CRUSHER SETTING ADJUSTMENT

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

4.6.1 Mechanical wedgesetting adjustment

The movement of the wedges changes the effective thickness "s" of the wedge pair, which in turn increases or decreases the Crusher setting, respectively.

The setting adjustment may be done mechanically by turning cap nut(s) manually, or alternatively hydraulically (option) through the use of an electrical control panel. For instructions concerning the hydraulic setting adjustment (option), refer to chapter 4.6.2.

The main components of the device are the adjusting wedges, cap nut(s) (2) and locking pipe(s) (3). Changing the setting requires the use of the ratchet delivered with the Crusher (special tool) to turn the cap nuts.

Figure 4.4 Mechanical setting adjustment

To change the setting, the locking nuts of the tension rod must be loosened, and then the cap nuts must be turned clockwise or counterclockwise to increase or decrease the Crusher setting,

respectively. A single complete rotation of one cap nut has a net effect on the Crusher setting as indicated in Table 4-1. Turning both cup nuts one complete rotation in the same relative direction will thus change the Crusher setting by twice as what is indicated in Table 4-1.

Table 4-1 Average change in setting per cap nut rotation Callout Description 1 Adjusting wedges 2 Cap nut 3 Locking pipe 4 Rubber bellow 4 WARNING!

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

IMPORTANT!

The wedges are self-restraining and their surfaces must not be lubricated. It may overload the adjusting mechanism.

Model Change in Setting mm (in) C80 2.3 (0.09) C96 2.2 (0.09) C100 2.3 (0.09) C106 2.2 (0.09) C110 2.0 (0.08) C116 2.3 (0.09) C3054 2.3 (0.09) C125 1.7 (0.07) C140 2.3 (0.09) C145 2.5 (0.10) C160 2.2 (0.09) C200 3.2 (0.12)

CHAPTER 4 - OPERATING INSTRUCTIONS

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

Required Rotations = (Desired Setting Change)/(Crusher Change in Setting)

Round the result to the nearest higher number.

4.6.1.1 Decreasing the Crusher Setting

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

1. Stop crushing, then stop the Crusher. 2. Determine how much the setting must be

decreased and calculate how many rotations the cap nuts must be turned.

3. Loosen the locking nuts of the tension spring (Figure 4.5). Be careful not to drop the toggle plate as the spring gets loose. 4. Remove the locking pin from the locking

pipe and push the pipe towards the Crusher. 5. Turn the cap nuts COUNTERCLOCKWISE.

Make sure that both wedges are adjusted equally so that their position in relation to the Crusher remains the same. If you have to change the setting remarkably, turn the cap nuts for a while and loosen the spring locking nuts again if necessary. There are washers fastened to the rear end of the adjusting wedges. When decreasing the setting, push the wedges only until these washers are against the guide plates. 6. Lock the pipes with the pin.

7. Adjust the spring length according to Table 4-2 (see Figure 4.5).

8. Start the Crusher and listen if the toggle plate knocks. If it knocks, contact Metso. 9. Start crushing.

Example:

To change the setting of a C125 by 10 mm (3/8"), turn the cap nuts as follows:

10 mm / 1.7 mm / rotation = 5.88 => 6 total rotations => 3 rotations per cap nut

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

WARNING!

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

WARNING!

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

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Figure 4.5 Mechanical wedge setting adjustment

Table 4-2 Tension Spring Operating Length

4.6.1.2 Increasing the Crusher Setting

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

1. Stop crushing, then stop the Crusher. 2. Determine how much the setting must be

increased and calculate how many rotations the cap nuts must be turned.

3. Loosen the locking nuts of the tension spring (Figure 4.5).

4. Remove the locking pin from the locking pipe and push the pipe towards the Crusher. 5. Turn the cap nuts CLOCKWISE. Make sure

that both wedges are adjusted equally so that their position in relation to the Crusher remains the same. Be careful not to drop the toggle plate as the spring gets loose.

6. Lock the pipes with the pin.

7. Adjust the spring length according to Table 4-2 (Figure 4.5).

8. Start the Crusher and listen if the toggle plate knocks. If it knocks, contact Metso. 9. Start crushing.

Model Tension Spring Length L mm (in.) C80 310 (12 ¼") C96 385 (15 ¼”) C100 370 (14 ½") C106 365 (14 ¼") C110 365 (14 ¼") C116 365 (14 ¼") C3054 440 (171_/ 3") C125 425 (16 ¾") C140 540 (21 ¼") C145 540 (21 ¼") C160 540 (21 ¼") C200 540 (21 ¼") WARNING!

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

CHAPTER 4 - OPERATING INSTRUCTIONS

4.6.2 Hydraulic wedgesetting adjustment (optional)

Hydraulic wedge setting adjustment enables remote setting adjustments that are much quicker and simpler as setting adjustments are made remotely by operating a control panel.

Figure 4.6 Hydraulic wedge setting adjustment

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

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

4.6.2.1 Oil heater (optional)

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

Use the heater for about 30 minutes before setting adjustment when the oil temperature is below 0°C (32°F).

4.6.2.2 Decreasing the setting

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

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

IMPORTANT!

The hydraulic setting adjustment system in the Lokotrack is different from the system shown here. See details in the Lokotrack manual.

IMPORTANT!

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Figure 4.7 Setting adjustment control panel

4.6.2.3 Increasing the setting

Turn the setting adjustment switch 6 (located in the control panel) to the "increase" position. Observe the wedge movement. Setting adjustment may stop if the pressure in the tension cylinder decreases. To adjust the setting more you have to turn the switch back to "neutral" position and again to "increase" position.

When the setting is increased, the pressure in the adjusting cylinder will rise automatically and the wedges will stop for a moment.

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

4.6.3 Active setting control adjustment (optional)

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

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

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

Figure 4.8 Active setting control

The active setting control also functions as a safety device. If there are any uncrushable objects in the jaw cavity, the pressure in the cylinders rises. When the pressure rises over a pre-set value, the pressure relief valves open and let the piston move

backwards. The crusher setting opens and the uncrushable material can exit the jaw cavity. In a Lokotrack, after the uncrushable material has left the cavity, the setting returns to where it was.

Callout Description

1 Main switch 2 Hydraulic pump 3 Hydraulic pump, ON

4 Setting (Increase <=> Decrease) 5 Hydraulic pump running

6 Oil heating (optional) 7 Oil heating, ON 1 3 5 7 2 4 6

CHAPTER 4 - OPERATING INSTRUCTIONS

4.6.3.1 Oil heater (optional)

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

4.6.3.2 Decreasing the setting

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

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

4.6.3.3 Increasing the setting

Turn the setting adjustment switch 6 (located in the control panel) to the "increase" position. Observe the pitman movement.

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