Refresh your VSI operation

In an industry where reducing the cost

per ton of an operation is paramount,
the new Orange Series Rotor delivers
results for Vertical Shaft Impactor (VSI)
operators by adding operational
uptime, securing faster service
turnaround times and a longer wear life
of parts.

The twin goals of availability and serviceability

Availability and serviceability of the Barmac VSI are greatly improved
with Orange Series Rotors offering both longer wear life and easier
servicing. Parts have been designed to more easily interchange and
replace components to maximize wear life potential. This is achieved
by reconfiguring components when and where needed.

Orange Series Rotor can be applied without any modifications to the

VSI models accepting the following rotors:

RC690DTR (27”) RC840DTR (33”) RC990DTR (39”)

B6000 ■
B6100 ■
B6150SE ■
B6900 ■
LT7150 ■
B7150SE ■
B8000 ■
B8100 ■
B9000 ■ ■
B9100 ■ ■
B9100SE ■ ■
B9600 ■ ■
 INTRODUCTION

Competitive advantage offered

Wear part lifetimes drastically increased
Primary components in the Orange Series Rotor will, in most cases, result in longer service
intervals caused by an increase in wear life. As a result, you will benefit from increased
uptimes and lower costs per crushed ton, reducing your total cost.

Wear life increase

Tip 30 - 50%
Cavity wear plate 20 - 30%

Upper and lower wear plates 30 - 40%

Multiple rapid change wear parts

The main wear parts are quick and easy to change. The new and unique
design of the retaining bar structure further enhances the ease in wear
parts replacement. Consequently this makes your work safer while
reducing downtime and service costs.

Reduction in replacement time (indicative)

Tip 80% from 90 to 20 min.

Cavity wear plate 85% from 90 to 15 min.
Upper and lower wear plates 66% from 180 to 60 min.

Reduction in number of parts

Several components are now integrated reducing the number of fixing
points making the Orange Series Rotors easier to maintain. The total
number of wear parts and components are reduced by 25%-30%. For
example, the 840DTR contains 48 wear parts, while the RC840 consists of
only 34 wear parts. Thanks to the reduction in the number of components
the need for inventory is also reduced.

Simple to maintain
• Fewer components
• Hard facing repairs not required
 COMPONENTS

Orange Series Rotor components

Multiple wear part replacement

If multiple wear parts need to be replaced, you may consider removing Tips, back-up tips, cavity wear plates,
the rotor and replacing it with a new assembly to keep downtime and
service costs to a minimum. The removed rotor can be cleaned, upper/lower wear plates and trail
rebalanced and wear parts replaced while the new assembly is in
operation.
plates are all supplied as weight
matched sets. When these wear parts
Dressing the rotor
Wear parts for the rotor are supplied either in sets or as individual
are being fitted, it is impor- tant to
components. All sets are weight matched to ensure the rotor is not subjected correctly position them onto the
to an imbalance because of the addition of wear parts. The bare rotor is
supplied pre balanced. To ensure the rotor remains in a balanced condition, rotor to distribute the weight evenly.
the procedures (as highlighted right) should be followed.
The correct position is one at each
port.
Top and bottom wear plates Retaining bars
Long lasting top and bottom wear plates
Installation Our retaining bars are designed to provide
provide maximum protection for the rotor
faster and timely maintenance. Access tips and
body. The rotor is no longer hard faced - no 1. Ensure mating surfaces are clean and free cavity wear plates by simply lifting up and
more costly weld repairs are required. of snags. swinging out each of the six retaining bars.
Removal/installation 2. Lower top wear plate onto rotor
weldment. The innovative design provides access to wear
Access: Through the roof and spider.
parts without bolts, washers and nuts.
3. Replace all six retaining bolts (apply an
It is not recommended to remove and install anti-seize compound to the thread) and
the top wear plate with the rotor still in the tighten. Torque bolts to 372Nm (274ft lbs).
crusher due to the requirement of rebalancing
4. Balance rotor as described in the rotor
the rotor after installation.
balancing section of this handbook (page
15).
Removal
5. Reinstall the rotor to the crusher.
1. Remove the rotor from the crusher.
2. Remove the six retaining bolts from the
underside of the rotor weldment top
plate.
3. Shock the top wear plate loose with a
hammer and lift free with suitable
lifting equipment.
4. Thoroughly scrub top plate of the rotor
weldment.
 COMPONENTS

SIMPLE TIP SELECTION GUIDE - ORANGE SERIES ROTORS

Red Black Yellow Green Orange

The best first Larger tungsten For faster tip speeds For abrasive materials Maximized lifetime with very
selection for all carbide gives more life when more with larger tungsten abrasive material
applications compared to red reduction is required than yellow

Features Hard tungsten (red/black) Extra hard (yellow/green) Extra X hard (orange)
Largest feed size (0-50 mm) Medium feed size (0-40 mm) Smallest feed size (0-25 mm)
Lowest abrasion resistance Medium abrasion resistance Highest abrasion resistance
Highest impact resistance Medium impact resistance Lowest impact resistance

Application Shaping, general crushing Fine crushing, manufactured sand Industrial minerals, mining

Rotor tips
Our wear plate tips - made of high quality
Disassembly Assembly
tungsten carbide - have optimized profiles for
extended wear life. 1. Loosen all the tips and the retaining bar in 1. Ensure all mating surfaces on rotor tips,
a port. This is best achieved by shocking back up tips and retaining bars are free of
The retaining bar holds wear plate tips in place the tip hangers and the retaining bar with a any high spots (dirt, weld spatter, burrs)
without the use of nuts and bolts, making large hammer. In some cases it may require and retaining bar locations are cleaned
them simple to change. All tips are accessible breaking away any excessive internal stone out.
through the service door decreasing your build up still in contact with the tips.
service time by up to 80%. 2. Place the tips into the desired position,
2. Once the tips and retaining bar have been ensuring the requirements of even weight
loosened, the bar can be lifted vertically distribution for all new parts fitted are
Removal/installation until it disengages with the bottom wear followed.
plate. Pulling the bottom of the retaining
Access: Through service door. 3. Engage the retaining bar into the top
bar away from the tips will result in the
wear plate and while lifting, move the
bar disengaging from the top wear plate.
bottom of the bar in towards the tips
3. With the retaining bar removed, the until it engages with the bottom wear
tips are free to be replaced or plate. Lower retaining bar to engage the
repositioned as their wear condition bottom wear plate.
requires.
4. Tapping the tip assembly with a hammer
will assist in the seating of the retaining
bar.

Tips must be changed in sets and distributed

evenly around the rotor; otherwise an
imbalanced condition will occur.
Back-up tips Cavity wear plates
For maximum protection against rotor body
Thanks to a retaining bar fixing method that Assembly
wear, our back-up tips are made of tungsten
carbide. does not require nuts and bolts, replace- ment
1. Ensure all mating surfaces on cavity wear
takes less than half the time compared to the
plates and retaining bars are free of any
Back-up tips are secured in slots in the rotor top previous Barmac rotor design.
high spots (dirt, weld spatter, burrs) and
and bottom wear plates. Tips, retaining bar and retaining bar locations are cleaned out.
upper and lower wear plates must be removed The cross section is increased providing extended
when replacing these parts. wear life. Additionally, further wear life can be 2. Place the cavity wear plates into the
Service door access makes back-up tips easy to achieved by reversing the cross section. desired position, ensuring the
replace. requirements of even weight
Removal/installation distribution for all new parts fitted are
Access: Through service door. followed.
3. Engage the retaining bar into the top wear
Disassembly
plate and while lifting, move the bottom
1. Loosen all the cavity wear plates and the of the bar in towards the cavity wear
retaining bar. This is best achieved by plates until it engages with the bottom
shocking the castings and the retaining wear plate. Lower retaining bar to engage
bar with a large dead blow hammer. the bottom wear plate.
Care should be taken not to break 4. Tapping the cavity wear plate assembly
reusable castings. with a hammer will assist in the seating of
2. Once the cavity wear plates and retain- ing the retaining bar.
bar are loosened, the bar can be lifted
vertically until it disengages from the Cavity wear plates must be changed in sets and
bottom wear plate. Pulling the bot- tom distributed evenly around the rotor; otherwise
of the retaining bar away from the cavity an imbalanced condition will occur.
wear plates will result in the bar
disengaging from the top wear plate.
3. With the retaining bar removed, the
cavity wear plates are free to be replaced
or repositioned as their wear condition
requires.
 COMPONENTS

Cavity upper and lower wear plates

Our wear plates have bolted keepers and rotating
Removal Installation
cam-locks for ease of replacement, dramatically
reducing service time. Our rotating cam-locks 1. Gain access to the rotor through the 1. Ensure mating surfaces are clean and free
are also bolted in place for effortless change service door as described in the of dirt.
out. Introduction.
2. Insert new wear plate through the
Removal/installation 2. Open locking cams (replace as a set if discharge port and slide into place.
Access: Through service door. worn).
3. Ensure the new plates are wedged under
3. Removing rotor tips and retaining bar the keepers (highlighted on upper left
It is possible to remove and install the upper assists upper wear plate removal. corner of illustration above).
wear plates through the service door, however it
4. Using a copper or rubber mallet, tap the 4. Close locking cams.
may be necessary to remove the tip assembly
wear plate to break free any material
first to provide a larger working environment. 5. Check tips for wear.
build up.
5. Using a pry bar, lever the wear plate
free of the rotor.
6. Withdraw the plate through the
discharge port.
7. Thoroughly scrub out the remaining
build-up with a wire brush or water
hose.
Distributor plates Trail plates
Removal/installation
Installation Removal/installation
Access: Through the roof and spider.
1. To protect the distributor plate from Access: Through service door.
breakage, ensure the top plate surface is
Removal
clear of obstructions before fitting. Disassembly
1. Gain access to the rotor through the roof
2. Place distributor plate in center of rotor. 1. Remove trail plate retaining bolts. Bolts
as described in the Introduction.
Insert distributor plate bolt (apply an anti- will be covered with build-up and will
2. Remove stones and protective cloth seize compound to the thread) and have to be knocked out with a hammer and
from distributor bolt hole. tighten. Torque bolt to 200Nm (150ft punch.
3. Remove distributor plate bolt. lbs). 2. If the trail plate is held in by the build-
up, a sharp blow with a hammer and bar
4. Lift out distributor plate. The use of large impact wrenches should be will break away the buildup and allow
avoided when tightening bolts. the trail plate to fall free.
Warning: There are safety risks due to the
heavy load of distributor plates. A two person Insert a piece of cloth into the distributor plate
lift is recommended. bolt hole and tamp firmly around bolt head. Assembly
This will keep dirt from getting around the bolt 1. Clean out any remaining build-up.
head and will make later removal much easier.
2. Position trail plate and insert bolts (apply
an anti-seize compound to the threads).
3. Insert bolt from the inside of the rotor.
4. Tighten bolt with appropriate wrench,
Torque bolts to 77Nm (57 ft. lbs.).

Trail plates must be changed in sets; otherwise

an imbalanced condition will occur.
 COMMON PARTS WITH EXISTING ROTORS

Feed tube Tapered sleeves Rotor taper check

Removal/installation
Tapered sleeves (Taperlock) are used for MKI, MII, First, add marking blue liquid to the bore of the
Access: Through the roof and spider. MKIII and 8000 shafts. A new taper lock should rotor boss and lower onto the taper lock on the
be installed with every rotor change. shaft (use the rotor lifting plate).
Disassembly
Alternatively the fit between the taper lock and Ensure the taper is properly seated under the
1. Open the roof with a lifter if available. If rotor boss should be checked. weight of the rotor and then remove.
the crusher does not have a lifter, raise the
hopper and crusher roof together. This is a quick reference list that does not apply A blue mark should be visible on the taper lock
2. Remove spring handle and feed clamp to every case. Check the old taper lock for the indicating contact with the rotor boss. This mark
plate from spider assembly (build-up exact taper lock option. should cover at least 90% of the circumference
needs to be removed). and 90% of the length of the taper.
MK II to models:
3. Lift out feed tube. • B7150SE Any less contact requires replacement of the rotor
• B8000 boss.
Assembly
• B8100
1. Lower feed tube into feed tube location • B9600
plate.
2. Refit feed tube clamp plate. MK III to models:
• B7160SE
3. Lock feed tube clamp plate into • B8000
position with spring handle. • B9600
• B9000
Refer to VSI maintenance manual for method to • B9100
adjust the feed tube position. • B9100SE