CT Series 20x36 Jaw Crusher Manual (250).pdf

TRIO E N G I N E E R E D

P R O D U C T S

Tr Trio Engineer Engineered ed Products, Products, Inc. Inc. • 12823 12823 Sc haba ha ba rum Ave. • Irwinda le, C A 9170 91706 6 • Telepho Telep hone ne 626-851 626-851-396 -3966 6 • Fax 626-851-9526

Parts and Operation Manual

CT Series 20” x36” Jaw Crusher Size: Se rial ia l Number: Numb er:

CT2036 CT2036 Jaw Crus her Manual

20 x x 36 ″

″

250

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HAZARD WARNING Any machinery may be hazardous to the user if it is not maintained and op era era ted proper prop erlly. The fol fo llowin ow ing g preca prec a utions utions should a lways wa ys be ob served erved::

CRUSHING MACHINERY 1. Ta Ta ke spe spec c ia l c a re to to see see tha tha t a ll pa rts of your your body bo dy are are cl c lea r of movi moving ng pa rts a nd pinch pinc h point p oints s befor be fore e starti tarting ng or oper op era a ting ting mac hiner hinery. y. 2. Make sure that all rotating sheaves, pulleys and belts are properly guarded to prevent being caught by them. 3. Be sure sure that the feed fee d a nd d isc isc har ha rg e systems ystems for mater mate rial pr p ro c essing essing equi eq uipme pment nt are des d esigned igned a nd mainta mainta ined so that pr p roc ess essed materials materials (roc (roc ks, gravel, co a l, etc.) etc .) are are reta reta ined withi within n the sys system. tem. Do not no t allow allow a ny par pa rt of your b o d y to to enter ente r in or nea r the mater ma terial ial flo flo w. 4. Never sit or stand on any component of the machinery while it is in operation to p revent eve nt injur injuries ies a rising ising fro fro m vibration. vibra tion. 5. Ver Ve rify ify tha thatt the sup supp p o rting ting struc tructur ture(s) e(s) p ro vided vide d b y yo yo ur c o mpa ny for the mac hiner hinery y is is suffic uffic ient to to supp ort b oth the tota l weight of the equi eq uipme pment nt and a nd the dynami dyna mic c loa d a nd stres tress ses crea crea ted by the eq uipme uipment nt..

CONVEYING MACHINERY 1. Be sure that all parts of your body are kept clear of moving conveyor belts, esp esp ec ially ially at a t pinch pinc h points p oints.. 2. Do NOT lubrica lubrica te ma c hinery hinery while while it is is in motion. 3. Never lea lea n over ove r a moving moving c onveyor onveyo r b elt, elt, or ride on o n a c onveyor onveyo r b elt intend intend ed o nly nly for materia materia l tr tra ns nsp p o rt. 4. Always Alwa ys keep ee p c lea r of feed fee d or disc disc har ha rge po ints ints of a ll materia materia l c onveyor onveyo r systems. 5. Be sur sure that tha t all a ll g uar ua rd s a re secur sec urely ely fastene fastened d in plac e o n s shea hea ves, ves, pulleys pulleys,, and belts before and during equipment operation.

SAFETY EQUIPMENT Tr Trio Engineer ngineered ed Prod Prod ucts uc ts,, Inc Inc.. provides provides only such uc h sa sa fety fety equi eq uipment pment and a nd guar gua rds a s a re spec pe c ified fied b y the the Purc Purc has ha ser on the Shop Shop O rd er or the C us ustomer tomer Ord Ord er A c knowledg knowled g ment. The Purcha Purc has ser must must furnis furnish h all a ll o ther req uired uired sa fety devi de vic c es.


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GENERAL SAFETY PRACTICES Sa fety Pra Pra c tic tic es a ffect ffec t everyone everyone.. A ny a nd al a ll per pe rsonnel onne l who oper op era a te or maintain your equipment are expected to comply with the basic safety prac tic tic es tha thatt foll follow. ow . Thi This s manual c ontains the the bes be st a vaila vaila ble informati nformation on on prop prop er ins nstal tallla tion, tion, op eration eration and a nd maintenanc e of the the equi eq uipme pment nt that it it a d dress dresses. es. It d oes oe s NOT replace or supersede applicable federal, state, or local regulations, your c o mpa mp a ny sa sa fety rules rules,, or ins insur ura a nc e c a rrier re q uireme uirements nts.. It It defini de finitely tely is is not no t intende ntended d to rep replla c e good go od judgment udg ment or common c ommon sens sense! e! Equipment operators, plant management and safety engineers are required and expected to be aware of potential hazards that may exist in the specific wor wo rkpla kpla c e wher whe re the equi eq uipme pment nt is ins installed talled a nd op o p era era ted. A ll per pe rsonnel onne l a re expected to develop, implement and maintain a safe work environment c ompa omp a tib tib le with with op o p era era ting ting c ondit ond itiions, ons, req requi uirrements, ements, and a nd prac tic tic es. es. Additional safety precautions suited to the specific conditions of the work site a nd the eq e q uipment insta install lla a tio tio ns a re the resp resp o ns nsibil ibilit ity y of o f the us user. er. Experience has demonstrated that the greatest numbers of workplace a c c idents ide nts a re c a us used ed b y fail fa ilur ure e to foll fo llo o w esta esta b lished ished sa fety rules. ules. Be sur sure e that tha t you are fully familiar with the safety program requirements applicable to o p erating this this typ typ e of equipment. eq uipment. C onsult onsult your supervi up ervis so r c o ncerni nc erning ng any a ny operating procedure that you are not sure about before operating or working o n this this equipment. eq uipment. 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 eq e q uipment descri d escrib b ed in this this manua ma nual. l. It is the respo respons nsibil ibilit ity y of the pur p urc c has ha ser of this this equi eq uipment pment to ensur ensure e that suc such h pl p la tform tforms s c ompl omp ly with with a pp lica b le federal, fed eral, state, a nd loc a l stand standa a rds and regul eg ula a tions tions..

PERSONAL SAFETY PRACTICES ARRANGEMENTS FOR EMERGENCY SITUATIONS Supervisory and operating personnel should develop an emergency response p ro file file for pos po ssible emer eme rg enc ies o n the wor wo rksit ksite. e. A ll p erso erso nnel sho should uld know the location of fire-extinguishers, where to obtain first-aid assistance and supplies, emergency report telephone numbers, power shut-off points, and other equi eq uip p ment shut-do hut-down wn c ontrol ontrol loc a tions tions.. Ap propr prop ria te tool too ls a nd equipment should be available to allow immediate response to emergency situations. A lwa ys follo follo w the req req uireme uirements nts a nd regul reg ula a tio tio ns o f yo yo ur c o mpa ny’s Emerg merg enc y Ac tion tion Pla Pla n. CT2036 CT2036 Jaw Crus her Manual

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SAFE MACHINERY INSTALLATION 1. Rea d a nd under unde rstand a ll pa rts of this this manua l inc inclluding G ener ene ra l Dimens Dimensiion Drawings. 2. Review your Plant Engineer’s Installation Drawings for this equipment. 3. Select, Assemble, and Test the correct hoisting and rigging equipment req uired uired to move the eq e q uipment to the insta installlation site site in your family. 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 a c tiviti tivities. es.

KNOW AND UNDERSTAND HOW THE EQUIPMENT WORKS It is a b so lutely essentia essentiall tha thatt mac hine op o p erator erato rs unders und erstand tand c o mpletely how the c rus usher her works works. The op o p erator erato r must must kno know w the loc a tio tio n and a nd func tio tio n of all a ll c o ntro ntro ls, ga uges uge s, indic indica a tors tors a nd al a la rms inc inc luded ude d with with the unit. unit. O p era era tors tors a nd maintenance personnel must be completely familiar with maintenance proc edur ed ures es a nd sc sc hedul hed ules es.. O nly nly if the the equi eq uip p ment is given maintena maintena nce nc e on o n the 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.

REA REA D THE THE MA NUAL A ND UNDERST UNDERSTA ND Y O UR MA C HINERY Have everyone READ THE MANUAL (and all related literature) furnished with your equipment to learn its its operati op erating ng and maintenanc maintena nce e cha ra c teris teristic tic s, c a pa c ities ities,, a nd limi limitations tations.. Learn the loca loc a tion tion and func tion o f ALL A LL C O NTROLS NTROLS,, indicators indica tors, war warning ning devic d evices es and WARNING WARNING ins instruc tructi tions. ons. READ AND OBSERVE THE SAFETY DECALS! REPLACE THE DECALS WHEN IT BECOMES NECESSARY


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INSPECT YOUR MACHINE BEFORE START-UP Make a visual inspection of the machine for loose, worn, or damaged parts or faulty fa ulty sa fety d evic e s. Insp Insp e c t a ll d rive belt be lts s a nd pull p ulleys eys for fo r e xc essive essive wea r. Te st a la rm systems ystems a nd c hec k fluid fluid leve levels ls.. M a ke sur sure e that tha t hydra hydra ulic ulic,, a ir, ir, a nd lubrication systems and their respective valves, drains, and fittings are in proper wor wo rking king or o rd er. Rep o rt o r rep a ir a ny p rob lem before be fore sta starrting ting the mac hine.

FOLLOW THE RECOMMENDED EQUIPMENT START-UP INSTRUCTIONS Be sur sure e that tha t co c o ntro ntro l systems ystems a nd a larms larms a re wo w o rking king p ro p erly. erly. C hec k g a uges uge s for proper prop er rea rea d ings. ngs. C hec k for for any unusua unusuall noises noises that may indic indica a te bea be a ring fa ilur ilure e o r o ther mec hanic ha nica a l p ro b lems. ems. C hec k for sudd ud d en ris rises es in lub lub rica ic a nt temperatur temp erature. e. Shut the the eq e q uipme uipment nt down do wn immed immediately iately if probl prob lems a re detec de tected ted,, and report ep ort the p ro b lem(s) em(s) to to your yo ur supervi up ervis so r. A lways lwa ys refer efe r to the O p erating Sec Sec tio tio n of this manual if you are unsure about a start-up procedure or for additional information.

STOP THE MACHINE PROPERLY AND SAFELY The The mac hine hine mus must be c ompletely ompletely stopp stopped ed with with power po wer off and a nd loc ked-out ed -out with with c o ntro ntro ls tag ged ge d b efor efo re a ny cl c lea ning, rep rep a irs irs, ad a d justments justments,, or servi servic c e is p erformed erformed.. A ll p rovisions ovisions o f y yo o ur c o mpa ny’s C o ntro ntro l o f H Ha a za rd o us Energy (Lo (Lo c kO ut/Ta ut/Ta g-O ut) p rog ra m mus mustt be follow followed ed..

REPORT THE NEED FOR NECESSARY REPAIRS IMMEDIATELY Report any situation involving the need for repair, replacement or adjustment of a n equi eq uip p ment c ompone omp onent nt immed mmediately iately.. Remember ememb er,, the most most minor minor d efec t c o uld result result in injur injuries ies to your yo urs se lf or o thers o r serio erio us d a mag ma g e to the ma c hinery if it is not no t co c o rrec ted p ro mptly. mptly. Do NOT work on the equipment unless you have been properly and completely tra tra ined ined to do d o the wor wo rk involv involved ed..

PREVENT FIRE HAZARDS Never weld or use a cutting torch near open or exposed fuels, lubricants, or o ther fla fla mmab le ma ma terials terials.. Fo llo llo w your c o mpa ny’s Hot Wo Wo rk Poli Po lic c y. Do not no t let g rea sy o r o ily ily ra g s a c c umula umula te in in poo po o rly ventila ventila ted a rea s. Store oily oily rags and other combustible materials in an approved storage container and d isp isp o se o f them pr p ro p erly. erly. Never us use a n open op en fla fla me to c hec k for flui fluid d lea ks in the the eq uipme uipment. nt. Use a n a p proved low volta volta ge elec tric tric light or o r fla fla shli hlight. Never Ne ver smoke in undesi und esig g nated na ted a rea s. Fo llo llo w your c ompa omp a ny’s Smoking Rul Rules. es. A lways lwa ys e xtinguish tinguish smoki mo king ng materi ma teria a ls p ro p e rly. ly. Know whe wh e re the nea re st fire fire exti extinguis nguisher her is is loc a ted, how ho w to op era era te it, it, and a nd what wha t types types of fir fires it it c ca an b be e us used ed CT2036 CT2036 Jaw Crus her Manual

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to ex e xting tinguis uish. h. M a ke sur sure e that tha t fir fire ex e xtinguis tinguishers hers a re in plac pla c e, ar a re in proper prop er wor wo rking king c o ndit nd ition, ion, and have ha ve a c urr urrent, va va lid lid insp insp ec tio tio n tta a g . If a fire fire extinguis extinguisher her is not no t rea rea d ily ily ava a vail ila a b le, or do es not meet mee t these these req uireme uirements nts,, rep rep o rt the sit situa uati tio on to your supervisor.

KEEP YOUR WORK AREA CLEAN Bec o me fully fully familiar familiar with with the work w orks site ite wher whe re the equipment eq uipment is insta install lled ed . Insp Insp ec t the area d a ily a nd see see that tha t uns unsa a fe c ondit ond itions ions a re c orrec orrec ted. Ma ke sur sure e that al a ll eq uipment gua g uarrd s a re secur sec urely ely fastene fastened d in plac e, that tha t step steps s, stair stairwa wa ys, ys, wor wo rk p latforms a nd b a rrier ra ils ils a re sound a nd free free o f sp sp ills ills o r o b struc tructi tio o ns ns.. Keep Kee p the floo floorr/ wor wo rk sur surfac fac e c lea n and a nd free free of oil o il,, grea grea sy ra ra gs gs,, c ca a bles, bles, c cha hain ins s, buc kets a nd other ob struc tructi tions ons.. Keep tool too ls a nd loos loo se pa p a rts in a too lbo x or a pp rop ria te storage torag e a rea s. Use high flas fla shpo hp o int/ int/ low toxic toxic ity ity so so lutions lutions for cl c lea ning.

HANDLE TOOLS, HEAVY PARTS, AND MACHINE COMPONENTS PROPERLY Do no t to to ss p a rts o r tools too ls o r d ro p them off platforms p latforms.. Do not no t lo lo wer we r o r swing elec tric tric or o r a ir p o wer we r tools too ls b y their their p o wer we r c o rd s o r a ir lines. lines. Use a suita uita b le rope rop e a nd/ or co ntainer to lower lowe r tool too ls or par pa rts to the floo floo r. Review job a c tivi tiviti ties es a nd a rra nge ng e to get ge t help befo b eforre you att a ttemp emptt to lif lift, t, c a rry o r move hea he a vy p a rts. ts. For hea vy or awkwa aw kwarrd lifts lifts us use e p ro p er hoisti hoisting ng d evices. evic es.

DRESS PROPERLY FOR THE JOB AND USE APPROPRIATE PERSONAL PROTECTIVE EQUIPMENT Fo llo llo w yo yo ur c o mpa ny Perso Perso nal na l Pro Pro tec tive tive Eq Eq uipment Polic Polic y. Disc Disc us uss s p ersona ersona l p ro tec tive tive eq e q uipment req req uireme uirements nts with yo yo ur supervi up ervis so r b efor efo re o p erating eq uipment or p erformi erforming ng servi servic c e, rep rep a ir o r a d justment justment wor wo rk. Don’t Do n’t wea r lo o se clothes or jewelry, and restrain long hair.

FOLLOW YOUR COMPANY SUBSTANCE ABUSE CONTROL POLICY Rep o rt any use use of o f presc presc ription or over ove r-the-c o unter medic med ica a tio tio ns to your supervisor prior to operating this equipment or making any adjustments or rep a irs irs to to it. ALCOHOL OR OTHER CONTROLLED SUBSTANCES SHOULD NOT BE USED PRIOR TO OR DURING WORK ON THIS EQUIPMENT.

AVOID SERIOUS EYE/SKIN INJURIES Hydra ydra ulic ulic flui fluid d or comp c omprress essed a ir c a n p pene enetr tra a te or o r burn burn the sk skin or damag da mage e the e yes c a us using ing serious serious injur injury, y, blindnes blindne ss, or o r d ea th. M inera inera l-ba -b a sed hydr hyd ra ulic ulic oil o il is haz ha za rd ous. A lways lwa ys wea we a r go g gles when whe n wor wo rking king with hydrauli hydra ulic c fluid fluid . Flus Flush h your you r skin kin or o r eyes eye s thor tho ro ughly ug hly with wa ter if if you spill spill or sp la sh hyd hyd ra ulic ulic fluid fluid on o n yo yo urs urself. Remove emo ve c lothing lothing on o n which hydraulic fluid fluid ha s sp la shed . G et immed immediate iate a ssista istanc nce e and a nd repo rep o rt the the matt ma tter er to your supervi up ervis so r. G et a ppr pp ropr op ria ted med mediic a l c a re. Wear a pp ropr op ria te per pe rsona l protec protec tive tive CT2036 CT2036 Jaw Crus her Manual

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eq uipment as a s set for fo rth in in your c o mpa ny’s Perso Perso nal na l Pro Pro tec tive tive Equipment Equipme nt Polic Polic y when handli ha ndling ng hydra hydra uli ulic flui fluid d . Wash Wash your your hands ha nds with with soa soa p a nd wa ter a fter fter hand ha ndli ling ng hydraulic fluid. fluid. Never Ne ver ea t, d rink or smoke while while hand ha ndli ling ng hydraulic hydraulic fluid. Make sure that all compressed air lines and couplings are in proper operating c o ndit nd ition ion at a t all times times.. Be sur sure e that tha t all c o mpress mpressed a ir lines lines intend intend ed for chip o r d us ustt re mova mo vall a re fitted fitted with OSHA OSHA c o mpli mp lia a nt press pressure ure re re lief lief noz no zzles. les. Never Ne ver us use e c ompr omp ress essed a ir to c lea n your c lothing othing or any pa rt of your bo d y.

DISPOSE OF ALL WASTE MATERIALS PROPERLY Disp Disp o se o f all a ll wa ste ma terials terials suc h a s fuels, fuels, lubrica lubrica nts, nts, hydraulic hydraulic fluid, fluid, etc e tc.. in accordance with your company waste management policies, and federal, state, a nd lloc oc a l regul eg ula a tions tions.. If you have ha ve a questi question on conc c onc erni erning ng prop prop er 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, d efec tive, tive, or wor wo rn pa rts c a n be ea sily ide identi ntifi fied ed.. M a ke da d a ily ily vis visual ua l c hec ks for mis missing, cr c ra c ked, ked , or fra fra yed V-b V -belts elts.. A lso lso c hec k d a ily ily for fra fra yed, yed , bro bro ken or kinked kinked c a bles. bles. Ins Inspec pe c t end c onnec onne c tions tions for wea r. Repl ep la c e shea sheaves ves with with c ra c ked rim rims s o r sp okes immed immediate iatelly. Rep o rt s sus usp p ec ted d efec efe c ts to your yo ur supervi up ervis so r.

PROPERLY GROUND MACHINE ELECTRICAL COMPONENTS C hec k freq freq uently to ensure ensure that tha t the the eq e q uipment is is p ro p erly erly g ro unded und ed a s stipulated tipulated in your c ompa omp a ny elec elec tri tric a l sa fety rules ules.. Prevent Prevent any a ny elec elec tric tric c a ble from from coming c oming in in conta c ontac c t with with water in pudd pud d les, es, d ra inage na ge c hannels ha nnels,, etc. etc . Protec Protec t p o wer we r c a b les fro fro m vehicular vehic ular tr tra ffic ffic such uc h as a s forkli forklifts fts a nd o ther motor moto r vehicles vehic les.. Power Pow er c a b les should be br b rid ged ge d over o ver tra tra ffic ffic lanes la nes.. All per pe rmanent mane nt elec tric tric c a bles should be b e in prop prop er c ondui ond uitt or other a p proved ins insula ula tion. tion. Follow ollow your company electrical safety rules with regard to periodic inspection of the c o ndit nd ition ion of elec tric tric line line insul insula a tio tio n and c o upl up lings. ings. Do NO T us use e po p o rtab le, flexi flexib b le elec tric tric c ords to deli d eliver ver elec tric tric p ower ow er to to the the equipment. e quipment.

CONTROL OF HAZARDOUS ENERGY (LOCK-OUT/TAG-OUT) PROGRAM C A UTION: ION : Purc Purc has ha ser must must impleme implement nt a C o ntro ntro l of Hazardo us Energy (Lo (Lo c kO ut/T ut/ Ta g -Out) -O ut) Pro Pro g ra m that tha t co c o mpli mp lie e s with 29 29 C FR 19 1910 10.1 .147 47 a nd 13 133 3 reg ulati ula tio o ns ns.. It is the respo respons nsibil ibilit ity y of the p urc urc has ha ser to pr p ro vid vid e a suita uita b le C o ntro ntro l of Haz Ha za rd o us Energy program for the protection of its’ employees while they are engaged in CT2036 CT2036 Jaw Crus her Manual

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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 M ine Sa Sa fety and Healt Hea lth h Ad minis ministr tra a tio tio n (MSHA (MSHA ) governs go verns reg ula ula tio tio ns c o ncerni nc erning ng this this subjec ub jec t. C erta erta in state, ta te, c o unty, unty, o r loc a l regulations eg ulations may ma y a lso lso ap a p p ly. ly. Assistance in establishing regulatory obligations may be obtained from regul eg ula a tory tory ag a g enc ies, ies, insur insura a nce nc e c a rriers iers, or pr p rivate c o ns nsul ulta tants nts.. 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, d oc umenta umenta tion tion and a nd maintena maintena nce nc e of your your program. Incl nc lus usion ion of the the names of these firms in this manual does not represent an endorsement of them by Trio Engineer nginee red Pro Pro d ucts uc ts,, Inc.. These hese fir firms p ro vid vid e so me of o f the mater ma terials ials req uired uired for a c ompr omp rehens ehe nsiv ive e pr p rogr og ra m. 1.

SETO N Name Pla Pla te C ompa omp a ny P. O . Box BD BD - 1331 New Ne w Haven Hav en,, C T 0650 06505-9 5-977 770 0 Telephone Telephone 203-48 -488-80 -8059 Toll Toll Free 800-24 -243-66 -6624 Fax Fa x To ll Fre Fre e 800-345-7819

2.

EMED C o., Inc. Telephone elep hone Graphic Communications Products Buffalo, NY 14240-0369 P. O . Bo Bo x 369 Toll Toll Free 800-44 -442-33 -3363 Fax Fa x To ll Fre Fre e 800-344-2578

3.

D & G Sign and La bel be l P. O . Bo Bo x LA LA - 157 Toll Toll Free 800-35 -356-92 -9269 Nort No rthfo hforrd , C T 0647 06472 2 Telephone Telephone 203-48 -483-04 -0491 Fax Fa x 203-488-4770 203-488-4770

The The Purc Purc haser haser has sole sole respo espons nsiibili bility for sa sa fe oper op era a tion tion of thi this equipment. equipment. The Purcha Purc has ser is is respons espo nsible ible for fo r ens en suring uring that tha t on-site on-site mac ma c hine op o p e ra tio tio n is in compliance with any and all applicable federal, state, county or city safety standards and regulations. The The equi eq uipment pment may b e moved from from o ne site to a nother a numbe numberr of times times by var va rious p urc urc has ha sers, ers, less lessees ee s, etc . C o ns nseq eq uently, uently, resp esp o ns nsibil ibilit ity y for c o mplianc e CT2036 CT2036 Jaw Crus her Manual

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with a p p lic lic a b le sa sa fety and enviro enviro nmental nmenta l c o d es lies lies with the entity entity respo respons nsible ible 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 se rvice vic e pla p latforms tforms.. Purchaser is required to perform periodic maintenance of the type and on the rec ommended ommend ed sc hedul hed ules es set forth forth in this this manual manua l. M a intena intenanc nce e sha shalll incl nc lude, ude , 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. Repl ep la c ement pa p a rts inc inc luding war wa rning ning a nd ins nstr truc ucti tiona ona l la la bel be ls a re a vaila vaila ble from from Tr Trio Engineered ngineered Prod Prod ucts uc ts,, Inc.. nc .. Purc Purc haser haser is invi invited to c a ll for a vaila vaila bili bility a nd c urr urre nt pr p rice ic e o f suc suc h pa p a rts a nd lab els a t 1-62 1-626-8 6-851 51-39 -3966 66.. Any modifications or machinery as designed, manufactured, and delivered by Tr Trio Engineer Engineered ed Prod Produc ucts ts,, Inc Inc.. with without out the the expr expres ess s wri written tten app a pprroval ova l a nd c onsent onsent 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 eneral Informatio nfo rmation n 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 CT2036 CT2036 Jaw Crus her Manual

9

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. 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 Machine Shipping Condit ion 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.


10

•

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

•

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

•

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

General eneral Installatio Installation n Informa Inform ation tio n Crusher Component Weights Weights

(Lbs)

Complete Crusher

Frame, Cheek Plates, Fixed Jaw And Rear. Front Wedge For Discharge Adj us tmen t

Fixed Jaw Die

Swing Jaw Die

Cheek Plates (Total)

Pitman

Eccentric Shaft

Toggle Plate

Flywheel and Sheave (Total)

Pitman, Eccentric Shaft , Bearings and Swing Jaw

25,245

11,540

1,430

1,430

590

4,686

1,151

247

3,865

9,471

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

CT20x36

POWER

OPERATING SPEED (FULL LOAD RPM)

HP

KW

250

75

55

Flywheel Rotation Direction


11

CT Jaw Capacity (TPH) Analysis for Given Clos Clos ed Side Side Setti Setti ng of Crusher Crush er 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"

50-130

80

92

110

133

148

180

24x36

3"---6"

75-160

120

147

165

190

230

275

30x42

3"---7"

75-180

190

220

280

340

36x48

4"---9"

100-220

240

42x54

5"---9"

125-240

47x63

6"---12"

150-300

26x46

2"---7"

50-180

90

103

125

155

175

32x54

4"---7"

90-180

105

118

135

170

185

295

360

450

500

570

330

390

515

575

630

700

500

590

650

740

800

210

250

340

235

310

420

950

1.

The above information is based on average average feed material that that weighs weighs approximately approximately 100 lbs/ft ³ crushed of a size which is readily fed into the crushing chamber without clogging.

2.

Capacities shown may vary depending on the type, size, size, moisture content, content, and clay content of material, material, the bulk density, density, method of material feeding. feeding. Undersize material 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.

12


CT Jaw Product Grading An alysis (% Passin Passin g) for Given Closed Side Settin Settin g of Crusher Product Size >250mm

>10"

250

10"

225

9"

200

8"

180

7"

150

6"

125

5"

100

4"

90

3-1/2"

75

3"

63

2-1/2"

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

100

90

83

75

70

60

90

83

75

70

65

55

100

90

83

75

70

63

60

52

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

95

83

75

70

60

55

50

45

40

35

30

100

83

75

70

65

55

50

45

35

30

25

25

100

90

75

68

60

55

50

42

35

30

25

22

22

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

CT Jaw Product Grading An alysis (% Passin Passin g) for Given Closed Side Settin Settin g of Crusher Product Size >250mm

>10"

250

10"

225

9"

200

8"

180

7"

150

6"

125

5"

100

4"

90

3-1/2"

75

3"

63

2-1/2"

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

100

90

83

75

70

60

90

83

75

70

65

55

100

90

83

75

70

63

60

52

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

95

83

75

70

60

55

50

45

40

35

30

100

83

75

70

65

55

50

45

35

30

25

25

100

90

75

68

60

55

50

42

35

30

25

22

22

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

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.


13

Foundation Recommendations 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 Feed Configur ation

Foundation Recommendations 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 Feed Configur ation 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 V-Belt Drive Inst allation 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.


14

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 Tension Rod and Toggle Plate 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 the hydraulic controlled adjustment wedges. Please refer to Appendix A: Discharge Setting Adjusting Procedure. 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. The spring free length is 312.5mm 312.5mm (12 5/16”). It should be compressed 39mm (1 1/2”) after completed assembled. Therefore the assembled spring length is 273.5mm (10 3/4”).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.


15

Removal 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.

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 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 Cheek Cheek 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 b etween them. A bearing lubricant must perform three three fundamental functions: 1. To provide a suitable film which separates the moving parts in a bearing. 2. As a heat transfer medium (to (to carry away heat) 3. To protect protect the bearing surfaces from corrosion corrosion and contamination.


16

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 .

Self-Aligni Self-Aligni ng 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 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 GREA SE AS EXCESSIVE GREASE WILL CAUSE OVERHEATING A ND SHORTEN THE BEARING LIFE. Grease Grease Specifications 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.


17

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 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-S Pre-Starting tarting Instruction s

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 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 startup period, check the bearing temperature temperature frequently. If temperatures are above the the recommended levels, lubricate according to the instructions provided in the lubrication section. 7. Check to ensure that the tension spring on the crusher 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 the crusher according to the crusher start-up start-up section.


18

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.


19

Parts Parts:: Tensio Tensio n Rod and Tog Toggl gle e Plate Plate Assembl As sembly y Illustration The following illustration identifies the essential parts comprising the tension rod and toggle seat assembly.


20

Parts Parts List Item 12 13 14 15 16 18 19 20 21 24 25 26 27 28 30 31 32 33 34 35 36 37 38 39 40 53 54 93 89 90 91 92

Part #

Description

QTY

C2036-8 C2036-9 C2036-10 GB5782/M12X35 GB93/12 C2036-11 C2036-11JC C2036-12 C2036-13 GB91/Ø8x75 C2036-14 C2036-15 GB70/M20X65

Buffer (Lower) Rubber Dust Apron Clamp Plate For Rubber Dust Apron Bolt For Rubber Dust Apron Lock Washer For Rubber Dust Apron Toggle Plate Longer Toggle Plate (Optional) Pin For Tension Rod Washer For Tension Rod Split Cotter For Tension Rod Buffer (Upper) Toggle Retainer Bolt M20x65

1 1 1 5 5 1 1 1 1 1 1 2 2

C2036-16 C2036-17 C2036-18A C2036-19 GB6170/M12x35 GB93/12 C2036-20 GB5782/M20x60 GB7244/20 C2036-21 C2036-22A GB6170/M36 T6090-19 GB5782/M24X80 GB7244/24 T6090-20 T6090-18 GB5782/M16x45 GB93/16

Rubber Dust Cover Tension Rod Spring Keeper (Lower) Clamp Plate For Rubber Dust Cover Bolt For Rubber Dust Cover Lock Washer For Rubber Dust Cover Guard Bolt For Guard Lock Washer For Guard Spring Spring Keeper (Upper) Nut For Tension Rod Upper Guider Plate Bolt M24X80 Lock Washer 24 Lower Guider Plate Limit Plate Bolt M16x45 Lock Washer 16

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

For more inf ormation about tog gle plate see Appendix C please. please.


21

Parts: Parts: Bearin Bearings gs and Eccentr Eccentric ic Shaft Assembly Assembl y Illustration The following illustrations identify the essential parts of the bearing and eccentric shaft assembly.


22

Parts List Item 56 57 58 59 60 61 96 62 63 64 65 66 67 68 99 69 70 71 72 73 74 75 76 100 77 78 79 80 81 82 83 84 85 86 87 88

Part # C2036.4 C2036-27 GB825/M16 C2036.6B GB6170/M24 C2036-28 GB1972/Ø50XØ25.4x3 GB5782/M24X70 GB7244/24 C2036-29A C2036-30 GB1095/12x30 23148CA/W33 C3 C2036-31 C2036-40 GB32.1/M20X65 GB7244/20 C2036-32 C2036-33 22244 CAK/W33 C3 GB6584/AH2244 C1251-39 C2036-34 C2036-41 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/GD10.9 C2036-37


Description Flywheel Assembly Bearing Housing Cover (LH) Eyebolt M16 Wedge For Fixed Jaw Die Nut For Fixed Jaw Die Wedges Washer For Fixed Jaw Die Wedges Belleville Washer For Fixed Jaw Die Wedges Bolt For Pitman Protection Plate Lock Washer For Pitman Protection Plate Eccentric Shaft Spacer Key 12x30 Pitman Bearing 23148CA/W33 C3 Pitman Seal (Bearing Cover) Shim Ø404xØ496x0.2 Bolt M20x65 Lock Washer 20 Middle Labyrinth Seal Bearing Housing Frame Bearing 22244 CAK/W33 C3 Adapter AH2244 Round Nut For Bearing Remove Bearing Housing Cover (RH) Shim Ø408XØ500X0.2 Round Nut M190x3 (LH, RH Each) Lock Washer For Round Nut Grease Fitting Outer Labyrinth Seal Key 12x35 Sheave Assembly Ringfeder Z2-170x225 Cover Bolt For Cover Lock Washer For Cover Bolt For Bearing Housing Washer For Bearing Housing

QTY 1 1 2 2 4 2 4 4 4 1 2 2 2 2 2 32 32 2 2 2 2 1 1 2 Total 2 2 4 2 2 1 2 2 6 6 12 12

23

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


24

Parts List Item

Part #

Description

1 2 3 4 5 6 (22) 98 7 8 9 10 11 17

C2036.1A C2036-1 C2036-2 T6090-4 C2036-38 GB7244/30 GB6170/M30 GB1972/Ø63XØ31x3.5 C2036-3 C2036-4B C2036-5A C2036-6 C2036-7 C2036-39A

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

22 95 59 60 61 96

GB6170/M30 GB1972/Ø71XØ36x4 C2036.6B GB6170/M24 C2036-28 GB1972/Ø50XØ25.4x3

Nut M30 For Swing Jaw Wedge Belleville Washer For Swing Jaw Wedge Wedge For Fixed Jaw Die Nut M24 For Fixed Jaw Die Wedges Washer For Fixed Jaw Die Wedges Belleville Washer For Fixed Jaw Die Wedges


QTY 1 1 Total 2 8 8 8 8 16 Total 2 1 2 1 4 1 8 16 2 4 2 4

25

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

Parts List Item 23 29 97

Part # Q/ZB220-77/M24X2 C2036.3A T6090-16


Description Drain Plug M24X2 Lubrication System Rubber Washer

QTY 2 1 2

26

Lubri cation System System

C2036.3A

Parts List Item 1 2 3 4 5 6 7

Part #

Description

QTY

C2036.3A

Lubrication System

1

1380.7.1

Connector Hose ID=Ø8mm 10MPa L=990mm Hose ID=Ø8mm 10MPa L=745mm Connector O Ring Distributor Grease Fitting M10X1

4 2 2 4 8 1 4

1380.7A-4 GB1235/Ø11X1.9 T6090.7-2 GB1152/M10X1


27

Ap A p p end en d i x A: A : Dis Di s c h arg ar g e Sett Set t i n g Ad A d j u s t i n g Pro Pr o c edu ed u r e

28


Parts List Item 41 42 43 44 45 46 47 48 49 50 51 52 53

Part # C2036-23 C2036-24 GB5782/M16x45 GB7244/16 T6090-31 GB5867/Z2-90x130 T6090-32 GB6170/M30

T6090-34 C2036-25 T6090-19

Description Rear Wedge For Discharge Adjustment Guider (I) Bolt M16x45 Lock Washer 16 Pin (I) Ringfeder Z2-90x130 Washer Nut M30 Hydra. Cylinder 390+125 Hydra. Cylinder 404+137 Pin (II) Guider (II) Upper Guider Plate

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

Parts List Item 41 42 43 44 45 46 47 48 49 50 51 52 53 54 93 55 94

Part # C2036-23 C2036-24 GB5782/M16x45 GB7244/16 T6090-31 GB5867/Z2-90x130 T6090-32 GB6170/M30

T6090-34 C2036-25 T6090-19 GB5782/M24X80 GB7244/24 C2036-26 C2036.7B


Description Rear Wedge For Discharge Adjustment Guider (I) Bolt M16x45 Lock Washer 16 Pin (I) Ringfeder Z2-90x130 Washer Nut M30 Hydra. Cylinder 390+125 Hydra. Cylinder 404+137 Pin (II) Guider (II) Upper Guider Plate Bolt M24X80 Lock Washer 24 Front Wedge For Discharge Adjustment Hydraulic System

QTY 1 1 12 12 2 2 4 4 1 1 2 1 2 8 8 1 1

29

Ad A d j u s t i n g t h e Dis Di s c h arg ar g e Sett Set t i n g

•

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 Increase the discharge opening or Bigger End of Wedge In – Decrease the discharge opening). Use pump through the hydraulic 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 Hydraulic Control Connectio Connectio n Diagram Diagram


30

Checkin Checking g t he Closed Closed Side Setti Setting ng The The J a w C rus usher her dis disc c harge harge setti etting (cl (c losed osed side setti etting) is the the shortes hortestt distance between the bottoms of the fixed and swing jaw dies measuring "pea pe a k to to pea pe a k".

J aw C rusher usher Top View Note: No te: While While the c rusher usher is a t rest, rest, the me a sureme urement nt taken ta ken is the c rusher usher op o p en side setting.

From the open side setting measurement taken, deduct the distance listed isted in the tab ta b le below be low to dete d eterrmine mine the c rus ushers hers exac t clos c losed ed side setting. INCHES

MM

Deduct the dimension in the

C T1030

0.394”

10㎜

table at right from your

C T1040

0.394”

10㎜

"peak to peak" open side

C T1048

0.394”

10㎜

measurement to arrive at

C T1252

0.591”

15㎜

your crusher's closed side

C T2036

1.000”

25㎜

setting.

C T2436

1.260”

32㎜

C T3042

1.417”

36㎜

NC T3042 3042

1.181”

30㎜

C T3254

1.023”

26㎜

C T3648

1.929”

49㎜

C T4254

2.087”

53㎜

C T4763

1.653”

42㎜

CT203 CT2036 6 Jaw Crush er Manual

31

Appendix B: Jaw Crus her Bearin g Greased Quantit y per Day (8 (8 Hrs Hrs.) .) Jaw Size

Grease Grease for Pitman Bearing

Grease Grease for Frame Bearing

Weight (Ounce)

Volume (Quart)

Weight (Ounce)

Volume (Quart)

CT10X30

0.44

0.015

0.44

0.015

CT10X40

0.44

0.015

0.44

0.015

CT10X48

0.50

0.018

0.50

0.018

CT12X52

0.94

0.033

0.94

0.033

CT20X36

0.70

0.025

0.61

0.021

CT24X36

0.89

0.031

0.72

0.025

CT30X42

1.62

0.057

1.55

0.055

NCT30X42

1.30

0.048

1.20

0.045

CT32X54

1.55

0.055

1.34

.047

CT36X48

1.62

0.057

1.55

0.055

CT42X54

1.90

0.067

1.68

0.060

CT47X63

2.6

0.091

2.5

0.090

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

Jaw Size

Grease Replace Period Perio d (Hrs)

CT10X30

2,600

CT10X40

2,600

CT10X48

2,200

CT12X52

2,200

CT20X36

2,000

CT24X36

1,900

CT30X42

1,600

NCT30X42

1,650

CT32X54

1,700

CT36X48

1,600

CT42X54

1,600

CT47X63

1,500

The quantity is ½ free room in the bearing housing. CT2036 CT2036 Jaw Crus her Manual

32

Jaw Crusher Crush er Labyri nth Seal Seal Grea Grease se Quantit Quantit y per Month

Jaw Size

Grease Grease For Middl e Labyri nth Seal Seal

Grease Grease For Outer Labyri nth Seal Seal

Weight (Ounce)

Volume (Quart)

Weight (Ounce)

Volume (Quart)

CT10X30

0.50

0.017

0.50

0.017

CT10X40

0.50

0.017

0.50

0.017

CT10X48

0.60

0.019

0.60

0.019

CT12X52

0.90

0.034

0.90

0.034

CT20X36

1.0

0.037

1.0

0.037

CT24X36

1.1

0.041

1.1

0.041

CT30X42

1.30

0.048

1.30

0.048

NCT30X42

1.20

0.045

1.20

0.045

CT32X54

1.50

0.055

1.50

0.055

CT36X48

1.60

0.059

1.60

0.059

CT42X54

1.80

0.063

1.80

0.063

CT47X63

2.00

0.071

2.00

0.071


33

Appendix C CT Jaw CSS Range by Toggle Plates Toggle Plate A

Machine

Total Jaw Dies Worn Allowed

Adjustment Range

Toggle Plate B Part # &（lengt length h）

Adjus Adjustm tment ent Rang Range e

Total Jaw Dies Worn Allowed

Part # &（length）

CT2036

75~130mm

70mm

C2036-11 （382mm）

50~110mm

70mm

C2036-11JC （398mm）

CT2436

105~160mm

80mm

T6090-15 （477mm）

75~130mm

80mm

T6090-15 JC（497mm）

CT3042

105~180mm

80mm

T7510-11B （514mm）

75~150mm

80mm

T7510-11JC（544mm）

CT3254

110~180mm

120mm

1380-16A （475.5mm）

90~160mm

120mm

1380-16JC （500mm）

CT3648

125~220mm

130mm

C3648H-16B （552mm）

100~190mm

130mm

C3648H-16JC（577mm）

CT4254

140~240mm

140mm

C4254-31A （621mm）

125~220mm

140mm

C4254-31JC （646mm）

CT4763

190~300mm

140mm

C4763-43A （820mm）

150~260mm

140mm

C4763-43JC （865mm）

Note: Toggle plate A =

Initial installed by the factory

Toggle plate B =

Longer toggle plate. It is OPTIONAL. You must contact Trio sales to discuss the feed size and the material properties before you place the order.

34


Ap A p p end en d i x D

B o l t s Tor To r q u e Spec Sp ecii f i c ati at i o n s

For Me Metric Bolt s Diamete r (mm)

6 8 10 10 12 12 14 14 16 16 18 18 20 20 22 22

Pitch (mm)

1.5 1.25 1.75 1.25 2 1.5 2 1.5 2.5 1.5 2.5 1.5 2.5 1.5

Grade 8.8 Dry FT-LBS 6.9 17.7 30 32 53 58 85 91 131 140 181 204 256 284 349 383

Grade 10.9 Lube

N-M 9.3 23.9 41 43 72 78 115 124 178 190 246 276 347 385 473 519

FT-LBS FT-LB S 5.2 13.3 24 24 41 44 65 70 101 108 139 156 197 218 268 294

Dry N-M 7 18 32 33 55 60 88 95 137 146 189 212 267 296 364 399

FT-LBS FT-LB S 9.7 24.9 44 46 77 85 124 134 192 204 265 297 374 415 510 560

Grade 12.9 Lube

N-M 13.2 33.8 60 63 105 115 168 181 260 277 359 403 507 563 692 759

FT-LBS 7.3 18.7 34 36 60 65 95 103 148 157 204 229 288 319 392 431

Dry N-M 9.9 25.4 46 49 81 88 129 139 200 213 276 310 390 433 532 584

FT-LBS 11.6 29.8 52 55 91 99 145 156 225 240 311 349 439 487 599 657

Lub N-M 15.7 40.4 71 74 123 134 196 212 305 325 421 473 595 660 812 891

FT-LBS 8.7 22.4 40 42 70 76 111 120 173 184 239 268 338 375 460 505

Ap A p p end en d i x D

B o l t s Tor To r q u e Spec Sp ecii f i c ati at i o n s

For Me Metric Bolt s Diamete r (mm)

6 8 10 10 12 12 14 14 16 16 18 18 20 20 22 22 24 24 27 27 30 36 42 48 56 64 72

Pitch (mm)

1.5 1.25 1.75 1.25 2 1.5 2 1.5 2.5 1.5 2.5 1.5 2.5 1.5 3 2 3 2

Grade 8.8 Dry FT-LBS 6.9 17.7 30 32 53 58 85 91 131 140 181 204 256 284 349 383 443 482 648 700 985 1716 2753 4156 6662 9954 14410

Grade 10.9 Lube

N-M 9.3 23.9 41 43 72 78 115 124 178 190 246 276 347 385 473 519 600 654 879 949 1335 2326 3732 5634 9032 13496 19536

FT-LBS FT-LB S 5.2 13.3 24 24 41 44 65 70 101 108 139 156 197 218 268 294 340 371 499 538 741 1290 2070 3124 5009 7484 10835

N-M 7 18 32 33 55 60 88 95 137 146 189 212 267 296 364 399 461 503 676 730 1004 1749 2806 4236 6791 10147 14689

Dry FT-LBS FT-LB S 9.7 24.9 44 46 77 85 124 134 192 204 265 297 374 415 510 560 647 705 949 1023 1389 2419 3882 5860 9393 14035 20319

Grade 12.9 Lube

N-M 13.2 33.8 60 63 105 115 168 181 260 277 359 403 507 563 692 759 877 956 1286 1387 1883 3280 5263 7944 12735 19028 27547

FT-LBS 7.3 18.7 34 36 60 65 95 103 148 157 204 229 288 319 392 431 497 543 729 787 1044 1819 2919 4406 7063 10553 15277

Dry N-M 9.9 25.4 46 49 81 88 129 139 200 213 276 310 390 433 532 584 674 736 989 1067 1416 2466 3957 5973 9575 14307 20712

FT-LBS 11.6 29.8 52 55 91 99 145 156 225 240 311 349 439 487 599 657 759 828 1112 1200 1665 2900 4652 7023 11259 16822 24353

Lub N-M 15.7 40.4 71 74 123 134 196 212 305 325 421 473 595 660 812 891 1029 1122 1508 1627 2257 3931 6307 9521 15264 22807 33016

ASSUMPTIONS: (1) The maximum torque values are based on 75% of the specified proof strength. (2) The term "lube" includes the application of thread lubricants, cadmium plating,

For SAE (Inch (Inch ) Bol ts Diameter (inches)

1/4 1/4 5/16 5/16 3/8 3/8 7/16 7/16 1/2 1/2 9/16 9/16 5/8

N (threads/in )

20 28 18 24 16 24 14 20 13 20 12 18 11

S.A. E. Grade 5 Dry FT-LBS 8 10 17 19 31 35 49 55 75 85 109 121 150

N-M 11 14 23 26 42 47 66 75 102 115 148 164 203

Lube FT-LBS 6 7 13 15 24 27 38 42 58 65 84 93 115

S.A. E. Grade 8 Dry N-M 8 9 18 20 33 37 52 57 79 88 114 126 156

FT-LBS 12 14 25 27 44 49 70 78 106 120 154 171 212

N-M 16 19 34 37 60 66 95 106 144 163 209 232 287

Lube FT-LBS 9 11 19 21 34 38 54 60 82 92 118 132 163

N-M 12 15 26 28 46 52 73 81 111 125 160 179 221

FT-LBS 8.7 22.4 40 42 70 76 111 120 173 184 239 268 338 375 460 505 583 637 856 923 1252 2180 3498 5280 8465 12648 18310

For SAE (Inch (Inch ) Bol ts Diameter (inches)

N (threads/in )

1/4 1/4 5/16 5/16 3/8 3/8 7/16 7/16 1/2 1/2 9/16 9/16 5/8 5/8 3/4 3/4 7/8 7/8 1 1 1 1/8 1 1/8 1 1/4 1 1/4 1 3/8 1 3/8 1 1/2 1 1/2 1 3/4 2 2 1/4 2 1/2 2 3/4 3

20 28 18 24 16 24 14 20 13 20 12 18 11 18 10 16 9 14 8 14 7 12 7 12 6 12 6 12 5 4.5 4.5 4 4 4

S.A. E. Grade 5 Dry FT-LBS 8 10 17 19 31 35 49 55 75 85 109 121 150 170 266 297 430 473 644 704 794 891 1120 1241 1469 1673 1949 2194 2286 3438 5027 6875 9321 12313

N-M 11 14 23 26 42 47 66 75 102 115 148 164 203 231 361 403 583 641 873 955 1077 1208 1519 1683 1992 2269 2643 2975 3100 4662 6817 9323 12639 16696

Lube FT-LBS N-M 6 8 7 9 13 18 15 20 24 33 27 37 38 52 42 57 58 79 65 88 84 114 93 126 115 156 131 178 205 278 229 311 330 447 364 494 495 671 542 735 611 829 685 929 862 1169 954 1294 1130 1532 1287 1745 1500 2034 1687 2288 1758 2384 2644 3585 3867 5244 5288 7171 7170 9723 9472 12844

S.A. E. Grade 8 Dry FT-LBS 12 14 25 27 44 49 70 78 106 120 154 171 212 240 376 420 606 668 909 995 1288 1445 1817 2012 2382 2712 3161 3557 4988 7500 10969 15000 17794 23507

N-M 16 19 34 37 60 66 95 106 144 163 209 232 287 325 510 570 822 906 1233 1349 1747 1959 2464 2728 3230 3677 4286 4823 6764 10170 14874 20340 24129 31875

Lube FT-LBS N-M 9 12 11 15 19 26 21 28 34 46 38 52 54 73 60 81 82 111 92 125 118 160 132 179 163 221 185 251 289 392 323 438 466 632 514 697 699 948 765 1037 990 99 0 1342 1111 1507 1398 1896 1548 2099 1832 2484 2086 2829 2432 3298 2736 3710 3837 5203 5769 7823 8438 11442 11538 15646 13688 18561 18082 24519

ASSUMPTIONS: (1) The maximum torque values are based on 75% of the specified proof strength. (2) The term "lube" includes the application of thread lubricants, cadmium plating, and the use of hardened washers; regardless of whether standard or lock nuts are used.


36

SAFETY DEC DECAL AL K IT

Sample Figure

ITEM NO.

PART NO.

DESCRIPTION

SDK-001 SDK-001

Safety Decal Kit and Charts


QTY.

37

Warranty Terms and Conditi ond itions ons 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 or 2,000 working hours, whichever occurs first, from the date of readiness for operation, but not more than fifteen (15) months from the date of shipment from Trio. All parts claimed to be defective shall be returned to Trio, freight prepaid, for inspection to determine that the said part or parts are defective. If it is determined that the fault lies with Trio, Trio will ship a replacement part or parts at no cost, but freight charges will be paid by customer. If it is determined that the fault does not lie with Trio, a replacement part or parts will be shipped, freight collect, to the customer with the receipt of a purchase order from the dealer or agent. Trio will not be responsible for freight costs associated with warranty claims. When petitioning for a warranty item, the serial number of the equipment must be referenced. The serial number must be clearly identifiable on the Trio nameplate on the equipment. This warranty is void if: •

The serial number plate and/or other markings identifying the machine 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.


38

CT Series 20x36 Jaw Crusher Manual (250).pdf

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