Jaw Rock Crusher

Jaw Crusher Repair and Overhaul Models 2044 and 3042

SAFETY Read and fully understand the precautions contained on the inside front cover of this manual before operating or servicing the crusher. Also refer to Chapter 1 for important quarry safety information.

WARNING !!! Failure to follow the safety precautions shown below may result in serious personal injury or death! •

Never attempt to work on quarry equipment while it is in operation. Always stop the machinery, lockout power and tag controls. . . 1. Before performing any lubrication, maintenance, adjustments or repairs. 2. Before removing spilled materials. 3. Before clearing jams or working inside the machinery. 4. If any unusual noises or sudden changes in operation are noticed.

• Stay clear of feed and dischar ge areas and other places where f alling rock is present. K eep away from loading vehicles. Wear and use personal protective equipment in accordance with all applicable health and safety regulations. Safety goggles, hard hat, ear plugs and steel toe shoes are mandatory when w orking near machinery. Wear and use additional personal protective equipment as required. • Stay clear of springs and other pinch points. Never reach in-between vibrating equipment and its support structure. Keep a safe distance from all moving components. • Never attempt to enter the crushing chamber when tramp iron or other uncrushable objects are wedged inside. These materials are under tremendous pressure and may be propelled upw ards through the feed opening at any time. On crushers not equipped with hydraulic clearing, use a pole, hook, grappling device or breaker bar to safely dislodge uncrushable objects. • Do not make equipment modifications that will result in a safety hazard or create a dangerous situation Never remove or disable safety de vices. Maintain all machinery in accordance with manuf acturer’s instructions and maintenance schedules. • Read the operator’ s manuals for the equipment that you operate. Be sure that you fully understand all phases of operation for each machine. A careful and well-trained operator is the best insurance against an accident. • Refer to the Telsmith Quarry Equipment Safely Guide for important quarry safety information. If your copy of the Safety Guide is missing, replacement copies may be obtained from your local Telsmith dealer or the Telsmith Parts Department. • All rotating power products are potentially dangerous and must be properly guarded. Placement of guards and other safety equipment is the user ’s responsibility. Such equipment must be installed where ver appropriate and maintained as required. • It is the purchaser’s responsibility to ensure that quarry equipment is installed and used in a safe and wful la manner. All machinery must be operated in compliance with applicable health and safety laws and general standards of reasonable care.

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Telsmith H-Series Gyrasphere

Table of Contents

Table of Contents Forword. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v Chapter 1 — Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 Chapter 2 — General Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1 Chapter 3— Repair and Overhaul Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1 Chapter 4 — . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1 Chapter 5 — . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

APPENDICES Torque Specifications — Appendix A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 Conversion Chart — Appendix B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1 Crusher Weights — Appendix C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1 Lubricant Specifications — Appendix D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1 Expendable Supplies — Appendix E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1

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INTRODUCTION

FINDING MODEL AND SERIAL NUMBERS

This manual contains complete repair and o verhaul instructions for Telsmith D-Series jaw crushers, models 2044 and 3042.

Model and serial numbers are located on a data plate attached to the crusher frame. Always lockout power and tag controls before reading data plate!

The procedures included in this manual are based on the latest information a vailable at the time of publication. However, due to Telsmith’s polic y of continuous improvement, features and specifications are subject t change without notice. Actual dimensions, weights, and clearances may be different than shown, due to fabrication variables, custom engineering or optional equipment. Finally, please note that some features shown in this manual may not be present on your crusher . Some equipment described may be optional at extra cost, or available only on selected models.

HOW TO CONTACT TELSMITH • Please use the follo wing phone numbers to contact the Telsmith factory for product support: Service Department: (414) 242-6600 Parts Department: (800) 688-6601 Fax: (414) 242-7861 Note: If calling from outside the U.S.A. or Canada, please use the Service Department phone number when ordering parts. • Please send all written correspondence to: Telsmith, Inc. 10910 N. Industrial Drive P.O. Box 539 Mequon, WI 53092-0539 U.S.A. • Please send all e-mail correspondence to: [email protected]

REQUESTING SERVICE ASSISTANCE If you have questions about the procedures contained in this manual, please contact your local Telsmith dealer. Their knowledgeable factory-trained personnel are prepared to address any concerns you may have regarding your Telsmith equipment. If additional assistance is required, please contact the Telsmith Service Department. Service technicians are available by telephone from 8:00 a.m. to 4:30 p.m. CST , Monday through Friday, except holidays. To ensure f aster response, always have your machine’s model and serial numbers ready when calling.

7F REPAIR AND OVERHAUL PROCEDURES This manual includes procedures for crusher repair and overhaul procedures only . For detailed operation and maintenance instructions, please refer to the Telsmith Jaw Crusher Operation & Maintenance Manual. The Operation & Maintenance Manual is provided with all new jaw crushers. If this manual is lost, ne w copies are available from your local Telsmith dealer or the Telsmith Parts Department.

ORDERING REPLACEMENT PARTS For replacement parts information, please refer to the Jaw Crusher Parts Catalog . This booklet contains e xploded diagrams and parts lists to help you quickly identify the major components and subassemblies used on your crusher.

The Parts Catalog is pro vided with all ne w Telsmith jaw crushers. If the Parts Catalog is lost, new copies are available from your local Telsmith dealer or the Telsmith Parts Department. To ensure that the correct parts are recei ved, always have your crusher’s model and serial numbers ready when placing your order.

SERVICE BULLETINS Telsmith periodically issues service b ulletins to inform customers of the latest repair and maintenance procedures. Service bulletins may have been included separately with this manual. Always read and understand all service b ulletins (if present) before starting any maintenance or service work.

INSTALLATION & ASSEMBLY DRAWINGS The follo wing installation and assembly dra wings (blueprints) are included with all new Telsmith jaw crushers: • Crusher Sectional Assembly Drawing • Oil System Assembly Drawing (if equipped) The drawings include specifications, dimensions and othe technical information that may be helpful during repair and overhaul procedures. Contact your local Telsmith dealer or the Telsmith Service Department if you ha ve any questions about information contained on the drawings. As required, additional dra wings may be pro vided to sho w model-specific design features and equipmen configurations

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If the drawings are lost, replacement copies may be ordered from your local Telsmith dealer or the Telsmith Parts Department.

SAFETY All quarry personnel operating or servicing the crusher must read and fully understand the safety information included in Chapter 1 of this manual. In addition, all quarry personnel must read and fully understand the safety information presented in the Telsmith Quarry Equipment Safety Guide. The Safety Guide is pro vided with all ne w crushers. Additional copies of the Safety Guide are available from your local Telsmith dealer or the Telsmith Parts Department.

ILLUSTRATIONS This manual contains some illustrations in which guards, access panels and other safety equipment has been remo ved to provide greater clarity . However, to pre vent serious

personal injury or death, be certain that all such equipment is properly reinstalled before operating the crusher.

Telsmith 2044 & 3042 Jaw Crushers

Chapter 1

Chapter 1 Safety SAFETY OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 HAZARD AND ADVISORY STATEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Hazard Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Advisory Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 LOCKOUT/TAGOUT. . . . . . . . . . . . . . . . . . Who Must Use Lockout/Tagout? . . . . . . . . . . What is Lockout/Tagout? . . . . . . . . . . . . . . When Must Lockout/Tagout Occur? . . . . . . . . How is Lockout/Tagout Performed? . . . . . . . . When Can Lockout/Tagout Devices be Removed?. Lockout/Tagout Devices . . . . . . . . . . . . . .

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1-3 1-3 1-3 1-4 1-4 1-5 1-5

Lockout/Tagout Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Additional Lockout/Tagout Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

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JAW CRUSHER SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 QUARRY SAFETY SUMMARY. . . . . . . . Know Your Machinery . . . . . . . . . . . Be Prepared for Emergencies . . . . . . . . Wear Personal Protective Equipment (PPE) Observe Personal Safety Precautions . . . . Help Prevent Accidents . . . . . . . . . . . Avoid Alcohol and Other Drugs . . . . . . Be Aware of Your Surroundings . . . . . . Practise Good Housekeeping . . . . . . . . Inspect And Maintain Machinery. . . . . .

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1-6 1-6 1-6 1-7 1-7 1-7 1-8 1-8 1-8 1-8

MACHINERY INSTALLATION SAFETY Foundations . . . . . . . . . . . . . . . Guarding . . . . . . . . . . . . . . . . Customer Modifications . . . . . . . . Electrical Hook-up . . . . . . . . . . .

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1-8 1-8 1-8 1-9 1-9

MAINTENANCE AND REPAIR SAFETY . . . . . . General Precautions. . . . . . . . . . . . . . . . . Electrical Systems . . . . . . . . . . . . . . . . . Pressurized Systems (hydraulic and air) . . . . . . Welding On Machinery . . . . . . . . . . . . . . . Clearing Jammed Material . . . . . . . . . . . . . Hazardous Materials . . . . . . . . . . . . . . . . Disposal Of Excess Fuels, Lubricants And Liquids Flammable and Combustible Liquids. . . . . . . . HOISTING AND HANDLING SAFETY . . . . . General Precautions. . . . . . . . . . . . . . . . . Wire Rope. . . . . . . . . . . . . . . . . . . . . . Connecting Or Clamping Wire Ropes . . . . . . . Chains . . . . . . . . . . . . . . . . . . . . . . . . Fiber Or Synthetic Slings . . . . . . . . . . . . . .

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TRANSPORTING MACHINERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

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SAFETY OVERVIEW It is the responsibility of the quarry management team to develop a comprehensive safety a wareness program, and to ensure that all quarry workers and support personnel receive appropriate safety training as required by federal, state and local regulations. Safety is basically common sense. There are standard safety rules, but each situation has its o wn peculiarities which can not always be covered by rules. Therefore, quarry personnel must continually w atch for possible safety hazards and be prepared to take prompt corrective action when necessary. Failure to observ e the precautions contained in this chapter can result in serious personal injury and even loss of life. As with most industrial work environments, a careful operator is the best insurance against an accident.

Safety

A Note is a basic informational statement or helpful suggestion. An Important is used to dra w attention to a procedure that must be observed to prevent machine damage or malfunction .

! DANGER

! WARNING!!! DANGER

Hazard Statements

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The complete observance of one simple rule w ould prevent many unnecessary injuries and deaths each year. This rule is: “Never attempt to clean, lubricate, repair or adjust any machinery unless it is stopped and properly locked out.” Please note that this chapter is only intended as a brief re view of basic quarry safety precautions and procedures. The general guidelines included in the follo wing paragraphs are not intended to supersede of ficial quarry safety procedures insurance company requirements, or applicable federal, state and local regulations.

! CAUTION DANGER !!!

Important

Advisory Statements

Note

HAZARD AND ADVISORY STATEMENTS Throughout this manual, the use of hazard and advisory statements has been emphasized. Examples of these are shown in Figure 1-1.

Figure 1–1. Hazard and Advisory Statements

LOCKOUT/TAGOUT

Hazard Statements The Caution, Warning and Danger statements are hazard statements used to alert w orkers of unsafe practises and potentially harmful or life-threatening situations. Each of these statements is preceded by the Safety Alert Symbol. • Failure to follow the instructions contained in a Caution statement may result in MINOR PERSONAL INJURY. • Failure to follow the instructions contained in a Warning statement could result in SERIOUS PERSON AL INJURY or DEATH. • Failure to follo w the instructions contained in a Danger statement will result in SEVERE PERSON AL INJURY or DEATH.

Advisory Statements The Note and Important statements are advisory statements which relate to equipment operation, maintenance and service procedures. They are used to draw attention to proper procedures and practises. 03/99

Who Must Use Lockout/Tagout? Quarry owners, managers, and safety officers must be ware of OSHA’s “lockout/tagout” standard: CRF Section 29 1910.147, The Control of Hazardous Energy. This standard is also recognized by MSHA. All mechanics, maintenance personnel, operators, and electricians must fully understand and comply with this standard to ensure the safety of all employees.

What is Lockout/Tagout? Lockout/tagout is a means to ensure that personnel who install, operate, repair, maintain, service or otherwise disable machines, equipment, or electrical ener gy systems are protected from harm due to une xpected energizing, or the release of stored energy by...

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Safety


1. Lockout – Placing a disconnect switch, circuit breaker, valve, or other ener gy-isolating mechanism in the of f or safe position and securing it with a lock so the ener gyisolating mechanism cannot be activated. 2. Tagout – A prominent written w arning (tag or label) placed on the ener gy-isolating mechanism indicating the name of the indi vidual placing the mechanism out-ofservice, and stating that the ener gy isolating mechanism cannot be activated until the tagout device is removed.

When Must Lockout/Tagout Occur? Lockout/tagout must occur whenever service or maintenance is performed, and injury could occur due to the une xpected start-up of equipment, or the release of stored ener gy. See Figure 1-2.

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In general, lock out/tagout procedures must be performed under the following circumstances: • Before cleaning, lubricating, adjusting or repairing machinery or equipment. • Before w orking on electrical, h ydraulic or pneumatic circuits or devices. • Before clearing jammed mechanisms, machinery or equipment. • Before removing guards or other protective devices. • Whenever a machine or its controls will be left unattended.

How is Lockout/Tagout Performed? OSHA has identified the foll wing step-by-step lock out/ tagout procedure: 1. Prepare for shutdown – Before shutting down a piece of equipment, kno w the type and magnitude of the ener gy that powers it, the hazards of that energy, and how to control it. Warn all employees that the machinery is about to be shut down. 2. Shutdown the equipment – After w arning all employees, shut down the machine, equipment, or electrical system by the normal stopping procedure. 3. Control stored energy – an y potentially hazardous stored energy (electrical, mechanical, h ydraulic, pneumatic, etc.) that remains must be released, dissipated, restrained, or otherwise rendered safe. If stored ener gy reaccumulates, monitor it until the possibility of accumulation no longer exists. 4. Isolate the equipment – Diseng age all isolating devices, both primary and secondary, so that the equipment is isolated from all of its energy sources (electrical, mechanical, hydraulic, pneumatic, etc.). 5. Apply lockout/tagout devices – Attach lockout tagout devices (according to your compan y’s safety program) in such a manner that the isolating de vice (circuit break er, control, etc.) will be held in a safe or off position. Attach tags to alert others that the machinery is being serviced.

LOCKOUT/TAGOUT POWER…

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• Before making inspections or adjustments. • Before performing any lubrication, maintenance or repairs. 1. Always lockout/tagout power to the crusher drive motor. 2. Always lockout/tagout controls for diesel engine (if equipped). Disconnect batteries and shut-off fuel supply. 3. Always lockout/tagout power to the crusher lubrication and hydraulic systems. 4. Always lockout/tagout power to all crusher feed and discharge equipment, such as feeders, conveyors and screens.

! WARNING!!! DANGER Failure to perform lockout/tagout procedures in accordance with OSHA/MSHA regulations will likely result in serious personal injury or death! Figure 1-2. Lockout/Tagout 1–4

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Safety

6. Verify that equipment is isolated – After warning all employees to stay clear , engage the start b utton to confir the machine is inoperable. Return the control to the of f position before proceeding with servicing.

When Can Lockout/Tagout Devices be Removed? Lockout/tagout devices can only be remo ved after the following conditions are met: • All guards and protecti installed.

ve de vices are properly re-

• All tools and repair equipment are remo equipment and the immediate area.

ved from the

• All mechanics and other personnel are clear of the equipment and its immediate area. • All personnel ha ve been w arned that the equipment is about to be restarted (sound w arning horn or acti vate warning lights). After removing lockout/tagout devices, always use the normal start-up procedure as described in the operator’ s manual for the machinery.

Lockout/Tagout Devices 1) locks 2) tags and labels 3) multiple lockout devices A lock must be suf ficiently durable, so it can withstand th environmental conditions (heat, cold, moisture, etc.) around it. A lock must also be strong enough so that it cannot be easily removed or forced open. A tag or label must be affi ed to each lock to alert others that service work is in progress. Each tag or label must ha ve the following characteristics: • Be sufficiently durable to withstand wear and a use, even if used in dirty or damp environments. ficult t

• Contain the name of the person that applied it. • Contain a w arning or other precautionary statement that briefly indicates w y the machine is locked out and what hazards could result if the equipment is started while service work is in progress. When tw o or more people are w orking on a piece of equipment, a multiple lock out device must be used. This allows each person to install their o wn lock, pre venting accidental start-up.

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• Always lockout/tagout any machinery before performing any adjustment, inspection, lubrication, maintenance or repair procedures. Failure to observe this precaution may result in serious personal injury or death. • Your compan y’s lock out/tagout program may be somewhat different than described in this manual. If so, be sure to completely follow your company’s official policie and procedures when lockout/tagout is necessary. Consult your company’s safety officer if you h ve any questions. • A lock must have only one user and one key. Anyone who installs a lock must keep the key in their possession at all times. Except in an emergency situation, only the person that installs a lock is authorized to remove it. • To prevent accidental start-up, never give your lock or its key to another employee.

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• Your key must open your lock only . Your key should not be capable of opening an y other locks. K eys for other locks should not be capable of opening your lock. • Except in an emer gency situation, ne ver attempt to remove anyone else’s lock. Do not allow others to remove your lock. • When disconnecting po wer, be sure that the circuit breaker handle (or other isolating de vice) is in the OFF position. Accidentally locking a control in the ON position could result in serious personal injury or death.

Lockout/tagout devices include:

• Be securely attached with a cable that is dif remove, cut or tear.

Lockout/Tagout Rules

• If tw o or more people are w orking on a machine, a multiple lock out de vice must be used to pre vent accidental start-up in the e vent that one person finishe working before another. • Each lock must ha ve a tag. If tw o or more people are working on a machine, each person must attach a separate tag to their lock. Never attach a lock without a tag. • Never use tags alone. A tag should al ways be accompanied by a lock which pre vents the isolating device from becoming energized.

Additional Lockout/Tagout Requirements • Be sure that the po wer is COMPLETELY turned of f. A motor may be stopped and lock ed out. Ho wever, interlocks, starters, and other supplemental electrical components may still be energized. Use a voltmeter and/ or ammeter to v erify that all electrical circuits are completely dead. • Always be sure that all peripheral equipment, such as feed conveyors, grizzly feeders and dischar ge conveyors, is also tagged and lock ed out. Serious personal injury or death can result if an y of these items starts une xpectedly while the crusher is being serviced.

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Safety

• Although lockout/tagout procedures are most commonly associated with electrical systems, be a ware that hydraulic, pneumatic and mechanical systems must also be tagged and lock ed out before servicing. This may involve the lockout/tagout of valves, levers and other nonelectrical devices. • For machinery po wered by internal comb ustion engines (diesel, gas, etc.), always disconnect batteries and shut-off fuel supply before servicing the machinery . Lockout/ tagout engine controls to ensure that engine is not accidentally started while the machinery is being serviced.

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• Always be sure that all h ydraulic or air pressure is completely relieved before w orking on h ydraulic or pneumatic systems. Dangerous pressures can be present, even when equipment is turned off and locked out. • After maintenance or repairs are completed, always warn all employees that the machinery is about to be restarted. Be sure no one is on or near the equipment before a lock and tag is removed. • As a precaution, al ways activate a w arning horn or light before restarting the machinery . This will pro vide additional w arning for personnel to stay clear of machinery that is about to be started.

JAW CRUSHER SAFETY • Perform a complete inspection before starting the crusher. Be sure that the crushing chamber is clear . Refer to the Jaw Crusher Operation and Maintenance Manual for crusher daily start-up procedures.

7F

• Be sure that all guards and other safety de vices are correctly installed and tightly secured before starting the crusher. Stay clear of rotating or mo ving parts during crusher operation. • Do not allow personnel to be on or near the crusher during operation. Stay clear of feed and dischar ge areas to prevent being injured or killed by flying or alling rock. • Rock projected upw ards through the feed opening can injure or kill. Do not look directly into the feed opening while the crusher is operating. Use mirrors or closedcircuit cameras if close observ ation of the feed arrangement is necessary for troubleshooting or evaluation purposes. • Never attempt to clear jammed material from the crushing chamber while the crusher is operating. Serious injury or death could result if you are pulled into, or fall inside, the crushing chamber. • Never attempt to adjust the dischar ge setting during crusher operation. Always w ait until the crusher is completely stopped before making any adjustments. 1–6


• Do not tamper with crusher alarm components (if equipped). Never attempt to defeat electrical interlocks or to disable crusher protective devices. • Stay clear of pinch-point areas. • Never stand on h ydraulic hoses or use them as steps. If hoses rupture, serious injury or death could result. As required, use a safety harness during servicing. • Always lockout/tagout power to the crusher drive motor and crusher oil lubrication system before performing an y inspection, adjustment lubrication, maintenance or repair procedures. Also lockout power to all crusher feed and discharge equipment. Be sure pressure is fully relie ved before servicing the crusher hydraulic system. • If the crusher is po wered by a diesel engine, al ways disconnect batteries and shut-of f fuel supply before performing any inspection, adjustment, lubrication, maintenance or repair procedures. Lockout/tagout engine controls to pre vent the engine from being accidentally started while the crusher is being serviced. • Always stop the crusher immediately if an y gauges show abnormal readings, or if there is a sudden obvious change in operation. Be alert for noises that might indicate trouble. • Inspect, lubricate, maintain and repair the crusher in accordance with the instructions contained in this manual and any additional manuals or documentation pro vided with the crusher.

QUARRY SAFETY SUMMARY Know Your Machinery • Read the manuf acturer’s operation and maintenance manuals for all machinery and equipment that you operate. Be sure that all hazard statements contained within the manuals are completely understood. • Become familiar with the controls, functions and settings of each machine. Fully understand all phases of each machine’s operation. • Be sure that you completely understand and follo w all start-up and shut-do wn procedures as described in the manufacturer’s manuals. • Be familiar with the safety signs on your equipment, and the hazards against which they warn. • Check the le gibility of all safety signs e very day. Order new signs from the machinery manuf acturer if the y become illegible or worn.

Be Prepared for Emergencies • Know the proper emergency shut-down procedures for the equipment you operate. 03/99


Safety

• Know where fire xtinguishers are k ept and ho w to use them. Be sure that fire xtinguishers are properly rated, and that they remain fully charged and ready for use at all times.

• Use walkways and ladders when working near machinery, or observing its operation. Use a safety harness when necessary. Keep handrails and machine contact surf aces clean.

• Know the procedure for contacting emer gency medical personnel. Keep a list of emer gency phone numbers handy at all times.

• To a void back injuries, al ways use proper lifting techniques to safely lift heavy objects. Lift with your legs and keep your back straight. Keep the materials or object close to your body. Have a co-worker assist you if the load cannot be lifted safely by one person.

• Know where first-aid kit, stretcher and other eme gency supplies are k ept. Be sure that first aid supplies ar properly maintained and ready for use.

• Never attempt to catch falling materials or objects.

• Make sure that a clear path to emer gency equipment and exits is al ways maintained. Do not allo w equipment, spilled materials or other obstructions to get in the way.

• Be a ware of flammable liquids and other potential fi hazards. Do not smok e when refilling engines or usin cleaning solvents.

• Know how to report accidents.Always report all accidents immediately to the appropriate supervisor.

• Do not stand under equipment or components that are being hoisted or suspended. Ne ver allow other quarry personnel to do so.

Wear Personal Protective Equipment (PPE)

• Before you assemble, operate, clean, lubricate, or adjust machinery, be sure to read and understand all procedures contained in the machinery manufacturer’s manual.

• Wear safety glasses or goggles whene ver outside of an approved operator’s enclosure. F ailure to wear appropriate eye protection can result in permanent e ye injuries and loss of sight. • Wear appropriate ear protection when working within 50 feet of any operating quarry machinery, and in other areas where noise le vels are high. Prolonged e xposure to high noise levels can cause permanent hearing loss. • Wear steel-toe safety boots, heavy-duty gloves and a hard hat. This equipment is mandatory in most areas of the quarry. • Use respirators in dusty locations and when working with hazardous substances. Prolonged exposure to rock dust or chemical fumes can cause permanent respiratory illness. • Other personal protecti ve equipment may be necessary for your specific job assignment, such as a full ace shield and safety harness. Wear or use these items when necessary and as required by applicable federal state and local regulations.

Observe Personal Safety Precautions • Never wear loose or ragged clothing when working on or around rotating po wer equipment. Avoid wearing necklaces, rings or other jewelry. These items can become caught or tangled in the machinery , resulting in se vere personal injury or death. • Keep hair short, if possible. Keep long hair securely tiedup to prevent it from becoming caught in the machinery. • Be especially careful whene ver using wet w alkways, platforms, or ramps. The combination of rock dust and wet metal can create an extremely slippery surface. Keep all walkways and other access structures clean, dry and free of grease or oil. 03/99

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• Be sure to operate quarry machinery in compliance with current OSHA and MSHA regulations, and all applicable federal, state or local regulations.

Help Prevent Accidents • Do not allow unauthorized personnel in or near the w ork area. Never allow unauthorized personnel to operate, adjust, maintain or repair machinery. • Allow only properly trained and experienced personnel to operate machinery. Be sure ine xperienced operators are carefully supervised at all times. • Before starting the machinery, check that no personnel are inside, on, under or beside the equipment. Unless absolutely necessary, do not allow anyone to be on or near the equipment while it is operating. • Do not allo w personnel to be near loading areas, or anywhere else that f alling or ejected material could hit them. • Before starting machinery , be sure that the surrounding area is clear of people, equipment and tools. Use warning horns, warning lights or other signal device to alert other workers that the equipment is about to be started. • Use extreme caution if the machinery must be operated for inspection or observ ation purposes. Stay a safe distance and wear appropriate personal protecti ve devices. • Before making repairs to the machinery , always clear all quarry material from the feed and dischar ge devices (feeders, conveyors, chutes, etc.).

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7F

Safety


• In areas which present a danger of f alling, use an appropriate fall protection device, such as a safety harness and lifeline. • Always report an y unsafe conditions or defecti equipment to the appropriate supervisor.

ve

Avoid Alcohol and Other Drugs • Do not operate or w ork near quarry machinery when under the influence of alcohol or other drugs.These items can result in reduced alertness and impaired judgement. Serious personal injury or death could result. • Some prescription and non-prescription medications can cause drowsiness or other adv erse side ef fects. Do not operate or w ork near quarry machinery when under the influence of such medications

1

Be Aware of Your Surroundings • The quarry environment contains many situations that are potentially hazardous. Use extreme caution to avoid being struck by haul trucks, loaders and other quarry mobile equipment. • Be a ware of idle machinery that could start-up without warning. Stay clear of such machinery and the immediate area. • Be a ware of o verhead obstructions, such as con veyors, support structures or power lines.

Practise Good Housekeeping • Do not store tools or equipment on walkways.

7F

• Be sure that all walkways, platforms, stairs and ramps are kept free of spilled material and trash. A build-up of material in these areas can cause slips and f alls. Make repairs as required in areas where spillage is present. • Do not allow machinery to become b uried under piles of spilled material. This will mak e the machinery more difficult to inspect and may hide bro en welds, loose fasteners and other serious problems that could cause a safety hazard. • Keep the areas around control panels and machinery free of spilled material. Free access must be maintained at all times. In the e vent of an emer gency, quick access to controls could prevent injury or death. • Clean up spilled fuel or oil immediately to eliminate slipping hazards. If necessary, use an oil absorbent. • Always be sure that power is tagged and locked out before cleaning spilled material or oils. Ne ver clean-up these items while the machinery is operating.

1–8

Inspect And Maintain Machinery • Always perform a safety inspection at the be ginning of each shift. Refer to the machinery manuf acturer’s operation and maintenance manuals for detailed pre-startup inspection and maintenance procedures. • Test all warning devices before starting the machinery to ensure that the y are w orking properly. Never disable or bypass any alarm systems or interlocks. • Be sure that an y defecti ve components or systems are properly repaired by a qualified technician before th machinery is started. Immediately report an y serious problems to the appropriate supervisor. • Before performing inspections or maintenance, al ways lock out power and tag controls to the machine drive, and to all feed and dischar ge equipment. Warn all personnel that the equipment is being serviced. Refer to theLockout/ Tagout section of this chapter for additional information. • Maintenance inspection procedures are included throughout this manual. Although maintenance is not typically a safety concern, machinery that is re gularly maintained and in proper w orking condition will minimize the occurrence of safety hazards and emergency situations.

MACHINERY INSTALLATION SAFETY Foundations Proper foundations and support structures are essential to ensure the safe and efficient operation of quarry equipment • Crushing machinery needs a firm foundation on which t operate. This does not need to be a poured pad, but it may not be on unstable ground.When selecting the location, be sure that the entire area is as level as possible. • Follow all manuf acturer’s installation dra wings and specifications when constructing the base pads fo permanent plants. • If any questions arise re garding foundation requirements or modifications necessary forTelsmith machinery, please contact the Telsmith Service Department. • Customer-designed support structures for Telsmith equipment must meet Telsmith’s engineering standards. All plans must be submitted in adv ance to the Telsmith Engineering Department for approval.

Guarding • Quarry management is responsible for the proper installation and placement of guards to prevent personnel from coming in contact with rotating or moving parts.

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• In addition to the guards supplied with the machinery , additional guards and related safety equipment may be required to comply with OSHA, MSHA and an y applicable local re gulations. The proper f abrication, installation and placement of these items is quarry management’s responsibility. • When f abricating guards, refer to MSHA ’s Guide to Equipment Guarding at Metal and Nonmetal Mines. Additional information can also be provided by the safety officer at your orksite. • Never remo ve guards until the machinery is stopped, power is locked out, and controls are tagged. Be sure that guards are properly re-installed before reconnecting power.

Customer Modifications • Do not modify quarry machinery in any way without prior approval from the manufacturer. Such modifications ma include (but are not limited to) changing machine speed or direction of rotation, drilling additional holes and welding or bolting additional equipment to the machinery. • All customer modifications to Telsmith machinery must be appro ved in writing in writing by the Telsmith Engineering Department.

Electrical Hook-up

! WARNING!!! DANGER

Safety

• All Telsmith machinery is designed with electrical components of the proper size and v oltage. Any modifications to these components or to the p wer supply must be approved in writing by the Telsmith Engineering Department. • Be sure that all connections are in accordance with the National Electric Code and an y applicable state or local codes.

MAINTENANCE AND REPAIR SAFETY

! WARNING!!! DANGER Always lockout/tagout power to machinery and conveying equipment before performing any maintenance or repairs. Warn all personnel that the machinery is being serviced.

General Precautions • To help ensure safe machine operation, use only genuine OEM replacement parts that are sold or appro ved by the machine’s manufacturer. Use of non-OEM parts may adversely affect machine operation and could result in an a hazardous situation. • Always tighten all f asteners to the proper torque as described in the repair procedures. When torque specifications are not listed, use the alues in the torque chart at the back of this manual. Refer to Appendix B of this manual.

When installing any electrical equipment, be sure t o c o m p l e t e l y f o l l o w t h e m a n u f a c t u r e r ’s instructions. Failure to observe this precaution could result in a dangerous electrical shock hazard.

• Be sure all replacement f asteners are of the proper grade and specifications. Replace a y w orn or damaged fasteners.

• Be sure that all electrical equipment is properly grounded.

Electrical Systems

• Lay out the po wer lines, especially those for portable plants, so that contact with standing water is minimized.

• Always read, understand and follow appropriate electrical system troubleshooting, maintenance and repair instructions in the machinery manufacturers’ manuals.

• Do not place po wer lines in an area where the y will be driven o ver by transport v ehicles or other quarry equipment. If it is absolutely necessary to extend a power line across a traf fic area, protect the cable with properl rated bridging. • Be sure that all auxiliary control panels or po wer supply panels can be securely lock ed out. This type of panel is mandatary. • Maintain adequate o verhead clearance from po wer lines or other obstructions, particularly when planning to use stacking conveyors for stockpiles. • Be sure that electrical po wer supplies are located in an area that will be safe from accidental contact during crushing operations. 03/99

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7F

• Allow only trained and licensed electricians to install, troubleshoot and repair electrical equipment. All procedures must be in compliance with the National Electric Code and an y applicable state or local regulations. • When servicing an electrical system, work with the power locked out and tagged. Always assume that an electrical system is live until it has been locked out. • Always tag and lock out po wer before remo ving cables with quick-disconnect plugs. • Repair an y ob viously w orn or damaged wires and connectors.

1–9

Safety


• Inspect power cables and connections daily for signs of wear, crack ed insulation and w orn or damaged connectors. Repair or replace as required.

• Do not operate any hydraulic or air system with obviously worn or damaged, or leaking components.Always replace any defective components immediately.

• Do not store tools inside electrical cabinets.

• Never place hands on h ydraulic c ylinder rods while equipment is in operation. Do not step on the h ydraulic relief cylinder hoses when climbing on the crusher.

• Verify that all tools are grounded with a three wire plug or double insulated. Be sure that all e xtension cords are grounded with a three wire plug.

Pressurized Systems (hydraulic and air) • Adjust, maintain and repair all pressurized systems only in accordance with the instructions contained in the manufacturer’s manuals provided with the machinery. • Never attempt to work on a pressurized system while it is pressurized or in operation.

1

• Before performing maintenance or repairs on an pressurized system:

y

- Cycle the controls through all operating positions to relieve any trapped pressure. - Check that ALL pressure is relie ved from the system. Pressure gauges must read zero (0) PSI. - Lockout and tag all controls. Be sure electrical power is properly locked out and tagged.

7F

• Refer to manuf acturer’s instructions when rechar ging hydraulic accumulators or checking accumulator pressure. Allow only trained hydraulic system technicians to depressurize, rechar ge or repair h ydraulic accumulators.

Welding On Machinery • Be sure to pro vide adequate v entilation when welding inside enclosed areas to prevent the buildup of hazardous fumes. Special concern should be exercised when welding chromium, manganese, cadmium, copper, cobalt, lead and nickel, as these materials are considered to be potentially carcinogenic. • Be sure to wear the proper welding shield, welding gloves and clothing. Do not wear synthetic f abric clothing or clothing which could be easily ignited by sparks.

• Allow time for hot hydraulic oil to cool before performing any maintenance or repairs. Hot oil can cause burns.

• Always follo w all standard safety procedures when welding. Be sure that all systems are shut down, power is locked out, and controls are tagged. Pro vide welding screens to protect other employees working in the area.

• Before loosening fittings or rem ving components, always recheck that ALL pressure is relie ved from the system. Pressure gauges must read zero (0) PSI.

• Relieve all h ydraulic pressure before welding near hydraulic components and lines. Co ver h ydraulic components to protect them from weld spatter and sparks.

• Never attempt to crack a h ydraulic fitting while hydraulic system is pressurized. You could be injured or killed by a stream of high pressure oil.

• Do not weld near flammable liquids or ydraulic oils.

• Never have your face near, or stand directly in front of a hydraulic line when cracking a fitting, ven after system pressure has been relie ved. Always assume that the line has pressure. • Use a piece of cardboard to check for hydraulic oil leaks, not your hand. Escaping fluid under pressure ca penetrate the skin, resulting in serious personal injury. • Clean-up an y spilled h ydraulic fluid. Hydraulic fluid extremely slippery, and can be especially dangerous if spilled on an elevated walkway or platform. • Repair an y leaks immediately . Always relie ve system pressure and lockout/tagout power before tightening fittings or making repairs • Never attempt to adjust pressure relief valves to above the machinery manuf acturer’s recommended settings. Serious personal injury and/or equipment damage could result. 1–10

• Welding lifting eyes or hooks to manganese steel castings is strongly discouraged, and should be done only if absolutely necessary. Always use a stainless steel or manganese weld rod. Ne ver allow personnel to w alk or work underneath castings being lifted or supported. • Never ground the welder so that the electrical po wer will fl w through bearings, hydraulic components or electrical equipment. Serious damage could result. • Be sure all compressed g as cylinders are stored upright, chained and capped. Turn-off all c ylinders when not in use.

Clearing Jammed Material • If material becomes jammed in the machinery: - Immediately stop the machinery. - Lockout/tagout power. Warn others that the machinery is being serviced. - Follow the instructions in the operation and maintenance manual of the affected equipment. 03/99


• To prevent serious personal injury or death, never attempt to remove jammed material while the machinery is in operation. • Always remove all jammed material before restarting the machinery. To prevent damage, never attempt to restart a stalled machine without first rem ving the jammed material. • Never use dynamite or other e xplosives to clear jams. Explosives are dangerous and can injure or kill personnel. Damage to machinery could also occur.

Hazardous Materials • Be a ware potentially hazardous chemicals or materials. Such items can be harmful if the y are improperly used, stored, mixed or transported, or if the y are inhaled, swallowed or allowed to contact the skin. • Consult your employer’s hazard communications plan for instructions regarding the proper handling and use of hazardous materials. Read and understand the labels attached to the product containers. Always follow the instructions carefully. • Consult the manuf acturer’s material data sheet (MMD) for potential hazards and appropriate medical procedures should an accident occur. • Store hazardous materials only in approved containers. Be sure containers are clearly labeled. • To a void potential health hazards, persons in re gular contact with h ydraulic oils must be a ware of the importance of thorough hygiene, and the proper methods for handling mineral oils. • Mineral-based hydraulic oils act as solvents on the natural oils of the skin. Frequent and prolonged skin contact can cause dermatitis or severe irritation. • Always wear suitable protecti ve clothing when handling hydraulic oil. • Be sure protective clothing and proper w ash-up facilities are available to all personnel that may come in contact with mineral-based hydraulic oils. • Always dispose of used rags or paper towels in the correct and safe fashion.

Disposal Of Excess Fuels, Lubricants And Liquids Quarry personnel are responsible for the proper disposal of unused fuels, used lubricating oils, used h ydraulic oils, and other toxic materials. DO NOT dispose of these materials in an unapproved manner. Follow all applicable federal, state and local regulations.

03/99

Safety

Flammable and Combustible Liquids • Store flammable liquids in a safe place, way from quarry machinery and personnel. Use approved safety containers and be sure that they are clearly marked. Containers must be covered when not in use. • Keep flammable liquids way from sparks, open flame and other ignition sources. Do not smok e around flammable liquids. Always obey posted “no smoking” signs. • Be f amiliar with the locations of fire xtinguishers throughout the quarry. Be sure the y remain accessible at all times, and are not blocked by obstructions. • Do not use g asoline or other flammable liquids to clea tools or parts. Use only appro ved non-flammabl solvents. • Always shut-of f engines before refueling. Ground fuel spout against the filler neck to pr vent static electricity. Never smoke while refueling.

1

• Use only appro ved safety containers for storing and transporting small quantities of flammable liquids. eep containers covered when not in use.

HOISTING AND HANDLING SAFETY General Precautions • Do not allo w personnel to w ork or w alk under loads supported by a crane or hoist. • Use appropriate lifting de vices to secure the load to the crane. See the follo wing paragraphs of this section for additional information. • Use the correct lifting hooks to support the load. Refer to the equipment manuf acturer’s manuals for lifting points and procedures. • Use extreme caution when operating a crane near po wer lines or electrical equipment. • Do not e xceed the crane’ s rated load capacity . Always subtract the weight of the hook block, slings, chains, spreader bars and any additional equipment to determine the maximum load that can be safely lifted.

Wire Rope Wire rope requires careful use, handling and maintenance to ensure long life and safe operation. Always observe the following precautions. • Be sure to use the correct wire rope for the application. • Be sure that the wire rope is inspected regularly following the manufacturer’s guidelines.

1–11

7F

Safety


• Avoid sudden loading in cold weather . Never use frozen wire rope. • Use suitable padding to protect wire rope from sharp corners or edges. • Avoid dragging wire rope underneath loads or o obstacles.

1

ver

! CAUTION DANGER !!!

• Never use wire rope that has is cut, badly kink ed, frayed or crushed.

Always follow proper rigging procedures as provided by the chain manufacturer. The angle of rigging may decrease the rated lifting capacity.

• Avoid reverse bends.

Fiber Or Synthetic Slings

• Be sure that rope ends are properly sized. • Use thimbles in eye fittings at all times

Slings require careful use, handling and maintenance to ensure long life and safe operation.

• Watch for local wear. Reposition or shorten wire rope to remove the worn section from the area of lifting tension.

• Be sure that slings are rated or coded for the hitch or application.

• Follow the manuf acturer’s instructions for lubrication if using wire rope for lifting purposes.

• Be sure that slings are inspected re gularly following the manufacturer’s guidelines.

Connecting Or Clamping Wire Ropes When connecting or clamping wire ropes, use one of the following: • Clamp and thimble connections combine both the clamp and thimble in one unit. Clamp and thimble connections are capable of supporting 80% of the rated wire rope load. • Cable clips are the most common way to secure a rope to a piece of equipment or to make an eye. The cable clip or “Crosby Clip” is made of a U-bolt and saddle. If this type of clip is used to make an eye, the use of a properly sized thimble is mandatory. If not, the cable may kink, forming a permanent weak spot.

7F

• Be sure that all connections between chain sections are completed with properly sized hardw are and lifting hooks.

Chains Chains require careful use, handling and maintenance to ensure long life and safe operation. • Be sure that the correct size chain is being used for the application. • Be sure that the chain is inspected regularly following the manufacturer’s guidelines. • Avoid sudden or shock loading (DO NO T jerk load upright). • Use suitable padding to protect the chain from sharp corners or edges. • Avoid dragging the chain under loads or over obstacles. • Use the proper fittings at all times • Watch for local wear . Reposition or shorten chain (as required) to remo ve the w orn section from the area of tension. • Inspect links to determine the amount of wear . Refer to manufacturer’s specifications for wear tolerance ranges 1–12

• Slings may be safely used in a temperature range of 20 to 180° F (-6 to 82°C) without decreasing load limits. F or temperatures beyond this range or for wet/frozen slings, follow manufacturer’s instructions for load reductions. • Do not use synthetic slings in temperatures e 180°F (82°C). • Avoid sudden or shock loading (DO NO upright).

xceeding T jerk load

TRANSPORTING MACHINERY • Be sure that the machinery is properly secured so that it cannot vibrate or move during transport. Remove any dirt, stones or other loose material from the machinery. • Install shipping brackets, wood blocking or other shipping materials as directed in the machinery manuf acturer’s manuals. Perform any shipment preparation procedures as indicated in the manuals. • Plan your route carefully . Know the clearance height of the machinery. Be aware of bridges, power lines and steep or uneven grades. Be aware of any other conditions which may present hazards or obstructions. • Be sure that all tractor-trailer components are working and in good condition. Test all systems (brak es, steering, lights, etc.) for proper operation and/or adjustment before beginning the mo ve. Check air pressure in all tires and replace any tires that are worn or damaged. • After the machinery has been transported, block the tires if the trailer will remain stationary for an extended period of time. • Refer to the Telsmith Portable Plant Installation and Maintenance Manual for additional portable plant transport instructions. 03/99


Chapter 2

Chapter 2 General Instructions WORK SAFELY AND USE COMMON SENSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 TOOLS AND SUPPLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 LUBRICANTS & SEALANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 PARTS IDENTIFICATION & INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 HANDLING SEALS & MACHINED PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 HANDLING BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 USING HEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Removing Hydraulic Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

2

7F

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General Instructions


2

7F

2–2

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WORK SAFELY AND USE COMMON SENSE • Refer to Chapter 1 of this manual for important quarry safety information. Also refer to the Telsmith Quarry Equipment Safety Guide for additional safety precautions. • Observe all precautionary statements (D ANGER, WARNING, CAUTION, IMPORTANT, and NOTE) that are included within the repair and overhaul procedures. • Be sure all lifting devices, slings and supports are in good condition and of adequate rated capacity . Refer to Appendix C for component weights. • Keep cleaning solvents and other combustibles away from heat and open flame. Do not smo e around flammabl liquids. • Wear appropriate personal protecti ve equipment (PPE). Keep the work area clean and well organized.


PARTS IDENTIFICATION & INSPECTION • Tag and mark all parts during remo val and disassembly procedures. • Clean all parts as remo ved. Verify that the y are free of cracks, nicks, burrs and other imperfections. • Check clearances and dimensions as instructed in the procedures. • Replace any excessively worn or damaged parts. • If possible, take reference photographs of the machinery as it is disassembled. During reassembly , use the photographs to v erify that all parts are correctly reinstalled.

HANDLING SEALS & MACHINED PARTS • Be careful not to cut or damage seals during installation.

• If service assistance is needed, contact your local Telsmith dealer or the Telsmith Service Department.

• Handle shafts carefully to prevent damage. Do not nick or mar finished sur aces.

TOOLS AND SUPPLIES

• If shafts, bearings or other machined items are to be removed from the machinery for more than a fe w days, cover them with a protecti ve coating of rust-preventative lubricant.

The following common tools, shop equipment and supplies are required to complete most repair and o verhaul procedures: • Chain puller (6000 lb. capacity).

HANDLING BEARINGS

• Impact wrench with a 3/4 inch dri ve minimum, 1 inch preferred.

• Remove an y loose dirt from the machinery before exposing bearings. Handle bearings with clean, dry hands.

• Set of sockets and breaker bars, minimum 3/4 inch dri ve with sockets up to 3-1/2 inches.

• Use only clean lint-free rags. Use clean tools in clean surroundings. Use clean solvents and flushing oils.

• Cold chisel, 3/4 inch.

• Install new bearings as removed from packaging without washing. Do not remo ve bearings from packaging until ready to use.

• Hammers (various sizes). • Cables, slings, and chains. • Crane or hoist of adequate capacity. (Refer to Appendix C for component weights) • Feeler gauge and inside/outside micrometers.

• Soak used bearings in solv ent. Then w ash the bearings and blo w them dry with filtered, moisture-fre compressed air. Dip the bearings in oil immediately after drying to prevent rust.

• Cleaning solvent.

! WARNING!!! DANGER

• Flushing oil. Refer to the Tools and Supplies Required heading at the beginning of each chapter for additional items needed to perform specific repair and verhaul procedures.

LUBRICANTS & SEALANTS Required lubricants and sealants are listed at the beginning of each chapter under the Tools and Supplies Required heading. Detailed specifications for these items are located i Appendixes D and E. 03/99

2

Always wear eye protection and face shield when using compressed air. Do not spin the bearings by hand or by air pressure after the bearing surfaces have dried.

USING HEAT • When using an oil bath, avoid contact with hot oil. • Use an acetylene torch if heat is required to remo ve an interference-fit part and it is not practical to use hot oil 2–3

7F



Keep flame m ving continuously. Do not let flame touc the part being removed. • If a part is to be destro yed by heat, be careful not to damage other reusable parts nearby. • Be careful when using heat and handling hot parts. To prevent burns, always wear appropriate hand, face and eye protection.

Removing Hydraulic Lines

! WARNING!!! DANGER Failure to observe the following precautions may result in serious personal injury or death. • Before loosening an y h ydraulic fittings or rem ving hydraulic lines, be sure that pressure is fully relieved and that all pressure g auges indicate zero (0) PSI. Lockout/ tagout power if the system is po wered by an electric pump.

2

• Never attempt to loosen a h ydraulic fitting while th system is pressurized. If hydraulic oil penetrates the skin, serious personal injury or death can result. • Never have your face near, or stand directly in front of a hydraulic line when cracking a fitting, ven after system pressure has been relie ved. Always assume that the line has pressure. • Before removing a hydraulic hose, check that the hose is relaxed and not stiff. A stiff hydraulic hose indicates that system pressure has not been fully relieved. If a hose feels stiff, do not attempt to loosen the hose fittings unti pressure has been relieved.

7F

• Be sure to wear appropriate personal protecti ve equipment, such as safety goggles or f ace shield. Some residual pressure may still be present in the system, e ven when all gauges indicate zero (0) PSI. • Have a suitable container ready to catch an y spilled hydraulic oil when hydraulic lines are removed. • To pre vent contamination of h ydraulic systems, cap all ports and hose fittings immediately after rem ving any hydraulic lines.

2–4

03/99


Chapter 3

Chapter 3 Repair and Overhaul Procedures Preliminary Instructions and Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 General Shutdown Procedure (Before Working on Crusher) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Stationary Jaw Die Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Stationary Jaw Die Key Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Swing Jaw Die Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Swing Jaw Guard Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Cheek Plate Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Flywheel Pulley/Sheave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 Tension Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 Toggle and Toggle Seat Replacement . . . . . Toggle Removal . . . . . . . . . . . . . Toggle Seat Replacement (Toggle Beam) Toggle Seat Replacement (Swing Jaw). . Toggle Installation . . . . . . . . . . . .

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. 3-23 . 3-23 . 3-24 . 3-24 . 3-25

Thrust Shaft (Model 3042 Only) . . . . . . Removal. . . . . . . . . . . . . . . . . Bronze Thrust Shaft End Replacement . Installation . . . . . . . . . . . . . . .

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. 3-29 . 3-30 . 3-31 . 3-31

Hydraulic Adjusting Cylinder Replacement. Removal. . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . .

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. 3-32 . 3-33 . 3-34 . 3-34

Swing Jaw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36

03/99

3–1

3

7F

Repair and Overhaul Procedures


3

7F

3–2

03/99


REPAIR AND OVERHAUL PROCEDURES Preliminary Instructions and Precautions

! WARNING!!! DANGER Failure to follow the instructions and precautions below may result in serious personal injury or DEATH! • Read the General Instructions in Chapter 2. • Lock out po wer source and tag crusher dri ve controls. Warn all personnel that crusher is being serviced. • Lock out power source and tag controls for crusher feed and discharge equipment. • Always use suitable rigging and hoisting equipment to stabilize and lift heavy objects. Lifting heavy components with inadequate hoisting apparatus can damage machinery and result in serious personnel injury or death. Refer to Appendix C for component weights.


Stationary Jaw Die Replacement TOOLS AND SUPPLIES REQUIRED • Suitable rigging and hoisting equipment • Lifting hook • 1-inch drive impact wrench or torque wrench with 2-1/4" socket for stationary jaw die fasteners • Hand grinder • Prybar • Tape measure • Appropriate equipment and materials for cleaning mating surfaces of crusher and stationary die • Lubricant (refer to specifications

Appendix D for lubricant

• New fabric washers

General Shutdown Procedure (Before Working on Crusher)

! WARNING!!! DANGER

3

Failure to follow the instructions and precautions below may result in serious personal injury or DEATH! 1.

Be sure there is no material lodged inside the crushing chamber.

2.

Lockout/Tagout power to the crusher drive motor. Shut off fuel supply if the crusher is po wered by a diesel engine. Refer to Chapter 1 for detailed lock out/tagout procedures.

3.

Lockout/Tagout power to the oil lubrication system, if equipped.

03/99

7F

3–3



02 01

03

2044

04

05 06 07 08

09 10 11 02

3

01

03

3042

7F

04

01 - Die (stationary jaw) 02 - Bolt 03 - Lifting hook pocket 04 - Key ‡ 05 - Fabric washer 06 - Steel washer 07 - Hex nut 08 - Jam nut 09 - Bushing ‡ 10 - Washer ‡ 11 - Bolt ‡

05 06 07 08

09

‡ Do not remove jaw die hardware unless jaw die is worn or broken

10 11

Figure 3–1. Stationary Jaw Exploded View 3–4

03/99


! WARNING!!! DANGER Lock out power source and tag controls for crusher drive motor, feed and discharge equipment before performing any maintenance or repairs. Always secure drive pulley if it is necessary to enter the crushing chamber. Warn all personnel that crusher is being serviced.


IMPORTANT: Mating surfaces must make solid contact. Always remove any dirt, nicks or burrs before replacing or reversing die. Clean all surfaces as required. Using a straightedge, check contact surfaces of both stationary jaw and jaw die for flatness. Check surfaces both longitudinally and diagonally to assure that 100 percent contact is accomplished.

Also, read and adhere to the instructions at the be ginning of this chapter entitled “Preliminary Instructions and Precautions” and “General Shutdo wn Procedure (Before Working on Crusher)” before performing an y maintenance or repairs.

! WARNING!!! DANGER A lw ay s u s e s u i t a b l e r i g g i n g a n d h o i s t i n g equipment to stabilize and lift heavy objects. Lifting heavy components with inadequate hoisting apparatus can damage machinery and result in serious personnel injury or death. Refer to Appendix C for component weights.

2.

Inspect key [04] and replace if worn or broken. Refer to the “Stationary Ja w Die K ey Replacement” section of this manual.

Removal

3.

Rotate die [01] 180° (if opposite end is not w orn) or place ne w die on lifting hook. Refer to Figure 3-3. Lower die [01] into position aligning k eyways of die with keys [04] of crusher frame. Refer to Figure 3-4.

NOTE: See Figure 3-1 for exploded view and numbered callouts [01 - 11]. Also refer to other figures as indicated. 1.

Loosen (but do not remove) nuts [07, 08] on lowest row of jaw die bolts [02].

2.

Remove nuts [07, 08] and w ashers [05 and 06] from upper ro w of ja w die bolts [02]. Refer to Figure 3-5. Remove upper row of jaw die bolts [02].

3.

Carefully pry top of ja w die [01] from crusher frame. Insert lifting hook into pocket located at back of die and support using an appropriate lifting de vice. Refer to Figure 3-3.

4.

5.

Remove nuts [07, 08] and w ashers [05, 06] from lo wer row of jaw die bolts [02]. Refer to Figure 3-5. Remo ve lower row of jaw die bolts [02].

Figure 3-2. Clean Mating Surfaces of Die and Frame

3 LIFTING HOOK

7F LIFTING POCKET

STATIONARY JAW DIE

Lift die [01] from crusher frame and mo ve to an appropriate work area.

Installation NOTE: See Figure 3-1 for exploded view and numbered callouts [01 - 11]. Also refer to other figures as indicated. 1.

Figure 3-3. Lift Stationary Jaw Die

Whether replacing or reversing the die [01], clean and check for nicks and burrs on the mating surfaces. Using a hand grinder, make sure all mating surfaces of frame and die are smooth. Refer to Figure 3-2.

03/99

3–5



FABRIC WASHER LIFTING HOOK

STEEL WASHER

STATIONARY JAW DIE

HEX NUT JAM NUT DIE KEYWAY FABRIC WASHERS

HEX NUTS

STEEL WASHER

DIE KEY

JAM NUTS

Figure 3-4. Install Stationary Jaw Die

3

4.

Position die [01] on crusher frame. Install a jaw die bolt [02] into each of the upper corners of the die. Loosely secure the two jaw die bolts [02] with nuts [08].

Figure 3-5. Install Stationary Jaw Die Fastening Hardware 6.

IMPORTANT: Install new fabric washers during Steps 5 and 6. Do not reuse old fabric washers. 5.

7F

3–6

Install lower row of ja w die bolts [02]. Coat threads of jaw die bolts with lubricant. Loosely secure bolts [02] with f abric w ashers [05], steel w ashers [06] and nuts [07, 08]. Refer to Figure 3-5.

Remove lifting hook and install upper ro w of ja w die bolts [02]. Coat threads of ja w die bolts with lubricant. Loosely secure bolts [02] with fabric washers [05], steel washers [06] and nuts [07, 08]. Refer to Figure 3-5.

IMPORTANT: In Step 7, the corrugations of the stationary jaw die must line up perfectly with the corrugations of the swing jaw die. 7.

Center jaw die [01] in main frame. Measure the distance between the edge of the jaw die [01] and the side wall of the main frame. Do this on both sides of the ja w die. Refer to Figure 3-6. Using a prybar, slide the jaw die so that it is perfectly centered in the main frame. Mak e sure that the measurement is equal on both sides. Corrugations of the stationary ja w and swing ja w must be “meshed” as illustrated in Figure 3-7.

03/99



Stationary Jaw Die Key Replacement SIDE WALLS OF CRUSHER

TOOLS AND SUPPLIES REQUIRED STATIONARY DIE

• 1-inch dri ve impact wrench or torque wrench with ?" socket • Hammer • Brass bar • Mallot • Appropriate equipment and materials for cleaning mating surfaces • Lubricant (refer to specifications


! WARNING!!! DANGER CENTER DIE BETWEEN WALLS (Measurement Must Be Equal on Both Sides)

Figure 3-6. Measure Distance Between Die and Wall SWING JAW DIE

Lock out power source and tag controls for crusher drive motor, feed and discharge equipment before performing any maintenance or repairs. Always secure drive pulley if it is necessary to enter the crushing chamber. Warn all personnel that crusher is being serviced. Also, read and adhere to the instructions at the be ginning of this chapter entitled “Preliminary Instructions and Precautions” and “General Shutdo wn Procedure (Before Working on Crusher)” before performing an y maintenance or repairs.

3

! WARNING!!! DANGER CORROGRATIONS MUST BE “MESHED”

STATIONARY JAW DIE

Figure 3-7. Check that Stationary and Swing Jaw Dies are “Meshed” 8.

Tighten all nuts [07, 08] e venly using a 1-inch dri ve impact wrench or torque wrench with 2-1/4" sock et. If the keys [04] were remo ved and/or replaced, install the washers [10] and bolts [11]. Refer to Figure 3-8. Torque all fasteners to the value specified in Appendix A.

IMPORTANT: After starting crushing with the machine, it is very important to go back every 8 hours for at least 3 days and retighten the bolts to ensure they are, in fact, staying tight.

03/99

A lw ay s u s e s u i t a b l e r i g g i n g a n d h o i s t i n g equipment to stabilize and lift heavy objects. Lifting heavy components with inadequate hoisting apparatus can damage machinery and result in serious personnel injury or death. Refer to Appendix C for component weights. The following procedures may be performed after the stationary jaw die is remo ved from the crusher . Refer to “Stationary Jaw Die Replacement” instructions in this section.

Removal NOTE: See Figure 3-1 for exploded view and numbered callouts [01 - 11]. Also refer to other figures as indicated. 1.

Remove bolts [11] and washers [10] from the stationary jaw die locating keys [04]. Refer to Figure 3-8. Remove keys [04] from the main frame.

2.

If replacing the b ushings [09], remo ve them from the main frame using a hammer and brass bar.

3–7

7F



tapping the b ushing [09] e venly around its entire cir cumference until it is flush with the all of the main frame. Install the second bushing [09] in the same manner. Refer to Figure 3-8.


Clean all mating surfaces of the new bushings [09] and main frame. Apply a light coat of lubricant to the bushing bores of the main frame.

2.

Align a ne w b ushing [09] (be vel end f acing inside of crusher) with the bore of the main frame. Using a mallot, tap the bushing [09] evenly around its entire circumference until it is partly installed in the bore. Continue

3.

Apply a light coat of lubricant to the bores of the b ushings [09]. Install the new keys [04] into the bores of the bushings [09].

NOTE: Do not install the bolts [11] and washers [10] at this time. This is completed after the stationary jaw is installed.

CRUSHER HOUSING WASHER BUSHING

DIE KEY

3

BOLT

DEVELED END OF BUSHING

7F

Figure 3-8. Stationary Jaw Die Key Components

3–8

03/99



Swing Jaw Die Replacement TOOLS AND SUPPLIES REQUIRED • Suitable rigging and hoisting equipment • Lifting hook • 1-inch dri ve impact wrench or torque wrench with the following socket for swing jaw die fasteners: 2-1/4" socket (2044 crusher) 2-3/4" socket (3042 crusher) • Hand grinder • Prybar • Appropriate equipment and materials for cleaning mating surfaces of swing jaw and swing jaw die • Lubricant (refer to specifications



08

08 07 06

09

05 04 03

02

01

04 03

07 06 05 09

02 01

10

10

3

11 11 12

13 01 - Fabric washer 02 - Steel washer 03 - Hex nut 04 - Jam nut 05 - Fabric washer 06 - Steel washer 07 - Hex nut 08 - Jam nut 09 - Swing jaw 10 - Guard 11 - Capscrew 12 - Wedges 13 - Bolt 14 - Die (swing jaw) 15 - Key

7F

13

15 15 14

2044

14

3042

Figure 3-9. Swing Jaw Exploded View

03/99

3–9



! WARNING!!! DANGER

LIFTING HOOK

Lock out power source and tag controls for crusher drive motor, feed and discharge equipment before performing any maintenance or repairs. Always secure drive pulley if it is necessary to enter the crushing chamber. Warn all personnel that crusher is being serviced.

LIFTING POCKET

Also, read and adhere to the instructions at the be ginning of this chapter entitled “Preliminary Instructions and Precautions” and “General Shutdo wn Procedure (Before Working on Crusher)” before performing any maintenance or repairs.

SWING JAW DIE


Removal

3

7F


Remove nuts [03, 04], washers [01, 02], wedge bolts [13] and wedges [12].

2.

Carefully pry top of die [14] from swing jaw [09]. Insert lifting hook in pock et and support die with hoist. Refer to Figure 3-10.

3–10

Figure 3-10. Support Jaw Die with Lifting Hook 3.

Lift die [14] from swing jaw [09] and move to an appropriate work area.


Whether replacing or reversing the die [14], clean and check for nicks and burrs on the mating surfaces. Using a hand grinder, make sure all mating surfaces of swing jaw and die are smooth. Refer to Figure 3-2.

IMPORTANT: Mating surfaces must make solid contact. Always remove any dirt, nicks or burrs before replacing or reversing die. Clean all surfaces as required. Using a straightedge, check contact surfaces of both swing jaw and jaw die for flatness. Check surfaces both longitudinally and diagonally to assure that 100 percent contact is accomplished. 2.

Inspect k ey [15] and replace if w orn or brok en. Also check welds around key [15]; reweld if necessary. Refer to Figure 3-11.

3.

Rotate die [14] 180° (if opposite end is not w orn) or place new die on lifting hook. Refer to Figure 3-10.

4.

Align die [14] with swing ja w [09], making sure die is properly seated o ver centering k ey [15] and supported by ledge. Refer to Figure 3-11.

03/99



WELD KEY INTO KEYWAY AT ALL JOINTS

WELD

DIE

KEY

3

SWING JAW LEDGE

7F

DIE SWING JAW LEDGE

WELD

KEY

Figure 3-11. Position Die into Jaw

03/99

3–11


5.

Remove lifting hook from pock et. Carefully place top of die [14] against swing jaw [09].

IMPORTANT: Mating surfaces must make solid contact. Always remove any dirt, nicks or burrs before installing wedges. Clean all surfaces as required. IMPORTANT: Install new fabric washers during Step 6. Do not reuse old fabric washers. 6.

7.


Position wedges [12] at top of die [14] and install wedge bolts [13]. Coat threads of wedge bolts [13] with lubricant. Secure bolts [13] with f abric w ashers [01], steel washers [02] and nuts [03, 04]. Tighten all nuts [03, 04] e venly using a 1-inch dri ve impact wrench or torque wrench with 2-1/4" sock et (2044 crusher) or 2-3/4" sock et (3042 crusher). Torque all fasteners to the value specified in Appendix A.


Removal NOTE: See Figure 3-9 for exploded view and numbered callouts [01 - 15]. Also refer to other figures as indicated. 1.

Remove nuts [03, 04], washers [01, 02], wedge bolts [13] and wedges [12].

2.

Remove nuts [07, 08], washers [05, 06] and guard bolts [11].

TOOLS AND SUPPLIES REQUIRED

3.

Lift guard [10] from swing jaw 09].

• Suitable rigging and hoisting equipment

Installation

• 1-inch dri ve impact wrench or torque wrench with the following socket for swing jaw die fasteners: 2-1/4" socket (2044 crusher) 2-3/4" socket (3042 crusher)

NOTE: See Figure 3-9 for exploded view and numbered callouts [01 - 15]. Also refer to other figures as indicated.

Swing Jaw Guard Replacement

3

• 1-inch dri ve impact wrench or torque wrench with the following socket for swing jaw guard fasteners: ?-?/?" socket (2044 crusher) ?-?/?" socket (3042 crusher) • Appropriate equipment and materials for cleaning mating surfaces of swing jaw, die and guard

7F

• Lubricant (refer to specifications


IMPORTANT: Mating surfaces must make solid contact. Always remove any dirt, nicks or burrs before installing guard. Clean all surfaces as required. 1.

IMPORTANT: Install new fabric washers during Steps 2 and 4. Do not reuse old fabric washers. 2.


! WARNING!!! DANGER Lock out power source and tag controls for crusher drive motor, feed and discharge equipment before performing any maintenance or repairs. Always secure drive pulley if it is necessary to enter the crushing chamber. Warn all personnel that crusher is being serviced. Also, read and adhere to the instructions at the be ginning of this chapter entitled “Preliminary Instructions and Precautions” and “General Shutdo wn Procedure (Before Working on Crusher)” before performing any maintenance or repairs.

3–12

Lift guard [10] into position aligning mounting holes of guard [10] and swing jaw [09].

3. 4.

5.

Coat threads of guard bolts [11] with lubricant. Install guard bolts [11], fabric washers [05], steel washers [06] and nuts [07, 08] hand tight. Position wedges [12] at top of die [14]. Coat threads of wedge bolts [13] with lubricant. Install wedge bolts [13], f abric w ashers [01], steel w ashers [02] and nuts [03, 04]. Torque all nuts [03, 04, 07, 08] to the v alue specified i Appendix A.

Cheek Plate Replacement TOOLS AND SUPPLIES REQUIRED • Suitable rigging and hoisting equipment • 1-inch drive impact wrench or torque wrench with 1-7/8" socket for cheek plate fasteners • Appropriate equipment and materials for cleaning mating surfaces of crusher and cheek plates • Lubricant (refer to Appendix D for lubricant specifications 03/99



01

02

03 04

2044

01

3 03

02

7F

06 05 04

3042

01 - Upper cheek plate 02 - Lower cheek plate 03 - Bolt 04 - Washer 05 - Hex nut 06 - Jam nut

Figure 3-12. Cheek Plate Exploded View 03/99

3–13



Installation



NOTE: See Figure 3-12 for exploded view and numbered callouts [01 - 06]. Also refer to other figures as indicated. IMPORTANT: Mating surfaces must make solid contact. Always remove any dirt, nicks or burrs before replacing or exchanging cheek plates. Clean all surfaces as required. 1.

Place new (or exchanged) check plate [01, 02] on hook or strap. Align cheek plate [01, 02] with bolt holes on crusher frame. Refer to Figure 3-13.

2.

2044 CRUSHER: Coat threads of bolt [03] with lubricant. Slide bolt [03] with w asher [04] through crusher frame and loosely install into lo wer open hole of cheek plate [01, 02]. Refer to Figure 3-14. 3042 CR USHER: Slide bolt [03] through lo wer open hole of cheek plate [01, 02] and crusher frame. Coat threads of bolt [03] with lubricant. Loosely install washer [04] and nut [05] on bolt end. Refer to Figure 314.

Removal

3


2044 CRUSHER: Completely remove bolt [03] and washer [04] from one bolt hole at top of cheek plate. Refer to Figure 3-14. 3042 CRUSHER: Completely remove bolt [03], washer [04] and nuts [05, 06] from one bolt hole at top of cheek plate. (For upper cheek plate, remove both bolts [03], washers [04] and nuts [05, 06].) Refer to Figure 3-14.

7F 2.

SLING

FASTENER (3042 Shown)

2044 CRUSHER: Loosen (but do not remove) the lower bolt [03] to provide room for lifting hook or strap. Insert lifting hook or strap through open bolt hole. Refer to Figure 3-13. 3044 CRUSHER: Loosen (but do not remove) nuts [05, 06] on other bolts [03] to pro vide room for lifting hook or strap. Insert lifting hook or strap through open bolt hole(s). Refer to Figure 3-13.

3.2044 CRUSHER: Support cheek plate [01, 02] with hoist and remove the remaining bolt [03] and w asher [04]. Lift cheek plate [01, 02] from crusher. 3042 CRUSHER: Support cheek plate [01, 02] with hoist and remove all remaining bolts [03], nuts [05, 06], and w ashers [04]. Lift cheek plate [01, 02] from crusher.

3–14

UPPER CHEEK PLATE

LOWER CHEEK PLATE

Figure 3-13. Installing Cheek Plate

03/99



3. CHEEK PLATE

3042 CRUSHER SIDE WALL WASHER

3042 CR USHER: Remo ve lifting hook or strap and install remaining bolt(s) [03]. Coat threads of bolt(s) [03] with lubricant. Secure bolt(s) [03] with w asher [04] and nuts [05, 06]. Install remaining nut [06] on lower bolt.

JAM NUT

HEX NUT

4.

BOLT CHEEK PLATE

2044 CRUSHER: Coat threads of remaining bolt [03] with lubricant. Remove lifting hook or strap and install remaining bolt [03] and washer [04].

2044 CRUSHER: Tighten all bolts [03] e venly using a 1-inch drive impact wrench or torque wrench with 1-7/8" socket. Torque all f asteners to the v alue specified i Appendix A. 3042 CRUSHER: Tighten all nuts [05, 06] evenly using a 1-inch dri ve impact wrench or torque wrench with 1-7/8" socket. Torque all fasteners to the value specifie in Appendix A.

CRUSHER SIDE WALL WASHER BOLT

2044

3 Figure 3-14. Installing Cheek Plate Fasteners

7F

03/99

3–15



Flywheel Pulley/Sheave TOOLS AND SUPPLIES REQUIRED • Suitable rigging and hoisting equipment • Torque wrench • Standard socket or open end wrenches • Hammer • Wedges (2) • Appropriate equipment and materials for cleaning eccentric shaft ends and flywheel pull y and/or flywhee sheave • Lubricant (refer to specifications


FLYWHEEL PULLEY 18 15

30

20

21

19

3 17 31

16

7F

FLYWHEEL SHEAVE

34 35 15

15 - Bolt 16 - Jam nut 19 17 - Hex nut 20 18 - Flywheel pulley 21 19 - Washer 20 - Washer 21 - Capscrew 30 - Eccentric shaft 17 31 - Key 16 34 - Flywheel sheave (2044) 35 - Flywheel sheave (3042) Shaft component parts not shown are listed in Figures 4-1 & 5-1.

30

31

Figure 3-15. Flywheel Pulley and Sheave Exploded View 3–16

03/99



Installation

! WARNING!!! DANGER Lock out power source and tag controls for crusher drive motor, feed and discharge equipment before performing any maintenance or repairs. Always secure drive pulley if it is necessary to enter the crushing chamber. Warn all personnel that crusher is being serviced. Also, read and adhere to the instructions at the be ginning of this chapter entitled “Preliminary Instructions and Precautions” and “General Shutdo wn Procedure (Before Working on Crusher)” before performing an y maintenance or repairs.


NOTE: See Figure 3-15 for exploded view and numbered callouts [15 - 21, 30, 31, 34, 35]. Also refer to other figures as indicated. 1.

Lubricate bore of flywheel pull y [18] or flywheel sheave [34, 35].

2.

Install a wedge into the split at both sides of the bore. This will open the bore slightly for easier installation.

3.

Align keyway of flywheel pull y [18] and/or flywhee sheave [34, 35] with keyway of eccentric shaft [30] and install on eccentric shaft [30].

4.

Install key [31]. Drive key [31] into place with hammer.

5.

Remove wedge from split at both sides of the bore.

6.

Install hub bolts [15] and secure with he x nut [17] and jam nut [16]. Torque nuts [16, 17] to the value specifie in Appendix A.

7.

Install shaft w asher [19], w ashers [20] and bolts [21]. Torque bolts to the value specified in Appendix A.

Tension Rod

Removal

TOOLS AND SUPPLIES REQUIRED

NOTE: See Figure 3-15 for exploded view and numbered callouts [15 - 21, 30, 31, 35]. Also refer to other figures as indicated.

• Standard socket or open end wrenches

1.

• Tape measure

2.

3.

Remove bolts [21], washers [20], and shaft washers [19] from appropriate end(s) of eccentric shaft [30]. Flywheel Pulle y Remo val: Remo ve nuts [16, 17] and hub bolts [15] from flywheel pull y hub [18]. Remo ve flywheel pull y [18] and k ey [31] from eccentric shaft [30].

• Pliers

3

• Appropriate equipment and materials for cleaning tension rod components • Grease (refer to Appendix D for lubricant specifications

7F

Flywheel Sheave Removal: Remove nuts [16, 17] and hub bolts [15] from flywheel she ve hub [34, 35]. Remove flywheel she ve [34, 35] and k ey [31] from eccentric shaft [30]. NOTE: If flywheel and/or flywheel sheave cannot be removed by hand, use a wedge to expand the split hub.

03/99

3–17



01 02

03

04

05

06

07

3

08

09

7F

01 - Nuts 02 - Spring washer 03 - Spring 04 - Sleeve 05 - Bracket 06 - Washer 07 - Bolt 08 - Tension rod 09 - Cotter pin 10 - Tension rod pin

10

Figure 3-16. Tension Rod Exploded View

3–18

03/99



1.

Remove nuts [01], spring washer [02] and spring [03] from tension rod [08].

2.

Remove tension rod sleeve [04].

! WARNING!!! DANGER Lock out power source and tag controls for crusher drive motor, feed and discharge equipment before performing any maintenance or repairs. Always secure drive pulley if it is necessary to enter the crushing chamber. Warn all personnel that crusher is being serviced. Also, read and adhere to the instructions at the be ginning of this chapter entitled “Preliminary Instructions and Precautions” and “General Shutdo wn Procedure (Before Working on Crusher)” before performing an y maintenance or repairs.


Removal NOTE: See Figure 3-16 for exploded view and numbered callouts [01 - 10]. Also refer to other figures as indicated.

NOTE: If sleeve bushings are worn, refer to the parts manual for replacement parts. 3.

Remove cotter pins [09], tension rod pin [10] and tension rod [08].

Installation NOTE: See Figure 3-16 for exploded view and numbered callouts [01 - 10]. Also refer to other figures as indicated. NOTE: Model 2044 has one tension rod. Model 3042 has two tension rods. 1.

Slide tension rod [08] through tension spring bracket [05] (bolted to bottom of toggle beam).

IMPORTANT: A grease fitting is located at the eye end of the tension rod. This fitting provides lubrication to the tension rod bushing and should be facing downward so that it will be easily accessible. 2.

Position tension rod [08] between brack et located at bottom of swing ja w. Install tension rod pin [10] through holes of brack et and tension rod [08]. Secure pin [10] with cotter pins [09]. Refer to Figure 3-17.

3

! CAUTION DANGER !!! Never stand directly behind tension rod spring when removing nuts. Spring could accidentally release, causing serious Injury.

03/99

7F

3–19


SWING JAW


TENSION ROD PIN TENSION ROD COTTER PIN

COTTER PIN BRACKET

GREASE FITTING

Figure 3-17. Install Tension Rod

3

IMPORTANT: A grease fitting is located on the side of the tension rod sleeve. This fitting provides lubrication to the tension rod. For Model 3042, this fitting should be facing inward so that it will be easily accessible. For Model 2044, this fitting may face either direction. 3.

7F

Slide tension rod slee ve [04] o ver threaded end of tension rod [08]. Position the tw o cast lugs between the mounting blocks of mounting brack et [05]. Refer to Figure 3-18.

3–20

03/99



TENSION ROD SLEEVE MOUNTING BRACKET

SPRING SPRING WASHER

MOUNTING BLOCKS

NUT CAST LUG TENSION ROD

3

7F Figure 3-18. Install Tension Rod Spring Components 4.

Install spring [03] and spring w asher [02] on tension rod end [08].

5.

Apply a light coating of grease to threads of tension rod [08]. Thread hex nut [01] onto tension rod [08] until it contacts the spring washer [02].

IMPORTANT: For Model 3042 (dual tension rod models), the exact amount of pressure must be applied to both tension rods.

! CAUTION DANGER !!! Never stand directly behind tension rod spring when tightening nuts. Spring could accidentally release, causing serious injury. 6.

Measure the distance between the tw o spring w ashers [02, 04]. Refer to Figure 3- 19. Tighten nut [01] until spring [03] is compressed one (1) full inch.

IMPORTANT: Never fully compress the spring. Springs must always have space in order to be effective.

03/99

3–21



MEASURE DISTANCE BETWEEN WASHERS

Figure 3-19. Measure Distance Between Washers 7.

Install the locknut [01] and lock it against the first nut [01]. Refer to Figure 3-20

3

7F TENSION ROD LOCK NUT

HEX NUT

SPRING SPRING WASHER

Figure 3-20. Install Locknut 8.

Apply grease to fittings on tension rod [08] and tension rod sle ve [04]. Refer to Appendix D for grease specifications

IMPORTANT: If the crusher “knocks” when operating, tighten tension rod nuts [01] to the point where the “knocking” stops. Do not overtighten. For Model 3042 (dual tension rod models), tighten nuts [01] on both tension rods evenly.

3–22

03/99



Toggle and Toggle Seat Replacement TOOLS AND SUPPLIES REQUIRED • Suitable rigging and hoisting equipment • Standard socket or open end wrenches • Optional auxiliary cylinder or hand winch • Cutting torch (toggle seat replacement) • Metal rod, hooked at end (see Figure 3-25) • Appropriate equipment and materials for cleaning mating surfaces of toggle and toggle seats

! WARNING!!! DANGER Lock out power source and tag controls for crusher drive motor, feed and discharge equipment before performing any maintenance or repairs. Always secure drive pulley if it is necessary to enter the

crushing chamber. Warn all personnel that crusher is being serviced. Also, read and adhere to the instructions at the be ginning of this chapter entitled “Preliminary Instructions and Precautions” and “General Shutdo wn Procedure (Before Working on Crusher)” before performing an y maintenance or repairs.


Toggle Removal NOTE: See Figure 3-21 for exploded view and numbered callouts [01 - 08]. Also refer to other figures as indicated.

01

3 02 03

7F 04

02 08

05 07

01 - Toggle beam 02 - Clamp 03 - Toggle seat (toggle beam) 04 - Toggle 05 - Toggle seat (swing jaw) 06 - Pin 07 - Bolt 08 - Washer

06

Figure 3-21. Toggle Assembly Exploded View 03/99

3–23



5.

Place four w ooden timbers inside rear of main frame. The wooden timbers will hold the lo wer portion of the swing ja w assembly in place when swing ja w is released during Step 6.

6.

Slowly release swing ja w assembly, allowing it to rest against wooden timbers.

7.

Check can vas protector (located abo ve toggle seat on swing jaw) for wear or damage; repair if necessary.

! WARNING!!! DANGER DO NOT enter the crusher at any time when replacing the toggle. Perform all work from outside the crusher. Failure to follow this precaution may result in serious personal injury or DEATH! 1.

Suspend hoist between cross member and swing jaw as illustrated in Figure 3-23.

2.

Lower sling through center ribs of toggle [04] and secure toggle to sling as illustrated in Figure 3-23.

3.

With the toggle [04] adequately supported, remo ve tension rod(s) as instructed in the section “T ension Rod, Removal” in this chapter.

Toggle Seat Replacement (Toggle Beam) NOTE: See Figure 3-21 for exploded view and numbered callouts [01 - 08]. Also refer to other figures as indicated.

! WARNING!!! DANGER ! CAUTION DANGER !!! Use extreme caution when removing the toggle from the crusher. Personal injury can occur to people under the crusher if the toggle is accidentally dislodged from hoist and allowed to fall. 4.

With the toggle [04] adequately supported, mo ve swing jaw forward as follows: a.

3 b.

7F

If crusher is equipped with the optional auxiliary cylinder (Model 3042 only), install the c ylinder between the swing jaw and rear of crusher as illustrated in Figure 3-24. Attach the auxiliary c ylinder to the h ydraulic hand pump. Use the pump to extend the c ylinder and mo ve the swing ja w for ward. If crusher is not equipped with an auxiliary c ylinder, f asten a cable or other de vice to bottom of swing jaw pulling it forward to make room for toggle [04] remo val. Lo wer toggle [04] through bottom of crusher.

Toggle seat replacement is most safely performed with the swing jaw removed from the crusher. Failure to follow this precaution may result in serious personal injury or DEATH! 1.

Remove bolts [07], washers [08] and clamps [02].

2.

Using a cutting torch, cut the toggle seat [03] in half (along the full length). Remo ve both halv es of toggle seat [03] from toggle beam [01].

3.

Clean and check new toggle seat [03] and toggle beam [01] for nicks and burrs and repair as necessary.

4.

Install new toggle seat [03] into toggle beam [01]. Secure with bolts [07], w ashers [08] and clamps [02]. Torque bolts [07] to the value specified in Appendix A.

Toggle Seat Replacement (Swing Jaw) NOTE: See Figure 3-21 for exploded view and numbered callouts [01 - 08]. Also refer to other figures as indicated.

! WARNING!!! DANGER

THRUST BRACKET SWING JAW

AUXILIARY CYLINDER

Figure 3-22. Optional Auxiliary Cylinder (Model 3042 Only) 3–24

Toggle seat replacement is most safely performed with the swing jaw removed from the crusher. Failure to follow this precaution may result in serious personal injury or DEATH! 1.

Using a cutting torch, cut the toggle seat [05] in half (along the full length). Remove both halves of toggle seat [05] from the swing jaw.

2.

Remove pin [06] from swing jaw.

3.

Clean and check new toggle seat [05], pin [06] and swing jaw for nicks and burrs and repair as necessary.

4.

Install new pin [06] into new toggle seat [05] making sure it is completely seated. 03/99


5.

Install new toggle seat [05] into swing jaw aligning pin [06] with hole in swing jaw.

6.

Stake toggle seat at six (6) locations: one (1) at each end and in the center at both top and bottom.


2.

Position the toggle [04] underneath the swing jaw.

3.

Suspend hoist between cross member and swing ja w as illustrated in Figure 3-23.

IMPORTANT: Refer to Appendix C for toggle weights.

Toggle Installation

4.

NOTE: See Figure 3-21 for exploded view and numbered callouts [01 - 08]. Also refer to other figures as indicated.

Lower sling through center ribs of toggle [04] and secure toggle to sling. Refer to Figure 3-23.

5.

Position toggle as follows:

NOTE: The swing jaw must be moved forward before the toggle can be installed.

! WARNING!!! DANGER DO NOT enter the crusher at any time when replacing the toggle. Perform all work from outside the crusher. Failure to follow this precaution may result in serious personal injury or DEATH! 1.

Move swing jaw forward as follows: a.

b.

If the crusher is equipped with the optional auxiliary cylinder (Model 3042 only), install the c ylinder between the swing ja w and rear of crusher as illustrated in Figure 3-22. Attach the auxiliary c ylinder to the hydraulic hand pump. Use the pump to extend the c ylinder and mo ve the swing ja w for ward. If crusher is not equipped with an auxiliary c ylinder, f asten a cable or other de vice to bottom of swing jaw pulling it forward to make room for toggle [04].

a.

Slowly raise toggle [04] into position fitting fir edge of toggle into toggle seat [03] located in toggle beam [01]. Refer to Figure 3-23.

b.

Continue lifting toggle [04] so that it pivots upward until second edge is aligned with toggle seat [05] located in swing jaw. Refer to Figure 3-24.

IMPORTANT: The canvas protecting apron must be lifted slightly so that when the toggle is seated in the toggle seat of the swing jaw, it forms a “U” with the top edge of the toggle. c.

Slowly release swing ja w allo wing it to mo ve toward back of crusher. Make sure that toggle [04] is aligned with seat [05]. Lift can vas protecting apron to pre vent it from being wedged between toggle [04] and seat [05]. Refer to Figure 3-25.

IMPORTANT: The toggle must be positioned between the two toggle seat clamps (bolted to toggle beam). The toggle must be fully seated in both toggle seats.

3

7F

03/99

3–25



3 SWING JAW

SLING

7F

SWING JAW TOGGLE SEAT

TOGGLE BEAM

TOGGLE TOGGLE SEAT

Figure 3-23. Insert Toggle into Toggle Seat of Toggle Beam 3–26

03/99



3 SLING SWING JAW

7F

TOGGLE BEAM

TOGGLE

TOGGLE SEAT

SWING JAW TOGGLE SEAT

Figure 3-24. Insert Toggle into Toggle Seat of Swing Jaw

03/99

3–27



USE A “HOOKED” METAL ROD TO LIFT CANVAS APRON SLING TOGGLE CANVAS PROTECTING APRON

3 Figure 3-25. Position Canvas Protector on Top of Toggle 6.

7F

Install and adjust tension rod(s) as instructed in the section “Tension Rod, Installation” in this chapter.

3–28

03/99



Thrust Shaft (Model 3042 Only) TOOLS AND SUPPLIES REQUIRED • Standard open end wrenches • Standard hex wrenches • Appropriate equipment and materials for cleaning mating surfaces of crusher and thrust shaft components • Lubricant (refer to specifications


• Feeler gauge

3 09 10 11

13

7F

12 10

01 02

09

08 07

03 04 06

05

01 - Thrust shaft end (bronze) 02 - Thrust shaft 03 - Socket head capscrews 04 - Thrust washer 05 - Washer 06 - Bolt 07 - Bolt 08 - Nut 09 - Connector 10 - Adapter 11 - Hose 12 - Strap 13 - Bolt 14 - Fitting

Figure 3-26. Thrust Shaft Exploded View 03/99

3–29



Removal



Remove grease lines [11] at fittings [09 and 10] at both sides of the crusher.

2.

Loosen adjustment bolt [07] and locknut [08] from thrust washer [04]. Refer to Figure 3-27.

3.

Remove bolts [06] and washers [05] from thrust washer [04]. Remove thrust washer [04].


3

7F

3–30

03/99



CRUSHER SIDE WALL WASHER BOLT THRUST WASHER BRONZE THRUST SHAFT END

LOCK NUT BOLT

THRUST SHAFT

3

Figure 3-27. Thrust Washer Components 4.

Slide thrust shaft [02] from thrust shaft holes on each side of crusher.

Bronze Thrust Shaft End Replacement NOTE: See Figure 3-26 for exploded view and numbered callouts [01 - 14]. Also refer to other figures as indicated. 1.

Remove socket head capscrews [03] from thrust shaft [02] and remove bronze thrust shaft end [01].

2.

Clean and check thrush shaft components for nicks and burrs and repair as necessary.

3.

Install a ne w bronze thrust shaft end [01] onto thrust shaft [02] using the sock et head capscre ws [03] pre viously remo ved. Tighten capscre ws [03] to the v alue specified in Appendix A.

03/99

7F

Installation NOTE: See Figure 3-26 for exploded view and numbered callouts [01 - 14]. Also refer to other figures as indicated. IMPORTANT: Inspect bronze shaft end for wear. To r e p l a c e , r e fe r t o “ B r o n z e T h r u s t S h a f t E n d Replacement” instructions in this section. 1.

Clean and check thrush shaft components for nicks and burrs and repair as necessary. Also check mating surfaces on crusher frame for nicks and burrs and repair as necessary.

2.

Center swing jaw assembly so that clearance is equal on both sides between crusher frame bearing mountings and swing jaw retaining rings.

3.

Apply a light coat of lubricate to the thrust shaft hole on each side of crusher . Refer to Appendix D for grease specifications. Slide thrust shafts [02] (bronze end firs 3–31


into thrust shaft holes on each side of crusher . Observe match marks (stamped on parts) to be sure that parts are installed on the correct side. Refer to Figure 3-27.


Hydraulic Adjusting Cylinder Replacement TOOLS AND SUPPLIES REQUIRED

4.

Secure thrust washers [04] with bolts [06] and w ashers [05]. Make sure lubrication hole faces rear of crusher.

• Standard open end wrenches

5.

Install grease fitting parts [09 through 14]

6.

Install adjustment bolt [07] and locknut [08] into thrust washer [04], if remo ved. Turn the adjustment bolt [07] inward until a 0.025" clearance is achieved between the thrust shaft and thrust brack et. Use a feeler g auge for checking clearance. F ollow this procedure for both sides. The combined clearance for both sides should be 0.050". Tighten locknut [08].

• Appropriate equipment and materials for cleaning mating surfaces of crusher and h ydraulic adjusting c ylinder components

7.

• Standard hex wrenches

• Screwdriver • Pliers • Lubricant (refer to specifications


Lubricate thrust shafts at grease fitting [14]. Refer t Appendix D for grease specifications

3

7F

3–32

03/99



01

01 - Cylinder 02 - Clamp 03 - Boot 04 - Pin 05 - Clip pin 06 - Fitting 07 - Hydraulic Hose

3

Figure 3-28. Hydraulic Adjusting Cylinder

! WARNING!!! DANGER

7F

! WARNING!!! DANGER

Lock out power source and tag controls for crusher drive motor, feed and discharge equipment before performing any maintenance or repairs. Always secure drive pulley if it is necessary to enter the crushing chamber. Warn all personnel that crusher is being serviced.

A lw ay s u s e s u i t a b l e r i g g i n g a n d h o i s t i n g equipment to stabilize and lift heavy objects. Lifting heavy components with inadequate hoisting apparatus can damage machinery and result in serious personnel injury or death. Refer to Appendix C for component weights.

Also, read and adhere to the instructions at the be ginning of this chapter entitled “Preliminary Instructions and Precautions” and “General Shutdo wn Procedure (Before Working on Crusher)” before performing any maintenance or repairs.

Removal

03/99


Disconnect hydraulic lines [07] from cylinder. Cap lines to prevent contaminants from entering the hydraulic system.

2.

Remove clip pins [05] from pins [04]. 3–33


3.

Remove front and rear pins [04] from c ylinder [01] and remove cylinder [01].

• Appropriate equipment and materials for cleaning mating surfaces of crusher, bearing mountings and bearing caps

4.

Remove clamps [02] and boot [03] from cylinder [01].

• Lubricant (refer to specifications

Inspection 1.

Inspect cylinder rods for scoring and pitting; if damaged, replace cylinders [01].

2.

Inspect cylinder seals for leakage. Check for h ydraulic fluid at bottom sur ace where c ylinder is mounted to crusher. If seals are leaking, replace as instructed in the manufacturer's repair instructions.

3.

Inspect pins [04] for wear or damage; replace if damaged.

4.

Inspect boot [03] for damage; replace if damaged.


3


Install boot [03] onto cylinder [01] and secure with clamps [02].

2.

Align cylinder [01] mounting holes with crusher mounting holes. Install front and rear pins [04] into mounting holes.

3.

Install clip pins [05] into each end of pins [04].

4.

Connect h ydraulic lines [07] to c ylinder. Activate hydraulic hand pump and check for leaks; repair as necessary.



Removal 1.

On oil lubricated crushers, remove oil feed and return hoses from swing jaw. Cap hoses to prevent contaminants from entering the oil system.

2.

Mark bearing caps for proper reassembly . Remove jam nuts and hex nuts from bearing cap studs. Refer to Figure 3-29.

3.

Thread eyebolt into each bearing cap and remo ve bearing cap from main frame bearing cap studs.

Swing Jaw

7F

TOOLS AND SUPPLIES REQUIRED • Suitable rigging and hoisting equipment • 1-inch drive impact wrench or torque wrench with ?-?/?" socket for bearing cap fasteners


• Eyebolts (2)

3–34

03/99



JAM NUT

HEX NUT STUD

BEARING CAP STUD

KEY (Welded in Keyway)

3

7F

Figure 3-29. Removing Bearing Caps 4.

Secure swing jaw to hoist with wire rope sling as illustrated in Figure 3-30.

5.

Attach a guide rope to the lo wer end of the swing ja w. Use the rope to help control swing ja w movement during Steps 6 and 7. Refer to Figure 3-30.

03/99

IMPORTANT: See Appendix C for swing jaw weights. 6.

Lift entire swing jaw assembly from crusher.

3–35



NOTE: Arrange timbers so that lower portion of swing jaw will move towards front of crushing chamber when jaw is lowered into main frame. LIFTING CABLE

IMPORTANT: See Appendix C for swing jaw weights. 2.

Support the swing jaw assembly in a wire rope sling as illustrated in Figure 3-32. Install blocking as shown.

LIFTING CABLE

BLOCKING THRUST BRACKETS (Model 3042 Only)

BEARING MOUNTING BEARING HOUSING

ATTACH GUIDE ROPE HERE

3

THRUST BRACKETS (Model 3042 Only)

Figure 3-30. Hoisting Swing Jaw 7.

Lower swing jaw onto blocking with jaw die facing up.

7F

SWING JAW

ATTACH GUIDE ROPE HERE

Figure 3-32. Swing Jaw in Sling

WOOD SUPPORTS

Figure 3-31. Rest Swing Jaw on Blocking

Installation If the swing jaw was shipped separately from the main frame, perform the following steps: 1.

Place four hardwood timbers inside the main frame toward the rear of crusher.

3–36

3.

Attach a guide rope to the lo wer end of the swing ja w. Use the rope to control ja w movement during Steps 4 through 7.

4.

Hoist swing jaw assembly over the main frame, with the front of swing jaw facing stationary jaw die. Lower jaw until bearing mountings are suspended over openings in crusher frame. Refer to Figure 3-33. NOTE: The main frame bearing mountings are keyed in position with steel keys. Key #1 prevents bearing mountings from rotating in the main frame. Key #2 restricts the lateral movement of the swing jaw. Key #1 is installed during Step 7. Key #2 is welded to crusher frame. 03/99



6.

Position swing ja w so that k eys (#2) on frame are in alignment with the corresponding k eyways on bearing mountings. NOTE: As jaw is lowered during Step 7, have assistants install keys (#1). Rotate bearing mountings and reposition jaw as required so that all keyways and keys are precisely aligned. Refer to Figure 3-35.

Figure 3-33. Align Key #1 Keyways

3 Figure 3-35. Align Keys with Bearing Mountings 7.

Slowly lo wer swing ja w until bearing mountings are seated in crusher frame openings. Model 3042 Only: As jaw is lowered, check that thrust brackets do not contact thrust shaft housings (in crusher frame).

8.

Install an eyebolt into each bearing cap. Install bearing caps on studs.

IMPORTANT: Bearing caps must be replaced on the same side and in the exact same position from which they were removed from shipment. Observe match marks on bearing caps and crusher frame. 9. Figure 3-34. Key and Keyway Locations 5.

Rotate bearing mountings until k eyways for k eys (#1) are in alignment with the corresponding k eyways on crusher frame openings. Refer to Figure 3-33.

03/99

Secure bearing caps with he x and jam nuts. Torque to the value specified in Appendix A.

10. Using a feeler g auge, check to mak e sure that bearing caps are seated tightly ag ainst crusher frame. Replace eyebolts with a bolt to k eep bearing cap lifting holes free of dirt.

3–37

7F



3

7F

3–38

03/99


APPENDIX

APPENDIX APPENDIX A - TORQUE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 APPENDIX B - CONVERSION TALBES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1 APPENDIX C - CRUSHER WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1 APPENDIX D - LUBRICANT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1

Appendix

APPENDIX E - EXPENDABLE SUPPLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1

7F

03/99

Appendix–1


Appendix

APPENDIX

Appendix–2

03/99

03/99

-

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

20 28 18 24 16 24 14 20 13 20 12 18 11 18 10 16 9 14 8 12 7 12 7 12 6 12 6 12 5 4-1/2

UNC UNF UNC UNF UNC UNF UNC UNF UNC UNF UNC UNF UNC UNF UNC UNF UNC UNF UNC UNF UNC UNF UNC UNF UNC UNF UNC UNF UNC UNC

Thread Series 5 6 11 13 20 23 32 36 49 55 70 78 92 105 165 180 200 225 300 340 430 480 605 670 795 905 1050 1186 1660 2500

4 5 8 10 15 17 25 27 38 42 54 60 71 81 125 140 155 170 230 260 330 370 465 515 610 670 810 915 1280 1920

Torque** Dry Lube

*Clamp loads are shown in 1000 pounds.

1.31 1.50 2.16 2.39 3.19 3.61 4.37 4.89 5.83 6.59 7.07 7.90 8.79 9.95 13.20 14.52 13.82 15.25 18.15 20.35 22.85 25.60 29.00 32.10 34.60 39.40 42.20 47.30 56.80 75.00

Clamp* Load #

R898 Class 4.6

ISO Designation

Dia.

SAE J429

2

ASTM/SAE Spec.

Grade

Identification Mark

8 10 17 19 31 35 49 55 75 85 110 120 150 170 270 295 395 435 590 660 795 890 1120 1240 1470 1670 1950 2190 3075 4620

2.02 2.31 3.33 3.69 4.93 5.58 6.76 7.55 9.03 10.20 11.58 12.93 14.40 16.30 21.31 23.75 27.00 29.80 35.40 39.70 42.30 47.50 53.80 59.59 64.20 73.00 78.00 87.70 105.50 138.50

10 12 21 24 38 43 61 68 93 105 135 150 185 210 330 365 530 585 795 890 1125 1260 1590 1765 2085 2370 2765 3110 4370 6550

8 9 16 18 29 33 47 52 72 80 105 115 145 160 250 280 405 450 610 685 865 970 1225 1355 1600 1830 2130 2400 3360 5050

Torque** Dry Lube 2.49 2.85 4.11 4.56 6.08 6.90 8.35 9.33 11.15 12.58 14.30 15.95 17.75 20.10 26.30 29.30 36.30 40.00 47.70 53.50 60.00 67.30 76.30 84.40 91.00 103.50 110.80 124.50 149.50 196.70

Clamp* Load #

**All torque values are given in foot-pounds.

6 7 13 15 24 27 38 42 58 65 84 93 115 130 205 230 305 335 455 510 610 685 860 955 1130 1290 1500 1690 2370 3550

Clamp* Load #

———

R898 Class 8.8 Torque** Dry Lube

SAE J429

7

ASTM A449

5

8

12 14 24 27 44 49 70 78 105 120 155 170 210 240 375 420 605 670 905 1030 1285 1440 1820 2010 2380 2710 3160 3555 4980 7480

9 11 18 21 34 38 54 60 82 90 120 132 165 185 290 320 455 515 695 785 990 1110 1400 1550 1830 2085 2430 2730 3810 5760

Torque** Dry Lube

2.86 3.26 4.70 5.21 6.95 7.88 9.55 10.68 12.75 14.38 16.35 18.25 20.30 23.00 30.00 33.50 41.50 45.80 54.50 61.20 68.70 77.00 87.20 96.50 104.00 118.30 126.50 142.20 171.00 225.00

Clamp* Load #

R898 Class 10.9

ASTM A354

RECOMMENDED MAXIMUM TORQUE VALIUES ±5%


Appendix A - Torque Table

7F

A–1

Appendix A - Torque Table


7F

A–2

03/99


Appendix B- Conversion Tables

Appendix B- Conversion Tables LINEAR MEASURE

SQUARE MEASURE

To Convert

Info

Multiply by

To Convert

Info

Multiply by

Inches Feet Centimeters Millimeters Meters Meters

Centimeters Meters Inches Inches lnches Feet

2.54 0.3048 0.3937 .0394 39.37 3.2808

Sq. Inches Sq. Miles Sq. Centimeters Sq. Meters Sq. Meters

Sq. Centimeters Sq. Kilometers Sq. Inches Sq. Inches Sq. Feet

6.452 2.59 0.15499 1549.9 10.763

CUBIC MEASURE

WEIGHT

To Convert

Info

Multiply by

To Convert

Info

Multiply by

Cu. Inches Cu. Feet Cu. Centimeters Cu. Meters Cu. Meters

Cu. Centimeters Cu. Meters Cu. Inches Cu. inches Cu. Feet

16.387 0.0283 0.06102 610233779.0 35.314

Kilograms Pounds Pounds/Sq. Inch Pounds/Sq. Foot

Pounds Kilograms Kilograms/Sq. Centimeter Kilograms/Sq. Meter

2.2046 0.4536 0.0703 4.8824

DEGREES FAHRENHEIT TO DEGREES CENTIGRADE

03/99

F

C

F

C

F

C

F

C

F

C

-30 -28 -26 -24 -22 -20 -18 -16 -14 -12 -10 -8 -6 -4 -2 0 +1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

-34.44 -33.33 -32.22 -31.11 -30.00 -28.89 -27.78 -26.67 -25.56 -24.44 -23.33 -22.22 -21.11 -20.00 -18.89 -17.78 -17.22 -16.67 -16.11 -15.56 -15.00 -14.44 -13.89 -13.33 -12.78 -12.22 -11.67 -11.11 -10.56 -10.00 -9.44 -8.89 -8.33 -7.78 -7.22

+20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54

-6.67 -6.11 -5.56 -5.00 -4.44 -3.89 -3.33 -2.78 -2.22 -1.67 -1.11 -0.56 0.00 +0.56 1.11 1.67 2.22 2.78 3.33 3.89 4.44 5.00 5.56 6.11 6.67 7.22 7.78 8.33 8.89 9.44 10.00 10.56 11.11 11.67 12.22

+55 56 57 58 59 60 61 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 89

+12.78 13.33 13.89 14.44 15.00 15.56 16.11 16.67 17.22 17.78 18.33 18.89 19.44 20.00 20.56 21.11 21.67 22.22 22.78 23.33 23.89 24.44 25.00 25.56 26.11 26.67 27.22 27.78 28.33 28.89 29.44 30.00 30.56 31.11 31.67

+90 91 92 93 94 95 96 97 98 99 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220

+32.22 32.78 33.33 33.89 34.44 35.00 35.56 36.11 36.67 37.22 37.78 40.55 43.33 46.11 48.89 51.67 54.44 57.22 60.00 62.78 65.56 68.33 71.11 73.89 76.67 79.44 82.22 85.00 87.78 90.55 93.33 96.11 98.89 101.67 104.44

+225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320 325 330 335 340 345 350 355 360 365 370 375 380 385 390 395

+107.22 110.00 112.78 115.56 118.33 121.11 123.89 126.67 129.44 132.22 135.00 137.78 140.55 143.33 146.11 148.89 151.67 154.44 157.22 160.00 162.78 165.56 168.33 171.11 173.89 176.67 179.44 182.22 185.00 187.78 190.55 193.33 196.11 198.89 201.67 B–1

7F



7F

B–2

03/99


Appendix C - Crusher Weights

Appendix C - Crusher Weights IMPORTANT: Weights listed are approximate weights and may vary by +/- 5 percent. Always use suitable rigging and hoisting equipment to stabilize and lift heavy objects. Contact the Telsmith Parts Department for weights not shown.

Weights — Pounds (Kilograms) Description

2044

3042

7F

03/99

C–1

Appendix C - Crusher Weights


7F

C–2

03/99


Appendix D - Lubricant Specifications

Appendix D - Lubricant Specifications Lubricating Oil Specifications (Oil System) Ambient Temperature Description

Below 40° F (4.5° C)

Above 40° F (4.5° C)

CKC-100

CKC-150

Viscosity AGMA Grade #250.04

3 EP

4 EP

Viscosity SUS @ 100 °F

469 to 575

709 to 871

Viscosity ISO Grade


61 to 67

74 to 82

Viscosity Index

95 Min.

95 Min.

Timken OK Load (lbs)

60 Min.

60 Min.

Extreme Pressure Agent (EP)

Yes

Yes

Rust and Oxidation Agent

Yes

Yes

Anti-Foaming Agent

Yes

Yes

Copper Strip Corrosion Test

Pass

Pass

Oil must not be corrosive to metals generally used in bearings, gears, shaftings, pumps and housings. Oil must have the least possible effect on rubber seals, synthetic seals, packings and hoses. Refer to the Jaw Crusher Operation & Maintenance Manual for detailed crusher lubrication procedures and oil capacities.

Hydraulic Oil Specifications (Hydraulic Adjusting System) Viscosity ISO Grade

68


317


53 to 57

Viscosity Index

95 Min.

API Gravity

29 Min.

Pour Point, °F

-10° to +10°

Flash Point, °F

400° to 425°

Anti-Wear Agent

Yes

Anti-Foaming Agent

Yes

Rust and Oxidation Inhibitor

Yes

7F

NOTE: Refer to the Jaw Crusher Operation and Maintenance Manual for detailed hydraulic system maintenance instructions and oil capacities.

11/97

D–1

Appendix D - Lubricant Specifications


NLGI #2 Grease Specifications NLGI Grade Number 2 Worked Penetration @ 77° (60 Strokes) 285 Worked Penetration @ 77° (100,00 Strokes) 300 Dropping Point °F 365 Copper Corrosion Test, 14 Days Pass Wheel Bearing Test @ 275 °F Pass Timken OK Load (lbs) 50 The above grease must contain an extreme pressure (EP) agent that is not harmful to bronze, brass or lead. For satisfactory lubrication, grease must be absolutely free from any ingredients which could cause corrosion, and from gritty material which could produce wear. Grease should also be uniform in texture, consistency, structure, stability, flow characteristics and lubricating characteristics.

Moly Based EP-2 Grease Specifications (Aluminum Complex with Molybdenum Disulfide) Worked Penetration

265/295

Dropping Point °F

510

Rust Prevention (ASTM D-1743)

Pass

Corrosion Prevention (ASTM D-1261)

Pass

Oxidation Stability (ASTM D-942)

7F

D–2

Oxygen Absorption (PSI) After 100 Hours 200 Hours 300 Hours

<3 <4 <5

Oil Viscosity, SUS @ 100 °F

1000

Extreme Pressure Performance Timken OK Load (lbs) Four Ball Weld Point Wear Scar

65 800 0.51 mm

Type of Soap

Aluminum Complex

Operating Temperature

0 to 450 °F

MoS2 % by Weight

3.0

11/97


Appendix E - Expendable Supplies

Appendix E - Expendable Supplies The following expndable supplies are used throughout the repair procedures of this manual. These supplies or their equivelents are commonly available at most local supply houses or distributors. Always read and understand manufacturer’s directions and safety precautions before using any expendable supplies.

Pipe Sealant Description Loctite® 592 PST® Pipe Sealant, Medium Strength, Slow Cure, Anti-Galling. Part No. 59241.

Manufacturer Loctite Corp

Thread Locking Compound Description Loctite® 242 Threadblocker, Removable

Manufacturer Loctite Corp.

Strength. Part No. 24241.

7F

03/98

E–1



Spray Primer (for use with Loctite 242 thread locking compound) Description Loctite 7471 Locquic® Primer T, Aerosol, Part No. 22477.

Manufacturer Loctite Corp.

Anti-Seize Compound Description

Manufacturer

Bostik Never-Seez®, Regular Grade,

Bostik Corp.

Copper Formula. Meets MIL SPEC A907E.

Silicone Sealant Description

Manufacturer

Red Devil RD ProTM 100% Silicone Sealant. Meets MIL SPEC 46106A.

Red Devil, Inc.

7F

E–2

03/98



Shellac Description

Manufacturer

Bulls Eye Shellac, Clear Sealer & Finish (Conforms to federal spec. TT-S-300A

Wm. Zinsser & Co., Inc.

7F

03/98

E–3



7F

E–4

03/98

Jaw Rock Crusher

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