Application guide

Barmac Orange
Series RC Rotor
crusher wear parts
 Maximize the
potential of your
Barmac crusher
2
Contents
Barmac Orange Series
RC Rotor
Refresh your VSI operation 4
Competitive advantages offered 5
Orange Series RC Rotor components 7
Top and bottom wear plates 8
Retaining bars 8
Rotor tips 9
Tip selection guide 9
Cavity wear plates 10
Back-up tips 11
Cavity upper and lower wear plates 11
Distributor plates 12
Trail plates - wide and narrow 12
Feed tube 13
Tapered sleeves for
MK & 8000 shafts 13
Rotor taper check 13
Rotor balancing 15

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Refresh your VSI operation
In an industry where reducing the cost per tonne of an operation is paramount,
the new Orange Series RC 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 RC690DTR (27”) RC840DTR (33”) RC990DTR (39”)
Availability and serviceability of the Barmac VSI are greatly improved B6000 ●

with Orange Series RC Rotors offering both longer wear life and easier B6100 ●

servicing. Parts have been designed to more easily interchange and B6150SE ●

replace components to maximize wear life potential. This is achieved by B6900 ●

reconfiguring components when and where needed. LT7150 ●

Orange Series RC Rotor can be applied without any modifications to B7150SE ●

the VSI models accepting the rotors in the table. B8000 ●

B8100 ●
B9000 ● ●
B9100 ● ●
B9100SE ● ●
B9600 ● ●

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 Orange Series RC Rotor - Components have been integrated Deep Rotor
when possible and the number of fixing points have been
reduced to make the Orange Series Rotors easier to maintain.

Competitive advantage offered

Wear part lifetime drastically increased Reduction in number of parts
Primary components in the Orange Series RC Rotor will, in most cases, Several components are now integrated reducing the number of fixing
result in longer service intervals caused by an increase in wear life. As points making the Orange Series RC Rotors easier to maintain. The
a result, you will benefit from increased uptime and lower costs per total number of wear parts and components are reduced by 25-30%.
crushed tonne, reducing your total cost. For example, the 840DTR contains 48 wear parts, while the RC840
consists of only 34 wear parts. Thanks to the reduction in the number
Wear life increase of components the need for inventory is also reduced.

Tip 30-50% Simple to maintain

Cavity wear plate 20-30%

• Fewer components
• Hard facing repairs not required
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

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6
 Orange Series RC Rotor components
Multiple wear part replacement Dressing the rotor
If multiple wear parts need to be replaced, you may consider Wear parts for the rotor are supplied either in sets or as
removing the rotor and replacing it with a new assembly to keep individual components. All sets are weight matched to ensure
downtime and service costs to a minimum. The removed rotor the rotor is not subjected to an imbalance because of the
can be cleaned, rebalanced and wear parts replaced while the addition of wear parts. The bare rotor is supplied pre balanced.
new assembly is in operation. To ensure the rotor remains in a balanced condition, the
procedures (as highlighted right) should be followed.

Tips, back-up tips, cavity wear plates, upper/lower wear plates and trail plates
are all supplied as weight matched sets. When these wear parts are being
fitted, it is important to correctly position them onto the rotor to distribute the
weight evenly. The correct position is one at each port.

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Top and bottom wear plates
Long lasting top and bottom wear plates provide maximum
protection for the rotor body. The rotor is no longer hard faced -
no more costly weld repairs are required.

Removal/installation
Access: Through the roof and spider.

It is not recommended to remove and install the top wear plate with
the rotor still in the crusher due to the requirement of rebalancing the
rotor after installation.

Removal
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.

Installation
5. Ensure mating surfaces are clean and free of snags.
6. Lower top wear plate onto rotor weldment.
7. Replace all six retaining bolts (apply an anti-seize compound to the
thread) and tighten. Torque bolts to 372Nm (274ft lbs).
8. Balance rotor as described in the rotor balancing section of this
handbook (page 15).
9. Reinstall the rotor to the crusher.

Retaining bars
Metso Outotec’s retaining bars are designed to provide faster and
timely maintenance. Access tips and cavity wear plates by simply lifting
up and swinging out each of the six retaining bars.

The innovative design provides access to wear parts without bolts,

washers and nuts.

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Rotor tips
Our wear plate tips, made of high quality tungsten carbide,
have optimized profiles for extended wear life.

The retaining bar holds wear plate tips in place without the use of Assembly
nuts and bolts, making them simple to change. All tips are accessible 4. Ensure all mating surfaces on rotor tips, back up tips and retaining
through the service door decreasing your service time by up to 80% bars are free of any high spots (dirt, weld spatter, burrs) and
retaining bar locations are cleaned out.
Removal/installation 5. Place the tips into the desired position, ensuring the requirements
Access: Through service door. of even weight distribution for all new parts fitted are followed.
6. Engage the retaining bar into the top wear plate and while lifting,
Disassembly move the bottom of the bar in towards the tips until it engages
1. Loosen all the tips and the retaining bar in a port. This is best with the bottom wear plate. Lower retaining bar to engage the
achieved by shocking the tip hangers and the retaining bar with bottom wear plate.
a large hammer. In some cases it may require breaking away any 7. Tapping the tip assembly with a hammer will assist in the seating
excessive internal stone build up still in contact with the tips. of the retaining bar.
2. Once the tips and retaining bar have been loosened, the bar can Tips must be changed in sets and distributed evenly around the
be lifted vertically until it disengages with the bottom wear plate. rotor; otherwise an imbalanced condition will occur.
Pulling the bottom of the retaining bar away from the tips will
result in the bar disengaging from the top wear plate.
3. With the retaining bar removed, the tips are free to be replaced or
repositioned as their wear condition requires.

Simple tip selection guide

Red Black Yellow Green Orange

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

Features Hard tungsten (red/black) Extra hard (yellow/green) XX 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

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

Back-up tips
For maximum protection against rotor body wear, our back-up tips are
made of tungsten carbide.

Back-up tips are secured in slots in the rotor top and bottom wear
plates. Tips, retaining bar and upper and lower wear plates must be
removed when replacing these parts. Service door access makes back-
up tips easy to replace.

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Cavity upper and lower wear plates
Our wear plates have bolted keepers and rotating cam-locks for ease of
replacement, dramatically reducing service time. Our rotating cam-locks are also
bolted in place for effortless change out.
Removal/installation Installation
Access: Through service door. 1. Ensure mating surfaces are clean and free of dirt.
It is possible to remove and install the upper wear plates through 2. Insert new wear plate through the discharge port and slide into
the service door, however it may be necessary to remove the tip place.
assembly first to provide a larger working environment. 3. Ensure the new plates are wedged under the keepers (highlighted
on upper left corner of illustration above).
Removal 4. Close locking cams.
1. Gain access to the rotor through the service door as described in 5. Check tips for wear.
the Introduction.
2. Open locking cams (replace as a set if worn).
3. Removing rotor tips and retaining bar assists upper wear plate
removal.
4. Using a copper or rubber mallet, tap the wear plate to break free
any material 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.

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Distributor plates
Removal/installation
Access: Through the roof and spider.
Removal
1. Gain access to the rotor through the roof as described in the
Introduction.
2. Remove stones and protective cloth from distributor bolt hole.
3. Remove distributor plate bolt.
4. Lift out distributor plate.
5. Warning: There are safety risks due to the heavy load of distributor
plates. A two person lift is recommended.

Installation
6. To protect the distributor plate from breakage, ensure the top plate
surface is clear of obstructions before fitting.
7. Place distributor plate in center of rotor. Insert distributor plate bolt
(apply an anti-seize compound to the thread) and tighten. Torque
bolt to 200Nm (150ft lbs).
8. The use of large impact wrenches should be avoided when
tightening bolts.
Insert a piece of cloth into the distributor plate bolt hole and tamp
firmly around bolt head. This will keep dirt from getting around the
bolt head and will make later removal much easier.

Trail plates
Removal/installation
Access: Through service door.
Disassembly
1. Remove trail plate retaining bolts. Bolts will be covered with build-up
and will have to be knocked out with a hammer and punch.
2. If the trail plate is held in by the build-up, a sharp blow with a
hammer and bar will break away the buildup and allow the trail plate
to fall free.
Assembly
3. Clean out any remaining build-up.
4. Position trail plate and insert bolts (apply an anti-seize compound to
the threads).
5. Insert bolt from the inside of the rotor.
6. 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.

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 Feed tube
Removal/installation
Access: Through the roof and spider.
Disassembly
1. Open the roof with a lifter if available. If the crusher does not
have a lifter, raise the hopper and crusher roof together.
2. Remove spring handle and feed clamp plate from spider
assembly (build-up needs to be removed).
3. Lift out feed tube.
Assembly
4. Lower feed tube into feed tube location plate.
5. Refit feed tube clamp plate.
6. Lock feed tube clamp plate into position with spring handle.
Refer to VSI maintenance manual for method to adjust the feed
tube position.

Tapered sleeves
Tapered sleeves (taperlock) are used for MKI, MII, MKIII and 8000 MK II to models:
shafts. A new taper lock should be installed with every rotor change. • B7150SE
Alternatively the fit between the taper lock and rotor boss should be • B8000
checked. • B8100
• B9600
This is a quick reference list that does not apply to every case. Check
the old taper lock for the exact taper lock option. MK III to models:
• B7160SE
• B8000
• B9600
• B9000
• B9100
• B9100SE

Rotor taper check

First, add marking blue liquid to the bore of the rotor boss and lower A blue mark should be visible on the taper lock indicating contact
onto the taper lock on the shaft (use the rotor lifting plate). Ensure with the rotor boss. This mark should cover at least 90% of the
the taper is properly seated under the weight of the rotor and then circumference and 90% of the length of the taper.
remove. Any less contact requires replacement of the rotor boss.

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14
Rotor balancing
Bearing
Adpater sleeve (840/990 only)

Balance shaft

Bearing

Bearing rest

Side plate

Joining plates

Threaded rod

Nut

First assemble the rotor balancing machine. Ensure the bearings are The balance of the rotor changes when wear parts are fitted.
not damaged or dirty. Clean off any dirt or old oil, and if they sound Genuine Barmac VSI wear parts are weight matched to maintain
or feel too worn, we recommend the bearings be changed. balance within acceptable limits. Exact guidelines for balancing can
After they are clean, add a little oil. Use a spirit level to be sure the be found in the Orange Series RC Rotor manual.
rotor balance machine is level. Make sure there is no loose material
or wear parts in the rotor that could move as it is turned.

Stage 1
Balance the rotor weldment.

Stage 2
Balance the rotor with top and bottom wear plates.

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Metso Outotec is a frontrunner in sustainable technologies, end-to-end
solutions and services for the aggregates, minerals processing and metals
refining industries globally. By improving our customers’ energy and water
efficiency, increasing their productivity, and reducing environmental risks with
our product and process expertise, we are the partner for positive change.

Copyright © 2021 Metso Outotec. Brochure code: 3124-12-21-EN-CNS. All rights reserved. Pinta/Libris, Helsinki, Finland.

Metso Outotec, Töölönlahdenkatu 2, FI-00100, Helsinki, Finland.

tel. +358 20 484 100, fax +358 20 484 101
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