Cedarapids Operation & Maintenance Manual Jaws

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J

AW

C

RUSHERS

Bolted Bearing Blocks Pull-Type Bearing Sleeves

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A Terex Company

To the Owner & Operator:

We have tried to provide information that gives our customers a clear understanding of equipment construction, function, capabilities and requirements. This information is based on the knowledge and experience of qualified people at our company and in our field organization. Proper use of this information rewards users of our equipment with high efficiency, maximum service life and low maintenance costs. That is why we strongly recommend that anyone using our equipment be familiar with this manual. Information presented here should not be considered authoritative in every situation. Users will as a matter of course encounter problems and circumstances that raise questions not anticipated here. Such questions should be directed to their distributor or the factory.

Anyone who uses this equipment for any purpose other than that for which it was intended assumes sole responsibility for dangers encountered and injuries sustained as a result of such misuse.

Federal, state and local safety regulations aim to protect both people and property from accident, injury and harmful exposure. When complied with, such regulations are often effective. Hazards to personnel and property are further reduced when this equipment is used in accordance with all operation and maintenance instructions. Generally:

(1) Read and heed all danger, warning, caution, and notice decals. Know what guards and protective devices are included and see that each is installed and in operational condition. Additional guards and protective devices may be required and must be installed by the user (owner) before operating.

(2) Never attempt to maintain, lubricate or adjust this equipment while it is running. Lock out and tag out all energy sources before doing maintenance, cleaning, adjusting or repairing this equipment. Make it impossible for anyone to start this machine while others are working on it or in it.

(3) Wear personal protective equipment such as hard hats, ear plugs, safety glasses and safety shoes when operating this equipment. Do not wear loose clothing or long hair.

(4) Think safety and act safely. Stay alert at all times. Eliminate or neutralize potential hazards as soon as you spot them. Never allow anyone to engage in horseplay when near this equipment.

Failure to take these precautions will result in death or severe personal injury.

DANGER

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Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm.

Wash hands after handling.

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About This Manual . . . .1 - 1

Section 2 - Safety

General Safety . . . .2 - 1 Decal Location . . . .2 - 3 Personal Safety . . . .2 - 4 Lockout & Tagout . . . .2 - 5

Section 3 - General Jaw Crusher Information

Crusher Description & Information . . . .3 - 1

General Description . . . .3 - 2 Operating Principle . . . .3 - 2 Crusher Sizes . . . .3 - 2 Left/Right Side Designation . . . .3 - 2 Crusher Weights . . . .3 - 3 Lifting Crusher . . . .3 - 4 Direction of Flywheel Rotation . . . .3 - 4 Crusher Drive Speed . . . .3 - 4 Maximum & Minimum Crusher Settings . . . .3 - 5 Capacity of Crusher . . . .3 - 5 Crusher Dimensions . . . .3 - 6

Section 4 - Set-up & Operation

Mounting & Set-up . . . .4 - 1 Mounting Crusher . . . .4 - 1

Mounting Clearance . . . .4 - 1 Flywheel Counterweight Installation . . . .4 - 1 Guarding . . . .4 - 2

Operation . . . .4 - 3

Prior To Starting . . . .4 - 3 Starting Crusher . . . .4 - 3 Cold Weather Startup Notes . . . .4 - 3 During Operation . . . .4 - 4 Oil Lubrication System . . . .4 - 4 Stopping Crusher . . . .4 - 4

Feeding The Crusher . . . .4 - 5

Material Feed Size . . . .4 - 5 Clay . . . .4 - 5

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Table of Contents

Section 5 - Lubrication & Maintenance

General Lubrication Information . . . .5 - 1

Capped Grease Fittings . . . .5 - 2 Grease Capacities . . . .5 - 2 Lubricating Stored Equipment . . . .5 - 3 Bearing Temperature . . . .5 - 3

Grease Lube Labyrinth Seal Crushers . . . .5 - 3

Labyrinth Seals . . . .5 - 3 Daily Lubrication . . . .5 - 3 Changing Lubricant . . . .5 - 5

Grease Lube Annular/Labyrinth Seal Crushers . . . .5 - 6

Annular/Labyrinth Seals . . . .5 - 6 Daily Lubrication . . . .5 - 6 Changing Lubricant . . . .5 - 7

Oil Lube Annular/Labyrinth Seal Crusher . . . .5 - 9

System Overview . . . .5 - 9 Low Oil Flow Alarm System . . . .5 - 11 Annular/Labyrinth Seals . . . .5 - 12 Daily Lubrication . . . .5 - 12 Periodic Lubrication . . . .5 - 14 Oil Heater (optional) . . . .5 - 16 Cycle Timer (optional) . . . .5 - 16

Periodic Maintenance . . . .5 - 18 Maintenance Benchmark Check Sheet . . . .5 - 19

Periodic Inspections . . . .5 - 20

Section 6 - Electrical

Standard Drive Electrical . . . .6 - 1

Section 7 - Troubleshooting

Troubleshooting . . . .7 - 1

Crusher Not Operating At Rated Capacity . . . .7 - 1 Bearings Overheating . . . .7 - 1 Excessive Jaw Wear . . . .7 - 2 Difficult to Adjust Closed Side Setting . . . .7 - 2

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Torque Charts . . . A - 1

Standard Torque Chart . . . A - 1 Metric Torque Chart . . . A - 1 Standard Torque Chart . . . A - 2 Metric Torque Chart . . . A - 3

Appendix B - General Belt Drive Care

General Belt Information . . . B - 1 Maintaining V-Belt Tension . . . B - 2 Check Belt Tension

with Mechanical Tester . . . B - 4 Belt Guards . . . B - 6 Idlers . . . B - 7

Inside Idler . . . B - 7 Back-Side Idler . . . B - 7 Kiss Idler . . . B - 7

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Section 1 - Introduction

About This Manual

This book is an operation and maintenance manual for the owner or operator of the equipment described within.

We strongly recommend that anyone working with this equipment become familiar with the manual, whether or not you have experience with similar equipment.

This manual will help you understand how to install your equipment, prepare it for operation, and perform normal operation and maintenance tasks.

This manual contains information necessary for proper and safe operation. Carefully read this manual before attempting to operate. Failure to read and heed instructions preceded by a safety-alert symbol can cause death or severe personal injury as well as equipment and environmental damage.

Experience has shown it is to your advantage to keep a copy of this manual where operators can consult it as needed and to have a copy on file in your office, so that shift leaders or supervisors can conveniently refer to it. Additional copies can be ordered through your distributor.

This equipment is precisely engineered, highly functional, and heavy-duty designed to provide years of excellent service performing to customer specifications. We are proud to manufacture this equipment for your use and profit. We also take pride in the quality of our service and replacement parts.

This manual, however, is not a parts catalog and should not be used to order parts. Only your Parts Book, identified with your machine’s serial number, is an authoritative source of part numbers and part descriptions for your equipment.

Ongoing improvement of product design may in the future result in changes to some parts. Use part numbers, model numbers and serial numbers from your Parts Book to communicate with your distributor.

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About This Manual

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Section 2 - Safety

General Safety

This equipment is designed expressly for processing rock and recycling concrete and asphalt. When our equipment is used for purposes other than those for which it was designed, user assumes sole responsibility for any injuries or damage that may result from said misuse.

There are many hazards involved in rock processing and in the use of rock-processing equipment. That is why we emphatically recommend that this equipment be operated only by personnel who are trained in its use.

We make no guarantee, either expressly or by implication, that this equipment meets all local or federal safety regulations. It is the responsibility of those individuals who own and/or operate this machine to verify that all safety regulations are complied with before starting either this unit or any associated equipment.

Safety Alert Symbol

The safety alert symbol (Figure 2 - 1) is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

Figure 2 - 1 Safety Alert Symbol

Hazard Classification

A multi-tier hazard classification system is used to communicate potential personal injury hazards. The following signal words used with the safety alert symbol indicate a specific level of severity of the potential hazard (Figure 2 - 2). Signal words used without the safety alert symbol relate to property damage and protection only. All are used as attention-getting devices throughout this manual as well as on decals and labels fixed to the machinery to assist in potential hazard recognition and prevention.

Figure 2 - 2 Hazard Classification

CAUTION

DANGER

CAUTION

NOTICE

WARNING

DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

CAUTION used without the safety alert symbol indicates a

potentially hazardous situation which, if not avoided, may result in property damage.

NOTICE indicates information or a company policy that relates directly or indirectly to the safety or protection of property.

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General Safety

Safety

Decals and Icons

Beneath all safety regulations lies a set of common-sense rules. Everyone who works with or near heavy equipment must be aware of those rules. To foster and maintain such an awareness in our customers, safety decals are fixed on our equipment.

Icons on our safety decals remind both workers and supervisors of common hazards and procedures that, in the course of a busy day, they might otherwise forget. The language of the icons is simple and direct (Figure 2 - 3).

Figure 2 - 3 Safety Pictograms Explained Place guards around all moving parts on this machine. Never start the machine if those guards are broken or missing.

Keep hands, feet, clothes and hair away from moving belts and sheaves.

Wear hearing protection when you’re near this equipment.

Wear respiratory protection when near this equipment. Rock dust is hard on your lungs.

Rock chips sometimes come flying out of equipment. Wear goggles or safety glasses near this equipment.

Falling rock is a hazard around any rock-processing operation. Wear your hard hat.

Read all the manuals that shipped with your equipment. Maintenance is done more easily and safely when you know what you’re doing.

Lockout & Tagout. Equipment may be energized. Lockout and tagout all energy sources prior to performing maintenance or adjustments.

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Decal Location

NOTES:

1. ASSEMBLY IS FOR ALL JAW CRUSHERS. DECAL LOCATIONS AS SHOWN, OR AS CLOSE AS POSSIBLE.

2. ITEMS MARKED * ARE ON PARTS LIST 03042ED (JAW OIL LUBE EMBLEMS). STAMP SERIAL NO.

IN PARENT METAL (SEE P/L 01376EAS) 1-1904494-100-04 * 1-1904494-100-01 1-3 04493-023 1-4 07073-015 1-1704418-031

STAMP SERIAL NO. IN PARENT METAL (SEE P/L 01376EAS) OR

NOTE: WIRE TIE DECAL AROUND GROOVED FLYWHEEL. (SEE P/L 05077SBK, DECAL P/N 04490-026).

Grease must extrude from the seals at all times to produce an effective dust & moisture seal. Greasing intervals must be established to maintain this visible grease slick. Every 1000 hours or seasonally, drain the supply tank and fill with flushing oil. Proceed with flushing operation. See specific instructions in Operations Manual. Brand Names: Ambient Temperature Guide - (Above 32˚f) [Below 32˚f] Chevron Gear Compound EP (220) [150] Exxon Spartan EP (220) [150] Shell Omala EP (220) [150] Texaco Meropa (220) [150] Mobil Mobilgear (630) [629]

DANGER Safety

Refer to Operation & Maintenance Manual for detailed lubrication instructions. Pitman & Side Bearings:

Seals: Lubricant: Lithium base, extreme pressure type, grade 2 grease. Lubricant: Extreme pressure lubricating oil. Fill supply tank with recommended lubricant.

Roller Bearing Crusher Circulating Oil System

04494-100-04a Refer to Operation & Maintenance Manual for detailed lubrication instructions. Lubricant: Lithium base, extreme pressure type, grade 1 grease.

Roller Bearing Crusher Grease Lubrication

Bearings & Seals: Grease must extrude from the seals at all times to produce an effective dust & moisture seal. Greasing intervals must be established to maintain this visible grease slick. Caution:Over lubrication will result in elevated operating temperatures.

04494-100-01a DANGER

Safety Brand Names: Chevron Dura-Lith EP1 Shell Alvania EP1 Exxon Lidok EP1 Texaco Multifak EP1 Mobil Mobilux EP1 Jaw, Impact Breaker, Hammermill

A Terex Company

SERIAL NUMBER CEDAR RAPIDS, IOWA U.S.A.

MODEL NUMBER DATE OF MANUFACTURE

4493-023

Crushing & Screening Patents

Built under one or more of the following patents: United States: 4,454,994 - 4,477,031 - 4,571,112 - 4,699,326 - 4,717,084 - 4,773,604 - 4,896,838 - 4,919,348 4,919,349 4,925,114 5,083,714 5,111,569 5,005,772 5,004,169 -5,996,916 - 5,312,053 - 5,350,125 - 5,718,390 - 5,875,981 - 5,927,623 - 5,718,391 - 5,799,886 5,803,382 5,944,265 5,971,306 5,810,268 6,070,819 6,070,820 -6,089,481 - 6,126,101 - 6,149,086 - 6,155,507 - 6,161,650 - 6,189,820 Canada: 1,282,391 - 1,313,170 - 2,015,298 - 2,015,299 - 2,112,946. France: 9010205 Great Britain: 2213398 - 2127500 New Zealand: 222,991 - 228,746 - 212,988Australia: 534,673 - 534,674 - 534,675 - 548,832 - 552,227 - 557,149 - 557,477 - 569,405 - 579,784 615,281

Other Patents Pending.

04418-031y

A Terex Company

1-1604494-104-01 1-1504418-542 1-1604494-104-01 1-1504418-542

Made In United States of America04418-955d

1-1404418-955

EQUIPMENT DAMAGE HAZARD May cause damage to motor or crusher.

Keep crusher pulley free of dust and dirt buildup to avoid shaking of machine.04492-005b

CAUTION 1-1104492-005 04490-103-01 1-10 04490-103-01 1-10 1-804490-031 DANGER ENTANGLEMENT HAZARD

EQUIPMENT LOCKED OUT

DANGERDANGERPELIGRO

DANGER

LOCKED OUT Do not reach into unguarded machine, you can be pulled in. Death or serious injury will result. Keep all guards in place.

SWITCH OFF and LOCKOUT & TAGOUT equipment before opening or removing guards. 04490-031

EQUIPMENT DAMAGE HAZARD May cause damage to motor or crusher.

Keep crusher pulley free of dust and dirt buildup to avoid shaking of machine.

04492-005b CAUTION 1-1104492-005 1-804490-031 DANGER ENTANGLEMENT HAZARD

EQUIPMENT LOCKED OUT

DANGERDANGERPELIGRO

DANGERLOCKED OUT Do not reach into unguarded machine, you can be pulled in. Death or serious injury will result. Keep all guards in place.

SWITCH OFF and LOCKOUT & TAGOUT equipment before opening or removing guards. 04490-031

PELIGRO DANGER EQUIPMENTLOCKEDOUT DANGER LOCKEDOUT HEARING HAZARD

May cause loss or degradation of hearing over a period of time. Wear proper hearing personal protection equipment. Wear proper respiratory personal protective equipment. May cause difficulty in breathing.

RESPIRATORY HAZARD FALLING MATERIAL

May cause death, or severe personal injury. Wear proper head personal protective equipment. Wear proper eye personal protective equipment. May cause loss or degradation of eye sight.

FLYING MATERIAL READ MANUALSRead all manuals prior to operation. DO NOT OPERATE equipment if you do not understand the information in the manuals. Consult your supervisor, the owner, or the manufacturer.

LOCKOUT & TAGOUT

Equipment may be energized. Lockout and Tagout all energy sources prior to performing maintenance or adjustments. 04490-103-01

DANGER

DANGER ENTANGLEMENT

HAZARD

Do not reach into unguarded machine, you can be pulled in. Death or serious injury will result. Keep all guards in place.

NOTICE WARNING PELIGRO DANGER EQUIPMENTLOCKEDOUT DANGER LOCKEDOUT HEARING HAZARD

May cause loss or degradation of hearing over a period of time. Wear proper hearing personal protection equipment. Wear proper respiratory personal protective equipment. May cause difficulty in breathing.

RESPIRATORY HAZARD FALLING MATERIAL

May cause death, or severe personal injury. Wear proper head personal protective equipment. Wear proper eye personal protective equipment. May cause loss or degradation of eye sight.

FLYING MATERIAL READ MANUALS

Read all manuals prior to operation. DO NOT OPERATE equipment if you do not understand the information in the manuals. Consult your supervisor, the owner, or the manufacturer.

LOCKOUT & TAGOUT

Equipment may be energized. Lockout and Tagout all energy sources prior to performing maintenance or adjustments. 04490-103-01

DANGER

DANGER ENTANGLEMENT

HAZARD

Do not reach into unguarded machine, you can be pulled in. Death or serious injury will result. Keep all guards in place.

NOTICE

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Personal Safety

Safety

Personal Safety

This equipment is designed with the safety of all personnel in mind. Never attempt to change, modify, eliminate or bypass any of the safety devices installed at the factory. Guards, covers and shields installed around moving parts at the factory are meant to prevent accidental injury to operators and other personnel. Do not remove them.

Sometimes, at a customer’s request, equipment is shipped without certain features such as a drive sheave. When this occurs, we attach a warning decal to alert installers that the related guard or other safety feature is missing. In such cases it is the customer’s responsibility to guard the machine properly.

Make sure that everyone working on or near this equipment is familiar with safety precautions. We recommend the following basic safety practices:

• Read all danger, warning, caution and notice

signs.

• Always lock out and tag out involved energy

sources before performing maintenance or adjustments on this equipment. Make it impossible for anyone to start this machine while others work on it or in it.

• Never remove any guard, cover or shield when

this equipment is in motion.

• Replace guards, covers and shields when the

task for which you removed them is finished.

• Block parts as necessary to prevent their

sudden movement while people are working on the machine.

• Never attempt to clear away jammed feed

material, discharge material or other stoppage while the machine is running. Stop the equipment, lock out and tag out before touching this machine with your tools or your hands.

• Wear proper personal protective equipment,

including eye protection, hard hat and safety shoes, whenever you’re near this machine while it is running.

• Dress appropriately in every way. Never wear

loose clothes, long hair, coat tails, jewelry, pockets full of tools or any other item that could get caught in moving parts.

• Know where your fellow workers are. Always

look around and inside this machine before starting it. Make sure nobody is in the way of moving parts or working on the machine.

• Lift with your legs, not with your back. Keep

the weight close to your body. If the load is more than 40 lbs., get someone to help you.

• Never engage in horseplay when near this

machine, or any other.

• Report any defective machinery or equipment

and unsafe conditions or activity to your boss immediately.

• Don’t limit safety practices to the few rules

listed here. Think safety and act safely at all times.

• Most of all, know your equipment. Understand

the machinery, the conditions under which it operates and what it is capable of doing.

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Work Area Safety

• Keep the work area as neat and clean as

practical.

• Keep all product safety signs clean, clear and

current.

• Make sure all electrical equipment is properly

grounded. Wet spots near electrical current are especially dangerous.

• Store hazardous materials in restricted access

areas and mark them clearly. Federal regulations require special labeling of certain materials.

• Never start an engine in an enclosed space

without properly venting the exhaust.

• Do not smoke or allow smoking near fuels and

solvents. Never strike a spark or use an open flame near fuels and solvents.

• Store flammable fuels, solvents and gases in

secure, well ventilated areas. Never allow fumes to accumulate in the storage area. Use nonflammable solvents for cleaning parts and equipment whenever possible.

• Know where fire extinguishers and other

fire-suppression equipment are located. Learn how to use them effectively.

• Be alert and wary around any pressurized

system, hydraulic or pneumatic. High-pressure oils and gases are very dangerous.

Equipment & Tools

• Clean tools that are properly labeled and stored

are safer tools. Keep your tools in good order.

• Keep drive belts and sheaves in good condition.

Frayed belts or cracked sheaves are not only dangerous, they cost you downtime.

• Always use mechanical assistance to lift heavy

loads. Never overload a hoist, crane, jack or other lifting device. Check lifting tackle regularly; replace it at the first sign of stretch, fraying or other wear.

• Keep your equipment clean, free of dirt and

grease, so that loose, cracked or broken parts are more easily spotted. Replace defective parts as soon as they are discovered.

Lockout & Tagout

Code of Federal Regulations number 1910.147 requires that employers establish and follow a Lockout & Tagout procedure and train their employees in that

procedure before any employee can operate, service or maintain any piece of power equipment. Employers are required to make periodic inspections to see that their Lockout & Tagout procedures are being followed, and they must monitor and update their program on an ongoing basis. Employees are responsible for seeing that equipment is locked out and tagged out in accordance with the employer’s policy.

To promote safety in its use, we ship a Lockout & Tagout Kit with the equipment. The kit and its contents are illustrated in (Figure 2 - 4).

Figure 2 - 4 Lockout & Tagout Kit

Do Not Operate!

FEDERAL REGISTER Additional instructions are available, but not in this block of text. Please refer to the inform

ation provided with this kit instead of trying to read this tiny text. Additional instructions are available, but not in this block of text. Please refer to the information provided with this kit instead of trying to read this tiny text.

Lockout - Tagout Kit

DANGER

THIS TAG & LOCK TO BE REMOVED ONLY BY THE PERSON LISTED ON BACK.

DANGER

DANGER PELIGRO Equipment Locked Out by / Equipo Puesto Bajo Llave Por ________

Date / Fecha ______

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Lockout & Tagout

Safety

What is Lockout & Tagout?

Lockout & Tagout is a procedure that’s designed to prevent absolutely the unexpected or accidental startup of equipment and to alert all workers whenever it is unsafe to operate any piece of equipment. When used as intended, Lockout & Tagout also protects personnel from energy stored in devices such as springs, accumulators, batteries, hydraulic systems, etc.

How to Lockout & Tagout

• Install one or more locks to hold

the master switch lever in the OFF position.

• If the switch is keyed, turn the key

to the OFF position and remove the key.

• Disconnect the batteries.

• Regardless of which lockout method is used,

place one or more tags on machine control panels, access doors and electrical panels.

When is Lockout & Tagout required?

• Any time anyone is maintaining, repairing,

lubricating, or, for whatever reason, working on the equipment.

• When the equipment is broken or, for whatever

reason, unfit or unsafe to operate.

• Whenever the equipment is left unattended.

Who must apply a lock & tag?

• Any person working on the equipment.

• Foreman or other person responsible for the

work being done.

• If several people are working on a machine at

the same time, each person must apply his or her own lock and tag.

When can a lock and tag be removed?

After performing these six steps: 1) All safety guards are back in place.

2) All work is complete and tools are put away. 3) All workers are notified that a lock is being

removed.

4) All workers are positioned safely for startup. 5) Controls are positioned for safe startup. 6) The machine is ready for safe operation.

Who can remove a lock and tag?

• Only the person who applied a lock and tag is

permitted to remove them.

Lockout & Tagout rules laid out here are generic. To get instructions for your particular workplace, consult your employer’s lockout/tagout procedure.

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Section 3 - General Jaw Crusher

Information

Crusher Description & Information

1 - Pitman 7 - Stationary jaw 13 - Tension spring

2 - Pitman bearing 8 - Movable jaw 14 - Tension spring collar

3 - Side bearing 9 - Toggle seat 15 - Hand pump

4 - Eccentric shaft 10 - Toggle plate 16 - Tension rods

5 - Key plate 11 - Toggle seat base 17 - Shims

6 - Base 12 - Hydraulic ram 18 - Shim cover

Figure 3 - 1 Jaw Crusher Parts

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

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Crusher Description & Information

General Jaw Crusher Information

General Description

Cedarapids roller bearing jaw crushers are used both as primary and secondary crushers depending on the size of the material to be crushed. They will break rock down to the size specified in one operation or to a size that can be further reduced by a secondary crusher such as a rollercone or a smaller jaw crusher. These crushers are made of welded type construction and can be used in either a stationary or portable plant.

The jaw crusher consists of two readily separable subassemblies; the base assembly and the shaft and pitman assembly. Refer to Figure 3 - 1. The base assembly consists of the crusher base, stationary jaw, key plates and adjusting mechanism. The shaft and pitman assembly is composed of the moving parts of the crusher; the eccentric shaft, pitman, movable jaw, side and pitman bearings, side bearing housings, all bearing seals and spacers and the two flywheels.

Operating Principle

The stationary jaw is wedged in place in the base by the key plates and the movable jaw, which is attached to the pitman. The pitman is mounted on roller bearings on the eccentric portion of the crusher shaft, the concentric ends of which are mounted in housed roller bearings rigidly attached to the crusher base. The lower end of the pitman is hinged on one end of the toggle plate; the other end of the toggle plate oscillates in a groove in the toggle bearing wedge, which is attached to the crusher base.

The replaceable cast iron toggle plate serves as a fuse or safety device in the crusher, as it will break when uncrushable material such as a shovel tooth passes between the jaws. Due to the eccentric shaft and the toggle plate, a combination crushing and downward motion is imparted to the pitman and movable jaw as the shaft is revolved. The horizontal length of the crushing motion gradually

diminishes between the top and the bottom of the movable jaw, producing a long primary crushing stroke at the top of the jaw and a short stroke for crushing to a more uniform size at the bottom.

Crusher Sizes

Jaw crusher size refers to the opening at the top of the crusher. This opening is rectangular and is measured from the top of the movable jaw (A) to the top of the stationary jaw (B), and from side key plates (C) to opposite side key plate (D) (Figure 3 -2). For example: a Model 3042 jaw crusher has an intake opening of 30 inches (762 mm) between jaws (A) to (B) and 42 inches (1067 mm) between key plates (C) to (D). The dimensions will vary slightly due to the casting tolerances of jaws and key plates.

Figure 3 - 2 Jaw Crusher Opening

Left/Right Side Designation

Right and left side of crusher are determined when standing facing the tension springs (Figure 3 - 2).

A B

C D

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Crusher Weights

The approximate weights listed in Table 3 - 1 are based on clean new standard components. Weights may vary and listed weights should be considered only an approximation.

Model

Complete Crusher (Base, Pitman Assy, & Flywheels)

Pitman Assembly (Pitman Assy & Flywheels)

Flywheel Only (Each) lbs kg lbs kg lbs kg 1016 5,306 2,406 2,844 1,293 690 314 1024 8,255 3,752 4,817 2,190 1,275 580 1036 12,551 5,705 7,449 3,386 1,223 556 1236 13,978 6,354 8,007 3,640 1,250 568 1242 19,521 8,873 12,120 5,509 2,098 954 1248 24,300 11,045 14,374 6,534 2,175 989 1524 12,305 5,593 6,771 3,078 1,215 552 1636 21,003 9,547 11,895 54,07 2,075 943 1642 33,998 15,454 19,642 8,928 2,741 1,246 1648 32,406 14,730 16,988 7,722 2,684 1,220 1824 12,426 5,648 6,771 3,078 1,215 552 1836 21,280 9,673 12,105 5,502 2,126 966 2236 24,903 11,320 14,266 6,485 2,785 1,266 2248 43,094 19,588 25,746 11,703 3,700 1,682 2436 46,737 21,244 22,861 10,391 3,462 1,574 2438 26,017 11,826 14,501 6,591 2,873 1,306 2540 45,000 20,455 18,950 8,614 4,200 1,909 2542 42,095 19,134 21,832 9,924 3,584 1,629 2742 48,520 22,055 25,842 11,746 4,194 1,906 3042 48,520 22,055 25,842 11,746 4,194 1,906 3054 52,740 23,973 27,525 12,511 4,194 1,906 3242 57,137 25,971 28,755 13,070 4,028 1,831 3648 79,653 36,206 39,524 17,965 5,560 2,527 3660 107,664 48,938 58,478 26,581 5,595 2,543 4242 58,838 26,745 28,755 13,070 4,028 1,831 4248 104,567 47,530 52,827 24,012 5,595 2,543 5460 196,258 89,208 102,715 46,689 10,570 4,805 5748 117,000 53,182 52,827 24,012 5,595 2,543

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Lifting Crusher

To lift crusher, always fasten chain or cable to crusher base. Never lift complete crusher with cables attached to flywheels or pitman. If only pitman, shaft and bearing assembly is to be removed from crusher base, fasten chain or cable to lifting lugs provided on top of pitman housing.

Direction of Flywheel Rotation

The overhead eccentric force feed jaw crusher are designed to have the shaft assembly with flywheel rotate downward and toward the crushing chamber. Standing on the left side of the crusher, the flywheels will be rotating in a counterclockwise direction (Figure 3 - 3). Right and left hand are determined when facing the tension spring.

Figure 3 - 3 Direction of Flywheel Rotation

Crusher Drive Speed

The correct speed of the crusher will be stamped into the crusher base (Figure 3 - 3). Correct speed is one of the basic requirements to obtain maximum capacities with minimum wear.

Always maintain speed of the crusher according to the factory recommendations. Crushers are designed to run at a certain speed with a specific flywheel and counterweight configuration. Changing speed will change the flywheel and counterweight requirements. Consult factory if operating speed will vary more than +/- 25 rpm from the speed marked on the crusher.

Operating with incorrect speeds and flywheels can increase compaction in the crusher and lead to premature shaft and bearing failure.

SPEED

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Maximum & Minimum Crusher Settings

Cedarapids has established limits for the discharge opening of each crusher. For safe and efficient operation, the following maximum and minimum openings should govern crushing extremes. Refer to Table 3 - 2.

Capacity of Crusher

Crusher capacity is measure both by the size of material that can be fed into the crusher and throughput of the crusher. In general, the maximum feed size for jaw crushers is 80% of the jaw opening in sand and gravel applications and 90% of the jaw opening in quarry applications. For example, a 3042 crusher with a jaw opening of 30” by 42” will have a maximum feed size of 24” by 33.6” in sand and gravel applications and 27” by 37.8” in quarry applications. These are general guidelines and may vary in certain applications. Crusher throughput capacities are based on average conditions and will vary widely with different types of rock and stone, uniformity of feed and moisture content of material being crushed. Crusher throughput and gradation information is available by contacting your Cedarapids distributor. Size Minimum Maximum inches mm inches mm 1016 3/4 19 3 1/2 89 1020 3/4 19 3 1/2 89 1024 3/4 19 3 1/2 89 1036 1 1/2 38 3 1/2 89 1236 1 1/2 38 5 127 1242 1 1/2 38 5 127 1248 1 1/2 38 5 127 1524 1 1/2 38 5 127 1636 1 1/2 38 5 127 1642 1 1/2 38 5 127 1648 1 1/2 38 5 127 1824 1 1/2 38 5 127 1836 1 1/2 38 5 127 2236 2 1/2 64 6 152 2248 2 1/2 64 6 152 2436 2 1/2 64 6 152 2438 4 1/2 114 8 203 2542 3 1/2 89 10 254 2742 3 1/2 89 10 254 3042 4 102 13 330 3054 3 1/2 89 13 330 3242 4 102 13 330 3648 4 102 13 330 3660 4 102 13 330 4242 14 356 23 584 4248 4 102 13 330 5460 6 152 20 508 5748 19 483 28 711

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Crusher Dimensions

Figure 3 - 4 Crusher Dimensions to nearest inch and mm

l e d o M 1016 1020 1024 1036 1236 1242 1248 1524 1636 1642 1648 1824 1836 2236 A 40 5 1 0 1 8 4 0 2 2 1 5 4 5 4 1 1 8 4 0 2 2 1 8 4 0 2 2 1 6 5 0 2 4 1 9 5 0 0 5 1 5 5 5 9 3 1 1 6 0 5 5 1 1 7 0 0 8 1 6 6 5 7 6 1 6 5 0 2 4 1 4 6 5 2 6 1 5 6 0 5 6 1 B – – – – – – – – – – – – – – – – – – 3 7 5 5 8 1 – – – – – – – – C 41 0 4 0 1 6 4 0 7 1 1 6 4 0 7 1 1 6 4 0 7 1 1 1 5 5 9 2 1 5 5 5 9 3 1 6 5 0 2 4 1 7 5 5 4 4 1 3 6 0 0 6 1 6 7 0 3 9 1 0 7 0 8 7 1 7 5 5 4 4 1 3 6 0 0 6 1 7 7 5 5 9 1 D 24 0 1 6 8 2 0 1 7 8 2 0 1 7 8 2 0 1 7 2 3 0 1 8 3 3 0 4 8 5 3 0 9 8 6 3 5 1 9 1 4 0 4 0 1 6 4 0 7 1 1 1 4 0 4 0 1 6 3 5 1 9 1 4 0 4 0 1 8 4 0 2 2 1 E 26 0 6 6 8 2 0 1 7 8 2 0 1 7 8 2 0 1 7 3 3 0 4 8 4 3 5 6 8 5 3 0 9 8 9 3 0 9 9 2 4 5 6 0 1 8 4 0 2 2 1 2 4 5 6 0 1 9 3 0 9 9 2 4 5 6 0 1 9 4 5 4 2 1 F 58 0 7 4 1 2 7 0 3 8 1 2 7 0 3 8 1 1 8 5 5 0 2 1 8 5 5 0 2 8 9 0 9 4 2 4 0 1 0 4 6 2 7 6 0 0 7 1 2 9 5 3 3 2 9 9 5 1 5 2 4 9 5 8 3 2 7 7 5 5 9 1 2 9 5 3 3 2 2 9 5 3 3 2 G 22 0 6 5 6 2 0 6 6 7 2 5 8 6 1 4 0 4 0 1 1 4 0 4 0 1 7 4 5 9 1 1 3 5 5 4 3 1 7 2 5 8 6 1 4 0 4 0 1 7 4 5 9 1 1 3 5 5 4 3 1 7 2 5 8 6 1 4 0 4 0 1 3 4 0 9 0 1 H 14 5 5 3 4 1 5 5 3 1 2 5 3 5 8 1 5 5 4 9 1 0 8 4 0 2 0 1 5 9 1 0 8 4 8 1 5 5 4 6 1 5 0 4 0 2 0 1 5 6 1 5 0 4 9 1 0 8 4 6 1 5 0 4 7 1 0 3 4 l e d o M 2248 2436 2438 2542 2742 3042 3054 3242 3648 3660 4242 4248 5748 5460 A 79 5 0 0 2 8 8 5 3 2 2 7 6 0 0 7 1 2 8 0 8 0 2 8 8 5 3 2 2 8 8 5 3 2 2 8 8 5 3 2 2 3 9 0 6 3 2 7 0 1 5 1 7 2 8 1 1 5 9 9 2 3 0 1 5 1 6 2 3 2 1 5 2 1 3 8 3 1 5 0 5 3 9 4 1 5 8 7 3 B 81 5 5 0 2 1 9 0 1 3 2 – – 5 8 0 6 1 2 8 8 5 3 2 2 1 9 1 1 3 2 1 9 1 1 3 2 9 9 5 1 5 2 3 1 1 0 7 8 2 – – 9 0 1 0 7 7 2 6 2 1 0 0 2 3 1 4 1 0 8 5 3 2 5 1 0 6 8 3 C 83 0 1 1 2 9 8 0 6 2 2 7 7 5 5 9 1 3 9 0 6 3 2 2 9 7 3 3 2 2 9 7 3 3 2 2 9 7 3 3 2 5 0 1 5 6 6 2 0 2 1 0 5 0 3 5 2 1 5 7 1 3 5 0 1 5 6 6 2 7 3 1 0 8 4 3 7 3 1 0 8 4 3 2 7 1 0 7 3 4 D 52 0 2 3 1 1 6 0 5 5 1 0 5 0 7 2 1 3 6 0 0 6 1 2 6 5 7 5 1 2 6 5 7 5 1 3 6 0 0 6 1 5 7 5 0 9 1 2 8 0 8 0 2 6 8 5 8 1 2 5 7 5 0 9 1 6 9 0 4 4 2 6 9 0 4 4 2 7 2 1 5 2 2 3 E 54 0 7 3 1 1 6 0 5 5 1 9 4 5 4 2 1 5 6 0 5 6 1 4 6 6 2 6 1 4 6 6 2 6 1 4 6 6 2 6 1 7 7 5 5 9 1 4 8 5 3 1 2 8 8 5 3 2 2 7 7 5 5 9 1 1 0 1 5 6 5 2 1 0 1 5 6 5 2 0 3 1 0 0 3 3 F 99 5 1 5 2 4 9 5 8 3 2 2 9 5 3 3 2 5 9 5 1 4 2 9 9 5 1 5 2 9 9 5 1 5 2 0 1 1 5 9 7 2 9 9 5 1 5 2 1 0 1 5 6 5 2 9 1 1 5 2 0 3 9 9 5 1 5 2 0 2 1 0 5 0 3 0 2 1 0 5 0 3 0 4 1 5 5 5 3 G 53 5 4 3 1 3 4 0 9 0 1 3 4 0 9 0 1 5 4 5 4 1 1 7 4 5 9 1 1 7 4 5 9 1 1 9 6 5 5 7 1 7 4 5 9 1 1 2 5 0 2 3 1 8 7 0 8 9 1 7 4 5 9 1 1 5 5 5 9 3 1 5 5 5 9 3 1 7 6 0 0 7 1 H 16 5 0 4 7 1 0 3 4 8 1 5 5 4 9 1 0 8 4 7 1 0 3 4 7 1 0 3 4 0 2 0 1 5 2 2 0 6 5 0 2 0 1 5 8 2 1 1 7 2 2 0 6 5 0 2 0 1 5 0 2 0 1 5 8 1 5 5 4 D H G F E C A

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Section 4 - Set-up & Operation

Mounting & Set-up

The jaw crusher may be installed on a portable plant or as a component for installation in a stationary plant or customer supplied portable plant. Mounting a jaw crusher requires careful planning to ensure:

• mounting structure is capable of supporting the

weight and forces generated by an operating jaw crusher.

• adequate clearance has been left around the

crusher to allow safe operation without interference.

• crusher flywheel and drive are appropriately

guarded to prevent access during operation.

• provisions are made allowing the power source

to be locked out and tagged out.

• guard rails and walkways are installed where

necessary.

• a means of feeding material to the crusher and

removing crushed material from under the crusher are provided.

Mounting Crusher

All foundations and crusher supports must be designed by a qualified engineer to meet local code requirements. Information needed to design the crusher foundation or support may be obtained from Cedarapids.

When installing crusher in a stationary plant, place on an adequately designed foundation. There must be ample clearance maintained between crusher discharge and receiving conveyor for the material to discharge without rubbing end of pitman. Consideration for overhead clearance must also be made should removal of the pitman become necessary.

The crusher must be perfectly level across the length of the shaft (side-to-side) to maintain even load on all the bearings and ensure proper lubrication of the bearings.

Mounting Clearance

Adequate clearances must be maintained above the crusher for feeding material into it as well as facilitate maintenance of the crusher. Likewise, adequate clearance must be below the crusher to allow for material to exit the crusher without buildup.

Flywheel Counterweight Installation

Normal flywheel counterweight location when the crusher is at rest, is indexed approximately 30° toward the crushing chamber from top dead center (12 o’clock) position.

It is very important that counterweights on one flywheel be directly across from the

counterweights on the other flywheel. (Figure 4 - 1) Incorrect flywheel counterweight positioning will cause the crusher to vibrate excessively.

Figure 4 - 1 Flywheel Counterweight Installation Flywheel with Counterweights

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Mounting Crusher

Set-up & Operation

Guarding

It is the responsibility of the equipment owner and operators to ensure that adequate guarding is designed and built. The following are situations that should be considered when installing a jaw crusher. Each installation is unique with special hazards that must be considered and guarded. The entire installation should be reviewed by a qualified safety engineer before operation begins.

• The drive system from the drive shaft on the

power unit to the flywheels on the crusher should be guarded to prevent access during operation. This includes the v-belts and both flywheels.

• The power unit must provide a means to

disengage the power source and install a lock and hasp to prevent accidental starting of the crusher. This could include accidental starting of the engine if a wrench falls onto the starter or start switch.

• The area between the crusher and feeder

should be guarded to prevent access during operation.

• Any conveyor, feeder or other equipment that

is overhead or accessible by workers while the crusher is operating must be guarded to prevent any worker from contacting moving parts. This equipment must also be guarded to prevent material from dropping off the equipment and hitting a worker.

• Guarding, handrails and walkways must be

designed and operated in compliance with all current applicable OSHA, MSHA, National Electric Code (NEC), federal, state, and local regulations.

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Operation

Prior To Starting

Perform all daily and periodic lubrication and maintenance tasks listed in Section 5.

Shut down, lock out and tag out all drives, power sources, and electric power panels prior to performing any maintenance.

Starting Crusher

Grease Lube Systems

1) Start or engage crusher drive.

2) Allow the crusher to run empty for a few minutes until the lubricant is warmed up. 3) Start under-crusher conveyor.

4) Start feeder.

Oil Lube Systems

1) If the crusher is equipped with the optional oil lubrication system with oil reservoir heaters, turn on heaters and allow oil to warm to operating temperature.

2) If the crusher is equipped with the optional oil lubrication system with optional cycle timer, switch the Day-Night switch to Day.

3) If the crusher is equipped with the optional oil lubrication system operate as follows.

A) Start oil lubrication pump.

B) Control valves regulate the oil flow to the bearings. Flow to each bearing is

controlled independently.

C) Fully open all valves. Brass indicators in the flow indicator tubes will rise to their highest points in the tubes.

D) Allow the crusher to run until the oil is warmed up.

E) Partially close the valves until all the indicators are at the same level. 4) Start or engage crusher drive.

5) Allow the crusher to run empty for a few minutes.

6) Start under-crusher conveyor. 7) Start feeder.

Cold Weather Startup Notes

• Allow the crusher extra time to run empty to

ensure the lubricant is warmed.

• If the crusher is hard to start, change to lighter

lubricant. Refer to lubrication instructions for more information.

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Operation

During Operation

Throughout the daily operating period the operator should check for unusual sounds or other signs of abnormal operation that warn of future trouble if not promptly corrected.

• Check crusher bearings for the appearance of

overheating. Do not operate crusher if bearings overheat until the cause is determined and corrected.

• Ensure tension springs are tight enough to

keep the toggle plate from clattering when the crusher is running empty. After changing the crusher discharge opening or replacing the toggle plate listen for a clattering or pounding noise, indicating the tension springs are too loose. Adjust tension springs before resuming operation.

• Observe the stationary jaw for slight up and

down movement. If such movement is visible, tighten the key plates. If crusher is operated with loose key plates, the resulting movement of the stationary jaw will cause unnecessary wear on the jaw and base as well as reduce the capacity of the crusher.

Oil Lubrication System

• Periodically check the level of the flow

indicators. If the level falls in any of the tubes, it could be a sign of bearing problems or clogged filters.

• The filter gauge shows the pressure in the feed

line to the filter. Readings will vary with ambient temperature, type of lubricant, operating temperature, etc.

• The suction gauge will normally show little or

no reading.

Stopping Crusher

1) Stop the feed to the crusher.

2) Allow the material in crusher to be fully crushed and empty out the crushing chamber. 3) Shut off the power to the crusher drive. 4) Shut off the power to the under-crusher

conveyor.

Avoid stopping the crusher when the jaws are full of material. Restarting the loaded crusher produces an excessive load on the power unit and an extreme pull on the belts. A plugged crusher should be at least partially emptied by hand before restarting.

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Feeding The Crusher

The most efficient operation of the crusher results when the crushing chamber is kept full of material and when a uniform method of feeding is used. The crusher should be kept full of material however, material should not be allowed to build up above the tops of the jaws.

Allowing material to build up to the pitman during crushing could damage the pitman. Do not allow material to build up higher than the tops of the jaw dies.

Material Feed Size

Material typically found in sand and gravel operations has rounded corners. Shot material typically found in quarry operations tends to be more cubical with square corners. Rounded material requires a smaller nip angle so the jaws can grab and crush the material. Material that is not grabbed by the jaws will slide up and down as the jaws open and close. This wears the jaws without producing product. This material should be removed from the crusher and broken up before attempting to crush again.

A rock breaker can be installed that will allow material to be broken up in the crusher or feeder.

Always turn off the crusher and feeder before using a rock breaker.

In general, the maximum feed size for jaw crushers is 80% of the jaw opening in sand and gravel applications and 90% of the jaw opening in quarry applications. For example, a 3042 crusher with a jaw opening of 30” by 42” will have a maximum feed size of 24” by 33.6” in sand and gravel applications and 27” by 37.8” in quarry applications. These are general guidelines and may vary in certain applications.

Do not use explosives in crusher chamber. The crushing chamber is not designed to withstand the forces generated by explosives. Explosives can cause premature failure of bearings and breakage of the pitman, eccentric shaft and base.

Running the crusher with oversized or uncrushable material sliding on the top of the pitman can damage the pitman. Shut down and remove oversized material.

Clay

Clay tends to build up in the corrugations of the jaw. This reduces jaw capacity and could damage the crusher. When crushing material containing clay, the crusher should be stopped periodically and clay should be cleaned from the jaw corrugations.

Material containing heavy clay should be scalped to remove clay before feeding into the jaw crusher.

CAUTION

DANGER

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Adjusting Closed Side Setting (CSS)

Adjusting Closed Side Setting (CSS)

The crusher discharge opening governs the size of finished material produced by the crusher.The size of the crusher discharge opening is changed by adding or removing shims from behind the toggle seat base. The opening is reduced by moving the base toggle seat forward with the hydraulic mechanism and shimming behind the seat. Refer to Figure 4 - 3. Adjust as follows:

1) When the crushing chamber is completely empty, stop the jaw crusher drive and lock out the power source.

2) Some crushers are equipped with toggle plate base wedges which lock the toggle plate base during operation. This prevents any rocking movement of the base during operation, reducing wear on the toggle seat insert and on the end of the toggle plate.

If your crusher is equipped with toggle plate base wedges, perform the following steps. Refer to Figure 4 - 2.

Figure 4 - 2 Toggle Plate Base Wedge A) When the crusher opening is to be

adjusted, loosen the four wedge tightening locknuts (2 per side) at the sides of the crusher base. Loosen 1/2 inch.

B) Insert a bar through the hole in each side of the crusher base side plate and through a slot in each of the support angles, to contact the wedges. Hit the bar with a sledge until wedge is loose and the toggle plate base is free to move.

3) Loosen tension spring nuts so that shim pack can be adjusted.

4) Install hydraulic rams to push toggle seat forward. Some crushers have two mounts near the bottom of the crusher used to adjust the crusher and a single mount around the

midpoint of the pitman used to push the pitman forward when installing a toggle plate. Always install the rams in the lower holes when adjusting the closed side setting. Refer to Figure 4 - 3.

5) Attach hydraulic pump to ram(s).

6) Make a wooden spacer similar to that shown in Figure 4 - 3, to the exact thickness of the correct discharge opening. When lumber of proper width or thickness is not available, make up a lamination, including plywood, hard fibre board, or metal to obtain the correct thickness. Spacer must be wide enough to bridge between several jaw plate tips as shown in Figure 4 - 3. This is especially important when the desired setting is close to the minimum closed side setting of the crusher. Adding a handle to spacer block will make it easier to properly position at the bottom of the jaws.

7) Rotate and hold the flywheel so that the eccentric shaft closes the jaws as much as possible. Using a ratcheting cable puller (come-along) will make it easier to rotate and hold the flywheel in the desired position.

Wedge Toggle Plate Base

Support Slot (for loosening wedge)

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8) Hold the wood spacer as shown in Figure 4 - 3 so that it is centered in the crushing chamber and extends below the jaws.

Never run the crusher while holding anything in the crushing chamber. Doing so could result in serious injury or death.

9) To change jaw opening,

A) Close valve on hydraulic pump.

B) Pump up rams to push toggle plate base forward relieving pressure on shims. C) If decreasing closed side setting, pump

hydraulic pump until jaw is tight against wood spacer.

A failure of the hydraulic system while adding or removing shims from the shim pack could result in serious personal injury. Keep hands and fingers clear of shims when adjusting crusher. Use a tool to pull shims out of shim pack.

D) Add shims as needed to achieve desired jaw spacing.

E) To increase closed side setting, force jaw forward, remove several shims and proceed with step C.

10) Tighten tension spring nuts to restore holding force on toggle plate.

11) Tighten all wedge bolt locknuts. This draws the support angles up tight against the ends of the toggle seat to prevent any movement. After the next day of crusher operation, retighten all wedge bolt locknuts.

12) Remove hydraulic pump and rams from crusher.

Failure to remove hydraulic rams before operating crusher could result in serious personal injury and/or damage to the equipment.

DANGER

WARNING

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Adjusting Closed Side Setting (CSS)

Figure 4 - 3 Setting closed side setting Racheting Cable Puller

Pitman Eccentric Rotated

Shims

Toggle Plate Base

Handle

Laminated Spacer

Spacer Must Span To Minimum Jaw Opening

Several Corrugations Same Thickness

As Desired CSS

Tension Spring Nuts Hydraulic Ram Toggle

Hydraulic Ram Adjusting

Toggle Plate Base Wedge

Plate Change Position

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Section 5 - Lubrication &

Maintenance

General Lubrication Information

Cedarapids has built crushers using three possible lubrication/seal configurations. It is important to know which type of seal and lubrication your crusher uses.

The three configurations are:

1) Grease lubrication with a labyrinth seal (Figure 5 - 1).

2) Grease lubrication with an annular/labyrinth seal (Figure 5 - 2).

3) Oil lubrication with an annular/labyrinth seal (Figure 5 - 2).

The differences between these configurations will be explained in depth later in this section. Most current production jaw crushers use the annular/ labyrinth seal configuration with grease or oil lubrication.

Figure 5 - 1 Labyrinth seal grease lube design

Figure 5 - 2 Annular/labyrinth seal grease or oil design

Never attempt to lubricate or maintain the crusher until flywheels are stopped and drive is locked out.

The greatest single factor governing the life and efficiency of any piece of machinery, where friction is encountered, is proper and intelligent lubrication. While it is generally known that insufficient lubrication will enable friction to reduce the efficiency and service life of key parts, it is also true that the presence of too large a quantity of grease in a bearing housing usually results in high operating temperatures and subsequent loss of efficiency.

Side Bearing

Seal

Side Bearing

Seal

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General Lubrication Information

Lubrication & Maintenance

Cleanliness in the handling of lubricants, fittings, grease guns and the openings and plugs of housings is of vital importance. Foreign substances contaminate lubricant. Be sure that all fittings and openings are thoroughly cleaned of all foreign substances before starting to inject lubricant. In using the grease gun always see that the gun makes proper contact with the cleaned fittings and that the nozzle has not been allowed to touch unclean surfaces.

Never mix different types of lubricant within the crusher. Always drain and flush out old lubricant before changing to a different brand, as chemical breakdown can occur in lubricant mixtures.

Capped Grease Fittings

A special type grease fitting with screw-on metal cap is used on all crushers. This type of fitting not only makes complete protection of the grease entrance point possible, the tight fitting cap also prevents grease from being squeezed back out of the crusher by internal pressure. Always keep the metal cap screwed down tight after each greasing (Figure 5 - 3).

Figure 5 - 3 Typical capped grease fitting

Grease Capacities

Table 5 - 1 lists amount of grease required to completely drain and refill each bearing housing with grease. Add 20% to the quantity listed when refilling after overhauling the crusher.

NOTICE

Install Cap After Greasing

Crusher Size Side Bearing (each) Pitman Bearings lbs kg lbs kg 1016 2 0.9 4 1.8 1020 2 0.9 5 2.3 1024 2 0.9 8 3.6 1036 2 0.9 14 6.4 1236 2 0.9 18 8.2 1242 4 1.8 27 12.3 1248 4 1.8 32 14.5 1524 3 1.4 8 3.6 1536 6 2.7 25 11.4 1636 6 2.7 25 11.4 1642 10 4.5 48 21.8 1648 9 4.1 38 17.3 1824 3 1.4 8 3.6 1836 6 2.7 25 11.4 2236 4 1.8 23 10.5 2248 8 3.6 55 25.0 2436 12 5.5 29 13.2 2442 7 3.2 33 15.0 2540 7 3.2 33 15.0 2640 10 4.5 48 21.8 2742 10 4.5 47 21.4 3040 10 4.5 48 21.8 3042 10 4.5 48 21.8 3054 10 4.5 48 21.8 3242 10 4.5 48 21.8 3648 12 5.5 64 29.1 4242 10 4.5 48 21.8 4248 9 4.1 51 23.2 5460 31 14.1 158 71.8 5748 9 4.1 51 23.2

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Lubricating Stored Equipment

Idle equipment whether new or used; must be turned over at least every 30 days either by power or hand to redistribute the lubricant. Rotating the bearing assemblies periodically redistributes lubricant on all surfaces of the bearing.

Failure to rotate bearings when crusher is idle will permit lubricant to drain to the bottom of the bearing assembly. Moisture from condensation could collect and set up a chemical reaction in the bearing assemblies know as corrosive staining. These stained areas are a positive point for premature bearing failures, as flaking will start at these points when the equipment is put back into operation.

Bearing Temperature

Normal operating bearing temperature should be 100° to 150°F (38° to 66°C) but in warm climates may reach 180° to 200°F (82° to 93°C). Excessive heat in the bearings may indicate the presence of foreign material between the fixed and rotating seals, and it is recommended that grease be injected into the bearings through the lubrication fittings to force the foreign material out and reduce heat generation. The reduction of temperature in the bearing will be slow because heat will continue to exist until the internal pressure inside the housing forces out the excess lubricant.

If the crusher stops, back up the shaft assembly one-half a revolution to see if foreign material has been expelled. Repeat process until shaft assembly turns over easily; if the grease seals do not break loose,” then a complete overhaul is the only solution.

Grease Lube Labyrinth Seal Crushers

Labyrinth Seals

Labyrinth seals are designed with a series of interlocking passages that block dirt from getting into the bearings (Figure 5 - 4). As the crusher runs, grease works its way through the labyrinth passages pushing dirt out of the seal. This causes a film of grease to constantly build up around the outside of the seal. This film helps keep dirt and moisture out of the seal and should be allowed to build up.

Figure 5 - 4 Labyrinth seal

Daily Lubrication

Grease should be added to one grease fitting on each side bearing and one on the center of the pitman (Figure 5 - 5). If the bearing is properly lubricated, a fresh film of grease will be present around the edge of the inner and outer seals of each bearing. As the bearings and grease seals become worn, more lubricant will be extruded from the seals. More frequent greasing may be required to maintain a film of grease around the outside of the seals.

Grease film forms outside of seal.

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Grease Lube Labyrinth Seal Crush-ers

Lubricate with a lithium base, extreme pressure, Grade 1 grease.

Typical brand names are: Chevron Dura-Lith EP1, Exxon Lidok EP1, Mobil Mobilux EP1, Shell Alvania EP1, Texaco Multifak EP1.

1 - Pitman grease fitting 3 - Side bearing grease fitting

2 - Pitman magnetic drain plug 4 - Side bearing magnetic drain plug

Figure 5 - 5 Grease lubrication points 1 2 3 4 Side Bearing Pitman Bearing 1 2 4

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Changing Lubricant

Under normal conditions, it is recommended that grease be changed every 1000 hours of actual crushing or once each year, whichever occurs first. 1) Before changing lubricant, run crusher long

enough to heat the existing lubricant to a consistency that allows it to flow freely. 2) Clean area around drain plugs and grease

fittings then remove plugs and fittings to drain free flowing lubricant. Refer to Figure 5 - 5. 3) Replace drain plugs and inject flushing oil in

each bearing to fill pitman barrel and base housing to top of fill hole. An extreme pressure 150 viscosity, Grade 46 flushing oil should be used.

4) Replace the grease fittings.

5) Run the crusher empty for at least 10 minutes. 6) Stop unit and remove drain plugs to drain

flushing oil.

Running crusher slowly while draining flushing oil will expedite the draining.

7) Thoroughly clean and replace the magnetic drain plugs and inject a recommended grease in each bearing.

8) Replace and tighten the grease fittings and fitting caps.

Failure to thoroughly clean drain plugs and fittings before installation could cause grease contamination. Grease must be kept clean to prevent damage to bearings.

9) Refill bearing housing with grease. In

determining the amount of grease to be used be governed by the fact that a pint of grease weighs slightly less than one pound. It is recommended in a complete overhaul, that 20% more lubricant be added in both of the side bearings and in the pitman.

When starting a new crusher for the first time, or after an overhaul, apply a liberal amount of gear lube to the area between the pitman and side bearing seals. Apply oil until grease inside bearing begins to extrude from the grease seals. This precautionary measure insures lubrication until the actual lubricating system begins to function. A crusher which has been idle for a period of time and exposed to the weather should receive the same consideration.

At the end of a season’s operation it is recommended that the lubricant be drained, flushed and new lubricant be injected into the housing. The crusher should be operated without load for approximately one hour to permit new lubricant to be evenly distributed in the bearing assembly and housing. New lubricant in the housing would tend to eliminate the possibility of corrosive reactions which might be evident if worked” and oxidized” lubricant is allowed to remain in the housing when the crusher is not in use for long periods of time.

NOTICE

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Grease Lube Annular/Labyrinth Seal Crushers

Grease Lube Annular/Labyrinth Seal

Crushers

Annular/Labyrinth Seals

Annular/labyrinth seals are designed with a series of annular rings and a labyrinth passage (Figure 5 -6). Clean grease is pumped into the seal fitting on the outer side bearing seal. All other seals are lubricated with grease that works into the seal from the bearing. As the crusher runs, grease works its way through the labyrinth passage pushing dirt out of the seal. This causes a film of grease to constantly build up around the outside of the seal. This film helps keep dirt and moisture out of the seal and should be allowed to build up. Grease also works its way into the annular rings where it creates a barrier to dirt and moisture entering the bearing.

Figure 5 - 6 Annular/labyrinth seal

Daily Lubrication

Grease should be added to one grease fitting on each of the four bearings and one on each outer side bearing seal (Figure 5 - 7). If the bearing is properly

lubricated, a fresh film of grease will be present around the edge of the inner and outer seals of each bearing. As the bearings and grease seals become worn, more lubricant will be extruded from the seals. More frequent greasing may be required to maintain a film of grease around the outside of the seals.

Lubricate with a lithium base, extreme pressure, Grade 1 grease.

Typical brand names are: Chevron Dura-Lith EP1, Exxon Lidok EP1, Mobil Mobilux EP1, Shell Alvania EP1, Texaco Multifak EP1.

Grease film forms outside of seal.

Annular Rings

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1 - Pitman bearing grease fitting 4 - Side bearing magnetic drain plug

2 - Pitman magnetic drain plug 5 - Side bearing outer seal grease fitting

3 - Side bearing grease fitting

Figure 5 - 7 Grease lubrication points

Changing Lubricant

Under normal conditions, it is recommended that grease be changed every 1000 hours of actual crushing or once each year, whichever occurs first.

1) Before changing lubricant, run crusher long enough to heat the existing lubricant to a consistency that allows it to flow freely. 2) Clean area around drain plugs and grease

fittings then remove plugs and fittings to drain free flowing lubricant. Refer to Figure 5 - 7.

2 3 4 Side Bearing Pitman Bearing 1 2 4 5

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Grease Lube Annular/Labyrinth Seal Crushers

3) Replace drain plugs and inject flushing oil in each bearing to fill pitman barrel and base housing to top of fill hole. An extreme pressure 150 viscosity, Grade 46 flushing oil should be used.

4) Replace the grease fittings.

5) Run the crusher empty for at least 10 minutes. 6) Stop unit and remove drain plugs to drain

flushing oil.

Running crusher slowly while draining flushing oil will expedite the draining.

7) Thoroughly clean and replace the magnetic drain plugs and inject a recommended grease in each bearing.

8) Replace and tighten the grease fittings and fitting caps.

Failure to thoroughly clean drain plugs and fittings before installation could cause grease contamination. Grease must be kept clean to prevent damage to bearings.

9) Refill bearing housing with grease. In

determining the amount of grease to be used be governed by the fact that a pint of grease weighs slightly less than one pound. It is recommended in a complete overhaul, that 20% more lubricant be added in both of the side bearings and in the pitman.

When starting a new crusher for the first time, or after an overhaul, apply a liberal amount of gear lube to the area between the pitman and side bearing seals. Apply oil until grease inside bearing begins to extrude from the grease seals. This precautionary measure insures lubrication until the actual lubricating system begins to function. A crusher which has been idle for a period of time and exposed to the weather should receive the same consideration.

At the end of a season’s operation it is recommended that the lubricant be drained, flushed and new lubricant be injected into the housing. The crusher should be operated without load for approximately one hour to permit new lubricant to be evenly distributed in the bearing assembly and housing. New lubricant in the housing would tend to eliminate the possibility of corrosive reactions which might be evident if worked” and oxidized” lubricant is allowed to remain in the housing when the crusher is not in use for long periods of time.

NOTICE

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Oil Lube Annular/Labyrinth Seal

Crusher

System Overview

The oil lubrication system is standard on the 5460 and optional on most other crusher models. Refer to Figure 5 - 8. It is recommended for use on larger crushers or when the crusher will be operated in cold environments. Oil is drawn from the reservoir by the oil pump. The oil pump is normally driven by an electric motor. An optional flywheel driven oil pump is available although, electric drive is usually preferred. The electric driven lube system can be started before engaging the crusher. This ensures lubrication of the bearings the moment the crusher is started.

The reservoir size is dependent upon the crusher size. Capacities will vary by crusher size. The reservoir is set lower that the bearings so that oil flows by gravity from the bearings to the reservoir. For operation in cold environments, an optional reservoir heater and cycle timer are available. The heaters are thermostatically controlled to maintain the oil at a working temperature. A cycle timer can be used to periodically start and stop the electrically driven oil pump when the crusher is not running. This ensures that oil in the lines and bearing cavities is circulated back to be warmed in the reservoir.

Oil is strained between the reservoir and pump and filtered between the pump and bearings. A vacuum gage is mounted on the strainer. A pressure gauge is mounted on the filter.

Oil from the filter runs through the flow control valves and indicator. Oil flow to each bearing is individually controlled and monitored.

From the flow indicator, the oil flows into the top of each bearing and flows by gravity through the bearing. Oil collects at the bottom of each of the bearing cavities and returns by gravity to the

reservoir. The flow indicators must be checked periodically during operation to ensure that flow to any of the bearings has not stopped.

A low oil flow alarm system will sound if low oil flow is detected on one or more of the bearing supply lines. If the feeder control is connected to the oil flow system as recommended, the feeder will shut down.

Some crushers were built with a stand pipe on the oil outlet at the bottom of each bearing cavity. This Stand pipe retained a small amount of oil in each cavity to ensure the bearings remained lubricated in case of lube pump failure. Use of the Stand pipes is no longer recommended on crushers equipped with electric motor driven pumps. If your crusher is equipped with electric pump drive and STAND pipes, the STAND pipes should be removed when the crusher is disassembled.