CT Series 20x36 Jaw Crusher[1]

TRIO E N G I N E E R E D

P R O D U C T S

Trio Engineered Products, Inc. • 12823 Schabarum Ave. • Irwindale, CA 91706 • Telephone 626-851-3966 • Fax 626-851-9526

Parts and Operation Manual

CT Series 20” x36” Jaw Crusher

CT2036 Jaw Crusher Manual

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HAZARD WARNING Any machinery may be hazardous to the user if it is not maintained and operated properly. The following precautions should always be observed:

CRUSHING MACHINERY 1. Take special care to see that all parts of your body are clear of moving parts and pinch points before starting or operating machinery. 2. Make sure that all rotating sheaves, pulleys and belts are properly guarded to prevent being caught by them. 3. Be sure that the feed and discharge systems for material processing equipment are designed and maintained so that processed materials (rocks, gravel, coal, etc.) are retained within the system. Do not allow any part of your body to enter in or near the material flow. 4. Never sit or stand on any component of the machinery while it is in operation to prevent injuries arising from vibration. 5. Verify that the supporting structure(s) provided by your company for the machinery is sufficient to support both the total weight of the equipment and the dynamic load and stresses created by the equipment.

CONVEYING MACHINERY 1. Be sure that all parts of your body are kept clear of moving conveyor belts, especially at pinch points. 2. Do NOT lubricate machinery while it is in motion. 3. Never lean over a moving conveyor belt, or ride on a conveyor belt intended only for material transport. 4. Always keep clear of feed or discharge points of all material conveyor systems. 5. Be sure that all guards are securely fastened in place on sheaves, pulleys, and belts before and during equipment operation.

SAFETY EQUIPMENT Trio Engineered Products, Inc. provides only such safety equipment and guards as are specified by the Purchaser on the Shop Order or the Customer Order Acknowledgment. The Purchaser must furnish all other required safety devices.


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GENERAL SAFETY PRACTICES Safety Practices affect everyone. Any and all personnel who operate or maintain your equipment are expected to comply with the basic safety practices that follow. This manual contains the best available information on proper installation, operation and maintenance of the equipment that it addresses. It does NOT replace or supersede applicable federal, state, or local regulations, your company safety rules, or insurance carrier requirements. It definitely is not intended to replace good judgment or common sense! Equipment operators, plant management and safety engineers are required and expected to be aware of potential hazards that may exist in the specific workplace where the equipment is installed and operated. All personnel are expected to develop, implement and maintain a safe work environment compatible with operating conditions, requirements, and practices. Additional safety precautions suited to the specific conditions of the work site and the equipment installations are the responsibility of the user. Experience has demonstrated that the greatest numbers of workplace accidents are caused by failure to follow established safety rules. Be sure that you are fully familiar with the safety program requirements applicable to operating this type of equipment. Consult your supervisor concerning any operating procedure that you are not sure about before operating or working on this equipment. Note: It is strongly recommended that properly constructed and guarded access platforms be erected at convenient locations on the equipment installation site to allow safe inspection, adjustment, maintenance and repair of the equipment described in this manual. It is the responsibility of the purchaser of this equipment to ensure that such platforms comply with applicable federal, state, and local standards and regulations.

PERSONAL SAFETY PRACTICES ARRANGEMENTS FOR EMERGENCY SITUATIONS Supervisory and operating personnel should develop an emergency response profile for possible emergencies on the worksite. All personnel should know the location of fire-extinguishers, where to obtain first-aid assistance and supplies, emergency report telephone numbers, power shut-off points, and other equipment shut-down control locations. Appropriate tools and equipment should be available to allow immediate response to emergency situations.


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Always follow the requirements and regulations of your company’s Emergency Action Plan.


5

SAFE MACHINERY INSTALLATION 1. Read and understand all parts of this manual including General Dimension Drawings. 2. Review your Plant Engineer’s Installation Drawings for this equipment. 3. Select, Assemble, and Test the correct hoisting and rigging equipment required to move the equipment to the installation site in your family. If there is any question regarding the proper rigging of the equipment or necessary hardware to make the lift/movement of the equipment to its’ designated mounting location, contact your local representative or Trio Engineered Products, Inc. to resolve the questions prior to beginning installation activities.

KNOW AND UNDERSTAND HOW THE EQUIPMENT WORKS It is absolutely essential that machine operators understand completely how the crusher works. The operator must know the location and function of all controls, gauges, indicators and alarms included with the unit. Operators and maintenance personnel must be completely familiar with maintenance procedures and schedules. Only if the equipment is given maintenance on the prescribed schedule can costly and time-consuming breakdowns be prevented. DO NOT OPERATE THE MACHINE WHEN ITS PARTS ARE WORN BEYOND DESIGNATED TOLERANCES. REPAIR OR REPLACE THEM BEFORE TROUBLE OCCURS.

INSPECT YOUR MACHINE BEFORE START-UP Make a visual inspection of the machine for loose, worn, or damaged parts or faulty safety devices. Inspect all drive belts and pulleys for excessive wear. Test alarm systems and check fluid levels. Make sure that hydraulic, air, and lubrication systems and their respective valves, drains, and fittings are in proper working order. Report or repair any problem before starting the machine.

FOLLOW THE RECOMMENDED EQUIPMENT START-UP INSTRUCTIONS Be sure that control systems and alarms are working properly. Check gauges for proper readings. Check for any unusual noises that may indicate bearing failure or other mechanical problems. Check for sudden rises in lubricant temperature. Shut the equipment down immediately if problems are detected, and report the problem(s) to your supervisor. Always refer to the Operating Section of this manual if you are unsure about a start-up procedure or for additional information.


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STOP THE MACHINE PROPERLY AND SAFELY The machine must be completely stopped with power off and locked-out with controls tagged before any cleaning, repairs, adjustments, or service is performed. All provisions of your company’s Control of Hazardous Energy (LockOut/Tag-Out) program must be followed.

REPORT THE NEED FOR NECESSARY REPAIRS IMMEDIATELY Report any situation involving the need for repair, replacement or adjustment of an equipment component immediately. Remember, the most minor defect could result in injuries to yourself or others or serious damage to the machinery if it is not corrected promptly. Do NOT work on the equipment unless you have been properly and completely trained to do the work involved.

PREVENT FIRE HAZARDS Never weld or use a cutting torch near open or exposed fuels, lubricants, or other flammable materials. Follow your company’s Hot Work Policy. Do not let greasy or oily rags accumulate in poorly ventilated areas. Store oily rags and other combustible materials in an approved storage container and dispose of them properly. Never use an open flame to check for fluid leaks in the equipment. Use an approved low voltage electric light or flashlight. Never smoke in undesignated areas. Follow your company’s Smoking Rules. Always extinguish smoking materials properly. Know where the nearest fire extinguisher is located, how to operate it, and what types of fires it can be used to extinguish. Make sure that fire extinguishers are in place, are in proper working condition, and have a current, valid inspection tag. If a fire extinguisher is not readily available, or does not meet these requirements, report the situation to your supervisor.

KEEP YOUR WORK AREA CLEAN Become fully familiar with the worksite where the equipment is installed. Inspect the area daily and see that unsafe conditions are corrected. Make sure that all equipment guards are securely fastened in place, that steps, stairways, work platforms and barrier rails are sound and free of spills or obstructions. Keep the floor/work surface clean and free of oil, greasy rags, cables, chains, buckets and other obstructions. Keep tools and loose parts in a toolbox or appropriate storage areas. Use high flashpoint/low toxicity solutions for cleaning.


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HANDLE TOOLS, HEAVY PARTS, AND MACHINE COMPONENTS PROPERLY Do not toss parts or tools or drop them off platforms. Do not lower or swing electric or air power tools by their power cords or air lines. Use a suitable rope and/or container to lower tools or parts to the floor. Review job activities and arrange to get help before you attempt to lift, carry or move heavy parts. For heavy or awkward lifts use proper hoisting devices.

DRESS PROPERLY FOR THE JOB AND USE APPROPRIATE PERSONAL PROTECTIVE EQUIPMENT Follow your company Personal Protective Equipment Policy. Discuss personal protective equipment requirements with your supervisor before operating equipment or performing service, repair or adjustment work. Don’t wear loose clothes or jewelry, and restrain long hair.

FOLLOW YOUR COMPANY SUBSTANCE ABUSE CONTROL POLICY Report any use of prescription or over-the-counter medications to your supervisor prior to operating this equipment or making any adjustments or repairs to it. ALCOHOL OR OTHER CONTROLLED SUBSTANCES SHOULD NOT BE USED PRIOR TO OR DURING WORK ON THIS EQUIPMENT.

AVOID SERIOUS EYE/SKIN INJURIES Hydraulic fluid or compressed air can penetrate or burn the skin or damage the eyes causing serious injury, blindness, or death. Mineral-based hydraulic oil is hazardous. Always wear goggles when working with hydraulic fluid. Flush your skin or eyes thoroughly with water if you spill or splash hydraulic fluid on yourself. Remove clothing on which hydraulic fluid has splashed. Get immediate assistance and report the matter to your supervisor. Get appropriated medical care. Wear appropriate personal protective equipment as set forth in your company’s Personal Protective Equipment Policy when handling hydraulic fluid. Wash your hands with soap and water after handling hydraulic fluid. Never eat, drink or smoke while handling hydraulic fluid. Make sure that all compressed air lines and couplings are in proper operating condition at all times. Be sure that all compressed air lines intended for chip or dust removal are fitted with OSHA compliant pressure relief nozzles. Never use compressed air to clean your clothing or any part of your body.


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DISPOSE OF ALL WASTE MATERIALS PROPERLY Dispose of all waste materials such as fuels, lubricants, hydraulic fluid, etc. in accordance with your company waste management policies, and federal, state, and local regulations. If you have a question concerning proper procedures to be followed, consult with your supervisor, or the company safety administrator.

SAFETY AND MAINTENANCE PRACTICES REPLACE LOOSE OR DEFECTIVE PARTS Keep the equipment clean and free of dirt and oil so that loose, broken, defective, or worn parts can be easily identified. Make daily visual checks for missing, cracked, or frayed V-belts. Also check daily for frayed, broken or kinked cables. Inspect end connections for wear. Replace sheaves with cracked rims or spokes immediately. Report suspected defects to your supervisor.

PROPERLY GROUND MACHINE ELECTRICAL COMPONENTS Check frequently to ensure that the equipment is properly grounded as stipulated in your company electrical safety rules. Prevent any electric cable from coming in contact with water in puddles, drainage channels, etc. Protect power cables from vehicular traffic such as forklifts and other motor vehicles. Power cables should be bridged over traffic lanes. All permanent electric cables should be in proper conduit or other approved insulation. Follow your company electrical safety rules with regard to periodic inspection of the condition of electric line insulation and couplings. Do NOT use portable, flexible electric cords to deliver electric power to the equipment.

CONTROL OF HAZARDOUS ENERGY (LOCK-OUT/TAG-OUT) PROGRAM CAUTION: Purchaser must implement a Control of Hazardous Energy (LockOut/Tag-Out) Program that complies with 29 CFR 1910.147 and 133 regulations. It is the responsibility of the purchaser to provide a suitable Control of Hazardous Energy program for the protection of its’ employees while they are engaged in the installation, maintenance, repair, or modification of equipment powered by electricity, hydraulic, pneumatic or mechanical energy in order to meet the regulations of the U.S. Dept. of Labor, Occupational Health and Safety Administration (OSHA). Under certain conditions and in certain operating environments, the Federal Mine Safety and Health Administration (MSHA) governs regulations concerning this subject. Certain state, county, or local regulations may also apply. CT2036 Jaw Crusher Manual

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Assistance in establishing regulatory obligations may be obtained from regulatory agencies, insurance carriers, or private consultants. Specific information concerning electrical operating characteristics such as output, rated capacity, etc. of electrical motors supplied with the equipment may be obtained by review of the technical data contained in this manual or from the specific equipment supplier stipulated in the Shop Order.

OBTAINING CONTROL OF HAZARDOUS ENERGY PROGRAM MATERIALS Listed below are three possible suppliers of materials to aid you in development, documentation and maintenance of your program. Inclusion of the names of these firms in this manual does not represent an endorsement of them by Trio Engineered Products, Inc.. These firms provide some of the materials required for a comprehensive program. 1.

SETON Name Plate Company P. O. Box BD - 1331 New Haven, CT 06505-9770 Telephone 203-488-8059 Toll Free 800-243-6624 Fax Toll Free 800-345-7819

2.

EMED Co., Inc. Telephone Graphic Communications Products Buffalo, NY 14240-0369 P. O. Box 369 Toll Free 800-442-3363 Fax Toll Free 800-344-2578

3.

D & G Sign and Label P. O. Box LA - 157 Toll Free 800-356-9269 Northford, CT 06472 Telephone 203-483-0491 Fax 203-488-4770

The Purchaser has sole responsibility for safe operation of this equipment. The Purchaser is responsible for ensuring that on-site machine operation is in compliance with any and all applicable federal, state, county or city safety standards and regulations. The equipment may be moved from one site to another a number of times by various purchasers, lessees, etc. Consequently, responsibility for compliance with applicable safety and environmental codes lies with the entity responsible for operating the equipment within each jurisdiction. Purchaser is wholly responsible for any ancillary or support equipment such as, but not limited to, processed material receiving devices, and inspection or service platforms.


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Purchaser is required to perform periodic maintenance of the type and on the recommended schedules set forth in this manual. Maintenance shall include, but is not limited to safety devices delivered with the equipment set forth in the Shop Order, and Warning and Instruction labels affixed to the equipment. Replacement parts including warning and instructional labels are available from Trio Engineered Products, Inc.. Purchaser is invited to call for availability and current price of such parts and labels at 1-626-851-3966. Any modifications or machinery as designed, manufactured, and delivered by Trio Engineered Products, Inc. without the express written approval and consent of Trio Engineered Products, Inc. will void all warranties and remove all responsibility of Trio Engineered Products, Inc. for any and all damages to persons or property.

Forward This parts section of this manual is intended to assist the informed installer and user of this jaw crusher in identifying wear and replacement parts that will be required during the operating of this equipment. Because of the extreme nature of crushing, parts replacement is an expected occurrence. The prepared operator should have certain parts on hand to minimize operating down time. Specific questions regarding the operation and maintenance should be addressed to your distributor. The manufacturer will constantly try to improve their equipment and there will therefore be changes from time to time that may require you to request up dates from the factory or your local representative.

Safety The manufacturer may not always know exactly how their equipment is installed, applied and used, and cautions all prospective operators that they must exercise the greatest care for the safety of individuals that happen in and around the machinery. Equipment used in the United States must be installed and operated with regard to safety either, per OSHA or MSHA regulations, or both. Operating the equipment beyond its published ratings or without the proper guards and protection for personnel is foolhardy and subjects the operator to potentially numerous penalties or imprisonment or both.

General Information This Operation and Maintenance Manual has been prepared to assist in the installation, operation, and maintenance of Trio jaw crushers. The information contained in this manual is intended to familiarize the operator with the general configuration and assembly of this equipment. It should aid in providing the necessary information for efficient operation and maintenance of this machine.


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Each crusher is delivered with this manual that illustrates the specific components comprising the jaw crusher. When ordering parts, please have the following information available: Crusher Size Crusher Serial Number Part name and reference number (from appendix) Complete shipping instructions (type of shipping required) Number of parts required

Recommended Spare Parts The following parts are recommended to have on hand for problems resulting from normal wear and tear on the machine. Stationary Jaw

Movable Jaw

Stationary Jaw Bolts

Movable Jaw Wedges & Bolts

Cheek Plates & Bolts

Toggle Plates

Recommended Tools The following tools are recommended for storage with the crusher, as they will be required for use during normal maintenance and repair. Jaw Lifting Cable

Metric Allen Head Wrenches

Hydraulic Jack

Box Wrench

Complete Set of Metric Tools

Machine Shipping Condition The crusher is assembled prior to delivery. However, a careful inspection of the machinery should be performed upon delivery in order to identify any damage that may have occurred during transportation. The following checklist should be reviewed to ensure that the crusher is received in proper operating condition. •

Examine the crusher for significant damage.

•

There should not be any abnormal conditions, such as scarring and wear on all frictional surfaces.

•

Verify that all removable plates are fastened tightly. Verify that the toggle plate is seated correctly.

•

Verify that the shims are seated correctly and that the pull rod bolt is adequately tightened.


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•

Rotate the flywheel to determine if rotation appears trouble free, the pulley and flywheel should turn smoothly.

•

Verify that the eccentric shaft and associated bearings are adequately lubricated.

General Installation Information Crusher Component Weights (Lbs) Complete Crusher

24,180

Frame and Cheek Plates

Fixed

Swing

Pitman

Jaw

Cheek Plates (Total)

Jaw

8,686

1,430

1,430

590

3,877

Eccentric Shaft

1,151

Toggle Plate

247

Flywheel (Total)

Pitman, Eccentric Shaft and Swing Jaw

3,865

6,458

Horsepower Requirements Electric motors are available for special duty crusher applications and are recommended over standard frame motors. MODEL

OPERATING SPEED (FULL LOAD RPM)

MOTOR HORSEPOWER (MIN.)

CT20x36

250

75

Flywheel Rotation Direction


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CT Jaw Capacity (TPH) Analysis for Given Closed Side Setting of Crusher Model

C.S.S. (Inch) C.S.S. (mm)

1"

1-1/2"

2"

2-1/2"

3"

3-1/2"

4"

5"

6"

7"

8"

9"

10"

12"

25

40

50

63

75

90

100

125

150

180

200

230

250

300

10x20

1"--3-1/2"

25-90

12

15

22

26

32

35

10x30

1"--3-1/2"

25-90

17

22

27

32

39

45

10x40

1"--3-1/2"

25-90

23

30

37

43

52

63

10x48

1"--3-1/2"

25-90

28

35

44

52

64

76

12x52

1"--3-1/2"

25-90

50

63

77

90

105

130

17x26

1-1/2"--5"

40-125

35

45

55

70

95

105

135

20x36

2"--5"

50-125

80

92

110

133

148

180

24x36

3"---7"

75-180

120

147

165

190

30x42

3"---7"

75-180

150

175

36x48

4"---9"

100-230

42x54

5"---10"

125-250

230

275

190

220

280

340

240

295

360

450

500

570

330

390

515

575

630

700

650

740

800

48x64

6"---12"

150-300

500

590

26x46

2"---7"

50-180

90

103

125

155

175

210

250

340

32x54

2"---7"

50-180

105

118

135

170

185

235

310

420

950

1.

The above information is based on average feed material that weighs approximately 100 lbs/ft³ crushed of a size which is readily fed into the crushing chamber without clogging.

2.

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

SETTINGS GREATER THAN INDICATED ARE WITHIN DESIGN CAPABILITIES OF THE MACHINES BUT ARE NOT SHOWN DUE TO ANTICIPATED HIGHER OPERATING COSTS.

The above tables are based on results obtained during actual operation and could vary depending on the type of material, gradation of feed, method of feeding, moisture and clay content, and other material characteristics. The indicated top size, also influenced by the above conditions, is provided to assist in the selection of the crushing equipment to follow. Contact your dealer for more details.


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CT Jaw Product Grading Analysis (% Passing) for Given Closed Side Setting of Crusher Product Size >250mm

>10"

250

10"

225

9"

200

8"

180

7"

150

6"

125

5"

100

4"

1"

1-1/2"

2"

2-1/2"

3"

3-1/2"

4"

5"

6"

7"

8"

9"

10"

12"

25mm

40mm

50mm

63mm

75mm

90mm

100mm

125mm

150mm

180mm

200mm

230mm

250mm

300mm

100 100

100

100

100

100

100

90

85

75

65

90

83

75

70

60

100

90

83

75

70

65

55

90

83

75

70

63

60

52

100

95

83

75

68

63

58

55

47

100

90

85

75

68

60

58

48

45

40

100

90

83

75

65

60

55

48

45

40

35

90

3-1/2"

75

3"

63

2-1/2"

50

2"

90

75

65

58

55

50

40

35

30

25

22

20

17

45

1-3/4"

85

70

60

55

50

45

35

30

25

22

20

17

13

40

1-1/2"

100

75

65

55

50

45

40

30

25

22

20

17

12

10

30

1-1/4"

95

70

55

50

40

35

30

25

22

20

17

15

10

7

25

1"

75

65

45

43

35

30

25

20

17

15

12

10

8

5

20

3/4"

70

55

40

30

25

22

20

17

15

12

10

7

5

3

100

95

83

75

70

60

55

50

45

40

35

30

100

83

75

70

65

55

50

45

35

30

25

25

90

75

68

60

55

50

42

35

30

25

22

22

15

5/8"

60

45

35

25

20

17

15

13

10

7

5

3

2

1

10

3/8"

45

30

25

20

15

13

10

7

5

3

2

1

1

0

5

3/16"

30

20

15

10

7

5

4

3

1

0

0

0

0

0

THE ABOVE TABLES ARE BASED ON RESULTS OBTAINED DURING ACTUAL OPERATION AND COULD VARY DEPENDING ON THE TYPE OF MATERIAL, GRADATION OF FEED, METHOD OF FEEDING, MOISTURE AND CLAY CONTENT, AND OTHER MATERIAL CHARACTERISTICS. THE INDICATED TOP SIZE, ALSO INFLUENCED BY THE ABOVE CONDITIONS, IS PROVIDED TO ASSIST IN THE SELECTION OF THE CRUSHING EQUIPMENT TO FOLLOW. CONTACT YOUR DEALER FOR MORE DETAILS. Jaw crushers reduce large rock to smaller stone using exceptional force. The

foundation therefore must be substantial enough to support the crusher without distortion.


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Foundation Recommendations Jaw crushers reduce large rock to smaller stone using exceptional force. The foundation therefore must be substantial enough to support the crusher without distortion. Jaw crushers may be installed on permanent concrete or steel structures or mobile equipment. Regardless of the application the foundation must withstand the forces of material impact and drive line loads. The design task is usually best handled by a qualified engineer. The interface between the crusher and foundation must be flat so that the crusher is given proper support. Where a flat surface cannot be obtained it may be necessary to use machinery grout between the two surfaces. The grout used of course must be adequate to the task when considering the impact and dimensional requirements. The installer will have to consider the configuration of chutes, hoppers, structural supports, etc., when designing the crusher foundation. In order to minimize the noise and vibration to the surrounding buildings as a result of the operating machinery, it maybe advisable to insert wooden planks, rubber sheets or other padding materials between the crusher and its foundation.

Feed Configuration In order to achieve the maximum operating efficiency for the crusher, an optimal feed arrangement must be utilized. This crusher can reach its maximum efficiency only when the feed is supplied in the correct amount and distributed evenly into the crushing chamber. The feed equipment should also allow for easy access to the crushing chamber in the event of material blockage, part replacement, or other maintenance.

Discharge Configuration The crusher discharge compartment can be manufactured out of metal or wood. The compartment should be readily accessible for cleaning, maintenance, and inspection. The compartment should also have a shelf or ledge to provide a “bed” of crushed material for falling material to impact on. This bed will absorb much of the impact of the falling material before it reaches the conveying belt. If a discharge chute is used, its slope must be at least 45° from the horizontal and increased if the material is sticky in nature.

V-Belt Drive Installation The crusher is powered by conventional “8V” or “C” section V-Belts. The drive sheaf on the machine carries the correct number of grooves to transmit the maximum allowable horsepower for the crusher. The size and number of belts should not be reduced. Refer to a table of electrical power requirements for recommended horsepower ratings. The crusher installer will determine the V-Belt drive installation, so the following notes are provided for general reference only. Clean all oil, dirt, grease or rust from the sheaf grooves. Verify the proper alignment of the sheaves and that the shafts are parallel. Shorten the center distance until the belts can be slipped on easily. Determine the minimum allowances for shortening or lengthening the center distance between sheaves after referencing and a V-belt installation manual. Always used a match set of belts from the same manufacturer. Never use a combination of warn and new belts.


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After placing the belts on the sheaves, run the drive for a few minutes. Tension the drive until only slight sag appears on the slack side of the belts when the drive is running. The slack side depends on the motor position and rotation of the crusher.

V-Belt Precautions V-Belt stretching and wear are potential problems for the user and frequent careful inspections are recommended in order to identify problem belts before the belts fail. This will serve to reduce the potential injuries that could result when belts break and give way.

Rust Protection A crusher is comprised of iron and steel parts; it is particularly vulnerable to rust corrosion. Once rust develops, the resulting porosity on the metal surfaces can cause an increased degradation of the crusher due to water and moisture collection. Rust could be a major cause of downtime, high maintenance costs, production loss, production waste, and short equipment life. It also could cause a potential safety risk to operating personnel. Because of the significant effects of rust on this machine’s operation, good service maintenance should be practiced. If the crusher is in storage or not being used for more than a significant period of time, the crusher should be operated for at least 10 minutes on a monthly basis. If there is no power supply to the crusher during this period, the flywheel must be manually rotated 5 to 10 times to ensure that the bearings to not deform and to ensure a proper disbursement of bearing grease. Moisture condensation will cause corrosion at the contact point between the bearing rollers and the inner and outer rings. This will degrade the finished surfaces of both the rollers and rings. When the crusher is operating, this surface wear will cause the bearings to become rough and fail prematurely.

Tension Rod and Toggle Plate Information The closed side setting of a Jaw Crusher is determined by the position of the toggle seat located within the transverse header. The toggle seat may be positioned closer or further away from the pitman by shims inserted at the rear of the seat. To decrease the closed side setting a larger shim pack is used, conversely to increase the opening shims are removed. Since the toggle plate is not mechanically attached to the pitman or the toggle seat tension rods and springs are used to hold it in position. In operation the toggle plate acts like a pivot that holds the closed side setting relatively fixed as the top of the pitman opens or closes by the amount of pitman eccentric.

Initial Assembly The toggle plate, toggle seat, buffer plates and tension rod assembly, as shipped, will be installed in the frame and should require no further attention other than final adjustment as explained in the operating instructions section of this manual. The toggle plate protects the pitman from the serious damage that could result if an uncrushable object enters the crushing chamber. The toggle plate is intended to bend or fracture when an overload occurs against the pitman die plate. The failure will result in an increase in the size discharge chute that will allow the uncrushable object to pass through the chamber. The tension spring on the toggle plate supplies the force required to prevent the pitman from pulling away from the toggle plate upon reaching its furthest point forward.

Removal and Installation During normal operation, the toggle plate, tension rod, or any of their respective components may require repair or replacement. Care should be taken when removing those parts to ensure that no personal injury results from the procedure.


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Flywheel and Pitman Information Maintenance personnel that are familiar with large diameter spherical roller bearings should accomplish removal and replacement of the flywheels and pitman. Work should be performed in a clean environment free of dust and moisture. Smart tips include: 1. Plan ahead and have all necessary tools on hand before work begins in order to minimize the bearings’ exposure to moisture and dirt. 2. Have all the required parts on hand as well. 3. Make sure that all shaft surfaces are clean and free of scarring or nicks. 4. Do not remove the bearing packaging until you are ready for immediate installation.

Jaw Dies and Side Plates Fixed Jaw Die Replacement The stationary jaw die plate is reversible and can be rotated 180° in order to distribute the wear over both ends that will extend the total life of the plate. The plate should be rotated before excessive wear on the lower end occurs. Swing Jaw Die Replacement Similar to the stationary plate, the movable jaw die plate, mounted on the pitman is reversible and can be rotated 180° to distribute wear across the entire plate.

Lubrication Lubrication procedures are performed primarily to deliver grease or oil to rotating or sliding surfaces to reduce friction and carry away heat. Pressure lubrication is also used to expel contaminants from seals and other openings. Certain lubricants are used to protect parts from corrosion. When grease lubrication is used, the grease should be packed into the bearing making sure it gets between the rollers and the cage – not just on the outside of these parts. When hand-packing bearings, force grease through the bearing under the cage from the large end to the small end to ensure proper grease distribution. Mechanical grease packers are also available which force grease through the bearing, filling the space between the roller and the cage. Grease should also be smeared on the outside of the rollers. Basic Lubricant Functions Lubrication can be defined as the control of friction and wear between adjacent bearing surfaces by the development of a lubricant film between them. A bearing lubricant must perform three fundamental functions: 1. To provide a suitable film which separates the moving parts in a bearing. 2. As a heat transfer medium (to carry away heat) 3. To protect the bearing surfaces from corrosion and contamination. Lube Recommendation Trio recommends daily lubrication application at the close of the shift (Refer to the appendix B); the grease will flow smoothly and allow easy purging around seals or out of the drain plug. NEW CRUSHER lubrication – It is recommended to completely purge bearings after the first 200 hrs. after that 10 hr. intervals or shift intervals should be followed. Trio recommends a maintenance book be used to keep a good account of activity on all aspects of the crusher.


18

Self-Aligning Spherical Roller Bearing

Lubrication of the spherical roller bearings is accomplished by using a manual type grease gun or an automatic lubricating system through four grease fittings. One grease fitting is located on each of the side bearing housings and two grease fittings are located on the pitman, one at each pitman bearing. If the grease gun method of lubrication is used, add the grease immediately after shut down while the bearings are still warm. Normally, a manual type grease gun requires 20 strokes to discharge one ounce of grease. AVOID USING TOO MUCH GREASE AS EXCESSIVE GREASE WILL CAUSE OVERHEATING AND SHORTEN THE BEARING LIFE. Grease Specifications Trio recognizes there are many factors that go into choosing a grease, a brand and a supplier, what we wish to do is select the proper grade and additive that best fits the machinery and application. The brand, the supplier (i.e. Texaco, Shell and so on) and the type (i.e. synthetic vs. non-synthetic) we will leave to the end user. Bearing greases must withstand high pressures and temperatures. Some bearing manufacturers can supply a high quality premium grease that may prolong the life of the equipment, however satisfactory performance can be obtained by using an NLGI #2. Choose type EP rated, ASTM D2509. Use the proper grade for the ambient temperature expected. The selection of the correct lubricant for ant application requires careful study of operational and environmental conditions. In the selection of the proper lubricant there are trade-offs and concerns other than fatigue life to consider. For instance changing lubricant viscosities will affect the bearing operating temperature. When severe operating conditions are anticipated the use of a lubricant with an extreme pressure additive may help prevent scoring damage in the cone-rib / roller-end contact area. EP additives are chemically complex material which, when activated by localized high temperatures, forms a low shear strength film at the contact area on the bearing thus preventing scoring. Grease life is dependent upon such factors as speed, environmental conditions and operating temperature. The higher the temperature the more rapid is the grease oxidation. Grease life is reduced by approximately one-half for every 18 degrees Fahrenheit rise in temperature. Therefore the higher the operating temperature the often the grease must be replenished. Past experience is the best guide to CT2036 Jaw Crusher Manual

19

republication frequency. Obviously, seal leakage will dictate frequent relubrication and every attempt should be made to maintain seals at top efficiency. Bearing Temperature A properly adjusted bearing should run at about 140 to 160 degrees Fahrenheit. If a bearing is suspected of running to hot it should be checked with a surface mount thermometer and checked to see if it is over 165 degrees Fahrenheit. A bearing that develops high temperature after it has been running satisfactorily for some time may be caused by over greasing. A newly installed bearing that overheats is usually caused by improper adjustments of the running clearance. A failed bearing that is overheating will probably be accompanied by some other indication such as grinding noises.

Dust Seals As stated above the bearings are protected from outside contamination by labyrinth seals that depend on sloughing grease to shed the dust, dirt and moisture.

Operating Instructions Pre-Starting Instructions Adhering to strict inspection habits will serve to help insure years of successful operation of this crusher. Memory alone will not ensure that proper maintenance is performed. Consequently, a written record book is recommended. By regularly performing pre-startup maintenance inspections, the operator will minimize down time and prolong the crusher’s useful life. Before starting the crusher, the following steps should be followed: 1. Check that the correct hydraulic oil is being used and is correctly installed in the hydraulic adjustment assembly. 2. Inspect to ensure that the crusher is free of tools and other potential mechanical obstructions. 3. Verify that all joints, bolts and fasteners are tightened properly and that there are no leakages in the lubricant system. 4. Before starting, pump several ounces of fresh grease into each bearing. Let the machine run for one half hour and add grease in intervals until grease appears on the bearing grease seals. 5. Listen carefully for any unusual sounds. When satisfied that all parts are running correctly, begin feeding a small amount of material and begin increasing the feed rate until the crusher is operating at its full capacity. 6. During this startup period, check the bearing temperature frequently. If temperatures are above the recommended levels, lubricate according to the instructions provided in the lubrication section. 7. Check to ensure that the tension spring on the crusher does not need re-adjustment. If an adjustment is required, make sure that all necessary parts are available. 8. After all of these steps have been followed, start the crusher according to the crusher start-up section.

Crusher Speed The correct speed (revolutions per minute - RPM) is very important for proper crusher operation. The sheave sizes recommended for driving the crusher are designed for maximum load operation -- therefore the crusher speed may be somewhat higher during lessened load periods. By operating at the recommended speeds, the crusher will produce its maximum output with uniform production size.


20

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


21

Parts List Item

Part #

12 13 14 15 16 18 19 20 21 22 24 25 26 27 28 30 31 32 33 34 35 36 37 38 39 40 89 90 91 92

C2036-8 C2036-9 C2036-10 GB5782/M12X35 GB93/12 C2036-11 C2036-12 C2036-13 GB91 GB6170/M30 C2036-14 C2036-15 GB70/M20X70 GB7244/20 C2036-16 C2036-17 C2036-18 C2036-19 GB6170/M12x35 GB93/12 C2036-20 GB5782/M20x60 GB7244/20 C2036-21 C2036-22 GB6170/M36 T6090-20 T6090-18 GB5782/M16x45 GB93/16

Description Buffer (Lower) Rubber Dust Apron Clamp Plate for Rubber Dust Apron Bolt M12X35 For Rubber Dust Apron Lock Washer 12 Toggle Plate Pin Washer Split Cotter 8x75 Nut M30 Buffer (Upper) Toggle Dog Bolt M20x70 Lock Washer 20 Rubber Dust Cover Tension Rod Spring Keeper (Lower) Clamp Plate Bolt M12x35 Lock Washer 12 Plate Bolt M20x60 Lock Washer 20 Spring Spring Keeper (Upper) Nut M36 Lower Guider Plate Bolt M16x45 Lock Washer 16


QTY

Unit Weight Lbs

1 1 1 5 5 1 1 1 1 16 1 1 2 2 1 1 1 1 4 4 1 2 2 1 1 2 2 2 2 2

63.8 4.4 2.2 .088 .0022 246.4 4.84 .11 .0066 .66 171.6 1.76 .40 .11 21.78 37.4 7.04 3.52 .077 .002 45.1 .33 .011 26.4 4.84 1.1 12.1 .33 .154 .0044

22

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


23

Parts List Item 56 57 58 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88

Part # C2036.4 C2036-27 GB825/M16 GB5782/M24X70 GB7244/24 C2036-29 C2036-30 GB1095/12x30 GB//T288 C2036-31 GB32.1/M20X65 GB7244/20 C2036-32 C2036-33 GB/T288 AH2244 KM48 C2036-34 GB812/M190X3 GB858/190 GB1152/M10x1 C2036-35 GB1095/12x35 C2036.5 GB5867/Z2-170x225 C2036-36 GB32.1/M16x65 GB7244/16 GB32.1/M36x130 C2036-37


Description

QTY

Flywheel Bearing Housing Cover (LH) Eyebolt M16 Bolt M24x70 Lock Washer 24 Eccentric Shaft Spacer Key 12x30 Pitman Bearing 23148CA/W33 C3 Pitman Seal Bolt M20x65 Lock Washer 20 Middle Seal Bearing Housing Frame Bearing 22244 CAK/W33 C3 Adapter AH2244 Round Nut Bearing Housing Cover (RH) Lock Nut M190x3 Lock Washer 190 Grease Fitting Outer Seal Key 12x35 Sheave Ringfeder Z2-170x225 Cover Bolt M16x65 Lock Washer 16 Bolt M36x130 Washer

1 1 2 4 4 1 2 2 2 2 32 32 2 2 2 2 1 1 L, R Each 2 4 2 2 1 2 2 6 6 12 12

Unit Weight Lbs 2008.6 66 .506 .66 .0374 1150.6 19.8 .05 150 46.2 .35 .011 44 350 116 16.28 13.64 66 8.36 .44 .044 35.2 .044 1,855 12.7 18.7 .22 .01 1.98 .396

24

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


25

Parts List Item 1 2 3 4 5 6 7 8 9 10 11 17 22 59 60 61

Part # C2036.1 C2036-1 C2036-2 T6090-4 T6090-1 GB7244/30 C2036-3 C2036-4 C2036-5 C2036-6 C2036-7 C2036.2 GB6170/M30 GB97/30 C2036.6 GB6170/M24 C2036-28

Description Frame Fixed Jaw Die Upper Cheek Plate (LH & RH Each) Bolt for Cheek Plate Washer Lock Washer 30 Lower Cheek Plate (LH & RH Each) Swing Jaw Die Wedge for Swing Jaw Die Pitman Protection Plate Bolt for Swing Jaw Wedge Pitman Nut M30 for Swing Jaw Wedge Washer 30 Wedge for Fixed Jaw Die Nut M24 for Fixed Jaw Die Wedges Washer


QTY

Unit Weight Lbs

1 1 Total 2 8 8 8 Total 2 1 1 1 4 1 8 4 2 4 2

8,096 1,430 143 2.42 .22 .07 152 1,430 86 226.6 8.36 3,876.4 .396 6.6 .22 .33

26

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

Parts List Item Part # 23 Q/ZB220-77 29 C2036.3

Description Drain Plug M24X2 Lubrication System


QTY 2 1

Weight .319 16

27

APPENDIX A: DISCHARGE SETTING ADJUSTING PROCEDURE


28

PUMP STATION

Parts List Item 40 41 42 43 44 45 46 47 48 49 50 51 52 55 59 60 61

Part # GB6170/M36 C2036-23 C2036-24 GB5782/M16x45 GB7244/12 T6090-31 GB5867/Z2-90x130 T6090-32 GB6170/M30

T6090-34 C2036-25 C2036-26 C2036.6 GB6170/M24 C2036-28


Description Nut M36 Rear Wedge for Discharge Adjustment Guider (I) Bolt M16x45 Lock Washer 12 Pin (I) Ringfeder Z2-90x130 Washer Nut M30 Hydra. Cylinder 390+125 Hydra. Cylinder 404+137 Pin (II) Guider (II) Front Wedge for Discharge Adjustment Wedge for Fixed Jaw Die Nut M24 for Fixed Jaw Die Wedges Washer

QTY

Unit Weight Lbs

2 1 1 12 12 2 2 4 4 1 1 2 1 1 2 4 2

1.1 358.6 2.2 .154 26.4 3.37 .154 .40

7.7 2.2 358.6 6.6 .22 .33

29

Adjusting the Discharge Setting •

•

Be sure the pump station is connected to the adjustment hydraulic cylinder properly (refer to the diagram below). Loosen the tension spring retainer nuts (item 40). Switch the valve to the desired flow direction (Bigger End of Wedge Out – Increase the discharge opening or Bigger End of Wedge In – Decrease the discharge opening). Use pump through the hydraulic cylinders to push/pull the wedges out/in to the desired discharge opening position. Tighten the tension spring retainer nuts (item 40).

•

Switch the valve back to the “Hold” position.

• • •

Hydraulic Control Connection Diagram


30

Hydraulic Fitting Parts Details CT2036 Jaw Crusher Manual

31

Appendix A: Jaw Crusher Bearing Greased Quantity per Day (8 Hrs.) Jaw Size

Grease for Pitman Bearing

Grease for Frame Bearing

Weight (Ounce)

Volume (Quart)

Weight (Ounce)

Volume (Quart)

SJ10X16

.43

.015

.43

.015

SJ16X24

.57

.02

.57

.02

SJ20X30

.74

.026

.74

.026

SJ24X36

.81

.029

.81

.029

SJ30X42

1.69

.059

1.69

.059

CT/SJ10X30

.44

.015

.44

.015

CT/SJ10X40

.44

.015

.44

.015

CT/SJ10X48

.50

.018

.50

.018

CT/SJ12X52

.94

.033

.94

.033

CT/C20X36

.70

..025

.61

.021

CT/C24X36

.89

.031

.72

.025

CT30X42

1.62

.057

1.55

.055

CT32X54

1.55

.055

1.34

.047

CT24X36

.89

.031

.72

.025

The grease is to be totally replaced when the machines have worked number of hours respectively as shown below:

Grease Replace Period (Hrs)

CT/SJ10X48

2,200

CT/SJ12X52

2,200

SJ10X16

3,500

CT/C20X36

2,000

SJ16X24

2,600

CT/C24X36

1,900

SJ20X30

2,000

CT30X42

1,600

SJ24X36

2,500

CT32X54

1,700

SJ30X42

1,500

CT24X36

1,900

CT/SJ10X30

2,600

CT/SJ10X40

2,600

Jaw Size


The quantity is ½ free room in the bearing housing. 32

WARRANTY TERMS AND CONDITIONS Seller warrants all new equipment manufactured or imported by Trio Engineered Products, Inc. (Trio) against defects in material or workmanship attributed to the original machine manufacturing. No other warranties are expressed or implied. Warranty claims must be made through the dealer or agent responsible for the original equipment sale, as the equipment will have been registered with them at the time of sale from Trio. Claims must be made within twelve (12) months from the date of readiness for operation, but not more than fifteen (15) months from the date of shipment from Trio. All parts claimed to be defective shall be returned to Trio, freight prepaid, for inspection to determine that the said part or parts are defective. If it is determined that the fault lies with Trio, Trio will ship a replacement part or parts at no cost, but freight charges will be paid by customer. If it is determined that the fault does not lie with Trio, a replacement part or parts will be shipped, freight collect, to the customer with the receipt of a purchase order from the dealer or agent. Trio will not be responsible for freight costs associated with warranty claims. When petitioning for a warranty item, the serial number of the equipment must be referenced. The serial number must be clearly identifiable on the Trio nameplate on the equipment. This warranty is void if: •

The serial number plate and/or other markings identifying the machine as Trio have been altered or removed.

•

The machine was not sold under the Trio brand name or another brand name approved by Trio.

•

Parts have been used other than those supplied by Trio.

Trio makes no warranty with respect to damages or defects in any product caused by improper installation, operation, maintenance, and storage or caused by negligence or accident. In addition, any product repaired or altered in any way as reasonably determined by Trio, that affects the performance or purpose for which the equipment was originally manufactured, will not be covered under this warranty. Under this warranty, the buyer will not be entitled to any labor charges involving the repair of the equipment involving warranty items, unless authorized by Trio in writing. Warranties of merchantability or of fitness for any particular purpose or arising from the course of dealing or usage of trade are specifically excluded. Any affirmation of fact, description of goods, or sample or model referred to in this agreement or elsewhere, whether or not the same relate to production or capability of the goods to perform, are not the basis of this agreement, unless specifically made a party of the agreement in writing. Under no circumstances will Trio be responsible for consequential or punitive damages of any nature, whether based on contract or tort, including but not limited to lost profits, loss of production, delays or other expenses. Under no circumstances shall the liability of Trio exceed the purchase price of the equipment furnished. The laws of the state of California shall govern the warranty. The parties agree that exclusive jurisdiction for any claim for breach of this warranty shall rest in the Los Angeles County Superior Court in the State of California.


33

CT Series 20x36 Jaw Crusher[1]

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