TP401.pdf

Mod Mo d els el s 38, 38, 44, 44, 52, 52, 57 and an d 68 H/SBS H/SBS Cone on e Cru Crush she ers Wear ear Lin L iner er Repl Replacement acement

ISSUE DATE: 07/09 (Rev 1)

TP401

SAFETY Be sure to read and fully understand the precaut ions shown on the inside front cover of this manual before operating or servicing your Telsmith product. Also refer to Chapter 1 for important safety information.

! WARNING Failur Failur e to follow t he safety safety precautions sho wn below may result in serious personal inju ry or death! •

Never attempt attempt to work on on quarry equipmen equipmentt while it is in operation. operation. Always Always stop the machine machinery ry,, lockout lockout power  and tag controls: 1. Before performing any lubrication, maintenance, adjustment, 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 clear of feed and and discharge discharge areas areas and and other places places where where falling rock rock is present. present. Keep Keep away from loading 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-toed shoes are mandatory when working near  machinery. machinery. Wear and use additional personal protective equipment as required.

•

Stay clear clear of springs springs and and other pinch pinch points. points. Never Never reach in-betwe in-between en vibrating vibrating equipment equipment and and its support support structure. Keep a safe distance from all moving components.

•

Never attempt to enter the crushing crushing chamber chamber when when tramp iron iron or other other uncrushable uncrushable objects objects are are wedged wedged inside. inside. These materials are under tremendous pressure and may be propelled upward through the f eed 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 make equipment equipment modification modificationss that will result result in a safety safety hazard hazard or create create a dangerous dangerous situation situation.. Never  remove or disable safety devices. Maintain all machinery in accordance with manufacturer’s instructions and  maintenance schedules.

•

Read the operato operator’s r’s manual manual for the equipme equipment nt that you operate operate.. Be sure that that you fully understa understand nd all phases phases of  operation for each machine. A careful and well-trained operator is the best insurance against an accident.

•

Refer to Chapter Chapter 1, Safety Safety,, for important important quarry safety safety information information.. If your copy copy is missing, missing, replacement replacement copies may be obtained from your local Telsmith Dealer or the Telsmith Parts Department.

•

All rotating rotating power products products are are potentially potentially dangerous dangerous and must be properly properly guarded guarded.. Placement Placement of guards guards and  other safety equipment is the user ’s responsibility. responsibility. Such equipment must be installed wherever appropriate and  maintained as required.

•

It is the purchase purchaser’s r’s responsib responsibility ility to ensure ensure that quarry quarry equipment equipment is installe installed d and used used in a safe and and lawful manner. All machinery must be operated in compliance with applicable health and safety laws and general standards of reasonable care.

! WARNING Failur Failur e to follow t he safety safety precautions sho wn below may result in serious personal inju ry or death! •

Never attempt attempt to work on on quarry equipmen equipmentt while it is in operation. operation. Always Always stop the machine machinery ry,, lockout lockout power  and tag controls: 1. Before performing any lubrication, maintenance, adjustment, 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 clear of feed and and discharge discharge areas areas and and other places places where where falling rock rock is present. present. Keep Keep away from loading 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-toed shoes are mandatory when working near  machinery. machinery. Wear and use additional personal protective equipment as required.

•

Stay clear clear of springs springs and and other pinch pinch points. points. Never Never reach in-betwe in-between en vibrating vibrating equipment equipment and and its support support structure. Keep a safe distance from all moving components.

•

Never attempt to enter the crushing crushing chamber chamber when when tramp iron iron or other other uncrushable uncrushable objects objects are are wedged wedged inside. inside. These materials are under tremendous pressure and may be propelled upward through the f eed 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 make equipment equipment modification modificationss that will result result in a safety safety hazard hazard or create create a dangerous dangerous situation situation.. Never  remove or disable safety devices. Maintain all machinery in accordance with manufacturer’s instructions and  maintenance schedules.

•

Read the operato operator’s r’s manual manual for the equipme equipment nt that you operate operate.. Be sure that that you fully understa understand nd all phases phases of  operation for each machine. A careful and well-trained operator is the best insurance against an accident.

•

Refer to Chapter Chapter 1, Safety Safety,, for important important quarry safety safety information information.. If your copy copy is missing, missing, replacement replacement copies may be obtained from your local Telsmith Dealer or the Telsmith Parts Department.

•

All rotating rotating power products products are are potentially potentially dangerous dangerous and must be properly properly guarded guarded.. Placement Placement of guards guards and  other safety equipment is the user ’s responsibility. responsibility. Such equipment must be installed wherever appropriate and  maintained as required.

•

It is the purchase purchaser’s r’s responsib responsibility ility to ensure ensure that quarry quarry equipment equipment is installe installed d and used used in a safe and and lawful manner. All machinery must be operated in compliance with applicable health and safety laws and general standards of reasonable care.

Foreword INTRODUCTION

ORDERING REPLACEMENT PARTS

This manual will help you achieve optimum performance from your Telsmith SBS Cone Crusher. It contains complete repair and overhaul instructions for all SBS-Series models.

For replacement parts information, please refer to the SBSSeries Cone Crusher Drawings. These drawings contains exploded diagrams and parts lists to help you quickly identify the major components used on your crusher.

The data and instructions contained in this manual are based  on the latest information at the time of publication. Telsmith's Telsmith's  p o l i c y o f c o n t i n u o u s i m p r o v e m e n t s , f e a t u r e s a n d  specifications are subject to change without notice. Actual dimensions, weights, and clearances may be different than shown, due to fabrication variables, custom engineering or optional equipment. Please note that some features shown in this manual may not  be present on your machine. machine. Some equipment described may  be opt ional io nal at ext ra cost co st,, or ava ilab il able le onl y on sel ect ed  models.

If your prints have been lost or damaged, new copies are available from your local approved Telsmith Distributor or  the Telsmith Parts Department. To ensure that you receive the correct parts for your machine, always include the model number and serial number when ordering.

MODEL and SERIAL NUMBER PLATE LOCATION

HOW TO CONTACT TELSMITH INC. Use the following information when you wish to contact Telsmith:

•

Gen er al : Phone Phone (262) (262) 242-66 242-6600 00 (24/7) (24/7) FAX (262) 242-5812

•

P ar t s :

Phone (800) 688-6601 (24/7) FAX (262) 242-7861

•

Wr i t t en :

Telsmith, Inc. 10910 N. Industrial Drive P.O. Box 539 Mequon, WI 53092-0539 U.S.A.

•

Sen d al al l ee-m ai ai l to to : [email protected]

REQUESTING SERVICE ASSISTANCE If service assistance is required or you have questions about maintenance or repair procedures in this manual, please contact your local approved Telsmith Distributor. If  additional assistance is necessary, contact the Telsmith Service Department. Service technicians are available by telephone 24 hours a day, day, seven days a week. To ensure faster response, always have your machine’s model and serial numbers ready when calling. Model and serial numbers are located on a data plate attached  to the machine main frame. Always lockout power and tag controls before reading data plate!

07/09 (Rev 1)

3

Foreword

OPERATION AND MAINTENANCE INSTRUCTIONS This manual includes procedures for cone crusher repair and  overhaul only. For detailed operation and maintenance instructions, please refer to the SB S-Series O peration and M aintenance M anual.

The Operation and Maintenance Manual is provided with all new SBS-Series cone crushers. Replacement copies, if  needed, may be ordered from your local Telsmith dealer or  the Telmith Parts Department.

SERVICE BULL ETINS Telsmith periodically issues service bulletins 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 bulletins  before starting any maintenance or service work.

SAFETY All quarry personnel operating or servicing the machine must read and fully understand the information included in Chapter 1, Safety of this manual.

ILLUSTRATIONS This manual contains some illustrations in which guards, access panels and other safety equipment have been r emoved  for instructional purposes or to provide greater clarity. However, to prevent serious personal injury or death, always  be sure all such equipment is installed before operating the  product.

Wear Liner Replacement Telsmith SBS Cone Crusher 

CONTACTS TELSMITH PARTS DEPARTMENT CONTACTS

Name: Phone (Office): Phone (Cell): FAX:

Name: Phone (Office): Phone (Cell): FAX:

TELSMITH SERVICE DEPARTMENT CONTACTS

Name: Phone (Office): Phone (Cell): FAX:

TELSMITH APPROVED DISTRIBUTOR CONTACTS

Name: Phone (Office): Phone (Cell): FAX:

INSTALLATION & ASSEMBLY DRAWINGS Installation and assembly drawings (blueprints) are provided  with all new Telsmith products. These drawings are normal ly included with the technical manuals but may be shipped  separately for some orders. The drawings include specifications, dimensions and other  information for use during installation and assembly  pr oc edur es. Co nt ac t yo ur lo cal Telsm it h de al er or th e Telsmith Service Department if you have any questions about information contained on the drawings. If the drawings are lost, replacement copies may be ordered  from your local Telsmith dealer or the Telsmith Parts Department.

4

OTHER CONTACTS

Name: Phone (Office): Phone (Cell): FAX:

Name: Phone (Office): Phone (Cell): FAX:

07/09 (Rev 1)

Table of Contents .

1

GENERAL INSTRUCTIONS  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

SUPPORT BOWL AND CONCAVE RING  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

MANTLE AND HEAD  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.

Appendix A - Torque Tables  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Appendix B - Conversion Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1 Appendix C - Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1 Appendix D - Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1 Appendix E - Sealants and Compounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1 Appendix F - Removal Clearances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-1 Appendix G - Wear Liner Wear Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-1

(Continued on next page) 07/09 (Rev 1)

1

Table of Contents

1–2

Wear Liner Replacement Telsmith

07/09 (Rev 1)

Wear Liner Replacement Telsmith Silver Bullet Series Gyrasphere

Chapter 1

Chapter 1 Safety Page

SAFETY OVERVIEW   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 HAZARD AND ADVISORY STATEMENTS . . . . . . . . . . . . . . . . . . . . . . 1-2 LOCKOUT/TAGOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1

GYRASPHERE SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 QUARRY SAFETY SUMMARY   . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 MACHINERY INSTALLATION SAFETY . . . . . . . . . . . . . . . . . . . . . . . . 1-8 MAINTENANCE AND REPAIR SAFETY . . . . . . . . . . . . . . . . . . . . . . . . 1-9 HOISTING AND HANDLING SAFETY . . . . . . . . . . . . . . . . . . . . . . . . 1-11 TRANSPORTING MACHINERY . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

7F

07/09 (Rev 1)

1–1

Safety

SAFETY OVERVIEW It is the responsibility of the quarry management team to develop a comprehensive safety awareness 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 own peculiarities which can not always be covered by rules. Therefore, quarry personnel must continually watch for possible safety hazards and be  prepared to take prompt corrective action when necessary. Failure to observe 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.

1

Wear Liner Replacement Telsmith SBS Cone Crusher  A  No te   is a basic informational statement or helpful suggestion. An  Imp ortant   is used to draw attention to a  procedure that must be observed to prevent machine damage or malfunction.

! DANGER

! WARNING!!! DANGER

Hazard Statements

The complete observance of one simple rule would 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 onl y intended as a brief review of basic quarry safety precautions and procedures. The general guidelines included in the following paragraphs should not be considered in lieu of a quarry’s official 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 have been emphasized. Examples of these are shown in Figure 1-1.

7F

Hazard Statements The Caution, Warning   and  Danger   statements are hazard statements used to alert workers of unsafe practises and  potentiall y harmf ul or life-threateni ng 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 PERSONAL INJURY or DEATH. • Failure to follow the instructions contained in a Danger statement will result in SEVERE PERSONAL 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 pr oper  procedures and practises. 1–2

Figure 1–1. Hazard and Advisory Statements

LOCKOUT/TAGOUT Who Must Use Lockout/Tagout? Quarry owners, managers, and safety officers must be aware 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 energy systems are  protected from harm due to unexpect ed energizing, or the release of stored energy by... 1. Lockout – Placing a disconnect switch, circuit breaker, valve, or other energy-isolating mechanism in the off or safe position and securing it with a lock so the energyisolating mechanism cannot be activated. 07/09 (Rev 1)

Wear Liner Replacement Telsmith SBS Cone Crusher 

Safety

2. Tagout  – A prominent written warning (tag or label)  placed on the energy-isolating mechanism indicating the name of the individual placing the mechanism out-ofservice, and stating that the energy isolating mechanism cannot be activated until the tagout device is removed.

When Must Lockout/Tagout Occur? Lockout/tagout must occur whenever service or maint enance is performed, and injury could occur due to the unexpected start-up of equipment, or the release of stored energy. See Figure 1-2. In general, lockout/tagout procedures must be performed under the following circumstances: • Before cleaning, lubricating, adjusting or repairing machinery or equipment. • Before working on electrical, hydraulic 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 following step-by-step lockout/ tagout procedure:

1. Prepare for shutdown  – Before shutting down a piece of equipment, know the type and magnitude of the energy 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 warning all employees, shut down the machine, equipment, or electrical system by the normal stopping procedure. 3. Control stored energy   – any potentially hazardous stored energy (electrical, mechanical, hydraulic, pneumatic, etc.) that remains must be released, dissipated, restrained, or otherwise rendered safe. If stored energy reaccumulates, monitor it until the possibility of accumulation no longer exists. 4. Isolate the equipment  – Disengage all isolating devices, both primary and secondary, so that the equipment is isolated from all of its energy sources (electrical, mechanical, hydraulic, pneumatic, etc.).

1

5. Apply lockout/tagout devices  – Attach lockout tagout devices (according to your company’s safety program) in such a manner that the isolating device (circuit breaker, control, etc.) will be held in a safe or off  position. Attach tags to alert others that the machinery is being serviced. 6. Verify that equipment is isolated  – After warning all employees to stay clear, engage the start button to confirm the machine is inoperable. Return the control to the off  position before proceeding with servicing.

LOCKOUT / TAGOUT POWER... • Before making inspections or adjustments.

7F

• Before performing any lubrication, maintenance or repairs. Crusher lockout/tagout summary: 1.

Always lockout/tagout power to 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 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 can result in serious personal injury or death!  Figure 1–2. Lockout/Tagout 07/09 (Rev 1)

1–3

Safety

When Can Lockout/Tagout Devices be Removed? Lockout/tagout devices can only be removed after the following conditions are met: • All guards and protective devices are properly reinstalled. • All tools and repair equipment are removed from the equipment and the immediate area. • All mechanics and other personnel are clear of the equipment and its immediate area. • All personnel have been warned that the equipment is about to be restarted (sound warning horn and activate warning lights).

1

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 Lockout/tagout devices include: 1) locks 2) tags and labels 3) multiple lockout devices A lock must be sufficiently durable, so it can withstand the 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 affixed to each lock to alert ot hers that service work is in progress. Each tag or label must have the following characteristics:

7F

• Be sufficiently durable to withstand wear and abuse, even if used in dirty or damp environments. • Be securely attached with a cable that is difficult to remove, cut or tear. • Contain the name of the person that applied it. • Contain a warning or other precautionary statement that  briefly indicates why t he machine is locked out and what hazards could result if the equipment is started while service work is in progress. When two or more people are working on a piece of equipment, a multiple lockout device must be used. This allows each person to install their own lock, preventing accidental start-up.

Lockout/Tagout Rules • 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. 1–4

Wear Liner Replacement Telsmith SBS Cone Crusher  • Your company’s lockout/tagout program may be somewhat different than described in this manual. If so, be sure to completely follow your company’s official  policies and procedures when lockout/tagout is necessary. Consult your company’s safety officer if you have 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. • Your key must open your lock only. Your key should not  be capable of openi ng any other locks. Keys for other locks should not be capable of opening your lock. • Except in an emergency situation, never attempt to remove anyone else’s lock. Do not allow others to remove your lock. • When disconnecting power, be sure that the circuit  breaker handle (or other isolating device) is in the OFF  po si ti on . Ac ci de nt al ly lo ck in g a co nt ro l in th e ON  position could result in serious personal injury or death. • If two or more people are working on a machine, a multiple lockout device must be used to prevent accidental start-up in the event that one person finishes working before another. • Each lock must have a tag. If two 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 always be accompanied by a lock which prevents the isolating device from becoming energized.

Additional Lockout/Tagout Requirements • Be sure that the power is COMPLETELY turned off. A motor may be stopped and locked out. However, interlocks, starters, and other supplemental electrical components may still be energized. Use a voltmeter and/ or ammeter to verify that all electrical circuits are completely dead. • Always be sure that all peripheral equipment, such as feed conveyors, grizzly feeders and discharge conveyors, is also tagged and locked out. Serious personal injury or death can result if any of these items starts unexpectedly while the crusher is being serviced. • Although lockout/tagout procedures are most commonly associated with electrical systems, be aware that hydraulic, pneumatic and mechanical systems must also  be tag ged and locked out before servicing . Thi s may involve the lockout/tagout of valves, levers and other nonelectrical devices. 07/09 (Rev 1)

Wear Liner Replacement Telsmith SBS Cone Crusher  • For machinery powered by internal combustion 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. • Always be sure that all hydraulic or air pressure is completely relieved before working on hydraulic 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, always activate a warning horn or light  be fo re re st ar ti ng th e ma ch in er y. Th is wi ll pr ov id e additional warning for personnel to stay clear of machinery that is about to be started.

GYRASPHERE SAFETY • Perform a complete walk around inspection before starting the crusher. Be sure that no persons are on, inside or under the crusher. Refer to the Operation and  Ma int e nance M anual   for crusher daily start-up  procedures. • Be sure that all guards and other safety devices are correctly installed and tightly secured before starting the crusher. Stay clear of rotating or moving parts during crusher operation. • Do not allow personnel to be on or near the crusher during operation. Stay clear of feed and discharge areas to  prevent being injured or killed by flying or falling rock. • Rock projected upwards 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 observation 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.

07/09 (Rev 1)

Safety

• Never attempt to manually clear jammed material from the crushing chamber while the upper frame is in the lowered (clamping) position. Any material lodged in the chamber could release without warning, and may be  prope lled upw ard throu gh the fee d ope ning. Ser iou s injury or death could result. Refer to the Operation and  Maintenance Manual  for jam removal procedures. • Do not tamper with crusher alarm components. Never attempt to defeat electrical interlocks or to disable crusher  protective devices. • Never place hands on cylinder rods. Stay clear of pinch point area between the upper and main frames. • Never stand on hydraulic 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, crusher oil lubrication system and crusher hydraulic system before performing any inspection, adjustment lubrication, maintenance or repair procedures. Also lockout power to all crusher feed and discharge equipment. Be sure pressure is fully relieved before servicing the hydraulic system.

1

• If the crusher is powered by a diesel engine, always disconnect batteries and shut-off fuel supply before  perf or mi ng any in spect ion, adj ustm ent, lubr icatio n, maintenance or repair procedures. Lockout/tagout engine controls   to prevent the engine from being accidentally started while the crusher is being serviced. • Support the crusher upper frame with hardwood blocking or steel safety spacers before entering the crushing chamber for service work. Never rely on hydraulic  pressure to keep the upper frame raised. You could be crushed and killed if the upper frame lowers unexpectedly. • Always stop the crusher immediately if any 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 provided with the crusher.

1–5

7F

Safety

QUARRY SAFETY SUMMARY Know Your Machinery • Read the manufacturer’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 follow all start-up and shut-down procedures as described in the manufacturer’s manuals. • Be familiar with the safety signs on your equipment, and the hazards against which they warn.

1

• Check the legibility of all safety signs every day. Order new signs from the machinery manufacturer if they  become illegible or worn.

Be Prepared for Emergencies • Know the proper emergency shut-down procedures for the equipment you operate. • Know where fire extinguishers are kept and how to use them. Be sure that fire extinguishers are properly rated, and that they remain fully charged and ready for use at all times. • Know the procedure for contacting emergency medical  per son nel . Kee p a li st of emergenc y pho ne num ber s handy at all times.

7F

• Know where first-aid kit, stretcher and other emergency supplies are kept. Be sure that first aid supplies are  properly maintained and ready for use. • Make sure that a clear path to emergency equipment and exits is always maintained. Do not allow equipment, spilled materials or other obstructions to get in the way. • Know how to report accidents. Always report all accidents immediately to t he appropriate supervisor.

Wear Personal Protective Equipment (PPE) • Wear safety glasses or goggles whenever outside of an approved operator’s enclosure. Failure to wear appropriate eye protection can result in permanent eye 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 levels are high. Prolonged exposure to high noise levels can cause permanent hearing l oss.

1–6

Wear Liner Replacement Telsmith SBS Cone Crusher  • 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 protective equipment may be necessary for your specific job assignment, such as a full face 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 power equipment. Avoid wearing necklaces, rings or other j ewelry. These items can become caught or tangled in the machinery, resulting in severe  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 whenever using wet walkways,  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. • Use walkways and ladders when working near machinery, or observing its operation. Use a safety harness when necessary. Keep handrails and machine contact surfaces clean. • To avoid back injuries, always 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. • Never attempt to catch falling materials or objects. • Be aware of flammable liquids and other potential fire hazards. Do not smoke when refilling engines or using cleaning solvents. • Do not stand under equipment or components that are  being hoisted or suspended. Never allo w other quarry  personnel to do so. • Before you assemble, operate, clean, lubricate, or adjust machinery, be sure to read and understand all procedures contained in the machinery manufacturer’s manual. • Be sure to operate quarry machinery in compliance with current OSHA and MSHA regulations, and all applicable state and local regulations.

07/09 (Rev 1)

Wear Liner Replacement Telsmith SBS Cone Crusher 

Safety

Help Prevent Accidents

Practice Good Housekeeping

• Do not allow unauthorized personnel in or near the work area. Never allow unauthorized personnel to operate, adjust, maintain or repair machinery.

• Do not store tools or equipment on walkways.

• Allow only properly trained and experienced personnel to operate machinery. Be sure inexperienced operators are carefully supervised at all times. • Before start-up, visually check that no personnel are inside, on, under or beside the machinery. Alert all workers that start-up is about to occur. Always sound warning horn before starti ng the machinery. • Do not allow personnel to be near loading areas, or anywhere else that falling or ejected material could hit them. • Use extreme caution if the machinery must be operated for inspection or observation purposes. Stay a safe distance from the machinery and wear appropriate  personal protective devices. • Before making repairs to the machinery, always clear all quarry material from the feed and discharge devices (feeders, conveyors, chutes, etc.). • In areas which present a danger of falling, use an appropriate fall protection device, such as a safety harness and lifeline. • Always report any unsafe conditions or defective equipment to the appropriate supervisor.

Avoid Alcohol and Other Drugs • Do not operate or work 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 adverse side effects. Do not operate or work near quarry machinery when under the influence of such medications.

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 aware of idle machinery that could start-up without warning. Stay clear of such machinery and the immediate area.

• 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 falls. Make repairs as required in areas where spillage is present. • Do not allow machinery to become buried under piles of spilled material. This will make the machinery more difficult to inspect and may hide broken 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 event of an emergency, 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. Never clean-up these items while the machinery is operating.

Inspect And Maintain Machinery • Always perform a safety inspection at the beginning of each shift. Refer to the machinery manufacturer’s operation and maintenance manuals for detailed pre-startup inspection and maintenance procedures. • Test all warning devices before starting the machinery to ensure that they are working properly. Never disable or  bypass any alarm systems or interlocks. • Be sure that any defective components or systems are  properly repaired by a qualified technici an before the machinery is started. Immediately report any serious  problems to the appropriate supervisor. • Before performing inspections or maintenance, always lock out power and tag controls to the machine drive, and to all feed and discharge equipment. Warn all personnel that the equipment is being serviced. Refer to the Lockout/ 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 regularly maintained and in proper working condition will minimize the occurrence of safety hazards and emergency situations.

• Be aware of overhead obstructions, such as conveyors, support structures or power lines.

07/09 (Rev 1)

1

1–7

7F

Safety

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 to operate. This does not need to be a poured pad, but it m ust not be unstable ground. When selecting the location, be sure that the entire area is as level as possible. • Follow all manufacturer’s installation drawings and specifications when constructing the base pads for  permanent plants. • If any questions arise regarding foundation requirements or modifications necessary for Telsmith machinery, please contact the Telsmith Service Department.

1

• Customer-designed support structures for Telsmith equipment must meet Telsmith’s engineering standards. All plans must be submitted in advance 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. • In addition to the guards supplied with the machinery, additional guards and related safety equipment may be required to comply with OSHA, MSHA and any applicable local regulations. The proper fabrication, installation and placement of these items is the user’s responsibility.

7F

• When fabricating guards, refer to MSHA’s Guide to  Equ ipmen t Gua rdin g at Met al and Non met al Mines . Additional information can also be provided by the safety officer at your worksite.

Wear Liner Replacement Telsmith SBS Cone Crusher 

Electrical Hook-up

! WARNING!!! DANGER When installing any electrical equipment, be sure to completely follow the manufacturer’s instructions. Failure to observe this precaution could result in a dangerous electrical shock hazard. • Be sure that all electrical equipment is properly grounded. • Lay out the power lines, especially those for portable  plants, so that contact with standing water is mini mized. • Do not place power lines in an area where they will be driven over by transport vehicles or other quarry equipment. If it is absolutely necessary to extend a power line across a traffic area, protect the cable with properly rated bridging. • Be sure that all auxiliary control panels or power supply  panels can be securely locked out. This type of panel is mandatary. • Maintain adequate overhead clearance from power lines or other obstructions, particularly when planning to use stacking conveyors for stockpiles. • Be sure that electrical power supplies are located in an area that will be safe from accidental contact during crushing operations. • All Telsmith machinery is designed with electrical components of the proper size and voltage. Any modifications to these components or to the power 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 any applicable state or local codes.

• Never remove 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 may 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 ap pr ov ed in wr it in g in wr it in g by th e Tel sm it h Engineering Department.

1–8

07/09 (Rev 1)

Wear Liner Replacement Telsmith SBS Cone Crusher 

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 approved 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 fasteners to the proper torque as described in the repair procedures. When torque specifications are not listed, use the values in the torque chart at the back of this manual. Refer to Appendix A of this manual. • Be sure all replacement fasteners are of the proper grade and specifications. Replace any worn or damaged fasteners.

Electrical Systems • Always read, understand and follow appropriate electrical system troubleshooting, maintenance and repair instructions in the machinery manufacturers’ manuals. • Allow only trained and licensed electricians to install, troubleshoot and repair electrical equipment. All  pro cedure s mus t be in com pli ance wit h the Nat ion al Electric Code and any 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 lockout power before removing cables with quick-disconnect plugs. • Repair any obviously worn or damaged wires and connectors. • Inspect power cables and connections daily for signs of wear, cracked insulation and worn or damaged connectors. Repair or replace as required. • Do not store tools inside electrical cabinets. • Verify that all tools are grounded with a three wire plug or double insulated. Be sure that all extension cords are grounded with a three wire plug.

07/09 (Rev 1)

Safety

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. • Before performing maintenance or repairs on any  pressurized system: - Cycle the controls through all operating positions to relieve any trapped pressure. - Check that ALL pressure is relieved 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. • Allow time for hot hydraulic oil to cool before performing any maintenance or repairs. Hot oil can cause burns.

1

• Before loosening fittings or removing components, always recheck that ALL pressure is relieved from the system. Pressure gauges must read zero (0) PSI. • Never attempt to crack a hydraulic fitting while a hydraulic system is pressurized. You could be injured or killed by a stream of high pressure oil. • Never have your face near, or stand directly in front of a hydraulic line when cracking a fitting, even after system  pressure has been relieved. 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 can  penetrate the skin, resulting in serious personal injury. • Clean-up any spilled hydraulic fluid. Hydraulic fluid is extremely slippery, and can be especially dangerous if spilled on an elevated walkway or platform. • Repair any leaks immediately. Always relieve system  pressure and lockout/tagout power  before tightening fittings or making repairs. • Never attempt to adjust pressure relief valves to above the machinery manufacturer’s recommended settings. Serious personal injury and/or equipment damage could result. • Do not operate any hydraulic or air system with obviously worn or damaged, or leaking components. Always replace any defective components immediately. • Never place hands on hydraulic cylinder rods while equipment is in operation. Do not step on the hydraulic relief cylinder hoses when climbing on the crusher.

1–9

7F

Safety

• Refer to manufacturer’s instructions when recharging hydraulic accumulators or checking accumulator  pre ssu re. Allow onl y trained and cer ti fied hyd raulic system technicians to depressurize, recharge or repair hydraulic accumulators.

Welding On Machinery • Be sure to provide adequate ventilation when welding inside enclosed areas to prevent the buildup of hazardous fumes. Special concern should be exercised when w elding 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 fabric clothing or clothing which could be easily ignited by sparks.

1

• Always follow all standard safety procedures when welding. Be sure that all systems are shut down, power is locked out, and controls are tagged. Provide welding screens to protect other employees working in the area. • Relieve all hydraulic pressure before welding near hydraulic components and lines. Cover hydraulic components to protect them from weld spatter and sparks. • Do not weld near flammable liquids or hydraulic oils. • 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. Never allow personnel to walk or work underneath castings being lifted or supported. • Never ground the welder so that the electrical power will flow through bearings, hydraulic components or electrical equipment. Serious damage could result.

7F

• Be sure all compressed gas cylinders are stored upright, chained and capped. Turn-off all cylinders when not in use.

Clearing Jammed Material • If material becomes jammed in the machinery:

Wear Liner Replacement Telsmith SBS Cone Crusher  • Always remove all jammed material before restarting the machinery. To prevent damage, never attempt to restart a stalled machine without first removing the jammed material. • Never use dynamite or other explosives to clear jams. Explosives are dangerous and can injure or kil l personnel. Damage to machinery could also occur.

Hazardous Materials • Be aware potentially hazardous chemicals or materials. Such items can be harmful if they are improperly used, stored, mixed or transported, or if they 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 manufacturer’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 avoid potential health hazards, persons in regular contact with hydraulic oils must be aware 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 protective clothing when handling hydraulic oil. • Be sure protective clothing and proper wash-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.

- Immediately stop the machinery. - Lockout/tagout power. Warn others that the machinery i s  being serviced. - Follow the instructions i n the operation and maintenance manual of the affected equipment. (The jam removal  procedure for Silver Bullet Series crushers is located in the Operation and Maintenance Manual ). • To prevent serious personal injury or death, never attempt to remove jammed material while the machinery is in operation.

1–10

07/09 (Rev 1)

Wear Liner Replacement Telsmith SBS Cone Crusher 

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

Flammable and Combustible Liquids • Store flammable liquids in a safe place, away 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.

Safety

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

• Keep flammable liquids away from sparks, open flame, and other ignition sources. Do not smoke around flammable liquids. Always obey posted “no smoking” signs.

• Avoid dragging wire rope underneath loads or over obstacles.

• Be familiar with the locations of fire extinguishers throughout the quarry. Be sure they remain accessible at all times, and are not blocked by obstructions.

• Avoid reverse bends.

• Do not use gasoline or other flammable liquids to clean tools or parts. Use only approved non-flammable solvents.

• Use thimbles in eye fittings at all times.

• Always shut-off engines before refueling. Ground fuel spout against the filler neck to prevent static electricity.  Never smoke while refueling.

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

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

When connecting or clamping wire ropes, use one of the following:

HOISTING AND HANDLING SAFETY General Precautions • Do not allow personnel to work or walk under loads supported by a crane or hoist. • Use appropriate lifting devices to secure the load to the crane. See the following paragraphs of this section for additional information. • Use the correct lifting hooks to support the load. Refer to the Operation and Maintenance Manual   for crusher lifting points and procedures. • Use extreme caution when operating a crane near power lines or electrical equipment. • Do not exceed 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.

• Never use wire rope that is cut, badly kinked, frayed or crushed.

• Be sure that rope ends are properly sized.

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

Connecting Or Clamping Wire Ropes

• 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 t o 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 ki nk, forming a permanent weak spot.

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 NOT jerk load upright).

07/09 (Rev 1)

1

1–11

7F

Safety

Wear Liner Replacement Telsmith SBS Cone Crusher 

• Use suitable padding to protect the chain from sharp corners or edges.

• Use the proper fittings at all times.

• Be sure that all tractor-trailer components are working and in good condition. Test all systems (brakes, steering, lights, etc.) for proper operation and/or adjustment before  beginning the move. Check air pressure in all tires and replace any tires that are worn or damaged.

• Watch for local wear. Reposition or shorten chain (as required) to remove the worn section from the area of tension.

• After the machinery has been transported, block the tires if the trailer will remain stationary for an extended period of time.

• Avoid dragging the chain under loads or over obstacles.

• Inspect links to determine the amount of wear. Refer to manufacturer’s specifications for wear tolerance ranges. • Be sure that all connections between chain sections are completed with properly sized hardware and lifting hooks.

1

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

Fiber Or Synthetic Slings Slings require careful use, handling and maintenance to ensure long life and safe operation. • Be sure that slings are rated or coded for the hitch or application. • Be sure that slings are inspected regularly following the manufacturer’s guidelines. • Slings may be safely used in a temperature range of 20 to 180° F (-6 to 82°C) without decreasing load limits. For temperatures beyond this range or for wet/frozen slings, follow manufacturer’s instructions for load reductions.

7F

• Do not use synthetic slings in temperatures exceeding 180°F (82°C). • Avoid sudden or shock loading (DO NOT jerk load upright).

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 manufacturer’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.

1–12

07/09 (Rev 1)

Wear Liner Replacement Telsmi th Silver Bul let Series Gyrasphere

Chapter 2

Chapter 2 General Instructions Page

WORK SAFELY AND USE COMMON SENSE   . . . . . . . . . . . . . . . . . . . . 2-2 TOOLS AND SUPPLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 LUBRICANTS & SEALANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2

PART IDENTIFICATION & INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 2-2 HANDLING SEALS & MACHINED PARTS   . . . . . . . . . . . . . . . . . . . . . . 2-2 HANDLING BEARINGS  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 USING HEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 HYDRAULIC SYSTEM SAFETY SUMMARY   . . . . . . . . . . . . . . . . . . . . . 2-3 DISCONNECTING HYDRAULIC LINES . . . . . . . . . . . . . . . . . . . . . . . . 2-3 DEPRESSURIZING THE POWER ROTATOR CIRCUIT   . . . . . . . . . . . . . . . 2-4

7F

07/09

2–1

General Instructions

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 (DANGER, 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 smoke around flammable liquids.

2

PART IDENTIFICATION & INSPECTION • Tag and mark all parts during removal and disassembly  procedures. • Clean all parts as removed. Verify that they 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  ph ot og rap hs to ve rif y tha t al l pa rt s ar e co rrec tly reinstalled.

HANDLING SEALS & MACHINED PARTS

• Wear appropriate personal protective equipment (PPE). Keep the work area clean and well organized.

• 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 surfaces.

TOOLS AND SUPPLIES The following common tools, shop equipment and supplies are required to complete the repair and overhaul procedures in the following chapters of this manual: • Impact wrench with a 3/4 inch drive minimum, 1 inch  preferred. • Set of sockets and breaker bars, minimum 3/4 inch drive with sockets up to 3-1/2 inches. • Cold chisel, 3/4 inch.

7F

Wear Liner Replacement Telsmi th SBS Cone Crusher 

• 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.

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

HANDLING BEARINGS • Remove any loose dirt from the machinery before exposing bearings. Handle bearings with clean, dry hands. • Use only clean lint-free rags. Use clean tools in clean surroundings. Use clean solvents and flushing oils. • Install new bearings as removed from packaging without washing. Do not remove bearings from packaging until ready to use. • Soak used  bearings in solvent. Then wash the bearings and blow them dry with filtered, moisture-free compressed air. Dip the bearings in oil immediately after drying to prevent rust.

• Cleaning solvent. • Flushing oil. Refer to the Tools and Supplies Required   heading at the  beginning of each chapt er for additional item s needed to  perform specific repair and overhaul procedures.

LUBRICANTS & SEALANTS

! WARNING!! DANGER !  Al way s wear eye pr ot ect io n and fac e sh ield wh en using c ompressed air. • To prevent bearing damage, do not spin the bearings by hand or with compressed air after the bearing surfaces have dried.

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 in Appendixes D and E.

2–2

07/09 (Rev 1)

Wear Liner Replacement Telsmi th SBS Cone Crusher 

USING HEAT • When using an oil bath, avoid contact with hot oil.

General Instructions

• Clean-up any spilled hydraulic oil. Hydraulic oil is extremely slippery, and can be especially dangerous if spilled on an elevated walkway or platform.

• Use an acetylene torch if heat is required to remove an interference-fit part and it is not practical to use hot oil. Keep flame moving continuously. Do not let flame touch the part being removed.

• Refer to Chapter 1 for additional safety precautions and warnings which apply to pressurized systems and related machinery.

• If a part is to be destroyed by heat, be careful not to damage other reusable part s nearby.

• Refer to the crusher operation and maintenance manual for complete hydraulic system operation, maintenance and troubleshooting procedures.

• Be careful when using heat and handling hot parts. To  prevent burns, always wear appropriate hand, face and eye protection.

DISCONNECTING HYDRAULIC LINES

HYDRAULIC SYSTEM SAFETY SUMMARY

! WARNING!!! DANGER L o c k o u t / t ag o u t p o w e r t o t h e h y d r a u l i c c o n t r o l console before performing any hydraulic system maintenance or r epairs.

! WARNING!!! DANGER Before disconnecting the power rotator hoses, be certain that any trapped pressure is completely relieved.

! WARNING!! DANGER ! Up to 3000 PSI (206 bar) may remai n tr apped in t he p o w e r r o t a t o r c i r c u i t e v e n w h e n t h e h y d r au l i c pump is off and the pressure gauge indicates zero (0) PSI. Before disconnecting the power rotator hoses, be certain that pressure is completely relieved. Refer to the following section of this chapter for procedure.

! WARNING!! DANGER !

Refer to the following sections of this chapter for additional information.

Failure to relieve pressure before disconn ecting the power rotator hoses may result in t he sudden r e l e as e o f p r e s s u r i z ed h y d r a u l i c o i l . S e r i o u s personal injury or death can occur if pressurized hydraulic oil penetrates the skin.

Observe the following precautions when performing hydraulic system maintenance or repairs:

Observe the following precautions when disconnecting hydraulic lines during maintenance and repair procedures:

• Allow only qualified hydraulic service technicians to  perform hydraulic system troubleshooting and repai rs. All persons working on the hydraulic system must have appropriate training and certification.

• Lockout/tagout power to the hydraulic control console  bef ore dis connec tin g hydrau lic lines. Be cer tai n tha t trapped pressure is completely relieved before loosening any hydraulic fittings (see next section of this chapter).

• Allow only licensed electricians to troubleshoot and repair hydraulic system electrical components and wiring.

• Wear appropriate eye, face and hand protection, when disconnecting hydraulic hoses or loosening hydraulic fittings. Wear or use additional personal protective equipment (PPE) as required.

• Use common sense when observing hydraulic system operation. Be aware of potential hazards at all times. Stay clear of all moving or rotating parts. • Wear appropriate eye, face and hand protection, when troubleshooting or repairing the hydraulic system. Wear or use additional personal protective equipment (PPE) as required. • Use a piece of cardboard to check for hydraulic oil leaks, not your hand. Escaping fluid under pressure can  penetrate the skin. • Avoid unnecessary contact with hydraulic oil.

07/09 (Rev 1)

2

• Always assume that the system is pressurized, even if  pressure appear s to have been relieved. Some residual  pre ssure may rem ain tra pped wit hin the system even when the pressure gauge indicates zero (0) PSI. • Before disconnecting a hydraulic hose, verify that it is relaxed and not stiff. A stiff hose indicates that pressure has not been relieved. • Never have your face directly in front of a hydraulic line when loosening a fitting, even after system pressure has  been relieved. Always assume that the line has pressure.

2–3

7F

General Instructions

Wear Liner Replacement Telsmi th SBS Cone Crusher 

• As hydraulic lines are disconnected, catch any oil leakage in an appropriate container. • To prevent contamination, cap all ports and hose fittings immediately after hydraulic lines are disconnected.

11. To verify that pressure has been relieved, check that both  power rotator hoses are relaxed and not stiff. A stiff hose indicates that high pressure remains trapped in the circuit.

ON

DEPRESSURIZING THE POWER ROTATOR CIRCUIT

       F        F        O

CRUSH CLEAR

MANUAL

EXTRACT HIGH SPEED

AUTO

START

STOP

CLOSE

 

OPEN

Crush/Clear  High Speed  Switch

! WARNING!!! DANGER

38/44 Models

Up to 3000 PSI (206 bar) may rem ain tr apped in t he power rotator circui t even when the hydraulic pump is off and the pressure gauge indicates zero (0) PSI. Be sure that the power rotator cir cuit is completely depressurized before disconnecting the power rotator hoses or servicing any hydraulic components in the power rotator circuit .

2

Old Style Models 52/57/68

The power rotator hoses must be disconnected before  perfor min g some repair and over haul procedu res in this manual. Before disconnecting hoses, depressurize the power rotator circuit as described in the following steps: 1. Stop the crusher. Lockout/tagout power to the crusher drive and to all feed and discharge equipment (Refer to Chapter 1 for complete lockout/tagout procedures). 2. Stop the hydraulic pump. Lockout/tagout power to the hydraulic control console. 3. Jog the Crush/Clear/High Speed switch on the Hydraulic Control Panel (Fig. 2-1) between CLEAR and CRUSH several times. Then allow the switch to r eturn to the CRUSH position.

New Style Models 52/57/68

4. Check the hydraulic pressure gauge or sensor readout. Verify that the gauge indicates zero (0) PSI. See Figure 2-1.

7F

(Pressure Sensor )

5. Locate counterbalance valve “A”. Refer to Figures 2-3 and 2-5 for valve locations. 6. Loosen the pressure adjustment screw locknut. Refer to Figure 2-2. 7. Turn the pressure adjustment screw CLOCKWISE about three turns. Listen for a “hissing” sound. This indicates that pressure is being relieved. 8. After relieving pressure, reset the pressure adjustment screw to its original setting (turn the pressure adjustment screw COUNTERCLOCKWISE the same number of turns as in step 6). 9.

Figure 2–1. Hydraulic Pressure Gauge Locations

Pressure Adjustment Screw

Re-tighten the pressure adjustment screw locknut.

10. Repeat steps 5 through 8 for counterbalance valve “B”. Refer to Figures 2-4 and 2-6 for valve locations.

IMPORTANT: Pressure must be relieved at both counterbalance valves to ensure that all pressure in the power rotator circuit is completely relieved. 2–4

Locknut  Figure 2–2. Counterbalance Valve Details 07/09 (Rev 1)

Wear Liner Replacement Telsmith SBS Cone Crush er 

Counterbalance Valve “ A”

 Figure 2–3. Counterbalance Valve “A” (Models 38 and 44)

General Instructions

Counterbalance Valve “ A”

2

 Figure 2–5. Counterbalance Valve “A” (Models 52, 57 and 68)

7F Counterbalance Valve “ B” Counterbalance Valve “ B”

 Figure 2–6. Counterbalance Valve “B” (Models 52, 57 and 68)  Figure 2–4. Counterbalance Valve “B” (Models 38 and 44)

07/09 (Rev 1)

2–5

General Instructions

Wear Liner Replacement Telsmith SBS Cone Crush er 

NOTES

2

7F

2–6

07/09 (Rev 1)

Chapter 3 Support Bowl and Concave Ring

3

CONTENTS Page GENERAL SHUTDOWN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 TOOLS AND SUPPLIES REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 EXPLODED VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Type A Support Bowl and Concave Ring Assembly . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Type B Support Bowl and Concave Ring Assembly . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Type C Support Bowl and Concave Ring Assembly . . . . . . . . . . . . . . . . . . . . . . . . 3-6 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 SUPPORT BOWL REMOVAL  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Type “A” and “B” Bowl Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Type “C” Bowl Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 CONCAVE RING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Old Style Type“A” and “B” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 New Style Type “C” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 CONCAVE RING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 Old Style Type “A” and “B” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 New Style Type “C” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 SUPPORT BOWL PREPARATION  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29 SUPPORT BOWL INSTALLATION  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33 Old Style “A” and “B” Support Bowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33 New Style “C” Support Bowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35 RECEIVING HOPPER INSTALLATION (Old Style “A” and “B”)  . . . . . . . . . . . . . . . . 3-36 DRIVE RING COVER INSTALLATION (New Style “C”) . . . . . . . . . . . . . . . . . . . . . . . 3- 38 MIXING AND POURING SMITHBOND  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39

07/09 (Rev 1)

3–1

Support Bowl and Concave Ring

Wear Liner Replacement Telsmith SBS Cone Crusher 

3

Support Bowl

Concave Ring

3–2

07/09 (Rev 1)

Wear Liner Replacement Telsmit h SBS Cone Crusher 

Support Bowl and Concave Ring

GENERAL SHUTDOWN PROCEDURE

TOOLS AND SUPPLIES REQUIRED •

Prior to Working On Crusher  1. Stop the material feed. Operate the SBS Crusher until the crushing chamber is completely empty. If necessary, use the hydraulic clearing function to clear the crushing chamber. 2. Lockout/tagout  power to the crusher drive motor. Refer  to Chapter 1 for detailed lockout/tagout information and   procedures. 3. Lockout/tagout  power to all crusher feed and discharge equipment. 4. Lockout/tagout  power to the crusher oil lubrication system. 5. Jog the CLEAR/CRUSH/HIGH SPEED switch on the Hydraulic Control Panel (Fig. 3-1) between CLEAR and  CRUSH several times. Then allow the switch to return to the CRUSH position. 6. Lockout/tagout  power to the crusher hydraulic control console.

Suitable rigging and hoisting equipment

• 5 pound hammer  • Sledge hammer  • Extension brackets (special tools - provided with crusher) • Eyebolts 3/4-10 UNC 2B (quantity = 3) • Crowbar   • Hand grinder  • Feeler gauge • Tape measure • Cold steel chisel • Cleaning solvent • Putty • Moly-based EP-2 grease (refer to Appendix D) • Smithbond backing compound (refer to Table 3-1)

7. Check that the hydraulic system pressure gauge on your  unit is registering zero (0) psi.

Crush Clear Extract High Spd

Manual Auto

 

Start

Stop

 

Close

Open

 Figure 3–1. SBS Hydraulic Controls

07/09

3–3

3

Support Bowl and Concave Ring

Wear Liner Replacement Telsmith SBS Cone Crusher 

C  A

3

B D E F G

Type “ A”

H

Crushers with slotted concave ring lugs only

I

W

K

X

X

J N

L M

O

Model 38 only

P

S

O

T

Q

X O U R

V

 Figure 3–2. Support Bowl and Concave Ring Assembly, Type “A”  A. Capscrew F. Flatwasher K. Concave Ring P. Extension Bracket U. Locknut Ring

3–4

B. Flatwasher G. Support Bowl Driver L. Filler Ring Q. Nut V. Ring Gear

C. Outer Receiving Hopper H. Inner Receiving Hopper M. Felt Seal R. Nut W. Tapered Key

D. Felt Seal I. Support Bowl N. Capscrew S. Drive Ring X. Wedge

E.Socket Head Capscrew J. Smithbond Compound O. Flatwasher   T. Upper Frame

07/09 (Rev 1)

Wear Liner Replacement Telsmith SBS Cone Crusher 

Support Bowl and Concave Ring

C

A

3

B

Type “B” D

Crushers with slotted concave ring lugs only E

F G

V H W I

Model 38 only

K J

W

A M

B O

L B

W

N R S P Q

T U

 Figure 3–3. Support Bowl and Concave Ring Assembly, Type “B”  A. Capscrew F. Socket Hd Capscrew K. Concave Ring P. Flatwasher U. Ring Gear

07/09

B. Flatwasher G. Flatwasher L. Extension Bracket Q. Nut V. Tapered Key

C. Outer Receiving Hopper H. Support Bowl Drive Key M. Filler Ring R. Drive Ring

D. Inner Receiving Hopper I. Support Bowl N. Nut S. Upper Frame

E. Felt Seal J. Smithbond Compound O. Felt Seal T. Locknut Ring

3–5

Support Bowl and Concave Ring

Wear Liner Replacement Telsmith SBS Cone Crusher 

B A

Type “B” TYPE “C”

3

38 SBS Non-Rimmed Wedge

C

44/52/57/68 SBS Rimmed Wedge

D

E F

G

H

I

J

K L M

N

 Figure 3–4. Support Bowl and Concave Ring Assembly, Type “C”  A. Drive Ring Cover F. Extension (3) K. Pin Retainer

3–6

B. Cover Fastener (12) G. Support Bowl L. Thrust Pin Bushing

C. Drive Ring H. Felt Seal M.Upper Frame

D. Keeper I. Locknut N. Felt Strip

E. Felt Seal J. Felt Strip

07/09

Wear Liner Replacement Telsmith SBS Cone Crusher 

Support Bowl and Concave Ring

DESCRIPTION The concave ring is a replaceable casting that forms the upper  surface of the crushing chamber. It is made from manganese steel, a wear-resistant alloy that work hardens during crushing.

A

3

The concave ring is mounted inside the crusher support bowl. Rotation of the support bowl raises or lowers the concave ring, allowing the crusher discharge setting to be adjusted as needed. During crushing, the support bowl is held stationary by a series of hydraulic locking cylinders and a threaded locknut ring. The locknut ring is located just above the upper frame.

B C

When energized, the locking cylinders exert an upward force on the locknut ring that is transmitted to the support bowl. This force lodges the slanted buttress threads of the support  bowl tight against the slanted buttress threads of the upper  frame, preventing any support bowl movement. See Fig. 3-5.

D

Depressing the open or close pushbutton on the hydraulic control console partially de-energizes the hydraulic locking cylinders. This unlocks the support bowl, allowing it to be turned in the desired direction. See Figure 3-6. The open pushbutton rotates the support bowl counterclockwise, increasing the discharge setting. The close  pushbutton rotates the support bowl clockwise, decreasing the discharge setting. Adjustments can be made at any time, even while crushing. Full locking force resumes immediately when either pushbutton is released.

 Figure 3–5. Support Bowl, Locked Position  A. Support Bowl C. Locking Cylinder

Support bowl rotation is achieved by one or two power  rotators (depending on crusher model) mounted on the upper  frame. A large ring gear transmits force from the power  rotator(s) to a drive ring weldment which engages and turns the support bowl.

B. Locknut Ring D. Upper Frame

A

On models 44, 52 and 57, one full rotation of the support bowl changes the discharge setting approximately 1-1/2 inches. On Model 68 only, a full rotation changes the discharge setting approximately 2 inches.

B C

To facilitate concave ring replacement, a special high-speed extract function allows the support bowl to be quickly unthreaded from the upper frame.

D

The concave ring is tightly secured to the support bowl by a series of tapered steel wedges. Smithbond, a special epoxy based backi ng compound, fil ls the void area betw een the concave ring and the support bowl. Smithbond must be re poured whenever the concave ring is replaced. Concave ring replacement intervals will vary, depending on the amount and type of material being crushed. However, replacement should always be performed before the concave ring becomes cracked or excessively worn. Refer to Appendix G for additional information.

 Figure 3–6. Support Bowl, Unlocked Position  A. Support Bowl C. Locking Cylinder

07/09

B. Locknut Ring D. Upper Frame

3–7

Support Bowl and Concave Ring

Wear Liner Replacement Telsmith SBS Cone Crusher 

SUPPORT BOWL REMOVAL

3

A

Remove the support bowl from the crusher upper frame as described in the following steps. Refer to Figures 3-2, 3-3 and 3-4 for exploded views and parts designations. Refer to other  figures as indicated.

B C

1. Lockout/tagout  power. Perform the General Shutdown  Proc edu re as described earlier in this chapter. Refer to Chapter 1 for complete lockout/tagout instructions. 2. Remove chutes, conveyors or other feeding devices above the crusher. 3. Verify that there is adequate clearance above the crusher  for support bowl removal. Refer to Appendix F for removal clearances.

Type “A” and “B” Bowl Removal 1. Remove capscrews (A) flatwashers (B), and nuts securing the outer receiving hopper (C) to the drive ring (Figs. 3-2 & 3-3).

B

D

! WARNING Always use suitable rigging and hoisting equipment to stabilize and lift heavy objects. Lifting heavy components with inadequate hoisting apparatus can damage machinery and may result in serious personal injury or death. Refer to Appendix C for  weights.

Figure 3–7. Extension Bracket (Type “A” Support Bowl Assemblies Only)  A. Capscrew C. Extension Bracket (3)

B. Flat Washer  D. Nut

.

A

2. Using an appropriate lifting device and cables, carefully lift the outer receiving hopper (C, Fig. 3-2 & 3-3) straight up and remove it from the support bowl (I, Fig. 3-2 & 3-3). The hopper is sealed with a felt seal and rope caulk, so some effort may be required to loosen it.

B C

3. Remove any loose dust and dirt from the area between the support bowl and the inner receiving hopper (H, Fig. 3-2 & D, Fig. 3-3). 4. Using an appropriate lifting device and cables, carefully lift the inner receiving hopper straight up and remove it from the support bowl (I, Fig. 3-2 & 3-3). 5. Install the extension brackets (C, Fig. 3-7 & C, Fig. 3-8) on the drive ring. Secure with capscrews, flatwashers and nuts.

B

D

 Figure 3–8. Extension Bracket (Type “B” and “C” Support Bowl Assemblies Only)  A. Capscrew C. Extension Bracket (3)

3–8

B. Flat Washer  D. Nut

07/09

Wear Liner Replacement Telsmith SBS Cone Crusher 

Support Bowl and Concave Ring

3

Cutaway View

Moly-Based EP-2  Figure 3–9. Buttress Thread Lubrication 6. Apply a generous amount of moly-based EP-2 grease at each of the four grease fittings around the upper frame. See Figure 3-9. Refer to Appendix D for grease specifications. 7. Be sure that power to the hydraulic power unit is lockedout, and that the hydraulic pressure gauge indicates zero (0) PSI. 8. Disconnect the hydraulic locking cylinder hose at the hydraulic power unit. Leave all other hoses connected. See Figure 3-10.

10. Visually check that no personnel are on, under, inside or   beside the crusher. 11. Connect power to the hydraulic control console. Move the function selector switch to EXTRACT-HIGH SPEED. See Figure 3-11 for typical control console diagram. 12. Depress the START button. The hydraulic pump will start.

Hydraulic Locking Cylinder Hose

Function Selector  Switch

 Figure 3–10. Hydraulic Locking Cylinder Hose

 Figure 3–11. Hydraulic Control Console

9. Check the oil level in t he hydraulic reservoir. Be sure that the oil level is up to the black line of sight gauge. Add oil if  oil level is low. Refer to Appendix D for oil specifications. 07/09

3–9

Support Bowl and Concave Ring

Wear Liner Replacement Telsmith SBS Cone Crusher 

A

3 B

C

D

 Figure 3–12. Unthreading Support Bowl  A. Support Bowl

B. Drive Ring

13. Depress and hold the OPEN button. Visually check that the ring gear (C, Fig. 3-12) begins turning slowly counterclockwise. On some crushers, there may be a brief  delay before the gear starts turning.

C. Ring Gear

D. Upper Frame

.

14. Depress and hold the OPEN button. Allow the support  bowl (A, Fig. 3-12) to become completely unthreaded from the upper frame (D, Fig. 3-12) and locknut ring. Approximately 7 to 10 revolutions will be required, depending on the initial position of the support bowl. 15. Depress the STOP button after the support bowl becomes completely unthreaded. Lockout/tagout power   to the hydraulic control console. 16. Type “A” support bowl assemblies only: Install 3/4 inch eyebolts in the three lifting holes on the support bowl driver. Secure the eyebolts with jamnuts. 17. Type “B” support bowl assemblies only: Install 3/4 inch eyebolts in the three lifting holes on the top edge of the support bowl (Fig. 3-13). Secure the eyebolts with jamnuts. 18. Using an appropriate lifting device and cables, carefully lift the support bowl straight up and remove it from the upper  frame. See Figure 3-13. 19. Suspend the support bowl over a clean, flat work area.

 Figure 3–13. Support Bowl Lifing Arrangement 3–10

07/09

Wear Liner Replacement Telsmith SBS Cone Crusher 

Support Bowl and Concave Ring

3

 Figure 3–14. Support Bowl on Blocking (cutaway view) 20. Arrange four evenly spaced hardwood blocks directly  beneath the outer edge of the support bowl . Each tim ber  should be exactly the same height (approximately 3 inches (7.6 cm). See Figure 3-14.

IMPORTANT: Do Not place timbers beneath the lower lip of the concave ring. This area must remain unobstructed to allow room for the concave ring removal. 21. Slowly lower the support bowl onto the timbers.

07/09

3–11

Support Bowl and Concave Ring

Wear Liner Replacement Telsmith SBS Cone Crusher 

Type “C” Bowl Removal 1. Remove the nine hex head capscrews and washers bolti ng the drive ring cover (A, Fig. 3-15) to the drive ring (B, Fig. 315).

B

A

A D

3 C

A C

D A

C

 Figure 3–16. Drive Key Extension Mounting Points  A. Drive Key Extension (3) C. Drive Ring

B. Support Bowl D. Drive Keys (3)

! CAUTION

B

 Figure 3–15. Drive Ring Cover Removal  A. Drive Ring Cover C. Drive Ring Lift Points

B. Drive Ring

2. Install lift eyes or lift hooks and a lifting harness of  sufficient capacity to the three lift eyes cast in the cover (Fig. 3-15). (Drive ring covers weigh in a range from 675 lbs (306 Kg) on 38SBS to 1330 Lbs (603 Kg) on 68 SBS). Lift the cover straight up off the drive ring to remove. 3. Transfer the drive ring cover capscrews and washers from the points on the cover with three adjacent fasteners to the three drive key extensions (Fig. 3-16) supplied loose with your crusher. (Drive key extensions are pn BE-272-2174W). Bolt the drive key extensions to the top of the drive ring with three fasteners per extension as shown in Fig. 3-16.

3–12

If you are using the EXTRACT HIGH SPEED mode to remove the support bowl, make certain all hydraulic pressure is released from the locking cylinder  circuit. Failure to disconnect the hydraulic pressure line to the cylinders could result in damage to the support bowl or locking nut threads if the control switch was inadvertently returned to the CRUSH position with hydraulic pressure still connected to the locking cylinders. 4. Move the control switch to the EXTRACT HIGH SPEED  position (Fig. 3-11) and press the OPEN button. Hold both switches in this position while the support bowl unthreads from the threaded portions of the main frame and locknut. DO  NOT allow th e con tr ol swi tch to return to th e CRUSH  position while the bowl is unthreading, as this could damage the threads. As the support bowl rises, watch for thread disengagement and release the switch from the EXTRACT HIGH SPEED position when the end of the thread on the support bowl becomes visible. 5. Press the STOP button on the hydraulic control panel and disconnect power to the hydraulic unit pump. 6. Before removing the support bowl f rom the crusher, mark  the point on the upper rim with paint where the external threads end at the bottom of the bowl. Mark the corresponding position on the locking ring where the i nternal threads start. This will help correctly position components and start thread engagement when replacing the support  bowl.

07/09

Wear Liner Replacement Telsmith SBS Cone Crusher 

Support Bowl and Concave Ring

7. Thread three 3/4” lift eyes fully into the upper rim of the support bowl (A, Fig. 3-17) and attach a lift harness and hoist of sufficient capacity to lift the bowl (bowls range in weight from 2700 lbs (1225 Kg) on the 38SBS to 13,000 lbs (5,900 Kg on the 68 SBS). Make certain the external threads on the support bowl are fully disengaged from the threads on the lock ring. Lift the support bowl straight up out of the drive ring until the drive keys (D, Fig. 3-16) clear the drive key extensions (A, Fig. 3-16).

A

A

D

B

3 C

C

A A

 Figure 3–18. Felt Seal Installation.  A. Felt Seal B. Support Bowl Upper Lip C. Rough Side Facing Out D. Smooth Side Facing Up

B

 Figure 3–17. Support Bowl Lift Eyes  A. Lift Eyes (3) B. Support Bowl External Thread C. Upper Frame Internal Thread

8. Lower the support bowl onto blocking, making certain the  blocking is placed under the support bowl casting, not the maganese concave liner. 9. Examine the condition of the drive keys (D, Fig. 3-16). If  keys are deformed, cracked or excessively worn replace them at this time. 10. Inspect the felt seal on the inside upper lip of the support  bowl. If it is worn, torn, damaged or heavily contaminated with metal filings or debris, remove it and replace with new felt. All SBS crushers with the exception of the Model 68, require 5/8 in. square felt approximately 15 feet long. Model 68 crushers will require 3/4 in square felt approximately 20 feet long. Install new felt into groove with the smooth side facing up, and the rough side facing out (Fig. 3-18). Use a rubber faced mallet to seat felt in groove. Trim felt to size so that ends meet square and no material is bulging from the groove. Just prior to installation of the support bowl, coat the rough face with moly based EP#2 grease.

07/09

3–13

Support Bowl and Concave Ring

Wear Liner Replacement Telsmith SBS Cone Crusher 

CONCAVE RING REMOVAL

3

Remove the concave ring from the support bowl as described in the following steps. Refer to Figures 3-1, 3-2 and 3-3 for  exploded views and component designations. Refer to other  figures as indicated.

Old Style Series “A” and “B” Removal 1. Place the support bowl on timbers as described in the  previous section of this chapter. Be sure that the timbers are located only under the concave ring outer edge. The timbers must not extend beneath the concave ring lower lip. See Figure 3-14. 2. Clean the area around the concave ring mounting lugs. Remove all accumulated dust and dirt.

! CAUTION The concave ring can release and drop at any time after the mounting lugs are cut. To prevent serious personal injury, be sure that all personnel are clear of the area between the concave ring lower lip and the ground. 3. Using a torch or air-arc, cut the concave ring mounting lugs. The number of lugs will vary depending on crusher  model. Refer to Figure 3-19. 4. Using a sledge hammer, strike the top edge of the concave ring until it breaks loose and drops from the support  bowl. 5. Units with standard concave ring lugs (Fig. 3-19): Using a torch, remove the cut-off lug ends from the taper wedge segments. Save the taper segments for later use.

CUT LUG HERE

6. Units with slotted concave ring lugs (Fig. 3-2 & 3-3): Using a torch, remove the cut-off lug ends from the tapered keys (W, Fig. 3-2). Save the keys and taper wedge segments (X, Fig. 3-2) for later use.

! WARNING Always use suitable rigging and hoisting equipment to stabilize and lift heavy objects. Lifting heavy components with inadequate hoisting apparatus can damage machinery and may result in serious personal injury or death. Refer to Appendix C for  weights. 7. Using an appropriate lifting device, move the support  bowl to a suit able work area wher e it can be thoroughly cleaned and inspected. 8. If present, remove the filler rings (M, Fig. 3-3) from the old concave ring. Save the filler rings for later use. 3–14

Note: Quantity of  lugs varies by crusher model

 Figure 3–19. Cutting Concave Ring Lugs

New Style Series “C” Removal 1. When the support bowl is removed from the upper frame, suspend it over a clean, flat work area. 2. Arrange four evenly spaced hardwood blocks directly  below the support bowl on the work area. Each timber must  be the same height. Timbers at least 3 inches (7.6 cm) tall are required.

07/09

Wear Liner Replacement Telsmith SBS Cone Crusher 

Support Bowl and Concave Ring

3. Slowly lower the support bowl onto the timbers (Fig. 320) Make certain the support timbers are placed beneath the lower ring of the support bowl only. If timbers protrude in and reach under the concave ring, they will prevent the concave ring from dropping during removal.

3

A

C

B

 Figure 3–20. Blocking Up Support Bowl  A. Support Bowl

B. Concave Ring Lip

C. Hardwood Mounting Blocks (4)

C

! CAUTION Removing the tapered wedges that support the concave ring may require standing inside the support bowl. Make certain your feet are not below the concave ring lower lip when driving out wedges. The concave liner could drop suddenly as the tapered wedges are driven out. Serious personal injury could result if all personnel are not clear of the area beneath the concave ring lower lip and the ground as the liner is prepared for removal. 4. Torch or grind off the welds holding the tapered wedges in place at the concave ring ears (B, Fig. 3-21). If possible, Do  Not   cut through the wedges, as they will be reused when mounting the new concave ring. 5. Use a sledge and driver bar to drive the tapered wedges out from beneath the mounting ears. The concave ring should drop down of its own weight as the final tapered wedge is driven out.

07/09

A

B

B

 Figure 3–21. Wedge Removal  A. Tapered Wedge

B. Weld

C. Concave Ear 

6. If the concave liner does not drop down after the wedges are removed, it will be necessary to strike the top edge of the liner and the ears with a sledge hammer to free the liner. 7. When the liner has dropped, use a torch to remove the wedges (and keys if used) from the torched off mounting ear  segments. If wedges and keys are not damaged they can be reused in the new liner installation.

3–15

Support Bowl and Concave Ring

Wear Liner Replacement Telsmith SBS Cone Crusher 

! WARNING

3

Always use suitable rigging and hoisting equipment to stabilize and lift heavy objects. Lifting the support bowl or concave ring with inadequate hoisting apparatus can damage machinery and may result in serious personal injury or death. 8. Using a hoist and crane of suitable rating, lift the support  bowl a slight distance off the concave ri ng and check for the location of the filler rings (if your crusher is equipped with filler rings). If filler r ings (L, Fig. 3-2) are stuck to the support  bowl by Smithbond, remove them before they drop and cause damage. If all filler rings have remained seated on the old concave ring, continue to lift the support bowl free of the concave ring.

! WARNING When grinding, cutting or breaking up pieces of  old Smithbond filler it is mandatory to wear a respirator that prevents inhalation of toxic fumes. Failure to provide adequate ventilation and filter toxic fumes could cause injury to personnel working on t he crusher. 9. Move the support bowl to a suitable stand or work area where it can be cleaned and examined. Clean any remaining Smithbond backing material from the bowl with a handheld grinder. Use a grinder to remove any weld in the area where the wedges were removed. Be careful not to nick or scratch the machined seat of the support bowl while cleaning or  grinding on the bowl. Check that the mounting surfaces for  the concave support ears are clean and flat. Check that the exterior threads on the bowl are undamaged. If support bowl is reusable, remove the old grease from threads, as contamination in the grease could cause problems during reassembly. 10. Remove the filler rings from the old concave ring and clean any Smithbond filler from the rings. Check the filler  rings (Fig. 3-22) for signs of damage, particularly at the lower  seating surface and at the mounting holes. If a filler ring is  bent , show s sign s of chat ter marks on the surface or has damaged mounting holes or broken or bent mounting feet, replace it.

3–16

B

A

D

C

 Figure 3–22. Filler Ring Inspection  A. Filler Ring C. Locator Mounting Hole

B. Lift Hole D. Mounting Feet (4)

CONCAVE RING INSTALLATION Old Style Series “A” and “B” 1. Place a new concave ring on hardwood blocking so it is raised about 3 or 4 inches (7.6 - 10.1 cm) off the ground. The ring must be evenly supported and completely level (Fig. 323).

 Figure 3–23. Concave Ring on Blocking 2. Inspect the machined seat area on both the support bowl and the new concave ring (Fig. 3-24). Remove any burrs or  rough spots with a grinder. The seating surfaces must be clean, dry and with a uniform surface free of r ust, paint etc. to  promote a proper seal.

07/09

Wear Liner Replacement Telsmith SBS Cone Crusher 

Support Bowl and Concave Ring

B

3

Coat With Heavy Gear Oil (ISO 150)

No Lube

N   o L  u b  e 

A

N   o L  u b  e 

 Figure 3–25. Lubricant Application Area 6. Install 3/4 inch eyebolts into the three lifting holes on the top edge of the support bowl. Secure the eyebolts with  jamnuts.

 Figure 3–24. Seat Inspection  A. Concave Ring

B. Support Bowl

3. Apply a coat of heavy gear oil (ISO 150) to the curved upper surface of the support bowl (Fig. 3-25). DO NOT apply any lubricant to the machined seat at the bottom.

IMPORTANT: DO NOT apply any lube to the concave ring. 4. Apply a thin coat of heavy gear oil to the complete surf ace of each filler ring. (Lubricant is applied to help prevent adhesion of filler compound.). 5. Lift each filler ring up into position on the concave ring with a suitable lifting device. Position the filler ring locator  mounting hole (C, Fig. 3-22) over the mounting stub on the concave ring and lower into position.

07/09

! WARNING Always use suitable rigging and hoisting equipment to stabilize and lift heavy objects. Lifting heavy components with inadequate hoisting apparatus can damage machinery and may result in serious personal injury or death. Support bowls range in weight from 2,600 lbs (1179 Kg) on the Model 38 to 12,000 lbs (5443 Kg) on the Model 68. 7. Slowly lower the support bowl onto the concave ring (Fig. 3-26. Align the support bowl so that the support bowl slots align with the concave ring lugs. Lower the support bowl so the slots pass down over the lugs.

3–17

Support Bowl and Concave Ring

Wear Liner Replacement Telsmith SBS Cone Crusher 

3

A

B

 Figure 3–27. Positioning The Concave Ring  A. Take Measurement at 4 places 90 o apart B. Space lugs evenly between support bowl cutouts

11. If necessary, shift the concave ring with a crowbar so that it is centered within the support bowl (Fig. 3-28).

 Figure 3–26. Lowering the Support Bowl onto the Concave Ring 8. When the support bowl slots are approximately 1/2” (1.2 cm) below the lugs, stop lowering the support bowl. Rotate the support bowl so that the lugs on the concave ring are centered between the slots (Fig. 3-27). Finish lowering the support bowl down onto the concave ring when the lugs are correctly aligned. 9. Remove the lifting cables from the support bowl. 10. When the concave ring lugs are correctly positioned in relation to the cutouts, check that the concave ri ng is centered in the support bowl. Measure the distance from the inner edge of the support bowl to the t op edge of the concave ring at four  locations 90o  degrees apart (Fig. 3-27). All four  measurements must be equal.

 Figure 3–28. Center Concave Ring 12. Install the wedges under the concave ring lugs. On models with slotted lugs, install the keys (W, Fig. 3-2).

3–18

07/09

Wear Liner Replacement Telsmith SBS Cone Crusher 

Support Bowl and Concave Ring

13. Using a hammer, alternately tap all wedge segments into  place until they are snug against the machined surface of the support bowl. 14. Switch to a sledge hammer and drive bar and alternately drive the wedge segments tight until they will not move (Fig. 3-29). Follow the sequence in Figure 3-30 when tightening the wedges on your model crusher.

3

38, 44 & 52

 Figure 3–29. Tightening Wedge Segments 57 Only

IMPORTANT: Be certain that all wedge segments are driven as tight as possible. Failure to fully tighten wedge segments could allow the concave ring to loosen during crushing. 15. Re-check the concave ring position in the support bowl when all wedges are tight. Check that the ring is still centered in the bowl and has not shifted. If measurements are unequal (Fig. 3-27), it will be necessary to drive the wedge segments  back out and re-center the ring in the bowl.

68 Only

 Figure 3–30. Wedge Tightening Sequence per Model 16. Using a feeler gauge check that the machined seat of the concave ring is TIGHT against the machined seat of the support bowl. Move completely (360 o) around the lower edge of the support bowl checking the clearance (Fig. 3-31). There should be no clearance at any point.

07/09

3–19

Support Bowl and Concave Ring

Wear Liner Replacement Telsmith SBS Cone Crusher 

3

 Figure 3–31. Checking Ring to Bowl Clearance

IMPORTANT: Make certain the concave ring is properly installed as described in the previous steps. Serious damage to the support bowl will occur if the concave ring is loose or  cocked when the crusher is put into production. 17. If any clearance is detected in Step 16, check again that the concave ring is centered in the support bowl, and that all wedges are fully seated. If the concave ring is correctly seated, any clearance may indicate that the support bowl has wear on the machined seat. Any worn areas will need to be sealed with putty before pouring the Smithbond sealant. This will prevent any of the backing sealant from leaking out through the worn areas.

Figure 3–32. Welding Wedge Segments 19. For crusher models equipped with a tapered key and a tapered wedge (Fig. 3-33), tack weld the wedge to the tapered key.

! CAUTION DO NOT weld the tapered wedges to the support bowl. Concave ring lugs may break if tapered wedges are welded to the support bowl. 18. For crusher models using a tapered wedge only (Fig. 332), tack weld the taper wedges to the concave ring lugs.

 Figure 3–33. Welding Taper Key Models

3–20

07/09

Wear Liner Replacement Telsmit h SBS Cone Crusher 

Support Bowl and Concave Ring

20. Before mixing and pouring Smithbond epoxy backing compound, determine the amount of Smithbond required for  your crusher model using Table 3-1. Make certain you have an adequate amount of compound to complete the job.

Table 3–1. Smithbond Required Quantities (22 Pound Containers) Fine Concave

Medium Fine Concave

Medium Concave

Medium Coarse Concave

Coarse Concave

Extra Coarse Concave

38S

N/A

N/A

2

2

2

N/A

38FC

6

N/A

6

N/A

6

N/A

44S

N/A

N/A

5

N/A

5

5

44FC

4

N/A

5

N/A

5

N/A

52S

N/A

N/A

8

N/A

6

6

52FC

7

N/A

6

N/A

6

N/A

57S

N/A

N/A

15

N/A

10

8

57FC

18

16

15

12

14

N/A

68S

N/A

N/A

16

N/A

16

16

68FC

24

N/A

22

N/A

22

N/A

Crusher  Model

NOTE: Quantities shown are approximate. Actual quantities required may vary. Consult Telsmith if your 

liner configuration is not shown above. 21. Mix each pail of Smithbond one-at-a-time as described in the  Mixing and Pouring Smithbond   section of this chapter. After mixing, pour the Smithbond mixture through the support bowl slots as shown in Figure 3-34.

22. Continue mixing and pouring Smithbond until the Smithbond is level with the bottom of the support bowl vertical face (Fig. 3-35). Do Not overfill the slots with Smithbond and allow the level to rise up and overflow onto the wedge seating surfaces. Correct Smithbond level can be determined by measuring Dimension “A” between the  bottom of the support bowl vertical face and the machined  wedge seating surface. The pour dimension is model specific as outlined in the dimension chart of Figure 3-35. Pouring time can be reduced if more than one individual pours Smithbond, allowing the pour to occur at multiple locations around the top of the support bowl at one time.

 Figure 3–34. Pouring Concave Ring Smithbond

07/09

3–21

3

Support Bowl and Concave Ring

Wear Liner Replacement Telsmith SBS Cone Crusher 

New Style “ C”

B

3

1. Place a new concave ring on hardwood blocking so it is raised about 3 or 4 inches (7.6 - 10.1 cm) off the ground. The ring must be evenly supported and completely level (Fig. 336).

 A B

C

D

E

F

Dimension A (Backing Fill Level): 38 SBS: 0.88” (2.2 cm) 44 H/SBS: 1.00” (2.5 cm) 52 H/SBS: 1.38” (3.5 cm) 57 H: 1.61” (4.0 cm) 57 SBS: 1.00” (2.5 cm) 68 H: 2.38” (6.0 cm) 68 SBS: 1.38” (3.5 cm)

 Figure 3–35. Support Bowl Backing Fill Level  A. Fill Dimension (Concave Ring) B. Smithbond Backing Levels C. Support Bowl D. Concave Ring E. Mantle F. Head

 Figure 3–36. Blocking Up New Concave Ring 2. Inspect the machined seat area on both the support bowl and the new concave ring. (Fig. 3-37). Remove any burrs or  rough spots with a grinder. The seating surfaces must be clean, dry and with a uniform surface free of r ust, paint etc. to  promote a proper seal.

23. Allow adequate time for Smithbond to harden. In most climates, at least four hours will be required. In colder  climates, allow at least eight hours or let Smithbond harden overnight. 24. Prepare and install the support bowl in the upper frame following the instructions in this chapter when the Smithbond  has fully hardened.

3–22

07/09

Wear Wear Liner Replacement Replacement Telsmit Telsmit h SBS Cone Crusher 

Support Bowl and Concave Ring

IMPORTANT: DO NOT apply any grease or gear oil to the concave ring.

3

N O  O GRE   A SE 

N O  O GRE   ASE 

N   O 

G R  E    A S  E  

 Figure  Figure 3–37. 3–37. Seat Seat Inspect Inspection ion 3. Apply a thin coat of NLGI#2 grease, or a generous coating of heavy gear oil to the curved upper surface of the support  bowl including the lug pockets (Fig. 3-38). DO NOT apply any grease or gear oil to the machined seat at the bottom.

 Figure 3–38. 3–38. Greasing Greasing the Support Support Bowl 4. Apply a thin coat of grease to the complete surface of each filler ring. (Gr ease is applied to help prevent adhesion of filler  compound.) 5. Lift each filler ring (if used) up into position on the concave ring with a suitable lifting device (Fig. 3-39). Position the filler ring locator mounting hole over the concave mounting stub (B, Fig. 3-39) and lower i nto position.

07/09

3–23

Su p p o r t B o w l an d Co n c av e Ri n g

Wear L i n er Rep l ac em en t Telsmith SBS Cone Crusher 

D

3

 A B C

 Figure  Figure 3–39. Concave Concave Ring Ring Installatio Installation n  A. Filler Ring C. Concave Ring

B.Concave Mounting Mounting Stub D. Lift Hole

6. Install 3/4 inch eyebolts into the three lifting holes on the top edge of the support bowl. Secure the eyebolts with  jamnuts.

! WARNING  A l w a y 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. L i f t i n g h e av av y c o m p o n e n t s w i t h i n a d e q u a t e hoisting apparatus can damage machinery and may result in serious personal injury or death. Support bowls range in weight from 2, 2,60 600 0 lbs (1179 (1 179 Kg) on the Mod el 38 to 12,0 12,000 00 lbs (54 (5443 43 Kg) on the Model 68. 7. Slowly lower the support bowl onto the concave ring (Fig. 3-40). Align the support bowl so that the support bowl slots align with the concave ring lugs. Lower the support bowl so the slots pass down over the lugs. Lower the support bowl until it is resting on the machined lip of the concave ring. DO  NOT rotate the suppor t bowl, b owl, the support bowl cutout slots must remain aligned with the ears on the concave ring.

 Figure 3–40. 3–40. Lowering Lowering the Support Support Bowl Bowl onto onto the Concave Ring 8. Remove the lifting cables from the support bowl. 9. Measure the distance from the inner edge of the support  bowl to the top edge of the concave concave ring at four locations 90o apart (Fig. 3-41). All four measurements must be equal.

3–24

07/09

Wear Wear Liner Replacement Replacement Telsmit Telsmit h SBS Cone Crusher 

Support Bowl and Concave Ring

IMPORTANT: 2 1

The taper wedges used on Model 38 liners differ from the wedges used on 44/52/57/68 liners. Model 38 wedges do not have a rim. Wedges are not interchangeable (see Fig. 3-44 & 3-45). 12. Switch to a sledge hammer and drive bar and alternately drive the wedge segments tight until they will not move (Fig. 3-43). Follow the sequence in Figures 3-44 & 3-45 when tightening the wedges on your model crusher.

4

3

 Figure 3–41. Concave Concave Ring Centerin Centering g Measurement Measurements s 10. If necessary, shift the concave ring with a crowbar so that it is centered within the support bowl (Fig. 3-42). When the concave ring is correctly centered, check to make sure that the ears are still located directly above the support bowl slots. If  not, rotate the concave ring until ears are above the slots.

 Figure 3–43. Tightenin Tightening g Wedge Wedge Segments Segments

1

4

3

Non-Rim Wedge

2

MODELS 38

 Figure 3–44. 3–44. Wedge Wedge Tightening Tightening Sequenc Sequence e Model 38  Figure 3–42. Centering Centering The The Concave Concave Ring. Ring. 11. Using a hammer, alternately tap all taper wedge segments into place until they are tight beneath the concave ring ears and have bridged the slots in the support bowl. 07/09

3–25

3

Support Bowl and Concave Ring

Wear Liner Replacement Telsmith SBS Cone Crusher 

IMPORTANT: Make certain that all wedge segments are driven as tight as possible. Failure to fully tighten wedge segments could allow the concave ring to loosen during crushing.

1

3 4

3 Rimmed Wedge 2

14. Using a feeler gauge, check that the machined seat of the concave ring is TIGHT against the machined seat of the support bowl. Move completely (360o) around the lower edge of the support bowl checking the clearance (Fig. 3-46). There should be no clearance at any point.

MODELS 44 & 52

4

5

13. Re-check the concave ring position in the support bowl when all wedges are tight. Check that the ring is still centered  in the bowl and has not shifted. If measurements are unequal (Fig. 3-41), it will be necessary to drive the wedge segments  back out and re -c ente r th e ri ng in th e bo wl . Wh en re tightening the wedges, make certain to alternate wedges every few blows to prevent the bowl from shifting to one side.

2 1 Rimmed Wedge 3

MODEL 57

1 6

 Figure 3–46. Measuring Seat Clearance 4

IMPORTANT:

3

Rimmed Wedge

5 2

MODEL 68

 Figure 3–45. Wedge Tightening Sequence per Model

3–26

Make certain the concave ring is properly installed as described in the previous steps. Serious damage to the support bowl will occur if the concave ring is loose or  cocked when the crusher is put into production. 15. If any clearance is detected in Step 14, check again that the concave ring is centered in the support bowl and that all wedges are fully seated. If the concave ring is correctly seated, any clearance may indicate that the support bowl has wear on the machined seat. Any worn areas will need to be sealed with putty before pouring the Smithbond sealant. This will prevent any of the backing sealant from leaking out through the worn areas.

07/09

Wear Liner Replacement Telsmit h SBS Cone Crusher 

Support Bowl and Concave Ring

16. Tack weld the taper wedges to the concave ring lugs (Fig. 3-47).

! CAUTION DO NOT weld t he tapered wedges to t he suppor t bowl. Concave ring lugs may break, if tapered wedges are welded to the suppor t bowl . 17. Before mixing and pouring Smithbond epoxy backing compound, determine the amount of Smithbond required for  your crusher model using Table 3-2. Make certain you have an adequate amount of compound to complete the job.

Figure 3–47. Welding Tapered Wedge Segments Table 3–2. Smithbond Required Quantities (22 Pound Containers) Crusher  Model

#1

#2

#3

#4

#5

#6

#7

#8

#9

38SBS

N/A*

N/A*

N/A*

NA*

NA*

NA*

N/A*

N/A*

N/A*

44SBS

7

7

7

7

3

3

3

N/A

N/A

52SBS

N/A

6

6

6

6

8

8

8

8

57SBS

N/A

16

11

11

11

8

8

6

6

68SBS

N/A

18

18

6

18

16

16

16

16

NOTE: Quantities shown are approximate. Actual quantities required may vary. Consult Telsmith if your liner configuration is not shown above.

*Model 38 SBS crushers use non-numbered liners. Use the 38S quantities in Table 3-1 when determining quantities for the SBS. 18. Mix each pail of Smithbond one-at-a-time as described in the  Mixing and Pouring Smithbond   section of this chapter. After mixing, pour the Smithbond mixture through the support bowl slots as shown in Figure 3-48.

07/09

3–27

3

Support Bowl and Concave Ring

Wear Liner Replacement Telsmith SBS Cone Crusher 

B

3  A B

C

D

E

 Figure 3–48. Pouring Smithbond Backing 19. Continue mixing and pouring Smithbond until the Smithbond is level with the bottom of the support bowl vertical face (Fig. 3-49). Do Not overfill the slots with Smithbond and allow the level to rise up and overflow onto the wedge seating surfaces. Correct Smithbond level can be determined by measuring Dimension “A” between the  bottom of the support bowl vertical face and the machined  wedge seating surface. The pour dimension is model specific as outlined in the dimension chart of Figure 3-49. Pouring time can be reduced if more than one individual pours Smithbond, allowing the pour to occur at multiple locations around the top of the support bowl at one time.

F

Dimension A (Backing Fill Level): 38 SBS: 0.88” (2.2 cm) 44 H/SBS: 1.00” (2.5 cm) 52 H/SBS: 1.38” (3.5 cm) 57 H: 1.61” (4.0 cm) 57 SBS: 1.00” (2.5 cm) 68 H: 2.38” (6.0 cm) 68 SBS: 1.38” (3.5 cm)

 Figure 3–49. Support Bowl Backing Fill Levell  A. Fill Dimension (Concave Ring) B. Smithbond Backing Levels C. Support Bowl D. Concave Ring E. Mantle F. Head

20. Allow adequate time for Smithbond to harden. In most climates, at least four hours will be required. In colder  climates allow at least eight hours or let Smithbond harden overnight. 21. Prepare and install the support bowl in the upper frame following the instructions in this chapter when the Smithbond  has fully hardened.

3–28

07/09

Wear Liner Replacement Telsmit h SBS Cone Crusher 

Support Bowl and Concave Ring

SUPPORT BOWL PREPARATION Prepare the support bowl for installation as described in the following steps. 1. Be sure that power remains locked-out. Refer to Chapter 1 for complete lockout/tagout instructions.

3

2. Replace the concave ring if it is cracked, damaged or  worn beyond its useful life. Refer to the procedures earlier in this chapter for concave ring removal and installation  procedures. 3. Remove all dirt, rust and old grease from the buttress threads of the support bowl (Fig. 3-50), the locknut ring and  the upper frame..

 Figure 3–50. Cleaning the Buttress Threads 4. Use a wire brush on the buttress threads. File any rough areas. Remove any nicks, burrs or scratches. 5. After cleaning, carefully inspect all buttress threads for  signs of damage or excessive wear. Make repairs as required. 6. Inspect the support bowl felt seal. On Type “A” assemblies, the seal is located inside t he support bowl driver. On Type “B & C” assemblies, the seal is located near the top of the support bowl. Replace the seal if it is worn or damaged. Refer to Figure 3-51 for seal lengths. See Figure 3-52 for seal orientation. 7. Inspect the felt seal at the bottom of the upper frame. Replace the seal if it is worn or damaged. Refer to Figure 351 for seal lengths. See Figure 3-52 for seal orientation.

07/09

3–29

Support Bowl and Concave Ring

Wear Liner Replacement Telsmith SBS Cone Crusher 

3  A B

Crusher Model Seal Length in feet/(cm) Seal Thickness in inches/(mm)

38

44

52

57

68

11.0 (335.3)

12.5 (381.0)

14.4 (438.9)

16.3 (496.8)

18.4 (560.8)

5/8 (16)

5/8 (16)

5/8 (16)

5/8 (16)

5/8 (16)

Note: All dimensions shown above are approximate

 Figure 3–51. Felt Seal Installation (Support Bowl)  A.Type “A” Support Bowl Felt Seal

B. Type “B & C” Support Bowl Felt Seal

8. Type “A” support bowl assemblies only: If removed, reinstall the support bowl driver. Secure with socket head  capscrews and flatwashers. Apply thread locking compound  to capscrews as installed. Refer to Appendix E for thread  locking compound specifications. See Appendix A for t orque specifications.

.

9. Type “B & C” support bowl assemblies only: If removed, reinstall the support bowl driver keys. Secure with socket head capscrews and flatwashers. Apply thread locking compound to capscrews as installed. Refer to Appendix E for  thread locking compound specifications. See Appendix A for  torque specifications

B  A

 Figure 3–52. Seal Orientation (all felt seals)  A. Rough Side Faces OUT

3–30

B. Smooth side faces UP

07/09

Wear Liner Replacement Telsmit h SBS Cone Crusher 

Support Bowl and Concave Ring

IMPORTANT: Use only moly-based EP-2 grease in the following steps. Refer to Appendix D for grease specifications. Before applying grease, be certain that the buttress threads are clean, in good condition and completely free of any rust, nicks or burrs.

.

10. Coat the buttress threads of the locknut ring and the upper  frame with moly-based EP-2 grease (Fig. 3-54). 11. Coat the buttress threads of the support bowl with moly based EP-2 grease (Fig. 3.54). 12. Coat the smooth lower surface of the support bowl with moly-based EP-2 grease. 13. Coat both felt seals with moly-based EP-2 grease.

IMPORTANT: Failure to apply grease as described in the previous steps may result in thread damage and/or  excessive thread wear.

Crusher  Model

Seal Length feet/(cm)

Seal Thickness inches/(mm)

38

12.3 (374.9)

5/8 (16)

44

13.3 (405.3)

5/8 (16)

52

16.4 (499.8)

5/8 (16)

57

18.0 (548.6)

5/8 (16)

68

20.0 (609.6)

3/4 (16)

Note: All dimensions shown are approximate

 Figure 3–53. Felt Seal Installation (Upper Frame)

07/09

3–31

3

Support Bowl and Concave Ring

Wear Liner Replacement Telsmith SBS Cone Crusher 

.

3

C

 A

 A

C

B

 Figure 3–54. Greasing Threads and Seals  A. Grease Buttress Threads

3–32

B. Grease Machined Surface

C. Grease All Felt Seals

07/09

Wear Liner Replacement Telsmit h SBS Cone Crusher 

Support Bowl and Concave Ring

SUPPORT BOWL INSTAL LATION Old Style “ A” and “B” Install the support bowl as described in the following steps:

6. If removed, reinstall the extension brackets onto the drive ring (Fig. 3-55). Secure the extension brackets with capscrews, flatwashers and nuts. Refer to Figures 3-7 and 38 for installation details.

1. Be sure that power remains locked-out. Refer to Chapter  1 for complete lockout/tagout procedures.

3

! WARNING

3. Type “A” support bowl assemblies only: Install 3/4 inch eyebolts into the three lifting holes on the support bowl driver  . Secure the eyebolts with jamnuts.

 Al way s us e sui table ri gg in g and h oi st in g equ ip men t to stabilize and lift heavy objects. Lifting heavy components with inadequate hoisting apparatus can damage machinery and may result in serious personal injury or death. Refer to Appendix C for  weights.

4. Type “B” support bowl assemblies only: Install 3/4 inch eyebolts into the three lifting holes on the top edge of the support bowl (Fig. 3-55). Secure the eyebolts with jamnuts.

7. Using an appropriate lifting device and cables, suspend  the support bowl several inches over the threaded bore of the locknut ring (Fig. 3-55).

5. If not done previously, disconnect the locking cylinder  hose at the hydraulic power unit. Leave all other hoses connected. Refer to Figure 3-10.

.

2. Prepare the support bowl for installation as described in the Support Bowl Preparation section of this chapter.

 A

B

C D

 Figure 3–55. Positioning The Support Bowl  A. Support Bowl Buttress Threads

07/09

B. Locknut Ring Threads

C. Allow 6 inches clearance between thread starts D. Extension Bracket

3–33

Support Bowl and Concave Ring

8. Slowly rotate the support bowl until the leading end of the support bowl buttress thread is positioned about 6 inches (15.2 cm) behind the start of the locknut ring buttress thread. See Figure 3-55.

3

9. Visually check that no personnel are on, under, inside or   beside the crusher. 10. Connect power to the hydraulic control console. Move the function selector switch to EXTRACT-HIGH SPEED. Refer  to Figure 3-11 for control console diagram. 11. Depress the START button. The hydraulic pump will start. 12. Type “A” support bowl assemblies only: Depress and  hold the OPEN or CLOSE pushbutton until the keys on the extension brackets become aligned with the keyways on the support bowl driver. 13. Type “B” support bowl assemblies only: Depress and hold  the OPEN or CLOSE pushbutton until the keyways on the extension brackets become aligned with the support bowl drive keys.

IMPORTANT: Be sure that the support bowl remains level as it is lowered in step 14 or 15. On some crushers, it may be necessary to loosen the extension brackets slightly to allow key engagement.

Wear Liner Replacement Telsmith SBS Cone Crusher 

20. Depress and hold the CLOSE button. Verify that the support bowl begins turning slowly clockwise. 21. Allow the support bowl to become threaded within the  bore of the locknut ring and the upper frame (Fig. 3-56). The support bowl will move slowly downward as it rotates. 22. Type “A” support bowl assemblies only: Continue to depress the CLOSE button until the keys on the drive ring  become fully engaged in the keyways of the support bowl driver. 23. Type “B” support bowl assemblies only: Continue to depress the CLOSE button until the support bowl drive keys  become fully engaged in the keyways of the drive ring. 24. Depress the STOP button. Lockout/tagout power to the hydraulic control console. Refer to Chapter 1 for  complete lockout/tagout procedures. 25. Remove capscrews, flatwashers, nuts and extension  brackets. 26. Install the inner and outer receiving hoppers. Refer to the  Receiving Hopper Installation  section of this chapter for   procedure.

. B

14. Type “A” support bowl assemblies only: Slowly lower the support bowl. Allow the keys on the extension brackets to enter the keyways in the support bowl driver. Continue lowering the support bowl until its bottom buttress thread is resting on the top buttress thread of the locknut ring . 15. Type “B” support bowl assemblies only: Sl owly lower the support bowl. Allow the drive keys to enter the keyways of  the extension brackets. Continue lowering the support bowl until its bottom buttress thread is resting on the top buttress thread of the locknut ring .

 A

16. Measure the support bowl height at all three extension  brackets. Measurements must be approximately equal in all three locations.

IMPORTANT: Be sure that the support bowl is not cocked. To ensure proper thread engagement, the support bowl must be completely level as it is threaded into the locknut ring.

C

 Figure 3–56. Threading Support Bowl  A. Extension C. Drive Ring

B. Support Bowl

17. Disconnect the lifting cables and remove the eyebolt. 18. Visually check that no personnel are on, under, inside or   beside the crusher. 19. With the function selector switch in the EXTRACTHIGH SPEED position, depress the START button. The hydraulic pump will start.

3–34

07/09

Wear Liner Replacement Telsmit h SBS Cone Crusher 

Support Bowl and Concave Ring

New Style “ C” 1. Apply Moly-based EP#2 grease to the support bowl felt seal as shown in Figure 3-57.

3

D

B

C

 A

 Figure 3–57. Felt Seal Installation.  A. Felt Seal B. Support Bowl Upper Lip C. Rough Side Facing Out D. Smooth Side Facing Up #

2. Apply a liberal amount of Moly-based EP 2 grease to the internal threads of the locknut and upper frame. Also apply grease to the external threads of the support bowl and the machined area beneath the threads (Fig. 3-58). 3. If your upper frame requires new inner or outer felt seals, install them at this time (Fig. 3-57), and coat outer face liberally with Moly-based EP#2 grease.

 Figure 3–58. Assembly Grease Points IMPORTANT: Failure to properly grease adjuster  component threads prior to assembly can result in thread damage and/or rapid thread wear. 4. Install the three 3/4 inch threaded lift eyes fully  in the support bowl as shown in Figure 3-59. Attach a lift device and  cables or chain of sufficient capacity to the lift eyes.

NOTE: It is recommended that a lift device with a hook or lift eye that can rotate 360 0 be used to ease the rethreading of the support bowl. The lifting device will need to rotate without binding or putting excess strain on the lift chains or cables while engaging the threads. 5. Carefully lift the support bowl and suspend a few inches above the drive key extensions. Make certain the support  bowl is completely level. Rotate the support bowl until the match marks you made previously on the support bowl and  the locking ring are aligned .

07/09

3–35

Support Bowl and Concave Ring

Wear Liner Replacement Telsmith SBS Cone Crusher 

9. Hold the control switch in the Extract High Speed  position and acti vate the Close  button. The support bowl should rotate slowly down into the upper frame. If any grinding, jerking or slowing of the rotation is noted, STOP the rotation immediately by releasing the Close button. If the  bowl does not rotate smoothly, this could be a sign of cross threading, damaged threads or resistance created by the lift apparatus.

E

 A

3

NOTE: If the lift apparatus remains attached while the bowl is descending into the upper frame, continue to provide additional slack in the lift harness. Failure to provide sufficient slack could result in the support bowl threads being pulled up against the upper frame threads, creating resistance to rotation.

D

B

RECEIVING HOPPER INSTALLATION

C

 Figure 3–59. Orienting Support Bowl  A. Drive Key (3) C. Locking Ring Match Mark E. Lift Eye (3)

10. When the support bowl has rotated completely to the  bottom of the upper frame, stop the rotation and remove the lift eyes and lift apparatus from the bowl if not removed   previously. Unbolt the drive key extensions (B, Fig. 3-59) from the drive ring.

B. Drive Key Extension (3) D. Support Bowl Match Mark

6. Rotate the support bowl back (counterclockwise) from the locking ring mark until the drive keys on the support bowl are aligned with the drive key extensions. (Rotating the bowl  back will help ensure that the threads engage properly in step 7). Lower the support bowl down, engaging the drive keys in the drive key extensions.

Old Style ‘A” and “ B” Reinstall the inner and outer receiving hoppers as described  in the following steps. Refer to Figures 3-2 and 3-3 for  exploded views. 1. Be sure that power remains locked-out. Refer to Chapter  1 for complete lockout/tagout procedures. 2. Reinstall the support bowl as described in the Support   Bowl Installation sections earlier in this chapter.

! WARNING

7. Manually rotate the support bowl clockwise a small amount to ensure the support bowl threads engage correctly with locking ring threads. (Using a long bar as a lever on top of the bowl may be necessary to rotate the bowl). If any resistance is felt or the bowl refuses to turn, back up and start over. Any resistance is an indication the threads are cross threaded or jammed.

 Al way s us e sui tab le ri gg in g and h oi st in g equ ip men t to stabilize and lift heavy objects. Lifting heavy components with inadequate hoisting apparatus can damage machinery and may result in serious personal injury or death. Refer to Appendix C for  weights.

8. Restore hydraulic and electrical power to the crusher. Provide some slack in the lift apparatus to allow the bowl to rotate down.

3. Using an appropriate lifting device and cables, slowly lower the inner receiving hopper straight down into the support bowl.

NOTE: When the support bowl has rotated several rotations and the threads have moved through the locking ring and down into the upper frame, it is permissible to stop the rotation and remove the lift apparatus and lift eyes from the bowl.

4. Clean the top surface of the drive ring and the mating surface of the outer receiving hopper. Apply a bead of caulk  completely around the drive ring. See Figure 3-60.

3–36

07/09

Wear Liner Replacement Telsmit h SBS Cone Crusher 

Support Bowl and Concave Ring

 A

3

B

 Figure 3–60. Caulk Application  A. Caulk

B. Drive Ring Upper Flange

5. If not done previously, coat the felt seal with moly-based  EP-2 grease. Refer to Appendix D for grease specifications. 6. Using an appropriate lifting device and cables, slowly lower the outer receiving hopper into the concave ring (Fig. 3-61). Be sure that bolt holes are aligned.

 Figure 3–61. Outer Receiving Hopper Installation 7. Remove the lifting cables from the outer receiving hopper. 8. Using a mallet, evenly tap completely around the edge of  the outer receiving hopper until it is firmly seated against the top of the drive ring. Secure the hopper with capscrews flatwashers and nuts. Torque fasteners to 150 ft. lb. (203 nm) . 9. Reconnect the locking cylinder hose at the hydraulic  power unit. 10. Restore power to the crusher, and rotate the support bowl open and closed to check adjusting assembly operation. If the unit is working correctly, set your crusher final discharge setting by following the instructions in your Operation and   Maintenance Manual. 11. Install any conveyors, chutes, hoppers or any other feed  equipment that was removed to gain access to the support  bowl.

07/09

3–37

Support Bowl and Concave Ring

DRIVE RING COVER INSTALLATION New Style “ C”

3

Wear Liner Replacement Telsmith SBS Cone Crusher 

6. Install any conveyors, chutes, hoppers or any other feed  equipment that was removed to gain access to the support  bowl.

1. Install the support bowl following the instructions in  Adjuster Assembly Support Bowl Installation in this chapter. 2. Remove drive key extensions and store for future use. 3. Install lift eyes and lift apparatus of sufficient capacity to the drive ring cover and lift cover into position above drive ring (Fig. 3-62). Align mounting holes with the threaded  holes in the drive ring where the drive key extensions were removed. Install nine (9) hex head cap screws and washers and torque to 150 Ft. lb. (203 Nm).

 Figure 3–62. Install Drive Ring Cover  4. Install the clamping cylinder hydraulic hoses at the hydraulic power unit manifold.

NOTE: If the hydraulic clamping cylinder hydraulic circuit was opened (cylinder replaced, cylinder hoses disconnected etc.) during adjusting assembly service, it will be necessary to bleed the hydraulic clamping cylinder circuit. Follow the instructions in Upper Frame Hydraulic System Service in this chapter. 5. Restore power to the crusher, and rotate t he support bowl open and closed to check adjusting assembly operation. I f the unit is working correctly, set your crusher final discharge setting by following the instructions in your Operation and   Maintenance Manual. 3–38

07/09

Wear Liner Replacement Telsmit h SBS Cone Crusher 

Support Bowl and Concave Ring

MIXING AND POURING SMITHBOND The epoxy based material required to fill the voids between the concave ring and support bowl of the crusher is Smithbond. This compound provides a solid backing surface that helps prevent the concave ring from becoming deformed  during crushing. New Smithbond is required whenever the concave ring is replaced.

 A

3

B

Smithbond Safety Precautions

! WARNING F ai l u r e t o o b s e r v e t h e f o l l o w i n g s a f et y precautions may result in serious personal injury or death. •

Mix and pour Smithbond only in a well ventilated area. Avoid inhaling fumes.

•

Wear rubber or plastic gloves when working with Smithbond. Always wear eye protection.

•

Avoid contact with Smithbond. Use soap and water to remove any Smithbond that comes in contact with the skin. Immediately flush eyes with running water if eye contact occurs.

•

Clothes soiled with Smithbond must be laundered before  being re-worn.

•

Provide adequate ventilation when removing parts backed  with Smithbond. Wear an airline grade respirator to  prevent inhalation of fumes when torch cutting, grinding or chopping Smithbond.

•

C

Read the labels on the Smithbond pail and the Smithbond  hardener can (Fig. 3-63) for additional warnings, directions and safety precautions.

D

E

F

 Figure 3–63. Smithbond Kit Components  A. Hardener Can C. Cover E. Stirring Rod

B. Plastic Partition D. Resin F. Pail

•

For best results, crusher parts should be between 65oF (18oC) and 90oF (32oC) during pouring.

Tips for Handling Smithbond •

The Smithbond “kit” is shipped in a plastic pail. Each kit contains a pre-measured amount of liquid resin. Included  separately inside the pail is a small can of liquid hardener  and a stirring rod (Fig. 3-63)

•

Subsequent batches required to completely fill the cavity may be mixed and added at any time. Newly poured  Smithbond will adhere to any Smithbond that has already hardened.

•

The required quantities of Smithbond are listed in the Tables under Concave Ring Installation  in this chapter. It is recommended that one extra pail of Smithbond be ordered as a precaution when preparing to pour concave ring backing.

•

Do not mix Smithbond in batches larger than 22 pounds. For best results, mix and pour each pail one at a time. Do  Not re-use stirring rods.

•

Store Smithbond at temperatures below 100oF (38oC). Smithbond is stable for at least 12 months after the date of  manufacture. Smithbond can be used up to 24 months after manufacture, but hardening times will increase as the kit grows older.

•

Ensure that Smithbond is at room temperature (about 70oF (21oC)) before mixing. If Smithbond is too cold, it can become viscous and have difficulty flowing into small spaces. If the Smithbond is too warm, it may harden  before it is completely poured.

07/09

3–39

Support Bowl and Concave Ring

Wear Liner Replacement Telsmith SBS Cone Crusher 

Mixing Smithbond 1. Read and understand all safety precautions on the Smithbond pail and hardener before proceeding with mixing.

3

2. Mix the resin using the stirring rod and a low speed  electric drill. Continue stirring the resin for about 5 minutes. If any crust has formed on the top of the resin use a sharp tool to break it up. 3. As stirring continues, add the entire contents of the hardener can into the pail at a slow, continuous rate. Mix until a uniform color is obtained. Be sure all settled material is thoroughly mixed (Fig. 3-64). 4. Pour Smithbond  IMMEDIATELY   after mixing in hardener.  DO NOT   allow Smithbond to stand. Hardening  begins quickly and the mixture will remain pourable for only about 15 minutes.

! CAUTION Smithbond may become hot when mixed, especially if pouring occurs during high ambient temperatures. To avoid burns, us e gloves when handling the Smithbond pail. Avoid contact with the concave ring while pouring Smithbond. 5. Mix and pour additional batches of Smithbond as required  to completely fill the cavity.

 Figure 3–64. Mixing Smithbond

3–40

07/09

Chapter 4 Mantle and Head

CONTENTS

Page EXPLODED VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 SHUTDOWN PROCEDURE  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 TOOLS AND SUPPLIES REQUIRED  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 MANTLE REMOVAL  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 MANTLE INSTALLATION  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 HEAD and SHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 Mantle Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 HEAD and SHAFT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 HEAD and SHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21 Mantle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21 Installation - Crushers Without Anti-Spin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21 Installation - Crushers With Anti-Spin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

4

FINAL INSTALLATION and ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26

07/09 (Rev 1)

4–1

Mantle and Head

Wear Liner Replacement Telsmith SBS Cone Crush er 

Shaft Nut Cap Mantle

Head

4

4–2

07/09 (Rev 1)

Wear Liner Replacement Telsmith SBS Cone Crusher 

Mantle and Head

G

H

F

B

E

D

I

4  A

C

 Figure 4–1. Exploded View, Head and Shaft Components (Type “A”)  A. Main Shaft B. Taper Head

07/09 (Rev 1)

C. Mantle D. Burn Ring

E. Shaft Nut (FC Only) F. Shaft Nut (S Only)

G. Feed Plate (FC Only) H. Shaft Nut Cap (S Only)

I. Inner Piston Ring

4–3

Mantle and Head

Wear Liner Replacement Telsmith SBS Cone Crush er 

H

G

I

F

E

D

C

 A

J B

4

K

 Figure 4–2. Exploded View, Head and Shaft Assembly (Type “B”)  A. Main Shaft B. Taper Head

4–4

C. Mantle D. Burn Ring

E. Shaft Nut F. Spacer (FC Only)

G. Feed Plate (FC Only) H. Shaft Nut Cap (S Only)

I. Inner Piston Ring J. Smithbond K. Shaft Nut Wrench

07/09 (Rev 1)

Wear Liner Replacement Telsmit h SBS Cone Crusher 

Model 38

Mantle and Head

Models 44-68 I H B G

F

E

D

 A

C

4  Figure 4–3. Exploded View, Head and Shaft Components (Type “C”)  A. Main Shaft B. Taper Head

07/09

C. Mantle D. Burn Ring

E. Shaft Nut F. Shaft Nut Cap

G. Washer  H. Hex Head Capscrew Gr5

I. Bolt Locking Plate

4–5

Mantle and Head

Wear Liner Replacement Telsmith SBS Cone Crusher 

DESCRIPTION The mantle (C, Fig. 4-1, 4-2 & 4-3) is a replaceable coneshaped maganese steel casting that forms the lower surface of  the crushing chamber. The mantle is secured by a shaft nut (E, Fig. 4-1, 4-2 & 4-3) located on the upper threaded portion of the main shaft. Before the nut is loosened for removal, a burning ring (D) located between the mantle and the nut must be cut away with a torch. A special wrench supplied with the special tools kit is required to remove the nut. Nuts come in several styles. A matching wrench is required for loosening and tightening each style nut. Smithbond, a special epoxy based backing compound, fills the void area between the top surface of the taper head (B) and the underside of the mantle (C).

B

Mantle replacement intervals will vary, depending on the amount and type of material being crushed. Replacement should always be performed before the mantle becomes excessively worn or cracked.  A

Mantle replacement can be performed in two ways. One method involves leaving the shaft and taper head in the crusher and removing only the mantle. The second method  involves removing the mantle, taper head and shaft assembly as a unit before removing the mantle. Both methods are covered in this chapter. It is recommended that the complete assembly be removed at every other mantle change to allow the shaft, taper head skirt, the inner piston ring and the upper  thrust bearing to be completely inspected.

4

C

 Figure 4–4. Type “C” Mantle Nuts and Wrenches  A. New Style Nut & Wrench (44-68) C. Model 38 Nut & Wrench

4–6

B. Old Style Nut & Wrench

07/09

Wear Liner Replacement Telsmit h SBS Cone Crusher 

SHUTDOWN PROCEDURE

Mantle and Head

TOOLS AND SUPPLIES REQUIRED •

Suitable rigging and hoisting equipment

•

Standard open-end and socket wrenches

•

Standard hex wrenches

•

Sledge hammer  

•

Shaft nut wrench*

•

Shaft nut cap lift lug*

•

Eyebolt, 1-1/4 inch or 1-1/2 inch

2. Lockout/ tagout power to the crusher drive motor. Shut off fuel supply and disconnect batteries if the crusher is  powered by a diesel engine. Refer to Chapter 1 for detailed  safety procedures and lockout/tagout information.

•

Crowbar  

•

Hand grinder  

•

Tape measure and feeler gauge

3. Lockout /tagout power to all crusher feed and discharge equipment.

•

Cold steel chisel

•

Cleaning solvent, clay and putty

•

Shaft nut burning ring (new)

•

NLGI #2 grease

•

Lubricating oil

•

Smithbond backing compound 

! WARNING  Al way s lo ck ou t/tagou t po wer bef or e p erf or mi ng any maintenance, adjustments, lubrication or  repairs. Failure to l ockout/tagout power m ay result in serious personal injury or death! 1. Stop the material feed, operate the crusher until the crushing chamber is completely empty. If necessary, use the hydraulic clearing function to clear the crushing chamber.

4. Lockout/tagout  power to the crusher oil-lubrication system.

IMPORTANT: Be sure that power remains connected to the hydraulic control console during the next step.

* Supplied with crusher special tools

5. Depress the STOP button on the hydraulic control console. Then jog the function selector switch between CLEAR, CRUSH, EXTRACT HI-SPEED positions several times. 6. Check that all hydraulic pressure gauges and indicators indicate zero PSI (0 bar). Repeat step 5 if any pressure is indicated. 7. Lockout/tagout power to the crusher hydraulic control console.

4

8. If you will be disconnecting the power rotator hoses or  servicing the hydraulic components in the power rotator  circuit, depressurize the power rotator circuit following the instructions in Chapter 10 of your SBS Operation and  Maintenance manual.

! WARNING Pressur es of u p to 4000 PSI (276 bar) may remain trapped in the power rotator circuit even when the hydraulic pump is off and the pressure gauge indicates zero PSI (0 bar). Relieve pressure as described in Chapter 10 of your  O p er a t o r M a n u a l b e f o r e d i s c o n n e c t i n g t h e power rotator hoses or servicing any hydraulic components in the power rotator circuit.

07/09

4–7

Mantle and Head

MANTLE REMOVAL 1. Lockout/tagout power. Perform the Shutdown Procedure described earlier in this chapter. Refer to Chapter 1 for  complete lockout/tagout instructions. 2. Remove chutes, conveyors or other feeding devices from above the crusher. 3. Remove the complete upper frame assembly from the crusher following the instructions in Chapter 3 of this manual.

Wear Liner Replacement Telsmith SBS Cone Crusher 

7. On Model 38 crushers the shaft nut cap can be lifted off  and removed by hand as it weighs approximately 20 lb. (9 kg). It is suggested that model 44-68 shaft nut caps be lifted  off using appropriately sized lift apparatus. The new “C” style shaft nut cap on models 44-68 can be lifted off using the lift lug supplied in the special tools kit. Insert the lifting lug (Fig 4-6) through the slot in the shaft nut cap and turn 90 o to engage the lifting lug tangs in the pockets of the cap. Use a  properly rated lift device to lift the lug and cap off the shaft nut.

4. Remove any built-up dirt or debris from inside the crusher. 5. Using a torch, cut through the perimeter of the burn ring (Fig. 4-5). Move completely around (360 o) the burn ring while cutting. Use the groove in the center of the ring as a guide while cutting the ring in half. The ring will collapse when cut, relieving pressure on the shaft nut.

B

! CAUTION To avoid heat damage when cutting the burn ring, dir ect the cutti ng torch away from the taper  head and the sh aft nut (Fig. 4-3).

 A

 Figure 4–6. “C” Style Shaft Nut Cap Removal  A. New Style Shaft Nut Cap

B. Shaft Nut Cap Lift Lug

8. Type “A” head and shaft assemblies only: Secure the shaft nut wrench to the shaft nut with capscrews, flatwashers and  nuts (Fig. 4-1). 9. Type “B” head and shaft assemblies only: Secure the shaft nut wrench to the shaft nut with capscrews (Fig. 4-2). 10. Note that the Type “C” 38 model shaft nut removal wrench, requires four 3/4” x 11/4” shoulder screws to bolt the wrench to the shaft nut. The new style shaft wrench used on Type “C” 44-68 models must be clamped around the shaft nut and tightened down into the pockets on the nut as shown in Figure 4-4.

4

11. Use a sledge hammer to loosen the shaft nut (Fig. 4-7 & 4-8). Drive the wrench COUNTERCLOCKWISE to loosen the nut.

 Figure 4–5. Burn Ring Removal 6. Use a torch to cut the welds holding t he bolt locking plate (I, Fig. 4-1) to the shaft nut cap (F, Fig. 4-1). Remove the locking plate, the hex head cap screw (H) and the flat washer  (G) from the shaft nut cap.

4–8

07/09

Wear Liner Replacement Telsmit h SBS Cone Crusher 

Mantle and Head

 Figure 4–7. Shaft Nut Removal (Style “A”)

 Figure 4–9. Breaking Mantle Loose

 Figure 4–8. Shaft Nut Removal (New Style “C”)

13. Lifting of the worn mantle from the taper head is most commonly done by welding lifting eyes to the mantle in three  places. Weld three pieces of mil d steel stock that can be bent to conform to the mantle surface into place using stainless steel welding rod AWSE3091L-17 (Fig. 4-10). Cut lift holes in the steel stock to mount lift eyes.

12. When the shaft nut is successfully removed, use the sledge hammer to strike the mantle in several places to break  it loose from the taper head (Fig.4-9). If the mantle will not  break loose using the sledge hammer, i t may be necessary to use the cutting torch to cut the mantle in half so it can be removed in two pieces.

4

! WARNING You must provide adequate ventilation when removing parts backed with Smithbond with a torch. Wear a properly rated respirator to prevent inhalation of fumes when torch cutting, grinding or choppi ng maganese and Smithbond.

 Figure 4–10. Mantle Lift Eye Installation

07/09

4–9

Mantle and Head

Wear Liner Replacement Telsmith SBS Cone Crusher 

! CAUTION Welding lift eyes to the mantle maganese must be done carefully with the correct equipment. Welds have a tendency to p ull o ut of t he surface of worn maganese if the lift eyes are not correctly welded into place with maganese c o m p a t i b l e w e l d i n g r o d . S t ai n l e s s s t e e l r o d  AWSE309L-17 is rec om men ded . 14. Using a suitable lifting device of correct capacity, lift the mantle a short distance off the taper head. Place blocking around the circumference of the mantle to hold it in the lifted   position. Remove the lift device and cables from the lift eyes. 15. Install mantle U hooks at three points around the lower lip of the mantle (Fig. 4-11). Transfer the lift device and cables to the U hooks (Fig. 4-11).

16. Using a hammer, chisel and hand grinder, remove all old  Smithbond and any accumulated debris from the surface of  the taper head. Do not nick or scratch the machined seat at the  bottom of the taper head.

! WARNING Provide adequate ventilation wh en removing Smithbond debris. Wear a certified respirator to prevent inhalation of fumes when torch cutting, g r i n d i n g o r b r e ak i n g u p S m i t h b o n d o r   components backed with Smithbond.

MANTLE INSTAL LATION 1. Inspect the machined seat on the taper head and the new mantle (Fig. 4-12). No paint, dirt, grease or rust should be  present on either machined surface. Remove any rough spots or burrs with a grinder.

D

C

 A

 A

4 B

 Figure 4–11. Mantle Lifting Arrangement  A. U Hook (3) B. Mantle

C. Cable or Lift Harness D. Lift Device

NOTE: If U hooks are not available, it is possible to sling through the mantle (running the slings through the shaft mounting hole at the top) at several places. When installing slings that run up the inside of the mantle, be aware of pieces of Smithbond backing that could break off and fall to the ground. 4–10

B

 Figure 4–12. Seat Inspection  A. Mantle Machined Seat

B. Taper Machined Seat

07/09

Wear Liner Replacement Telsmit h SBS Cone Crusher 

Mantle and Head

2. When both the taper head and the new mantle are clean and dry, apply a coat of heavy gear oil (ISO 150) to the unmachined upper surface of the taper head (Fig. 4-13). Do  Not apply any oil to the machined seat of the taper or any  portion of the new mantle.

C

B

 A

 Ap pl y ISO 150 Gear Oil

NO LUBE ON SEAT

 Figure 4–14. Burning Ring Installation  Figure 4–13. Taper Head Lubrication Area

 A. Mantle C. Shaft

B. Burn Ring

! WARNING  Al way s us e su it abl e ri gg in g and ho is ti ng wh en lifting the mantle into place. Lifting heavy components with inadequate or incorrectly stabilized hoisting apparatus could damage components or result in serious injury or death to personnel. 3. Install U hooks at three points around the mantle (Fig.411). Install an appropriate lift device and cables and lower the new mantle down into the crusher onto the taper head.

4

! CAUTION Do Not weld lifti ng eyes to a new mantle. Welding on t he new maganese could damage the new mantle if th e lift eyes were to fail. Use only l ift U hooks or lift harnesses to install the new mantle on t he taper head. 4. Remove the lifting apparatus and the U-hooks from the mantle. 5. Place a new burning ring around the threaded portion of  the main shaft (Fig. 4-14). Center it on the upper lip of the mantle. If the new burn ring will not drop down into position, it may be necessary to use a pry bar to center the top of the mantle in relation to the main shaft (Fig. 4-15).

07/09

 Figure 4–15. Centering Mantle 6. Measure from the shaft to the inside edge of the mantle at four positions 90o apart as shown in Figure 4-16. All four  measurements must be equal; if they are not, continue using the pry bar to position the mantle.

4–11

Mantle and Head

Wear Liner Replacement Telsmith SBS Cone Crusher 

B

 A

C D E

F G

H

 Figure 4–16. Mantle Measurements

IMPORTANT: Telsmith introduced a new style tapered shaft nut for all sizes of H/SBS cone crushers in 2008. When replacing your burn ring, it will be necessary to use the new style nut, a new style cap and a new style shaft nut wrench for the installation (Fig. 4-17).

I

Figure 4–17. Required New Parts and Tool

4

 A. Cap Bolt Locking Plate B. Shaft Nut Cap Bolt C. Washer D. Cap Lifting Lug E. Shaft Nut Cap F. Shaft Nut Wrench G. Tapered Shaft Nut H. Burn Ring I. Mantle/Head and Shaft Assembly

7. Secure the shaft nut wrench ( F, Fig. 4-17) to the shaft nut (G), and hand thread the shaft nut onto the shaft until it is snug against the burn ring (H). 8. Final tighten the shaft nut using a sledge hammer to strike the shaft nut wrench (Fig. 4-18). Tighten the nut CLOCKWISE until it stops turning. To prevent the mantle from loosening during crushing, the shaft nut must be as tight as possible against the burning ring.

4–12

07/09

Wear Liner Replacement Telsmit h SBS Cone Crusher 

Mantle and Head

 Figure 4–18. Tightening Shaft Nut 9. Remove the shaft nut wrench and all mounting hardware and store for future use. 10. Using a feeler gauge, check that the machined seat of the mantle is tight against the machined seat of the taper head. Check clearance at multiple points moving 360 o around the taper head (Fig 4-19). There should be no clearance at any  point.

IMPORTANT: Carefully inspect the joint between the mantle and the taper head. Seal any worn areas that create a gap with putty to prevent Smithbond leakage during backing installation. If any major clearance is detected, check that the mantle is not cocked, or the shaft nut not fully tightened.

 Figure 4–19. Checking Mantle to Taper Clearance 11. Install the shaft nut cap using the lift lug (D, Fig. 4-17) to lower the cap into position. Install the washer and Grade 5 hex head capscrew torquing to specification.

Table 4–1. Shaft Nut Torque Values Cone Model

Torque Specification

38

840 Ft-lb. (1138 N-m)

44

840 Ft-lb. (1138 N-m)

52

1500 Ft-lb. (2033 N-m)

57

1500 Ft-lb. (2033 N-m)

68

1500 Ft-lb. (2033 N-m)

4

NOTE: It is possible to use a new style shaft nut cap on an old style shaft nut on models 44, 52 and 57 cone crushers. To use the new style cap, grind off the locating lug (Fig. 4-20) until it is smooth with the surrounding surface.

07/09

4–13

Mantle and Head

Wear Liner Replacement Telsmith SBS Cone Crusher 

 A  A

 A

 Figure 4–20. Modifying a New Style Cap  A. Grind Lug Flush With Surface

12. The void between the mantle and the taper head will now need to be filled with Smithbond epoxy-based backing compound. Refer to Table 4-2 for the approximate amount of  Smithbond needed for your particular model crusher. Be sure that an adequate supply of Smithbond is available before  beginning the pour.

Table 4–2. Smithbond Quantities - Mantle* Crusher Model

4

Quantity

 Figure 4–21. Mantle Pouring Holes  A. Pour equal amounts of Smithbond through each access hole.

14. Mix a pail of Smithbond as described in the  Mixing and  Pouring Smithbond section in Chapter 3. 15. Slowly pour the Smithbond mixture into the clay pouring funnel at one of the pouring holes (Fig. 4-22). Allow the Smithbond to flow into the cavity between the mantle and  taper head. Continue pouring until the pail is completely empty.

(22 Pound Container)

38S/FC

2

44S

2

44FC

3

52S/FC

4

57S

8

57FC

6

68S/FC

7

*Quantities are approximate, actual quantities may vary

13. Form a clay funnel around each of the two pouring holes near the top of the mantle (Fig. 4-21).

 Figure 4–22. Pouring Smithbond 16. Mix another pail of Smithbond and pour i nto the opposite funnel from the first pour. Continue pouring until the pail is completely empty. Pouring should be alternated between the two pouring holes.

4–14

07/09

Wear Liner Replacement Telsmit h SBS Cone Crusher 

Mantle and Head

17. Mix and pour additional pails of Smithbond until the level  just reaches the lower edge of the pour hole on the mantle (Fig. 4-23). DO NOT fill the holes so that backing compound   backs up into the clay funnels. If this occurs, quickly remove the clay funnels and allow backing compound to drain down to the correct level.

23. Weld the shaft nut cap to the burning ring using stainless steel weld rod E (R) 309L. Apply 2” welds in four places as shown in Figure 4-24.

W E L D 

 WEL D

 A

C  A B

B

C

D

 Figure 4–23. Smithbond Fill Level  A. Mantle Fill Level C. Taper Head

B. Mantle D. Shaft

18. Check for Smithbond leakage at the joint between the mantle and the taper head (Fig. 4-19). Seal any leaks with  putty.

 WEL D

 Figure 4–24. Installing Shaft Nut Cap and Locking Devices  A. Shaft Nut Cap Bolt B. Washer  C. Shaft Nut Cap Bolt Locking Plate

19. Allow Smithbond to fully harden. In most climates, at least four hours will be required. In cold climates allow 8 hours.

4

20. After the Smithbond has fully hardened, remove the clay  pouring funnels and any clay putty that was used at the mantle  joint. Grind off any excess Smithbond residue. 21. Tack weld the shaft nut locking plate to the shaft nut cap (Fig. 4-24) using stainless steel weld rod E (R) 309L.

IMPORTANT: If the shaft nut cap bolt locking plate i s not welded to the shaft nut cap, the bolt could loosen and cause damage to the shaft nut cap or crusher. If you have further  questions on how or where to weld the shaft nut, shaft nut cap or burning ring, contact Telsmith Service. 22. Weld the burning ring to the mantle using stainless steel weld rod E (R) 309L. Apply 2” welds in four places as shown in Figure 4-24.

07/09

4–15

Mantle and Head

Wear Liner Replacement Telsmith SBS Cone Crusher 

HEAD and SHAFT REMOVAL If removal of the mantle also requires removal of the shaft and head assembly, remove the complete assembly as follows: 1. Lockout/tagout power. Perform the Shutdown Procedure described earlier in this chapter. Refer to Chapter 1 for  complete lockout/tagout instructions. 2. Remove chutes, conveyors or other feed devices from above the crusher. 3. To provide access, remove the complete upper frame assembly as detailed in Chapter 4 of this manual. 4. Verify that there is adequate space above the crusher to allow head and shaft removal.

NOTE: Perform steps 5 and 6 ONLY if your crusher is equipped with the anti-spin option (4-25). If your crusher is not equipped with anti-spin, skip steps 5 and 6.

 Figure 4–26. Bottom of Head Skirt to Frame Arm Measurement

With Anti-Spin

6. At a point near the Step 5 match marks, place additional match marks on the taper head skirt, the rotary seal ring, the main frame hub and the main frame liner (Fig. 4-27). These marks will be used dur ing reassembly.

4

Without Anti-Spin

 Figure 4–25. Anti-Spin Option Check 5. At one of the crusher arms, measure the distance between the top of the frame arm and the bottom of the taper head  skirt. (Fig. 4-26). Record this measurement for further use. It will be checked again during reassembly procedures.

4–16

07/09

Wear Liner Replacement Telsmit h SBS Cone Crusher 

Mantle and Head

B

 A C

 Figure 4–28. Shaft Nut Cap Removal (New Style)  A

 A. New Style Shaft Nut Cap

10. Thread an eyebolt of suitable capacity to support the head  and shaft assembly into the tapped hole at the top of the shaft (Fig. 4-29). Make certain the eyebolt is threaded completely into the hole until it is tight. Install a suitable lift device through the eyebolt.

B

 Figure 4–27. Match Marks  A. Main Frame C. Head Skirt

B. Shaft Nut Cap Lift Lug

B. Rotary Seal Ring

7. Remove the shaft nut cap bolt, washer and shaft nut locking plate from the shaft nut (Fig. 4-24). It will be necessary to use a cutting torch to remove the weld holding shaft nut locking plate to the shaft nut cap.

! WARNING  A l w ay s u s e s u i t ab l e r i g g i n g an d h o i s t i n g equipment to stabilize and lift heavy objects. L i f t i n g h e av y c o m p o n e n t s w i t h i n a d e q u a t e hoisting apparatus can damage machinery and may result in serious personal injury or death.

8. Use a torch to cut the weld holding the shaft nut locking  plate (Fig. 4-24) to the shaft nut cap. Remove the locking  plate, the hex head cap screw and the flat washer from the shaft nut cap.

4

9. On Model 38 crushers, the shaft nut cap can be lifted off  and removed by hand as it weighs approximately 20 lb. (9 kg). It is suggested that the new styl e shaft nut cap on models 44-68 be lifted off using the lift lug supplied in the special tools kit. Insert the lifting lug (Fig 4-28) through the slot in the shaft nut cap and turn 90 o to engage the lifting lug tangs in the pockets of the cap. Use a properly rated lift device to lift the lug and cap off the shaft nut.

07/09

4–17

Mantle and Head

Wear Liner Replacement Telsmith SBS Cone Crusher 

 A

 A

B C

D B

E C

D

E

 Figure 4–30. Head and Shaft Removal (“C” Style)

4

F

 Figure 4–29. Head and Shaft Removal (“A” Style)  A. Shaft and Mantle Assembly C. Bearing Cage E. Rotary Seal Ring

B. Upper Bearing Race D. Lower Bearing Race F. Bakelite Seals

 A. Shaft and Mantle Assembly C. Bearing Cage E. Eccentric Assembly

B. Upper Bearing Race D. Lower Bearing Race

IMPORTANT: The upper bearing race (B, Fig. 4-29 & 4-30) may temporarily stick to the inside of the taper head due to oil adhesion. To prevent bearing damage, do not l ift the taper head more than 2 inches off the eccentric before determining if the upper bearing race has detached from the head. 11. Slowly lift the head and shaft assembly approximately two inches off the eccentric. Stop and wait several minutes while listening for the upper race to drop. A distinctive “clunk” should be audible when the race drops down out of  the taper head.

4–18

07/09

Wear Liner Replacement Telsmit h SBS Cone Crusher 

! WARNING Do Not reach or work u nder the taper head while it is suspended. If the race remains stuck to the underside of the taper head, use a sling to r etain it as described below. Serious personal inj ury or  death will result if the race loosens and falls on personnel. 12. If there is a question whether t he race has dropped, lift the head and shaft assembly up several more inches and check  visually with a mirror to see if the race has dislodged. Do Not under any circumstances place any portion of your body under the shaft assembly while checking for the position of  the upper race.

NOTE: Hitting the side of the mantle with a sl edge hammer may help loosen a stuck upper race. 13. If the race still has not dropped down, loop a sling around  the lower end of the main shaft to f orm a noose. Do Not reach under the taper head while positioning the noose. Secure the loose end of the sling to the eyebolt at the upper end of the shaft. 14. Using the lift device, slowly lift the head and shaft assembly completely from the crusher and place on suitable work supports (Fig.4-31).

Mantle and Head

Mantle Removal Remove the mantle from the head and shaft assembly as detailed in MANTLE REMOVAL in this chapter.

! CAUTION Make certain the head and shaft assembly is securely supported when removing the mantle (Fig. 4-31). A sledgehammer will be required to break the mantle free. The head and shaft assembly m ust be securely blocked to prevent the head and shaft assembly from moving while the mantle is being broken loose.

! WARNING If the mantle must be removed by cutting with a torch, provide adequate ventilation when removing Smithbond debris. Wear a certified respirator to prevent inhalation of fumes when t o r c h c u t t i n g , g r i n d i n g o r b r e ak i n g u p S m i t h b o n d o r c o m p o n e n t s b ac k e d w i t h Smithbond.

HEAD and SHAFT INSPECTION When the head and shaft assembly is removed from the crusher, the following checks and inspections should be made. It is recommended that during the inspection  procedures the head and shaft assembly be turned over to allow a more complete inspection of the underside of the taper head. 1. Inspect the entire surface of the main shaft (Fig. 4-32) for  cracks, grooves, scratches, score marks, burn marks, pits or  rust. Attempt to polish out burn marks, scratches, rust and  scoring with an emery cloth or sandpaper.

IMPORTANT: The shaft assembly has a 16 RMS finish that can be damaged if handled improperly. NEVER attempt to remove nicks, scratches or burrs by working in a vertical motion with sandpaper, emery cloth or a file. If attempts are made to remove imperfections, use only a fine file and work horizontally when attempting to repair the surface. If the shaft will not be reused immediately, coat it with grease or oil to prevent rust.

 Figure 4–31. Supporting the Head and Shaft Assembly

2. If the shaft shows cracks, vertical grooves or surface checking (fine cracks in an area on the surface) it is recommended that the shaft be replaced.

15. If the upper bearing race remains stuck in the head, again rap on the mantle with a sledgehammer to l oosen the race and  get it to fall into the noose wrapped around the head. 07/09

4–19

4

Mantle and Head

Wear Liner Replacement Telsmith SBS Cone Crusher 

 A

B

B  A

C

D

E C

F

 Figure 4–32. Shaft and Taper Head Inspection  A. Taper Head Machined Surface C. Main Shaft

4

B. Taper Head Flange

3. Check the taper head on both the inside and outside for  signs of cracks or other damage. Cracking on the taper head  will typically be visible on the flange (B, Fig. 4-32) or on the inside of the taper at the main shaft junction. Check the inside of the taper for signs of scoring that could indicate the upper   bearing has spun. If the taper head is cracked or badly scored, it must be replaced. 4. Check the machined surface of the taper flange for  denting or gouging. Remove any surface imperfections with a grinder. 5. Check the taper flange for dents or caved in areas that could cause the flange to hang up on the eccentric assembly. If it is not possible to bend the flange back into position or  into the correct shape, it wi ll be necessary to replace the taper. 6. Inspect the upper bakelite seals (D, Fig. 4-33) for wear. Replace the seals if worn or damaged.

4–20

G

 Figure 4–33. Eccentric Assembly Components  A. Upper Bearing Race C. Lower Bearing Race E. Rotary Seal Ring G. Eccentric

B. Bearing Roller Cage D. Bakelite Seals F. Inner Piston Ring

7. Inspect the inner piston ring (F, Fig. 4-33) for cracks or  damage. File or sand any rough areas on the ring and clean out the piston ring groove thoroughly. If the piston ring is cracked or damaged, it must be replaced. 8. Inspect the upper thrust bearing components (A, B and C, Fig. 4-33) for wear, scratches, score marks, cracks in the cages, roller wear or damage, pitting in rollers or races, rust, etc. Replace the bearing if any damage is present or wear is evident.

07/09

Wear Liner Replacement Telsmit h SBS Cone Crusher 

9. Inspect the inner bronze sleeve (located inside the eccentric) for wear, burn marks, gouging or cracks. Replace the sleeve if damage is evident or the sleeve shows extensive wear.

HEAD and SHAFT INSTALLATION

IMPORTANT: If the main shaft, taper head, bearing components or the bronze sleeve in the eccentric were replaced with new components after the inspection procedure, it will be necessary to check head and shaft tolerances before re-installing the head and shaft in the crusher. Refer to the H or SBS service manual for the correct procedures on measuring tolerances.

Mantle and Head

3. Prefit the inner piston ring in the groove on the eccentric assembly to check for fit. If the ring is a loose fit in the groove, it will be necessary to shim the ends of the ring. Braze material on the ends of the ring to tighten the fit. If the ring is a tight fit and does not enter the groove and seat correctly at all points around the circumference, it will be necessary to file the ends of the ring to gain clearance. 4. Thoroughly clean the underside of the taper head making certain the labyrinth grooves are free of dust and dirt. Remove the piston ring from the eccentric and fit it in the groove on the underside of the taper head (Fig. 4-34).

 A

Mantle Installation Install a new mantle on the taper head following the instructions in MANTLE INSTALLATION  in this chapter.

IMPORTANT: Before installing the new mantle on the taper head, make certain all old Smithbond and other debris has been removed from the taper head. If it is necessary to remove material using a grinder or hand chisels, be careful not to nick or scratch the machined seat at the bottom of the taper head.

C B

D

Installation - Crush ers Without Ant i-Spin 1. Make certain that power to the crusher remains locked  out. Refer to Chapter 1 for complete lockout/tagout instructions.

4

2. If the upper thrust bearing was removed from the eccentric, install it at this time. Make certain the races are aligned correctly with the large bevel facing away from the roller cage (Fig. 4-34). The roller cage must be oriented with the notched side of the cage facing down (Fig.4-34). NOTE: Thrust bearings are supplied in two styles, TYPE 1 and TYPE 2. If you have questions on bearing type and  installation procedure, refer to the H or SBS service manual.

! CAUTION Failure to properly install and align bearing components will result in bearing failure which could d amage other comp onents on the crusher.

E

Figure 4–34. Bearing Component Orientation  A. Top Race Large Bevel Facing Up B. Bottom Race Large Bevel Facing Down C. Notches In Roller Cage Facing Down D. This Side Of Cage Facing Up E. This Side Of Cage Facing Down

5. If the eyebolt was removed, reinstall the eyebolt into the tapped hole at the top of the main shaft. 6. Lubricate the mating surfaces of the main shaft and the inner bronze sleeve with crusher lube oil.

07/09

4–21

Mantle and Head

Wear Liner Replacement Telsmith SBS Cone Crusher 

NOTE:

! WARNING  A l w ay s u s e s u i t ab l e r i g g i n g an d h o i s t i n g equipment to stabilize and lift heavy objects. L i f t i n g h e av y c o m p o n e n t s w i t h i n a d e q u a t e hoisting apparatus can damage machinery and may result in serious personal injury or death. 7. Attach a lift cable or chain to the eyebolt. Using a properly rated lifting device, carefully suspend the head and shaft assembly over the crusher. 8. Align the bottom of the main shaft with the bore of the  bronze sleeve in the eccentric (Fig. 4-35). Slowly lower the head and shaft assembly into the crusher. DO NOT rotate the assembly as it is being lowered into the sleeve.

 A

E

If the taper head will not turn in Step 11 or is difficult to turn, the inner piston ring (F, Fig. 4-33) may not have seated correctly in the bore of the rotary seal ring.  Attempt to seat the piston ring by rapping on the mantle with a sledge hammer at several points on the circumference. Check again for free rotation of the head. If the taper head is still difficult to turn, raise the head and shaft and re-center the piston ring within its groove. Re-seat the head and shaft assembly. 12. Remove the eyebolt from the shaft and store for future use. 13. Install the shaft nut cap and secure with a capscrew and  flatwasher (Fig. 4-17). Torque the shaft nut to the correct torque for your m odel crusher (Table 4-1). 14. Install the shaft nut bolt locking plate and weld the plate, the burn ring and the shaft nut cap as shown in Figure 4-24. A stainless steel weld rod E (R) 309L is required when making these welds. 15. Install the complete upper frame assembly to the crusher  following the instructions in Chapter 4 of this manual.

C B

16. Install any chutes, conveyors or other feeding devices that were removed previously.

Installation - Crushers with Anti-Spin 1. Make certain that power to the crusher remains locked out. Refer to Ch. 1 for complete lockout/tagout instructions.

4 D

F

2. If the anti-spin assembly was removed, install it on the lower frame at this time. Make certain the slider plate is aligned with the input shaft and the inspection plug hole (units built after 3/09 have inspection holes) on the front of  the anti-spin housing when bolting the unit to the bottom of  the crusher (Fig. 4-36).

 Figure 4–35. Lowering Head and Shaft Assembly  A. Lift Eyebolt C. Eccentric Assembly E. Taper Head

B. Main Shaft D. Bronze Sleeve F.Thrust Bearing Upper Race

9. Continue lowering the head and shaft assembly until the underside of the taper head is seated on the top race of the thrust bearing.

 A

10. Remove the lifting apparatus from the eyebolt when the taper and shaft assembly is fully seated. 11. Block the flywheel sheave so it cannot move. Attempt to turn the taper head by hand. The assembly should turn freely and smoothly in both directions.

B

 Figure 4–36. Aligning the Slider Plate  A. Slider Plate Groove

4–22

B. Front Inspection Hole

07/09

Wear Liner Replacement Telsmit h SBS Cone Crusher 

3.

If the upper thrust bearing was removed from the eccentric, install it at this time. Make certain the races are aligned correctly with the large bevel facing away from the roller cage (Fig. 4-34). The roller cage must be oriented with the notched side of the cage facing down (Fig. 4-34). !

Mantle and Head

6.

Thoroughly clean the underside of the taper head making certain the labyrinth grooves are free of dust and dirt. Remove the piston ring from the eccentric and fit it in the groove on the underside of the taper head (Fig. 4-37).

CAUTION

Failure to properly install and align bearing components will result in bearing failure which could d amage other comp onents on the crusher. 4.

Place a long bar down through the bore of the eccentric. Using the bar, shift the slider plate from side to side until the rectangular center hole is aligned with the round center hole of the adapter plate (Fig.4-37).

 A

 Figure 4–38. Taper Head Labyrinth Grooves  A. Piston Ring Groove

.

NOTE: Crushers built after 3/09 have two threaded inspection plugs on the anti-spin cover. These plugs should be removed and used to help visually align anti-spin components when installing the shaft drive tang into the slider plate groove. Best results can be obtained by shining a light in through the side hole (A, Fig. 4-39) and viewing the tang and slider plate through the front inspection hole (B).

 Figure 4–37. Centering the Slider Plate 5.

Prefit the inner piston ring in the groove on the eccentric assembly to check for fit. If the ring is a loose fit in the groove, it will be necessary to shim the ends of the ring. Braze material on the ends of the ring to tighten the fit. If the ring is a tight fit and does not enter the groove and seat correctly at all points around the circumference, it will be necessary to file the ends of the ring to gain clearance.

B

 Figure 4–39. Anti Spin Inspection Plugs  A. Side Inspection Plug

07/09

 A

B. Front Inspection Plug

4–23

4

Mantle and Head

Wear Liner Replacement Telsmith SBS Cone Crusher 

7. Manually turn the eccentric until the highest and lowest  points are aligned with the end of the slider plate tang groove (Fig. 4-40). When the alignment is correct, the oil duct (52 & 57 models only) will be centered directly below the eccentric high point and the counterweight will be centered over the input shaft.

ECCENTRIC HIGH POINT

9.

Lubricate the mating surfaces of the main shaft and the inner bronze sleeve with crusher lube oil. !

WARNING

 A l w ay s u s e s u i t ab l e r i g g i n g an d h o i s t i n g equipment to stabilize and lift heavy objects. L i f t i n g h e av y c o m p o n e n t s w i t h i n a d e q u a t e hoisting apparatus can damage machinery and may result in serious personal injury or death. 10. Attach a lift cable or chain to the eyebolt. Using a properly

B

rated lifting device, carefully suspend the head and shaft assembly over the crusher (Fig. 4-41).

B

C  A

ECCENTRIC LOW POINT

D

C

 A

 Figure 4–41. Aligning The Head and Shaft  A. Drive Tang

B. Main Shaft

11. Align the bottom end of the main shaft with the bore of the

inner bronze sleeve. With the shaft suspended above the bore, slowly rotate the head and shaft assembly until the drive tang is precisely aligned with the drive tang groove on the slider   plate (Fig. 4-42).

4  A

E

 Figure 4–40. Aligning the Eccentric and Tang Groove  A. Align Tang Groove C. Counterweight E. Eccentric High Side

B. Oil Duct D. Countershaft

If the eyebolt was removed, reinstall the eyebolt into the tapped hole at the top of the main shaft. 8.

4–24

07/09

Wear Liner Replacement Telsmit h SBS Cone Crusher 

Mantle and Head

1

B

1 Turn

C

1/4 Turn

 A

 Figure 4–43. Rotation Check 17. Rotate

the taper head slowly clockwise by hand. Verify that it turns freely for at least 1/4 turn. Due to a one-way valve inside the anti-spin unit, the amount of effort required will increase gradually as the head is rotated in this direction. D

NOTE:  Figure 4–42. Aligning Drive Tang with Groove  A. Adapter Plate C. Drive Tang

B. Slider Plate Groove D. Inspection Hole (New Style Covers Only)

12. Slowly

lower the head and shaft assembly into the crusher. To ensure drive tang engagement, DO NOT rotate the assembly as it is being lowered into the bronze sleeve. 13. Continue

lowering the head and shaft assembly until the underside of the taper head is seated on the top race of the upper thrust bearing. 14. Remove

the lifting chain from the eyebolt. Rock the head  slightly to check that the tang has seated in the tang groove. 15. Block

the flywheel sheave so that the eccentric assembly cannot turn. 16. Rotate

the taper head slowly counter-clockwise by hand. Verify that it turns freely for at l east one full turn (Fi g. 4-43).

If the taper head is difficult to turn in steps 15 and 16, raise the taper head and shaft and make the following checks: - Check that the slider plate is properly positioned. - Verify that the piston ring is correctly centered in the groove on the inside of the taper head. - Make certain the drive tang is aligned with the slider   plate groove (Fig. 4-39). 18. Remove

the blocking from the flywheel sheave.

19. From

under the crusher, locate the match marks that were made prior to head and shaft removal (Fig. 4-27). 20. Verify

that all match marks are aligned. If necessary, rotate the taper head and rotary seal ring so that match marks on these components are aligned with match marks on the crusher main frame. 21. At

the frame arm nearest the match marks, measure the distance between the top of the frame arm and the bottom of  the taper head skirt (Fig. 4-26). Compare this measurement with the measurement taken earlier during disassembly.

07/09

4–25

4

Mantle and Head

Wear Liner Replacement Telsmith SBS Cone Crusher 

22. If

the new measurement matches the measurement taken earlier this indicates that the head and shaft assembly is fully seated and the drive tang is engaged in the slider plate groove.

IMPORTANT:

27. When

the shaft nut cap is correctly installed, install the shaft nut cpascrew locking plate and weld the plate, the burn ring and the shaft nut cap as shown in Fi gure 4-45. A stainless steel weld rod E (R) 309L is required when making these welds.

If the drive tang has not engaged the sl ider plate groove, the measurement made in step 20 will be approximately 1 /2 to 1 inch (1.25 to 2.5 cm) longer than the earlier  measurement. If the measurement is too long, raise the shaft and head assembly and install the assembly again re-aligning the drive tang and the slider plate groove (Fig. 4-39).

W E L D 

 WELD

C  A B

CAUTION

!

Never reach between the rotary seal ring and the underside of the taper head to check clearance. Serious personal injury will result if the rotary seal ring is lowered onto hands or fingers. 23. Tang

engagement can also be checked at the top of the crusher. Lay a long straight edge or bar across the top of the main frame (Fig. 4-44) parallel to the tang direction. Observe the bar in relation to the taper head. The bar to head should  show a 3o gap on the eccentric low point side. If no gap is  present, thi s is an indic ati on that the sha ft tan g has not correctly seated in the slider groove.  WEL D

 Figure 4–45. Shaft Nut Welding Requirements  A. Capscrew C. Capscrew Locking Plate

B. Flat Washer 

FINAL INSTALLATION and ASSEMBLY

4

1.

B

 A

 Figure 4–44. Tang Engagement Check  A. Check Gap At This Point

B. Straight Bar 

24. On

units with a new style anti-spin cover, re-install the inspection plugs (Fig. 4-39) that were removed to visually determine drive tang engagement. 25. Remove

the lifting eyebolt from the shaft and store for 

On Anti-Spin equipped units, make certain all hydraulic lines are correctly installed and that the anti-spin hydraulic system has been successfully bled (See SBS Operation and  Maintenance Manual or TP405 Anti Spin Unit - Installation, Operation and Troubleshooting manual). 2.

Re-install the upper frame assembly following the instructions in Chapter 3 of this manual. Restore hydraulic and electrical power to the crusher. 3.

Install all chutes, hoppers and feed equipment that were removed previously to provide access to the crusher. 4.

Adjust the crusher discharge setting and resume crushing with a normal feed of material.

future use. 26. Install

the shaft nut cap, flatwasher and capscrew. Torque the shaft nut capscrew t o specification (Table 4-1).

4–26

07/09

 Appendix A - Torque Tables

Wear Li ner Replacement Telsmith SBS Cone Crusher 

Fastener Information Size

Thread Type

Threads Per Inch (n)

Major Dia. (in)

SAE J429 Grade 2 Tensile Stress  Area

SAE J429 Grade 5

(in2)

Torque Dry in-lb/ft-lb (Nm)

Torque Lubricated in-lb/ft-lb (Nm)

Torque Dry in-lb/ft-lb (Nm)

Torque Lubricated in-lb/ft-lb (Nm)

1/4

UNC UNF

20 28

0.2500 0.2500

0.0318 0.0364

66 (7.4) 75 (8.4)

49 (5.5) 56 (6.3)

100 (11.2) 120 (13.5)

76 (8.5) 87 (9.8)

5/16

UNC UNF

18 24

0.3125 0.3125

0.0524 0.0581

11 (14.9) 13 (17.6)

8 (10.8) 9 (12.2)

17 (23.0) 19 (25.7)

13 (17.6) 14 (18.9)

3/8

UNC UNF

16 24

0.3750 0.3750

0.0775 0.0878

20 (27.1) 23 (31.1)

15 (20) 17 (23)

31 (42.0) 35 (47.4)

23 (31.1) 26 (35.2)

7/16

UNC UNF

14 20

0.4375 0.4375

0.1063 0.1187

32 (42.3) 36 (48.8)

24 (32.5) 27 (36.6)

49 (66.4) 55 (74.5)

37 (50.1) 41 (55.5)

1/2

UNC UNF

13 20

0.5000 0.5000

0.1419 0.1600

49 (66.4) 55 (74.5)

37 (50.1) 41 (55.5)

75 (101) 85 (115)

57 (77.2) 64 (86.7)

9/16

UNC UNF

12 18

0.5625 0.5625

0.1819 0.2030

70 (94.9) 78 (106)

53 (71.8) 59 (79.9)

110 (149) 120 (162)

82 (111) 91 (123)

5/8

UNC UNF

11 18

0.6250 0.6250

0.2260 0.2560

97 (131) 110 (149)

73 (98.9) 83 (112)

150 (203) 170 (230)

110 (149) 130 (176)

3/4

UNC UNF

10 16

0.7500 0.7500

0.3345 0.3730

170 (230) 190 (258)

130 176) 140 (188)

270 (366) 300 (407)

200 (271) 220 (298)

7/8

UNC UNF

9 14

0.8750 0.8750

0.4617 0.5095

170 (230) 180 (244)

120 (163) 140 (190)

430 (583) 470 (630)

320 (434) 360 (488)

1

UNC UNF

8 12

1.0000 1.0000

0.6057 0.6630

250 (339) 270 (366)

190 (258) 210 (285)

640 (868) 710 (963)

480 (651) 530 (719)

1 1/8

UNC UNF

7 12

1.1250 1.1250

0.7633 0.8557

350 (474) 400 (542)

270 (366) 300 (407)

800 (1085) 890 (1207)

600 (813) 670 (908)

1 1/4

UNC UNF

7 12

1.2500 1.2500

0.9691 1.0729

500 (677) 550 (746)

380 (515) 420 (569)

1,100 (1491) 1,200 (1627)

840 (1139) 930 (1260)

1 3/8

UNC UNF

6 12

1.3750 1.3750

1.1549 1.3147

660 (895) 740 (1003)

490 (664) 560 (760)

1,500 (2033) 1,700 (2304)

1,100 (1491) 1,300 (1762)

1 1/2

UNC UNF

6 12

1.5000 1.5000

1.4053 1.5810

870 (1179) 980 (1328)

650 (881) 730 (989)

2,000 (2711) 2,200 (2982)

1,500 (2033) 1,600 (2169)

 ASTM A307 Grade A

ASTM A449

1 3/4 1 3/4

UNC UN

5 12

1.7500 1.7500

1.8995 2.1873

1,400 (1898) 1,600 (2169)

1,000 (1355) 1,200 (1627)

2,300 (3118) 2,600 (3525)

1,700 (2304) 2,000 (2711)

2 2

UNC UN

4 1/2 12

2.0000 2.0000

2.4982 2.8917

2,100 (2847) 2,400 (3254)

1,500 (2033) 1,800 (2440)

3,400 (4609) 4,000 (5423)

2,600 (3525) 3,000 (4067)

2 1/4 2 1/2 2 3/4 3

UNC UNC UNC UNC

4 1/2 4 4 4

2.2500 2.5000 2.7500 3.0000

3.2477 3.9988 4.9340 5.9674

3,000 (4067) 4,100 (5559) 5,600 (7592) 7,400 (10033)

2,300 (3118) 3,100 (4203) 4,200 (5694) 5,600 (7592)

5,000 (6779) 6,900 (9355) 9,400 (12745 12,000 (16270)

3,800 (5152) 5,200 (7050) 7,000 (9491) 9,200 (12473)

Torque Coefficients

07/09

Dry: 0.20 Lubricated: 0.15

 A–1

7F

Wear L iner Replacement Telsmith SBS Cone Crush er 

Torque Tables

Fastener Information Size

7F

Thread Type

Threads Per Inch (n)

Major Dia. (in)

SAE J429 Grade 8 Tensile Stress  Area

 Alloy Socket Head Cap Screws ASTM A574

(in2)

Torque Dry ft-lb (Nm)

Torque Lubricated ft-lb (Nm)

Torque Dry ft-lb (Nm)

Torque Lubricated ft-lb (Nm)

1/4

UNC UNF

20 28

0.2500 0.2500

0.0318 0.0364

12 (16.2) 14 (18.9)

9 (12.2) 10 (13.5)

14 (18.9) 16 (21.6)

10 (13.5) 12 (16.2)

5/16

UNC UNF

18 24

0.3125 0.3125

0.0524 0.0581

25 (33.8) 27 (36.6)

18 (24.4) 20 (27.1)

29 (39.3) 32 (43.3)

22 (29.8) 24 (32.5)

3/8

UNC UNF

16 24

0.3750 0.3750

0.0775 0.0878

44 (59.6) 49 (66.4)

33 (44.7) 37 (50.1)

51 (69.1) 58 (78.6)

38 (51.5) 43 (58.3)

7/16

UNC UNF

14 20

0.4375 0.4375

0.1063 0.1187

70 (94.9) 78 (106)

52 (71.8) 59 (79.9)

82 (111) 91 (123)

61 (82.7) 68 (92.1)

1/2

UNC UNF

13 20

0.5000 0.5000

0.1419 0.1600

110 (149) 120 (163)

80 (109) 90 (122)

120 (162) 140 (188)

93 (126) 110 (149)

9/16

UNC UNF

12 18

0.5625 0.5625

0.1819 0.2030

150 (203) 170 (230)

120 (162) 130 (176)

-----

-----

5/8

UNC UNF

11 18

0.6250 0.6250

0.2260 0.2560

210 (285) 240 (325)

160 (217) 180 (244)

240 (325) 270 (366)

180 (244) 200 (271)

3/4

UNC UNF

10 16

0.7500 0.7500

0.3345 0.3730

380 (515) 420 (569)

280 (379) 320 (433)

420 (569) 470 (637)

320 (434) 350 (474)

7/8

UNC UNF

9 14

0.8750 0.8750

0.4617 0.5095

610 (827) 670 (908)

460 (624) 500 (677)

680 (922) 750 (1017)

510 (691) 560 (759)

1

UNC UNF

8 12

1.0000 1.0000

0.6057 0.6630

910 (1234) 1,000 (1356)

680 (922) 750 (1017)

1,000 (1350) 1,100 (1491)

770 (1044) 840 (1139)

1 1/8

UNC UNF

7 12

1.1250 1.1250

0.7633 0.8557

1,300 (1762) 1,400 (1898)

970 (1315) 1,100 (1491)

1,400 (1898) 1,600 (2169)

1,100 (1491) 1,200 (1627)

1 1/4

UNC UNF

7 12

1.2500 1.2500

0.9691 1.0729

1,800 (2440) 2,000 (2711)

1,400 (1898) 1,500 (2003)

2,000 (2711) 2,300 (3118)

1,500 (2003) 1,700 (2305)

1 3/8

UNC UNF

6 12

1.3750 1.3750

1.1549 1.3147

2,400 (3254) 2,700 (3660)

1,800 (2440) 2,000 (2711)

2,700 (3660) 3,000 (4068)

2,000 (2711) 2,300 (3118)

1 1/2

UNC UNF

6 12

1.5000 1.5000

1.4053 1.5810

3,200 (4338) 3,600 (4881)

2,400 (3254) 2,700 (3660)

3,600 (4881) 4,000 (5423)

2,700 (3660) 3,000 (4068)

 ASTM A354 Grade BD 1 3/4 1 3/4

UNC UN

5 12

1.7500 1.7500

1.8995 2.1873

5,000 (6779) 5,700 (7728)

3,700 (5017) 4,300 (5830)

5,600 (7592) 6,400 (8677)

4,200 (5694) 4,800 (6508)

2 2

UNC UN

4 1/2 12

2.0000 2.0000

2.4982 2.8917

7,500 (10169) 8,700 (11796)

5,600 (7593) 6,500 (8813)

8,400 (11389) 10,000 (13588)

6,300 (8541) 7,300 (9897)

2 1/4 2 1/2 2 3/4 3

UNC UNC UNC UNC

4 1/2 4 4 4

2.2500 2.5000 2.7500 3.0000

3.2477 3.9988 4.9340 5.9674

11,000 (14914) 15,000 (20338) 18,000 (24405) 24,000 (32540)

8,200 (11118) 11,000 (14914) 13,000 (17626) 18,000 (24405)

12,000 (16270) 17,000 (23049) 23,000 (31184) 30,000 (40676)

9,300 (12609) 13,000 (17626) 17,000 (23049) 23,000 (31184)

Torque Coefficients

 A–2

Dry: 0.20 Lubricated: 0.15 07/09

Wear Liner Replacement Telsmith SBS Cone Crusher– Appendix B

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 0.0394 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

07/09

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

F +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

C +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

F

C

+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

F +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

C +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

 Ap pen di x B - Con ver si on Tabl es

Wear Li ner Repl acem ent Telsmi th SBS Cone Crusher 

NOTES

7F

B–2

 

07/09

 Appendix C - Weights

Wear Liner Replacement Telsmi th Silver Bul let Series Gyrasphere

Appendix C - Weights

Model 38 Weights – Pounds (Kilograms) Item Crusher - complete and assembled w/o Anti-Spin Crusher - complete and assembled with Anti-Spin

26,912 (12207) 27, 275 (12371)

Crusher - Base Unit Including Mantle, Nut and Cap, Anti-Spin and Flywheel Including Mantle, Nut and Cap, Bottom Plate and Flywheel

16,389 (7433) 16,026 (7269)

Crusher - Upper frame Includes upper frame assembly, rotator, support bowl and concave ring.

10, 885 (4937)

Main (lower) frame only

8440 (3828)

Thrust bearing (each)

175 (79)

Rotary seal ring with lead

453 (205)

Inner bronze sleeve

40 (18)

Outer bronze sleeve

96 (44)

Eccentric

859 (390)

Main drive gear

263 (119)

Bottom cover plate (units without anti-spin only)

121 (55)

 Anti-spin unit - Includes bottom plate, gearbox, hydraulic motor, adapter plate, slider plate and gearbox cover. Upper frame only

508 (230) 4070 (1846)

Hydraulic relief cylinder (each)

94 (43)

Receiving hopper, outer

557 (253)

Receiving hopper, inner

223 (101)

Locknut

1431 (649)

Hydraulic locking cylinder (each)

30 (14)

Support bowl with inner hopper and concave ring

4360 (1977)

Concave ring

1300 (590)

Smithbond for concave ring (Typical - Refer to Chapter 3 for exact quantities)

44 (20)

Head and shaft assembly, with mantle and nut.

07/09

38

7F

3083 (1398)

C–1

 Ap pen di x C - Weig ht s

Wear Li ner Repl acem ent Telsmit h Silver Bull et Series Gyrasphere

Model 38 Weights – Pounds (Kilograms) Item Taper head only

1290 (585)

Main (tapered) shaft only

545 (247)

Mantle only

1022 (464)

Smithbond for mantle (Typical - Refer to Chapter 4 for exact quantities)

44 (20)

Countershaft box assembly w/flywheel

7F

38

1,475 (669)

Countershaft

125 (57)

Bevel pinion gear (countershaft)

60 (27)

Flywheel sheave

162 (73)

Power rotator assembly, including motor, gearbox and adapter plate.

200 (91)

Power rotator mounting bracket

54 (24)

Power rotator pinion gear

35 (16)

Crusher ring gear

780 (354)

Support Bowl Driver Forging (early models only - if equipped)

326 (148)

Drive ring weldment

509 (231)

Oil lubrication system with water cooler (empty - no oil in tank)

1380 (626)

Oil lubrication system with air-oil cooler (empty - no oil in tank)

1880 (853)

Hydraulic power unit (empty - no oil in tank)

600 (272)

V-belt drive guard

520 (236)

Important: All weights shown are estimated and may vary by +/-5 percent. When available, always refer to the bill-of-lading or packing list for actual weights.

C–2

07/09

Wear Liner Replacement Telsmi th Silver Bul let Series Gyrasphere

Appendix C - Weights

Model 44 Weights – Pounds (Kilograms) Item Crusher - complete and assembled w/o Anti-Spin Crusher - complete and assembled with Anti-Spin

32,818 (14885) 33,178 (15049

Crusher - Base Unit Including Mantle, Nut and Cap, Anti-Spin and Flywheel Including Mantle, Nut and Cap, Bottom Plate and Flywheel

20,436 (9269) 20,074 (9105)

Crusher - Upper Frame Includes upper frame, locknut, locknut cover, support bowl, concave ring, feed hoppers, Smithbond, and hyd. unlock cylinders.

12,744 (5780)

Main (lower) frame only

9010 (4087)

Thrust bearing (each)

185 (84)

Rotary seal ring with lead

1041 (472)

Inner bronze sleeve

40 (18)

Outer bronze sleeve

130 (59)

Eccentric

1069 (485)

Main drive gear

263 (119)

Bottom cover plate (units without anti-spin only)

121 (55)

 Anti-spin unit - Includes bottom plate, gearbox, hydraulic motor, adapter p late, slider plate and gearbox cover. Upper frame only

508 (230) 3320 (1506)

Hydraulic relief cylinder and manifold (each)

150 (68)

Receiving hopper, outer

732 (332)

Receiving hopper, inner

263 (119)

Locknut

1664 (755)

Hydraulic locking cylinder (each)

30 (14)

Support bowl with inner hopper and concave ring Concave ring - S Concave ring - FC Smithbond for concave ring S & FC (Typical - Refer to Chapter 3 for exact quantities)

07/09

44

7F

4791 (2173) 1600 (726) 1700 (771) 110 (50)

C–3

 Ap pen di x C - Weig ht s

Wear Li ner Repl acem ent Telsmit h Silver Bull et Series Gyrasphere

Model 44 Weights – Pounds (Kilograms) Item Head and shaft assembly, including mantle and nut

4380 (1986)

Taper head only

2280 (1034)

Main (tapered) shaft only

640 (290)

Mantle only

1325 (601)

Smithbond for mantle (Typical - Refer to Chapter 4 for exact quantities)

44 (20)

Countershaft box assembly w/flywheel

7F

44

1,519 (689)

Countershaft

125 (57)

Bevel pinion gear (countershaft)

60 (27)

Flywheel sheave

320 (145)

Power rotator assembly, including motor, gearbox and adapter plate.

234 (106)

Power rotator mounting bracket

54 (24)

Power rotator pinion gear

35 (16)

Crusher ring gear

385 (175)

Drive ring weldment

960 (435)

Oil lubrication system with water cooler (empty - no oil in tank)

1380 (626)

Oil lubrication system with air-oil cooler (empty - no oil in tank)

1880 (853)

Hydraulic power unit (empty - no oil in tank)

600 (272)

V-belt drive guard

520 (236)

Important: All weights shown are estimated and may vary by +/-5 percent. When available, always refer to the bill-of-lading or packing list for actual weights.

C–4

07/09

Wear Liner Replacement Telsmi th Silver Bul let Series Gyrasphere

Appendix C - Weights

Model 52 Weights – Pounds (Kilograms) Item Crusher - complete and assembled w/o Anti-Spin Crusher - complete and assembled with Anti-Spin

50,053 (22074) 50,454(22886)

Crusher - Base Unit Including Mantle, Nut and Cap, Anti-Spin and Flywheel. Including Mantle, Nut and Cap, Bottom Plate and Flywheel

31,857(14,454) 31,465 (14,272)

Crusher - Upper Frame Includes upper frame, locknut, locknut cover, support bowl, concave ring, feed hoppers, Smithbond, and hyd. unlock cylinders.

16740 (7593)

Main (lower) frame only

13500 (6123)

Thrust bearing (each)

350 (159)

Rotary seal ring with lead

1426 (647)

Inner bronze sleeve

125 (57)

Outer bronze sleeve

173 (78)

Eccentric

1550 (703)

Main drive gear

486 (220)

Bottom cover plate (units without anti-spin only)

173 (78)

 Anti-spin unit - Includes bottom plate, gearbox, hydraulic motor, adapter plate, slider plate and gearbox cover. Upper frame only

570 (259) 4080 (1851)

Hydraulic relief cylinder and manifold (each)

202 (92)

Receiving hopper, outer

875 (397)

Receiving hopper, inner

229 (104)

Locknut

1663 (754)

Hydraulic Locking Cylinder (each)

30 (14)

Support bowl, with inner hopper and concave ring

8503 (3857)

Smithbond for concave ring S Smithbond for concave ring FC (Typical - Refer to Chapter 3 for exact quantities)

176 (80) 132 (60) (80)

Head and shaft assembly, including mantle and nut.

07/09

52

7F

8405 (3812)

C–5

 Ap pen di x C - Weig ht s

Wear Li ner Repl acem ent Telsmit h Silver Bull et Series Gyrasphere

Model 52 Weights – Pounds (Kilograms) Item Taper head only

5196 (2357)

Main (tapered) shaft only

1258 (571)

Mantle only

1626 (738)

Smithbond for mantle (Typical - Refer to Chapter 4 for exact quantities)

88 (40)

Countershaft box assembly w/flywheel

7F

52

2310 (1048)

Countershaft

223 (101)

Bevel pinion gear (countershaft)

160 (73)

Flywheel sheave

540 (245)

Power rotator assembly, including motor, gearbox and adapter plate.

200 (91)

Power Rotator Mounting Bracket

54 (24)

Power rotator pinion gear

35 (16)

Crusher ring gear

355 (161)

Drive ring weldment

1367 (620)

Oil lubrication system with water cooler (empty - no oil in tank)

1880 (853)

Oil lubrication system with air-oil cooler (empty - no oil in tank)

2465 (1118)

Hydraulic power unit (empty - no oil in tank)

1280 (581)

V-belt drive guard

778 (353)

Important: All weights shown are estimated and may vary by +/-5 percent. When available, always refer to the bill-of-lading or packing list for actual weights.

C–6

07/09

Wear Liner Replacement Telsmi th Silver Bul let Series Gyrasphere

Appendix C - Weights

Model 57 Weights – Pounds (Kilograms) Item Crusher - complete and assembled w/o Anti-Spin Crusher - complete and assembled with Anti-Spin

70,078 (31989) 70, 523 (31787)

Crusher - Base Unit Including Mantle, Nut and Cap, Anti-Spin and Flywheel Including Mantle, Nut and Cap, Bottom Plate and Flywheel

44,739 (20293) 44,294 (20091)

Crusher - Upper Frame Includes upper frame, locknut, locknut cover, support bowl, concave ring, feed hoppers, Smithbond, and hyd. unlock cylinders.

29102 (13200)

Main (lower) frame only

19708 (8940)

Thrust bearing (each)

475 (215)

Rotary seal ring with lead

2342 (1062)

Inner bronze sleeve

280 (127)

Outer bronze sleeve

280 (127)

Eccentric

2800 (1270)

Main drive gear

1040 (472)

Bottom cover plate (units without anti-spin only)

283 (128)

 Anti-spin unit - Includes bottom plate, gearbox, hydraulic motor, adapter plate, slider plate and gearbox cover. Upper frame only

734 (333) 9187 (4167)

Hydraulic relief cylinder and manifold (each)

210 (95)

Receiving hopper - outer

1292 (586)

Receiving hopper - inner

569 (258)

Locknut

5700 (2586)

Hydraulic locking cylinder (each)

7F

30 (14)

Support bowl with inner hopper and concave ring

13,589 (6164)

Concave ring

4000 (1814)

Smithbond for concave ring (S & FC) (Typical - Refer to Chapter 3 for exact quantities)

07/09

57

330 (150)

C–7

 Ap pen di x C - Weig ht s

Wear Li ner Repl acem ent Telsmit h Silver Bull et Series Gyrasphere

Model 57 Weights – Pounds (Kilograms) Item Head and shaft assembly, including mantle and nut.

10,662 (4,836)

Taper head only

5883 (2668)

Main (tapered) shaft only Mantle only Smithbond for mantle (Typical - Refer to Chapter 4 for exact quantities) Countershaft box assembly with flywheel

7F

57

1713 (777) 2653 (1203) 176 (80) 2,243 (1,018)

Countershaft

240 (109)

Bevel pinion gear (countershaft)

200 (91)

Flywheel sheave

750 (340)

Power rotator assembly, including motor, gearbox and adapter plate.

234 (106)

Power rotator mounting bracket

78 (35)

Power rotator pinion gear

35 (16)

Crusher ring gear

1240 (562)

Drive ring weldment

1725 (782)

Support bowl driver forging (early models only - if equipped)

569 (258)

Oil lubrication system with air-oil cooler (empty - no oil in tank)

2680 (1216)

Hydraulic power unit (empty - no oil in tank)

1280 (581)

V-belt drive guard

506 (230)

Important: All weights shown are estimated and may vary by +/-5 percent. When available, always refer to the bill-of-lading or packing list for actual weights.

C–8

07/09

Wear Liner Replacement Telsmi th Silver Bul let Series Gyrasphere

Appendix C - Weights

Model 68 Weights – Pounds (Kilograms) Item Crusher - complete and assembled w/o anti-spin Crusher - complete and assembled w/ anti-spin Crusher - Base Unit Including Mantle, Nut and Cap, Anti-Spin and Flywheel Including Mantle, Nut and Cap, Bottom Plate and Flywheel

106,643 (48372) 107,102 (48581) 65,783 (29838) 65,324 (29630)

Crusher - upper framey Includes upper frame, locknut, locknut cover, support bowl, concave ring, feed hoppers, Smithbond, and hyd. unlock cylinders.

40460 (18352)

Main (lower) frame only

29564 (13410)

Thrust bearing (each)

750 (340)

Rotary seal ring with lead

748 (339)

Inner bronze sleeve

265 (120)

Outer bronze sleeve

345 (156)

Eccentric

4400 (1996)

Main drive gear

3270 (1483)

Bottom cover plate (units without anti-spin only)

296 (134)

 Anti-spin unit - Includes bottom plate, gearbox, hydraulic motor, adapter plate, slider plate and gearbox cover.

755 (342)

Upper frame only

11509 (5220)

Hydraulic relief cylinder and manifold (each)

225 (102)

Receiving hopper - outer

1543 (700)

Receiving hopper - inner

306 (139)

Locknut

4896 (2221)

Hydraulic unlock cylinder (each)

7F

122 (55)

Support bowl with Inner Hopper and Concave Ring

20,485 (9,292)

Concave ring

5120 (2322)

Smithbond for concave ring 68S Smithbond for concave ring 68FC (Typical - Refer to Chapter 3 for exact quantities)

07/09

68

352 (160) 484 (220)

C–9

 Ap pen di x C - Weig ht s

Wear Li ner Repl acem ent Telsmit Telsmit h Silver Bull et Series Series Gyrasphere

Model 68 Weights – Pounds (Kilograms) Item Head and shaft assembly, including mantle and nut.

15882 (7177)

Taper head only

7412 (3362)

Main (tapered) shaft only

2949 (1338)

Mantle only

3280 (1488)

Smithbond for mantle (Typical (Typical - Refer to Chapter 4 for exact quantities) Countershaft box assembly with flywheel

154 (70) 3,728 (1,691)

Countershaft

373 (169)

Bevel pinion gear (countershaft)

480 (218)

Flywheel sheave

870 (395)

Power rotator assembly, including motor, gearbox and adapter plate.

234 (106)

Power rotator mounting bracket

78 (35)

Power rotator pinion gear

35 (16)

Crusher ring gear

7F

68

2934 (1331)

Drive ring weldment

647 (293)

Support bowl driver forging (early models only - if equipped)

647 (293)

Oil lu lubrication sy system wi with wa water co cooler (e (empty - no no oi oil in in ta tank)

2760 (1252)

Oil lubrication system with air-oil cooler (empty pty - no oil in tank)

3660 (1660)

Hydraulic power unit (empty - no oil in tank)

1280 (581)

V-belt drive guard

739 (335)

Important: All Important:  All weights shown are estimated and may vary by +/-5 percent. When available, always refer to the bill-of-lading or packing list for actual weights.

C–10

07/09

Wear L i n er Rep l ac em en t Telsmi Telsmi th SBS Cone Crusher 

A p p en d i x D - L u b r i c an t s

 Ap  A p p end en d i x D - Lu L u b r i c ants an ts

Lubricating Oil Specifications  Ambi  Am bient ent Temp Temp erat ur e Below 40° F (4.5° C)

 Abov  Ab ove e 40° F (4.5° C)

Viscosity ISO Grade

C-100

C-150

Viscosity AGMA Grade #250.04

3 EP

4 EP

Viscosity SUS @ 100 °F

469 to 575

709 to 871

Viscosity SUS @ 210 °F

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

Yes

Yes

Pass

Pass

 Anti-Foaming Agent Agent Copper Strip Corrosion Test

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

7F Hydraulic Oil Specifi Specifi cations Viscosity ISO Grade

68

Viscosity SUS @ 100 °F

317

Viscosity SUS @ 210 °F

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 Agent

Yes

 Anti-Foaming Agent Agent

Yes

Rust and Oxidation Inhibitor

Yes

NOTE: Refer to the Gyrasphere Operation and Maintenance Manual for Manual for detailed hydraulic system maintenance instructions and oil capacities. 07/09

D–1

 Ap pen di x D - Lu br ic ant s

Wear Li ner Repl acem ent Telsmi Telsmi th SBS Cone Crusher 

NLGI #2 #2 Grease Grease Specifi catio ns 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

NOTE: 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 EP-2

Moly B ased EP-2 EP-2 Grease Grease Specif Specif icati ons (Aluminum Complex with Molybdenum Disulfide) Worked Penetration

7F

265/295

Dropping Point °F

510

Rust Prevention (ASTM D-1743)

Pass

Corrosion Prevention (ASTM D-1261)

Pass

Oxidation Stability (ASTM D-942) Oxygen Absorption (PSI)  After 100 Hours 200 Hours 300 Hours Oil Viscosity, SUS @ 100 °F Extreme Pressure Performance Timken OK Load (lbs) Four Ball Weld Point Wear Scar  Type of Soap Operating Temperature MoS2 % by Weight

D–2

<3 <4 <5 1000 65 800 0.51 mm Aluminum Complex 0 to 450 °F 3.0

07/09

Wear Liner Replacement Telsmi th SBS Cone Crushers

Appendix E - Sealants and Compounds

 Appendix E - Sealants and Compounds The following sealants and compounds are used throughout the repair procedures of this manual. These items or their equivalents are commonly available at most local supply houses or distributors. Always read and understand manufacturer’s directions and safety precautions before using any items shown.

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

Manufacturer   Loctite Corp

Thread Locking Compou nd Description

Manufacturer  

Loctite® 242 Threadblocker, Removable Strength. Part No. 24241.

Loctite Corp.

Loctite® 271 Threadlock, Permanent Strength. Part No. 10T77.

Loctite Corp.

7F

Spray Primer  (for use with Loctite 242 thread locking compound)

07/09

Description

Manufacturer  

Loctite 7471 Locquic® Primer T, Aerosol, Part No. 22477.

Loctite Corp.

E–1

 Ap pen di x E - Sealan ts and Com po un ds

Wear L in er Replac emen t Telsmith SBS Cone Crushers

 An ti -Seize Co mp ou nd Description

Manufacturer  

Bostik Never-Seez®, Regular Grade, Copper Formula. Meets MIL SPEC A907E.

Bostik Corp.

Silico ne Sealant Description

Manufacturer  

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

Red Devil, Inc.

Shellac

7F

E–2

Description

Manufacturer  

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

Wm. Zinsser & Co., Inc.

07/09

Wear Liner Replacement Telsmi th SBS Cone Crusher 

Appendix F - Removal Clearances

 Appendix F - Removal Clearances

Type “A” Gear   Arrangement

      C

      A

      B

Type “B” Gear   Arrangement

Note: Check crusher gear arrangement before using the table below.

7F Support Bowl Removal Clearances Dimensions in inches (centimeters)

Crusher 

Crushers With Type “A” Gear Arrangement Dimension A

Crushers With Type “B” Gear Arrangement

Dimension B

Dimension C

Dimension A

Dimension B

Dimension C

Model 38

104 (264)

67 (170)

5 (13)

106 (269)

67 (170)

5 (13)

Model 44

N/A

N/A

N/A

104 (264)

67 (170)

5 (13)

Model 52

N/A

N/A

N/A

116 (295)

76 (193)

5 (13)

Model 57

133 (338)

87 (221)

5 (13)

125 (318)

83 (211)

5 (13)

Model 68

144 (366)

96 (244)

5 (13)

142 (361)

94 (239)

5 (13)

NOTE: Measurements shown above are typical. Actual measurements may vary, due to product changes, custom engineering or fabrication variables. See the inset views above to determine gear arrangement.

07/09

F–1

 Ap pen di x F - Remo val Clear anc es

Wear Li ner Repl acem ent Telsmi th SBS Cone Crusher 

Type “A” Upper  Frame Assembly

      A      B

C

Type “B” Gear   Arrangement

Note: Check crusher  gear arrangement before using the table below.

7F Head and Shaft Removal Clearances Dimensions in inches (centimeters)

Crusher 

Crushers With Type “ A” Gear Arrangement

Crushers With Type “ B” Gear Arraangement

Dimension A

Dimension B

Dimension C

Dimension A

Dimension B

Dimension C

Model 38

136 (345)

130 (330)

5 (13)

136 (345)

130 (330)

5 (13)

Model 44

N/A

N/A

N/A

141 (358)

132 (335)

5 (13)

Model 52

N/A

N/A

N/A

161 (409)

151 (384)

5 (13)

Model 57

182 (462)

169 (429)

5 (13)

177 (450)

164 (417)

5 (13)

Model 68

203 (516)

188 (478)

5 (13)

201 (511)

186 (472)

5 (13)

NOTE: Measurements shown above are typical. Actual measurements may vary, due to product changes, custom engineering or fabrication variables. See the inset views above to determine gear arrangement. If crusher is NOT equipped with anti-spin, Dimensions A and B will be approximately 6 inches less than shown. F–2

07/09

Wear Liner Replacement Telsmi th SBS Cone Crusher 

Appendix G - Wear Liner Wear Limits

 Appendix G - Wear Liner Wear Limits

7F

CONCAVE RING WEAR MEASUREMENT 1. Stop the crusher. Locko ut/Tagout pow er to the crusher drive. 2. Raise the upper frame using the hydraulic clearing feature. Place hardwood blocks or safety spacers between the upper and main frames. Refer to the crusher operator’s manual for instructions. 3. Lockou t/Tagout Power to the hydraulic power unit. 4. At the bottom lip of the concave ring, measure dimension A. 5. Place a straight edge along the concave ring wear surface. Measure Dimension B. 6. Subtract Dimension B from Dimension A. This measurement should be 3/4 to 1 inch minimum. 7. If measurement is less than 1 inch, the concave ring should be replaced.

07/09

G–1