OPERATING INSTRUCTIONS CHAPTER
CHAPTER 4 OPERATING INSTRUCTIONS
4.7 TOGGLE PLATE
For spontaneous overloading or uncrushable objects that are larger than the Crusher setting, such as excavator bucket teeth, the Crusher is equipped with a toggle plate that serves as a safety device. In the event of overloading, the toggle plate collapses through elastic buckling, frequently preventing damage to more costly parts.
The function of the toggle seats is based upon a rolling concept against the roll-shaped surfaces with different radii against each other. Therefore the toggle seats should be kept dry and must not be lubricated.
IMPORTANT!
The active setting control works as a safety device only in the adjustment range of the cylinders. If the uncrashable object is larger than the maximum setting, the toggle plate collapses through elastic buckling. (See chapter 4.7)
IMPORTANT!
Do not let the jaw dies hit each other.
IMPORTANT!
Note that the toggle plate is designed to buckle when overload events occur in the lower half of the crushing cavity. The toggle plate will not buckle if the crusher is overloaded due to oversized feed or an inadequate feed arrangement. Thus, in these cases, certain crusher components such as the eccentric shaft, flywheels, bearings and bearing housings will be unnecessarily loaded.
IMPORTANT!
Although the toggle plate is designed to protect the more expensive Crusher components, certain overload events are often so violent in nature that it is possible for other components such as the tension spring, tension rod and tension spring bracket to fail when the toggle plate buckles
IMPORTANT!
Toggle plate is not protecting crusher components of fatigue damages when crusher is continuously overloaded with smaller setting than allowed by Metso.
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CHAPTER 4 - OPERATING INSTRUCTIONS
Check the condition of the seats and protection rubber regularly during weekly maintenance. They must be kept clear of dust and dirt. If dust has entered the seat surfaces, flush with running water. If there is no water available, compressed air may be used. It is important that dust doesn't enter these areas and contaminate seat surfaces.
Toggle plate and seat installation and removal described in Maintenance chapter.
IMPORTANT!
Do not lubricate the toggle seats, toggle plate or toggle plate ends. This area of the crusher is designed to operate without lubrication.
IMPORTANT!
Always use original Metso toggle plates. Using a toggle plate that is not manufactured by Metso will put the Crusher at risk and will void the Crusher's warranty.
CHAPTER 4 - OPERATING INSTRUCTIONS
4.8 SPACER
A spacer may be placed between the lower adjusting wedge and the toggle seat holder (not applicable to models with the active setting control).
The use of the spacer reduces both the Crusher's minimum and maximum setting. Refer to the Crusher parts book for details concerning the effect of the spacer on the Crusher setting range for a specific jaw die profile.
Spacer installation and removal instructions can be found in Maintenance chapter.
Figure 4-9 Spacer
IMPORTANT!
The use of the spacer makes it possible to use two different Crusher setting ranges, but its use does not permit that the Crusher is used with settings smaller than the minimum allowed settings (see the Crusher Setting section).
Callout Description
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CHAPTER 4 - OPERATING INSTRUCTIONS
4.9 TROUBLESHOOTING
PROBLEM CAUSE REMEDY
Toggle plate falls out of seat.
Feed material is too large. Feed the Crusher with proper size material. Make sure the feed hopper's rear wall is properly designed. Tension spring too loose. Tighten the tension spring.
Material fed directly onto the upper pitman cover.
Material must be fed into the crushing chamber without hitting the upper pitman cover. Make sure the feed hopper's rear wall is properly designed.
Tension cylinder hydraulic pressure too low.
Check the pressure. Toggle plate seating
surfaces wear prematurely.
Tension spring too loose. Tighten the tension spring.
Toggle plate breaks (buckles).
Feed material is too small. Feed the Crusher with proper size material. Tramp iron or other
uncrushable material caught near the bottom of the crushing chamber.
Empty the crushing chamber to remove tramp iron or other uncrushable material.
Toggle plate not installed correctly.
When installing the toggle plate, inspect the toggle seats for good condition and smooth, even surfaces. Feed hopper has
loosening or breaking bolts.
Feed material is being crushed too high in the chamber.
RESTRICT FEED! Feed to keep the chamber 2/3 full with proper size material for greatest efficiency. Bolt fastener not applied to
the feed hopper bolts.
Apply bolt fastener. jaw die bolts loosening
or breaking.
Incorrect jaw dies installed. Use Metso jaw dies. Jaw dies installed
incorrectly.
Re-install the jaw dies. Insufficient capacity. Feed too large. Check for proper feed size.
Wrong direction of flywheel rotation.
Make sure the flywheels turn in the correct direction. Incorrect speed. Check for proper speed.
Discharge setting too small.
Increase the discharge setting. jaw dies worn excessively. Replace the jaw dies.
Loose jaw dies. Tighten the jaw die bolts.
Wrong jaw die profile. Consult your Metso representative. Stalled Crusher. Large rock or tramp iron
jammed in the crushing chamber.
Remove stuck material. DO NOT USE EXPLOSIVES TO CLEAR A STALLED CRUSHER!
Discharge setting is too small.
Each Crusher has a minimum recommended setting. DO NOT use a smaller setting unless authorized by Metso.
Power failure. Check all fuses in the motor electrical control panel. Motor failure. Check the motor.
CHAPTER 4 - OPERATING INSTRUCTIONS
Damaged and/or loose V-belts.
Check the condition of the V-belts.
Excessive vibration. Wrong speed. Operate the Crusher at the recommended speed. Flywheels loose. Tighten the flywheels properly. Weld the bolts together
with plates to prevent them from coming loose. Flywheel aligned with the
wrong keyway (gibkey) during assembly.
Remount the flywheel with the appropriate keyway (gibkey).
Counterweights incorrectly installed.
Consult your Metso representative. Bearings too hot. Bearings damaged. Consult your Metso representative.
Too much or insufficient grease.
Use correct quantity of grease for each bearing. Seat a schedule for greasing of the bearings.
Incorrect crusher speed. Check the Crusher's speed. Crusher operating at a
smaller setting than recommended.
Each Crusher has a minimum recommended setting. DO NOT use a smaller setting unless authorized by Metso.
Crusher not level. Check or re-level the Crusher. Feeding the Crusher with
very fine material.
Feed the Crusher with proper size material. Crusher speed varies. Damaged and/or loose
V-belts.
Check the condition of the V-belts. Inadequate plant voltage
level.
Check the plant's voltage level. A "knocking" is heard
while operating.
Tension spring too loose. Tighten the tension spring. Toggle plate improperly
seated.
Check the toggle plate and seats for wear. Loose jaw dies. Tighten the jaw die bolts.
Jaw dies hitting each other. Check the Crusher's discharge setting. Tension cylinder hydraulic
pressure too low.
Check the pressure. Movement of the jaw
dies.
Loose jaw dies. Tighten the jaw die bolts.
Inadequate clearance. Check that the clearance between the upper and lower jaw dies is between 5-8 mm (3/16-5/16"). Centralizing lug worn out. Repair the lug.
Adjusting wedges don´t move
Wedge surfaces worn. Drop a couple of small stones to cavity to decrease friction between wedges.
Active setting control: The setting opens by itself. There is no uncrushable material in the cavity.
The seals are leaking. Check the possible oil leaks.
Pressure relief valves are faulty.
Contact Metso.
Feed material is too small. Feed the crusher with proper size material.
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CHAPTER 4 - OPERATING INSTRUCTIONS