Chancadora Trio

Weir Minerals Latin America Vulco Perú S.A.

Installation, Operation and Maintenance Manual

JAW CRUSHER MODEL CT3042 SAN RAFAEL PROJECT

MINSUR S.A. PO: 4600017596 OF: 103774 Rev.0

Av. Separadora Industrial 2201 Ate – Lima, Perú T: +51 (1) 6187575 E: [email protected] UNIDAD SAN RAFAEL W: www.weirminerals.com ☒ Aprobado – A

Revisado por:

Luis Pérez Abad

☐ Aprobado con Comentarios – AWC ☐ Revisado y Comentado - RWC ☐ Reca!ado - RS

Feca:

23-feb-2016

Operation & Maintenance Manual

To the Owner & Operator

We have tried 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 thi s information provides users of our 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. 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 their distributor or the manufacturer. 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.

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 personnel 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 operational 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 personal protective equipment such as hard hats, ear plugs, safety glasses and safety shoes 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.

CRSH-OM-0003ENG(OCT-2014)

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ModelCT-SeriesJawCrushers


The following warning applies to 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.

The following warning applies to equipment supplied with diesel powered engines:

WARNING Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

Product Registration:

All equipment must be registered within 14 days of start-up to receive warranty coverage. Registration information will only be accepted fromthe end-users of the equipment, however dealers can register the equipment for the end-user provided the information registered is the end-user’s information. In addition to this registration, all cone crushers, vertical shaft impact crushers, and all screens using urethane media must have an application data sheet on file and approved by Trio. After completion of the registration and application data sheet, if required, all submitted information will be reviewed and a confirmation email sent to the email address provided to Trio. Warranty will be fully enforced upon confirmation of payment and receipt of the above information. Register online at: http://www.trioproducts.com/register/form or call Trio at +1 626 851 3966.


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Warranty Terms & Conditions Seller warrants all new equipment manufactured or imported by Trio Engineered Products, Inc. (Trio) against defects in material or workmanship attributed to the srcinal machine manufacturing. No other warranties are expressed or implied. Warranty claims must be made through the dealer or agent responsible for the srcinal equipment sale, as the equipment will have been registered with them at the time of sale from Trio. Claims must be made within twelve (12) months or 2,000 working hours, whichever occurs first, from the date of readiness for operation, but not more than fifteen (15) months from the date of shipment from Trio. All parts claimed to be defective shall be returned to Trio, freight prepaid, for inspection to determine that the said part or parts are defective. If it is determined that the fault lies with Trio, Trio will ship a replacement part or parts at no cost, but freight charges will be paid by customer. If it is determined that the fault does not lie with Trio, a replacement part or parts will be shipped, freight collect, to the customer with the receipt of a purchase order from the dealer or agent. Trio will not be responsible for freight costs associated with warranty claims. When petitioning for a warranty item, the serial number of the equipment must be referenced. The serial number must be clearly identifiable on the Trio nameplate on the equipment. This warranty is void if: The serial number plate and/or other markings identifying the machine as Trio have been altered or removed. The machine was not sold under the Trio brand name or another brand name approved by Trio. Parts have been used other than those supplied by Trio. Trio makes no warranty with respect to damages or defects in any product caused by improper installation, operation, maintenance, and storage or caused by negligence or accident. In addition, any product repaired or altered in any way as reasonably determined by Trio, that affects the performance or purpose for which the equipment was srcinally manufactured, will not be covered under this warranty. Under this warranty, the buyer will not be entitled to any labor charges involving the repair of the equipment involving warranty items, unless authorized by Trio in writing. Warranties of merchantability or of fitness for any particular purpose or arising from the course of dealing or usage of trade are specifically excluded. Any affirmation of fact, description of goods, or sample or model referred to in this agreement or elsewhere, whether or not the same relate to production or capability of the goods to perform, are not the basis of this agreement, unless specifically made a party of the agreement in writing. Under no circumstances will Trio be responsible for consequential or punitive damages of any nature, whether based on contract or tort, including but not limited to lost profits, loss of production, delays or other expenses. Under no circumstances shall the liability of Trio exceed the purchase price of the equipment furnished. The laws of the state of California shall govern the warranty. The parties agree that exclusive jurisdiction for any claim for breach of this warranty shall rest in the Los Angeles County Superior Court in the State of California.


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Operation & Maintenance Manual Table of Contents

Copyright © 2014 Trio Engineered Products, Inc. All rights reserved. . . . Cover Back Page To the Owner & Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a Warranty Terms & Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . c

Section 1 - Introduction About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 1 Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 1 Safety Alert Symbol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 1

Section 2 - Safety Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 1 Symbols and Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 1 Hazard Classification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 1 Safety Signs and Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 2 Safety Sign Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 2 Personal Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 3 Management Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 3 Operator Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 3 Work Area Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 4 Equipment & Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 4 Training and Knowledge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 4 What is Lockout & Tagout? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 5 When is Lockout & Tagout required? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 5 Who must apply a lock & tag? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 5 When can a lock and tag be removed? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 5 Who can remove a lock and tag? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 5

Section 3 - General Information Jaw Crusher Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 1 Serial Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 1 Flywheel Rotation Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 1 Jaw Crusher Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 2 Jaw Crusher Capacities Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 3 Jaw Crusher Gradation Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 4 Jaw Crusher Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 5 Jaw Crusher Weight & Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 5


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Section 4 - Set-Up & Installation Crusher Receiving and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 1 Level the Crusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 1 Lifting the Crusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 1 Positioning the Crusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 2 Crusher Auxiliary Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 2 Hydraulic Line Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 2

Section 5 - Inspection, Lubrication & Maintenance Checks General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 1 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 1 Inspection Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 1 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 2 General Lubrication Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 2 Lubricant Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 2 Lubrication Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 3 Bearing Daily Lubrication Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 4 Jaw Crusher Seal Lubrication Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 5 Jaw Crusher Bearing Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 6 Jaw Crusher Seal Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 6 Changing Grease in Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 7 Maintenance Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 9 Exterior Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 9

Interior Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 9 Jaw Crusher Daily Inspection Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 11 Pre-Start-up Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 11 Start-up Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 12 Jaw Crusher Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 13

Section 6 - Start-Up & Operation Start-Up & Operation Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 1 Crusher Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 2 Oversize Feed Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 2 Unblocking Jammed Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 2

Section 7 - Adjustments & Wear Parts Replacement Adjustments & Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 1 Jaw Crusher Crushing Chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 1 Closed Side Setting (CSS) Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 1 Shim-Type CSS Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 2 Shim-Type CSS Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 2


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Hydraulic Wedge-Type CSS Adjustment (Manual Hyd. Pump) . . . . . . . . . . . . . . . . . . . . . .7 - 3 Hydraulic Wedge-Type CSS Adjustment (Manual Hyd.Pump) Procedure . . . . . . . . . . . . .7 - 3 Power Hydraulic Pump Unit for CSS Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 4 Power Hydraulic Pump Unit With Electrical Control Box . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 5 Power Hydraulic Pump Unit Hydraulic Schematic Type 1 Connections . . . . . . . . . . . . . . . .7 - 6 Power Hydraulic Pump Unit Hydraulic Schematic Type 2 Connections . . . . . . . . . . . . . . . .7 - 8 Hyd. Wedge-Type CSS Adjustment (Power Hyd. PumpType 1 Connections) . . . . . . . . . .7 - 10 Hyd. Wedge-Type CSS Adjustment (Power Hyd. Pump Type1 Connections) Procedure . .7 - 11 Hyd. Wedge-Type CSS Adjustment (Power Hyd. PumpType 2 Connections) . . . . . . . . . .7 - 12 Hyd. Wedge-Type CSS Adjustment (Power Hyd. Pump Type2 Connections) Procedure . .7 - 13 Direct . . . . . . . . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .7 14 Direct Hydraulic Hydraulic Toggle Toggle Plate-Type Plate-Type CSS CSS Adjustment Adjustment .Procedure .7 -- 14 Standard Toggle Seat Tension Rod Spring Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 17 Fully Hydraulic Toggle Plate-Type CSS Adjustment System . . . . . . . . . . . . . . . . . . . . . . .7 - 19 Hydraulic Pump Control Unit Hose Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 20 Hydraulic Control Unit Standby Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 21 CSS Decrease Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 21 CSS Increase Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 21 Tension Rod Spring Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 22 Toggle Cylinders Oil Supplement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 22 Tension Cylinders Oil Supplement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 22 Tramp Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 22 Toggle and Tension Cylinder Fast Reset After Tramp Release . . . . . . . . . . . . . . . . . . . . . . .7 - 23 Hydraulic Unit Valve Pressure Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 23 Toggle Cylinder Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 24 Fully Hydraulic Toggle Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 24 Fully Hydraulic Toggle Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 25 Jaw Die Lifting Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 26 Cheek Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 28 Upper Cheek Plate Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 28 Lower Cheek Plate Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 29 Installation of Lower Cheek Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 29 Installation of Upper Cheek Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 30 Tightening Cheek Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 31 Stationary Jaw Die . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 31 Stationary Jaw Die Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 32 Stationary Jaw Die Rotation or Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 33 Stationary Jaw Die Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 33 Swing Jaw Die . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 34 Swing Jaw Die Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 34 Swing Jaw Die Rotation or Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 36 Swing Jaw Die Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 36 Check & Tighten Jaw Dies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 36 Re-adjust Crusher Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 36


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Toggle Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 37 Toggle Plate Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 37 Toggle Plate Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 39 Jaw Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 40 Frame Bearing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 40 Frame Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 42 Pitman Bearing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 44 Pitman Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 46

Appendix A - Torque Specs Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A - 1 Standard Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A - 1 Metric Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A - 1 Standard Bolt Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A - 2 Metric Bolt Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A - 3

Appendix B - V-Belt Drive Information General Belt Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B - 1 General Belt Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B - 1 Belt Drive Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B - 2 Maintaining V-Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B - 4 Tension-Deflection Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B - 4 Belt Type Cross-Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B - 6 Belt Idlers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B - 6

Inside Idler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B - 6 Backside Idler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B - 6 Kiss Idler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B - 6


iv


Operation & Maintenance Manual About This Manual

Section 1 - Introduction

DANGER

About This Manual This book is an operation and maintenance manual for the owner or operator of the equipment described within. We strongly recommend that anyone working with this equipment become familiar with the manual, whether or not you have experience with similar equipment. This manual will help you understand how to install your equipment, prepare it for operation, and perform normal operation and maintenance tasks. Intended Use

The Jaw Crusher described within is designed to crush rock, recycle concrete, and also a wide range of other products and materials. Use of this machinery in any other way is prohibited and contrary to its intended use.

Figure 1 - 2 Safety Alert Hazard Level Symbol

This manual contains information necessary for proper and safe operation. Carefully read this manual before attempting to operate. Failure to read and heed instructions preceded by a safetyalert symbol (Figure 1 - 2) can cause death or severe personal injury as well as equipment and environmental damage. Experience has shown it is to your advantage to keep a copy of this manual where operators can consult it as needed and to have a copy on file in your office, so that shift leaders or supervisors can conveniently refer to it. Additional copies can be ordered through your distributor. This equipment is precisely engineered, highly

Safety Alert Symbol The safety alert symbol (Figure 1 - 1) is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

functional, and heavy-duty designed to provide years of excellent service performing to customer specifications. We are proud to manufacture this equipment for your use and profit. We also take pride in the quality of our service and replacement parts. Only your Parts Catalog, identified with your machine’s serial number, is an authoritative source of part numbers and part descriptions for your equipment.

Figure 1 - 1 Safety Alert Symbol


Ongoing improvement of product design may in the future result in changes to some parts. Use part numbers, model numbers and serial numbers from your Parts Catalog to communicate with your distributor.

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Operation & Maintenance Manual About This Manual



1-2


Operation & Maintenance Manual Introduction

Section 2 - Safety

Hazard Classification

Introduction The Jaw Crusher is designed to crush rock, recycle concrete, and also a wide range of other products and materials. Use of this machinery in any other way is prohibited and contrary to its intended use. When our equipment is used for purposes other than those for which it was designed, user assumes sole responsibility for any injuries or damage that may result from said misuse. We emphatically recommend that this equipment be operated only by personnel who are trained in its use. We make no guarantee, either expressly or by implication, that this equipment meets all local or federal safety regulations. It is the responsibility of those individuals who own and/or operate this equipment to verify that all safety regulations are complied with before starting either this unit or any associated equipment.

A multi-tier hazard classification system is used to communicate potential personal injury hazards. The following signal words used with the safety alert symbol indicate a specific level of severity of the potential hazard (Figure 2 - 1). Signal words used without the safety alert symbol relate to property damage and protection only. All are used as attention-getting devices throughout this manual as well as on decals and labels fixed to the machinery to assist in potential hazard recognition and prevention.

DANGER

DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

WARNING

WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION

CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

Symbols and Standards Important symbols and hazard classification standards relating to safe equipment operation are used throughout this manual. Make sure you read, understand and follow all DANGER, WARNING and CAUTION decals on equipment.

CAUTION

CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage. NOTICE indicates information or a company policy that relates directly or indirectly to the safety or protection of proper ty.

Figure 2 - 1 Hazard Classification


2-1


Operation & Maintenance Manual Symbols and Standards

Safety Signs and Icons

Beneath all safety regulations lies a set of common-sense rules. Everyone who works with or near heavy equipment must be aware of those rules. To foster and maintain such an awareness in our customers, safety signs are fixed on our equipment. Icons on our safety signs remind both workers and supervisors of common hazards and procedures that, in the course of a busy day, they might otherwise forget. The language of the icons is simple and direct (Figure 2 - 2).

Read manual.

Safety alert symbol.

Lock out power before servicing machine. Wear hearing protection when you’re near this equipment.

Safety Sign Maintenance

Replace any missing or damaged safety signs. Keep operator safety in mind at all times. Use mild soap and water to clean safety signs. Do not use solvent-based cleaners because they may damage the safety sign material.

Wear eye protection when you’re near this equipment.

Wear respiratory protection when you’re near this equipment.

Wear head protection when you’re near this equipment.

Entanglement hazard. Death or serious injury can result by getting caught in belting.

Ensure all guards are in place.

Figure 2 - 2 Safety Pictograms Explained


2-2


Operation & Maintenance Manual Personal Safety

Personal Safety This equipment is designed with the safety of all personnel in mind. Never attempt to change, modify, eliminate or bypass any of the safety devices installed at the factory. Guards, covers and shields installed around moving parts at the factory are meant to prevent accidental injury to operators and other personnel.Do not remove them.

•

Replace guards, covers and shields when the task for which you removed them is finished.

•

Block parts as necessary to prevent their sudden movement while people are working on the machine.

•

Never attempt to clear away jammed feed material, discharge material or other stoppage while the machine is running. Stop the equipment, lock out and tag out before touching this machine with your tools or your hands.

•

Wear proper personal protective equipment, including eye protection, hard hat and safety shoes, whenever you’re near this machine while it is running.

•

Dress appropriately in every way. Never wear loose clothes, long hair, coat tails, jewelry, pockets full of tools or any other item that could get caught in moving parts.

•

Know where your fellow workers are. Always look around and inside this machine before starting it. Make sure nobody is in the way of

DANGER Sometimes, at a customer’s request, equipment is shipped without certain features such as a drive sheave. In such cases it is the customer’s responsibility to guard the machine properly. We recommend the following basic safety practices: Management Responsibilities

•

•

Make sure that everyone working on or near this equipment is familiar with safety precautions. Have a supervisor at the job site responsible for job safety.

•

Give crew members specific safety responsibilities and instruct them to report any unsafe conditions to their supervisor

•

Never engage in horseplay when near this machine, or any other.

•

Report any defective machinery or equipment and unsafe conditions or activity to your boss immediately.

•

Don’t limit safety practices to the few rules listed here. Think safety and act safely at all times.

•

Most of all, know your equipment. Understand the machinery, the conditions under which it operates and what it is capable of doing.

Operator Responsibilities

•

Read all danger, warning, caution and notice signs.

•

Always lock out and tag out involved energy sources before performing maintenance or adjustments on this equipment. Make it impossible anyone to instart while othersfor work on it or it. this machine

•

Never remove any guard, cover or shield when this equipment is in motion.


2-3

moving parts or working on the machine. Lift with your legs, not with your back. Keep the weight close to your body. If the load is more than 40 lbs., get someone to help you.


Operation & Maintenance Manual Personal Safety

Work Area Safety

Equipment & Tools

•

Keep the work area as neat and clean as practical.

•

Clean tools that are properly labeled and stored are safer tools. Keep your tools in good order.

•

Keep all product safety signs clean, clear and current.

•

•

Make sure all electrical equipment is properly grounded. Wet spots near electrical current are especially dangerous.

Keep drive belts and sheaves in good condition. Frayed belts or cracked sheaves are not only dangerous, they cost you downtime.

•

Always use mechanical assistance to lift heavy loads. Never overload a hoist, crane, jack or

•

Store hazardous materials in restricted access areas and mark them clearly. Federal regulations require special labeling of certain materials.

•

Never start an engine in an enclosed space without properly venting the exhaust.

•

Do not smoke or allow smoking near fuels and solvents. Never strike a spark or use an open flame near fuels and solvents.

•

•

•

Store flammable fuels, solvents and gases in secure, well ventilated areas. Never allow fumes to accumulate in the storage area. Use nonflammable solvents for cleaning parts and equipment whenever possible. Know where fire extinguishers and other firesuppression equipment are located. Learn how to use them effectively. Be alert and wary around any pressurized system, hydraulic or pneumatic. High-pressure oils and gases are very dangerous.


2-4

other lifting device. Check lifting tackle regularly; replace it at the first sign of stretch, fraying or other wear. •

Keep your equipment clean, free of dirt and grease, so that loose, cracked or broken parts are more easily spotted. Replace defective parts as soon as they are discovered.

Training and Knowledge

Proper training and equipment knowledge is essential to the safe operation of this machine. Carefully read the entire manual before attempting to operate. Keep this manual for future reference.

WARNING Do not operate this equipment until you have been trained in its operation or maintenance. This equipment may only be operated or maintained by trained personnel, who have demonstrated their ability to do so safely.


Operation & Maintenance Manual What is Lockout & Tagout?

What is Lockout & Tagout?

When can a lock and tag be removed?

Lockout & Tagout is a procedure that’s designed to prevent the unexpected or accidental startup of equipment and to alert all workers whenever it is unsafe to operate any piece of equipment. When used as intended, Lockout & Tagout also protects personnel from energy stored in devices such as springs, accumulators, batteries, hydraulic systems, etc.

After performing these six steps:

•

When the equipment is broken or, for whatever reason, unfit or unsafe to operate.

•

While clearing mechanisms.

•

Whenever the equipment is left unattended.

or

3) All workers are notified that a lock is being removed. 4) All workers are positioned safely for startup.

6) The machine is ready for safe operation.

Any time anyone is maintaining, repairing, lubricating, or, for whatever reason, working on the equipment.

blocked

2) All work is complete and tools are put away.

5) Controls are positioned for safe startup.

When is Lockout & Tagout required?

•

1) All safety guards are back in place.

Who can remove a lock and tag?

•

Only the person who applied a lock and tag is permitted to remove them.

Lockout & Tagout rules laid out here are generic. To get instructions for your particular workplace, consult your employer’s lockout/tagout procedure.

jammed

Who must apply a lock & tag?

•

Any person working on the equipment.

•

Foreman or other person responsible for the work being done.

•

If several people are working on a machine at the same time, each person must apply his or her own lock and tag.


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Operation & Maintenance Manual What is Lockout & Tagout?



2-6


Operation & Maintenance Manual Jaw Crusher Description

Section 3 - General Information

Serial Numbers

Jaw Crusher Description

Crushers are assigned a serial number which is stamped on a plate on the machine.

The Jaw Crusher is a high-capacity compressiontype crusher that fractures material along its natural fault lines.

Other components on the crusher may have separate serial numbers or identifying numbers.

Product size is controlled by adjusting the distance between the fixed jaw die and the moveable

Always give the model and serial number or identifying number of your crusher when ordering parts or requesting information. If parts are

(swing) jaw die fastened to the pitman assembly. These jaw dies are replaceable and come in several different profiles depending upon the type of material to be crushed and customer preference.

required for the other certain components, you should supply that serial number or identifying number as well as the crusher numbers.

The pitman is protected from damage by the toggle plate. The toggle plate is intended to bend or fracture if an uncrushable object enters the crushing chamber, and thus opens the chamber allowing the object to pass through.

Flywheel Rotation Direction Crushers are fitted with two flywheels, one of which acts as the driven sheave. The direction of rotation and orientation to the crusher is shown in (Figure 3 - 2).

The Jaw Crusher may be mounted or installed in static stationary, modular skid, as well as portable wheel or mobile track plant applications. No matter which type application the Jaw Crusher is used in, it must be level to operate properly.

Figure 3 - 2 Flywheel Rotation Direction

Figure 3 - 1 Typical Jaw Crusher


3-1


Operation & Maintenance Manual Jaw Crusher Components

Jaw Crusher Components Be familiar with the crusher’s components. See (Figure 3 - 3)

Each model/size jaw crusher consists of similar components, however certain models/sizes may not have all the same components as other models/ sizes. To be certain your machine has the proper components, check to ensure it was equipped as ordered.

8

4 3

21

2

6

7 9

5

1

10 11

1 2 3 4 5

20

12

19

13

18

17

16

15

-

6 -7 8 9 1011121314151617181920-

Crusher Frame Stationary Jaw Die Cheek Plate (Key Plate) Flywheel Swing Jaw Die Pitman Bearing Liner Frame Pitman Pitman Bearing Eccentric Shaft Spring Guards Adjustment Hydraulic Ram Tension Rod Spring Tension Rod Shims Upper Buffer Toggle Plate Lower Buffer Rubber Dust Apron Wedges for Stationary Jaw

21- Wedges for Swing Jaw

14

Figure 3 - 3 Typical Jaw Crusher Components


3-2


Operation & Maintenance Manual Jaw Crusher Capacities Chart

Jaw Crusher Capacities Chart . CT SERIES JAW CRUSHERS OPEN CIRCUIT MAXIMUM CAPABILITIES (STPH) Jaw Model

C T1030

C.S.S. Size Opening 1" 23 25 mm 1-1/2" 28

C T1040

30 37

35 44

C T1048

C T 1252

C T2036

C T2436

C T2645

C T3042

N C T3042

C T3254

C T3648

C T4254

C T4763

50 63

38mm 2" 34 45 55 77 90 96 250 50mm 2-1/2" 42 56 68 90 110 1 50 126 300 64mm 3" 5 0 66 80 105 140 170 155 200 220 340 76mm 3-1/2" 6 0 79 95 130 170 190 189 230 240 370 90mm 4" 190 210 218 260 280 400 330 100mm 5" 230 250 300 300 320 440 310-400 380-500 127mm 6" 250-300 391 300-400 320-420 400-500 370-470 450-580 500-650 150mm 7" 320-400 522 350-460 380-500 470-570 430-540 520-650 590-750 675-980 175mm 8" 490-610 575-730 650-840 780-1100 200mm 9" 550-700 630-810 740-930 860-1215 225mm 10" 700-900 800-1010 950-1340 250mm 11" 880-1100 1030-1455 280mm 12" 950-1180 1120-1575 305mm

1.

The above information is based on average feed material that weighs approximately 100 lbs/ft readily fed in to the crushing chamber without clogging.

2.

Capacities shown may vary depending on the type, size, moisture content, and clay content of material, the bulk density, method of material feeding. Undersize material should be removed from the crusher feed to eliminate packing and excess wear.

³

crushed of a size which is

SETTINGS GREATER THAN INDICATED M AY BE WITHIN DESIGN CAPABILITIES OF THE M ACHINES BUT ARE NOT SHOWN DUE TO ANTICIP ATED HIGH ER OPERATING COSTS.

The above tables are based on results obtained during actual oper ation a nd could vary depending o n the type of m aterial, gradation of feed, method of feeding, moi sture and cl ay content, and other material ch aracteristics. The indicated to p size, also influenced by the above c onditions, is rovided to assist in the selection of the c rushin e ui ment to follow. Contact our dealer for more details.


3-3


C T 6080

Operation & Maintenance Manual Jaw Crusher Gradation Chart

Jaw Crusher Gradation Chart . CT SERIES JAW CRUSHERS PRODUCT GRADATIONS (PERCENT PASSING) C.S.S. Size Opening Product Size

1" 25 mm

1-1/2" 38mm

2" 50mm

2-1/2" 64mm

3" 76mm

3-1/2" 90mm

4" 100mm

5" 127mm

6" 150mm

7" 175mm

15" 380mm 14" 356mm 13" 330mm 12" 305mm 11" 280mm 10" 250mm 9" 225mm 8" 200mm 7" 175mm 6" 150mm 5" 127mm 4" 100mm 3-1/2" 90mm 3" 76mm 2-1/2" 64mm 2" 50mm 1-3/4" 45mm 1-1/2" 38mm 1-1/4" 32mm 1" 25mm 3/4" 19mm 5/8" 13mm 3/8" 10mm 1/4" 6mm

8" 200mm

9" 225mm

10" 250mm

11" 280mm

12" 305mm 100

100

90

100

90

100 100

100 100

100

95

9 0

83

75

70

65

75

70

65

60

90

83

75

75

70

75

70

83

83

68

68

75

75

90

90

75

85

85

90

100

83

85

90

90

100 100

100

85

70

63

60

65

63 58

58

45

45

45

40

40

90

83

75

65

60

55

95

83

75

70

60

55

50

45

40

35

25

22

45

35

30

25

22

20

75

70

65

55

50

90

75

68

60

55

50

42

75

65

58

55

50

40

35

30

25

22

20

17

12

85

70

60

55

50

45

35

30

25

22

20

17

12

10

75

65

55

70

55

50

50

45

40

75

65

45

43

35

30

70

55

40

30

25

22

60

45

35

45

30

25

30 2

0 1

5 1

25

20

20 0

17

15 7

30

30 25

4

3

10 5

1

7 3

0

5 2

0

0

0

6

6

5

3 1

4

4

2

1

1

0

0

0

8

8

8

7

17

10

10

10

10

20

12

15

12

12

22

17

17

15

15

13

20

20

17

17

7

22

22

20

20

10

25

25

15

13 5

40

35

25

25

90

95

30

35

100

100

35

40

35

100

83

45

55

55

55

48

48

60

60

1 0

0

THE ABOVE TABLES ARE BASED ON RES ULTS OB TAINED DURING ACTUAL OPERATION A ND CO ULD VARY DEPENDING OF MATERIAL , GRADATION OF FEED , M ETHOD OF FEED ING , MOISTURE AND CLAY CONTENT , AND OTHER MATERIAL

ON THE TYPE

CHARACTERISTICS . THE INDICATED TOP S IZE , ALSO INFLUENCED BY THE ABOV E CO NDITIO NS , IS PROVIDED TO A SSIST IN THE SELECTION OF THE CR USHING EQUIPM ENT TO FOLLOW . C ONTACT YOUR DEALER FOR MORE DETA ILS .

Jaw crushers reduce large rock to smaller stone using exceptional force. The foundation therefore must be substantial enough to support the crusher without distortion.


3-4


Operation & Maintenance Manual Jaw Crusher Specifications

Jaw Crusher Specifications

Jaw Crusher Weight & Dimensions

Specifications for the jaw crusher are found in the serial specific parts manual.

Weights and dimensions for the jaw crusher are found in the serial specific parts manual.


3-5


Operation & Maintenance Manual Jaw Crusher Weight & Dimensions



3-6


Operation & Maintenance Manual Crusher Receiving and Inspection

Section 4 - Set-Up & Installation

Level the Crusher

Crusher Receiving and Inspection When the crusher is delivered, thoroughly check for damage that might have occurred during transport. Do not set up the unit until the inspection is complete.

Wherever the crusher is installed, it must be mounted level. For stationary units,the supporting structure must belevel when completed. For skidmounted, mobile, or portable plant units, the frame must be leveled. Use leveling jacks or suitable blocking as needed to bring the unit to a level position.

Note any damage on the shipper’s bill of lading and have the deliverer sign your description of any problem(s). Keep a copy of the marked-up bill of lading for your files. Take photos if possible. File a claim with the carrier within 30 days of receipt of the equipment. Check loose parts, small parts boxes, and tools against the packing list to ensure all items shipped are present.

Installation To operate correctly, the crusher must be installed on a firm, level foundation. Make sure the foundation and supporting structures are strong enough to support the dynamic load of the operating crusher and related equipment with material moving through it.

Lifting the Crusher To lift the crusher, use machinery, lifting slings, and equipment of sufficient size to safely handle the load. When hooking lifting slings to the crusher, always attachto the crusher frame. Never lift complete crusher by attaching to flywheels or pitman. If only pitman, shaft, and bearing assembly is to be removed from crusher frame, fasten lifting slings and equipment to lifting lugs provided on top of pitman housing. See (Figure 4 - 1)

Lifting Lugs

Lifting Lugs

Figure 4 - 1 Typical Jaw Crusher Lifting Lugs


4-1


Operation & Maintenance Manual Installation

Positioning the Crusher

Hydraulic Line Connections

Allow enough room around the crusher for conveyors, loaders, and maintenance equipment and personnel. Allow enough clearance below crusher for discharge material conveyor and also clearance above and behind the unit for access. Crusher Auxiliary Equipment

The crusher utilizes a system to provide hydraulic power to adjust the jaw die opening. Make sure this system’s hydraulic lines are properly connected and tightened as well as the electrical drive motor (if used) is properly connected and runs in the correct direction.


4-2

While making line connections between the hydraulic power unit and the crusher, air may become trapped in the lines. It is necessary to purge the trapped air. This can usually be closing accomplished by opening and the jaw several times before initial operation.


Operation & Maintenance Manual General

Section 5 - Inspection, Lubrication & Maintenance Checks

Inspection Procedures

The following are major steps in a daily inspection of your crusher:

General To insure efficient operation, the crusher should be inspected, lubricated, and have necessary maintenance adjustments and repairs made at regular intervals.

2) Look the complete crusher over carefully. When sure that everything is in good order and safe, the crusher should be ready to operate.

Inspection Performing a daily inspection is a good way to keep your crusher performing safely and efficiently. Utilizing the Daily Inspection Form at the end of this section as a guide will help you establish a maintenance routine, provide a maintenance record, and help monitor the condition of the equipment.


1) Lockout & Tagout all power to crusher before any lubrication or maintenance is performed.

5-1

3) Remove the lock and tag. 4) Clear the area and prepare to start the crusher.


Operation & Maintenance Manual Lubrication

Lubrication General Lubrication Information

The greatest single factor governing the life and efficiency of any piece of machinery, where friction is encountered, is proper lubrication. While it is generally known that insufficient lubrication will enable friction to reduce the efficiency and service life of key parts, it is also

fittings and openings are cleaned thoroughly before starting to inject lubricant.In using a grease gun make sure the nozzle makes proper contact with the cleaned fittings or openings and that the nozzle has not been allowed to touch uncleaned surfaces. Never mix different brands or types of lubricant within the crusher. Always drain and flush out old lubricant before changing to a different brand as

true that the presence of too large a quantity of grease in a bearing housing usually results in high operating temperatures and subsequent loss of efficiency.

chemical breakdown can occur in lubricant mixtures.

Cleanliness in the handling of lubricants, fittings, grease guns, and the openings and plugs of housings is of vital importance. Foreign substances contaminate lubricant. Be sure all

Refer to (Table 5 - 1) as a guide for the proper lubricants used on the crusher. If you do not have access to the brands shown, see your lubricant distributor for an equivalent.

Lubricant Specifications

Table 5 - 1 Jaw Crusher Lubricant Specifications Lubricant Type

Ambient Temperature °F (°C)

Specification

Below 100 (Below 38)

NLGI 2, with EP Additives

Above 100 (Above 38)

NLGI 2, with EP Additives

Below 40 (Below 4)

ISO 32, HVI AW Low Pour Point

Mobil DTE 13M

Mobil SHC 524

Above 40 (Above 4)

ISO 68, Antiwear

Mobil DTE 26

Mobil SHC 526

Recommended Standard Lubricant

Recommended Synthetic Lubricant

Mobil Delvac Xtreme

Mobilith SHC 220

Grease

Hydraulic Oil (Used in Adjusting or Controls Hydraulic Systems)


5-2

-

Mobilith SHC 460



Lubrication Intervals

The bearings and seals should use the specified lubricant shown in (Table 5 - 1). See (Table 5 - 2) for recommended lube intervals. Table 5 - 2 Jaw Crusher Lubrication Intervals ITEM

DAILY or Every 8 Hours

WEEKLY or Every 40 Hours

MONTHLY or Every 160 Hours

YEARLY or Every 2000 Hours

Shaft Labyrinth Seals

--

--

Add Grease to Each Seal

Check

Pitman Bearings

Add Grease to Each Bearing


--

Change Grease

Frame Bearings



--

Change Grease

Hydraulic Oil

Check

Check

--

Change as Required


5-3



Bearing Daily Lubrication Quantity

The following table shows the approximate amount of grease to be added daily to each bearing for the particular model jaw crusher.

Note that it takes approximately 20 strokes from a manual type grease gun to discharge 1 ounce of grease.

Table 5 - 3 Jaw Crusher Bearing Daily Lubrication Quantity PitmanBearing MODEL

Volume

FrameBearing Weight

Volume

Weight

L

Qu a r t

gram

O unce

L

Qu a r t

gram

Ounce

CT1030

0.014

0.015

12.5

0.44

0.014

0.015

12.5

0.44

CT1040

0.014

0.015

12.5

0.44

0.014

0.015

12.5

0.44

CT1048

0.017

0.018

14.2

0.50

0.017

0.018

14.2

0.50

CT1252

0.031

0.033

26.6

0.94

0.031

0.033

26.6

0.94

CT2036

0.024

0.025

19.8

0.70

0.020

0.021

17.3

0.61

CT2436

0.029

0.031

25.2

0.89

0.024

0.025

20.4

0.72

CT2645

0.036

0.038

31.7

1.12

0.029

0.031

25.6

0.88

CT3042

0.054

0.057

45.9

1.62

0.052

0.055

43.9

1.55

NCT3042

0.045

0.048

36.9

1.30

0.043

0.045

34.0

1.20

CT3254

0.052

0.055

43.9

1.55

0.044

0.047

38.0

1.34

CT3648

0.054

0.057

45.9

1.62

0.052

0.055

43.9

1.55

CT4254

0.063

0.067

53.9

1.90

0.057

0.060

47.6

1.68

CT4763

0.086

0.091

73.7

2.60

0.085

0.090

70.9

2.50

CT6080

0.158

0.167

139.2

4.88

0.141

0.149

123.7

4.4


5-4



Jaw Crusher Seal Lubrication Quantity

The following table shows the approximate amount of grease to be added to each seal for the particular model jaw crusher.

Note that it takes approximately 20 strokes from a manual type grease gun to discharge 1 ounce of grease.

Table 5 - 4 Jaw Crusher Seal Lubrication Quantity MiddleLabyrinthSeal MODEL

Volume

OuterLabyrinthSeal

Weight

Volume

Weight

L

Qu a r t

gram

O unce

L

Qu a r t

gram

Ounce

CT1030

0.016

0.017

14.2

0.5

0.016

0.017

14.2

0.5

CT1040

0.016

0.017

14.2

0.5

0.016

0.017

14.2

0.5

CT1048

0.018

0.019

17.0

0.6

0.018

0.019

17.0

0.6

CT1252

0.032

0.034

25.5

0.9

0.032

0.034

25.5

0.9

CT2036

0.035

0.037

28.3

1.0

0.035

0.037

28.3

1.0

CT2436

0.039

0.041

31.2

1.1

0.039

0.041

31.2

1.1

CT2645

0.039

0.041

31.2

1.1

0.039

0.041

31.2

1.1

CT3042

0.045

0.048

36.9

1.3

0.045

0.048

36.9

1.3

NCT3042

0.043

0.045

34.0

1.2

0.043

0.045

34.0

1.2

CT3254

0.052

0.055

42.5

1.5

0.052

0.055

42.5

1.5

CT3648

0.056

0.059

45.4

1.6

0.056

0.059

45.4

1.6

CT4254

0.060

0.063

51.0

1.8

0.060

0.063

51.0

1.8

CT4763

0.067

0.071

56.7

2.0

0.067

0.071

56.7

2.0

CT6080

0.074

0.078

62.4

2.2

0.074

0.078

62.4

2.2


5-5



Jaw Crusher Bearing Lubrication Points

Jaw Crusher Seal Lubrication Points

Do not over-grease bearings. Too much grease in bearings will cause overheating and premature bearing failure.

Grease should be added to seals until a fresh bead of grease appears around the seals to provide a moisture and dust barrier.

See (Figure 5 - 1) illustration showing the bearing lubrication points on a jaw crusher.

See (Figure 5 - 2) illustration showing the seal lubrication points on a jaw crusher.

Hoses to Grease the Bearings

Grease Fittings

Figure 5 - 1 Typical Jaw Crusher Bearing Lubrication Points

Grease Fittings Figure 5 - 2 Typical Jaw Crusher Seal Lubrication Points


5-6


Operation & Maintenance Manual Changing Grease in Bearings

Changing Grease in Bearings

4) Replace the grease fittings.

Under normal conditions, it is recommended that grease be changed at least once each year or every 2000 hours of operation, which ever comes first. See (Figure 5 - 3)

5) Run the crusher empty for at least 10 minutes. 6) Stop unit and remove drain plugs to drain flushing oil. 7) Replace drain plugs when bearings have been sufficiently flushed. 8) Install the recommended amount of grease into each bearing. See (Table 5 - 5)

Frame bearings do not have drains on the bearing housings. Purging may require care to avoid a mess.

Drain Plugs Figure 5 - 3 Typical Jaw Crusher Pitman Bearing Grease Drain Points

1) Before changing lubricant, run crusher long enough to heat the existing lubricant to a consistency that allows it to flow freely. 2) Clean area around drain plugs and grease fittings then remove plugs and fittings to drain free flowing lubricant. 3) Replace drain plugs and inject flushing oil in each bearing to fill pitman barrel and frame bearing housing to top of fitting holes. An extreme pressure 150 viscosity, Grade 46 flushing oil can be used.


5-7


Operation & Maintenance Manual Changing Grease in Bearings

Table 5 - 5 Jaw Crusher Bearing Lubrication Replacement Quantity PitmanBearing MODEL

Volume

FrameBearing Weight

Volume

Weight

L

Gal.

Kg

Lbs.

L

Ga l .

Kg

Lbs.

CT1030

1.06

0.28

0.93

2.06

0.94

0.25

0.83

1.83

CT1040

1.06

0.28

0.93

2.06

0.94

0.25

0.83

1.83

CT1048

1.32

0.35

1.16

2.55

1.06

0.28

0.93

2.06

CT1252

3.19

0.84

2.81

6.18

3.19

0.84

2.81

6.18

CT2036

1.89

0.50

1.66

3.66

1.71

0.45

1.50

3.30

CT2436

2.64

0.70

2.32

5.11

1.89

0.50

1.66

3.66

CT2645

3.70

0.98

3.26

7.17

2.54

0.67

2.24

4.92

CT3042

6.01

1.59

5.29

11.63

4.99

1.32

4.39

9.65

NCT3042

3.44

0.91

3.02

6.65

2.82

0.74

2.48

5.46

CT3254

6.01

1.59

5.29

11.63

4.99

1.32

4.39

9.65

CT3648

7.24

1.91

6.37

14.01

7.06

1.87

6.21

13.67

CT4254

10.27

2.72

9.04

19.89

7.24

1.91

6.37

14.01

CT4763

16.60

4.39

14.61

32.14

14.47

3.83

12.73

28.01

CT6080

35.51

9.40

31.25

68.75

31.02

8.21

27.30

60.06


5-8


Operation & Maintenance Manual Maintenance Checks

Maintenance Checks

Interior Inspection

Exterior Inspection

1) Lockout & Tagout power to crusher drive, crusher hydraulic unit, and all other associated equipment.

The jaw crusher does not have an enclosed, interior crushing chamber, but does have items underneath or inside the frame which may require close inspection. Care must be taken to do this. 1) Verify Lockout & Tagout of crusher drive.

DANGER

DANGER

Failure to Lockout & Tagout all energy sources will result in death or severe personal injury. Make it impossible to start this machine or associated equipment while people are working on or in it.

Failure to Lockout & Tagout will result in death or severe personal injury.

2) Check all exterior components, including drives, belts, guards, covers and inspection doors, bearings, seals, hardware and hydraulic parts to make sure all are in good condition. 3) Repair or replace as necessary any parts that are missing or in faulty condition.

2) Inspect all crushing chamber components, including stationary jaw die, swing jaw die, cheek plates, pitman shaft housing liner to make sure all are in good condition. 3) Repair or replace as necessary any parts that are damaged, missing, excessively worn, or in faulty condition. See Section 7 for wear items adjustment and replacement information. Start-Up

4) Tighten any loose hardware or loose hydraulic fittings. See Appendix A for hardware torque specifications.

When all inspection and repairs or necessary replacements are complete, perform the following to prepare crusher for start-up.

5) See Appendix B for v-belt drive information. 1) Remove Lockout & Tagout from crusher drive. 2) Make sure everyone is clear of crusher. 3) Crusher should now be ready for start-up.


5-9


Operation & Maintenance Manual Maintenance Checks



5-10


Operation & Maintenance Manual Jaw Crusher Daily Inspection Form

Jaw Crusher Daily Inspection Form

7) Flywheel bolts - tight  OK  Not OK See Notes

Date __________ Signature _______________________________

8) Flywheel counterweights - tight  OK  Not OK See Notes

Pre-Start-up Checklist

1) Lockout & Tagout - crusher & assoc. equip.  OK Initials ______________________

9) Jaw dies and cheek plate bolts - tight & jaw dies in good condition  OK  Not OK See Notes

2) Under-crusher discharge area - clear of debris  OK  Not OK See Notes

10) Pitman tension rod springs tensioned properly  OK  Not OK See Notes

3) Belt guards - present, in good condition  OK  Not OK See Notes

11) Crusher setting (C.S.S.) checked & adjusted properly _________Inches _________mm  OK  Not OK See Notes

4) Belts - tensioned, clean, in good condition  OK  Not OK See Notes

12) Hydraulic System: a. Breather cap, control levers & valves - in place, secure & tight, no leaks, no damage  OK  Not OK See Notes b. Lines & hoses - in place, secure & tight, no leaks, no damage  OK  Not OK See Notes c. Cylinder(s) - securely pinned, no leaks, no

5) Sheaves - aligned, clean, in good condition  OK  Not OK See Notes 6) Pitman Shaft: a. Seals - good condition  OK  Not OK See Notes b. Seals - greased properly  OK  Not OK See Notes c. Bearings - housing bolts tight  OK  Not OK See Notes d. Bearings - greased properly  OK  Not OK See Notes Last Greased at _______________________ Initials ______________________________

damage  OK  Not OK See Notes d. Cylinder hydraulic pressure is adequate and replenished.  OK  Not OK See Notes e. Reservoir - oil clean and at proper level  OK  Not OK See Notes Oil Added - Qts. ______________________ Initials ______________________________ f. Oil & Filter Changed - Qts._____________ Initials ______________________________

Notes: _____________________________________ _____________________________________

Notes: ________________________________________ ________________________________________

_____________________________________ _____________________________________ _____________________________________

________________________________________ ________________________________________ ________________________________________


5-11


Operation & Maintenance Manual Jaw Crusher Daily Inspection Form

Start-up Checklist

20) Crusher run 50% load - 2 hours minimum  OK  Not OK See Notes

13) Remove Lockout & Tagout - crusher & associated equipment  OK Initials ______________________ 14) Jog crusher drive motor to verify pitman shaft rotates in proper direction (See Diagram)  OK  Not OK See Notes

21) 50% load bearing temperatures checked (140-160°F. / 60-70°C.)  OK  Not OK See Notes 22) 50% load power draw _____________Amps  OK  Not OK See Notes 23) 50% load crusher balance is good  OK  Not OK See Notes 24) Crusher run 75% load - 4 hours minimum  OK  Not OK See Notes 25) 75% load bearing temperatures checked (140-160°F. / 60-70°C.)  OK  Not OK See Notes 26) 75% load power draw _____________Amps  OK  Not OK See Notes

15) Crusher shaft runs at ______________RPM  OK  Not OK See Notes

27) 75% load crusher balance is good  OK  Not OK See Notes

16) Crusher run no load - 2 hours minimum  OK  Not OK See Notes

28) 100% load power draw _____________Amps  OK  Not OK See Notes

17) No load bearing temperatures checked (140-160°F. / 60-70°C.)  OK  Not OK See Notes

29) 100% load bearing temperatures checked (140-160°F. / 60-70°C.)  OK  Not OK See Notes

18) No load power draw _____________Amps  OK  Not OK See Notes

30) Crusher at work Diesel Engine RPM ____________________ Electric Motor Amps ___________________ Total Crushing Hours Today _____________ Downtime Today ______________________

19) No load crusher balance is good  OK  Not OK See Notes Notes: ________________________________________ ________________________________________ ________________________________________ ________________________________________ ________________________________________


5-12

Notes: ________________________________________ ________________________________________ ________________________________________ ________________________________________


Operation & Maintenance Manual Jaw Crusher Troubleshooting Chart

Jaw Crusher Troubleshooting Chart The following chart outlines some of the issues, possible causes, and solutions to those issues you may encounter with the jaw crusher. Table 5 - 6 Jaw Crusher Troubleshooting ISSUE

POSSIBLE CAUSE

Crusherwillnotstart

S OL U T I ON

Incorrectwiring

Checkwiringdiagram

Nopower

Crusher stops under load

Checkpowersource

Defective motor

Check motor. Replace if defective.

Soft start issues

Ensure soft start is functioning properly

Crushing chamberfull

Clearcrushingchamber

Excessive amp draw

Possible voltage drop. Check power source.

Excessive fines in feed

Remove fines from feed.

Un-crushable object in crushing chamber

Clear crushing chamber

Damagedorwornbearings

Replacebearings

Discharge opening set too close

Adjust discharge opening to within specifications

Crusher shakes/

Flywheel/Drive sheave turned

vibrates

on shaft Excessive fines build up in flywheels

Clean dust or material build up from flywheels

Crusher running too fast

Ensure crusher is running at proper RPM

Crusher not secured to mounting structure Excessive noise (knocking, squeaking, rattling, etc.)

Ensure crusher foot mounting bolts are secure to structure

Loose toggle plate

Check tension springs. Adjust as required.

Gap between upper buffer and upper buffer guide too large

Add shims to close gap to between .5

Loosediebolts

~ 1.0 mm

Tightendieboltsasrequired

Dirt/material buildup in toggle plate seats Loose bolts


Re-mount flywheel/drive sheave in proper position

Remove dirt/material buildup Tighten all loose bolts as required

5-13



Table 5 - 6 Jaw Crusher Troubleshooting ISSUE

POSSIBLE CAUSE

Crusher loses RPM

Excessive fines in crushing chamber

S OL U T I ON Check material feed and remove fines

Lowvoltage

Checkpowersource

Loose or worn drive belts

Adjust belt tension and replace belts as required

Worn drive sheave Poor crusher performance

Replace drive sheave as required

Improper jaw dies for application

Check with TRIO for jaw die options

Electrical power issues

Toggle plate drift

Check power source, wire size, drive motor

Drive belt issue

Check and adjust belt tension and replace belts as required

Tension springs not equally adjusted


Worn buffer(s)

Inspect and replace buffer(s) as required

Worn toggle plate

Inspect both ends of toggle plate to check wear

Crusher not level Uneven toggle plate wear

Check and make sure crusher is level

Material build up on top of toggle entering lower buffer

Keep toggle plate area free of material build up and debris

Tension springs not equally adjusted


Crushing on one side only Cracked/broken toggle plate

Ensure feed is centered and not segregated

Un-crushable object(s) went through machine

Remove un-crushable object(s) from feed

Exceeding recommended reduction ratio

Adjust feed size or adjust C.S.S.

Uneven jaw die wear

Improper feed to crusher

Cracked jaw dies

Jaw dies excessively worn

Ensure feed is centered and not segregated Replace jaw dies at 80% wear

Crusher frame parent steel worn

Remove dies, inspect and repair crusher frame as required

Un-crushable object(s) went through machine

Remove un-crushable object(s) from feed

Application issues


Evaluate crusher application

5-14



Table 5 - 6 Jaw Crusher Troubleshooting ISSUE

POSSIBLE CAUSE

S OL U T I ON

Bearingsoverheating

Incorrectgrease

Usespecifiedtypegrease

Over greasing or under greasing

Use proper quantity of lubricating grease

Crusher is overloaded Adjustment wedges will not move

Adjustment wedges open during operation

Eliminate overload condition

Low oil level in system

Ensure oil reservoir is at proper level

Hydraulic pump not operating

Ensure hydraulic pump has power and is activated

Low hydraulic pressure

Ensure hydraulic system pressure is adequate

Hydraulic lines incorrectly connected

Check and ensure lines are correctly connected

Air in hydraulic system

Bleed air by removing tension spring tension and attempting to open and close C.S.S. two full cycles

Damaged wedge surface(s)

Ensure wedge surface(s) are smooth and clear of debris. Replace as required.

Hydraulicleak

Checkandrepairleaks

Hydraulic lines incorrectly connected


Check and ensure lines are correctly connected

5-15





5-16


Operation & Maintenance Manual Start-Up & Operation Information

Section 6 - Start-Up & Operation Start-Up & Operation Information The jaw crusher is generally used as a component of an overall plant system. Specific equipment start-up procedures will depend on the particular plant and the material flow as well as the type of controls used. Always refer to controls schematics and information received with your particular equipment for start-up and operation. The following steps should be used as a guide to operation of the jaw crusher: 1) Check the surrounding area to ensure no personnel are in a dangerous position prior to start-up.

WARNING Always sound horn or other warning device to warn others that you are about to start up the equipment. 2) If the crusher is part of a plant system, make sure it is started in proper sequence with other components.

3) Start up all other components on the plant in the proper sequence prescribed for your particular plant system. If no prescribed sequence is available, start with the last piece of equipment to discharge material and work back toward the initial feed point until all components are operating empty. 4) Make sure crusher is running at the proper RPM. See (Table 6 - 1) Table 6 - 1 Jaw Crusher Operating Speeds JawModel

RPM

CT1030

300

CT1040

300

CT1048

300

CT1252

300

CT2036

250

CT2436

250

CT2645

300

CT3042

250

NCT3042

250

CT3254

250

CT3648

225

CT4254

220

CT4763

200

CT6080

200

5) Begin material flow to the plant. Keep safety in mind. 6) Record any observation about plant operating conditions in the plant log book.


6-1


Operation & Maintenance Manual Crusher Feed

Crusher Feed The most efficient operation of the crusher results when the crushing chamber is kept full of material and when a uniform method of feed is used. The crusher should ideally be kept full of material but it should not be allowed to build up above the top of the jaws. During normal operations, the flow of material to the machine and crushed material out of the machine forms a steady stream of product from the crusher. Oversize Feed Material

Avoid feeding material into the crusher that is too large to pass through the crushing chamber. If a piece of material is too large, it should be broken down before it gets to the crushing chamber. A hydraulic breaker may be installed to assist in this process.

DANGER Failure to Lockout & Tagout will result in death or severe personal injury. 3) Use extreme caution when attempting to dislodge or remove jammed objects. These objects under tremendous pressure can fractureare or dislodge and be thrown outand at high speeds at any time.

DANGER Never use explosives in a crusher to clear jammed objects. The crushing chamber and machine components are not designed to withstand the forces generated by explosives.

CAUTION

WARNING If a hydraulic breaker is installed, it should never be used to fracture rocks inside the crushing chamber. Damage to bearings or other parts may occur. Never use a hydraulic breaker to break rocks on the apparatus feeding the crusher.

Never attempt to walk or stand on jammed or bridged material. The material could break free at any time. 4) Remove as much loose material from the top of the crushing chamber as possible. When the jammed object becomes accessible, try to loosen it with a pole, rock hook or breaker bar. If necessary, use a grappling device to remove the object out of the feed opening.

Unblocking Jammed Material

If material becomes jammed in the machinery: 1) Stop the machinery immediately! 2) Lockout & Tagout power.

WARNING Never attempt to dislodge jammed object directly by hand.


6-2

a



CAUTION If a hydraulic breaker is used when the feed opening is blocked, extreme care must be taken to break the jammed rock only. Never directly hammer on any part of the crusher or its components. Never pry against the crusher to free the blockage. 5) After unblocking and clearing is completed, remove any objects, loose material or debris from the crusher discharge area. 6) Remove the Lockout & Tagout from the power source. Crusher should now be able to be restarted.


6-3





6-4


Operation & Maintenance Manual Adjustments & Replacement

Section 7 - Adjustments & Wear Parts Replacement

Closed Side Setting (CSS) Adjustment The jaw crusher’s crushing chamber discharge opening governs the size of finished material produced.

Adjustments & Replacement As equipment is used, wear parts must be adjusted and/or replaced to keep the machinery operating efficiently and properly. The following will give guidance to adjustment procedures and replacement for wear items on your jaw crusher.

Jaw Crusher Crushing Chamber The jaw crusher’s crushing chamber consists of the stationary jaw die, the swing jaw die (sometimes called the moveable jaw), and the cheek plates (sometimes called key plates). The pitman shaft housing area is also protected by a replaceable liner. See (Figure 7 - 1) 3

2

1

The CSS is the closest distance the stationary and swing jaw die faces come measured peak to peak at the bottom of the chamber. See (Figure 7 - 2) While the crusher is at rest, the opening at the bottom of the chamber is somewhat larger and known as the open measurement. To determine the CSS, deduct the amount shown in the table below from the open measurement . Table 7 - 1 Deduction To Determine CSS JawModel

Inches

Metric

CT1030

0.394

10mm

CT1040

0.394

10mm

CT1048

0.394

10mm

CT1252

0.591

15mm

CT2036

1.000

25mm

CT2436

1.260

32mm

CT2645

N/A

N/A

CT3042

1.417

36mm

NCT3042

1.181

30mm

CT3254

1.023

26mm

CT3648

1.929

49mm

CT4254

2.087

53mm

CT4763

1.653

42mm

CT6080

N/A

N/A

1 - Swing Jaw Die 2 - Stationary Jaw Die 3 - Cheek Plates (Key Plates) Figure 7 - 1 Typical Jaw Die & Cheek Plate Arrangement


7-1


Operation & Maintenance Manual Closed Side Setting (CSS) Adjustment

Shim-Type CSS Adjustment Procedure

1) Lockout & Tagout crusher drive.

DANGER Failure to Lockout & Tagout will result in death or severe personal injury. 2) Loosen bolts on both sides of machine that secure the shims. 3) Loosen tension rod spring nuts on both sides of machine. Measure peak to peak when crusher is at rest, then deduct amount from table to get CSS.

4) Activate hydraulic hand pump to extend cylinder to push the pitman forward and relieve the weight off the stack of shims.

Figure 7 - 2 Jaw Crusher Closed Side Setting (CSS)

5) Add or subtract shims as required to achieve the desired CSS.

Shim-Type CSS Adjustment

On smaller model jaws, the size of the opening is changed by adding or subtracting shims between the upper buffer and the frame housing. See (Figure 7 - 3).

6) With the desired number of shims seated, retract the hydraulic cylinder to allow the pitman to rest against the shim stack. 7) Re-tighten the bolts on both sides of machine securing the shims. 8) Re-set tension rod spring tension on both sides of machine. 9) Once complete, remove Lockout & Tagout.

Figure 7 - 3 Shim-Type CSS Adjustment


7-2



Hydraulic Wedge-Type CSS Adjustment (Manual Hyd. Pump)

Hydraulic Wedge-Type CSS Adjustment (Manual Hyd. Pump) Procedure

On some larger model jaws, the size of the opening is changed by operating a manual hydraulic pump connected to cylinders moving wedges between the upper buffer and the frame housing. See (Figure 7 - 4).

DANGER Failure to Lockout & Tagout will result in death or severe personal injury.

6 5


4

2) Ensure the hydraulic pump unit is properly connected to the hydraulic cylinders on the wedges.

3

While making line connections between the hydraulic power unit and the crusher, air may become trapped in the lines. It is necessary to purge the trapped air. This can usually be accomplished by opening and closing the jaw several

1 2

2

times before initial operation. 1 2 3 4 5 6

-

Wedges In Wedges Out Manual Hand Pump Valve Direction - Wedges In Valve Direction - Wedges Out Valve Direction - Hold Position

3) Loosen tension rod spring nuts on both sides of machine. 4) Move the valve to the desired flow direction (Wedge Out - Increases Opening) (Wedge In - Decreases Opening) 5) Activate hydraulic hand pump to push or pull the wedges in or out to the desired CSS.

Figure 7 - 4 Hydraulic Wedge-Type CSS Adjustment (Manual Hyd. Pump)

6) Move the valve back to the Hold position. 7) Re-set tension rod spring tension on both sides of machine. 8) Once complete, remove Lockout & Tagout.


7-3



Power Hydraulic Pump Unit for CSS Adjustment

Some larger model jaw crushers utilize a powered hydraulic pump unit to supply power for the CSS adjustment mechanism.

The powered hydraulic pump unit may or may not have the electrical control box mounted on the unit. Either unit contains the same hydraulic components. See (Figure 7 - 5)

Unit Without Electrical Control Box

15 7 17

18 16 13

14

4

5

16 17 15

12

5

18

19 9 8 6 1

11

17

11

10

16

20 Unit With Electrical Control Box 1 2 3 4

-

Motor Coupling Gear Pump Relief Valve

8 9 1011-

5 - Directional Control Valve 6 - Oil Level Gauge 7 - Return Oil Filter

Reservoir Cap / Breather Check Valve One-way Throttle Valve Synchronous Valve

12- Pressure Gauge 13- Gauge Fitting 14- Gauge Hose

15161718-

P Port / High Pressure Hose B Port / High Pressure Hose A Port / High Pressure Hose T Port / Low Pressure Hose

19- Electrical Control Buttons 20- Electrical Control Box

Figure 7 - 5 Power Hydraulic Pump Unit Components


7-4



Power Hydraulic Pump Unit With Electrical Control Box

The electrical schematics below are for reference when the power hydraulic pump unit used has the electrical control box mounted. Circuit Breaker

Pump Motor

Transformer Control and Protection

Pump Motor Control

Stop

Start

Electric Schematic (380V)

Circuit Breaker

Pump Motor

Transformer Control and Protection

Pump Motor Control

Stop

Start

Electric Schematic (460V) Figure 7 - 6 Power Hydraulic Pump Unit Electrical Schematics


7-5



Power Hydraulic Pump Unit Hydraulic Schematic Type 1 Connections

The hydraulic schematic below is for reference when the power hydraulic pump unit is used on the following model jaw crushers.

CT2036, CT2036SA, CT2036T, CT2036TA CT2436, CT2436J, CT2436JS, CT2436JT, CT2436TB, CT2436TC, CT2436S CT2645A CT3042, CT3042T, CT3042TAC, CT3042S, CT3042SB, CT3042SC, CT3042SD, CT3042TA, CT3042TP CT3254, CT3254PN, CT3254TA, CT3254TB, CT3254TC, CT3254TD, CT3254TE, CT3254TS CT3648, CT3648HT, CT3648HTS CT4254, CT4254S, CT4254SA, CT4254SB, CT4254T, CT4254U CT4763, CT4763T, CT4763U, CT4763Y CT6080


7-6



Rated Flow Rated Pressure Motor Power Motor Speed RPM Filtration Oil Reservoir Volume

1 2 3 4 5

-

Motor Coupling Gear Pump Relief Valve Directional Control Valve

6 7 8 9 10-

Oil Level Gauge Return Oil Filter Reservoir Cap / Breather Check Valve One-way Throttle Valve

111213141516-

4 ml/r 21 MPa 3KW / 380V or 3.6KW / 460V 1410 / 380V or 1710 / 460V 20 µm 65L (17 Gal.)

Synchronous Valve Pressure Gauge Gauge Fitting Gauge Hose P Port / High Pressure Hose B Port / High Pressure Hose

Figure 7 - 7 Power Hydraulic Pump Unit Hydraulic Schematic Type 1 Connections & Specifications


7-7



Power Hydraulic Pump Unit Hydraulic Schematic Type 2 Connections

The hydraulic schematic below is for reference when the power hydraulic pump unit is used on the following model jaw crushers.


7-8

CT3254A, CT3254C, CT3254D CT4254B, CT4254HA



Rated Flow Rated Pressure Motor Power Motor Speed RPM Filtration Oil Reservoir Volume

1 2 3 4 5 6

-

Motor Coupling Gear Pump Relief Valve Directional Control Valve Oil Level Gauge

7 8 9 101112-

Return Oil Filter Reservoir Cap / Breather Check Valve One-way Throttle Valve Synchronous Valve Pressure Gauge

131415161718-

4 ml/r 21 MPa 3KW / 380V or 3.6KW / 460V 1410 / 380V or 1710 / 460V 20 µm 65L (17 Gal.)

Gauge Fitting Gauge Hose P Port / High Pressure Hose B Port / High Pressure Hose A Port / High Pressure Hose T Port / Low Pressure Hose

Figure 7 - 8 Power Hydraulic Pump Unit Hydraulic Schematic Type 2 Connections & Specifications


7-9



Hyd. Wedge-Type CSS Adjustment (Power Hyd. Pump Type 1 Connections)

7

On some larger model jaws, the size of the opening is changed by operating a power hydraulic pump connected to cylinders moving wedges between the upper buffer and the frame housing. See (Figure 7 - 9).

4

6

5

3

2

2

1 1 - Wedges In 2 - Wedges Out 3 4 5 6 7

-

Power Hydraulic Pump Unit Valve Direction - Wedges In Valve Direction - Wedges Out Valve Direction - Hold Position Pressure Gauge

Figure 7 - 9 Hydraulic Wedge-Type CSS Adjustment (Power Hyd. Pump - Type 1 Connections)


7-10



Hyd. Wedge-Type CSS Adjustment (Power Hyd. Pump Type 1 Connections) Procedure

4) Engage power to the hydraulic pump unit. 5) Move the control valve lever in the desired flow direction to move the wedges in or out to the desired CSS. (Wedge Out - Increases Opening) (Wedge In - Decreases Opening)



6) Once the desired CSS has been achieved, move the control valve lever back to the Hold position.

2) Ensure the power hydraulic pump unit is properly connected to the hydraulic cylinders on the wedges. See (Figure 7 - 9)

7) Disengage power to the hydraulic pump unit. 8) Re-set tension rod spring tension on both sides of machine. 9) Once complete, remove Lockout & Tagout.

While making line connections between the hydraulic power unit and the crusher, air may become trapped in the lines. It is necessary to purge the trapped air. This can usually be accomplished by opening and closing the jaw several times before initial operation. 3) Loosen tension rod spring nuts on both sides of machine.


7-11



Hyd. Wedge-Type CSS Adjustment (Power Hyd. Pump Type 2 Connections)

7

On some larger model jaws, the size of the opening is changed by operating a power hydraulic pump connected to cylinders moving wedges between the upper buffer and the frame housing. See (Figure 7 - 10).

6

4

5

3

2

2

1 1 - Wedges In 2 - Wedges Out 3 4 5 6 7

-

Power Hydraulic Pump Unit Valve Direction - Wedges In Valve Direction - Wedges Out Valve Direction - Hold Position Pressure Gauge

Figure 7 - 10 Hydraulic Wedge-Type CSS Adjustment (Power Hyd. Pump - Type 2 Connections)


7-12



Hyd. Wedge-Type CSS Adjustment (Power Hyd. Pump Type 2 Connections) Procedure

4) Engage power to the hydraulic pump unit. 5) Move the control valve lever in the desired flow direction to move the wedges in or out to the desired CSS. (Wedge Out - Increases Opening) (Wedge In - Decreases Opening)



6) Once the desired CSS has been achieved, move the control valve lever back to the Hold position.

2) Ensure the power hydraulic pump unit is properly connected to the hydraulic cylinders on the wedges. See (Figure 7 - 10)

7) Disengage power to the hydraulic pump unit. 8) Re-set tension rod spring tension on both sides of machine. 9) Once complete, remove Lockout & Tagout.

While making line connections between the hydraulic power unit and the crusher, air may become trapped in the lines. It is necessary to purge the trapped air. This can usually be accomplished by opening and closing the jaw several times before initial operation. 3) Loosen tension rod spring nuts on both sides of machine.


7-13



Direct Hydraulic Toggle Plate-Type CSS Adjustment

On certain model jaws, the size of the opening is changed by adding or subtracting shims between the upper buffer and a hydraulic cylinder mechanism directly acting against the frame housing. See (Figure 7 - 11).

Figure 7 - 11 Direct Hydraulic Toggle Plate-Type CSS Adjustment

The toggle plate hydraulic cylinder mechanism as well as the tension rod spring cylinder mechanisms are powered and held hydraulically by a separate hydraulic pump control unit. See (Figure 7 - 12) Make sure the hydraulic pump control unit is properly connected to the crusher hydraulic cylinders. See (Figure 7 - 15) schematic. Operating hydraulic pressure on toggle cylinder mechanism is 16.5 Mpa (2393 psi) and the tension rod spring cylinders is 12 Mpa (1740.5 psi). During normal operation, hydraulic unit should be turned on and running before crusher started the Auto/Manual Switch should be setisto Auto.and


7-14

Figure 7 - 12 Direct Hydraulic Toggle Plate-Type Hydraulic Pump Control Unit

Direct Hydraulic Toggle Plate-Type CSS Adjustment Procedure


DANGER Failure to Lockout & Tagout will result in death or severe personal injury. 2) Place a “Safety Block” between the pitman and the back cross member as shown. See (Figure 7 - 13)



Shims

Shim Bolt

Figure 7 - 14 Direct Hydraulic Toggle Plate-Type CSS Adjustment Shims

Safety block installed between pitman and frame cross member.

8) Add or remove shims as required to achieve the desired CSS. Each shim removed will reduce the CSS by approximately 23mm.

Safety block should be made from solid hardwood material. Figure 7 - 13 Direct Hydraulic Toggle Plate-Type CSS Adjustment Safety Block Installed

9) Re-install bolts on both sides of machine to secure the shims.

3) Turn Auto/Manual Switch to Manual

10) Turn the Auto/Manual Switch to Auto. This allows the hydraulic control unit to pressurize the Toggle Cylinder set and Tension Cylinders.

4) Push the Tension Cylinder Relief button to release tension cylinder hydraulic pressure. 5) Push the Toggle Cylinder Relief button to release toggle cylinder set hydraulic pressure.

12) Re-install adjustment mechanism covers on both sides of machine.

6) Remove the adjustment mechanism covers from both sides of machine.

13) Once complete, remove crusher drive Lockout & Tagout.

7) Loosen bolts on both sides of machine that secure the shims. See (Figure 7 - 14)


11) Once pressurized, remove the Safety Block.

7-15


Operation & Maintenance Manual Closed Side Setting (CSS) Adjustment .

Tension

Toggle

Release

1 2 3 4 5 6 7 8 9 1011-

Oil Pump Pump Coupling Electric Pump Motor Motor Pump Joint Flange Reservoir Breather Oil Level Gauge Return Line Filter Hose Fitting Accumulator Pressure Gauge

1213141516171819202122-

Rated Pressure

20MPa

Max. Pressure Rated Flow Operating Voltage Operating Temp Filtration Oil Volume Motor Power

21MPa 18 L/Min. 24V 60° + or - 5° C 10um 200L 7.5Kw/380V/50Hz

Pressure Gauge Check Valve Solenoid Valve Valve Block Solenoid Valve Flow Control Valve Check Valve Ball Valve Tension Rod Cylinders Toggle Cylinder Assembly Oil Reservoir

Figure 7 - 15 Direct Hydraulic Toggle Plate-Type Hydraulic Controls Schematic


7-16


Operation & Maintenance Manual Standard Toggle Seat Tension Rod Spring Adjustment

Standard Toggle Seat Tension Rod Spring Adjustment

1) Completely loosen spring tension rod nuts until springs are at their full, no-load length. See A above.

After crusher CSS is set, the toggle seat tension rod springs must be adjusted to apply the proper amount of spring tension to keep the toggle plate contained in its seats. See (Figure 7 - 16)

2) Record this length A.

When measuring spring free length, each spring length may vary. It is important to compress each spring the same amount as shown in (Table 7 - 2) even though this may make the spring overall lengths differ. The important issue is that the compression amount be equal on each side to ensure the toggle plate remains centered during operation. 3) See (Table 7 - 2) for the amount to compress springs for your particular model crusher. See B above.

B A

4) When springs are compressed the amount specified in (Table 7 - 2), that length will be

A - Spring Free Length B - Spring Compression Deduction Amount

dimension B subtracted from dimension A.

Figure 7 - 16 Typical Toggle Seat Tension Rod Spring Adjustment


7-17


Operation & Maintenance Manual Standard Toggle Seat Tension Rod Spring Adjustment

Table 7 - 2 Tension RodSpring Length Deduction Jaw Model

Initial mm (inch)

CT1030

21(0.826)

CT1040

31(1.220)

25~37 (0.984~1.456)

CT1048

57(2.244)

CT1252

64(2.519)

CT2036

39(1.535)

35~45 (1.377~1.771)

CT2436

35(1.377)

30~40 (1.181~1.574)

CT2645

N/A

N/A

CT3042

55(2.165)

50~60 (1.968~2.362)

NCT3042

22 (0.866)

18~27 (0.708~1.062)

CT3254

34(1.338)

30~40 (1.181~1.574)

CT3648

32(1.259)

30~38 (1.181~1.496)

CT4254

35(1.377)

35~50 (1.377~1.968)

CT4763

65(2.559)

65~100 (2.559~3.936)

CT6080

55(2.165)

53~60 (2.086~2.362)


6) Listen for a knocking sound. If a knocking is heard, the toggle is not held tight enough by the springs.

Range mm (inch) 20~30 (0.787~1.181)

5) When the springs are adjusted on both sides, start the crusher.

7) Further tighten (compress) the tension springs a slight amount.

50~62 (1.968~2.440) 50~65 (1.968~2.559)

8) Run the crusher again and repeat until no toggle plate knocking sound is detected.

For proper operation and optimum toggle plate wear performance, the tension rod springs must be adjusted evenly on both sides so the toggle plate will run in the center of the upper and lower buffer seats. The important issue is that the compression amount be equal on each side to ensure the toggle plate remains centered during operation.

7-18


Operation & Maintenance Manual Fully Hydraulic Toggle Plate-Type CSS Adjustment System

Fully Hydraulic Toggle Plate-Type CSS Adjustment System On certain model jaws, the size of the opening is changed by a fully hydraulic cylinder mechanism directly acting against the frame housing and the swing jaw. The toggle plate tension mechanismis accomplished by having dual-acting cylinders between the frame housing and the swing jaw in addition to tension rods and springs. See (Figure 7 - 17).

1 2 3

1

3

5

7 9

4

1 2 3 4

-

5

6

7

Toggle Cylinder 5 - Adapter Toggle Beam 6 - Tension Rod Toggle Plate 7 - Tension Spring Tension Cylinder

2

Figure 7 - 17 Fully Hydraulic Toggle Plate-Type CSS Adjustment

The toggle plate hydraulic cylinder mechanism as well as the tension cylinder mechanisms are powered and held hydraulically by a separate hydraulic pump control unit. See (Figure 7 - 18)

4

6

1 - Power 2 - Pump Start 3 - Filter Blocked Indicator 4 - Pump Stop 5 - CSS Increase

8

6 - CSS Decrease 7 - Adjust/Operate Mode Switch 8 - E-Stop 9 - Main Power Switch

Figure 7 - 18 Fully Hydraulic Toggle Plate-Type Hydraulic Control Unit


7-19



Hydraulic Pump Control Unit Hose Connections

.

Make sure the hydraulic pump control unit is properly connected to the crusher hydraulic components andcylinders. See (Figure 7 - 19) and (Figure 7 - 24) schematic.

Figure 7 - 19 Fully Hydraulic Toggle Plate-Type Hydraulic Pump Unit Hose Connections


7-20



Hydraulic Control Unit Standby Mode

CSS Increase Adjustment Procedure

When the control unit is first started, no matter if the panel switch is in Adjustment Mode or Operation Mode, the unit will be in a Standby Mode. CSS Decrease Adjustment Procedure

1) Turn control unit on. 2) Turn control panel switch to Adjustment Mode. 3) Push the CSS Increase button on the control panel to move the toggle cylinders in until the desired position is reached.

1) Turn control unit on. 2) Turn control panel switch to Adjustment Mode. 3) Push the CSS Decrease button on the control panel to move the toggle cylinders out until the desired position is reached.

The displacement of the toggle cylinder is measured by the sensor ST1 or ST2 on the toggle cylinders. Output current ranges from 4 to 20mA. See (Figure 7 - 24) schematic. If pressure measured by pressure sensor (32) is below its upper limit of 12 MPa (1740 psi), oil will be supplied to the tension cylinder rod side chamber until it reaches the upper limit.

The displacement of the toggle cylinder is measured by the sensor ST1 or ST2 on the toggle cylinders. Output current ranges from 4 to 20mA. See (Figure 7 - 24)

4) The toggle cylinder displacement is now

schematic. If (32) pressure measured by pressure sensor is below its upper limit of 12 MPa (1740 psi), oil will be supplied to the tension cylinder rod side chamber until it reaches the upper limit.

recorded as the default value for cylinder reset. 5) CSS adjustment is complete and now control panel switch can be moved to Operation Mode and tension rod spring adjustment should now be made.

4) The toggle cylinder displacement is now recorded as the default value for cylinder reset. 5) CSS adjustment is complete and now control panel switch can be moved to Operation Mode and tension rod spring adjustment should now be made.


7-21



Tension Rod Spring Adjustment

Toggle Cylinders Oil Supplement

When the crusher CSS has been set or changed as described above, the tension rod springs must be adjusted.

While the hydraulic control unit is in operation, the toggle cylinders must maintain their default value (CSS setting) described above. When the difference between toggle cylinders actual displacement and the default displacement reaches the maximum deviation, the valve will be actuated to move the cylinders to maintain position. This will continue through the entire crushing process.

1

Tension Cylinders Oil Supplement

2

While the hydraulic control unit is in operation, the tension cylinders must maintain their position and pressure relative to (CSS setting) described above. Tension cylinder oil supplement depends on the pressure measured by the sensor (32). If the measured pressure is below the lower limit of 5MPa (725 psi), the valve will be actuated to move the cylinder rod side until the measured pressure reaches the upper limit of 12MPa (1740 psi). This will continue through the entire crushing process.

3

4

5

6

7

1 - Toggle Cylinder 2 - Toggle Beam

When both toggle cylinders and tension cylinders need oil supplement, the tension cylinders have

3 4 5 6 7

priority.

-

Toggle Plate Tension Cylinder Adapter Tension Rod Tension Spring: Compress springs 28mm (1 - 1/8 in.) Compressed length 312mm (12 - 3/8 in.) Both springs should be equally adjusted.

Figure 7 - 20 Fully Hydraulic Toggle Plate-Type CSS Tension Rod Spring Adjustment

Tramp Release

If an uncrushable piece of material in the crushing chamber causing the pressure in safety valve (29.2) to rise above its setting of 25MPa (3625 psi), it will allow most of the oil to flow across check valve in (29.1) to toggle cylinder rod side chamber and the remaining oil to flow back to tank. See (Figure 7 - 21) and (Figure 7 - 24)

1) Completely loosen spring tension rod nuts until springs are at their full, no-load length.

Response time is 2 milliseconds and the cylinder maximum retract speed is 15mm/s.

2) See (Figure 7 - 20) for the amount to compress

Once the tramp release has occurred, according to the displacement sensor signal, the hydraulic control unit will ready itself for cylinder reset.

springs. 3) When springs are compressed the amount specified, tighten tension rod jam nuts.


7-22



Toggle and Tension Cylinder Fast Reset After Tramp Release

Hydraulic Unit Valve Pressure Adjustments

The fast reset is the follow-up movement after tramp release. If the toggle cylinders stop their retracting and the pistons do not bottom (according to the signal from the displacement sensor), once the tramp release is finished, the toggle cylinders will need to be reset. Reset as outlined above in CSS Decrease procedure. If the toggle cylinders pistons bottom, or the displacement sensor reading does not change and motor current overloads when toggle cylinders are resetting, it is a “tramp release failure”. To protect the crusher and hydraulic unit, the crusher motor should be shut down. Manual tramp release should be performed. 8

9

The default system pressure setting is 24MPa (3481 psi). See (Figure 7 - 22) The tension cylinder maximum pressure setting is 13MPa (1885 psi). See (Figure 7 - 22) The toggle cylinder rod side default pressure setting is 7 - 8MPa (1015 - 1160 psi) Generally there is no need to adjust it. See (Figure 7 - 21) The toggle cylinder piston side pressure should be adjusted according to the material strength being crushed. The adjustment range on the valve is 5.5 - 25MPa (798 - 3626 psi). See (Figure 7 - 21) 2

10

1

7

6 5 1

4 3

1 2 3 4 5 6 7 8

-

2

3

Rod Side Pressure Setting Piston Side Pressure Setting Piston Side Connect Between Cylinders To Piston Side - From Valve To Rod Side - From Valve Piston Side Test Point Displacement Sensor (Inside) Rod Side Test Point

1 - System Pressure Setting 2 - Tension Cylinder Pressure Setting 3 - Manual Unloading Relief Valve Figure 7 - 22 Fully Hydraulic Toggle Plate-Type CSS Adjustment Manifold Valve Pressure Setting

9 - Rod Side Connect Between Cylinders 10 - To Tank Figure 7 - 21 Fully Hydraulic Toggle Plate-Type CSS Adjustment Toggle Cylinder and Valve


7-23



Toggle Cylinder Maintenance

2) Shut off hydraulic control unit.

Make sure all hoses, valves and fittings are checked regularly.

DANGER

3) Open manual unloading relief valve to release hydraulic pressure. See (Figure 7 - 22) 4) If pressure gauge reading is 0, close unloading relief valve.

Extreme care should be taken due to the toggle cylinder large oil capacity and the hydraulic lock

5) If pressure is not 0, release the pressure by carefully loosening pressure hose to the piston

valves.

side of cylinder.

If it becomes necessary to disconnect hoses, valves or fittings from the cylinders, make sure to relieve all hydraulic pressure before service.

6) Once pressure is relieved, make sure hoses, valves and fittings are re-tightened. Fully Hydraulic Toggle Electrical Schematic

1) Retract cylinders to the maximum CSS.

.

Figure 7 - 23 Fully Hydraulic Toggle Plate-Type Electrical Controls Schematic


7-24



Fully Hydraulic Toggle Hydraulic Schematic .

DT4 B2

DT3

A2 21.1 A1 DT1

DT2 B1

14

20

23

17

13MPa 33

16

19

32

24MPa

13

18

22

21.2

DT6 B3

A3 DT5

PI DPI1 26

15 12

24. 1

25.1

27.2

27.1

24.2

8MPa 29.2

29.1

D

7

25.2

8

28

31 30.1

PDS1

3, 4, 5, 6

9 Rod Side Chamber Pressure: 35-210Bar

10

Max. Pressure 25MPa, adjust as need

30.2

ST1

ST2

Piston Side Chamber Pressure: 55-315Bar

11

1, 2

Specifications: 1. Rated Pressure: 25MPa 2. Rated Flow: 36L/min 3. Operation Voltage: 24V DC 4. Operation Hydraulic Oil Temp. : 60±5 °C 5. Filtration: 10μm 6. Tank Volume: 240L 7. Motor: 18.5 kW, 575V AC, 60HZ

1 2 3 4 5 6 7 8 9 101112-

Reservoir Cabinet Pump Motor Mount Pump Coupling Gear Pump Pump Drive Motor Hose Oil Return Filter Reservoir Breather Cap Oil Level Gauge Ball Valve Valve Manifold

131415161718192021222324-

Relief Valve Solenoid Valve Fitting Gauge Hose Pressure Gauge Manual Relief Valve Relief Valve Hydraulic Lock Solenoid Valve Hose Accumulator Hose

252627282930-

Tension Cylinder Bi-directional Hydraulic Lock Hose Valve Manifold Unidirectional Sequence Valve Toggle Cylinder (with Displacement Sensor) 31- Hose 32- Pressure Sensor 33- Check Valve

Figure 7 - 24 Fully Hydraulic Toggle Plate-Type Hydraulic Controls Schematic


7-25


Operation & Maintenance Manual Jaw Die Lifting Tools

Jaw Die Lifting Tools For replacement or rotating jaw dies, it will be necessary to have a sufficient lifting tool attached to the dies. Trio manufactures its jaw dies with wedge slots in each end to facilitate this lifting. The following drawings give general illustrations as to these lifting tool attachments. See (Figure 7 - 25) and (Figure 7 - 26)

1 - Lifting Eye 2 - Steel Plate 3 - Wedge-Shaped Steel Block 4 - Tack Weld Area

1 2 3

These tools may be fabricated locally. Contact Trio for details regarding the lifting tools for your specific size machine. 1 - Lifting Eye 2 - Steel Plate 3 - Wedge-Shaped Steel Block 4 - Tack Weld Area

1 2 3

4

Figure 7 - 26 Typical Swing Jaw Die Lifting Tool Arrangement

4

Figure 7 - 25 Typical Stationary Jaw Die Lifting Tool Arrangement


7-26


Operation & Maintenance Manual Jaw Die Lifting Tools

Make sure wedge-shaped steel blocks are made from at least 1 inch (25 mm) thick steel and lifting eyes are large enough to hold the weight of the jaw die. The wedge-shaped steel blocks must be drilled and tapped to accept the size threads of the lifting eye used.

WARNING When welding mild steel to manganese jaw dies or cheek plates, proper welding procedures and standards are to be observed (such as ASTM A128 / A128M). In particular, use a stainless 310 welding (orin equivalent), 5/32a inch (3.97rod mm) diameter; make number of passes rather than one large pass; no pre-heating or afterwelding heating (keep welded surfaces below 500°F (260°C); follow all safety precautions when lifting.


7-27


Operation & Maintenance Manual Cheek Plates

Cheek Plates

Upper Cheek Plate Removal

The cheek plates, in addition to acting as wear liners for the crushing chamber, also hold the stationary jaw die in place on the frame by pressing on the sides of the die and holding it up tight against the frame.


If the crusher is left to operate with loose cheek plates, the stationary jaw will move, causing excessive wear on the jaw and frame as well as reducing the capacity of the crusher. To operate properly, the cheek plates should be driven down tight and the bolts be kept well tightened to hold them firmly against the sides of the frame and the stationary jaw. The crusher may have both upper cheek plates and one or more lower cheek plates while other crushers may have a single cheek plate on each side (depending upon the crusher size). Generally more wearing action occurs on the lower cheek plates and they will have to be replaced more often than the upper plates. Never allow the plates to become worn completely through or let wear take place on the crusher frame.

DANGER Failure to Lockout & Tagout will result in death or severe personal injury. 2) Install chains or slings to upper cheek plate using holes on the top of plate or, if no holes are present, fashion a hook and eye assembly to fasten to each plate. This may require welding a lifting hook or eye to the plate.

WARNING When welding mild steel to manganese jaw dies or cheek plates, proper welding procedures and standards are to be observed (such as ASTM A128 / A128M). In particular, use a stainless 310 welding rod (or equivalent), 5/32 inch (3.97 mm) in diameter; make a number of passes rather than one large pass; no pre-heating or afterwelding heating (keep welded surfaces below 500°F (260°C); follow all safety precautions when lifting.

CAUTION Caution should be used during the following procedures and proper personal protection equipment and tools are to be used to ensure personnel and equipment safety.

3) With a suitable lifting device, put slight tension on chains or slings to keep cheek plate in place. 4) Remove bolts from cheek plate.

Before replacement of cheek plates, it is best to adjust the machine to its most open adjustment setting as this will allow the most room to work.


7-28



5) Remove upper cheek plate from crusher frame. If it does not come free when bolts are removed, it may be necessary to strike the plate to jar it loose.

5) Remove lower cheek plate from crusher frame. If it does not come free when bolts are removed, it may be necessary to strike the plate to jar it loose.

6) Set upper cheek plate aside.

6) Set lower cheek plate aside.

7) Repeat above procedure to remove each upper plate.

7) Repeat above procedure to remove each lower plate.

Lower Cheek Plate Removal

Installation of Lower Cheek Plate

1) Once upper cheek plate is removed, fashion a hook and eye assembly to fasten to each lower cheek plate. This may require welding a lifting hook or eye to the plate.

Before installation of lower cheek plates into crusher, make sure stationary jaw die is aligned properly in the frame in relationship to swing jaw die. For installation of stationary jaw, see procedure in this section.

WARNING

1) Fashion a hook and eye assembly to fasten to each lower cheek plate. This may require welding a lifting hook or eye to the plate.

When welding mild steel to manganese jaw dies or cheek plates, proper welding procedures and standards are to be observed (such as ASTM A128 / A128M).

WARNING When

In particular, useequivalent), a stainless 5/32 310 welding rod (or inch (3.97 mm) in diameter; make a number of passes rather than one large pass; no pre-heating or afterwelding heating (keep welded surfaces below 500°F (260°C); follow all safety precautions when lifting.

welding

mild

steel

to

manganese jaw dies or cheek plates, proper welding procedures and standards are to be observed (such as ASTM A128 / A128M). In particular, use a stainless 310 welding rod (or equivalent), 5/32 inch (3.97 mm) in diameter; make a number of passes rather than one large pass; no pre-heating or afterwelding heating (keep welded surfaces below 500°F (260°C); follow all safety precautions when lifting.

2) Install chains or slings to lower cheek plate using the hook or eye assembly fastened to plate. 3) With a suitable lifting device, put slight tension on chains or slings to keep cheek plate in place.

2) Install chains or slings to lower cheek plate using the hook or eye assembly fastened to plate.

4) Remove bolts from cheek plate.


7-29



Installation of Upper Cheek Plate

3) With a suitable lifting device, lift cheek plate into place in crusher frame.

1) Install chains or slings to upper cheek plate using holes on the top.

4) Using a suitable driver and bar, drive plate into place tight up against jaw die.

2) With a suitable lifting device, lift cheek plate into place.

5) Install bolts and snug them up to keep plate in place.

3) Install bolts and snug them up to keep plate in place.

6) Using the same methods listed above, install remaining lower cheek plate. 7) When both side lower cheek plates are in place and tight against the stationary jaw die, tighten all bolts to the proper torque. 8) With both lower cheek plates in place, proceed to installation of upper cheek plates.

4) Using a suitable driver, drive plate into place tight up against jaw die. 5) Repeat above procedure to install each upper plate. 6) When both side upper cheek plates are in place and tight against the stationary jaw die, tighten all bolts to the proper torque. 7) When all cheek plates are in place and tight, remove crusher drive Lockout & Tagout.


7-30


Operation & Maintenance Manual Stationary Jaw Die

Tightening Cheek Plates

Cheek plates may become loose, permitting the stationary jaw die to move and cause wear to both the die and crusher frame. Check periodically to make sure the cheek plates are tight against the stationary jaw die. If the stationary jaw die moves during crushing operation, the cheek plates should be tightened. The following method permits tightening of the lower plates without removing

8) Using a suitable driver, drive upper plate down until very tight against the jaw die. 9) Tighten bolts on the upper cheek plate to the proper torque. 10) Repeat these steps for each side. 11) When all cheek plates are in place and tight, remove crusher drive Lockout & Tagout.

the upper plates.

Stationary Jaw Die


DANGER Failure to Lockout & Tagout will result in death or severe personal injury. 2) Loosen bolts on the upper cheek plates until they are loose enough to allow the plates to be lifted up.

The stationary jaw die is locked in a rigid position against the back of the crusher frame by the cheek plates and tapered wedges at the top of the crusher frame. See (Figure 7 - 27) The stationary jaw die may be reversed by rotating it top-to-bottom to gain additional wear life. The worn side of the jaw die must not be allowed to wear too thin as this will weaken that side of the die and could potentially cause damage to the crusher.

3) With a suitable lifting device, lift upper cheek plate approximately 1/2 inch (12.7 mm) and place a piece of steel plate or bar as a spacer between it and the lower cheek plate.

3

4) Loosen the lower cheek plate bolts slightly until they are snug, but not tight, and will allow the plate to be driven down.

2

5) Using a suitable driver, drive upper plate down until the lower plate is driven down very tight against the jaw die. 6) Tighten bolts on the lower cheek plate to the proper torque.

1 1 - Stationary Jaw Die 2 - Stationary Jaw Die Wedges

7) Remove the steel spacer from between the plates.

3 - Cheek Plates Figure 7 - 27 Typical Stationary Jaw Die & Wedge Arrangement


7-31



Stationary Jaw Die Removal

2) Cheek plates must be removed prior to removal of the stationary jaw die. See procedures in this section for removal.

WARNING

3) Fashion a hook and eye assembly to fasten to the top of the stationary jaw die. See jaw die lifting tool information in this section.

Failure to replace jaw dies when corrugations are worn or running crusher until die concave sections are worn will reduce capacity of the crusher. Jaw dies not replaced at

WARNING

the proper oftime can incause compaction material the crushing chamber and could result in premature bearing failure, excessive toggle plate breakage or other damage to crusher.

When welding mild steel to manganese jaw dies or cheek plates, proper welding procedures and standards are to be observed (such as ASTM A128 / A128M). In particular, use a stainless 310 welding rod (or equivalent), 5/32 inch (3.97 mm) in diameter; make a number of passes rather than one large pass; no pre-heating or afterwelding heating (keep welded surfaces below 500°F (260°C); follow all safety precautions when lifting.


4) Install chains or slings to stationary jaw die using the hook or eye assembly fastened to die. 5) With a suitable lifting device, put slight tension on chains or slings to keep jaw die in place.

Before replacement of the stationary jaw die, it is best to adjust the machine to its most open adjustment setting as this will allow the most room to work.

6) Loosen stationary jaw die wedge bolts and hammer wedges toward center of crusher frame to loosen the die.


DANGER

7) Lower slightly the jaw die and move it toward the pitman until it clears the crusher frame.



8) Lift the stationary jaw die out of the crusher frame and set aside.

7-32



9) Remove the hook or eye assembly fastened to the jaw die.

3) Lift the jaw die enough to slide stationary jaw die top over the wedges and so the bottom of jaw die is up tight and seated on bottom of crusher frame.

Stationary Jaw Die Rotation or Replacement

If stationary jaw die has enough wear life left to accommodate rotating it, the hook or eye assembly removed from it as described above should be attached to the opposite end at the top. Use the same steps also described above to fasten the hook or eye assembly to the jaw die. If stationary jaw die is to be replaced with a new one, use the same steps also described above to fasten the hook or eye assembly to the top of jaw die. Both the back of the jaw die and the mating surface of the crusher frame must be clean and free of debris before installation into crusher. Stationary Jaw Die Installation

4) Tighten wedge bolts on each side evenly just enough to hold jaw die fully seated along the bottom edge of crusher frame while making sure the die is centered in the crusher frame. 5) Cheek plates can now be re-installed in the crusher frame per procedures outlined in this section. 6) Wedge bolts on each side can now be fully tightened. 7) Check to make sure the bottom of the stationary jaw die has remained fully seated along the bottom edge of the crusher frame. 8) Once jaw die and cheek plates are in place, remove the Lockout & Tagout.

1) Install chains or slings to stationary jaw die using the hook or eye assembly fastened to die. 2) With a suitable lifting device, lift jaw die into crusher frame and lower it until the bottom of the die slides over the bottom of the crusher frame.


7-33


Operation & Maintenance Manual Swing Jaw Die

Swing Jaw Die

Swing Jaw Die Removal

The swing jaw die is held in position against the face of the pitman by the swing jaw wedges bolted through at the upper end of the pitman.See(Figure 7 - 28) There may be two types of pitman design, one which has a replaceable lower wedge bolted to the pitman or the wedge area machined into the pitman itself. The swing jaw die may be reversed by rotating it top-to-bottom to gain additional wear life. The worn side of the jaw die must not be allowed to wear too thin as this will weaken that side of the die and could potentially cause damage to the crusher. 3

WARNING Failure to replace jaw dies when corrugations are worn or running crusher until die concave sections are worn will reduce capacity of the crusher. Jaw dies not replaced at the proper oftime can incause compaction material the crushing chamber and could result in premature bearing failure, excessive toggle plate breakage or other damage to crusher.


2 1 1 - Swing Jaw Die 2 - Swing Jaw Die Wedges 3 - Swing Jaw Bolts

Pitman Design Types

Figure 7 - 28 Typical Swing Jaw Die & Wedge Arrangement


7-34



3) Install chains or slings to swing jaw die using the hook or eye assembly fastened to die. 4) With a suitable lifting device, put slight tension on chains or slings to keep jaw die in place.

Before replacement of the swing jaw die, it is best to adjust the machine to its most open adjustment setting as this will allow the most room to work.

5) Remove jaw die wedge bolts from through the pitman and remove the jaw die wedge block(s).


DANGER

DANGER


Care must be taken to stay clear of inside of crusher while performing jaw die replacement as falling jaw die will result in death or severe personal injury.

2) Fashion a hook and eye assembly to fasten to the top of the swing jaw die. See jaw die lifting tool information in this section.

6) Lift the swing jaw die up off the pitman and out of the crusher frame and set aside.

WARNING When

welding

mild

steel

7) Remove the hook or eye assembly fastened to the jaw die.

to

manganese jaw dies or cheek plates, proper welding procedures and standards are to be observed (such as ASTM A128 / A128M). In particular, use a stainless 310 welding rod (or equivalent), 5/32 inch (3.97 mm) in diameter; make a number of passes rather than one large pass; no pre-heating or afterwelding heating (keep welded surfaces below 500°F (260°C); follow all safety precautions when lifting.


7-35



Swing Jaw Die Rotation or Replacement

Check & Tighten Jaw Dies

If swing jaw die has enough wear life left to accommodate rotating it, the hook or eye assembly removed from it as described above should be attached to the opposite end at the top. Use the same steps also described above to fasten the hook or eye assembly to the jaw die.

Both the stationary and swing jaw dies should be checked periodically to make sure they are kept tight within the crusher.

If swing jaw die is to be replaced with a new one, use the same steps also described above to fasten the hook or eye assembly to the top of jaw die. Both the back of the jaw die and the mating surface of the pitman must be clean and free of debris before installation into crusher.

In addition to making sure the stationary jaw die wedges are kept tight, the cheek plates must be kept tight as well as described above in this section. The wedge bolts should be checked daily after a new die is installed due to the die stretching. The swing jaw die wedge bolts have spring washers installed to prevent the bolts from breaking when the new die stretches. The bolts should also be checked for tightness.

Swing Jaw Die Installation

1 1) Install chains or slings to swing jaw die using the hook or eye assembly fastened to die.

2

2) With a suitable lifting device, lift jaw die into crusher frame and lower it until the bottom of the die slides over the bottom seating area of the pitman. 3) Center the jaw die on the pitman.

3 1 - Wedge Block 2 - Retaining Bolt 3 - Spring Washers

4) Install the jaw die wedge block(s) and the retaining bolts with spring washers through the pitman and tighten to proper torque. See (Figure 7 - 29) 5) Remove the hook or eye assembly fastened to the jaw die.

Figure 7 - 29 Typical Swing Jaw Die Retaining Bolt Arrangement

Re-adjust Crusher Setting

6) Once jaw die is in place, remove the Lockout & Tagout.

Once all jaw dies and/or cheek plates have been replaced or rotated and tightened, then crusher closed side setting should be re-adjusted to the desired setting.


7-36


Operation & Maintenance Manual Toggle Plate

Toggle Plate

Toggle Plate Removal

The pitman is protected from damage by the toggle plate. See (Figure 7 - 30) The toggle plate is intended to bend or fracture if an uncrushable object enters the crushing chamber, and thus opens the chamber allowing theobject to pass through. If the toggle plate becomes damaged or wears out at the seat areas, it will be necessary to replace it.

CAUTION Caution should be used during the following procedures and proper personal protection equipment and tools are to be used to ensure personnel and equipment safety. 1) Lockout & Tagout crusher drive.


DANGER 3

2

Care must be taken to stay clear of inside of crusher as well as underneath the crusher while performing toggle plate replacement as falling plate will result in death or severe personal injury.

1

2) Install chains or slings through toggle plate and run up the back side of the pitman to support toggle plate. See (Figure 7 - 31)

1 - Tension Rod Spring 2 - Tension Rod 3 - Toggle Plate Figure 7 - 30 Typical Jaw Tension Rod &Toggle Plate Arrangement

3) Loosen tension rod springs completely and remove tension rods, springs and nuts from machine. 4) Install chains or slings to pitman at the tension rod connection point. 5) Move crusher adjustment wedges to maximum possible open setting.


7-37



6) With a suitable lifting device, put slight tension on chains or slings to hold toggle plate in place.

Hold & Lower Toggle Plate

7) With a suitable device, pull pitman forward and hold in place until toggle plate canbe lowered free from seats. 8) Lower toggle out of frame of machine until it can safely be handled and set aside.

Pull Pitman Forward Figure 7 - 31 Toggle Plate Removal


7-38



Toggle Plate Installation

2) Maintain the installed chains or slings to pitman at the tension rod connection point as in the removal procedure.

CAUTION

3) Place new toggle plate in an area close enough so it can be lifted up into machine frame.

Caution should be used during the following procedures and proper personal protection equipment and tools are to be used to ensure personnel and equipment safety.

4) Install chains or slings through toggle plate and run up the back side of the pitman to support toggle plate. See (Figure 7 - 31)


5) With a suitable lifting device, lift toggle plate into place taking care it is completely engaged into upper seat in the frame.


6) With toggle plate fitted into upper seat, slowly release pitman and allow it to move backward to engage toggle plate into the lower seat. 7) Remove chains or slings from tension rod attachment points.

DANGER

8) Install tension rods, springs and nuts back onto machine.

Care must be taken to stay clear of inside of crusher as well as underneath the crusher while performing toggle plate replacement as falling plate will result in death or severe personal injury.


9) Re-adjust crusher to desired closed side setting and re-set tension rod spring tension. 10) Finally, finish byremoving Lockout & Tagout of crusher drive.

7-39


Operation & Maintenance Manual Jaw Bearings

Jaw Bearings

Frame Bearing Removal

The jaw crusher is equipped with double row, spherical roller, self-aligning bearings. Both frame and pitman bearings are protected against loss of lubricant and entrance of dirt, sand and grit by labyrinth-type grease seals.

When bearings are determined to need replacement, it is recommended to remove as much of the lubricant from the bearing housings by draining them while still warm from operation. The following procedures should then be followed:

12

11

10 7 8

CAUTION

9 16

15

17 Caution should be used during the following procedures and proper personal protection equipment and tools are to be used to ensure personnel and equipment safety. 1) Lockout & Tagout crusher drive.

2

DANGER

3 Failure to Lockout & Tagout will result in death or severe personal injury.

4

13 14

6 5

DANGER

1

123456789-

Flywheel/Drive Sheave Outside Seal Lock Nut Lock Washer Frame Bearing Housing Crusher Frame Frame Bearing Withdrawl Sleeve Frame Bearing Cover

1011121314151617-

Care must be taken to stay clear of inside of crusher as well as underneath the crusher while performing bearing replacement as falling parts will result in death or severe personal injury.

Pitman Seal Pitman Bearing Cover Pitman Bearing Grease Keeper Pitman Pitman Shaft Ringfeder Pitman Cover

2) Mark the flywheel/drive sheave and pitman shaft so it can be re-installed in the same location.

Figure 7 - 32 Typical Jaw Bearing Arrangement


3) Install appropriate lifting slings and use an adequate lifting device to support flywheel/ drive sheave.

7-40



4) Remove pitman shaft cover and remove ringfeder that retains flywheel/drive sheave to pitman shaft. See (Figure 7 - 32) 5) Remove flywheel/drive sheave from shaft and set aside. 6) Slide outside seal and key off of pitman shaft and set aside. 7) Remove the frame bearing cover from the frame bearing housing andset aside. This will expose the bearing lock nut and lock washer that retains the frame bearing to the pitman shaft.

12) Using a spanner wrench or suitable special tool, tighten the withdrawl nut against the frame bearing to force the withdrawl sleeve from between the pitman shaft and frame bearing inner race. Remove the sleeve and nut and set aside. 13) With adequate lifting device and slings to support the frame bearing housing, slide the bearing housing with the bearing out off of the pitman shaft. 14) The frame bearing will now be able to be removed from the housing. 15) Place the frame bearing housing on suitable blocking and push bearing out of housing using a press, dead blow hammer or other appropriate driver. See (Figure 7 - 33)

8) The pitman housing should now be supported by an adequate method of blocking or lifting so the pitman shaft will not drop or lower during the next steps. 9) Once the pitman is supported, remove the bolts holding the frame bearing housing to the crusher frame. 10) Straighten the lock washer tab(s) on the bearing lock nut then remove the nut and washer with a spanner wrench or suitable special tool. 11) Install a withdrawl nut (not shown) onto the withdrawl sleeve on the frame bearing.

Figure 7 - 33 Frame Bearing Removal From Housing

16) Clean and inspect all parts to replace as necessary.


7-41



Frame Bearing Installation

Replacement with a new bearing requires determining the bearing’s unmounted radial internal clearance before installation. See (Figure 7 - 34) This clearance measurement should be taken and recorded to be referenced later when setting bearing final clearance after mounting in crusher.

Feeler Gauge Blade

4) Install the withdrawl sleeve onto pitman shaft and slide it into bearing inner race as far as possible. 5) At this time, install the lock nut without the lock washer and screw the nut up snug against the withdrawl sleeve. 6) Using a spanner wrench or suitable special tool, tighten the lock nut against the withdrawl sleeve until the final bearing clearance measurement is reached. See the following tables for reduction in unmounted clearance as well as the final mounted clearance listed by machine model.

Internal Clearance

Table 7 - 3 Frame Bearing Reduction in Radial Internal Clearance Jaw Model

Figure 7 - 34 Jaw Bearing Radial Internal Clearance Measurement

1) After recording unmounted bearing radial internal clearance described above, install bearing into frame bearing housing. 2) With adequate lifting device and slings to support the frame bearing housing, slide the bearing housing with the bearing onto the pitman shaft taking care that labyrinth seal fingers are aligned and slide toghether with no interference. 3) Bolt frame bearing housing securely to crusher frame and tighten bolts.


7-42

Min.

Max.

mm

i n.

mm

in.

CT1030

0.08

0.0031

0.11

0.0043

CT1040

0.08

0.0031

0.11

0.0043

CT1048

0.09

0.0035

0.13

0.0051

CT1252

0.10

0.0039

0.14

0.0055

CT2036

0.10

0.0039

0.14

0.0055

CT2436

0.11

0.0043

0.15

0.0059

CT2645

0.11

0.0043

0.15

0.0059

CT3042

0.15

0.0059

0.21

0.0083

NCT3042

0.12

0.0047

0.17

0.0067

CT3254

0.15

0.0059

0.21

0.0083

CT3648

0.17

0.0067

0.23

0.0091

CT4254

0.17

0.0067

0.23

0.0091

CT4763

0.21

0.0083

0.28

0.0110

CT6080

0.21

0.0083

0.28

0.0110



9) Re-check the bearing mounted clearance again to make sure the proper clearance was Table 7 - 4 Frame Bearing Allowable Final Mounted maintained. Clearance Jaw Model

Min.

10) Install the frame bearing cover and tighten bolts to secure it to the frame bearing housing.

Max.

mm

in.

mm

in.

CT1030

0.10

0.0040

0.18

0.0071

CT1040

0.10

0.0040

0.18

0.0071

CT1048

0.10

0.0040

0.20

0.0079

CT1252

0.12

0.0045

0.22

0.0087

CT2036

0.12

0.0045

0.22

0.0087

CT2436

0.13

0.0050

0.24

0.0094

CT2645

0.13

0.0050

0.24

0.0094

CT3042

0.17

0.0065

0.32

0.0126

NCT3042

0.14

0.0055

0.27

0.0106

CT3254

0.17

0.0065

0.32

0.0126

CT3648

0.19

0.0075

0.35

0.0138

CT4254

0.19

0.0075

0.35

0.0138

CT4763

0.23

0.0090

0.42

0.0165

CT6080

0.23

0.0090

0.42

0.0165

Example: Model CT1030 Unmounted clearance = 0.010 in. Minus max. reduction = 0.0043 in. Equals - 0.0057 in. This falls within the min. of 0.0040 in. and the max. of 0.0071 in.

11) Install the outside seal and key onto the pitman shaft making sure the labyrinth seal fingers are aligned and slide together with no interference. 12) Using appropriate lifting slings and an adequate lifting device, re-install the flywheel/ drive sheave and ringfeder onto the pitman shaft using the marks made during disassembly. 13) Re-tighten the ringfeder to lock the flywheel/ drive sheave onto the pitman shaft. 14) Re-install the pitman cover on the end of the shaft and tighten bolts. 15) Remove blocking or supports from under the pitman used to hold it in place. 16) Replenish grease into the bearing and seals using the appropriate quantity as described in the tables in the Lubrication Section of this manual. 17) Remove the Lockout & Tagout from the crusher drive. Crusher should now be ready to re-start.

6) Once the bearing clearance has been reached, remove lock nut, install the lock washer and lock nut back on shaft.

7) Re-tighten lock nut. 8) Bend a tab of the lock washer into one of the slots in the lock nut.


7-43



Pitman Bearing Removal

To remove and replace pitman bearings it will be necessary to remove the pitman and shaft assembly from the crusher frame. When bearings are determined to need replacement, it is recommended to remove as much of the lubricant from the bearing housings by draining them while still warm from operation. The following procedures should then be followed:

3) Mark the flywheel/drive sheave and pitman shaft so it can be re-installed in the same location. 4) Install appropriate lifting slings and use an adequate lifting device to support flywheel/ drive sheave. 5) Remove pitman shaft cover and remove ringfeder that retains flywheel/drive sheave to pitman shaft. See (Figure 7 - 32)


6) Remove flywheel/drive sheave from shaft and set aside. 7) Slide outside seal and key off of pitman shaft and set aside.


8) Repeat this for the opposite side flywheel/ drive sheave so that both sides have been removed.


9) Install appropriate lifting slings and use an adequate lifting device to support the entire pitman and shaft assembly. 10) Once the pitman and shaft assembly is supported, remove the bolts holding both side frame bearing housings to the crusher frame.

DANGER Care must be taken to stay clear of inside of crusher as well as underneath the crusher while performing bearing replacement as falling parts will result in death or severe personal injury.


2) Using the procedure shown earlier in this section, remove the toggle plate from the crusher.

11) Once the bolts are removed, lift the pitman and shaft assembly from the crusher frame. See (Figure 7 - 35)

7-44



16) Remove bolts from both pitman bearing covers, remove coversand set aside. See (Figure 7 - 37)

Figure 7 - 35 Pitman and Shaft Assembly Removal From Crusher Frame

12) Lift pitman and shaft assembly and place it onto cribbing or platform on the ground. See (Figure 7 - 36)

Figure 7 - 37 Pitman Bearing Covers

17) Next, support pitman shaft at outer ends and fasten slings from a suitable lifting device. 18) While supported, press shaft with bearings through and out of the bore of the pitman housing. See (Figure 7 - 38)

Figure 7 - 36 Pitman and Shaft Assembly Placed on Ground

13) The frame bearings and housings will now be able to be removed from the pitman shaft using the procedure found earlier in this section. 14) Once the frame bearings and housings are removed from the shaft, proceed to the next steps to remove the shaft with bearings from the pitman housing. 15) Remove pitman seals from the shaft. Figure 7 - 38 Pitman Shaft and Bearings Being Pressed from Housing


7-45



Pitman Bearing Installation

19) Place shaft with bearings onto suitable cribbing or platform supported at the outer ends of the shaft. See (Figure 7 - 39)

Replacement with a new bearing requires determining the bearing’s unmounted radial internal clearance before installation. See (Figure 7 - 41) This clearance measurement should be taken and recorded to be referenced later when checking bearing final clearance after mounting in the pitman housing. Thoroughly clean the pitman housing, shaft and all parts that are to be re-used.

Figure 7 - 39 Pitman Shaft and Bearings Removed from Housing

20) Press or pull each bearing and grease keeper from shaft while maintaining support on the shaft. See (Figure 7 - 40)

Feeler Gauge Blade

Internal Clearance

Figure 7 - 40 Pitman Shaft Bearings Being Pressed Off Shaft

21) To fully remove each bearing and grease keeper from the shaft, it will be necessary to lift each end of the shaft from its support so bearings and grease keepers can be slid off shaft.


Figure 7 - 41 Jaw Bearing Radial Internal Clearance Measurement

7-46



1) Lift and slide grease keepers onto shaft making sure they seat fully against the machined surfaces of the shaft. See (Figure 7 - 42)

Figure 7 - 43 Pitman Shaft Bearings On Shaft

4) With adequate lifting device and slings lift the shaft assembly and start the bearing into the pitman housing bore, making sure it is square with the face of the pitman housing.

Figure 7 - 42 Pitman Shaft Grease Keepers On Shaft

2) Bearing installation onto the shaft will be easier if they are first heated to expand slightly. The bearings can be heated using several methods. One method is using an oil bath. Maximum temperature ofthe oil bath should not exceed 120° C (250° F).

5) Apply pressure on the shaft assembly and press it into the pitman housing until each bearing race is the same distance from the edge of the pitman housing. See (Figure 7 - 44)

Bearings should be allowed to heat long enough to fully expand. Do not allow bearings to come into direct contact with the heat source. 3) With adequate lifting device and slings lift each of the heated bearings into place against the grease keepers and hold them firmly in postition until they cool enough to seat on the shaft. See (Figure 7 - 43)

Figure 7 - 44 Pitman Shaft and Bearings Pressed into Housing


7-47



6) Measure each bearing’s internal installed clearance to assure that the bearings have the proper amount of clearance once installed. See (Table 7 - 5)

7) Using the proper type grease shown in the tables in the Lubrication Section of this manual, inject grease into the voids between the rollers in the bearing, making certain that it is forced into the center ofthe bearing. Note the amount of grease injected into each of the Table 7 - 5 Pitman Bearing Radial Internal Installed pitman bearings. Clearance Jaw Model

Min.

Max.

8) Install each side pitman bearing cover and torque bolts to proper torque. See (Figure 7 - 45)

CT1030

mm 0.20

in. 0.0079

mm 0.26

in. 0.0102

CT1040

0.20

0.0079

0.26

0.0102

CT1048

0.20

0.0079

0.26

0.0102

CT1252

0.22

0.0087

0.29

0.0114

CT2036

0.24

0.0094

0.32

0.0126

CT2436

0.26

0.0102

0.35

0.0138

CT2645

0.26

0.0102

0.35

0.0138

CT3042

0.31

0.0122

0.41

0.0161

NCT3042

0.26

0.0102

0.35

0.0138

CT3254 CT3648

0.31 0.34

0.0122 0.0134

0.41 0.45

0.0161 0.0177

CT4254

0.37

0.0146

0.50

0.0197

9) Re-install pitman seals onto shaft.

CT4763

0.41

0.0161

0.55

0.0217

CT6080

0.44

0.0173

0.60

0.0236

10) Re-install frame bearings onto shaft using procedures shown earlier in this section.


7-48

Figure 7 - 45 Pitman Bearing Covers Installed



11) Install appropriate lifting slings and use an adequate lifting device to support the entire pitman and shaft assembly.

13) Torque frame bearing housing boltsto proper torque. 14) Reinstall each side flywheel/drive sheave using the procedures shown earlier in this section.

12) Lift pitman and shaft assembly into crusher frame, align frame bearing housings with crusher frame and install bolts. See (Figure 7 - 46)

15) Reinstall toggle plate using the procedures shown earlier in this section. 16) Once pitman and shaft is re-assembled into the crusher, complete grease replenishment into each pitman and frame bearing and seals using the quantities listed in the tables in the Lubrication Section ofthis manual. Take into consideration also the amount of grease put into each pitman bearing initially. 17) Remove the Lockout & Tagout from the crusher drive. Crusher should now be ready to re-start.

Figure 7 - 46 Pitman and Shaft Assembly Installed Into Crusher Frame


7-49




7-50


Operation & Maintenance Manual Torque Charts

Appendix A - Torque Specs Torque Charts The following pages contain charts for use as guides when tightening bolts and nuts. These specifications should be followed unless specific torques are given elsewhere in this manual.

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" applies to cadmium plating and/or application of thread lubricants. Hardened washers should always be used, regardless of whether standard nuts or lock nuts are employed. Metric Bolt Torque

Standard Bolt Torque

Table A - 1 is a list of recommended torque values for standard bolts. Use this torque chart to avoid overstressing standard nuts and bolts used on equipment. These specifications should be followed unless specific torques are given. Trio uses various bolts Grades 2, 5, and 8. The


A-1

Table A - 2 is a list of torque values recommended for metric bolts. The maximum torque values are based on 75% of the specified minimum proof strength. 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.



Standard Bolt Torque Chart S.A.EGrade2 dia. (in.)

Dr y pitch (thd/in.) (ft-lbs) N-M

S.A.EGrade5 Lube

S.A.EGrade8

Dr y

Lube

Dr y

Lube

(ft-lbs)

N- M

(ft-lbs)

N- M

(ft-lbs)

N-M

(ft-lbs)

N-M

(ft-lbs)

N- M

1/4

20

5

7

4

5

8

11

6

8

12

16

9

12

1/4

28

6

8

5

7

10

14

7

9

14

19

11

15

5/16

18

11

15

9

12

17

23

13

18

25

34

19

26

5/16

24

12

16

10

14

19

26

15

20

27

37

21

28

3/8

16

20

27

15

20

31

42

24

33

44

60

34

46

3/8 7/16

24 14

23 32

31 43

17 25

23 34

35 49

47 66

27 38

37 52

49 70

66 95

38 54

52 73

7/16

20

36

49

27

37

55

75

42

57

78

106

60

81

1/2

13

49

66

38

52

75

102

58

79

106

144

82

111

1/2

20

55

75

42

57

85

115

65

88

120

163

92

125

9/16

12

70

95

54

73

109

148

84

114

154

209

118

160

9/16

18

79

107

60

81

121

164

93

126

171

232

132

179

5/8

11

97

132

75

102

150

203

115

156

212

287

163

221

5/8

18

110

149

85

115

170

231

131

178

240

325

185

251

3/4

10

157

213

121

164

266

361

205

278

376

510

289

392

3/4

16

180

244

133

180

297

403

229

311

420

570

323

438

7/8

9

210

285

160

217

430

583

330

447

606

822

466

632

7/8

14

230

312

177

240

473

641

364

494

668

906

514

697

1

8

320

434

240

325

644

873

495

671

909

1233

699

948

1 1-1/8

14 7

340 350

461 475

255 270

346 366

704 794

955 1077

542 611

735 829

995 1288

1349 1747

765 990

1037 1342

1-1/8

12

395

536

305

414

891

1208

685

929

1445

1959

1111

1507

1-1/4

7

495

671

380

515

1120

1519

862

1169

1817

2464

1398

1896

1-1/4

12

550

746

425

576

1241

1683

954

1294

2012

2728

1548

2099

1-3/8

6

655

888

500

678

1469

1992

1130

1532

2382

3230

1832

2484

1-3/8

12

745

1010

570

773

1673

2269

1287

1745

2712

3677

2086

2829

1-1/2

6

865

1173

665

902

1949

2643

1500

2034

3161

4286

2432

3298

1-1/2

12

975

1322

750

1017

2194

2975

1687

2288

3557

4823

2736

3710

1-3/4

5

1370

1857

1055

1430

2286

3100

1758

2384

4988

6764

3837

5203

2

4.5

2060

2793

1585

2149

3438

4662

2644

3585

7500

10170

5769

7823

2-1/4

4.5

3015

4088

2320

3146

5027

6817

3867

5244

10969 14874

8438

11442

2-1/2

4

4125

5593

3170

4298

6875

9323

5288

7171

15000 20340 11538 15646

2-3/4

4

5590

7579

4300

5830

9321

12639

7170

9723

17794 24129 13688 18561

3

4

7385

10013

5680

7701

12313 16696

9472

12844 23507 31875 18082 24519

Table A - 1: Torque Values for Standard Hardware


A-2



Metric Bolt Torque Chart Property Class = 8.8 Dr y dia pitch (mm) (mm) (ft-lbs) N-M 6 8

Property Class = 10.9

Lube

Dr y

Property Class = 12.9

Lube

Dr y

Lube

(ft-lbs)

N- M

(ft-lbs)

N-M

(ft-lbs)

N-M

(ft-lbs)

N- M

(ft-lbs)

N- M

6.9

9.3

5.2

7

9.7

13.2

7.3

9.9

11.6

15.7

8.7

11.8

17.7

23.9

13.3

18

24.9

33.8

18.7

25.4

29.8

40.4

22.4

30.4

10

1.5

30

41

24

32

44

60

34

46

52

71

40

54

10

1.25

32

43

24

33

46

63

36

49

55

74

42

57

12

1.75

53

72

41

55

77

105

60

81

91

123

70

95

12 14

1.25 2

58 85

78 115

44 65

60 88

85 124

115 168

65 95

88 129

99 145

134 196

76 111

103 151

14

1.5

91

124

70

95

134

181

103

139

156

212

120

163

16

2

131

178

101

137

192

260

148

200

225

305

173

234

16

1.5

140

190

108

146

204

277

157

213

240

325

184

250

18

2.50

181

246

139

189

265

359

204

276

311

421

239

324

18

1.5

204

276

156

212

297

403

229

310

349

473

268

364

20

2.5

256

347

197

267

374

507

288

390

439

595

338

458

20

1.5

284

385

218

296

415

563

319

433

487

660

375

508

22

2.5

349

473

268

364

510

692

392

532

599

812

460

624

22

1.5

383

519

294

399

560

759

431

584

657

891

505

685

24

3

443

600

340

461

647

877

497

674

759

1029

583

791

24

2

482

654

371

503

705

956

543

736

828

1122

637

863

27

3

648

879

499

676

949

1286

729

989

1112

1508

856

1160

27 30

2

700 985

949 1335

538 741

730 1004

1023 1389

1387 1883

787 1044

1067 1416

1200 1665

1627 2257

923 1252

1252 1697

36

1716

2326

1290

1749

2419

3280

1819

2466

2900

3931

2180

2956

42

2753

3732

2070

2806

3882

5263

2919

3957

4652

6307

3498

4742

48

4156

5634

3124

4236

5860

7944

4406

5973

7023

9521

5280

7159

56

6662

9032

5009

6791

9393

12735

7063

9575

11259 15264

8465

11477

64

9954

13496

7484

10147 14035 19028 10553 14307 16822 22807 12648 17148

72

14410 19536 10835 14689 20319 27547 15277 20712 24353 33016 18310 24824 Table A - 2: Torque Values for Metric Hardware


A-3





A-4


Operation & Maintenance Manual General Belt Care

Appendix B - V-Belt Drive Information

5) Do not overtighten belts. Overtightening shortens the useful life of belts and sheaves. This can also cause premature bearing failures. Ideal belt tension is the lowest at which belts won’t slip under peak loads.

General Belt Care V-belts achieve more service life if kept clean and dry. Rock dust and rust from metals are abrasive. Oils and acids deteriorate belt material. Dust and moisture on beltscan cause slippage. Dust buildup in sheaves can cause harmful vibration. Belt dressing compounds are available and are sometimes used for various reasons. While they may be used, belt dressing may actually shorten belt life. Clean, well cared for belts are the best way to care for belt problems. Daily cleaning of belts and sheaves by blowing them off with compressed air can increase their useful life.

6) Periodically inspect v-belt drives for wear on belts or sheaves. See (Figure B - 1) and (Figure B - 2) Replace worn sheaves. Worn Sheave

Worn Belt or Sheave

Normal

Store un-used belts in a cool and dry environment with no direct sunlight. Store on shelves or in srcinal containers. Do not allow belts to be bent to diameters smaller that what is recommended for the belt cross section. Figure B - 1 Typical Belt & Sheave Wear

General Belt Recommendations 1) Keep belts and sheaves clean. 2) Avoid belt or sheave rubbing. Don’t let belts or sheaves rub against a guard (or anything else) while they are running. 3) Drive belts with motors mounted on adjustable bases. This allows convenient and proper installation of belts without prying on belts. 4) Keep belts properly tightened. Most belt stretch occurs in the first 30-40 hours of operation. Check belt tension frequently during this period.


Figure B - 2 Sheave Gauge Shows Wear

B-1


Operation & Maintenance Manual Belt Drive Troubleshooting

7) Keep belts straight. Don’t allow v-belts to run out of alignment. To run properly, sheaves must be parallel and grooves must be in line. See (Figure B - 3)

8) If a drive uses multiple belts, use only matched belts. A matched set of belts last longer and loading is evenly divided among all the belts. Belts from different manufacturers should not be mixed in a set because material differences could reduce belt life. Always replace belts in full sets. 9) Don’t overload belts. If the drive has 10 sheave grooves, use 10 belts. Using less than the designed number puts stress on the remaining ones. This can cause premature failure.

Belt Drive Troubleshooting Good maintenance practices should help you experience minimal trouble with belts and sheaves, however there may be times when troubles are experienced. The following table can be used as a troubleshooting tool. Figure B - 3 Sheave Alignment


B-2


Operation & Maintenance Manual Belt Drive Troubleshooting

Table B - 1 Belt Drive Troubleshooting Trouble Belt Slip (sidewalls glazed) Drive squeals

Belts roll over

Mismatched belts

Cause Insufficient tension


Replace belts; increase tension

Overloaded drive Arc of contact too short Heavy starting load

Find cause and correct Increase distance between hubs Increase tension

Broken cord caused by prying Overloaded drive Impulse loads

Replace belt correctly Redesign drive Apply proper tension

Misalignment Worn sheave grooves Flat idler sheave

Realign drive Replace sheave Align and reposition

Excessive vibration

Check drive design, mounting Consider banded belts

New belts installed with old

Replace belts with matched set

Sheave grooves worn unevenly Improper groove angle

Replace sheaves

Shafts not parallel

Align drive

Shock loads

Apply proper tension

Heavy starting load

Apply proper tension Use compensator starting

Belt pried over sheaves Foreign object in drive

Replace belt correctly Determine source of object, design guard to correct problem

Sheave grooves worn Sheave diameter too small Mismatched belts Drive overloaded

Replace sheaves Redesign drive Replace with matched set Redesign drive

Belt slips Sheaves misaligned Oil present Excessive heat present

Increase tension Align sheaves Eliminate oil Ventilate drive

Belt breaks

Belt wears prematurely

Correction

B-3


Operation & Maintenance Manual Maintaining V-Belt Tension

Maintaining V-Belt Tension V-belt tension must be maintained to provide proper drive effectiveness. The following method of tensioning v-belts has been established as an acceptable and preferred method. Tension-Deflection Method

1) Place a straightedge across the top of both sheaves. See (Figure B - 4)

1/64 inch per each inch of span length. Example: For a 100 inch span, the deflection would be 100/64, or approximately 1-1/2 inches. 4) Compare the force measurement to the recommended ranges shown in(Table B - 2) below for the appropriate belt cross section type shown in. 5) Tighten or loosen belt to bring it into the recommended range.

2) Measure the span length.

6) When installing new belts, tighten them to “Initial Installation” tension. This tension will drop during the run-in period.

3) Using a spring scale at right angle to belt at 1/2 of span length, apply a force to the scale on one of the belts enough to deflect the belt

4

1 2 3

7

9

5

8 6

1 - Straightedge

5 - Motor Drive Sheave

2 - Span Length

6 - V-belt

3 - 1/2 Span

7 - Spring Scale

4 - Deflection Measurement - 1/64 Inch for each Inch of Span Length

8 - Force Measurement 9 - Driven Sheave

Figure B - 4 Tension-Deflection Diagram


B-4


Operation & Maintenance Manual Maintaining V-Belt Tension

Table B - 2 Belt Deflection Forces Recommended Belt Deflection Force (Pounds) V-Belt Cross Section

Smallest Sheave Diameter Range (Inches)

Initial Installation

A

- 3.0 3.1 - 4.0 4.1 - 5.0 5.1 -

B

Retensioning Maximum

Minimum

3.6 4.2 5.2 6.1

3.1 3.6 4.6 5.3

2.4 2.8 3.5 4.1

- 4.6 4.7 - 5.6 5.7 - 7.0 7.1 -

7.3 8.7 9.3 10.0

6.4 7.5 8.1 8.8

4.9 5.8 6.2 6.8

C

- 7.0 7.1 - 9.0 9.1 - 12.0 12.1 -

12.5 15.0 18.0 19.5

10.7 13.0 16.3 16.9

8.2 10.0 12.5 13.0

D

12.0 - 13.0 13.1 - 15.5 15.6 - 22.0

25.5* 30.0* 32.0*

22.1 26.0* 28.0*

17.0 20.0 21.5

E

18.0 - 22.0 22.1 -

45.0* 52.5*

39.0* 45.5*

30.0* 35.0*

AX

- 3.0 3.1 - 4.0 4.1 - 5.0 5.1 -

5.1 5.5 6.0 6.7

4.4 4.8 5.2 5.9

3.4 3.7 4.0 4.5

- 4.6 4.7 - 5.6 5.7 - 7.0

10.0 11.0 11.5

8.7 9.5 9.9

6.7 7.3 7.6

7.1 - 12.0

10.1

7.8

CX

- 7.0 7.1 - 9.0 9.1 - 12.0 12.1 -

18.0 19.5 20.0 21.0

15.6 16.9 17.6 18.2

12.0 13.0 13.5 14.0

3V

2.65 - 3.35 3.65 - 4.50 4.75 - 6.0 6.5 - 10.6

4.6 5.5 6.4 7.3

4.0 4.8 5.6 6.4

3.1 3.7 4.3 4.9

5V

7.1 - 10.3 10.9 - 11.8 12.5 - 16.0

16.5 19.5 21.0

14.3 16.9 18.2

11.0 13.0 14.0

8V

12.5 - 16.0 17.0 - 20.0 21.2 - 24.4

39.0* 45.0* 51.0*

33.8* 39.0* 44.2*

26.0* 30.0* 34.0*

3VX

2.2 - 2.5 2.65 - 4.75 5.0 - 6.5 6.9 -

4.8 5.7 7.2 8.7

4.2 4.9 6.2 7.5

3.2 3.8 4.8 5.8

5VX

5.9- 5.5 - 8.0 8.5 - 10.9 11.8 -

15.0 19.0 21.0 22.0

13.0 16.9 18.2 19.5

10.0 13.0 14.0 15.0

BX

* Note: For banded belts, multiply the force in table by the number of belts in the band.


B-5


Operation & Maintenance Manual Belt Type Cross-Sections

Belt Type Cross-Sections

Backside Idler

A backside idler increases the arc of contact on both sheaves. However, it forces a backward bend in the v-belt that can contribute to premature failure. The idler puts additional stress on the bottom portion of the belt which will result in bottom cracking. If a backside idler mustbe used, the diameter should be at least 1 - 1/2 times the diameter of the small sheave. It should also be located as close as possible to the small sheave.

Figure B - 5 Belt Type Cross-Sections Figure B - 7 Backside Idler

Belt Idlers

Kiss Idler

A properly designed v-belt drive does not require and idler to deliver full horsepower if proper belt tension can be maintained. Idlers should be avoided if possible because it puts additional bending stress points on the belt. Due to drive design parameters, idlers aresometimes used. The following are general descriptions of the types of idlers that may be used. Inside Idler

A v-grooved idler located on the inside of the belts on the slack side of drive would be recommended over a backside idler. The idler should be located near the large sheave to minimize reduction of the arc of contact on the small sheave. The diameter should be equal to or larger than that of the small sheave.

A kiss idler differs from the backside idler because the kiss idler does not penetrate the belt span and create a backward bend on the belt. A kiss idler does not contribute to premature belt failure. Use of a kiss help control beltand vibration and whip on idler drivescansubject to shock pulsating loads. If a kiss idler is used, the diameter should be at least 1 - 1/2 times the diameter of the small sheave.

Figure B - 8 Kiss Idler

Figure B - 6 Inside Idler


B-6


Trio Engineered Products, Inc. 12823 Schabarum Ave. Irwindal e, CA 



91706



Telephone 626-851-3966 Fax 626-851-9526 

CT Series 30” x42”A Jaw Crusher

Parts Manual

Size:

30″ x 42″

Serial Number:

CT3042-346-AU1078

2015.12.08 CT3042A Jaw Crusher Manual

1

Parts: Jaw Crusher(With Drive)

CT3042AJaw Crusher Manual

2

Parts List Item

Part #

Description

QTY. STOCK CODE

CT3042A-AU1078

30"×42" Jaw Crusher(With Drive)

1

C3042A.00

CT3042 Jaw Crusher Assembly

1

101711000

2

T7510-1

Fixed Jaw Die

1

301701053

3

T7510-6

Swing Jaw Die

1

301701058

4

C3042FHZ.3

Guard For Sheave

1

301711008

5

C3042FHZ.4

Guard For Flywheel

1

301711009

6

GB13575.2

V-Belt 25N 6980mm

7

424001185

7

NEP447T-6

Motor 150HP/460V/60HZ +5000m

1

421300032

8

GB5782-zn/M20×90/GD8.8

Bolt M20×90

4

401022055

9

GB93/20

Lock Washer 20

4

403015010

10

GB97.1/20

Washer 20

4

403020008

11

GB6170-zn/M20/GD8

Nut M20

4

402011006

12

CMS132A.2

Motor Mount

1

101750074

13

CT.APP.WEG.6

Hydraulic Unit

1

102000251

14

T7510P-2

Drive Sheave

1

101750013

15

T7510P-3

Bushing

1

101750014

16

GB5782-zn /M16×220/GD8.8

Bolt M16×220

3

401022090

17

GB93/16

Lock Washer 16

3

403015008


3

Parts: Tension Rod and Toggle Plate Assembly Illustration The following illustration identifies the essential parts comprising the tension rod and toggle seat assembly.

CT3042A Jaw Crusher Manual

4


5

Parts List Item

Part #

Description

QTY. STOCK CODE

41

T7510-15

Guard

1

101701070

42

GB5782-zn/M24×65/GD8.8

Bolt For Guard

2

401022098

43

GB7244/24

Lock Washer For Guard

2

403005005

44

T7510-29

Tension Rod

2

101701084

45

GB6170-zn/M48/GD8

Nut For Tension Rod

2

402011016

46

GB56-zn/M48/GD8

Nut For Tension Rod

2

402009010

47 48

T7510-30A T7510-31

Spring Keeper (Upper) Spring

2 2

101701086 301701087

49

T7510-32A

Spring Keeper (Lower)

2

101701089

52

C3042A-1

Buffer (Upper)

1

101711002

53

T7510-34A

Buffer Retainer For Buffer (Upper)

2

101701093

54

GB70.1-zn/M24×65/GD8.8

Bolt For Buffer (Upper)

2

405009056

55

T7510-35

Limit Plate

2

101701094

56

GB5782-zn/M16×45/GD8.8

Bolt M16×45

2

401022025

57

GB93/16

Lock Washer 16

2

403015008

58

T7510A-12

Rubber Dust Cover

1

101710004

59

T7510-14

Rubber Clamping For Rubber Dust Cover

1

101701069

60

GB5782-zn/M10×30/GD8.8

Bolt For Rubber Dust Cover

5

401022143

61

GB93/10

Lock Washer For Rubber Dust Cover

5

403015005

62 63

T7510-38 1380-49

Pin Shaft For Tension Rod Washer

2 2

301701097 301301146

64

GB91-zn/Ø8×70

Split Cotter For Tension Rod

2

410011026

65

T7510-11B

Toggle Plate

1

101701066

102

T7510-36

Rubber Dust Apron

1

101701095

103

T7510-37

Clamping Plate For Rubber Dust Apron

1

101701096

104

GB93/10

Lock Washer For Rubber Dust Apron

4

403015005

105

GB5782-zn/M10×30/GD8.8

Bolt For Rubber Dust Apron

4

401022143

106

C3042A.DE-1

Buffer (Lower)

1

101711003

107

T7510.6-2

Buffer Retainer For Buffer (Lower)

2

101701048

108

GB70.1-zn/M10×25/GD8.8

Bolt M10×25

4

405011006


6

Parts: Bearings and Eccentric Shaft Assembly Illustration The following illustrations identify the essential parts of the bearing and eccentric shaft assembly.


7

Parts List Item 12 13 14 15 16 17 18 19 20 21 22 23 24 25 69 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 (86) 99 100 101

Part # T7510A.3 T7510.4A T7510-16 GB1972/A80-2 GB6170-zn/M36/GD8 T7510A.5 GB5867/Z2-280×355 T7510-20 GB32.1-zn/M30×90/GD8.8 GB7244/30 GB343-zn GB32.1-zn/M42×165/GD10.9 JB/ZQ4335-86 GB343-zn T7510-39B T7510-9A 1380-27-R 1380-27-L GB825-zn/M20 GB1152/M10×1 1380-33 GB1096/16×35 GB288/23168CA/W33C3 T7510-17 T7510-49 T7510-18 GB288/23164 CAK/W33C3 GB6584/AH3164 1380-28A 1380-50 GB32.1-zn/M20×65/GD10.9 GB7244/20 GB343-zn 1380-31 GB1096/16×35 1380-30 C3254A.2-2RH C3254A.2-2LH 1380-51


Description Flywheel Assembly Wedge For Fixed Jaw Die Washer For Fixed Jaw Wedge Belleville Washer For Fixed Jaw Wedge Nut For Fixed Jaw Wedge Sheave Assembly Locking Assembly Z2-280×355 Shaft Cover Bolt For Shaft Cover Lock Washer For Shaft Cover Steel Wire Ø3 L=800 Bolt For Bearing Housing Washer 42 Steel Wire Ø5 L=1450 Pitman Eccentric Shaft Bearing Housing(RH) Bearing Housing(LH) Eyebolt M20 Grease Fitting M10×1 Grease Retainer Key 16×35 Pitman Bearing Pitman Seal (Bearing Cover) Shim Ø586×Ø718×0.2 Middle Labyrinth Seal Frame Bearing Withdraw Sleeve Bearing Housing Seal (RH) Shim Ø550×Ø680×0.2 Bolt M20×65 Lock Washer 20 Steel Wire Ø3 L=1200 Outer Labyrinth Seal Key 16×35 Lock Washer For Round Nut Round Lock Nut For Round Nut (RH) Round Lock Nut For Round Nut (LH ) Bearing Housing Seal (LH)

Qty.

Stock Code

1 2 2 4 4 1 2 2 6 6 2 16 16 2 1 1 1 1 2 6 2 2 2 2 2 2 2 2 1 2 48 48 4 2 2 2 1 1 1

101710012 101701043 301701071 425004007 402011011 101710016 411002009 101701075 401012019 403005007 401014029 403023004 101701100 101701061 101301204 101301118 405031003 428001000 101301124 409001008 407003040 101701072 101701120 101701073 407003039 412001005 101301182 101301148 401014017 403005003 101301122 409001008 301301121 101314035 101314018 101301183

8

Parts: Jaw Dies and Cheek Plates Illustration The following illustrations identify the essential components comprising the jaw dies and cheek plates.


9

Parts List Item

Qty.

Stock Code

1

T7510A.1

Part # Frame

Description

1

101710001

2

T7510-1

Fixed Jaw Die

1

301701053

T7510-2-L

Upper Cheek Plate(LH)

1

301701054

3 T7510-2-R

Upper Cheek Plate(RH)

1

301701123

4

1380-5

Bolt For Cheek Plate

8

301301084

5

T6090-53

Washer For Cheek Plate

8

301250123

6

GB1972/A63-2

Belleville Washer For Cheek Plate

16

425004005

7

GB6170-zn/M30/GD8

Nut For Cheek Plate

8

402011010

8

GB6172.1-zn/M30

Nut M30

8

402020003

T7510-3-L

Lower Cheek Plate(LH)

1

301701055

T7510-3-R

Lower Cheek Plate(RH)

1

301701124

10

C3042A.DE

Pitman Assembly

1

101711001

13

T7510.4A

Wedge For Fixed Jaw Die

2

101701043

14

T7510-16

Washer For Fixed Jaw Wedge

2

301701071

15

GB1972/A80-2

Belleville Washer For Swing Jaw Wedge

4

425004007

16

GB6170-zn/M36/GD8

Nut For Swing Jaw Wedge

8

402011011

70

T7510-6 T7510-5A-L

Swing Jaw Die Wedge For Swing Jaw Die(LH)

1 1

301701058 301701057

T7510-5A-R

Wedge For Swing Jaw Die(RH)

1

301701125

72

T7510-7

Bolt For Swing Jaw Wedge

4

301701059

73

C1048-29

Washer For Swing Jaw Wedge

4

301101076

74

GB1972/A80-2

Belleville Washer For Fixed Jaw Wedge

16

425004007

75

GB6170-zn/M36/GD8

Nut For Fixed Jaw Wedge

8

402011011

76

T7510-4

Pitman Guard

1

101701056

77

GB5782-zn/M24×80/GD8.8

Bolt For Pitman Guard

4

401022087

78

GB7244/24

Lock Washer For Pitman Guard

4

403005005

9

71


10

Parts: Lubrication Illustration The following illustration identifies the location of each grease fittings on the jaw crushers.

Parts List Item

Qty.

Stock Code

69

T7510-39B

Part # Pitman

1

101701100

79

JB/ZQ4450/M20×1.5

Drain Plug M20×1.5

2

432250001

80

JB982/20

Washer

2

499001205

84

GB1152/M10×1

Grease Fitting M10×1

6

428001000

11

T7510A.7

Lubrication System

1

101710003


Description

11

Lubrication System

T7510A.7

Parts List Item

Part #

Description

Qty.

Stock Code

T7510A.7

Lubrication System

1

101710003

1

1380.7.1

Connector

4

101301071

2

GB9065.3/DN8/M16×1.5, L=1400mm

Hose DN8/M16×1.5, L=1400mm

2

426001017

3

GB9065.3/DN8/M16×1.5, L=1050mm

Hose DN8/M16×1.5, L=1050mm

2

426001009

4

JB984/M14×1.5/16×1.5

Connector M14×1.5/16×1.5

4

427420000

5

GB3452.1/ 8x1.8

O Ring

8

413003072

6

1380.7-3A

Distributor

1

101301179

7

GB1152/M10×1

Grease Fitting M10×1

4

428001000

8

GB5783-zn/M12×80/GD8.8

Bolt M12×80

2

401034092

9

GB93/12

Lock Washer 12

2

403015006


12

Appendix A: Discharge Setting Adjusting Procedure


13

Parts List Item

Qty.

Stock Code

16

GB6170-zn/M36/GD8

Part # Nut M36

8

402011011

26

T7510-27

Rear Wedge For Discharge Adjustment

1

101701082

27

T7510-28

Front Wedge For Discharge Adjustment

1

101701083

28

GB5782-zn/M24×95/GD8.8

Bolt M24×95

8

401022088

29

GB7244/24

Lock Washer 24

8

403005005

30

T7510-25

Guider (II)

1

101701080

31

GB5782-zn/M16×45/GD8.8

Bolt M16×45

12

401022025

32

GB7244/16

Lock Washer 16

12

403005002

33

T7510-13

Pin (I)

2

101701068

34

GB5867/Z2-90×130

Locking Assembly Z2-90×130

2

411002013

35

T7510-24

Washer

4

301701079

36

T7510-YYG-X

Hydraulic Cylinder 431+183

1

301710009

37

T7510-YYG-Z

Hydraulic Cylinder 416+167.5

1

301710010

38

T7510-23

Pin (II)

2

101701078

39

T7510-22

Guider (I)

1

101701077

50

T7510-21

Support Plate (I)

3

101701076

51

T7510-26

Support Plate (II)

1

101701081


Description

14

CT.APP-WEG.6


Hydraulic Unit Parts

15

Parts List ITEM

QTY.

STOCK CODE

CT.APP.WEG.6

PART #

Hydraulic Unit

1

102000251

1

CT.APP 100

Valve Subassembly

1

102000027

2

CT.LM 010

Valve Base

1

102000107

3

6C-18LN/RN

Connector

2

427120139

4

CT.APP 200

Box

1

102000028

5

A-1416SC

Control Box

1

433050012

6 7

GB70.1-zn/M8×20/GD8.8 GB93/8

Bolt M8×20 Lock Washer 8

4 4

405009003 403015004

8

GB97.1/8

Washer 8

4

403020002

9

PT-7

Fitting

1

437001392

10

GB70.1-zn/M8×65/GD8.8

Bolt M8×65

3

405009082

11

SD5/1-P(KG-3)/28LAET

Valve

1

434001143

12

RSO-31TN/36M4-1000

Hose

1

437001389

13

Y-60ZT

Pressure Gauge

1

434005024

14

1CB-18-06WD/RN

Connector

4

427120177

15

1CM-18WD/RN

Connector

2

427070011

16

CT.APP 500

Hose

2

102000163

17

CT.APP 600

Hose

1

102000164

18

CT.APP 700

Hose

1

102000165

19 20

5B-06-04WD CT.APP 300A

Connector Tank Cover Assembly

1 1

480001506 102000188

21

GB70.1-zn/M8×25/GD8.8

Bolt M8×25

8

405009070

22

GB93-zn/8

Lock Washer 8

8

403014002

23

GB97.1/8

Washer 8

8

403020002

24

CT.APP 001

Seal For Tank Cover

1

102000031

25

CT.APP 400

Tank

1

102000032

26

GB70.1-zn/M12×25/GD8.8

Bolt M12×25

4

405009080

27

GB97.1/12

Washer 12

4

403020004

28

W21-100L-4

Motor 3kW/W V/BT5/IE2

1

421150060

ITEM

DESCRIPTION

QTY.

STOCK CODE

29

CT.APP.PP.1

PART #

Hose

2

102000045

30

CT.APP.PP.2

Hose

4

102000046


DESCRIPTION

16


17

Parts List ITEM

QTY.

STOCK CODE

CT.APP 300A

PART #

Tank Cover Assembly

1

102000188

1

CT. APP 310

Cover Assembly

1

102000036

2

RFA-40×20LY

Filter

1

480002469

3

GB70.1-zn/M8×25/GD8.8

Bolt M8×25

4

405009070

4

VST-M27×2WD

Plug

1

427150013

5

GB5782-zn/M12×60/GD8.8

Bolt 12×60

5

401022012

6

GB93-zn/12

Lock Washer 12

4

403014004

7

GB97.1/12

Washer 12

4

403020004

8

CT.APP 301

Gasket

1

102000037

9

2MC-14-16WD

Connector

1

480001483

10

1C-16-22

Connector

1

427070101

11

2C9-22RN

Connecter

1

427070032

12

15×2CF

Steel Pipe

0.2m

480002593

13

CBWmb-F4.0-ALP

Pump

1

416005024

14

GB70.1-zn/M10×30/GD8.8

Bolt M10×30

2

405009007

15

GB97.1/10

Washer 10

2

403020003

16

1CM-18-14WD/RN

Connector

1

427070100

17

12×1.5CF

Steel Pipe

0.3m

480003075

18

1CM-18WD/RN

Connector

1

427070011

19

PAF2-0.02-0.75-20-F

Air Filter

1

480002470

20

BR250

Guard

1

422300263

21

CR24 Ø28×50/Ø12×30

Coupling

1

480002471


DESCRIPTION

18

Chancadora Trio

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