensate,
but feeding straight down to center of feed tube
allows throw device to distribute feed more
evenly to anvils.
Product gradation is varied primarily by throw device

speed. Gradation is also affected by adjusting feed
tube, varying feed size and varying feed rate.
Increasing rpm generally increases percentage of
fines. Decreasing rpm generally decreases percentage
of fines. See Changing Table RPM.
Keep anvils adjusted to proper height to avoid

slotting. Cedarapids/ElJay VSI's are designed
for vertical adjustment of anvils to maximize
anvil wear life.
21052 (3/97)
Page 10.6
When using table with anvils, using a table

with more shoes generally increases percentage
of fines. Tables with fewer shoes generally
have a smaller percentage of fines.
Decreasing input volume generally increases
percentage of fines.
LJ1093200
A Terex Company
Section 10
Applications
Properly adjusting feed tube can increase
percentage of fines. If feed tube is too high
above a table, rock goes over tops of shoes,
missing anvils and giving a lower percentage
of fines. If feed tube is too high above a rotor,
wear rate increases and results poorer gradation.
Changing Throw Device RPM

Warning! Lockout power source before
beginning adjustment.
Warning! Standard cast iron sheaves can
explode when run at excessive speeds. Sheave
rim speed must not exceed 1981 meters per
minute (6500 fpm). Ductile iron or steel
sheaves are required when speeds greater
that 6500 fpm are required.
Adjusting Trailing Angle Position

Trailing angles control pattern of material buildup in
CastRotor (Figures 6-12, 6-13, and 6-14). Buildup is
controlled by tilt of trailing angle, distance from
wear tip, depth and profile. Too much material
buildup wears both feed tube and feed eye quickly.
Too little buildup can undermine wear tips. Always
adjust trailing angles as a set. See Section 6 for
details of how to adjust trailing angle position.
Table Requires Anvil Ring
To crush rock efficiently, table/shoes option requires
anvil ring stationary impact surface. Use of rock
shelf with table/shoe throw device is not
recommended.
VSI-GD (Gear Driven)
Cedarapids developed gear driven (GD) model for
applications that demand:
For VSIs with diesel drive, adjust diesel engine

throttle. The upper limit is controlled by a governor,
preset at factory.
On VSIs with electric drive:
1) Change crusher sheave or crusher and motor
sheaves to change throw device rpm. The
following charts show sheave sizes required to
give designated speeds. Stock sheave sizes are
457.2 mm (18.0") diameter on crusher and 508
mm (20.0") diameter on electric motors. (The
metric equivalents are calculated for
convenience and may not represent available
metric sheaves, nor will a metric sheave fit
pinion/drive shaft on a VSI.)
2) Consult your Cedarapids/ElJay distributor
when using sheaves other than those listed.
Low overall height

Using horizontal electric motors
3) See Sheaves and Bushings, in Section 7 for

correct removal and installation procedures.
Using a diesel engine

When electrically powered, speed changes are easier
on gear driven (GD) models because sheaves are
more accessible. On diesel powered units, users can
change sheaves to allow even slower throw device
speeds while still keeping engine in proper rpm
operating range.
21052 (3/97)
Page 10.7
LJ1093200
A Terex Company
Section 10
Applications
1800 RPM (1775 Actual RPM) Electric Motors-Sheave Combinations
GD Throw
Device RPM
VBD Throw
Device RPM
1710 (18 Rrs*)
GD Pinion
RPM
GD Pinion or
VBD Sheave
Motor
Sehave
1876
12.5"
13.2"
1618
1775 (18 Rrs*)
1775
13.2"
13.2"
1525 (18 Ra, 21 R*)
1672
1672
14.0"
13.2"
1422 (18 T5*)
1559 (18 Ra, 21 R*)
1559
15.0"
13.2"
1332
1460
1460
16.0"
13.2"
1252 (21 T5*)
1374 (18 T5*)
1374
17.0"
13.2"
1182 (21 T5*)
1296
1296
18.0"
13.2"
1119
1227 (18 T6*)
1227
19.0"
13.2"
1063 (21 T6*)
1165 (21 T5*)
1165
20.0"
12.5"
20.0"
13.2"
1103 (**)
1002
1099
1099
21.2"
13.2"
948
1039 (21 T6*)
1039
22.4"
13.2"
22.4"
12.5"
983
855
938
24.8"
13.2"
809
888
24.8"
12.5"
* Maximum RPM for different configurations: 18=1800 VSI. 21=2100 VSI. R=Rotor. rs=Rock Shelf.
a=Anvil Ring. T5=3, 4, or 5-shoe Table with Anvil Ring. T6=6-shoe Table with Anvil Ring
** Largest and smallest sheave combination for an 1800 VSI
1800 RPM Diesel-Sheave Combinations
GD Throw Device RPM
GD Pinion RPM
GD Pinion Sheave
Motor Sheave
1735 (18 Rrs)
1902
12.5"
13.2"
1641
1800
13.2"
13.2"
1546 (18 Ra, 21 R*)
1696
14.0"
13.2"
1442 (18 T5*)
1581
15.0"
13.2"
1350
1481
16.0"
13.2"
1270 (18 T6*)
1393
17.0"
13.2"
1199 (21 T5*)
1315
18.0"
13.2"
1135
1245
19.0"
13.2"
1078
1182
20.0"
13.2"
1016 (21 T6*)
1114
21.2"
13.2"
961
1054
22.4"
13.2"
867
951
24.8"
13.2"
820
900
24.8"
12.5"
21052 (3/97)
Page 10.8
LJ1093200
A Terex Company
Section 10
Applications
1200 RPM (1185 Actual RPM) Electric Motor-s-Sheave Combinations
GD Throw
Device RPM
VBD Throw
Device RPM
GD Pinion
RPM
GD Pinion or
VBD Sheave
Motor
Sehave
1739 (18 Rrs*)
1908
12.5"
20.0"
1646
1805
13.2"
20.0"
12.5"
18.0"
14.0"
20.0"
13.2"
18.0"
15.0"
20.0"
14.0"
18.0"
16.0"
20.0"
15.0"
18.0"
17.0"
20.0"
16.0"
18.0"
18.0"
20.0"
17.0"
18.0"
1715 (18 Rrs*)

1550 (18 Ra. 21 R*)
1700
1623
1445 (18 T5*)
1585
1528 (18 Ra, 21 R*)
1354
1485
1425 (18 T5*)
1274 (18 T6*)
1397
1335
1202 (21 T5*)
1318
1250 (18 T6*)
1138
1248
19.0"
20.0"
1080
1185
20.0"
20.0"
1185 (21 T5*)
18.0"
18.0"
1118
18.0"
17.0"
1019 (21 T6*)
1117
21.2"
20.0"
964
1057
22.4"
20.0"
1052 (21 T6*)
18.0"
16.0"
996
19.0"
16.0"
24.8"
20.0"
946
20.0"
16.0"
933
19.0"
15.0"
24.8"
19.0"
892
21.2"
16.0"
870
19.0"
14.0"
24.8"
18.0"
843
22.4"
16.0"
826
20.0"
14.0"
24.8"
17.0"
790
22.4"
15.0"
778
20.0"
13.2"
373
22.4"
14.0"
736
20.0"
12.5"
870
954
826
906
782
857
738
21052 (3/97)
809
Page 10.9
LJ1093200
A Terex Company
Section 10
Applications
1500 RPM (1480 Actual RPM) 50 hz Electric Motors-Sheave Combinations
GD Throw
Device RPM
VBD Throw
Device RPM
GD Pinion
RPM
GD Pinion or
VBD Sheave**
Motor
Sehave**
1733 (18 Rrs*)
1901
12.5"
16.0"
1640
1799
13.2"
16.0"
1545 (18 Ra, 21 R*)
1694 (18 Rrs*)
1694
14.0"
16.0"
1440 (18 T5*)
1580 (18 Ra*)
1580
15.0"
16.0"
1349
1480 (21 R*)
1480
16.0"
16.0"
1269 (18 T6*)
1392 (18 T5*)
1392
17.0"
16.0"
1198 (21 T5*)
1314
1314
18.0"
16.0"
1134
1244 (18 T6*)
1244
19.0"
16.0"
1077
1181 (21 T5*)
1181
20.0"
16.0"
1015 (21 T6*)
1114
1114
21.2"
16.0"
20.0"
15.0"
22.4"
16.0"
1032
20.0"
14.0"
987
22.4"
15.0"
972
20.0"
13.2"
24.8"
16.0"
920
22.4"
14.0"
919 (**)
20.0"
12.5"
24.8"
15.0"
22.4"
13.2"
24.8"
14.0"
22.4"
12.5"
24.8"
13.2"
1106
960
1053 (21 T6*)
867
1053
951
812
890
867
757
830
820
713
21052 (3/97)
782
Page 10.10
LJ1093200
A Terex Company
Section 10
Applications
1000 RPM (985 Actual RPM) 50 Hz Electric Motors-Sheave Combinations
GD Throw Device RPM
GD Pinion RPM
GD Pinion Sheave
Motor Sheave
1699 (18 Rrs*)
1864
13.2"
24.8"
1601
1756
14.0"
24.8"
1493 (18 Ra, 21 Rrs*)
1637
15.0"
24.8"
1398 (18 T5*)
1534
16.0"
24.8"
1315 (21 Ra*)
1442
17.0"
24.8"
1241 (18 T6*)
1361
18.0"
24.8"
1175 (21 T5*)
1289
19.0"
24.8"
1116
1224
20.0"
24.8"
1052 (21 T6*)
1154
21.2"
24.8"
995
1091
22.4"
24.8"
898
985
24.8"
24.8"
810
889
24.8"
22.4"
767
841
24.8"
21.2"
723
793
24.8"
20.0"
* Maximum RPM for different configurations: 18=1800 VSI. 21=2100 VSI. R=Rotor. rs=Rock Shelf.
a=Anvil Ring. T5=3, 4, or 5-shoe Table with Anvil Ring. T6=6-shoe Table with Anvil Ring
** Largest and smallest sheave combination for an 1800 VSI
21052 (3/97)
Page 10.11
LJ1093200
A Terex Company
Section 10
Applications
21052 (3/97)
Page 10.12
LJ1093200
A Terex Company
Section 11
Troubleshooting
Too Much Vibration
For gear-driven VSIs:
Warning! If VSI vibrates, shut down

immediately and determine cause. Too much
vibration can be dangerous,. Do not allow
persons near a VSI that has violent vibrations.
Broken gear teeth

Defective pinion shaft bearing
For VSIs with CastRotor:
Trailing angles not adjusted properly
Notice: If VSI vibrates, shut down immediately

and determine cause. Too much vibration can
cause serious damage to VSI, incurring downtime
and unnecessary expense.
Possible Causes of Excessive Vibration:
Bridging of material inside rotor where material

blocks an exit port
Oversize rock knocks out material buildup
For VSIs with diesel drive:
Feed cone or feed eye is off-center
Defective Power Take Off (PTO) bearing. To

check for diesel-associated vibration or noise,
run VSI up to operating speed, release clutch
and shut off diesel engine. As crusher coasts to
a stop, noise and vibration can be listened to
without noise from diesel drive
Oversize rock or branch is stuck on throw

device
VSI is not level
Improper installation of throw device (Bolts
into flywheel are too long; throw device is not
set down over lip in flywheel)
Broken, worn, or unbalanced wear parts (parts
not installed in balanced sets on throw device)
Loose bolts in vertical shaft assembly
Worn vertical housing (can be a cause or result
of too much vibration)
Dirt buildup on sheaves
Loose bushing in sheave
High Operating Temperature

Indication:
If oil temperature gauge reads above 110C (230F),
be alert to possible damage to VSI.
Notice: If oil temperature gauge reads 115C
(240F) or above, shut down immediately. Find
cause and fix before starting up for normal
operation.
Possible Causes of High Operating
Temperature:
Drive belt tension is too loose

Loose motor mount bolts
Defective bearing
Defective drive take-up
Defective seal at flywheel flinger and vertical

housing top cover plate (sometimes known as
a labyrinth seal)
Defective seal at flywheel flinger and vertical

housing top cover plate (sometimes known as
a labyrinth seal)
Defective seal (on gear drive models) at pinion
inner and outer flinger or cover (also sometimes
known as a labyrinth seal)
Defective seal (on gear drive models) at pinion

inner and outer flinger or cover (also sometimes
Bad drive motor bearing (likely with VBD)
Operating in very high ambient temperature

conditions (See hot weather start-up Sec. 4)
VSI not bolted firmly enough to stand or trailer
Using improper oil
Bad bearing
21052 (3/97)
Page 11.1
LJ1093200
A Terex Company
Section 11
Troubleshooting
Too Much Noise
Anvils Worn at Top:
Defective bearing
Feed tube adjusted too low
Defective seal at the flywheel flinger and

vertical housing top cover plate (sometimes
Defective seal (on gear drive models) at the
pinion inner and outer flinger or cover (also
sometimes known as a labyrinth seal)
Anvils Worn at Bottom:

Feed tube adjusted too high
Shoes Worn at Top:
Feed size too large
Broken wear part
Feed cone is worn
Broken gear tooth
Shoes Worn at Bottom:
Too much gear tooth backlash
High percentage of fines in feed
Bad motor bearing
Low rate of feed (low tonnage)
Worn vertical housing assembly
Feed cone is worn

Rapid Wear
Too Much Oil Consumption
Possible Causes of General Wear:
Leaking seal
Surges in feed rate
Broken oil line
Recirculation of already-sized material
CastRotor Wear Tips Failing Too Soon
High percentage of fines
Check tips for undermining of holder material

in front of carbide. If you find undermining,
adjust trailing plates according to instructions
in How To Change Trailing Angles, Section 6
Check carefully for cracks. A slightly cracked
tip can be run but should be checked carefully
at end of shift and every four hours of operation
Uneven Wear
Wet feed
Trickle feed or not choke fed
Wear to Shoe or shoe bracket:
Loose shoe
Wear to Feed Tube:
Uneven wear is typical for stationary parts, but if

rotating parts wear unevenly they cause vibration.
All VSI parts that come in contact with rock wear
much faster if material is too wet. Water causes
smaller rock particles to cling to surfaces and increase
abrasive wear. A broken cast part anywhere can
cause uneven wear
Crusher feed is off center

Wear to Feed Eye:
Wear to Lid Liners:
Possible Causes of Uneven Wear

Anvils:

Wear to Upper Tub and Ring behind Anvil:
Worn shoes
21052 (3/97)
Page 11.2
LJ1093200
A Terex Company
Section 11
Troubleshooting
Bearing Failure
Low Production Tonnage
Indications:
Possible Causes of Low Production:
Too much vibration could indicate bearing

failure or could lead to bearing failure
Feed rate not constant
Abnormally high amperage draw in electric

motor
Recirculation of already-sized material

Throw device rpm too high
Oil temperature higher than normal
Worn shoes and/or anvils
Noise: A change in the normal sound which

could be in pitch (higher or lower) or in volume
Abnormal oil sample readings, that include
brass or other metal particles
See Section 10
Plugging of Hopper
Possible Cause of Plugging:
Oversize rock or branch stuck on throw device
Possible Causes of Bearing Failure:

Contamination of lubrication system. Not
starting with clean oil. Getting dirt in oil when
disassembling or reassembling parts. Not
changing filter elements when needed. Not
using proper filter elements
Horn Sounds
Possible Causes of Horn Sounding:
Low oil level
Broken oil line
Oil level too low or oil too old
Defective oil pump
Rotor or table imbalance
Faulty horn wiring
Too much vibration
V-Belts
Faulty installation or removal procedures.

Jamming or cocking bearing or part of bearing
on shaft. Hammer blows during installation or
removal
Broken Drive Belts:
Rust and corrosion of bearing surfaces. See

Section 3 for VSI storage procedures
Too much tension
Wear Part Breakage

Possible Causes of Wear Parts Breaking:
Belts damaged during installation. Do not pry

belts over sheave. See Section 7 for installation.
Loose tension, causing shock load
Foreign object between belt and sheave
Belts Wearing Too Quickly:
Oversize feed
Worn sheave; belts riding too low in groove.
Tramp iron in circuit
Dirty or rusty sheave
Warped castings
Belts mismatched
Overtightened bolts
Seating surface of wear parts not cleaned when
last replaced
21052 (3/97)
Loose tension
Page 11.3
Too much abrasive dust
LJ1093200
A Terex Company
Section 11
Troubleshooting
Possible Cause of Split Belts:
Too much tension
Possible Causes of Belts Turning Over:
Worn sheave
Motor and crusher sheaves misaligned
Loose tension
Broken cord caused by prying onto sheave
Too much belt vibration caused by loose
mounting
Possible Cause of Belts Squealing:
Belts too loose
Causes of Belts Stretching Too Soon:
Worn sheave
Too tight
Causes of Belts Misaligned at Installation:
Not a matched set
Using a mix of old and new belts, or different
manufacturers
Motor and crusher shafts not parallel
21052 (3/97)
Page 11.4
LJ1093200
A Terex Company
Section 12
Other Information
Temperature Conversion Chart
To convert from Centigrade to Fahrenheit, locate C
in center column and read F value in column to left.
To convert from Fahrenheit to Centigrade, locate F
in center column and read C value in column to right.
For other temperatures:
C = 5/9 (F - 32); F = 9/5 C + 32
F
-40
-36.4
-32.8
-29.2
-25.6
-22.0
-18.4
C
F
-40
-38
-36
-34
-32
-30
-28
F
75.2
78.8
82.4
86.0
89.6
93.2
96.8
C
F
24
26
28
30
32
34
36
C
-40.0
-38.9
-37.8
-36.7
-35.6
-34.4
-33.3
-14.8
-11.2
-7.6
-4.0
-0.4
3.2
6.8
10.4
14.0
17.6
21.2
24.8
28.4
32.0
35.6
39.2
42.8
-26
-24
-22
-20
-18
-16
-14
-12
-10
-8
-6
-4
-2
0
2
4
6
46.4
50.0
53.6
57.2
60.8
64.4
68.0
71.6
F
190.4
194.0
197.6
201.2
204.8
208.4
212
C
F
88
90
92
94
96
98
100
C
-4.4
-3.3
-2.2
-1.1
0
1.1
2.2
-32.2
-31.1
-30.0
-28.9
-27.8
-26.7
-25.6
-24.4
-23.3
-22.2
-21.1
-20.0
-18.9
-17.8
-16.7
-15.6
-14.4
100.4
104.0
107.6
111.2
114.8
118.4
122.0
125.6
129.2
132.8
136.4
140.0
143.6
147.2
150.8
154.4
158.0
38
40
42
44
46
48
50
52
54
56
58
60
62
64
66
68
70
8
10
12
14
16
18
20
-13.3
-12.2
-11.1
-10.0
-8.9
-7.8
-6.7
161.6
165.2
168.8
172.4
176.0
179.6
183.2
22
-5.6
186.8
F
30.56
309.2
312.8
316.4
320.0
323.6
327.2
C
F
152
154
156
158
160
162
164
C
31.1
32.2
33.3
34.4
35.6
36.7
37.8
C
66.7
67.8
68.9
70.0
71.1
72.2
73.3
3.3
4.4
5.5
6.7
7.8
8.9
10.0
11.1
12.2
13.3
14.4
15.6
16.7
17.8
18.9
20.0
21.1
215.6
219.2
222.8
226.4
230.0
233.6
237.2
240.8
244.4
248.0
251.6
255.2
258.8
262.4
266.0
269.6
273.2
102
104
106
108
110
112
114
116
118
120
122
124
126
128
130
132
134
38.9
40.0
41.1
42.2
43.3
44.4
45.6
46.7
47.8
48.9
50.0
51.1
52.2
53.3
54.4
55.6
56.7
330.8
334.4
338.0
341.6
345.2
348.8
352.4
356.0
359.6
363.2
366.8
370.4
374.0
377.6
381.2
384.8
388.4
166
168
170
172
174
176
178
180
182
184
186
188
190
192
194
196
198
74.4
75.6
76.7
77.8
78.9
80.0
81.1
82.2
83.3
84.4
85.6
86.7
87.8
88.9
90.0
91.1
92.2
72
74
76
78
80
82
84
22.2
23.3
24.4
25.6
26.7
27.8
28.9
276.8
280.4
284.0
287.6
291.2
294.8
298.4
136
138
140
142
144
146
148
57.8
58.9
60.0
61.1
62.2
63.3
64.4
392.0
395.6
399.2
402.8
406.4
410.0
413.6
200
202
204
206
208
210
212
93.3
94.4
95.6
96.7
97.8
98.9
100
86
30.0
302.0
150
65.6
Figure 12-1
21052 (3/97)
Page 12.1
LJ1093200
A Terex Company
Section 12
Other Information
U.S. Standard Sieve Series for Wire Cloth- Selected Sizes
Size
(English)
Nominal
Sieve
Opening
Nominal
Wire
Diameter
Size
(SI)
Size
(English)
Nominal
Sieve
Opening
Nominal
Wire
Diameter
Size
(SI)
4"
4"
6.30 mm
100 mm
3/8"
0.375"
2.27 mm
9.5 mm
3-1/2"
3.5"
6.08 mm
90 mm
5/16"
0.312"
2.07 mm
8.0 mm
3"
3"
5.80 mm
75 mm
1/4"
0.250"
1.82 mm
6.3 mm
2-1/2"
2.5"
5.50 mm
63 mm
4M
0.187"
1.54 mm
4.75 mm
2"
2"
5.05 mm
50 mm
5/32" (5M)
0.157"
1.37 mm
4.0 mm
1-3/4"
1.75"
4.85 mm
45 mm
8M
0.0937"
1.00 mm
2.36 mm
1-1/2"
1.5"
4.59 mm
37.5 mm
10M
0.0787"
0.900 mm
2.00 mm
1-1/4"
1.25"
4.23 mm
31.5 mm
16M
0.0469"
0.650 mm
1.18 mm
1"
1"
3.80 mm
25.0 mm
30M
0.0234"
0.390 mm
0.60 mm
7/8"
0.875"
3.50 mm
22.4 mm
40M
0.0165"
0.290 mm
0.425 mm
3/4"
0.750"
3.30 mm
19.0 mm
50M
0.0117"
0.215 mm
0.30 mm
5/8"
0.625"
3.00 mm
16.0 mm
100M
0.0059"
0.110 mm
0.15 mm
1/2"
0.500"
2.67 mm
12.5 mm
200M
0.0029"
0.053 mm
0.075 mm
Figure 12-2
21052 (3/97)
Page 12.2
LJ1093200
A Terex Company
Section 12
Other Information
Standard Bolt and Nut Torque
Specifications
To prevent standard threaded bolts and nuts used on
Cedarapids equipment from being overstressed when
tightened, use torque chart on pages 12.4, and 12.5.
Follow these specifications unless other specific
torques are given in this manual. Cedarapids uses
grade 5 as standard. Grades 2 and 8 are used when
required and are identified in the manual.
The maximum torque values are based on 75% of
specified minimum proof strength of the bolt steel in
order to provide a safety factor. The term Lube in
the chart includes applying thread lubricants and
cadmium plating.
21052 (3/97)
Notice Regarding Wear Parts Fasteners: Except

Page 12.3
LJ1093200
21052 (3/97)
Page 12.4
20
28
18
24
16
24
14
20
13
20
12
18
11
18
10
16
9
14
8
14
7
12
7
12
6
12
6
12
5
4.5
4.5
4
4
4
(inches)
1/4
1/4
5/16
5/16
3/8
3/8
7/16
7/16
1/2
1/2
9/16
9/16
5/8
5/8
3/4
3/4
7/8
7/8
1
1
1-1/8
1-1/8
1-1/4
1-1/4
1-3/8
1-3/8
1-1/2
1-1/2
1-3/4
2
2-1/4
2-1/2
2-3/4
3
5590
7385
1370
2060
3015
4125
655
745
865
975
350
395
495
550
165
180
245
270
97
110
170
190
49
55
70
79
20
23
32
36
5
6
11
12
4300
5680
1055
1585
2320
3170
500
570
665
750
270
305
380
425
125
140
190
210
75
85
130
145
38
42
54
60
15
17
25
27
4
5
9
10
Lube
122010
147750
47020
61870
80430
99000
28580
32540
34770
39120
18880
21180
23980
26550
11430
12590
14990
16400
9320
10560
13770
15380
5850
6590
7500
8370
3190
3620
4380
4890
1310
1500
2160
2390
Clamp
Load (lbs)
9320
12310
2285
3435
5025
6875
1465
1670
1945
2190
790
890
1120
1240
425
470
640
700
150
170
265
295
75
85
109
121
31
35
49
55
8
10
17
19
Dry
7165
9470
1755
2640
3865
5285
1130
1285
1495
1685
610
685
860
950
330
360
495
540
115
130
200
225
58
65
84
93
24
27
38
42
6
7
13
15
Lube
203360
246260
78370
103120
134060
165000
64100
72980
77970
87740
42340
47500
53770
59550
29450
32440
38630
42260
14400
16320
21290
23770
9040
10190
11600
12940
4940
5590
6770
7560
2020
2320
3340
3690
Clamp
Load (lbs)
Torque (ft-lbs)
Dry
Torque (ft-lbs)
ASSUMPTIONS: (1) The maximum torque values are based on 75% of the specified proof strength.
(2) The term "lube" includes the application of thread lubricants, cadmium plating,
and the use of hardened washers; regardless of whether standard or lock nuts are used.
(threads/in.)
Diameter
S. A. E. Grade 5
S. A. E. Symbol
S. A. E. Grade 2
S. A. E. Symbol
17790
23500
4985
7500
10960
15000
2380
2710
3160
3555
1285
1440
1815
2010
605
665
905
990
210
240
375
415
106
120
150
170
44
49
70
78
12
14
25
27
Dry
13680
18080
3835
5765
8435
11530
1830
2085
2430
2735
990
1110
1395
1545
465
510
695
765
160
180
285
320
82
92
115
130
34
38
54
60
9
11
19
21
Lube
Torque (ft-lbs)
388230
470130
170990
225000
292500
360000
103950
118350
126450
142290
68670
77040
87210
96570
41580
45810
54540
59670
20340
23040
30060
33570
12770
14390
16380
18270
6970
7900
9560
10680
2860
3270
4710
5220
Clamp
Load (lbs)
S. A. E. Grade 8
S. A. E. Symbol
Recommended Maximum Torque Values (5%) Use "LUBE" column values
A Terex Company
Section 12
Other Information
Use the following torque chart to avoid overstressing standard nuts and bolts used on Cedarapids equipment. These specifications should
be followed unless specific torques are given in our equipment manual. Cedarapids uses Grades 2, 5, and 8. The maximum torque values are
based on 75% of the specified minimum proof strength of the bolt steel in order to provide a safety factor. The term "lube" includes the application
of thread lubricants, cadmium plating, and the use of hardened washers.
Steel type and hardness range are as follows: For SAE Grade 2 plain low carbon (1018 or 1020) steel, hardness is Rockwell "B" 85-100.
For SAE Grade 5 plain medium carbon (1035, 1038, & 1045), hardness is Rockwell "C" 19-30. For SAE Grade 8 medium carbon alloy (4140,
8642 & 5147), hardness is Rockwell "C" 32-38. All SAE bolt head symbols are listed on the Torque Chart next to the SAE grade.
LJ1093200
21052 (3/97)
Page 12.5
1.5
1.25
1.75
1.25
1.5
1.5
2.50
1.5
2.5
1.5
2.5
1.5
10
10
12
12
14
14
16
16
18
18
20
20
22
22
24
24
27
27
949
879
654
600
519
473
385
347
276
246
190
178
124
115
78
72
43
41
Dry
730
676
503
461
399
364
296
267
212
189
146
137
95
88
60
55
33
32
Lub.
53540
49616
41517
38070
35970
32767
29322
26438
23353
20787
18063
16920
13451
12467
9944
9101
6609
6263
Clamp
Load (lbs)
Property Class = 8.8
1387
1286
956
877
759
692
563
507
403
359
277
260
181
168
115
105
63
60
Dry
1067
989
736
674
584
532
433
390
310
276
213
200
139
129
88
81
49
46
Lub.
78302
72563
60719
55678
52606
47922
42884
38665
34154
30401
26417
24746
19672
18234
14543
13310
9666
9159
Clamp
Load (lbs)
ASSUMPTIONS: (1) The maximum torque values are based on 75% of the specified proof strength.
(2) The term "lube" includes the application of thread lubricants, cadmium plating,
and the use of hardened washers; regardless of whether standard or lock nuts are used.
Pitch (mm)
Diameter
(mm)
8.8
Property class is noted

on bolt head.
1627
1508
1122
1029
891
812
660
595
473
421
325
305
212
196
134
123
74
71
Dry
1252
1160
863
791
685
624
508
458
364
324
250
234
163
151
103
95
57
54
Lub.
91854
85122
71228
65315
61711
56216
50306
45357
40066
35663
30989
29029
23077
21389
17060
15614
11339
10745
Clamp Load
(lbs)
Recommended Maximum Torque Values (+/- 5%) Use "Lube" values
A Terex Company
Section 12
Other Information
Use the following torque chart to avoid overstressing metric nuts and bolts used on Cedarapids equipment. These specifications should
be followed unless specific torques are given in our equipment manual. Cedarapids uses Class 8.8, 10.9, and 12.9 metric bolts. The maximum
torque values are based on 75% of the specified minimum proof strength of the bolt steel in order to provide a safety factor. The term "lube"
includes the application of thread lubricants, cadmium plating, and the use of hardened washers.
LJ1093200
A Terex Company
Section 12
Other Information
Inches- Millimeters
Inches
1/16"
1/8"
3/16"
1/4"
5/16"
3/8"
7/16"
1/2"
9/16"
5/8"
11/16"
Millimeters
1.59
3.18
4.76
6.35
7.94
9.53
11.11
12.7
14.29
15.88
17.46
Inches
3/4"
13/16"
7/8"
15/16"
1"
1-1/4"
1-1/2"
1-3/4"
2"
3"
4"
Millimeters
19.05
20.64
22.23
23.81
25.4
31.75
38.1
44.45
50.8
76.2
101.6
Figure 12-4
Millimeter Equivalents of Common Sizes in Inches
Millimeters- Inches
Millimeters
10
11
Inches
0.03937
0.07874
0.11811
0.15748
0.19685
0.2362
0.2756
0.3150
0.3543
0.3937
0.4331
Millimeters
12
13
14
15
16
17
18
19
20
25
30
Inches
0.4724
0.5118
0.5512
0.5906
0.6299
0.6693
0.7087
0.7480
0.7874
0.9843
1.1811
Millimeters
35
40
45
50
60
70
80
90
100
200
300
Inches
1.3780
1.5748
1.7127
1.9685
2.3622
2.7559
3.1496
3.5433
3.937
7.874
11.811
Figure 12-5
Inch Equivalents of Common Sizes in Millimeters
Common Conversion Factors

English-Metric (SI)
Metric (SI)-English
1 inch = 25.4 millimeters (mm)
1 millimeter (mm) = 0.03937 inches (")
1 gallon = 3.785 liters (l)
1 liter (l) = 0.2644 U.S. gallons (gal)
1 pound (force) = 4.448 Newtons (N)
1 Newton (N) = 0.2248 pounds (lb)
1 pound (mass) = 0.4536 kilograms (kg)
1 kilogram (kg) = 2.2046 pounds (lb)
1 ton (2000 lbs.) = 0.9072 tonnes
1 tonne (1000 k) = 1.1023 tons
1 foot-pound (ft-lb) = 1.356 newtonmeters (Nm)
1 newtonmeter (Nm) = 0.7376 foot-pounds (ft-lb)
1 horsepower (hp) = 0.746 kilowatts (kW)
1 kilowatt (kW) = 1.341 horsepower (hp)
1 pound/inch2 (psi) = 6.895 kilopascals (kPa)
1 kilopascal (kPa) = 0.145 pound/inch2 (psi)
1 pound/inch2 (psi) = 0.06895 bars
1 bar = 14.504 pound/inch2 (psi)
(note: 1 bar = 100kPa)
21052 (3/97)
Page 12.6
LJ1093200

Vsi 1800-2100 O&m

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Operation & Maintenance Instructions

Operation & Maintenance Manual

To the Owner & Operator:

Operation & Maintenance Manual

Operation & Maintenance Manual

Operation & Maintenance Manual

Experience shows it is to your advantage to have a

safely operate your VSI

Cedarapids/ElJay is proud to manufacture the

get maximum life from your wear parts

Operation & Maintenance Manual

About This Manual ........................................... 1.1

1800 VSI-VBD ................................................. 3.9

2100 VSI-VBD ............................................... 3.13

Personal Safety Hints and Rules ....................... 2.1

VSI Daily Start-up Inspection Form ................. 4.3

Leveling on a Sturdy Foundation ..................... 3.1

Daily Start-up Detail- Continued ...................... 4.5

Access ............................................................... 3.1

Expected Flow Rates ........................................ 4.6

Transporting Your VSI ..................................... 3.1

Cold Weather Start-up ...................................... 4.7

Lock Down the Throw Device ......................... 3.2

Hot Weather Start-up ........................................ 4.7

VSI with Table/Shoes ....................................... 4.5

Reinstall the Locking Bolts Before Travel ....... 3.2

Operation & Maintenance Manual

Monitoring the Anvil Ring ............................... 7.5

Maintain Balance with Matching Sets .............. 6.2

Replacing Tub Liner ......................................... 7.8

When to Change the Top Retaining Plates ....... 6.9

How to Change Top Retaining Plates .............. 6.9

Lubricant Oil Specifications ............................. 8.1

How to Remove the CastRotor ....................... 6.10

Oil Properties at Operating Temperature.......... 8.1

Changing Rim Liners ..................................... 6.11

Acceptable Lubricants ...................................... 8.1

Changing Side Plates ...................................... 6.11

Switching to Other Grades ............................... 8.1

When to Change the Bottom Retaining Plate . 6.12

Oil Analysis: When to Change Oil ................... 8.1

How to Change the Bottom Retaining Plate... 6.12

Taking Oil Samples .......................................... 8.2

Installing Rotor Studs ..................................... 6.12

Checking Oil Level with the Dip Stick ............ 8.3

Oil Flow Patterns .............................................. 8.4

The Feed Tube .................................................. 7.1

Oil Flow Monitoring System ............................ 8.6

Removing and Reinstalling the Feed Tube....... 7.2

Flow Meter/Switch Settings ............................. 8.7

Adjusting the Feed Tube Height ....................... 7.2

Expected Oil Flow Rates .................................. 8.7

Adjusting Feed Tube with an Open Table ........ 7.3

Adjusting Feed Tube with a CastRotor ............ 7.4

Junction Box (J-Box) ........................................ 9.1

Removing the Lid Assembly ............................ 7.4

Oil Pump ........................................................... 9.1

Types of Impact Surfaces ................................. 7.5

Flow Switch and Warning Horn ....................... 9.1

Anvils ............................................................... 7.5

Vibration Switch ............................................... 9.2

Rock Shelf ........................................................ 7.5

Start Delay ........................................................ 9.2