C_Jaw_Instruction_EN_Rev_N (140588) (Updated).pdf

NORDBERG C SERIES JAW CRUSHERS INSTRUCTION MANUAL 140588-EN

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NORDBERG C SERIES JAW CRUSHERS

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This manual is valid for the Nordberg C Series Jaw Crushers manufactured by Metso. These crushers are high capacity jaw crushers, intented to be used in primary crushing applications.

Because of the continuous development of the product, the manufacturer reserves a right to alter the technical specifications written in this manual, without any advance information. In case of conflicts between different language versions, the English version of this manual is the original and prevails. Manufacturer: Metso Minerals, Inc., Tampere Works Lokomonkatu 3, P.O. Box 306 33101 Tampere Finland Phone: +358 204 84 142 Fax: +358-204-84 143

email: [email protected] www.metso.com Copyright © 2010 Metso. Printed in Tampere, Finland.

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Table of Contents NORDBERG C SERIES JAW CRUSHERS PREFACE 1.1 FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1.2 SAFETY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

SAFETY 2.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2.1.1 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 2.1.2 Operation safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 2.1.3 Maintenance safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 2.2 WARNING SIGNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 2.2.1 Warning sign codes and texts (ANSI). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 2.2.2 Warning sign codes and texts (ISO). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

GENERAL CRUSHER INFORMATION 3.1 CRUSHER TERMINOLOGY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3.2 CRUSHER COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 3.3 SPARE PARTS BOOK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 3.4 ORDERING PARTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 3.5 ESTIMATING CRUSHER CAPACITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 3.6 ESTIMATING CRUSHER PRODUCT GRADATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 3.7 CRUSHER SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 3.8 CRUSHER SETTING LIMITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 3.9 OPTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 3.9.1 Intermediate Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 3.9.2 Protection Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 3.9.3 Conveyor Belt Protector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 3.9.4 Hydraulic Setting Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 3.9.5 Automatic Lubrication Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14


Table of Contents OPERATING INSTRUCTIONS 4.1 PREPARATIONS BEFORE STARTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4.2 STARTING THE CRUSHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4.3 STOPPING THE CRUSHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4.4 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 4.4.1 Oversized Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 4.4.2 Tramp Iron/Uncrushables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 4.4.3 Packing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 4.5 RE-STARTING A CRUSHER STALLED UNDER LOAD . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 4.6 CRUSHER SETTING ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 4.6.1 Mechanical wedge setting adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 4.6.2 Hydraulic wedge setting adjustment (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 4.6.3 Active setting control adjustment (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 4.7 TOGGLE PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 4.8 SPACER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 4.9 TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

MAINTENANCE 5.1 SPACER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 5.1.1 Spacer Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 5.1.2 Spacer Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 5.2 TOGGLE PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 5.2.1 Replacing the Toggle Plate And Toggle Seats (with wedge setting adjustment) . . . . . . 5-7 5.2.2 Replacing the Toggle Plate And Toggle Seats with Active Setting Control . . . . . . . . . . 5-9 5.3 LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 5.3.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 5.3.2 Grease Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 5.3.3 Eccentric Shaft Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 5.3.4 Eccentric Shaft Bearing Temperatures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 5.3.5 Jack-shaft Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17 5.3.6 Jack-shaft Bearing Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18 5.3.7 Thrust Bearing And Cap Nut Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18 5.3.8 Tension Cylinder Slide Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18 5.3.9 Electric Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18 5.3.10Toggle Seats And Toggle Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19 5.3.11Setting Adjustment Wedges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20


Table of Contents 5.4 INSTRUCTIONS FOR LIFTING A JAW CRUSHER WHEN REPLACING CRUSHER SUPPORT BRACKET DAMPERS . . . . . . . . . . . . . . . . . . . . . . . . . 5-20 5.5 HYDRAULIC POWER UNIT (OPTIONAL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22 5.5.1 Checking oil level and temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22 5.5.2 Changing oil and filter (Figure 5.11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22 5.5.3 Oil recommendation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24 5.5.4 Bleeding the hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25 5.6 PERIODICAL MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28 5.6.1 Daily maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28 5.6.2 Weekly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29 5.6.3 Monthly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30 5.6.4 Twice a Year. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30 5.6.5 Regularly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30 5.7 MAINTENANCE INTERVALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31 5.8 BOLT TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33

REPLACEMENT OF WEAR PARTS 6.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 6.2 JAW DIE SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 6.3 JAW DIE WORK HARDENING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 6.4 CHEEK PLATE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 6.4.1 Cheek Plate Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 6.4.2 Cheek Plate Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 6.5 CHANGING OR ROTATING THE JAW DIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 6.5.1 One piece jaw dies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 6.5.2 Two-piece jaw die removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17 6.5.3 Welding lifting lugs to the jaw die . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28 6.6 PITMAN EYE PROTECTION PLATE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31 6.7 FEED HOPPER LINER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31 6.8 TOGGLE PLATE SEAT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31


Table of Contents APPENDIX A

1. 2. 3. 4. 5. 6. 7. 8. 9.

SAFETY, OPERATING AND MAINTENANCE INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . .A-1 Purpose of the jaw die lifting tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Storage of the jaw die lifting tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Safe use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Commissioning and operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2 The jaw die lifting tool verification before first use and in service . . . . . . . . . . . . . . . . . .A-2 Handling the load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3 Operating instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5

APPENDIX B

1. 2. 3. 4. 5. 6. 7. 8. 9.

SAFETY, OPERATING AND MAINTENANCE INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . .B-1 Purpose of the cheek plate lifting tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1 Storage of the cheek plate lifting tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1 Safe use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1 Commissioning and operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2 The cheek plate lifting tool verification before first use and in service . . . . . . . . . . . . . .B-2 Handling the load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3 Operating instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7

PREFACE

CHAPTER

1

1.1 FOREWORD

1.2 SAFETY

This instruction manual provides guidance for first time operators of the crusher as well as technical procedures as a reference for the experienced crusher operator. Read, study, and keep it for future reference.

BASIC RULES REGARDING SAFETY IN AND AROUND A CRUSHING PLANT ARE OUTLINED IN THE SECTION ENTITLED "SAFETY."

The instructions given are for the operation and basic maintenance procedures only, as this instruction book is not a repair manual. Should maintenance procedures not covered in this manual be required, contact Metso. Illustrations and instructions guide the operator through correct procedures for checking, operating and maintaining the crusher and its accessories. Operating techniques outlined in this manual are basic. Operating skills and additional techniques will develop through experience as the operator gains knowledge of the crusher and its capabilities.

OPERATOR SAFETY AND THE SAFETY OF OTHERS DEPEND UPON REASONABLE CARE AND JUDGEMENT IN THE OPERATION OF THIS CRUSHER. A CAREFUL OPERATOR IS GOOD INSURANCE AGAINST AN ACCIDENT. MOST ACCIDENTS, NO MATTER WHERE THEY OCCUR, ARE CAUSED BY FAILURE TO OBSERVE AND FOLLOW SIMPLE FUNDAMENTAL RULES OR PRECAUTIONS. FOR THIS REASON RECOGNIZING HAZARDS AND TAKING STEPS TO AVOID THEM CAN PREVENT MOST ACCIDENTS. REGARDLESS OF THE CARE USED IN THE DESIGN AND CONSTRUCTION OF THIS TYPE OF EQUIPMENT, THERE ARE CONDITIONS THAT CANNOT BE COMPLETELY SAFEGUARDED AGAINST WITHOUT INTERFERING WITH REASONABLE ACCESSIBILITY AND EFFICIENT OPERATION. WARNINGS ARE INCLUDED IN THIS INSTRUCTION MANUAL TO HIGHLIGHT THESE CONDITIONS.

Continuing improvement and advancement of product design may result in changes to your new machine that may not be included in this publication. As required, each publication is reviewed and revised to update and include appropriate changes in the later editions. The descriptions and specifications in this manual were in effect at the time this manual was approved for printing. Metso reserves the right to discontinue models at any time and to change specifications and designs, without notice and without incurring obligation. Whenever a question arises concerning your crusher, or this publication, please consult your Metso representative for the latest available information.

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SAFETY

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2.1 GENERAL The instructions of the safety guide, these safety instructions and other manuals and safety labels for the equipment must be read, understood and used by each person who works with this equipment.

2

This manual uses the alert symbol, with words such as DANGER, WARNING or CAUTION, to alert you and other Crushing Plant personnel of actions or conditions that pose a potential safety hazard, with an attending risk of personal injury (including death) or property damage. The machine also displays safety signs, labels and tags at appropriate points to show safety risks that may exist.

WARNING! In addition to these unit-specific safety instructions, the operators of this equipment must also read the safety guide with instructions for general operational safety.

DANGER

The following symbol is used in this manual and on the machine to call attention to instructions, which will help prevent machine related injuries.

WARNING

When you see this symbol on your machine or in this manual, be alert to the potential for personal injury.

CAUTION Sign

Figure 2.1 Alert Symbol

Description

Immediate hazards or unsafe practices DANGER that will result in severe personal injury or death. Hazards or unsafe practices that could WARNING result in severe personal injury or death Hazards or unsafe practices that could CAUTION result in minor personal injury or equipment damage Figure 2.2 Danger, warning, caution signs and their meaning

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CHAPTER 2 - SAFETY

Personal protective equipment and clothing such as foot protection, helmet, hearing protection, dust protective devices, safety glasses or other personal protective clothing and equipment should be worn at all times.

2.1.1 General safety instructions

WARNING! Before performing any maintenance or repair work, make sure that the crusher is stopped and locked out. LOCKOUT PROCEDURE of the Lokotrack installed crushers 1. Switch off engine 2. Remove the ignition key and keep it on person during lockout 3. Place appropriate maintenance warning signs (TAG OUT) LOCKOUT PROCEDURE of the electrical motor driven crushers 1. Switch off motor 2. Lock the main switch of the motor with a padlock or make sure in some other way that the engine cannot be started 3. Lock the main switch of the hydraulic adjustment power unit (if delivered) with padlock 4. Keep the keys on person during lockout 5. Place appropriate maintenance warning signs (TAG OUT).

Figure 2.3 Personal safety equipment

DANGER! When working outside service platforms, safety harnesses must be worn!

1. Ignoring the safety instructions or the warning signs increases the risk of the severe injury or death. 2. Nordberg C series jaw crushers has been designed for safe operation when used by professional staff in the operating situations included in this instruction manual. All other service and repair procedures must be performed by specially trained personnel or authorized Metso service staff. 3. The crushing plant and auxiliary equipment such as chutes, transfer stations, screens,

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etc. can create dust and, if not contained, the dust can escape into the air. Metso highly recommends that dust protective devices such as an appropriate respirator be worn by anyone exposed to airborne dust to prevent its inhalation. It is the responsibility of the Owner and Operator to determine the necessity and adequacy of protective devices and warnings, to provide them, and to ensure that they are used and followed!

2.1.2 Operation safety instructions 1. Never operate the crusher without proper covers and safety devices. If the covers or safety devices have not been purchased from Metso, a customer has to ensure that the covers and safety devices are according to law and regulations. 2. Before starting the crusher make sure that no one is near the crusher.

4. The noise level is dangerously high near the crusher. All personnel working near the crusher must wear hearing protection. The noise level is typically about 102-110 dB next to the crusher during crushing.

3. It is prohibited to stay in the danger area during the crushing process. The crushing material may be thrown into a few meters distance from the crusher. Always use helmet and safety glasses.

5. Keep the warning signs clean. Replace illegible and damaged signs before starting the crusher. Make sure that the warning signs are not hidden from sight when installing the crusher. If a part with a warning sign is replaced, make sure that the new part also has the required warning signs.

4. Do not look into the jaw cavity during crushing. Material may be thrown from the crusher during crushing and cause injuries. Always use a helmet and safety glasses. 5. Because the crusher is installed on rubber dampers, it moves during crushing. This movement causes a crushing danger. Never put your hands or feet between the moving parts and the structure of the crusher during crushing. The movement may be as much as ± 10mm. 6. Clearing a jammed cavity is extremely dangerous. Do not attempt to clear the cavity until the crusher has stopped completely.

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CHAPTER 2 - SAFETY

2.1.3 Maintenance safety instructions 1. The crusher does not stop immediately after the motor has been turned off. Make sure that the crusher has stopped completely before opening any covers, performing any maintenance, or adjusting the crusher. 2. Before performing any maintenance or repair work, make sure that the crusher is stopped and locked out. 3. The surfaces of the crusher may become hot during crushing. Hot surfaces can cause severe burn injuries. Make sure that the surfaces have cooled before performing any maintenance work. 4. Before changing any wear parts of the crusher, read chapter 6: Replacement of wear parts and appendixes A and B carefully. 5. Before lifting any wear parts, check the weight of the component and ensure that lifting equipment being used is adequate to lift the weight. In addition, familiarize yourself with all the special tools provided with the crusher specifically for replacing the wear parts. 6. Read the instructions regarding the lifting tools and replacing wear parts carefully before replacing any wear parts. Make sure that the parts are adequately supported before lifting. Never go under the suspended load. The lifting tools delivered with the crusher are designed to be used only with original Metso wear parts. 7. The spring of the mechanical setting adjustment may accumulate significant amount of energy. Follow the instructions strictly and be extremely accurate when adjusting the spring. Never release the protective plate. 8. The pressure accumulator of the hydraulical setting adjustment may be charged only by a professional. If the pressure accumulator is charged incorrectly, it may explode. Do not charge the accumulator yourself. Release the pressure from the hydraulic system according to instructions before any maintenance to the system.

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CHAPTER 2 - SAFETY

WARNING! Ensure that the crusher has stopped to the “rest position”. In other words there is no potential energy remaining in the flywheels. This can be determined from the position of the gib key. It should point down. (Figure 2.4) NOTE: If the gib key is not pointing down, start the crusher for a second.

Figure 2.4 At the “rest position” the gib key is pointing down

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CHAPTER 2 - SAFETY

2.2 WARNING SIGNS The warning signs attached to the equipment must always be kept readable and clean. Damaged or loose signs must be replaced at once before starting the crusher. Make sure that the warning signs are not covered during installation. If a part of the crusher attached a warning sign are replaced, always make sure that the warning signs needed are included in a new part.

IMPORTANT! There are two different sets of warning signs depending on the delivery country. You can check which set of warning signs is used on your machine from the side of the machine or the spare part manual.

Figure 2.5 The locations of the warning signs

The number and exact locations of the warning signs may vary according to options (for example, guards).

IMPORTANT!

The warning signs 1, 2, 3, and 4 are located on both sides of the crusher.

Warning signs 1, 2, 3 and 4 are not attached on crushers installed in Lokotracks or Nordwheelers.

The warning signs 3 are delivered only if the crusher delivery includes the drive guards. The warning sign 5 is delivered only with crushers that have a mechanical setting adjustment. The warning signs 6, 7, and 9 are delivered only with crushers that have a hydraulical setting adjustment.

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CHAPTER 2 - SAFETY

1

2

4

3

7

6

5

8 9

Figure 2.6 Warning signs (ANSI)

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CHAPTER 2 - SAFETY

2.2.1 Warning sign codes and texts (ANSI) 1. MM0229994 WARNING Read and understand instruction manual before using or maintaining this machine. Failure to follow operating instructions may result in death or serious injury. DANGER Lung disease hazard. Dust protection required. WARNING Risk of eye injury. Use of eye protection required. CAUTION Risk of head injury. Use of a helmet required. CAUTION Hazardous noise level. Use of ear protection required. 2. MM0229995 DANGER Moving parts can crush and cut. Do not insert tools in the crusher cavity when the motor is running. WARNING Material can fall out. do not stand in the vicinity of the crusher when the motor is running.

5. MM0229998 DANGER Spring in compression. Read and understand instruction manual before adjusting or servicing. Do NOT remove this protection plate. 6. MM0230002 WARNING Servicing while pressurized can cause severe injury. Lock out source and relieve pressure before servicing. 7. MM0230006 CAUTION Hot surface. Contact with skin may cause burns. Do not touch. 8. MM0230004 CAUTION Hot surface. Contact with skin may cause burns. Do not touch. 9. MM0230447 WARNING Pressurized device. Only authorized personnel should service this dev ice. See instruction manual for safety information.

3. MM0229997 WARNING Exposed moving parts can cause severe injury. Do not open drive guard before machine is completely stopped. 4. MM0229996 WARNING Exposed moving parts can cause severe injury. Do NOT operate this machine without proper guards.

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CHAPTER 2 - SAFETY

1

3 4

2

6

5

7

8

9

Figure 2.7 Warning signs (ISO)

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CHAPTER 2 - SAFETY

2.2.2 Warning sign codes and texts (ISO) 1. MM0250258 WARNING Read and understand instruction manual before using or maintaining this machine. Failure to follow operating instructions may result in death or serious injury. DANGER Lung disease hazard. Dust protection required. WARNING Risk of eye injury. Use of eye protection required. CAUTION Risk of head injury. Use of a helmet required. CAUTION Hazardous noise level. Use of ear protection required. 2. MM0250251 DANGER Moving parts can crush and cut. Do not insert tools in the crusher cavity when the motor is running. WARNING Material can fall out. do not stand in the vicinity of the crusher when the motor is running.

5. MM0250242 DANGER Spring in compression. Read and understand instruction manual before adjusting or servicing. Do NOT remove this protection plate. 6. MM0250241 WARNING Servicing while pressurized can cause severe injury. Lock out source and relieve pressure before servicing. 7. MM0250239 CAUTION Hot surface. Contact with skin may cause burns. Do not touch. 8. MM0251117 CAUTION Hot surface. Contact with skin may cause burns. Do not touch. 9. MM0250104 WARNING Pressurized device. Only authorized personnel should service this device. See instruction manual for safety information.

3. MM0250244 WARNING Exposed moving parts can cause severe injury. Do not open drive guard before machine is completely stopped. 4. MM0250244 WARNING Exposed moving parts can cause severe injury. Do NOT operate this machine without proper guards.

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GENERAL CRUSHER INFORMATION

CHAPTER

3

3.1 CRUSHER TERMINOLOGY Throughout this instruction manual, technical terms are used to describe the crusher, its components and its operation. These terms are defined herein with the intent of avoiding any confusion or misunderstanding.

Callout 1 2 3 4

Description Feed opening depth Moving jaw Stationary jaw Closed side setting (c.s.s)

Callout Description 5 Stroke 6 Nip angle 7 Feed opening width

Figure 3.1 Jaw crusher terminology

Feed: The raw material to be crushed, such as the rock type (limestone, basalt, granite, etc.) or man-made materials such as concrete and asphalt. The feed size is typically denoted in terms of a size distribution or based on an average top (maximum) size. Product size: The size of the material after it has been crushed. Similarly to the feed size, the product size is typically denoted in terms of a size

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distribution or based on an average top (maximum) size. Capacity: The output of the crusher in tons per hour. Feed Opening: The opening where the feed material is fed into the crusher. The feed opening has two dimensions: a width and a depth. The feed opening depth is a critical dimension because it dictates the maximum feed size a given jaw crusher model can accept.

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CHAPTER 3 - GENERAL CRUSHER INFORMATION

Maximum Recommended Feed Size: As a general guideline, the maximum average recommended feed size should be about 80% of the feed opening depth. Such measures will ensure that any bridging events resulting from oversized feed are kept to a minimum. A rock hammer is recommended for applications where the maximum feed size is regularly close to the feed opening depth.

Feed Opening

C80 C96 C100 C106 C110 C116 C3054 C125 C140 C145 C160 C200

mm 800 X 510 930 X 600 1000 X 760 1060 X 700 1100 X 850 1150 X 800 1380 X 760 1250 X 950 1400 X 1070 1400 X 1100 1600 X 1200 2000 X 1500

inch 20 X 32 24 X 37 30 X 40 28 X 42 34 X 44 32 X 45 30 X 54 37 X 49 42 X 55 43 X 55 47 X 63 59 X 79

Stroke: The difference between the maximum and minimum distances at the bottom of the fixed and moving jaws during one revolution of the eccentric shaft.

Maximum Rec. Feed Size mm 408 480 608 560 680 610 608 760 856 880 960 1200

inch 16 19 24 22 27 24 24 30 34 35 38 47

Table 3-1 Maximum recommended feed sizes

Nip Angle: The angle between the fixed and moving jaws. The nip angle is often referred to as the "bite" angle as well. Jaws: The members that perform the crushing are commonly referred to as jaws. The jaws consist of a stationary and moving jaw, and depending on the model each one of these may consist of either 1 or 2 pieces. Different jaw die profiles are available for different applications. Discharge Setting: The shortest distance between the bottom of the fixed and moving jaws as measured at the point where the jaws are at their closest relationship during their work cycle (i.e. the closed side setting, or c.s.s.). The method in which the setting is measured varies depending on the jaw die profile. These differences are explained in detail in the CRUSHER SETTING section.

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3.2 CRUSHER COMPONENTS

Callout 1 2 3 4 5 6 7 8 9 10 11

Description Front frame Upper wedge Filling wedge jaw die bolt Disc spring package Cheek plate, upper Fixed jaw, upper Moving jaw, upper Center wedges Cheek plate, lower Fixed jaw, lower

Callout 12 13 14 15 16 17 18 19 20 21 22

Description Moving jaw, lower Frame bolt Fixed wedge Pitman eye protection plate Flywheel Eccentric shaft Pitman bearing Pitman Frame connecting rods Side plate Toggle seat

Figure 3.2 Jaw crusher main components

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Active setting control adjustment

Mechanical wedge setting adjustment

Hydraulic wedge setting adjustment

Callout 1 2 3 4 5 6 7

Description Rear frame Adjustment wedges Spacer Toggle seat holder Toggle seat Locking nuts with thrust bearing Tension spring

Callout 8 9 10 11 12 13 14 15

Description Tension rod Toggle plate Piston rod Piston Pressure relief valve Pressure accumulator Tension cylinder Cylinder cover

Figure 3.3 Jaw crusher rear frame components

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3.5 ESTIMATING CRUSHER CAPACITY

3.3 SPARE PARTS BOOK A Spare Parts Book containing various assembly drawings pertaining to your crusher will be sent immediately after the crusher has been shipped. This book illustrates each and every part used in the assembly of the machine and is to be used when ordering spare or replacement parts.

3.4 ORDERING PARTS Metso endeavors to carry an ample supply of parts in stock to provide prompt and efficient service on all orders for repairs and replacements. To avoid delay and the possibility of incorrect parts being furnished, the following information should be given:

The capacity of the crusher depends on factors such as the type of feed (material type, size distribution, fracture characteristics, moisture content, etc.), type of operation (feed availability, feed arrangement) and discharge setting. To obtain an estimate of the capacity, refer to the following capacity table. These capacities are based on results obtained in actual practice with hard granite that has a bulk density of 1.6 t/m3 (100 lb/ft3), and are where the feed has been properly graded so that bridging does not take place. To obtain more accurate capacity estimates specific to your actual crushing application, contact your local Metso sales representative to request a computer simulation of your circuit's operating condition

1. Crusher size. 2. The serial number of the crusher which is stamped on the crusher nameplate. The serial number is also on the cover of the spare parts books. 3. Complete name and part code number as shown in the Spare Parts Book. 4. Exact quantity of each part ordered. 5. Complete shipping instructions. If your crusher Spare Parts Books have been lost, destroyed or misplaced, an additional set can be ordered. For proper operation, only genuine factory parts should be installed. These are guaranteed as to accuracy, workmanship and material. Using pirate parts may put your safety and that of your crusher at risk. Make sure you completely understand your crusher's Warranty conditions at all times.

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c.s.s. mm 40

in 1-5/8”

50 2” 60 2-3/8” 70 2-3/4” 80 3-1/8” 90 3-1/2” 100 4” 125 5” 150 6” 175 7” 200 8”

C80

C96

C100

C106

C116

C110

C125

C140

C145 C3054 C160

C200

Mtph Stph 63 72 80 90 97 107 114 125 131 143 148 161 165 185 207 232 250 280 292 327

Mtph Stph

Mtph Stph

Mtph Stph

Mtph Stph

Mtph Stph

Mtph Stph

Mtph Stph

Mtph Stph

Mtph Stph

Mtph Stph

150 165 171 187 192 209 213 238 265 296 317 355 369 413 421 471

168 185 190 208 213 232 235 263 291 325 346 388 402 450 458 513

185 204 207 227 230 250 252 282 308 344 363 407 419 469 475 531

190 209 212 232 235 256 257 287 313 350 368 412 424 475 480 537

520 581 596 666 672 751 748 836 824 921 900 1006 976 1091

760 849 853 953 946 1058 1039 1162 1132 1266 1225 1370

120 132 140 154 160 175 180 196 200 224 250 280 300 336 350 392

225 9” 250 10” 275 11” 300 12”

290 324 350 391 410 458 470 525 530 593 590 660 650 727

386 432 454 508 522 584 590 659 657 735 725 811

400 447 470 526 541 605 611 683 681 762 752 841 822 920

Mtph Stph

240 264 268 293 295 322 323 361 392 439 462 516 531 594 600 671

Table 3-2 Nominal jaw crusher capacities

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3.6 ESTIMATING CRUSHER PRODUCT GRADATION

These product gradations are based on results obtained in actual practice with hard granite. To obtain more accurate product gradation estimates, contact your local Metso sales representative to request a computer simulation of your circuit's operating conditions.

The crusher's product gradation depends on the same factors that affect capacity. The following figure gives an indication of the product gradation as a function of the closed side setting (c.s.s.).

1"

2"

4"

8"

16"

100

90 css

40 50

70

100 130 160 200 250

300

80

Percentage passing, weight %

70

60

50

40

30

20

10

0 1

10

100

1000

Product size

Figure 3.4 Crusher product gradation

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3.7 CRUSHER SETTING The Crusher setting is the most important Crusher parameter since it determines the Crusher's capacity as well as the top size of the Crusher product. It is therefore indispensable for everyone to understand how the Crusher setting is measured. The discharge setting is the shortest distance between the bottoms of the fixed and moving jaws during their work cycle. This distance is referred to as the closed side setting (c.s.s.), and it is a calculated distance as the Crusher setting is typically measured when the Crusher is at rest. The largest distance between the bottoms of the fixed and moving jaws is referred to as the open side setting (o.s.s.), and it is typically a distance that is directly measured when the Crusher is at rest.

The Crusher setting is measured in three different ways, first referring to the tooth groove (bottom) or crown (top) of the stationary jaw and then to the tooth groove (bottom) or crown (top) of the movable jaw. Thus, the setting is always measured from the Stationary (bottom or top) to the Movable jaw (bottom or top). The three alternatives are shown in Table 3-3. The measurement type depends on the profile as well as on the Crusher model. This information is also found in the Crusher Spare Parts Book.

Measurement Type 1 2 3

Reading Sequence (Jaws) Stationary Bottom Top Top

to to to to

Movable Top Top Bottom

Table 3-3 Measurement types

Figure 3.5 Crusher setting measurement

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For example, the setting of the C125, equipped with Quarry jaw dies, is measured from Top to Top (Type 2). However, with Standard jaw dies, the setting is measured from Bottom to Top (Type 1). IMPORTANT! The Crusher setting must always be measured in a straight line at the bottom of the crushing cavity. Measure the setting always from the least worn area.

Example Crusher: C140 Stroke: 42 mm (15/8” ) (Table 3-4) jaw die Profile: Quarry (top to top) O.S.S.: 230 mm (9") C.S.S.: 230 – 42 = 188 mm (9" – 1 5/8" = 7 3/8")

It is easiest to measure the setting when the Crusher is at rest with a device such as a block of wood of known dimensions (several blocks should be available if more than one setting is typically used). The distance measured this way is larger than the closed side setting (c.s.s.) because the pitman always stops at its lowest point. This value is close (±2mm/±0.08") to the open side setting (o.s.s.). As previously mentioned, the closed side setting is calculated by deducting the stroke from the open side setting (Table 3-4).

Model C80 C96 C100

Stroke mm Inch 24 1 32 1¼ 32 1¼

C106

34

13/8

C110

36

17/16

C116 C3054

37 32

1½ 1¼

C125

41

15/8

C140

41

15/8

C145

41

15/8

C160

41

15/8

C200

50

2

Table 3-4 Dimension (stroke) to be deducted from the open side setting (o.s.s.) to calculate the closed side setting (c.s.s.).

Dimension (stroke) to be deducted from the open side setting (o.s.s.) to calculate the closed side setting (c.s.s.).

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Figure 3.6 Measuring the setting

NOTE: The C.S.S does not have to be calculated if the user knows the Crusher setting limits in terms of the O.S.S. The C.S.S. is typically calculated because Crusher capacity is always denoted in terms of the C.S.S. only.

3.8 CRUSHER SETTING LIMITS All C-Series Crusher models have a maximum possible setting as well as a minimum allowed setting, and it is very important that the user understands why these are important to keep these in mind at all times. The maximum possible setting is simply the maximum setting that the Crusher is physically able to accommodate. Typically, such setting is indicated with new jaw dies, and the setting actually depends on the jaw die profile as well as on whether a spacer is being used or not. This

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information is always found in the Crusher Spare Parts Book. The minimum allowed setting (c.s.s. or o.s.s.) is the minimum setting at which the Crusher can be used when the Crusher is operated according to Metso ' recommendations. The minimum allowed setting is very important as it takes into account the design and operation limits of the Crusher. Not respecting these recommendations can lead to a poor utilization of the jaw dies (high scrap rate) as well as a shortened Crusher life. The minimum allowed setting varies depending on whether the application is a normal rock application (Normal), or a recycling application (Special), when materials such as concrete, asphalt and bricks are being crushed. Note that the minimum allowed setting does not depend on the jaw die profile (it is always the same for a specific Crusher model). See Table 3-5.

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Crusher model

C80 C96 C100 C106 C110 C116 C3054 C125 C140 C145 C160 C200

CSS Hard rock Soft Rock (>150 Mpa) (<150 MPa) Recycling (> 22 000 psi) (<22 000 psi) mm

mm

mm

40 60 70 70 70 70 70 100 130 125 150 175

30 45 60 50 60 60 60 N.A N.A N.A N.A N.A

20 25 45 25 45 45 45 N.A N.A N.A N.A N.A

Stroke mm

24 32 32 34 36 37 32 39 42 36 39 50

CSS Crusher model

C80 C96 C100 C106 C110 C116 C3054 C125 C140 C145 C160 C200

Hard rock Soft Rock (>150 Mpa) (<150 MPa) Recycling (> 22 000 psi) (<22 000 psi) in in in 1 5/8 1 2/8 7/8 2 4/8 1 7/8 1 2 7/8 2 4/8 1 7/8 2 7/8 2 1 2 7/8 2 4/8 1 7/8 2 6/8 2 3/8 1 6/8 2 7/8 2 4/8 1 7/8 4 1/8 N.A N.A 5 2/8 N.A N.A 5 1/8 N.A N.A 6 1/8 N.A N.A 7 1/8 N.A N.A

Stroke in

1 1 2/8 1 2/8 1 3/8 1 4/8 1 4/8 1 2/8 1 5/8 1 6/8 1 4/8 1 5/8 2

OSS Hard rock Soft Rock (>150 Mpa) (<150 MPa) Recycling (> 22 000 psi) (<22 000 psi) mm

mm

mm

64 92 102 104 106 107 102 139 172 161 189 225

54 77 92 84 96 97 92 N.A N.A N.A N.A N.A

44 57 77 59 81 82 77 N.A N.A N.A N.A N.A

OSS Hard rock Soft Rock (>150 Mpa) (<150 MPa) Recycling (> 22 000 psi) (<22 000 psi) in in in 2 5/8 2 2/8 1 6/8 3 6/8 3 1/8 2 3/8 4 1/8 3 6/8 3 1/8 4 3/32 3 5/16 2 21/64 4 3/8 3 7/8 3 2/8 4 2/8 3 7/8 3 2/8 4 1/8 3 6/8 3 1/8 5 5/8 N.A N.A 7 N.A N.A 6 5/8 N.A N.A 7 6/8 N.A N.A 9 1/8 N.A N.A

Table 3-5 Minimum allowed settings for hard rock, soft rock and recycling applications.

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• WARNING! The minimum allowed setting of a Crusher must be respected at all times unless otherwise indicated by Metso. Not respecting these recommendations can lead to a poor utilization of the jaw dies (high scrap rate) as well as to a shortened Crusher life. Moreover, operating the Crusher at settings smaller than allowed will void the Crusher's warranty.

To change the profile of the cavity so that the crusher starts the crushing higher in the cavity (prolonging the service life of wear parts) when the feed material is continuously significantly smaller than the maximum feed material size of the crusher.

The intermediate plate is not available for all models. Moreover, multiple plate thicknesses are available with certain models. Before ordering intermediate plate consult Metso if it fits to your application.

3.9.2 Protection Plates

WARNING! The maximum size of tramp iron (rebars, excavator teeth, etc.) must be smaller than the Crusher closed side setting (c.s.s.).

Protection plates are designed for additional protection of the crusher's front frame and pitman. They are recommended when using small settings (always greater than or equal than the minimum recommended setting) and/or when the rock to be crushed is very hard (very low crushability). Of course, these can be used at any time for added protection.

3.9 OPTIONS

NOTE: The front frame protection plate is not used when an intermediate plate is used.

Following options can be installed on Crusher after start-up.

Protection plates are not available options with all C-Series crusher models. 3.9.1 Intermediate Plate IMPORTANT! Fitting an intermediate (backing) plate behind the fixed jaw reduces the nip angle of the crusher. The intermediate plate reduces the feed opening and the setting range by approximately the same amount as its thickness. However the intermediate plate does not, under normal circumstances, allow the user to use a smaller setting than the minimum recommended setting.

When using protection plates, different bottom retaining wedges must be used. NOTE: Excessive replacement of the protection plates indicated a feed problem. Contact Metso if such is the case with your Crusher.

If available with the specific C-Series jaw crusher model, an intermediate plate may be used for the following reasons: •

To improve the nip angle (by decreasing the nip angle) when crushing slippery material (material that is difficult to bite).

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Callout Description 1 Front frame protection plate

Callout Description 2 Pitman protection plate

Figure 3.7 Protection plates

3.9.3 Conveyor Belt Protector Conveyor belt protector prolongs lifetime of conveyor belt under Crusher. Angle of the protector can be adjusted. Especially in recycling applications, rebars can damage the belt.

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3.9.5 Automatic Lubrication Unit The lubrication system automatically lubricates the four (4) eccentric shaft bearings in accordance with the recommendations provided by the factory. Refer to Chapter 5.3 and Installation Manual Chapter 6.5.

Callout 1 2 3 4 5 6 7 8 9

Description Protector plate Support holder Eye screw Split pin Washer Washer Hex screw Hex nut Joint pin

Figure 3.8 Conveyor belt protector

3.9.4 Hydraulic Setting Adjustment A Crusher equipped with mechanical setting adjustment can be retrofitted with the hydraulic setting adjustment. Refer to Chapter 4.6.2.

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OPERATING INSTRUCTIONS

CHAPTER

4.1 PREPARATIONS BEFORE STARTING Good inspection habits will do much to insure years of successful operation of the Crusher. Do not rely on memory alone to regulate required periodic maintenance, keep an accurate written record. Regularly performing pre-start and maintenance inspections will pay off in the way of eliminating costly down time and prolonging the life of the Crusher.

4

2. Start the electric motor or diesel engine. If a slip ring motor is used, wait until its starting resistor reaches the operating stage. If a pounding or thumping sound is heard, refer to the TROUBLESHOOTING section of this chapter (page 14). 3. Start the feeder. This is a brief outline of the control logic sequence that is required to start the Crusher. Other measures may be taken in accordance with local conditions.

WARNING! Before starting the Crusher, perform the following operations: 1. Make a final inspection of the Crusher to be certain that no tools or mechanical obstructions are on the Crusher, that all joints and fasteners are properly tightened, that no leaks are apparent and that there is no other reason why the Crusher should not be started. 2. Ensure that the Crusher cavity is empty. 3. Ensure that there is a protective cover in the feed hopper and that it is closed during operation. 4. Ensure also that there are no persons in the area whose safety may be endangered. Walk around the Crusher and ensure that there is nobody on, by or below the Crusher. Warn everybody in the vicinity before starting.

Figure 4.1 Starting and stopping sequence

4.3 STOPPING THE CRUSHER To stop the Crusher, proceed as follows: 1. Stop the feeder.

4.2 STARTING THE CRUSHER

2. Wait until the Crusher cavity is empty. 3. Stop the electric motor or diesel engine.

An electric motor or diesel engine drives the Crusher. Starting the Crusher merely amounts to starting the motor or engine according to the manufacturers' instructions. Do not introduce any feed to the Crusher during starting. To start the Crusher, proceed as follows:

4. Stop the discharge conveyor. WARNING! After stopping the Crusher motor or diesel engine, the Crusher may coast down up to seven minutes.

1. Start the discharge conveyor.

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CHAPTER 4 - OPERATING INSTRUCTIONS

4.4.1 Oversized Feed

4.4 OPERATION

Avoid trying to crush oversized feed (feed too large for the cavity). Having to reposition rock wastes time, reduces capacity and imposes unnecessary loads on the Crusher. Therefore attention must be paid to the size of feed. A stationary grizzly is a suitable alternative for limiting oversized feed. A hydraulic hammer can be used for breaking oversized material and is recommended if such problems are foreseen.

WARNING! Single stones may be thrown from the crusher cavity. Ensure the even material flow to the crusher. Feed the material to the Crusher evenly in accordance with the feed arrangement recommendations. Note that the Crusher operates most efficiently when the crushing cavity is two-thirds (2/3) full. An ultrasonic level sensor may be integrated into the Crusher control in order to optimize the feed level of the Crusher.

WARNING! Lift or turn the rocks in the cavity only when the Crusher is stopped. Do not try to clear the blocked crushing cavity when the Crusher is running. Be always very careful when clearing the cavity. Never use an iron bar to turn oversized feed.

NOTE: Metso recommends that the level detector is used to prevent the overflow of the feed material.

DANGER! Never use explosives to clear a blocked crushing cavity. Make sure no explosives enter the Crusher The oversized rock can be lifted out of the cavity with a "clamp" and crane or it can be turned to a better position. When the Crusher is running a hydraulic hammer can be used for breaking the oversized or blocked feed.

Figure 4.2 Recommended filling ratio

Refer to the WEAR PARTS section for operating instructions pertaining to wear parts.

4.4.2 Tramp Iron/Uncrushables Uncrushable ("tramp iron") material larger than the Crusher's c.s.s., such as excavator teeth, should be prevented from entering the Crusher by installing a magnetic separator. Uncrushable material larger than the c.s.s will cause the toggle plate to buckle, and will impose unnecessary stresses on the Crusher. If tramp iron enters and stays in the Crusher, stop the feeder and Crusher immediately. Be extremely

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5. Incorrect jaw dies.

cautious when emptying the cavity and removing the tramp iron. If possible increase the Crusher setting to remove the tramp iron.

To prevent packing, all possible causes must be addressed. If, however, the causes cannot be eliminated, the material level in the Crusher cavity must be lowered and/or the Crusher setting must be increased.

IMPORTANT! Always inspect the toggle plate, tension rod and spring (or hydraulic cylinder) for possible damage.

4.4.3 Packing The Crusher should never be operated when the feed is packing in the crushing cavity (i.e. when the feed packs in such a way that it cannot be reduced in size), as this results in a drastic reduction of the Crusher lifetime. IMPORTANT! Never operate the Crusher when the feed is packing in the cavity. This will result in a drastic reduction of the Crusher lifetime. When packing occurs, the: 1. Crusher speed slows down. 2. Engine speed slows down. 3. Load of the Crusher rises. 4. The Crusher is overloaded. Packing can occur due to the following reasons: 1. There is too much fines in the feed material. 2. The maximum feed size relative to the feed opening is very small (less than 50 % of the feed opening width). 3. The material is very brittle and readily breaks into fines (material characteristics). 4. Wet feed material.

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4.5 RE-STARTING A CRUSHER STALLED UNDER LOAD A stalled Crusher MUST be treated as possibly being jammed and therefore a potential hazard. Clear the plant area of all personnel. Notify the manager or his deputy of a stalled Crusher situation immediately. WARNING! Be extremely cautious when checking the crusher cavity. Tramp iron could be ejected from the crushing cavity. Serious personal injury can result. Find out why the Crusher stalled. If, after careful examination, there appears to be no electrical or mechanical reason why the Crusher has stalled, it would indicate that the Crusher is jammed by the ingress of foreign matter and is in a hazardous state. If a Crusher stalls under load any stored energy within a mechanism due to tramp material can be reduced to insignificant level by ensuring that the jaws are moved to the open position. After that start the Crusher. If the Crusher won't start, repeat this procedure. When the jaws are fully open, don't start the Crusher anymore. In this case stones and tramp metal must be removed from the Crusher manually.

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WARNING! Ensure that the crusher has stopped to the “rest position”. In other words there is no potential energy remaining in the flywheels. This can be determined from the position of the gib key. It should point down. (Figure 4-3) NOTE: If the gib key is not pointing down, start the crusher for a second.

Figure 4-3 At the “rest position” the gib key is pointing down

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4.6 CRUSHER SETTING ADJUSTMENT The setting adjustment of C Series Jaw Crushers is done either by means of moving two wedges against or away from each other or optionally with a active setting control.

WARNING! Turning the cap nuts should be made with the ratchet provided with the Crusher. NO HYDRAULIC OR PNEUMATIC WRENCH MAY BE USED

4.6.1 Mechanical wedge setting adjustment The movement of the wedges changes the effective thickness "s" of the wedge pair, which in turn increases or decreases the Crusher setting, respectively. The setting adjustment may be done mechanically by turning cap nut(s) manually, or alternatively hydraulically (option) through the use of an electrical control panel. For instructions concerning the hydraulic setting adjustment (option), refer to chapter 4.6.2. The main components of the device are the adjusting wedges, cap nut(s) (2) and locking pipe(s) (3). Changing the setting requires the use of the ratchet delivered with the Crusher (special tool) to turn the cap nuts.

IMPORTANT! The wedges are self-restraining and their surfaces must not be lubricated. It may overload the adjusting mechanism. To change the setting, the locking nuts of the tension rod must be loosened, and then the cap nuts must be turned clockwise or counterclockwise to increase or decrease the Crusher setting, respectively. A single complete rotation of one cap nut has a net effect on the Crusher setting as indicated in Table 4-1. Turning both cup nuts one complete rotation in the same relative direction will thus change the Crusher setting by twice as what is indicated in Table 4-1.

Model 4

Callout 1 2 3 4

Description Adjusting wedges Cap nut Locking pipe Rubber bellow

C80 C96 C100 C106 C110 C116 C3054 C125 C140 C145 C160 C200

Change in Setting mm (in) 2.3 (0.09) 2.2 (0.09) 2.3 (0.09) 2.2 (0.09) 2.0 (0.08) 2.3 (0.09) 2.3 (0.09) 1.7 (0.07) 2.3 (0.09) 2.5 (0.10) 2.2 (0.09) 3.2 (0.12)

Table 4-1 Average change in setting per cap nut rotation

Figure 4.4 Mechanical setting adjustment

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4.6.1.1 Decreasing the Crusher Setting

To calculate how many rotations the cap nuts must be turned to change the Crusher setting, simply divide the desired setting change amount by the appropriate value in Table 4-1 and the quantity of cap nuts.

WARNING! With mechanical setting adjustment the crusher setting can be adjusted only while the crusher is at the rest. Adjusting the tension spring during crusher running can cause return rod breakage, which may lead up to a serious injury or death.

Required Rotations = (Desired Setting Change)/(Crusher Change in Setting) Round the result to the nearest higher number.

Example:

The Crusher setting can only be adjusted while the crusher is at rest.

To change the setting of a C125 by 10 mm (3/8"), turn the cap nuts as follows: 10 mm / 1.7 mm / rotation = 5.88 => 6 total rotations => 3 rotations per cap nut

1. Stop crushing, then stop the Crusher.

3/8" / 0.07" / rotation = 5.35 => 6 total rotations => 3 rotations per cap nut

2. Determine how much the setting must be decreased and calculate how many rotations the cap nuts must be turned. 3. Loosen the locking nuts of the tension spring (Figure 4.5). Be careful not to drop the toggle plate as the spring gets loose. 4. Remove the locking pin from the locking pipe and push the pipe towards the Crusher. 5. Turn the cap nuts COUNTERCLOCKWISE. Make sure that both wedges are adjusted equally so that their position in relation to the Crusher remains the same. If you have to change the setting remarkably, turn the cap nuts for a while and loosen the spring locking nuts again if necessary. There are washers fastened to the rear end of the adjusting wedges. When decreasing the setting, push the wedges only until these washers are against the guide plates. 6. Lock the pipes with the pin. 7. Adjust the spring length according to Table 4-2 (see Figure 4.5). 8. Start the Crusher and listen if the toggle plate knocks. If it knocks, contact Metso. 9. Start crushing. WARNING! Always tighten and loosen the spring from the side. Never remove the protection plate

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4.6.1.2 Increasing the Crusher Setting The Crusher setting can only be adjusted while the crusher is at rest. 1. Stop crushing, then stop the Crusher. 2. Determine how much the setting must be increased and calculate how many rotations the cap nuts must be turned. Figure 4.5 Mechanical wedge setting adjustment

3. Loosen the locking nuts of the tension spring (Figure 4.5). 4. Remove the locking pin from the locking pipe and push the pipe towards the Crusher.

C80 C96 C100 C106 C110 C116

Tension Spring Length L mm (in.) 310 (12 ¼") 385 (15 ¼”) 370 (14 ½") 365 (14 ¼") 365 (14 ¼") 365 (14 ¼")

C3054

440 (17 1/3")

C125 C140 C145 C160 C200

425 (16 ¾") 540 (21 ¼") 540 (21 ¼") 540 (21 ¼") 540 (21 ¼")

Model

5. Turn the cap nuts CLOCKWISE. Make sure that both wedges are adjusted equally so that their position in relation to the Crusher remains the same. Be careful not to drop the toggle plate as the spring gets loose. 6. Lock the pipes with the pin. 7. Adjust the spring length according to Table 4-2 (Figure 4.5). 8. Start the Crusher and listen if the toggle plate knocks. If it knocks, contact Metso. 9. Start crushing. WARNING! Always tighten and loosen the spring from the side. Never remove the protection plate

Table 4-2 Tension Spring Operating Length

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4.6.2.1 Oil heater (optional)

4.6.2 Hydraulic wedge setting adjustment (optional) IMPORTANT! The hydraulic setting adjustment system in the Lokotrack is different from the system shown here. See details in the Lokotrack manual. Hydraulic wedge setting adjustment enables remote setting adjustments that are much quicker and simpler as setting adjustments are made remotely by operating a control panel.

The hydraulic setting adjustment power unit is equipped with a hydraulic oil heater. The heater’s thermostat is set to switch the heater on when the oil temperature is below 35°C (95°F). The heater can be switched on/off from the control panel (7, Figure 4.7). Use the heater for about 30 minutes before setting adjustment when the oil temperature is below 0°C (32°F).

4.6.2.2 Decreasing the setting Turn the setting adjustment switch 6 (located in the control panel) to the "decrease" position. Observe the wedge movement. Time relay in control panel will stop the adjusting after 6 sec. To adjust the setting more you have to turn the switch back to "neutral" position and again to "decrease" position. IMPORTANT! Do not let the jaw dies hit each other. Figure 4.6 Hydraulic wedge setting adjustment

The system is powered with an independent hydraulic unit, or it can be connected to a large hydraulic system, as in the Lokotrack. The hydraulic oil pressure forces the wedges either towards or apart from each other, therefore decreasing or increasing the setting, respectively.

Adjust the setting in several stages. Check the setting between adjustments, see the minimum setting in chapter General Crusher Information. After adjustment, check the pressure value in the tension cylinder.

Setting can be adjusted while the Crusher is at rest or idling. If adjustment of setting is done during crushing lifetime of crusher components is shorter. For detailed information, refer to the Installation Manual, Chp. 4.7 Installing the Hydraulic Unit.

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4.6.3 Active setting control adjustment (optional) 3 1

5 Active setting control adjustment is used in basically the same way as the hydraulic wedge setting adjustment.

2 4

The system is powered with an independent hydraulic unit, or it can be connected to a large hydraulic system, as in the Lokotrack. The hydraulic oil pressure moves the cylinder, which increases or decreases the setting.

7

Setting can be adjusted while the Crusher is at rest, idling or running. 6

Callout 1 2 3 4 5 6 7

Description Main switch Hydraulic pump Hydraulic pump, ON Setting (Increase <=> Decrease) Hydraulic pump running Oil heating (optional) Oil heating, ON

Figure 4.7 Setting adjustment control panel

4.6.2.3 Increasing the setting

Figure 4.8 Active setting control

Turn the setting adjustment switch 6 (located in the control panel) to the "increase" position. Observe the wedge movement. Setting adjustment may stop if the pressure in the tension cylinder decreases. To adjust the setting more you have to turn the switch back to "neutral" position and again to "increase" position. When the setting is increased, the pressure in the adjusting cylinder will rise automatically and the wedges will stop for a moment.

The active setting control also functions as a safety device. If there are any uncrushable objects in the jaw cavity, the pressure in the cylinders rises. When the pressure rises over a pre-set value, the pressure relief valves open and let the piston move backwards. The crusher setting opens and the uncrushable material can exit the jaw cavity. In a Lokotrack, after the uncrushable material has left the cavity, the setting returns to where it was.

After adjustment, check the pressure value in the tension cylinder.

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4.7 TOGGLE PLATE IMPORTANT! The active setting control works as a safety device only in the adjustment range of the cylinders. If the uncrashable object is larger than the maximum setting, the toggle plate collapses through elastic buckling. (See chapter 4.7)

For spontaneous overloading or uncrushable objects that are larger than the Crusher setting, such as excavator bucket teeth, the Crusher is equipped with a toggle plate that serves as a safety device. In the event of overloading, the toggle plate collapses through elastic buckling, frequently preventing damage to more costly parts.

4.6.3.1 Oil heater (optional)

IMPORTANT!

The hydraulic setting adjustment power unit is equipped with a hydraulic oil heater. The heater’s thermostat is set to switch the heater on when the oil temperature is below 20°C (68°F). The heater can be switched on/off from the control panel (7, Figure 4.7). Use the heater for about 30 minutes before setting adjustment when the oil temperature is below 0°C (32°F).

Note that the toggle plate is designed to buckle when overload events occur in the lower half of the crushing cavity. The toggle plate will not buckle if the crusher is overloaded due to oversized feed or an inadequate feed arrangement. Thus, in these cases, certain crusher components such as the eccentric shaft, flywheels, bearings and bearing housings will be unnecessarily loaded.

4.6.3.2 Decreasing the setting Turn the setting adjustment switch 6 (located in the control panel) to the "decrease" position. Time relay in control panel will stop the adjusting after 6 sec. To adjust the setting more you have to turn the switch back to "neutral" position and again to "decrease" position.

IMPORTANT! Although the toggle plate is designed to protect the more expensive Crusher components, certain overload events are often so violent in nature that it is possible for other components such as the tension spring, tension rod and tension spring bracket to fail when the toggle plate buckles

IMPORTANT! Do not let the jaw dies hit each other.

IMPORTANT!

Adjust the setting in several stages. Check the setting between adjustments, see the minimum setting in chapter General Crusher Information.

Toggle plate is not protecting crusher components of fatigue damages when crusher is continuously overloaded with smaller setting than allowed by Metso.

After adjustment, check the pressure value in the tension cylinder. 4.6.3.3 Increasing the setting Turn the setting adjustment switch 6 (located in the control panel) to the "increase" position. Observe the pitman movement. After adjustment, check the pressure value in the tension cylinder.

EN

The function of the toggle seats is based upon a rolling concept against the roll-shaped surfaces with different radii against each other. Therefore the toggle seats should be kept dry and must not be lubricated.

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IMPORTANT! Do not lubricate the toggle seats, toggle plate or toggle plate ends. This area of the crusher is designed to operate without lubrication.

IMPORTANT! Always use original Metso toggle plates. Using a toggle plate that is not manufactured by Metso will put the Crusher at risk and will void the Crusher's warranty. Check the condition of the seats and protection rubber regularly during weekly maintenance. They must be kept clear of dust and dirt. If dust has entered the seat surfaces, flush with running water. If there is no water available, compressed air may be used. It is important that dust doesn't enter these areas and contaminate seat surfaces. Toggle plate and seat installation and removal described in Maintenance chapter.

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4.8 SPACER A spacer may be placed between the lower adjusting wedge and the toggle seat holder (not applicable to models with the active setting control).

The use of the spacer reduces both the Crusher's minimum and maximum setting. Refer to the Crusher parts book for details concerning the effect of the spacer on the Crusher setting range for a specific jaw die profile. Spacer installation and removal instructions can be found in Maintenance chapter.

IMPORTANT! The use of the spacer makes it possible to use two different Crusher setting ranges, but its use does not permit that the Crusher is used with settings smaller than the minimum allowed settings (see the Crusher Setting section).

Callout 1 Spacer

Description

Figure 4-9 Spacer

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4.9 TROUBLESHOOTING

PROBLEM CAUSE Toggle plate falls out of Feed material is too large. seat. Tension spring too loose. Material fed directly onto the upper pitman cover.

Toggle plate seating surfaces wear prematurely. Toggle plate breaks (buckles).

Feed hopper has loosening or breaking bolts.

jaw die bolts loosening or breaking.

Insufficient capacity.

Stalled Crusher.

Tension cylinder hydraulic pressure too low. Tension spring too loose.

Tighten the tension spring.

Feed material is too small. Feed the Crusher with proper size material. Tramp iron or other uncrushable material caught near the bottom of the crushing chamber. Toggle plate not installed correctly. Feed material is being crushed too high in the chamber. Bolt fastener not applied to the feed hopper bolts. Incorrect jaw dies installed. Jaw dies installed incorrectly. Feed too large. Wrong direction of flywheel rotation. Incorrect speed. Discharge setting too small. jaw dies worn excessively. Loose jaw dies. Wrong jaw die profile. Large rock or tramp iron jammed in the crushing chamber. Discharge setting is too small. Power failure. Motor failure.

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REMEDY Feed the Crusher with proper size material. Make sure the feed hopper's rear wall is properly designed. Tighten the tension spring. Material must be fed into the crushing chamber without hitting the upper pitman cover. Make sure the feed hopper's rear wall is properly designed. Check the pressure.


Empty the crushing chamber to remove tramp iron or other uncrushable material.

When installing the toggle plate, inspect the toggle seats for good condition and smooth, even surfaces. RESTRICT FEED! Feed to keep the chamber 2/3 full with proper size material for greatest efficiency. Apply bolt fastener. Use Metso jaw dies. Re-install the jaw dies. Check for proper feed size. Make sure the flywheels turn in the correct direction. Check for proper speed. Increase the discharge setting. Replace the jaw dies. Tighten the jaw die bolts. Consult your Metso representative. Remove stuck material. DO NOT USE EXPLOSIVES TO CLEAR A STALLED CRUSHER! Each Crusher has a minimum recommended setting. DO NOT use a smaller setting unless authorized by Metso. Check all fuses in the motor electrical control panel. Check the motor.

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PROBLEM

Excessive vibration.

Bearings too hot.

Crusher speed varies.

A "knocking" is heard while operating.

Movement of the jaw dies.

CAUSE Damaged and/or loose V-belts. Wrong speed. Flywheels loose.

REMEDY Check the condition of the V-belts.

Flywheel aligned with the wrong keyway (gibkey) during assembly. Counterweights incorrectly installed. Bearings damaged. Too much or insufficient grease. Incorrect crusher speed. Crusher operating at a smaller setting than recommended. Crusher not level. Feeding the Crusher with very fine material. Damaged and/or loose V-belts. Inadequate plant voltage level. Tension spring too loose. Toggle plate improperly seated. Loose jaw dies. Jaw dies hitting each other. Tension cylinder hydraulic pressure too low. Loose jaw dies. Inadequate clearance.

Operate the Crusher at the recommended speed. Tighten the flywheels properly. Weld the bolts together with plates to prevent them from coming loose. Remount the flywheel with the appropriate keyway (gibkey). Consult your Metso representative. Consult your Metso representative. Use correct quantity of grease for each bearing. Seat a schedule for greasing of the bearings. Check the Crusher's speed. Each Crusher has a minimum recommended setting. DO NOT use a smaller setting unless authorized by Metso. Check or re-level the Crusher. Feed the Crusher with proper size material. Check the condition of the V-belts. Check the plant's voltage level. Tighten the tension spring. Check the toggle plate and seats for wear. Tighten the jaw die bolts. Check the Crusher's discharge setting. Check the pressure. Tighten the jaw die bolts. Check that the clearance between the upper and lower jaw dies is between 5-8 mm (3/16-5/16"). Repair the lug. Drop a couple of small stones to cavity to decrease friction between wedges. Check the possible oil leaks.

Centralizing lug worn out. Adjusting wedges don´t Wedge surfaces worn. move Active setting control: The seals are leaking. The setting opens by itself. There is no uncrushable material in the cavity. Pressure relief valves are Contact Metso. faulty. Feed material is too small. Feed the crusher with proper size material.

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MAINTENANCE

CHAPTER

5


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CHAPTER 5 - MAINTENANCE



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5.1 SPACER

5.1.1 Spacer Installation

A spacer is only used in crushers with wedge setting adjustment.

1. Open the crusher’s setting to maximum

A spacer may be placed between the lower adjusting wedge and toggle seat holder (Figure 5.2). Use of the spacer makes it possible to use two different crusher setting ranges. Never use a setting smaller than the minimum allowed setting even using the spacer. After installing or removing the spacer the crusher setting must be adjusted (also when using hydraulic setting adjustment). Before you operate the machine make sure that there is no clearance between the upper and lower wedge. When using the spacer make sure there is no clearance between the spacer and adjusting wedges. IMPORTANT! After installing or removing the spacer the Crusher setting and the spring tension must be adjusted.

2. a. Hydraulic setting: In the valve unit, release the hydraulic pressure from the return cylinder by turning the knob of the shut-off valve (1) counter-clockwise. You can check the pressure level from the pressure gauge (2).

Figure 5.2 Spacer makes it possible to use two different crusher setting ranges

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IMPORTANT! Be careful not to drop the toggle plate.

2b. Mechanical setting: Loosen the tension spring in order to be able to move the pitman. 3. Use a come-along in order to retract the pitman. Attach a shackle (1) and the wire rope/chain (2) to the back of the pitman. Attach the come-along properly to the frame structures to use it safely.

5. Insert the spacer between the front wedge and toggle seat holder by inserting the spacer through the side plate hole. WARNING! Always tighten and loosen the spring from the side. Never remove the protection plate

1 2 4. Inch the come-along until the lower adjustment wedge touches the washers (or the jaw dies contact each other). DANGER! Do not stay directly under the crusher when using the come-along. Falling toggle plate may crush and cut.

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6. Release the pitman and remove the come-along and shackles. 7. a. Hydraulic setting: Pressurize the return cylinder by turning the knob of the shut-off valve clockwise in the valve unit (check the pressure level from the pressure gauge). 7 b. Mechanical setting: Fasten the locking nuts of the tension spring. Adjust the tension spring length. IMPORTANT! After installing or removing the spacer the Crusher setting and the spring tension must be adjusted

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5.1.2 Spacer Removal 1. When removing the spacer pull the setting adjustment wedges as far out as possible. Secure the wedges so that they do not slide down when spacer is being removed.

2. Make sure that the toggle plate does not fall down.

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3. Loosen the tension rod spring to make it possible to move the pitman.

4. Pull the pitman forward with a come-along. Remove the flange from the end of the spacer. Then pull the spacer out.

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5.2 TOGGLE PLATE

6. Support the lower setting adjustment wedge to its position by using a proper sling. Make sure that the sling is properly tensioned.

5.2.1 Replacing the Toggle Plate And Toggle Seats (with wedge setting adjustment) If the toggle plate has to be replaced, it is recommended that the following steps be followed: 1. Open the crusher's setting to maximum.

5_9_1_3

7. a. Hydraulic setting:

5_9_1_1

In the valve unit, release the hydraulic pressure from the return cylinder by turning the knob of the shut-off valve (1, fig below) counterclockwise. You can check the pressure level from the pressure gauge (2, fig below).

2. Remove all necessary covers. 3. Attach and tighten lifting hooks (3, fig below) to the toggle plate on both sides. 4. Attach the chain of a come-along to the toggle plate lifting tool (3, fig below) and upper end for example to the eyebolt of the pitman (4, fig below).

5_9_1_2

5. Tension the come-along so that the toggle plate does not drop.

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7 b. Mechanical setting: Remove the locking nuts of the tension spring (fig below).

DANGER! Do not stay directly under the crusher when using the come-along.

WARNING!

Falling toggle plate may crush and cut.

Always tighten and loosen the spring from the side. Never remove the protection plate

11. Lower the toggle plate on to the discharge conveyor belt and take it out. 12. Check the condition of the toggle seats and other related components. 13. Replace the toggle seats if they are damaged. 14. Install the new toggle plate and release the pitman. 15. Remove lower adjusting wedge support. 16. a. Hydraulic setting:

5_9_1_5

8. a. Hydraulic setting: Unfasten the return cylinder from the pitman. 8 b. Mechanical setting: Unfasten the tension rod from the pitman. 9. Use a come-along in order to retract the pitman. Attach a shackle (1) and the wire rope/chain (2) to the back of the pitman. Attach the come-along properly to the frame structures to use it safely.

Attach the return cylinder to the pitman and pressurize the hydraulic return cylinder 16 b. Mechanical setting: Attach the tension rod to the pitman and fasten the locking nuts of the tension spring. Adjust the tension spring length according to Table 5.1 17. Remove the toggle plate lifting tool.

1 2 10. Inch the come-along until the toggle plate is loose.

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2. Remove all necessary covers. Callout 1 2 3 4

3. Attach and tighten lifting hooks (3, fig below) to the toggle plate on both sides.

Description Lifting tool Chain block Protection rubber Chain block

4. Attach the chain of a come-along to the toggle plate lifting tool (3, fig below) and upper end for example to the eyebolt of the pitman (4, fig below).

Figure 5.3

Model C80 C96 C100 C106 C110 C116

Tension Spring Length L mm inch 310 12 ¼ 385 15 ¼ 370 14 ½ 365 14 ¼ 365 14 ¼ 365 14 ¼

C3054

440

17 1/3

C125 C140 C145 C160 C200

425 540 540 540 540

16 ¾ 21 ¼ 21 ¼ 21 ¼ 21 ¼

5_9_1_2

5. Tension the come-along so that the toggle plate does not drop. 6. Ensure that the pistons cannot move.

Table 5.1 Tension spring operating length

7. In the valve unit, release the hydraulic pressure from the return cylinder by turning the knob of the shut-off valve (1, fig below) counterclockwise. You can check the pressure level from the pressure gauge (2, fig below).

5.2.2 Replacing the Toggle Plate And Toggle Seats with Active Setting Control If the toggle plate has to be replaced, it is recommended that the following steps be followed: 1. Open the crusher's setting to maximum.

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13. Replace the toggle seats if they are damaged. 14. Install the new toggle plate and release the pitman. 15. Release the pistons. 16. Attach the return cylinder to the pitman and pressurize the hydraulic return cylinder 17. Remove the toggle plate lifting tool.

8. Unfasten the tension cylinder from the pitman. 9. Use a come-along in order to retract the pitman. Attach a shackle (1) and the wire rope/chain (2) to the back of the pitman. Attach the come-along properly to the frame structures to use it safely.

1 2 10. Inch the come-along until the toggle plate is loose. DANGER! Do not stay directly under the crusher when using the come-along. Falling toggle plate may crush and cut. 11. Lower the toggle plate on to the discharge conveyor belt and take it out. 12. Check the condition of the toggle seats and other related components.

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5.3 LUBRICATION Brand CASTROL BP ESSO GULF KLUBER MOBIL SHELL SKF CALTEX TOTAL

5.3.1 GENERAL The appropriate lubrication of your crusher is of outmost important. To ensure that your crusher is appropriately lubricated at all times, follow the instructions provided in this chapter diligently.

5.3.2 Grease Specifications For lubrication points, lithium-based multi-purpose grease with the following characteristics is required:

Type APS 2 Energrease LS-EP 2 Mobilux EP 2 Gulfcrown Grease EP 2 Centoplex 2 EP Mobilux EP 2 Alvania Grease EP 2 LG EP 2 Starplex EP 2 Complex EP 2

Table 5.2 Recommended grease brands

•

NLGI-class of 2

WARNING!

•

Minimum viscosity of the base oil must be 160 mm2/s (cSt) in +40ºC/104ºF with a minimum viscosity-index 80.

•

Appropriate for cold temperatures (-30ºC/-22ºF) and hot temperatures (continuous operating temperatures of +100ºC/212ºF).

Do not use grease types containing molybdenum or calcium as their solid components cause additional wear in the bearings and thus decrease bearing lifetime.

•

Good resistance to water

•

The grease must not oxidize easily and it must contain EP-additives.

Some of the recommended lithium based grease brands are as follows. Other grease brands with similar characteristics may be used as well.

EN

IMPORTANT! C Series crushers are not designed to operate at temperatures lower than -30ºC/-22ºF. Should operating temperatures be lower than -30ºC/-22ºF, contact Metso. Metso does not recommend that different brands of grease are mixed. When in doubt, please contact Metso.

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5.3.3 Eccentric Shaft Bearings IMPORTANT! Lubrication of the jaw crusher spherical roller bearings is accomplished by using a manual type grease gun or an automatic lubricating system through four grease fittings. Refer to Figure 5.4 and Figure 5.5. Some crushers are equipped with the distributor unit with grease nipple (Figure 5.6). Through that nipple, grease is distributed to all four bearings. NOTE: When adding grease, make sure that the amount of grease is adequate for four bearings. Refer to Table 5.4.

In cold operating temperature: Crushers equipped with the distributor with grease nipple or the automatic lubrication system ensure the function of the greasing system. Stiffened grease might not reach the lubrication point. If necessary, disconnect the grease hoses and lubricate manually through the grease nipple on each point.

IMPORTANT! Use only grease brands recommended by Metso even in the very cold temperatures.

Figure 5.4 Lubrication of jaw crusher spherical roller bearings with grease gun

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Callout 1 Pump unit

Description

Callout Description 2 Distributor unit

Figure 5.5 Lubrication of jaw crusher spherical roller bearings using automatic lubricating system

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Callout Description 1 Grease nipple

Callout Description 2 Distributor unit

Figure 5.6 Distributor unit with grease nipple

During operation there is always a very slight working of the grease out through the pitman and frame bearings and adjacent labyrinth seals. Movement of the grease out of the bearing and the adhering of grease outside the seal, protects the bearing and seal from foreign particles. By observation of this grease working action, the operator will soon be able to estimate the amount and frequency of bearing grease requirements. The amount of grease required and the length of time between greasings will vary in accordance with operating conditions.

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Before greasing the bearings, thoroughly clean the area around each grease fitting before removing the cover from the fitting. If the grease gun method of lubrication is used, add the grease immediately after shut down while the bearings are still warm. Refer to the Lubrication Schedule in Table 5.3.

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Model

C80 C96 C100 C106 C110 C116 C3054 C125 C140 C145 C160 C200

Manual Lubrication Normal Conditions Very Dusty Conditions (every 80 hours) (every 40 hours) Grease Amount/Nipple Grease Amount/ Nipple grams (oz.) grams (oz.) 60 (2.1) 30 (1.1) 125 (4.4) 63 (2.2) 175 (6.1) 88 (3.1) 125 (4.4) 63 (2.2) 175 (6.1) 88 (3.1) 175 (6.1) 88 (3.1) 175 6.1) 88 (3.1) 250 (8.8) 125 (4.4) 300 (10.5) 150 (5.3) 300 (10.5) 150 (5.3) 400 (14) 200 (7) 500 (17.5) 250 (8.8)

Automatic Lubrication All Conditions (continous) Grease Amount/ Nipple g/h (oz./h) 1.1 - 1.8 (.04 - .06) 2.0 - 3.4 (.07 - .11) 2.9 - 4.8 (.1 - .17) 2.0 - 3.4 (.07 - .11) 2.9 - 4.8 (.1 - .17) 2.9 - 4.8 (.1 - .17) 2.9 - 4.8 (.1-.17) 3.9 - 6.5 (.14 - .23) 4.7 - 7.8 (.16 - .27) 4.7 - 7.8 (.16 - .27) 5.9 - 9.8 (.2 - .34) 7.7 - 12.9 (.27 - .45)

Table 5.3 Lubrication schedule of eccentric shaft bearings

Model

C80 C96 C100 C106 C110 C116 C3054 C125 C140 C145 C160 C200

Manual Lubrication (distributor with grease nipple) Normal Conditions Very Dusty Conditions (every 80 hours) (every 40 hours) Grease Amount Grease Amount grams (oz.) grams (oz.) 240 (8.4) 120 (4.4) 500 (17.6) 252 (8.8) 700 (24.4) 352 (12.4) 500 (17.6) 252 (8.8) 700 (24.4) 352 (12.4) 700 (24.4) 352 (12.4) 700 (24.4) 352 (12.4) 1000 (35.2) 500 (17.6) 1200 (42) 600 (21.2) 1200 (42) 600 (21.2) 1600 (56) 800 (28) 2000 (70) 1000 (35.2)

Table 5.4 Lubrication schedule of eccentric shaft bearings (distributor with grease nipple (Figure 5.6))

IMPORTANT! Avoid using too much grease as excessive grease will cause overheating and shorten the bearing life.

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5.3.4 Eccentric Shaft Bearing Temperatures Bearing temperature should be checked frequently and greasing accomplished immediately if an unusual temperature rise is noted. During operation, bearings will feel warm to the touch but it should always be possible to touch them for a few seconds without discomfort to the hand. Normal bearing operating temperature is 40-70°C (104-158°F). Should operating temperature reach 75°C (167°F) or in very warm conditions 90°C (194°F) a check should be made to determine the cause. A check should also be made, if one bearing is over 10-15°C (18-27°F) warmer than the other bearings. IMPORTANT! C Series crushers are not designed to operate at temperatures lower than -30ºC/-22ºF. Should operating temperatures be lower than -30ºC/-22ºF, contact Metso.

IMPORTANT! If temperature sensors are not installed on the crusher, temperature reading must be done when the crusher is at rest.

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5.3.5 Jack-shaft Bearings When applicable, the jack-shaft bearings must be lubricated manually with a grease gun. Before greasing the bearings, thoroughly clean the area around each grease fitting before removing the cover from the fitting. If the grease gun method of

lubrication is used, add the grease immediately after shut down while the bearings are still warm. Refer to the Lubrication Schedule in Table 5.5.

Figure 5.7 Jack-shaft bearings lubrication (electric drive)

Figure 5.8 Jack-shaft bearings lubrication (hydraulic drive)

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5.3.7 Thrust Bearing And Cap Nut Bearings

Model

C80 C96 C106 C110 C116 C3054 C125 C140 C145 C160 C200

This only applies to crushers equipped with mechanical setting adjustment. The turning cap nut(s) and the thrust bearing must be manually lubricated in accordance with the following Lubrication Schedule (Table 5.6).

Very Dusty Normal Conditions Conditions (every 80 hours) (every 40 hours) Grease Amount/ Grease Amount/ Nipple Nipple grams (oz.) grams (oz.) 40 (1.4) 20 (0.7) 40 (1.4) 20 (0.7) 40 (1.4) 20 (0.7) 70 (2.5) 35 (1.2) 55 (2) 28 (1) 55 (2) 28 (1) 70 (2.5) 35 (1.2) 70 (2.5) 35 (1.2) 70 (2.5) 35 (1.2) 80 (2.8) 40 (1.4) 80 (2.8) 40 (1.4)

Model C80 C96 C106 C110 C116 C3054 C125 C140 C145 C160 C200

Table 5.5 Lubrication schedule of jack-shaft bearings

IMPORTANT!

Thrust Bearings Cap Nut(s) Grease Grease Amount/ Amount/Nipple Nipple grams (oz.) grams (oz.) n/a 20 (0.7) 20 (0.7) 20 (0.7) 20 (0.7) 20 (0.7) 20 (0.7) 20 (0.7) 20 (0,7) 20 (0,7) 20 (0.7) 20 (0.7) 20 (0.7) 20 (0.7) 20 (0.7) 20 (0.7) 20 (0.7) 20 (0.7) 20 (0.7) 20 (0.7) 20 (0.7) 20 (0.7)

Table 5.6 Lubrication schedule of thrust bearings

Avoid using too much grease as excessive grease will cause overheating and shorten the bearing life.

5.3.8 Tension Cylinder Slide Bearings 5.3.6 Jack-shaft Bearing Temperatures Bearing temperature should be checked frequently and greasing accomplished immediately if an unusual temperature rise is noted. During operation, bearings will feel warm to the touch but it should always be possible to touch them for a few seconds without discomfort to the hand. Normal bearing operating temperature is 40-70°C (104-158°F). Should operating temperature reach 75°C (167°F) or in very warm conditions 90°C (194°F) a check should be made to determine the cause.

This only applies to crushers equipped with tension cylinder. Add 20 g (0.7 oz.) grease per grease nipple every 80 h (40 h in very dusty conditions). Stop the crusher and release the pressure before performing the lubrication. For more detailed instructions refer to the section 5.1.1.

5.3.9 Electric Drive Motor For instructions, refer to the motor documentation that has been provided with the crusher.

IMPORTANT! If temperature sensors are not installed on the crusher, temperature reading must be done when the crusher is at rest.

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5.3.10 Toggle Seats And Toggle Plate

IMPORTANT! Do not lubricate the toggle seats, toggle plate or toggle plate ends. This area of the crusher is designed to operate without lubrication

Figure 5.9 Do not lubricate the toggle seats, toggle plate or toggle plate ends

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5.3.11 Setting Adjustment Wedges

5.4 INSTRUCTIONS FOR LIFTING A JAW CRUSHER WHEN REPLACING CRUSHER SUPPORT BRACKET DAMPERS

CAUTION! Do not lubricate the setting adjustment wedges. This area of the crusher is designed to operate without lubrication. Water or dust suppression spray mists must be kept away from this area of the Crusher.

Two crusher lifting brackets (if applicable) are used to lift a jaw crusher when replacing crusher support bracket dampers. The crusher is lifted one side at a time. For location of the crusher lifting bracket in relationship to the crusher, refer to Figure 5.10. 1. Loosen and remove stop block bolts and rubber dampers. 2. Fasten the lifting brackets with bolts to crusher support bracket. WARNING! Make sure that the lifting bracket bolts are properly tightened before attempting to lift the crusher. 3. Once the lifting brackets are secured to the crusher brackets, place a hydraulic jack (cylinder) under each lifting bracket. WARNING! Make sure that the jacks that were selected are capable of lifting the crusher weight. Weight of the crusher should be checked from the machine plate of the crusher. 4. Once desired height is achieved to remove worn dampers, block the crusher with timber or steel blocks. WARNING! Do not attempt to remove the worn dampers before the crusher is properly blocked. 5. Remove worn dampers and replace with new. Refer to Table 5.11. 6. Remove the blocks. 7. Simultaneously lower the crusher on the dampers. 8. Remove the jacks and crusher lifting brackets. 9. Repeat the procedure on the opposite side.

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2 3

1 4

Callout Description 1 Lifting bracket 2

Bolt

Callout Description 3 Washer Hydraulic cylinder (not a part of the 4 delivery) Figure 5.10

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5.5 HYDRAULIC POWER UNIT (OPTIONAL) The hydraulic setting adjustment is powered with an independent hydraulic power unit, or it can be integrated to an extensive hydraulic system, as in the Lokotrack. Hydraulic power unit produces oil flow to the adjusting cylinders and keeps the correct pressure level in the tension cylinder. Hydraulic setting adjustment system has a dump valve, which automatically releases the tension cylinder pressure when the crusher is stopped. This helps adjustment wedges to move smoother. This function is tightly limited to take place only when the crusher is completely stopped. After the power of the crusher motor is switched off, time relay prevents valve to open until preset time (Table 5.7). This prevents pressure release while the crusher is coasting down. The pressure release while crusher is rotating will cause the drop of the toggle plate.

Model

Time relay setting (min)

C80 C96 C100 C106 C110 C116 C3054 C125 C140 C145 C160 C200

2 2 2 2 2 2 2 3 3 3 4 7

Table 5.7

Hydraulic setting adjustment system relief valve pressure settings and pressure accumulator filling pressures are shown in Table 5.9.

5.5.1 Checking oil level and temperature Hydraulic oil level can be checked from sight glass (3) on the tank's front panel. Oil level is correct when the oil level is visible in the sight glass. The glass also houses a thermometer showing the temperature of the oil in the tank.

5.5.2 Changing oil and filter (Figure 5.11) Change oil and the filter in the hydraulic unit for the first time after 100 operating hours. After that the oil and the filter must be changed at 1000 hour intervals or at least twice a year. •

Stop the crusher and wait until it is completely stopped.

•

Turn off and lock out power from main switch (located in the control panel).

•

Remove cover of the hydraulic power unit.

•

Blow off the dust on the unit using pressurized air.

•

In the valve unit, release the hydraulic pressure from the tension cylinder by turning the knob of the shutoff valve (1) counterclockwise. You can check the pressure level from the pressure gauge (2). Remember to shut the pressure gauge valve after checking.

•

Drain oil by removing the drain plug (5).

•

Loosen the filter cover (4) screws.

•

Pull the cover out carefully. Observe the filter assembly when it is dismantled for the first time.

•

Pull the filter cartridge out. If possible, clean the filter base groove. Protect the filter housing from contamination when changing filter cartridges.

•

Install a new cartridge.

WARNING! Only authorized personnel can adjust relief valves and refill the accumulator.

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•

Check the seal surfaces and renew seal if necessary.

•

Replace the cover carefully, so that the cartridge settles into the correct position.

•

Fill the oil tank with new oil. Oil amount is: –

40 litres (10½ gal) in all crushers other than C200

–

125 litres (33 gal) in C200 and machines with Active Setting Control.

•

Tighten the pressure relief knob (1).

•

Turn the main switch on and check the pressure level of the tension cylinder from pressure gauge (2). Correct pressure values are shown in Table 5.9. Remember to shut the pressure gauge valve after checking.

•

Check the oil level.

Figure 5.11 Hydraulic power unit

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5.5.3 Oil recommendation Oil amount in the hydraulic unit is: –

40 litres (10½ gal) in all crushers other than C200

–

125 litres (33 gal) in C200 and machines with Active Setting Control.

Use only high quality hydraulic oil with good resistance to corrosion, water, air and foam. The oil must not oxidize easily. The minimum viscosity index is 100. Suitable brands are listed in Table 5.8. Ambient Ambient temperature temperature -40...+35°C -10...+60°C (-22...+77°F) (+14...+140°F) BP Bartran HV 32 Bartran HV 46 ESSO Nuto H 32 Nuto H 46 SHELL Tellus Oil T 32 Tellus Oil TX 46 Tebo Hydraulic Lift Tebo Hydraulic Lift TEBOIL 32 46 MOBIL DTE 13M DTE 15M CASTROL Rando HD 32 Rando HD 46 Table 5.8 Suitable oil brands

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Model C80 C96 C100 C106 C110 C116 C3054 C125 C140 C145 C160 C200

Tension cylinder lower limit bar (PSI) 80 (1160) 100 (1450) 135 (1960) 135 (1960) 135 (1960) 160 (2321) 135 (1960) 80 (1160) 135 (1960) 135 (1960) 90 (1305) 100 (1450)

Tension cylinder upper limit bar (PSI) 100 (1450) 115 (1670) 155 (2250) 155 (2250) 155 (2250) 175 (2538) 155 (2250) 100 (1450) 155 (2250) 155 (2250) 105 (1520) 120 (1740)

Pressure accumulator filling pressure bar (PSI) 70 (1015) 80 (1160) 100 (1450) 100 (1450) 100 (1450) 130 (1885) 100 (1450) 70 (1015) 100 (1450) 100 (1450) 75 (1090) 85 (1230)

Pressure relief valve bar (PSI) 120 (1740) 125 (1815) 170 (2465) 170 (2465) 170 (2465) 190 (2756) 170 (2465) 120 (1740) 170 (2465) 170 (2465) 125 (1815) 145 (2100)

Table 5.9 Tension cylinder and accumulator pressures

Model C96

Tension cylinder lower limit bar (PSI) 100 (1450)

Tension cylinder upper limit bar (PSI) 150 (2175)

Pressure accumulator filling pressure bar (PSI) 80 (1160)

Pressure relief valve bar (PSI) 170 (2465)

Table 5.10 Tension cylinder and accumulator pressures for crushers with active setting control

WARNING!

5.5.4 Bleeding the hydraulic system

Air in the tension cylinder may cause the toggle plate fall down.

WARNING! Pressurized oil in the system. Oil can splash causing severe injury or death.

CAUTION!

Use eye protection and safety gloves.

Read the oil supplier’s safety instructions before handling hydraulic oil. Beware of hot oil!

Air in the hydraulic system can be bled with the following procedures. When installing the adjusting cylinders, tension cylinder and pipes/hoses must be properly filled with hydraulic oil. Observe oil level during bleeding and add oil if necessary. Recover all hydraulic oil coming out from the system during bleeding. Waste it properly.

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Bleeding the tension cylinder when the cylinder is removed for maintenance or is new: 1. Place the tension cylinder and the pressure accumulator beside the crusher. Turn hose couplings upwards and the piston rod end of the cylinder higher than the other end.

6. Ask an assistant to turn the hydraulic power unit on and observe the oil coming out from the system. Recover the oil to a container and waste it properly. 7. Wait until the oil has no air bubbles in it and tighten the screw immediately.

2. Push the piston rod fully in. 3. Fill the cylinder, accumulator and hoses with new hydraulic oil. Prevent contamination. 4. Connect the hoses and disconnect the C-line from the hydraulic power unit (refer to the Installation Manual, fig. 4-11 and 4-12). Plug the C-line hose by the power unit. Prevent contamination. 5. Install the accumulator and the tension cylinder’s cap end to the rear frame. 6. Ask an assistant to unplug the C-line hose and pull the piston rod of the tension cylinder out enough to install it to pitman. Use a come-along if needed. The oil coming out from the C-line hose must be recovered and wasted properly. The hose must be connected to the power unit immediately after the rod is out enough. 7. Install the rod end of the tension cylinder. Bleeding the tension cylinder when the cylinder has not been removed. 1. Stop the crusher and wait until it is completely stopped. 2. Turn off the hydraulic unit power from the main switch (located in the control panel). 3. Make sure that the toggle plate does not drop (See chapter 5.2.1). 4. In the valve unit, release the hydraulic pressure from the return cylinder by turning the knob of the shutoff valve (Figure 5.11: 1) counterclockwise. You can check the pressure level from the pressure gauge (Figure 5.11: 2). Remember to shut the pressure gauge valve after checking. 5. Loosen the vent screw (Figure 5.12: 1) of the pressure accumulator carefully using a 10mm wrench. Do not turn the screw for more than 8 revolutions.

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Figure 5.12 Pressure accumulator vent screw

Bleeding the adjusting cylinders: 1. Stop the crusher and wait until it is completely stopped. 2. Adjust the setting to maximum. 3. Slightly loosen the hoses at the inner ends of the adjusting cylinders. Recover the oil to a container and waste it properly. 4. Turn the setting adjustment switch to the "decrease" position. Observe the oil coming from the hose. Tighten the hoses when the oil has no air bubbles in it. 5. Slightly loosen the hoses at the outer ends of the adjusting cylinders. Recover the oil to a container and waste it properly. 6. Turn the setting adjustment switch to the "decrease" position. Observe the oil coming from the hose. Tighten the hoses when the oil has no air bubbles in it. Do not let the jaw dies hit each other!

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Bleeding the active setting control cylinders: 1. Stop the crusher and wait until it is completely stopped. 2. Decrease the setting, if it is increased, to fill the cylinders with oil. 3. Loosen the bleeding screws (Figure 5.13: 1). 4. Turn the setting adjustment switch to the "increase" position. Observe the oil coming from the hose. Tighten the screw when the oil has no air bubbles in it. Recover the oil to a container and waste it properly.

Figure 5.13 Active setting control vent screws

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5.6 PERIODICAL MAINTENANCE

3. Check the tightness of the cheek plate bolts (B), see the tightening torque in chapter 5.8.

5.6.1 Daily maintenance •

4. Check that the protection rubber of the toggle plate (C) is in good condition and in place.

BEFORE STARTING See Figure 5.14 for reference. 1. Check the tension of the V-belts. See chapter 3.8.2 Installation Manual. 2. Check the tightness of the jaw die bolt nuts (A). The washers must be in the level with the disc spring housing 0-0,5mm (0-0.02")

5. Clean all safety signs and ensure that they are legible. 6. Active setting control: Drive the setting to the minimum and to the maximum to ensure the functioning of the lubrication. 7. Active setting control: Check for possible oil leaks. 8. Check the tension and operation of the return rod, see chapter 4.4 - 4.7 Installation Manual.

Figure 5.14 C80, C96, C100, C106, C110, C116, C125, C140, C145, C160, C200

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•

Lubricate the cap nut bearings of the setting adjustment device and check their rubber bellows (mechanical setting adjustment), see Chapter 5.3.7 .

DURING OPERATION

Listen to the sound of the bearings and check their temperature (max. 75°C/167°F). Check for the proper outflow of grease.

Check the wear on the cheek plates. Change if necessary. 5.6.2 Weekly Maintenance

Check the toggle plate for alignment, straightness and cracks.

If an automatic lubrication device is not used, lubricate the eccentric shaft bearings (Figure 5.15). Before lubrication, the grease nipples must be cleaned. Under normal operating conditions add grease every 80 operating hours. Under dusty condition the frequency must be doubled (to every 40 hours). See the required grease quantity in Table 5.3.

Check the toggle seats and their stopper plates. Clean or replace if necessary. Check the tightness of the frame tie bolts. Check the mounting and condition of the flywheel and the tightness of the gib keys. Check the mounting of the crusher.

Figure 5.15 Lubricate eccentric shaft bearings weekly

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5.6.3 Monthly Maintenance

5.6.4 Twice a Year

Check the tightness of the frame mounting bolts on the side plates.

Check the condition of the eccentric shaft bearings, using e.g. a hearing device.

Check the rubber dampers under the crusher's mounting brackets. If any damper is damaged, it should be changed. Refer to Table 5.11.

Check for any wear on the seating surfaces of the pitman as well as the front frame.

Model C80 C96 C100 C106 C110 C116 C3054 C125 C140 C145 C160 C200

Height of the rubber damper (mm) worn, installed new, uninstalled (to be replaced) 15 11 20 14 16 12 15 11 32 25 32 25 32 25 32 25 32 25 32 25 32 25 35 26

Check for any wear on the seating surfaces between the side plates and cheek plates. Check the active setting control seals for leaks. Replace the seals, if necessary. Check the pressure of the pressure accumulator. This is allowed only for authorized personnel.

5.6.5 Regularly Change oil and the filter in the hydraulic unit first time after 100 operating hours. After that the oil and the filter must be changed at 1000 hours intervals or at least twice a year.

Table 5.11 Height of the rubber damper

NOTE: The rubber dampers must be installed to the crusher when they are measured.

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5.7 MAINTENANCE INTERVALS ITEM

Daily

Check V-belt tension. Check the tightness of jaw die bolts. Check the tightness of cheek plate bolts. Check wear on the jaw dies Check the sound, temperature (max. 75°C/167°F) and grease flow in the eccentric bearings. Lubricate eccentric shaft bearings. Check wear on the cheek plates. Check toggle plate for alignment, straightness and cracks Check the toggle seats and their stopper plates. Clean or replace as necessary. Check the tightness of the mounting bolts of the labyrinth covers. Check the tightness of the frame tie rods Check the mounting and condition of the flywheel and the tightness of the gib keys. Lubricate crusher drive jackshaft (optional). Check the tightness of the frame mounting bolts on the side plates. Check the rubber dampers under the crusher's mounting brackets, and the mounting of the crusher. Check the bearings on the eccentric shaft. Check for any wear on the contact surfaces of the pitman and front frame. Check for any wear on the contact surfaces between the side plates and cheek plates. Mechanical wedge setting adjustment Check tension and operation of tension rod spring. Lubricate the cap nuts of the setting adjustment device Check the rubber covers Lubricate thrust bearing. Hydraulic wedge setting adjustment Check the pressure of the tension cylinder. Check operation and oil amount (add oil if necessary). Change oil and filter. Check the pressure accumulator pressure (only authorized person). Active setting control Drive the setting to the minimum and to the maximum to ensure the functioning of the lubrication. Check for possible oil leaks. Check the seals for leaks. Replace the seals, if necessary. Check the pressure accumulator pressure (only authorized person).

X X X X

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Weekly Monthly

Every 6 months

X X X X X X X X X X X X X X

X X X X X X X X

X X X X



ITEM

Daily

Automatic lubricating device Check operation and grease amount (add grease if necessary).

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Weekly Monthly

Every 6 months

X

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5.8 BOLT TORQUE VALUES NOTE: Tightening torques of the bearing housing bolts, frame tie rods and flywheel bolts must be checked from the Installation Manual. All other bolts must be tightened according to the table below. Correct pretightening is possible only with clean , unlubricated screw threads that are not surface treated. The table applies to bolts with property class 8.8.

Bolt M10 M12 M16 M20 M24 M30 M36 M42 M48 M52 M56 M64 M72 M80 M100

Nm 47 81 196 382 662 1320 2310 3700 5590 7180 8960 13460 19350 26850 53340

Torque kpm 4.8 8.3 20 39 67 135 236 378 570 733 914 1370 1970 2740 5440

ft lbs 35 60 145 285 490 975 1705 2730 4125 5295 6610 9930 14275 19805 39280

Table 5.12

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REPLACEMENT OF WEAR PARTS

CHAPTER

6

DANGER! When lifting the crusher or its components, be extremely cautious! Never go under the suspended load! Make sure that there are no people in the lifting area during lifting! All lifting operations must be performed by the experienced professional! Before lifting ensure that all lifting tools and lifting points are in good condition!


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CHAPTER 6 - REPLACEMENT OF WEAR PARTS



6.1 GENERAL Before performing any maintenance or repair work, make sure that the crusher is stopped and locked out. Nordberg C-Series crusher jaw dies are made from Manganese steel which work hardens. For different materials and applications there are different jaw die profiles to obtain the best possible capacity to jaw die cost ratio.

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Before lifting any wear parts, check the weight of the component and ensure that lifting equipment being used is adequate to lift the weight. In addition, familiarize yourself with all the special tools provided with the crusher specifically for replacing the wear parts.

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application, contact your Metso representative. When inquiring about the correct jaw die profile, the following information must be provided:

DANGER! Before entering into the crushing cavity, remove any loose rocks from the feed hopper and the feeder.

1. Feed size and gradation 2. Feed type and characteristics 3. End product gradation 4. Capacity required

WARNING!

5. Options; intermediate plate, spacer

The lifting tools are designed by Metso to lift Metso manufactured wear parts. Metso cannot be responsible for any personal injury or property damage, bodily harm, or equipment damage resulting from attempting to lift other manufacturer’s wear parts.

6. Crusher setting 6.3 JAW DIE WORK HARDENING

These lifting tools are sized based on the wear part being lifted. If a customer decides to purchase a one-piece jaw die instead of a two-piece jaw die, then a different lifting tool must be purchased to make that lift. Never attempt to lift a jaw die with a lifting tool that is intended for a lighter jaw die.

Because the wear and work hardening does not occur evenly in the crushing cavity, it is recommended that the following measures are taken to maximize the useful life of the jaw dies:

CAUTION! Damage to the crusher side plates, pitman and front casting will result if the cheek plates and jaw dies are allowed to wear through.

–

When using 2-piece jaw dies, and to optimize the wear profile, flip the upper and lower jaw dies after first 50 to 200 hours. Hardness of the feed material will dictate when to rotate the jaw dies.

–

Flip the upper and lower jaw dies after every 400 to 500 operating hours (200 hours if the material is very hard) to properly work harden the jaw dies.

6.4 CHEEK PLATE REPLACEMENT DANGER!

For more detailed information on lifting accessories, see appendices A and B.

Before lifting the cheek plate, check the condition of the lifting hole in the plate. Lifting hole is acceptable when the lifting tool locks into the cheek plate and does not come loose in any position.

6.2 JAW DIE SELECTION There are several different jaw dies available for the Nordberg C-Series jaw crusher. For profile details and application guidelines contact a Metso representative.

If the lifting tool comes loose from the cheek plate, do not try to lift the plate. Contact Metso for more information.

The type of jaw die must be selected according to the feed material and desired end product. Because of many different applications and variables, one jaw die profile is capable of performing in many applications. If you are experiencing problems with your existing application or would like to improve the

EN

The lower cheek plates will normally wear before the upper cheek plates. When the lower cheek plates are replaced, a small shelf may form between the upper and lower cheek plate. This shelf may slow down the material movement through the crusher.

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6.4.1 Cheek Plate Removal To remove the cheek plate, refer to Figure 6.3 and proceed as follows:

WARNING! The cheek plate lifting tools are designed by Metso to lift Metso manufactured cheek plates. Metso cannot be responsible for any personal injury or property damage, bodily harm, or equipment damage resulting from attempting to lift other manufacturer’s cheek plates.

1. Loosen the lock nuts approximately 12 mm (1/2”) and pull the cheek plate away from the side plate,so that the cam of the lifting tool can be rotated into the locked position. (Figure 6.2).

Figure 6.2

2. Lock the lifting tool. WARNING! Make sure that the hoist being used is capable of lifting the cheek plate weight.

3. When the lifting tool is engaged and locked to the cheek plate, remove the lock nuts (5), washers (4), and bolts (3). 4. Lift the upper cheek plate (1) out from the crusher. 5. Follow the above procedure for removal of the lower cheek plates (2).

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Callout Description 1 Cheek plate, upper 2 Cheek plate, lower 3 Bolt

Callout 4 Washer 5 Locking nut

Description

Figure 6.3 Cheek plate removal

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6.4.2 Cheek Plate Assembly

Callout Description 1 Cheek plate, upper

Callout Description 2 Cheek plate, lower

Figure 6.4 Cheek plate assembly

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To assemble the cheek plates, refer to Figure 6.4 and proceed as follows:

6.5 CHANGING OR ROTATING THE JAW DIES

1. Insert and lock the cheek plate lifting tool into the cheek plate. Refer to appendix B. DANGER!

2. Align the lower cheek plate with the bolt holes. DANGER!

Never place yourself or other personnel in a position beneath or adjacent to a jaw die that is not properly secured against unintended movement.

Make sure e.g. with a wooden block, that the cheek plate does not fall onto you.

DANGER! A working platform should be installed into the crushing cavity before entering.

3. Insert bolts and washers and tighten the nuts so that a 12 mm (1/2”) gap exists between the cheek plate and the side plate. 4. Unlock and remove the lifting tool by turning the lever. 5. Tighten the cheek plate bolts to torque specified in Table 6.1. Follow the above procedure to install the upper cheek plate (1).

Bolt Size C80 C96 C100 C106 C110 C116 C3054 C125 C140 C145 C160 C200

M24 M24 M30 M24 M36 M24 M24 M36 M42 M42 M48 M42

Torque Nm 216 216 437 216 760 216 216 760 1216 1216 1834 1216

kpm 22 22 44.5 22 77.5 22 22 77.5 124 124 187 124

NOTE: Metso’s customers have different preferences regarding material choice and configuration of their work platforms. As a result Metso does not sell working platforms for use with the C-Series jaw crushers. Regardless of the material or configuration of the working platform, it must rest securely in the jaw cavity, must protect the personnel against fall hazards, and must restrain the jaw dies to prevent unintended movement.

ftlbs 160 160 325 160 560 160 160 560 900 900 1355 900

WARNING! It is the customer’s responsibility to provide a safe working environment for his employees, including safe working platforms.

DANGER! The lifting holes in a worn jaw die may have worn bigger from the original size. After locking the lifting tool in the lifting hole, carefully ensure that the locked lifting tool cannot come loose from the jaw die in any position. If the lifting tool comes loose from the jaw die, stop working and move to section 6.5.3

Table 6.1 Cheek plate bolt torques.

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6.5.1 One piece jaw dies 6.5.1.1 Removal

WARNING!

To remove the jaw die, refer to Figure 6.5, Figure 6.6, and Figure 6.7 and proceed as follows:

The lifting tool’s locking mechanism must be engaged (cammed over into the locking position and secured with the butterfly screw) prior to attempting to remove any jaw die locking components. Never attempt to lift a jaw die without the lifting tool’s locking mechanism fully engaged and in the locked position.

1. Stationary jaw die removal DANGER! A working platform should be installed into the crushing cavity before entering. –

Insert a working platform into the crushing cavity.

–

Remove material build up from the jaw die lifting holes.

–

Remove material build up between the stationary jaw die and cheek plates.

–

Insert the jaw die lifting tool into the lifting holes of the jaw die, and lock it in place. Refer to Appendix A for additional information. DANGER!

–

Remove the hex nuts (10) and the jaw die disc spring assembly (8).

–

Remove the jaw die bolts (6), tightening wedge (4) and filling wedge (3).

–

Exit the crushing cavity and remove the working platform.

–

Remove the jaw die. (Figure 6.5, b)

–

Place the jaw die on wooden blocks. (Figure 6.6)

NOTE: If the jaw die is being rotated, before installation make sure that all the jaw die seating surfaces are clean.

After locking the lifting tool in the lifting hole, carefully ensure that the locked lifting tool cannot come loose from the jaw die in any position. If the lifting tool comes loose from the jaw die, stop working and move to section 6.5.3 . DANGER! Properly retain the jaw die from unintended movement before releasing the locking mechanism of the lifting tool. –

6-8

Make sure the lifting hoist is capable of lifting the weight of the one piece jaw die.


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a

b

Figure 6.5

EN

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. DANGER! Properly retain the jaw die from unintended movement before releasing the locking mechanism of the lifting tool. –

Make sure that the lifting hoist is capable of lifting the weight of the one piece jaw die.

WARNING! The lifting tool’s locking mechanism must be engaged (cammed over into the locking position and secured with the butterfly screw) prior to attempting to remove any jaw die locking components. Never attempt to lift a jaw die without the lifting tool’s locking mechanism fully engaged and in the locked position.

Figure 6.6

2.1 Movable jaw die removal (all jaw crusher models except C106 and C116) Figure 6.7 DANGER!

–

Remove the hex nuts (10) and jaw die disc spring assembly (8) (Figure 6.7).

A working platform should be installed into the crushing cavity before entering.

–

Remove the jaw die bolts (7), tightening wedge (5), and filling wedge (3).

–


–

Exit the crusher cavity and remove the working platform.

–


–

Remove the jaw die (2).

–

–

Remove any loose material from between the movable jaw die and cheek plates.


–

Insert the jaw die lifting tool into the lifting holes of the jaw die, and lock it in place. Refer to Appendix A for additional information.

NOTE: If the jaw die is being rotated, before reinstallation make sure that all the jaw die seating surfaces are clean.

DANGER! After locking the lifting tool in the lifting hole, carefully ensure that the locked lifting tool cannot come loose from the jaw die in any position. If the lifting tool comes loose from the jaw die, stop working and move to section 6.5.3

6-10


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EN


c

d

Figure 6.7

2.2 Movable jaw die removal C106 and C116 (Figure 6.8) DANGER! A working platform should be installed into the crushing cavity before entering.

EN

–


–


–

Remove any loose material from between the movable jaw die and cheek plates.

–

Insert the jaw die lifting tool into the lifting holes of the jaw die, and lock it in place. Refer to Appendix A for additional information. . DANGER! After locking the lifting tool in the lifting hole, carefully ensure that the locked lifting tool cannot come loose from the jaw die in any position. If the lifting tool comes loose from the jaw die, stop working and move to section 6.5.3

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DANGER! Properly retain the jaw die from unintended movement before releasing the locking mechanism of the lifting tool. –

Make sure that the lifting hoist is capable of lifting the weight of the one piece jaw die.


WARNING! Make sure that the pitman protection plate (11) is securely attached to the pitman so that it cannot fall.

6-12

–

Remove the hex nuts (10) and jaw die disc spring assembly (8).

–


–

Exit the crusher cavity and remove the working platform.

–


–



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NOTE: If the pitman protection plate or the tightening wedge are worn, replace them when replacing the jaw die.

Figure 6.8

EN

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6.5.1.2 Assembly CAUTION! Before installing new or partially worn jaw dies, make sure that the jaw die and crusher cavity (front frame and pitman) seating surfaces are cleaned. The jaw dies must have metal to metal contact on all seating surfaces. (Figure 6.9).

DO NOT install jaw dies into the crusher if the jaw die seating surfaces are not straight. Warped or distorted jaw dies can cause severe damage to the crusher seating surfaces. Contact your Metso representative for assistance.

Check the condition of the protection plate (if equipped). Replace if necessary.

NOTE: If the ends of the jaw dies are bent in, or distorted, excess material must be removed to original shape by torching before the jaw dies can be installed.

IMPORTANT! When rotating the jaw dies, it is a good practice to check the seating surfaces of the jaw die for straightness. This is easily accomplished with the use of a straight edge. The jaw die can warp or deform if the jaw die is not properly tightened, or is allowed to wear thin while crushing.

Figure 6.9 Checking the straightness of a jaw die

6-14


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Figure 6.10 jaw die seating surfaces

1. Stationary jaw die installation (Figure 6.5)

EN

–

Clean all jaw die seating surfaces (Figure 6.10).

–

Insert and lock the the jaw die lifting tool to the jaw die according to appendix A.

–

Install the jaw die into the crushing cavity, making sure that the jaw die seating surface makes full contact with the lower wedge.


140588-6_N

–

Insert the working platform into the crushing cavity.



– WARNING! Properly retain the jaw die from unintended movement before releasing the locking mechanism of the lifting tool. – –


Install the filling wedge (3), tightening wedge (4) and jaw die bolts (6).

–

Install the disc spring assembly (8). Make sure that the disc spring stack up is according to Figure 6.16.

–

Tighten the spring assembly per Chapter 5.6 , and lock with double hex nuts (10).

–

Remove the jaw die lifting tool.

–

Remove the working platform.

Install the jaw die into the crushing cavity. Make sure that the jaw die seating surface has full contact with the lower wedge.

Insert the working platform into the crushing cavity. WARNING! Properly retain the jaw die from unintended movement before releasing the locking mechanism of the lifting tool.

–


–

Install the disc spring assembly (8). Make sure that the disc spring stack up is according to Figure 6.16.

–

Tighten the spring assembly per Chapter 5.6 , and lock with double hex nuts (10).

–


–


IMPORTANT! Check the compression of the disc springs shortly after the re-start of the jaw crusher. Retighten the disc springs if necessary.

2. Movable jaw die installation (Figure 6.7) IMPORTANT! IMPORTANT! This installation and removal procedure of the jaw dies is also used on a C3054 jaw crusher with one exception. The C3054 does not use the filling wedges.

6-16

–


–

Insert and lock the jaw die lifting tool to the jaw die according to appendix A.


Check the compression of the disc springs shortly after the re-start of the jaw crusher. Retighten the disc springs if necessary.

IMPORTANT! Prior to starting the crusher, the crusher discharge setting must be adjusted.

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6.5.2 Two-piece jaw die removal

–

WARNING!

To remove a two piece jaw die, refer to Figure 6.11 and proceed as follows:


1. Stationary jaw dies DANGER! A working platform should be installed into the crushing cavity before entering. –


–


–

Remove material build up from the upper jaw die lifting holes.

–


–

Remove material build up between the stationary upper jaw die and cheek plates.

–


–

Insert the jaw die lifting tool into the lifting holes of the upper jaw die and lock it in place. Refer to Appendix A for more information..

–

Remove the upper jaw die.

–



DANGER!

DANGER! A working platform should be installed into the crushing cavity before entering. –


NOTE: A smaller working platform might be required, as it is fitted further into the crushing cavity when the lower two piece jaw die is removed.

Properly retain the jaw die from unintended movement before releasing the locking mechanism of the lifting tool.

EN

Make sure the lifting hoist is capable of lifting the weight of the two piece jaw die.

DANGER! Properly retain the jaw die from unintended movement before releasing the locking mechanism of the lifting tool.

140588-6_N

–

Remove material build up from the lower stationary jaw die lifting holes.

–

Remove material build up between the stationary lower jaw die and cheek plates.



–

Insert the jaw die lifting tool into the lifting holes of the lower jaw die and lock it in place. Refer to Appendix A for more information DANGER! Never place yourself or other personnel in a position beneath or adjacent to a jaw die that is not properly secured against unintended movement.


6-18

–

Remove the disc spring assembly (11) from center jaw die bolts (7)

–

Remove the jaw die bolts and center wedge.

–


–

Remove the lower jaw die.

–

Place the jaw die on wooden blockins. (Figure 6.6)


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EN


Callout 1 3 4 6

Description Fixed jaw die Center wedge Filling wedge Filling wedge

Callout 7 8 11 13

Description Jaw die bolt Jaw die bolt Spring package Hex nut

Figure 6.11 Removal of a fixed jaw die

EN

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2. Movable jaw die removal (ref. Figure 6.12) DANGER! A working platform should be installed into the crushing cavity before entering. – – –

–

Insert a working platform into the crushing cavity. Remove material build up from the upper movable jaw die lifting holes. Remove any loose material from between the upper movable jaw die and cheek plates. Insert the jaw die lifting tool into the lifting holes of the jaw die, and lock it in place. Refer to Appendix A for additional information.


–


–


–


–


NOTE: If the jaw die is being rotated, before reinstallation make sure that all the jaw die seating surfaces are clean. –


NOTE: Smaller working platform might be required, as it is fitted further into the crushing cavity when the lower two piece jaw die is removed.


DANGER! Properly retain the jaw die from unintended movement before releasing the locking mechanism of the lifting tool.

6-20

–

–

Remove material build up from the lower movable jaw die lifting holes.

–

Remove any loose material from between the lower movable jaw die and cheek plates.

–

Insert the jaw die lifting tool into the lifting holes of the jaw die, and lock it in place. Refer to Appendix A for additional information.

–

Remove the disc spring assembly from the center movable jaw die bolts (9).

–

Remove the jaw die bolts and center wedge.

–

Exit the crushing cavity and remove the work platform..

WARNING!

DANGER!


Never place yourself or other personnel in a position beneath or adjacent to a jaw die that is not properly secured against unintended movement.


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–

Remove the lower jaw die.

–


EN


NOTE: If the jaw die is being rotated, before reinstallation make sure that all the jaw die seating surfaces are clean.

Callout 2 3 4 5

Description Moving jaw die Center wedge Filling wedge Tightening wedge

Callout 9 10 11 13

Description Jaw die bolt Jaw die bolt Spring package Hex nut

Figure 6.12

EN

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6.5.2.1 Two Piece jaw die assembly Before installing new or partially worn jaw dies, make sure that the jaw die and crusher cavity (front frame and pitman) seating surfaces are clean. The jaw dies must have metal to metal contact on all seating surfaces. Check the condition of the protection plate (if equipped). Replace if necessary. IMPORTANT! When rotating the jaw dies, it is a good practice to check the seating surfaces of the jaw die for straightness (Ref. Figure 6.9). This is easily accomplished with the use of a straight edge. The jaw die can warp or deform if the jaw die is not properly tightened, or allowed to wear thin while crushing.

CAUTION! DO NOT install jaw dies into the Crusher if the jaw die seating surfaces are not straight. Warped or distorted jaw dies can cause severe damage to the crusher seating surfaces. Contact your Metso representative for assistance.

NOTE: If the ends of the jaw dies are bent in, or distorted, before the jaw dies can be installed, excess material must be removed to original shape by torching. To install a two piece jaw die refer to Figure 6.13, Figure 6.14, Figure 6.15, and Figure 6.16 and proceed as follows:

6-22


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Figure 6.13 Jaw die seating surfaces

1. Two Piece Stationary jaw die installation (Figure 6.11)

EN

DANGER!

–


–


–

Install the jaw die into the crushing cavity, making sure that the jaw die seating surface makes full contact with the lower wedge.

A working platform should be installed into the crushing cavity before entering.

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–




WARNING!

–


–


Properly retain the jaw die from unintended movement before releasing the locking mechanism of the lifting tool.

IMPORTANT! Check the compression of the disc springs shortly after the re-start of the jaw die crusher. Retighten the disc springs if necessary.

–

Install the center wedge (3) and jaw die bolts (7).

–

Install the spring assembly (11) making sure that the disc spring stack up is according to Figure 6.16.

–

Tighten the center jaw die bolt nuts until most of the clearance between all the wedge retention components is removed. The center wedge should be positioned farthest away from the front casting on top of the lower jaw die.

– – –

2. Movable Two Piece jaw die installation (Figure 6.12) –

Clean all jaw die seating surfaces of the stationary upper jaw die (Figure 6.13).


–



–

Install the lower movable jaw die into the crushing cavity, making sure that the jaw die seating surface makes full contact with the lower wedge.

Install the jaw die into the crushing cavity, making sure that the jaw die seating surface makes full contact with the center wedge.



– – –

–

6-24

– Insert the working platform into the crushing cavity.


–


Install the center wedge (3) and jaw die bolts (9).

–

Install the spring assembly (11) making sure that the disc spring stack up is according to Figure 6.16.

–

Tighten the center jaw die bolt nuts until most of the clearance between all the wedge retention components is removed. The center wedge should be positioned farthest away from the pitman on top of the lower jaw die.

With center jaw die bolt hex nuts, adjust the gap between the lower and upper jaw die. A gap of 5 - 8 mm (.20” - .30”) must exist between the two jaw dies. Refer to Figure 6.14. Tighten the disc spring assembly per Chapter 5.6 , and lock with a double hex nut (13).


140588-6_N

EN


–

Clean all jaw die seating surfaces of the movable upper jaw die (Figure 6.13).

–


–

Install the jaw die into the crushing cavity, making sure that the jaw die seating surface makes full contact with the center wedge.

–

With center jaw die bolt hex nuts, adjust the gap between the lower and upper jaw die. A gap of 5 - 8 mm (.20” - .31”) must exist between the two jaw dies. Refer to Figure 6.14.

–

Install the disc spring assembly making sure that the disc spring stack up is according to Figure 6.16

–

Tighten the filling wedge spring assembly Chapter 5.6 , and lock with double hex nut.

–


–



–


–


–

With center jaw die bolt hex nuts, adjust the gap between the lower and upper jaw die. A gap of 5 - 8 mm (.20” - .31”) must exist between the two jaw dies. Refer to Figure 6.14.

WARNING! Properly retain the jaw die from unintended movement before releasing the locking mechanism of the lifting tool.

IMPORTANT!

–

Clean all jaw die seating surfaces of the stationary upper jaw die (ref. Figure 6.13).

–


–

Install the lower movable jaw die into the crushing cavity, making sure that the jaw die seating surface makes full contact with the lower wedge.

Check the compression of the disc springs shortly after the re-start of the jaw crusher. Retighten the disc springs if necessary.

IMPORTANT! Prior to starting the crusher, the crusher discharge setting must be adjusted.


EN

–


–

Install the filling wedge, tightening wedge and jaw die bolts.

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Figure 6.14

Figure 6.15

6-26


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Callout 1 2 3 4

Description Washer Cup spring Spring casing Rubber plate Figure 6.16 Assembly order

EN

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6.5.3 Welding lifting lugs to the jaw die The jaw die lifting holes may get worn and become larger. When using the lifting tool intended for lifting the jaw dies, carefully ensure that the locked tool cannot come loose from the jaw die in any position. If the locked tool comes loose, it must absolutely not be used for lifting the jaw die. Instead, separate lifting lugs must be welded to the jaw die according to the following instructions. The jaw dies are made of special manganese steel, due to which the welding process differs from the welding of standard steel. Thus, the person performing the welding must be appropriately skilled. If you have doubts concerning the success of the welding, please contact your local Metso representative. Model 1 C80 C96 C100 C106 C110 C116 C3054 C125 C140 C145 C160 C200

mm 100 100 100 100 100 100 100 150 150 150 150 150

Measure 3 mm inch 50 2” 50 2” 50 2” 50 2” 50 2” 50 2” 50 2” 60 2 3/8” 60 2 3/8” 60 2 3/8” 60 2 3/8” 60 2 3/8”

2 inch 4” 4” 4” 4” 4” 4” 4” 6” 6” 6” 6” 6”

mm 50 50 50 50 50 50 50 75 75 75 75 75

inch 2” 2” 2” 2” 2” 2” 2” 3” 3” 3” 3” 3”

4 mm 90 90 90 90 90 90 90 125 125 125 125 125

5 inch 3 5/8” 3 5/8” 3 5/8” 3 5/8” 3 5/8” 3 5/8” 3 5/8” 5” 5” 5” 5” 5”

mm 40 40 40 40 40 40 40 50 50 50 50 50

inch 1 5/8” 1 5/8” 1 5/8” 1 5/8” 1 5/8” 1 5/8” 1 5/8” 2” 2” 2” 2” 2”

Figure 6.17 Measures of the lifting lug

Make two lifting lugs according to Figure 6.17. Use 10mm (3/8") thick steel plate made from ISO-EN10025-S355 (ASTM A 572/572M-04 Gr. 50) or similar. Weld the lugs to the jaw die according to Figure 6.18. Use the following welding procedure:

6-28


140588-6_N

DANGER! Welding or flame cutting manganese steel generates gas that is extremely hazardous to health and causes manganese poisoning. This kind of work must be done outdoors or in well-ventilated premises equipped with local exhaust ventilation.

EN


(392°F). Observe the temperature closely and let the jaw die cool down if necessary.

1. Insert the working platform into the crushing cavity.

4. Carefully grind the surfaces to be welded.

2. Use austenitic stainless steel electrodes: AWS A5.4: E 307-16 EN 1600: E 18 8 Mn R26 (e.g. ESAB OK 67.45)

5. Weld the lugs to the jaw die by a fillet weld (a=5 mm (1/5")) around the lug. 6. Fill any craters.

3. Do not preheat the jaw die. Interpass temperature must remain under 200°C

Figure 6.18 Lifting lugs welded on the jaw die

EN

–

–

After welding the lugs, attach a suitable lifting tool (e.g., chain sling) to the lugs. (Figure 6.19)

–

Exit the crushing cavity and remove the service platform.

–

Ensure that there are no persons near the machine.

–

Lift the jaw die out of the cavity with extreme caution.

–

Lower the jaw die onto the ground as soon as possible.

Install the new jaw die using the jaw die lifting tool. Do not use welded lugs for lifting the new jaw die.

DANGER!

140588-6_N

Lifting the jaw die using the welded lugs is highly dangerous. Ensure that all persons in the area have been warned and that there is no-one near the suspended jaw die at any stage.



Figure 6.19 Lifting the jaw die using welded lugs

6-30


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6.6 PITMAN EYE PROTECTION PLATE REPLACEMENT Pitman eye protection plate is designed to protect the pitman from wear. The wear to the protection plate is contributed by feed material impact if the feed material enters the crushing cavity too fast. In addition, the protection plate will show premature wear, if it is allowed for the feed material to be crushed to high in the cavity. To prevent the protection plate from wearing through, periodic replacement is necessary.

EN

6.7 FEED HOPPER LINER REPLACEMENT The jaw crusher feed hopper is lined with an abrasion resistant plate. This liner should be replaced, and not allowed to be worn through. Abrasion of the material being crushed will dictate the frequency of replacement. 6.8 TOGGLE PLATE SEAT REPLACEMENT The toggle plate seats are hardened in the toggle plate contact area. The hardness depth is approximately 3 mm (.12”). If the seats are worn more than 3 mm (.12”), they should be replaced.

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6-32


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A

APPENDIX A

NORDBERG C-SERIES JAW CRUSHER'S JAW DIE LIFTING TOOL SAFETY, OPERATING AND MAINTENANCE INSTRUCTIONS

The lifting tool's locking mechanism must be engaged (cammed over into the locking position) prior to attempting to remove any jaw die locking components.

1. Purpose of the jaw die lifting tool The jaw die lifting tool that is provided with Nordberg C Series jaw crushers is intended for lifting of genuine Metso Nordberg C Series wear parts (jaw dies) only. The jaw die lifting tool is not designed nor tested for lifting of other types of jaw dies (including copies of the Nordberg C Series jaw dies). 2. Storage of the jaw die lifting tool When not in use the jaw die lifting tool should be kept out from the weather elements. After use, and to protect the tool from damage, it should be properly stored. In applications where the lifting tool is used infrequently, to protect the tool from corrosion, after each use, the tool should be cleaned and moving parts lightly lubricated.

3. Safe use

DANGER! Never attempt to lift a jaw die without the lifting tool's locking mechanism fully engaged and in the locked position. Falling jaw die can crush and cut. This tool was designed by Metso to lift Metso manufactured jaw dies, and Metso can not be responsible for any personal injury or property damage, bodily harm, or equipment damage resulting from an attempt to use this tool if a tool fails, attempting to lift other manufacturers jaw dies. While crushing, mud and rock will fill the lifting holes, and voids between the side plates, cheek plates and jaw dies. When removing used jaw dies from the crusher the lifting holes in the jaw dies must be cleaned. In addition material build up between the dies and side plates must be removed. When operating in cold climates, chipping of ice and frozen mud between the die and the side plate might be required.

Read carefully all instructions concerning the jaw die lifting tool and make sure that the tool is inspected regularly.

DANGER! The lifting holes in a worn jaw die may have worn bigger from the original size. After locking the lifting tool in the lifting hole, carefully ensure that the locked lifting tool cannot come loose from the jaw die in any position. If the lifting tool comes loose from the jaw die, stop working and move to section 6.5.3

This procedure will insure that the jaw die lifting tool is lifting the weight of the jaw die only, and not trying to break the jaw die loose from a jammed and stuck condition. DANGER!

WARNING! Before lifting any wear parts, check the weight of the component and ensure that the lifting equipment being used is adequate to lift the weight.

EN

N11450704_N

Never place yourself or other personnel in a position beneath or adjacent to a jaw die that is not properly secured against unintended movement. A worker must never be in the crushing cavity while a jaw die is being lifted out or lowered in.

JAW DIE LIFTING TOOL A-1

APPENDIX A

4. Commissioning and operating conditions

A damaged jaw die lifting tool must be replaced or repaired immediately. Special attention should be paid to the condition of the threads, welds and fasteners.

The jaw die lifting tool is supplied fully assembled and it is ready for immediate use.

Prior to inspection, the tool should be cleaned. Inspection should be carried out in a well lit shop atmosphere. All components of the jaw die lifting tool should be inspected for wear, distortion and external damage.

The jaw die lifting tool can be used in the same operating conditions as the jaw crusher.

5. Technical data The maximum lifting load is mentioned on the attached tag of the jaw die lifting tool. Table 1 shows available lifting tools.

Lifting tool 582133 582151 585042

7. Handling the load Preparation Attention should be given to any specific instructions provided for the handling of the load. Before starting the lift, it should be ensured that the load is free to move and is not bolted down or otherwise obstructed.

Maximum lifting load (Working load limit, WLL) 1500 kg (3307 lbs) 2800 kg (6173 lbs) 5000 kg (11023 lbs)

Mass of the load It is essential that the mass of the load to be lifted is known. If the mass is not marked the information should be obtained from the instruction manual, packing documents, or contacting Metso representative.

Table 1

6. The jaw die lifting tool verification before first use and in service

Centre of gravity The position of the centre of gravity of the load should be established in relation to the possible points of attachment of the chain sling. To lift the load without it tilting or toppling the following conditions should be met:

Before first use Before the tool is used for the first time, the following should be verified: a. the jaw die lifting tool is as ordered

a. For two leg chain slings the attachment points should be either side of and above the centre of gravity.

b. the working load limit marking on the jaw die lifting tool is bigger than the weight of the jaw die to be lifted

b. The hook to which the jaw die lifting tool is attached should be directly above the centre of gravity.

Before each use Before each use the jaw die lifting tool should be inspected for any damage or deterioration (see section 8.Maintenance / Inspection). If damage is found during this inspection, follow procedure outlined in section 8.

Method of connection

Prior to every lift, visual jaw die lifting tool inspection should be made. To ensure the tool is in good working order, a detailed inspection should be made at least once a year. See detailed instructions below. Inspection records should be maintained.

A-2

JAW DIE LIFTING TOOL

The jaw die lifting tool is attached to the load and the crane by means of terminal fittings such as hooks and links. Chains should be without twists or knots. Hooks that are permanently attached to the ends of wire rope or chain slings must not be point loaded or wedged on a load. For the same reason, the master link should be free to incline in any direction on the hook to which it is fitted.

N11450704_N

EN

APPENDIX A

The chain sling should be withdrawn from service and sent to a authorized inspection facility. The jaw die lifting tool should be inspected for the following:

Straight leg In this case lower terminals are connected directly to the attachment points. Selection of hooks and attachment points should be such that the load is carried in the seat of the hook and point loading of the hook is avoided.

a. The chain sling markings are illegible, i.e. information on the chain sling identification and/or the working load limit.

In order to prevent dangerous swaying of the load and to position it for loading, a tag line is recommended.

b. Distortion of the upper or lower terminals.

When loads are accelerated or decelerated suddenly, high dynamic forces occur which increase the stresses in the chain. Such situations, should be avoided. Check the hitch at all points when the slack has been taken out to see that it is safe, secure and in balance.

c. Chain stretch can exist if the links are elongated or if there is any lack of free movement between the links or noticeable difference in the leg length of multi-leg chain slings.

Safety of lift Hands and other parts of the body should be kept away from the chain to prevent injury as the slack is being removed. Once the slack is removed, the load should be raised slightly and checked to make sure that it is secure and assumes the position intended. This is especially important with basket or other loose hitches where friction retains the load. Landing the load

d. Wear by contact with other objects usually occurs on the outside of the straight portions of the links where it is easily seen and measured. Wear between adjoining links is hidden. The chain should be slack and adjoining links rotated to expose the inner end of each link. Inter-link wear, as measured by taking the diameter indicated ( d1) and one at right angles, (d2) may be tolerated until the mean of these diameters has been reduced to 90 % of the nominal diameter (dn) (see Figure 1) provided

A clear area with adequate blocking should be prepared when selecting a place for the load. Avoid placing the load on weak structures, aisles, roadways or heavy occupied areas.

d +d 2 1

2

> 0.9d n

8. Maintenance Inspection During service, the jaw die lifting tool is exposed to conditions which affect their safety.It is necessary therefore to ensure, that the chain sling is safe for continuous use. If the tag or label identifying the chain sling and its working load limit becomes detached and the necessary information is not marked on the master link itself, or by some other means, the jaw die lifting tool should be removed from service.

EN

Figure 1

e. Cuts, nicks, gouges, cracks, excessive corrosion, heat discoloration, bent or distorted links or any other defects.

N11450704_N


A-3

APPENDIX A

f. Check the condition of the pin in position 1 (see Figure 2) below. If the pin is worn by 10% (or more) of its original dimension, it must be replaced immediately.

h. Lubricate the mechanism (6) with spray vaseline oil and turning the lever. i. Check the surfaces of the centre pin (7) and shoulder (8) visually. j. The locking bolt (9) must be able to lock the lever during lifting. If worn or damaged replace the jaw die lifting tool immediately. Thorough examination A thorough examination should be carried out by a authorized person at intervals not exceeding twelve months. Records of such examinations should be maintained. Chains slings should be thoroughly cleaned so as to be free from oil, dirt and rust prior to examination. Any cleaning method which does not damage the parent metal is acceptable. Methods to avoid are those using acids, overheating, removal of metal or movement of metal which may cover cracks or surface defects. Inspection should be carried out in a well lit shop atmosphere. The chain sling should be examined throughout its length to detect any evidence of wear, distortion or external damage. Repair

Figure 2

Dimension L (4), measured between positions 2 and 3, must not exceed 10% of the value given in Table 2 below. If dimension L (4) exceeds 10% of the original value, the jaw die lifting tool must be replaced immediately. Lifting tool

Check dimension L

582133

382 +38 mm (15.04" +1.50")

582151

367 +37 mm (14.45" +1.47")

585042

395 +40 mm (15.55” +1.57”)

Table 2 g. Check the condition of the locking mechanism (5).

A-4


Any replacement component or part of the chain sling should be in accordance with the appropriate local standard for that component or part. If any chain link within the leg of a chain sling is required to be replaced then the entire chain within that leg should be replaced. Components that are cracked, visibly distorted or twisted, severely corroded or have deposits which cannot be removed should be discarded and replaced. Minor damage such as nicks and gouges may be removed by careful grinding or filing. The surface should blend smoothly into the adjacent material without abrupt change of cross section. The complete removal of the damage should not reduce the thickness of the section at that point to less than the manufacturers specified minimum dimensions or by more than 10 % of nominal thickness of the section.

N11450704_N

EN

APPENDIX A

In the case of the jaw die lifting tool on which repair work has involved welding, each repaired chain sling should be proof tested following heat treatment using a force equivalent to twice the working load limit and thoroughly examined before it is returned to use. However, where repair is carried out by inserting a mechanically assembled component, proof-testing is not required providing that the component has already been tested by the manufacturer in accordance with the relevant European standard.

e. Remove all slack from the chains of the jaw die lifting tool. f. Remove all wedge bolts and wedges. Make sure fines are cleaned from between the jaw dies and crusher cheek plates.

The accuracy of the tensile test equipment should be of class 2 as given in EN 10002-2.

9. Operating instructions

WARNING! Never place yourself or other personnel in a position beneath or adjacent to a jaw die that is not properly secured against unintended movement. A worker must never be in the crushing cavity while a jaw die is being lifted out or lowered in.

WARNING! Before lifting any wear parts, check the weight of the component and ensure that the lifting equipment being used is adequate to lift the weight. a. Clean lifting holes of the jaw dies ensuring that the cam of the jaw die lifting tool can be placed in a locked position. b. jaw die lifting holes can be kept clean by filling them with polyurethane. The polyurethane must withstand ambient temperatures and must be melted away with a torch prior to inserting the jaw die lifting tool. c. Rotate the locking handle of the jaw die lifting tool in a down vertical position. This aligns the lifting pins with the cam of the tool. (Ref. Figure 3 B). d. Insert both lifting pins of the jaw die lifting tool into the lifting holes, and rotate the locking handles 180 degrees in the up vertical position. This off-sets the cam from the locking pin, and prevents the pin from sliding out from the lifting hole.(Ref. Figure 3 A). To prevent the tool from premature disengagement from the jaw die, a locking wing nut is screwed in finger tight.

EN

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A-5

APPENDIX A

Figure 3 Lifting tool usage: A) Locked B) Unlocked

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EN

B

APPENDIX B

NORDBERG C-SERIES JAW CRUSHER'S CHEEK PLATE LIFTING TOOL SAFETY, OPERATING AND MAINTENANCE INSTRUCTIONS

The lifting tool's locking mechanism must be engaged (cammed over into the locking position) prior to attempting to remove any cheek plate locking components.

1. Purpose of the cheek plate lifting tool The cheek plate lifting tool that is provided with Nordberg C Series jaw crushers is intended for the lifting of genuine Metso Nordberg C Series wear parts (cheek plates) only. The cheek plate lifting tool is not designed nor tested for the lifting of other types of objects.

DANGER!

2. Storage of the cheek plate lifting tool

Falling cheek plate can crush and cut.

Never attempt to lift a cheek plate without the lifting tool's locking mechanism fully engaged and in the locked position.

When not in use the cheek plate lifting tool should be kept out from the weather elements. After use, and to protect the tool from damage, it should be properly stored. In applications where the lifting tool is used infrequently, to protect the tool from corrosion, after each use, the tool should be cleaned and moving parts lightly lubricated.

This tool was designed by Metso to lift Metso manufactured cheek plates, and Metso can not be responsible for any personal injury or property damage, bodily harm, or equipment damage resulting from an attempt to use this tool if a tool fails, attempting to lift other manufacturers cheek plates. While crushing, mud and rock will fill the lifting holes, and voids between the side plates, cheek plates and jaw dies.

3. Safe use WARNING! Before lifting any wear parts, check the weight of the component and ensure that the lifting equipment being used is adequate to lift the weight.

DANGER! Before lifting the cheek plate, check the condition of the lifting hole in the plate. Lifting hole is acceptable when the lifting tool locks into the cheek plate and does not come loose in any position.

When removing used cheek plates from the crusher the lifting holes in the cheek platess must be cleaned. In addition material build up between the dies and side plates must be removed. When operating in cold climates, chipping of ice and frozen mud between the die and the side plate might be required. This procedure will insure that the cheek plate lifting tool is lifting the weight of the cheek plate only, and not trying to break the cheek plate loose from a jammed and stuck condition.

If the lifting tool comes loose from the cheek plate, do not try to lift the plate. Contact Metso for more information.

EN

DANGER! Never place yourself or other personnel in a position beneath or adjacent to a cheek plate that is not properly secured against unintended movement. A worker must never be in the crushing cavity while a cheek plate is being lifted out or lowered in.

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CHEEK PLATE LIFTING TOOL B-1

APPENDIX B

4. Commissioning and operating conditions The cheek plate lifting tool is supplied fully assembled and it is ready for immediate use. The cheek plate lifting tool can be used in the same operating conditions as the jaw crusher.

5. Technical data The maximum lifting load is mentioned on the attached tag of the cheek plate lifting tool. Table 1 shows available lifting tools and the corresponding lifting hole sizes. Lifting tool MM0209800 MM0209814

Maximum lifting load (Working load limit, WLL) 1000 kg (2204 lbs) 500 kg (1102 lbs)

Diameter of lifting hole 80 mm (3.1”) 40 mm (1.6”)

Table 1

6. The cheek plate lifting tool verification before first use and in service

should be paid to the condition of the threads, welds, and fasteners.

Before first use

Prior to inspection, the tool should be cleaned. Inspection should be carried out in a well lit shop atmosphere. All components of the cheek plate lifting tool should be inspected for wear, distortion and external damage.

Before the tool is used for the first time, the following should be verified: a. the cheek plate lifting tool is precisely as ordered b. the working load limit marking on the cheek plate lifting tool is bigger than the weight of the cheek plate to be lifted Before each use Before each use the cheek plate lifting tool should be inspected for any damage or deterioration (see section 8.Maintenance / Inspection). If damage is found during this inspection, follow procedure outlined in section 8. Prior to every lift, visual cheek plate lifting tool inspection should be made. To ensure the tool is in good working order, a detailed inspection should be made at least once a year. See detailed instructions below. Inspection records should be maintained. A damaged cheek plate lifting tool must be replaced or repaired immediately. Special attention

B-2

CHEEK PLATE LIFTING TOOL

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APPENDIX B

7. Handling the load

In order to prevent dangerous swaying of the load and to position it for loading, a tag line is recommended.

Preparation Attention should be given to any specific instructions provided for the handling of the load. Before starting the lift, it should be ensured that the load is free to move and is not bolted down or otherwise obstructed. Mass of the load It is essential that the mass of the load to be lifted is known. If the mass is not marked the information should be obtained from the instruction manual,

When loads are accelerated or decelerated suddenly, high dynamic forces occur that increase the stresses in the chain. Such situations, should be avoided. Check the hitch at all points when the slack has been taken out to see that it is safe, secure and in balance. Safety of lift Hands and other parts of the body should be kept away from the chain to prevent injury as the slack is being removed. Once the slack is removed, the load should be raised slightly and checked to make sure that it is secure and assumes the position intended. This is especially important with basket or other loose hitches where friction retains the load.

packing documents, or contacting Metso representative. Centre of gravity The position of the centre of gravity of the load should be established in relation to the possible points of attachment of the chain sling. To lift the load without tilting or toppling it, the following conditions should be met:

Landing the load

a. For two leg chain slings the attachment points should be on either side of and above the centre of gravity.

A clear area with adequate blocking should be prepared when selecting a place for the load. Avoid placing the load on weak structures, aisles, roadways or heavy occupied areas.

b. The hook to which the cheek plate lifting tool is attached should be directly above the centre of gravity.

8. Maintenance Inspection

Method of connection The cheek plate lifting tool is attached to the load and the crane by means of terminal fittings such as hooks and links. Chains should not have any twists or knots. Hooks that are permanently attached to the ends of wire rope or chain slings must not be point loaded or wedged on a load. For the same reason, the master link should be free to incline in any direction on the hook to which it is fitted. Straight leg In this case the lower terminals are connected directly to the attachment points. The hooks and attachment points should be selected so that the load is carried in the seat of the hook and point loading of the hook is avoided.

EN

During service, the cheek plate lifting tool is exposed to conditions which affect their safety. It is necessary therefore to ensure, that the chain sling is safe for continuous use. If the tag or label identifying the chain sling and its working load limit becomes detached and the necessary information is not marked on the master link itself, or by some other means, the cheek plate lifting tool should be removed from service. The chain sling should be withdrawn from service and sent to a authorized inspection facility. The cheek plate lifting tool should be inspected for the following:

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APPENDIX B

a. The chain sling markings (information on the chain sling identification and/or the working load limit) are illegible. b. Distortion of the upper or lower terminals. c. Chain stretch can exist if the links are elongated or if there is any lack of free movement between the links or noticeable difference in the leg length of multi-leg chain slings. d. Wear by contact with other objects usually occurs on the outside of the straight portions of the links where it is easily seen and measured. Wear between adjoining links is hidden. The chain should be slack and adjoining links rotated to expose the inner end of each link. Inter-link wear, as measured by taking the diameter indicated (d1) and one at right angles, (d2) may be tolerated until the mean of these diameters has been reduced to 90 % of the nominal diameter (dn) provided. (see Figure 1)

d +d 2 1

B-4

2

Figure 1

e. Cuts, nicks, gouges, cracks, excessive corrosion, heat discoloration, bent or distorted links or any other defects. f. Check the condition of the pin in position 1 (see Figure 2). If the pin is worn by 10% (or more) of its original dimension (MM0209800 = 10 mm, 0.39"; MM0209814 = 8 mm, 0.31”), it must be replaced immediately.

> 0.9d n


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EN

APPENDIX B

Figure 2

Dimension L (4), measured between positions 2 and 3, must be within the values given in Table 2. If dimension L (4) is outside of the values given in the table, the cheek plate lifting tool must be replaced immediately.

Lifting tool MM0209800 MM0209814

Min. length L 210 mm (8.3”) 182 mm (7.2”)

Max. length L 250 mm (9.8”) 222 mm (8.7”)

g. Check the condition of the locking mechanism (8). h. Lubricate the mechanism (7) with spray vaseline oil and turning the lever. i. Check the surfaces of the centre pin (5) and shoulder (6) visually. j. The locking bolt must be able to lock the lever during lifting. If worn or damaged replace the cheek plate lifting tool immediately.

Table 2

EN

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APPENDIX B

Thorough examination A thorough examination should be carried out by a authorized person at intervals not exceeding twelve months. Records of such examinations should be maintained.

The accuracy of the tensile test equipment should be of class 2 as given in EN 10002-2.

Chains slings should be thoroughly cleaned so as to be free from oil, dirt and rust prior to examination. Any cleaning method which does not damage the parent metal is acceptable. Methods to avoid are those using acids, overheating, removal of metal, or movement of metal which may cover cracks or surface defects. Inspection should be carried out in a well lit shop atmosphere. Adequate lighting should be provided and the chain sling should be examined throughout its length to detect any evidence of wear, distortion or external damage. Repair Any replacement component or part of the chain sling should be in accordance with the appropriate local standard for that component or part. If any chain link within the leg of a chain sling has to be replaced then the entire of the chain within that leg should be replaced. Components that are cracked, visibly distorted or twisted, severely corroded, or have deposits which cannot be removed should be discarded and replaced. Minor damage such as nicks and gouges may be removed by careful grinding or filing. The surface should blend smoothly into the adjacent material without abrupt change of cross section. The complete removal of the damage should not reduce the thickness of the section at that point to less than the manufacturer’s specified minimum dimensions or by more than 10 % of nominal thickness of the section. If the repair work of the cheek plate lifting tool has involved welding, each repaired chain sling should be proof-tested following heat treatment using a force equivalent to twice the working load limit, and thoroughly examined before it is returned to use. However, where repair is carried out by inserting a mechanically assembled component, proof-testing is not required providing that the component has already been tested by the manufacturer in accordance with the relevant European standard.

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EN

APPENDIX B

9. Operating instructions WARNING! Before lifting any wear parts, check the weight of the component and ensure that the lifting equipment being used is adequate to lift the weight. a. Clean lifting holes of the cheek plates ensuring that the cam of the cheek plate lifting tool can be placed in a locked position. b. Cheek plate lifting holes can be kept clean by filling them with polyurethane. The polyurethane must withstand ambient temperatures and must be melted away with a torch prior to inserting the cheek plate lifting tool. c. Rotate the locking handle of the cheek plate lifting tool in a down vertical position. This aligns the lifting pins with the cam of the tool. d. Insert both lifting pins of the cheek plate lifting tool into the lifting holes, and rotate the locking handles 180 degrees in the up vertical position.This off-sets the cam from the locking pin,and prevents the pin from sliding out from the lifting hole. To prevent the tool from premature disengagement from the cheek plate, a locking wing nut is screwed in finger tight e. Remove all slack from the chains of the cheek plate lifting tool. f. Remove all wedge bolts and wedges. Make sure fines are cleaned from between the jaw dies and crusher cheek plates. DANGER! Never place yourself or other personnel in a position beneath or adjacent to a cheek plate that is not properly secured against unintended movement. A worker must never be in the crushing cavity while a cheek plate is being lifted out or lowered in.

EN

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B-7

APPENDIX B


B-8


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EN

C_Jaw_Instruction_EN_Rev_N (140588) (Updated).pdf

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