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Operation & Maintenance Manual

JAW CRUSHERS
Bolted Bearing Blocks Pull-Type Bearing Sleeves

A Terex Company
22783 (8/02)

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.

DANGER
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.

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

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A Terex Company

The following warning applies to equipment supplied with lead-acid batteries:

WARNING
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.

22783 (8/02)

Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers

A Terex Company

22783 (8/02)

Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers

Table of Contents

Section 1 - Introduction
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 Adjusting Closed Side Setting (CSS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 6

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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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Table of Contents

Appendix A - Torque Specs


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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintaining V-Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Check Belt Tension with Mechanical Tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Belt Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Idlers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inside Idler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Back-Side Idler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kiss Idler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1 B-2 B-4 B-6 B-7 B-7 B-7 B-7

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Table of Contents

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Introduction

About This Manual

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.

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 machines 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.

DANGER
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 safetyalert symbol can cause death or severe personal injury as well as equipment and environmental damage.

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Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers

Introduction

About This Manual

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Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers

Safety

General Safety

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.

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.

DANGER

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.

WARNING

CAUTION

CAUTION

NOTICE

Figure 2 - 1 Safety Alert Symbol

Figure 2 - 2 Hazard Classification

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Safety

General Safety

Decals and Icons Beneath all safety regulations lies a set of commonsense 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).

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 youre 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.

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

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

Figure 2 - 3 Safety Pictograms Explained

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Safety

Decal Location

Decal Location

1-16

04494-104-01

1-15

04418-542
STAMP SERIAL NO. IN PARENT METAL (SEE P/L 01376EAS)

1-16

04494-104-01

1-15

04418-542

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

DANGER
ENTANGLEMENT HAZARD

1-8

04490-031
CAUTION

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

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
T
DANGER

LOCKED OUT

DANGER

PELIGRO

EQUIPMEN LOCKED OUT

LOCKED OUT

DANGER

PELIGRO

EQUIPMEN LOCKED OUT

1-8

04490-031
CAUTION
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

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

1-11

04492-005

1-11
Roller Bearing Crusher Grease Lubrication
Jaw, Impact Breaker, Hammermill

04492-005

Lubricant:

Lithium base, extreme pressure type, grade 1 grease.


Over lubrication will result in elevated operating temperatures.

Caution:

Brand Names:
Chevron Dura-Lith EP1 Exxon Lidok EP1 Mobil Mobilux EP1 Shell Alvania EP1 Texaco Multifak EP1

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.
Safety
DANGER

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

Refer to Operation & Maintenance Manual for detailed lubrication instructions.


04494-100-01a

1-19

04494-100-01 OR

04418-955d

Made In United States of America

1-14
Crushing & Screening Patents
Built under one or more of the following patents:

04418-955

Roller Bearing Crusher Circulating Oil System


Pitman & Side Bearings:
Lubricant: Extreme pressure lubricating oil. Fill supply tank with recommended lubricant.

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

1,282,391 - 1,313,170 - 2,015,298 - 2,015,299 - 2,112,946.

DANGER

DANGER

Seals:
Lubricant: Lithium base, extreme pressure type, grade 2 grease. 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.
Safety
DANGER

LOCKE

LOCKE

May cause loss or degradation of hearing over a period of time.


Wear proper hearing personal protection equipment.

DANGER

Equipment may be energized.


Lockout and Tagout all energy sources prior to performing maintenance or adjustments.

DANGER

Brand Names: Ambient Temperature Guide - (Above 32f) [Below 32f] Chevron Gear Compound EP (220) [150] Exxon Spartan EP (220) [150] Shell Omala EP (220) [150] Texaco Meropa (220) [150] Mobil Mobilgear (630) [629] Every 1000 hours or seasonally, drain the supply tank and fill with flushing oil. Proceed with flushing operation. See specific instructions in Operations Manual.

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

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.
4493-023

WARNING
FALLING MATERIAL
May cause death, or severe personal injury.
Wear proper head personal protective equipment.

NOTICE
MENT D EQUIP LOCKE OUT

PELIGRO

France:
9010205

MODEL NUMBER DATE OF MANUFACTURE

Great Britain:
2213398 - 2127500

FLYING MATERIAL
May cause loss or degradation of eye sight.
Wear proper eye personal protective equipment.

RESPIRATORY HAZARD
May cause difficulty in breathing.
Wear proper respiratory personal protective equipment.

READ MANUALS
DANGER

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

Wear proper head personal protective equipment.

Wear proper hearing personal protection equipment.

OUT

OUT

May cause death, or severe personal injury.

PELIGRO

Canada:

MENT D EQUIP LOCKE OUT

HEARING HAZARD

LOCKOUT & TAGOUT

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.
04490-103-01

Refer to Operation & Maintenance Manual for detailed lubrication instructions.


04494-100-04a

New Zealand:
222,991 - 228,746 - 212,988

Australia:
534,673 - 534,674 - 534,675 - 548,832 - 552,227 - 557,149 - 557,477 - 569,405 579,784 - 615,281

1-19

04494-100-04

1-3 1-4

Other Patents Pending.

04493-023 07073-015

1-10

04490-103-01

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).

DANGER
ENTANGLEMENT HAZARD

WARNING
FALLING MATERIAL HEARING HAZARD
May cause loss or degradation of hearing over a period of time.

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

FLYING MATERIAL
May cause loss or degradation of eye sight.
Wear proper eye personal protective equipment.

RESPIRATORY HAZARD
May cause difficulty in breathing.
Wear proper respiratory personal protective equipment.

READ MANUALS
DANGER

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.
04490-103-01

1-10

04490-103-01

A Terex Company
04418-031y

1-17

04418-031

22783 (8/02)

2-3

Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers

Safety

Personal 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.

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 youre 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. Dont 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.

DANGER
Sometimes, at a customers 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 customers 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.

22783 (8/02)

2-4

Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers

Safety

Lockout & Tagout

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 firesuppression 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.

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.
Do No tO per ate !

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 employers 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).

Equipment & Tools


K it

L o c k o u t T a g o u t

FED ER AL

DDDDDDDDDD AAAAAAAAAA NNNNNNNNNN GPGPGPGPG G G G G P P P P PGP EEEEEEEEE E E E E E E E E EEE L L L L LRLRLRLRLRLR R R R R IGIGIGIGIGIGIGIGIGIG RRRRRRRRRR OOOOOOOOOO

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.

Out ajo ed ut B O o aj o Lock uest B __ Ped ut o__ ent Lo ck O o __ __ po __ pm tui ue Baj __st Ped __ ut o__ Eq Lo or O Equipm / en __ Pck __ ao______ tui e po ue Baj __st by en Ped ut ch o__ av Eq or O Equipm /Ll __ Fe Pck po Lo __ /st ao______ tui e ue ed Baj __ by en ui e P ut ch o__ av ck Eq at or O Eq pm /Ll tui st __ Fe PD ed po Lo __ ao______ Baj __ by en e /st Pue ut ch o__ ave ck Eq at or O o__ Equipm /Ll __ Fe PD po Lo aj __ / a t e ue ui ed B __ by en ui e P st ut ch o______ o__ av Lo ck Eq at or O Eq pm /Ll __ Fe PD __ a ____ tui e po ue Baj __ by en e /st Ped ut ch o__ av ck Eq at or O o Equipm /Ll __ __ Fe D P po Lo aj __ / tui e ck ue B a ____ __ by en e st Ped ut ch o__ av Eq at or O Equipm /Ll __ Fe PD po Lo __ ao______ tui e ue Baj __ by en e /sto__ Ped av ck Eq at or Equipm /Ll __ Fech__ PD po Lo a __ __ tui e __ by en e / __ Pue av Eq at or Equipm /Ll __ Fech ____ PD e po by Eq e / cha ____ avui at__ or Equi /Ll by ave PDate / Fecha __ Ll D / Fe e Dat

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RE GIS TER

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it

Figure 2 - 4 Lockout & Tagout Kit


22783 (8/02) 2-5 Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers

R R R R R E E E E E GGGGG NNNNN A A A A A D D D D D

CK CK CK CK CK LO D LO D LO D LO D LO D E& E& E& E & E& G VG OVG OVG OVG OV O TA MTA E MTA E MTA E MTA E M E IS RIES THRIS ETDHRIS ETDHRIS ETDHR ETDH ED TH BETH BYBETH ISBTYBETH ISBTYBETH ISBTYBE ISBTY IST TO LYTO NLLYTO NLLYTO NLLYTO NLLY N L ON RSOON CRKS.OON CRKS.OON CRKS.OON CRKS. O CK. PE BPAE BPAE BPAE BPAE BA ON ON ON ON ON

Safety

Lockout & Tagout

What is Lockout & Tagout? Lockout & Tagout is a procedure thats 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.

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.

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.

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

22783 (8/02)

2-6

Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers

General Jaw Crusher Information

Crusher Description & Information

Section 3 - General Jaw Crusher Information


1 2

Crusher Description & Information

18

17

16

15

14 1 - Pitman 2 - Pitman bearing 3 - Side bearing 4 - Eccentric shaft 5 - Key plate 6 - Base

13

12

11

10

8 13 - Tension spring 14 - Tension spring collar 15 - Hand pump 16 - Tension rods 17 - Shims 18 - Shim cover

7 - Stationary jaw 8 - Movable jaw 9 - Toggle seat 10 - Toggle plate 11 - Toggle seat base 12 - Hydraulic ram Figure 3 - 1 Jaw Crusher Parts

22783 (8/02)

3-1

Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers

General Jaw Crusher Information

Crusher Description & 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
22783 (8/02)

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.
B

LEFT SIDE

RIGHT SIDE

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).

3-2

Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers

General Jaw Crusher Information

Crusher Description & Information

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.
Complete Crusher (Base, Pitman Assy, & Flywheels) lbs kg Pitman Assembly (Pitman Assy & Flywheels) lbs kg Flywheel Only (Each) lbs kg

Model

1016 1024 1036 1236 1242 1248 1524 1636 1642 1648 1824 1836 2236 2248 2436 2438 2540 2542 2742 3042 3054 3242 3648 3660 4242 4248 5460 5748

5,306 8,255 12,551 13,978 19,521 24,300 12,305 21,003 33,998 32,406 12,426 21,280 24,903 43,094 46,737 26,017 45,000 42,095 48,520 48,520 52,740 57,137 79,653 107,664 58,838 104,567 196,258 117,000

2,406 3,752 5,705 6,354 8,873 11,045 5,593 9,547 15,454 14,730 5,648 9,673 11,320 19,588 21,244 11,826 20,455 19,134 22,055 22,055 23,973 25,971 36,206 48,938 26,745 47,530 89,208 53,182

2,844 4,817 7,449 8,007 12,120 14,374 6,771 11,895 19,642 16,988 6,771 12,105 14,266 25,746 22,861 14,501 18,950 21,832 25,842 25,842 27,525 28,755 39,524 58,478 28,755 52,827 102,715 52,827

1,293 2,190 3,386 3,640 5,509 6,534 3,078 54,07 8,928 7,722 3,078 5,502 6,485 11,703 10,391 6,591 8,614 9,924 11,746 11,746 12,511 13,070 17,965 26,581 13,070 24,012 46,689 24,012

690 1,275 1,223 1,250 2,098 2,175 1,215 2,075 2,741 2,684 1,215 2,126 2,785 3,700 3,462 2,873 4,200 3,584 4,194 4,194 4,194 4,028 5,560 5,595 4,028 5,595 10,570 5,595

314 580 556 568 954 989 552 943 1,246 1,220 552 966 1,266 1,682 1,574 1,306 1,909 1,629 1,906 1,906 1,906 1,831 2,527 2,543 1,831 2,543 4,805 2,543

Table 3 - 1 Approximate Crusher and Component Weights

22783 (8/02)

3-3

Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers

General Jaw Crusher Information

Crusher Description & Information

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.

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.

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

SPEED

Figure 3 - 3 Direction of Flywheel Rotation

22783 (8/02)

3-4

Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers

General Jaw Crusher Information

Crusher Description & Information

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.
Minimum Size inches mm inches mm Maximum

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.

1016 1020 1024 1036 1236 1242 1248 1524 1636 1642 1648 1824 1836 2236 2248 2436 2438 2542 2742 3042 3054 3242 3648 3660 4242 4248 5460 5748

3/4 3/4 3/4 1 1/2 1 1/2 1 1/2 1 1/2 1 1/2 1 1/2 1 1/2 1 1/2 1 1/2 1 1/2 2 1/2 2 1/2 2 1/2 4 1/2 3 1/2 3 1/2 4 3 1/2 4 4 4 14 4 6 19

19 19 19 38 38 38 38 38 38 38 38 38 38 64 64 64 114 89 89 102 89 102 102 102 356 102 152 483

3 1/2 3 1/2 3 1/2 3 1/2 5 5 5 5 5 5 5 5 5 6 6 6 8 10 10 13 13 13 13 13 23 13 20 28

89 89 89 89 127 127 127 127 127 127 127 127 127 152 152 152 203 254 254 330 330 330 330 330 584 330 508 711

Table 3 - 2 Closed Stroke Setting Limits

22783 (8/02)

3-5

Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers

General Jaw Crusher Information

Crusher Description & Information

Crusher Dimensions

C D E

A B
Model A B C D E F G H Model A B C D E F G H 1016 40 1015 41 1040 24 610 26 660 58 1470 22 560 14 355 2248 79 2005 81 2055 83 2110 52 1320 54 1370 99 2515 53 1345 16 405 1020 48 1220 46 1170 28 710 28 710 72 1830 26 660 14 355 2436 88 2235 91 2310 89 2260 61 1550 61 1550 94 2385 43 1090 17 430 1024 45 1145 46 1170 28 710 28 710 72 1830 27 685 21 535 2438 67 1700 77 1955 50 1270 49 1245 92 2335 43 1090 18 455 1036 48 1220 46 1170 28 710 28 710 81 2055 41 1040 18 455 2542 82 2080 85 2160 93 2360 63 1600 65 1650 95 2415 45 1145 19 480 1236 48 1220 51 1295 32 810 33 840 81 2055 41 1040 19 480 2742 88 2235 88 2235 92 2337 62 1575 64 1626 99 2515 47 1195 17 430 1242 56 1420 55 1395 33 840 34 865 98 2490 47 1195 20 510 3042 88 2235 91 2311 92 2337 62 1575 64 1626 99 2515 47 1195 17 430

Tension Spring Location on 1016 & 1020


1248 59 1500 56 1420 35 890 35 890 104 2640 53 1345 19 480 3054 88 2235 91 2311 92 2337 63 1600 64 1626 110 2795 69 1755 20 510 1524 55 1395 57 1445 36 915 39 990 67 1700 27 685 18 455 3242 93 2360 99 2515 105 2665 75 1905 77 1955 99 2515 47 1195 22 560 1636 61 1550 63 1600 41 1040 42 1065 92 2335 41 1040 16 405 3648 107 2715 113 2870 120 3050 82 2080 84 2135 101 2565 52 1320 20 510 1642 71 1800 73 1855 76 1930 46 1170 48 1220 99 2515 47 1195 20 510 3660 118 2995 125 3175 86 2185 88 2235 119 3025 78 1980 28 711 1648 66 1675 70 1780 41 1040 42 1065 94 2385 53 1345 16 405 4242 103 2615 109 2770 105 2665 75 1905 77 1955 99 2515 47 1195 22 56 0 1824 56 1420 57 1445 36 915 39 990 77 1955 27 685 19 480 4248 123 3125 126 3200 137 3480 96 2440 101 2565 120 3050 55 1395 20 510 1836 64 1625 63 1600 41 1040 42 1065 92 2335 41 1040 16 405 5748 138 3505 141 3580 137 3480 96 2440 101 2565 120 3050 55 1395 20 510 2236 65 1650 77 1955 48 1220 49 1245 92 2335 43 1090 17 430 5460 149 3785 152 3860 172 4370 127 3225 130 3300 140 3555 67 1700 18 455

Figure 3 - 4 Crusher Dimensions to nearest inch and mm


22783 (8/02) 3-6 Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers

Set-up & Operation

Mounting & Set-up

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.

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 oclock) 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.
Flywheel with Counterweights

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.
22783 (8/02) 4-1

Figure 4 - 1 Flywheel Counterweight Installation

Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers

Set-up & Operation

Mounting Crusher

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.

22783 (8/02)

4-2

Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers

Set-up & Operation

Operation

Operation
Prior To Starting Perform all daily and periodic lubrication and maintenance tasks listed in Section 5.

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.

WARNING
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.

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.

22783 (8/02)

4-3

Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers

Set-up & Operation

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.

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.

CAUTION
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.

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.

22783 (8/02)

4-4

Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers

Set-up & Operation

Feeding The Crusher

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.

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.

CAUTION
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. 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.

DANGER
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.

WARNING
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.

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

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4-5

Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers

Set-up & Operation

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.

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 Slot (for loosening wedge)

Toggle Plate Base Support

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.
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4-6

Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers

Set-up & Operation

Adjusting Closed Side Setting (CSS)

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.

DANGER
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.

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.

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

WARNING
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.

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4-7

Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers

Set-up & Operation

Adjusting Closed Side Setting (CSS)

Racheting Cable Puller

Pitman Eccentric Rotated To Minimum Jaw Opening

Hydraulic Ram Toggle Plate Change Position

Shims Hydraulic Ram Adjusting CSS Position Toggle Plate Base

Handle Laminated Spacer Same Thickness As Desired CSS

Toggle Plate Base Wedge

Tension Spring Nuts

Spacer Must Span Several Corrugations Figure 4 - 3 Setting closed side setting

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4-8

Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers

Lubrication & Maintenance

General Lubrication Information

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.
Side Bearing

Side Bearing

Seal

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

WARNING
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.

Seal

Figure 5 - 1 Labyrinth seal grease lube design

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5-1

Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers

Lubrication & Maintenance

General Lubrication Information

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.

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.
Crusher Size Side Bearing (each) lbs kg Pitman Bearings lbs kg

1016 1020 1024 1036 1236 1242 1248 1524 1536 1636 1642 1648 1824 1836 2236 2248 2436 2442 2540 2640 2742 3040 3042 3054 3242 3648 4242 4248 5460 5748

2 2 2 2 2 4 4 3 6 6 10 9 3 6 4 8 12 7 7 10 10 10 10 10 10 12 10 9 31 9

0.9 0.9 0.9 0.9 0.9 1.8 1.8 1.4 2.7 2.7 4.5 4.1 1.4 2.7 1.8 3.6 5.5 3.2 3.2 4.5 4.5 4.5 4.5 4.5 4.5 5.5 4.5 4.1 14.1 4.1

4 5 8 14 18 27 32 8 25 25 48 38 8 25 23 55 29 33 33 48 47 48 48 48 48 64 48 51 158 51

1.8 2.3 3.6 6.4 8.2 12.3 14.5 3.6 11.4 11.4 21.8 17.3 3.6 11.4 10.5 25.0 13.2 15.0 15.0 21.8 21.4 21.8 21.8 21.8 21.8 29.1 21.8 23.2 71.8 23.2

NOTICE
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).
Install Cap After Greasing

Figure 5 - 3 Typical capped grease fitting


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Table 5 - 1 Crusher grease capacities


Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers

Lubrication & Maintenance

Grease Lube Labyrinth Seal Crushers 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 150F (38 to 66C) but in warm climates may reach 180 to 200F (82 to 93C). 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.
Grease film forms outside of seal.

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.
Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers

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5-3

Lubrication & Maintenance

Grease Lube Labyrinth Seal Crushers 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.

2 4

Side Bearing 1 3 Pitman Bearing

4 2 1 - Pitman grease fitting 2 - Pitman magnetic drain plug 3 - Side bearing grease fitting 4 - Side bearing magnetic drain plug

Figure 5 - 5 Grease lubrication points

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5-4

Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers

Lubrication & Maintenance

Grease Lube Labyrinth Seal Crushers 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.

CAUTION
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 seasons 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
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.

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5-5

Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers

Lubrication & Maintenance

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.

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. Labyrinth

Annular Rings 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
22783 (8/02) 5-6 Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers

Lubrication & Maintenance

Grease Lube Annular/Labyrinth Seal Crushers

2 4

3 5

Pitman Bearing

Side Bearing

4 2 1 - Pitman bearing grease fitting 2 - Pitman magnetic drain plug 3 - Side bearing grease fitting 4 - Side bearing magnetic drain plug 5 - Side bearing outer seal 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.

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5-7

Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers

Lubrication & Maintenance

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. 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 seasons 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
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.

CAUTION
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.

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5-8

Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers

Lubrication & Maintenance

Oil Lube Crusher

Annular/Labyrinth

Seal

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
22783 (8/02)

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.

5-9

Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers

Lubrication & Maintenance

Oil Lube Crusher

Annular/Labyrinth

Seal

7 6

7 9 10

17 16 4 15 3 3 2 11 1 12 14 13

1 - Breather/filler cap 2 - Suction vacuum gauge 3 - Side bearing drain lines 4 - Pitman bearing drain lines 5 - Electric motor/pump 6 - System pressure gauge

7 - Bearing supply lines 8 - Flow indicators/controls 9 - Low flow alarm horn 10 - Lube system junction box 11 - Reservoir 12 - Reservoir sight gauge Figure 5 - 8 Electric drive oil Lube system

13 - Reservoir drain 14 - Oil heaters (optional) 15 - Suction strainer 16 - Bypass line 17 - Filter

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5 - 10

Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers

Lubrication & Maintenance

Oil Lube Crusher Low Oil Flow Alarm System The low oil flow alarm system will sound when the flow of oil to the bearings drops below minimum setting. If the electrical system is wired according to the schematic in Figure 5 - 9, the feeder will shut down when the low oil flow alarm is activated.

Annular/Labyrinth

Seal

Figure 5 - 9 Low oil flow alarm system schematic

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5 - 11

Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers

Lubrication & Maintenance

Oil Lube Crusher Annular/Labyrinth Seals Annular/labyrinth seals are designed with a series of annular rings and a labyrinth passage (Figure 5 10). Clean grease is pumped into the seal fitting. 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. Grease stored in the annular rings also prevents oil in the bearings from leaking out of the seal.

Annular/Labyrinth

Seal

Oil leaking from the seals indicates that more frequent greasing of the seals is required. Lubricate seals with a lithium base, extreme pressure, Grade 2 grease. The oil level in the reservoir should be checked daily before operation begins. Oil level is checked at the sight gauge on the side of the oil reservoir. Refer to Table 5 - 2 when selecting the proper lubrication oil.

Grease film forms outside of seal. Labyrinth

Annular Rings Figure 5 - 10 Annular/Labyrinth seal

Daily Lubrication Grease should be added to each of the six seal fittings (Figure 5 - 11). If the seal 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 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.
22783 (8/02) 5 - 12 Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers

Lubrication & Maintenance

Oil Lube Crusher

Annular/Labyrinth

Seal

2 4

5 3 5

1 Pitman Bearing

Side Bearing

4 2 1 - Pitman bearing inlet line 2 - Pitman drain line 3 - Side bearing inlet line 4 - Side bearing drain line 5 - Seal grease fittings Figure 5 - 11 Grease lubrication points

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5 - 13

Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers

Lubrication & Maintenance

Oil Lube Crusher Periodic Lubrication Lubricating oil should be changed every 1000 hours of crusher operation or once each year, whichever occurs first. 1) The oil should be changed after the crusher has been run and the oil is at operating temperature. 2) Stop the crusher and clean area around drain plugs, fill plugs, and reservoir. 3) Drain the reservoir by removing the drain plug in the bottom of the reservoir. Since the oil in the bearing cavities drains by gravity back to the reservoir, draining the reservoir removes most of the oil from the crusher. 4) Remove the screen from suction strainer and clean it. 5) Reinstall the screen and drain plugs. 6) Add at least 10 gallons of flushing oil to the supply reservoir. 7) Run the crusher empty for at least 10 minutes. 8) Stop the crusher. 9) Drain the flushing oil from the reservoir. If it appears extremely dirty, repeat the flushing with fresh flushing oil to remove more of the contaminants until the drained flushing oil appears sufficiently clean. 10) Remove the screen from suction strainer once again and clean it. 11) Reinstall the screen. 12) Remove and replace the filter element.

Annular/Labyrinth

Seal

13) Refill the reservoir with the appropriate oil listed in Table 5 - 2. Selecting the proper oil viscosity is critical to maintaining lubrication of the bearings. Thinner oils have less lubricating ability. Thicker oils may not flow freely at lower temperatures which could cause insufficient oil to be delivered to the bearings. Regardless of which oil is used, the temperature of the oil returning from the bearings (operating temperature) must not exceed the Maximum Operating Temperature listed in Table 5 - 2.

CAUTION
Failure to use oil of proper viscosity could result in insufficient bearing lubrication. This could lead to premature bearing failure.

CAUTION
Do not allow the crusher to operate when the temperature of the oil returning from the bearings exceeds the temperature listed in Table 5 - 2. Failure to follow this warning could cause premature bearing failure.

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5 - 14

Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers

Lubrication & Maintenance

Oil Lube Crusher

Annular/Labyrinth

Seal

Brand

Ambient Temp 32F (0C) or above

Ambient Temp 32F (0C) to 0F (-18C)

Ambient Temp below 0F (--18C)

Chevron Gear Compound EP Exxon Spartan EP Shell Omala EP Mobil Mobilgear Texaco Meropa Maximum Operating Temperature (Returning from bearings)

220 220 220 630 220 190F (88C)

150 150 150 629 150 170F (77C) 68 68 68 68 130F (54C)

Table 5 - 2 Recommended oil viscosities/brands

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5 - 15

Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers

Lubrication & Maintenance

Oil Lube Crusher Oil Heater (optional) For operation in cold weather, an optional oil heater system is available. Immersion heaters mounted in the tank maintain oil at a thermostatically controlled temperature. Set the temperature of the thermostat no higher than the Maximum Operating Temperature listed in Table 5 - 2. When using the oil heaters, the temperature of the oil returning from the bearings to the reservoir should be monitored to ensure that the operating temperature does not exceed maximum operating temperature for the viscosity of oil being used. This

Annular/Labyrinth

Seal

is especially important when using the lower viscosity oils since their maximum operating temperature is low.

CAUTION
Do not heat oil by applying a torch flame directly to the reservoir. Extreme heating could burn the oil and reduce the oils ability to lubricate. The optional oil heaters should be installed according to the schematic in Figure 5 - 12.

30 Amp 104 Heater Power OFF 104 105 ON OFF 104 106 ON

120 VAC by customer 30 Amp Service 100 102

Heater #1 1000 W

Heater #2 1000 W

Figure 5 - 12 Oil heater electrical schematic

Cycle Timer (optional) When operating in cold weather with the optional oil heater system, an optional cycle timer can be used to warm the crusher and oil when not operating. The cycle timer can be set to run the lubrication pump for short periods of time when the crusher is not in operation. With the heaters
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running, the warm oil in the reservoir will be passed through the bearings and hoses to prevent oil in these areas from gelling. The cycle timer should be installed and wired as shown in the typical wiring schematic shown in Figure 5 - 13.
Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers

5 - 16

Lubrication & Maintenance

Oil Lube Crusher The timer can be set to cycle time from 0.6 seconds to 24 hours. By changing dip switch settings, the time range of the timer dials is changed. The Off timer controls the amount of time that the lube pump will shut off. The On timer controls the length of time that the lube pump will be running. Setting the dip switches to the setting shown in Figure 5 - 13 will give the Off timer a range of 1145 minutes. The On time will have a range of 1.5 -

Annular/Labyrinth

Seal

5.5 minutes. Other time ranges can be selected by changing the dip switch settings according to the chart on the side of the timer. For normal operation the Day-Night switch should be in the Day position which will allow the lube pump to run continuously when started. When the Day-Night switch is in the Night position the lube pump will run on the timed cycle set by the timer dials.

Timer Dials

Timer Dip Switches

Figure 5 - 13 Lube pump cycle timer

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5 - 17

Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers

Lubrication & Maintenance

Periodic Maintenance

Periodic Maintenance
Maintenance Benchmark Checklist The maintenance benchmark checklist can be a useful tool to determine if bearings or components are operating outside of normal operating ranges. Refer to Table 5 - 3. When the crusher is first put into service and at operating temperature, record the following in the Benchmark column. Bearing Temperature Electrical Component Temperature Full Load Amps and Voltages Belt Tension

Each month the readings should be taken again and recorded in the appropriate column. Always remember to use the same measuring procedure. If a reading varies significantly from previous or benchmark readings, investigate the cause.

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5 - 18

Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers

Lubrication & Maintenance

Maintenance Sheet

Benchmark

Check

Maintenance Benchmark Check Sheet


Benchmark September November December February January October August March June April July May

I) Temperatures A. Bearings 1. Drive Side 2. Non Drive Side 3. Drive Side Pitman 4. Non Drive Side Pitman 5. Jack Shaft/Outboard Bearing B. Electrical Components 1. Starters 2. Breakers 3. Motor 4. Plug II) Electrical Checks A. Full Load Amps 1. At Motor 2. Below Starter 3. Top of Starter 4. Below Breaker 5. Above Breaker B. Voltage (each leg) 1. L1 2. L2 3. L3 III) Belt Tension A. Drive Belts B. Oil Pump Drive

Table 5 - 3 Maintenance Benchmark Check Sheet

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Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers

Lubrication & Maintenance

Maintenance Sheet Periodic Inspections 1) Check and tighten all fastening and mounting bolts, cap screws and set screws. 2) Inspect the stationary and movable jaws for wear. To maintain efficient operation the jaws should be turned when the corrugations at the lower end are worn almost smooth, or replaced after both ends are worn. The stationary jaw will generally require turning or replacing more often than the movable jaw.

Benchmark

Check

5) The toggle plate needs no care other than lubrication and replacement when natural wear reduces the balls on both ends. When the balls have worn 1 inch (25.4 mm) on each end or half the original ball, replace toggle plate. Do this before excessive wear occurs to toggle seat insert in pitman and the base toggle seat. Be sure the toggle plate is located as centrally in position as possible in relation to the toggle seat insert in the pitman.

WARNING
Failure to replace jaws when corrugations are worn smooth, or running crusher until concave sections are worn in jaws will reduce capacity of crusher. Also, jaws not changed when recommended will cause compaction of material in crushing chamber and could result in premature bearing failure, excessive breakage of toggle plates or shaft or base breakage. 3) Inspect the key plates, especially the lower sections, for wear. Replace when worn through. Tighten both of the key plates. 4) Check and tighten the movable jaw wedge to prevent the movable jaw from becoming loose and causing wear or damage to the pitman.

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Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers

Electrical

Standard Drive Electrical

Section 6 - Electrical Standard Drive Electrical


No drive electrical controls are provided as standard with the crusher. It is usually controlled from the main power panel. Check with the supplier of the electrical system for specific information.

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Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers

Electrical

Standard Drive Electrical

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Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers

Troubleshooting

Troubleshooting

Section 7 - Troubleshooting Troubleshooting


Crusher Not Operating At Rated Capacity 1) Pitman shaft direction of rotation incorrect. 2) Stationary jaw loose. 3) Speed incorrect. 4) Jaws excessively worn. 5) Attempting to feed raw material larger than crushing chamber. 6) Incorrect toggle plate for size of crusher discharge opening. 7) Lack of raw material or erratic feeding of crusher. 8) Insufficient power or v-belt slippage. Bearings Overheating The bearings normally operate at 100 to 150F (38 to 66C) but in warm climates may reach 180 to 200F (82 to 93C). Under these conditions and within these limits the bearings are not overheating. However, if a bearing maintains 212F (100C) or higher, it is considered to be overheating. The cause should be found and corrected. Temperature should be checked on housing closest to the bearing or on the end plate nearest the bearing.

The following are some of the most common causes of bearing overheating: 1) Improper lubricant level. Too much lubricant will not allow for proper circulation and air space inside housing. Fill only to correct levels. 2) Insufficient, dirty or improper lubricant. 3) Operating at a speed faster than recommended. 4) Crusher out of level. This will cause lubricant to flow away from the high bearing. Make sure crusher is level. 5) Side bearing outer seal and flinger not turning with shaft. 6) Insufficient radial clearance between side bearing outer seal and end cap. 7) Toggle plate improperly seated. 8) Bearing(s) damaged and/or failing. 9) Movable jaw rubbing on base or key plates. 10) Bent pitman shaft. 11) Seals Rubbing.

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Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers

Troubleshooting

Troubleshooting

Excessive Jaw Wear 1) Stationary jaw loose. 2) Closing crusher below minimum recommended discharge opening. 3) Operating faster than recommended. 4) Not using genuine Cedarapids jaws. 5) Very abrasive material. Difficult to Adjust Closed Side Setting 1) Tension spring not released. 2) Support angles on base not loose. 3) Toggle seat loose and peened into base.

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Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers

Torque Specs

Torque Charts

Appendix A - Torque Specs Torque Charts


The following pages contain charts for use as guides when tightening bolts and nuts. These specifications should be followed unless specific torques are given elsewhere in this manual. Standard Torque Chart Table A - 1 is a list of recommended torque values for standard bolts. Use this torque chart to avoid overstressing standard nuts and bolts used on the equipment. These specifications should be followed unless specific torques are given. The equipment uses Grades 2, 5, and 8. The maximum torque values are based on 75% of the specified minimum proof strength of the bolt steel in order to provide a safety factor. The term lube applies to cadmium plating and/or application of thread lubricants. Hardened washers should always be used, regardless of whether standard nuts or lock nuts are employed. Metric Torque Chart Table A - 2 is a list of torque values recommended for metric bolts. The maximum torque values are based on 75% of the specified minimum proof strength. The term lube includes the application of thread lubricants, cadmium plating and the use of hardened washers regardless of whether standard or lock nuts are used.

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Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers

Torque Specs

Torque Charts

Standard Torque Chart


S.A.E Grade 2 dia. pitch (inches) (thread/in.) 1/4 1/4 5/16 5/16 3/8 3/8 7/16 7/16 1/2 1/2 9/16 9/16 5/8 5/8 3/4 3/4 7/8 7/8 1 1 1-1/8 1-1/8 1-1/4 1-1/4 1-3/8 1-3/8 1-1/2 1-1/2 1-3/4 2 2-1/4 2-1/2 2-3/4 3 20 28 18 24 16 24 14 20 13 20 12 18 11 18 10 16 9 14 8 14 7 12 7 12 6 12 6 12 5 4.5 4.5 4 4 4 Torque (ft-lbs) Dry 5 6 11 12 20 23 32 36 49 55 70 79 97 110 170 190 165 180 245 270 350 395 495 550 655 745 865 975 1370 2060 3015 4125 5590 7385 Lube 4 5 9 10 15 17 25 27 38 42 54 60 75 85 130 145 125 140 190 210 270 305 380 425 500 570 665 750 1055 1585 2320 3170 4300 5680 Clamp Load (lbs) 1310 1500 2160 2390 3190 3620 4380 4890 5850 6590 7500 8370 9320 10560 13770 15380 11430 12590 14990 16400 18880 21180 23980 26550 28580 32540 34770 39120 47020 61870 80430 99000 122010 147750 S.A.E Grade 5 Torque (ft-lbs) Dry 8 10 17 19 31 35 49 55 75 85 109 121 150 170 265 295 425 470 640 700 790 890 1120 1240 1465 1670 1945 2190 2285 3435 5025 6875 9320 12310 Lube 6 7 13 15 24 27 38 42 58 65 84 93 115 130 200 225 330 360 495 540 610 685 860 950 1130 1285 1495 1685 1755 2640 3865 5285 7165 9470 Clamp Load (lbs) 2020 2320 3340 3690 4940 5590 6770 7560 9040 10190 11600 12940 14400 16320 21290 23770 29450 32440 38630 42260 42340 47500 53770 59550 64100 72980 77970 87740 78370 103120 134060 165000 203360 246260 S.A.E Grade 8 Torque (ft-lbs) Dry 12 14 25 27 44 49 70 78 106 120 150 170 210 240 375 415 605 665 905 990 1285 1440 1815 2010 2380 2710 3160 3555 4985 7500 10960 15000 17790 23500 Lube 9 11 19 21 34 38 54 60 82 92 115 130 160 180 285 320 465 510 695 765 990 1110 1395 1545 1830 2085 2430 2735 3835 5765 8435 11530 13680 18080 Clamp Load (lbs) 2860 3270 4710 5220 6970 7900 9560 10680 12770 14390 16380 18270 20340 23040 30060 33570 41580 45810 54540 59670 68670 77040 87210 96570 103950 118350 126450 142290 170990 225000 292500 360000 388230 470130

Table A - 1: Torque Values for Standard Hardware

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Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers

Torque Specs

Torque Charts

Metric Torque Chart


Property Class = 8.8 Dry dia pitch (mm) (mm) (ft-lbs) N-M 10 10 12 12 14 14 16 16 18 18 20 20 22 22 24 24 27 27 1.5 1.25 1.75 1.25 2 1.5 2 1.5 2.50 1.5 2.5 1.5 2.5 1.5 3 2 3 2 37 39 65 71 104 112 161 172 230 258 325 360 443 486 562 612 823 889 50 53 88 96 141 152 218 233 312 350 441 488 601 659 762 830 1116 1205 Lube (ft-lbs) 29 30 50 55 80 86 124 132 177 199 250 277 341 374 432 471 633 683 N-M 39 41 68 75 108 117 168 179 240 270 339 376 462 507 586 639 858 926 53 56 93 101 148 160 230 246 318 357 450 499 613 673 777 847 1139 1229 Property Class = 10.9 Dry (ft-lbs) N-M 72 76 126 137 201 217 312 334 431 484 610 677 831 913 1054 1149 1544 1667 41 43 71 78 114 123 177 189 245 275 346 384 471 518 598 652 876 945 Lube (ft-lbs) N-M 56 58 96 106 155 167 240 256 332 348 469 521 639 702 811 884 1188 1281 62 66 109 119 173 187 269 287 372 418 525 583 716 786 908 990 1331 1436 Property Class = 12.9 Dry (ft-lbs) N-M 84 89 148 161 235 254 365 389 504 567 712 791 971 1066 1231 1342 1805 1947 48 51 83 91 133 144 207 221 286 321 404 448 551 605 698 762 1024 1105 Lube (ft-lbs) N-M 65 69 113 123 180 195 280 300 388 435 548 607 747 820 946 1033 1389 1498

Table A - 2: Torque Values for Metric Hardware

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Torque Specs

Torque Charts

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Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers

General Belt Drive Care

General Belt Information

Appendix B - General Belt Drive Care General Belt Information


You get more service from V-belts if you keep them clean and dry. Rock dust and rust from metals are abrasive. Oils and acids deteriorate belt material. Dust buildup in sheaves causes harmful vibration. On belts, dust or water causes slippage. For maintenance purposes, so-called belt dressing compounds are worse than worthless. Most belt dressings actually shorten belt life. Clean, well cared for belts are the best answer to problems that belt dressings are meant for but do not solve. Daily cleaning of belts and sheaves by blowing them off with compressed air increases their useful life and saves you money. 1) Keep belts and sheaves clean. 2) Avoid belt or sheave rubbing. Don't let belts or sheaves rub against the guard (or anything else) while theyre running. 3) Drive your belts with motors mounted on adjustable bases. Mount drive motors on a slotted base, so you can shorten the distance from motor to driven sheave when you need to do so. This allows convenient and proper installation of belts. Prying on belts with tools cracks and prematurely breaks them. With belts already lightly seated in their grooves, you can tighten the belts correctly by moving the motor and rolling the sheaves at the same time. 4) Keep belts tight. Most belt stretch occurs in the first 30-40 hours of operation after new belts are installed. Check belt tension frequently during this period. Slack belts cause slipping and excessive wear. They cost you money by delivering less power and causing more frequent replacement.

5) Periodically inspect the V-belt drive for wear (Figure B - 2) and for proper sheave alignment (Figure B - 1). 6) Do not overtighten belts. Overtightening shortens useful life of belts and sheaves and also places undue strain on shafts which, in turn, causes premature bearing failure. Ideal belt tension is lowest at which belts won't slip under peak load.

OK

OK

Figure B - 1: Align Sheaves

7) Keep belts straight (Figure B - 1). Don't allow V-belts to run out of alignment. To run properly, sheaves must be parallel and grooves must be in line. 8) Use only matched belts. A matched set of belts lasts longer because loading is evenly divided among all the belts.

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Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers

General Belt Drive Care

Maintaining V-Belt Tension

Belts often wear at the sides, so their crosssectional area decreases. They stretch with use and age. New belts ride higher in sheave grooves. They travel faster and take higher tension than worn belts. If its center cord breaks, a belt stretches and won't carry its load. Putting one or two new belts on a partially used set very soon wears and stretches the new ones until they are in poor condition. Their cost is wasted. Belts from different manufacturers should not be mixed in a set because of slight material and quality differences that could reduce the life of all the belts. Always replace belts in full sets. 9) Don't overload. If the sheave has 10 grooves, use 10 belts. Using less than the designed number of drive belts puts too much strain on remaining ones. They will break down quickly and cause you downtime. 10) Replace worn sheaves. Worn sheaves reduce belt life. If the sheave is worn enough that belts touch bottom in the grooves, belts soon start to slip and burn. If your maintenance program takes all of those things into account, your troubles with belts and sheaves will be minimal. Still, youre bound to experience some problem, sooner or later. When you do, use Table B - 1 as a diagnostic tool.

5) If belts are not tight enough, loosen drive motor mount bolts and adjust take-up bolts to tighten belts. Retighten motor mount bolts to hold tension.
Worn Sheave Worn Belt or Sheave Just Right

Figure B - 2: Belt & Sheave Wear

Maintaining V-Belt Tension


Figure B - 3: Sheave Gauge Shows Wear

1) Check drive belt tension daily. Check condition of belts and sheaves (Figure B - 2). 2) If belts are worn, replace with a matched set. 3) Use a sheave gauge (Figure B - 3) to look for steps worn in sheave grooves. Steps are a measure of sheave wear. Belts must not bottom out in grooves. 4) If sheaves are worn excessively, replace them.

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Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers

General Belt Drive Care

Maintaining V-Belt Tension

Trouble Belts slip (sidewalls glazed)

Cause Insufficient tension Overloaded drive. Arc of contact too short. Heavy starting load. Rock gets into drive. Broken cord caused by prying. Overloaded drive. Impulse Loads.

Correction Replace belts; increase tension Find cause and correct. Increase distance between hubs. Increase tension. Replace belt correctly. Redesign drive. Apply proper tension. Realign drive. Replace sheave. Align and reposition. Check drive design, mounting. Consider banded belts. Replace belts with matched set. Replace sheaves.

Drive squeals.

Belt rolls over.

Misalignment. Worn sheave grooves. Flat idler sheave. Excessive vibration. New belts installed with old.

Mismatched belts

Sheave grooves worn unevenly. Improper groove angle. Shafts not parallel. Shock loads. Heavy starting load.

Align drive. Apply proper tension. Apply proper tension. Use compensator starting. Replace belt correctly. Determine source of object, design guard to correct problem. Replace sheaves. Redesign drive. Replace with matched set. Redesign drive. Increase tension. Align sheaves. Eliminate oil. Ventilate drive.

Belt breaks Belt pried over sheaves. Foreign object in drive. Sheave grooves worn. Sheave diameter too small. Mismatched belts. Drive overloaded. Belt slips. Sheaves misaligned. Oil present. Excess heat present.

Belt wears prematurely.

Table B - 1: Belt-Drive Diagnostics

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Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers

General Belt Drive Care

Check Belt Tension with Mechanical Tester

Each 1/64" mark equals 1" of belt span (Centimeters on Opposite Side)

Each Mark Equals 1 Pound Pressure (Kilograms on Opposite Side)

Large O-ring

Small O-ring

Figure B - 4: Belt Tension Tester (Cedarapids P/N 45500-036-08)

Bottom of Straightedge or Top of Adjacent Belt

Small O-ring

Span "t"

Deflection to be 1/64" Per Inch Span

Large O-ring

Figure B - 5: Using the Belt Tension Tester

Check Belt Tension with Mechanical Tester


1) Measure span length "T" (Figure B - 5). 2) Position large O-ring on tester at 1/64 inch (0.397 mm) for each inch of belt span. Set small O-ring at zero (Figure B - 5). Example: For belt span of 48 inches (1.219 m), setting would be 48/64 inch (3/4 inch, or 19.05 mm). 3) At center of belt span, push yellow tipped plunger until bottom of large O-ring is level with top of adjacent belt (Figure B - 5). If there is no adjacent belt, lay straight edge between sheaves for reference.

4) Remove tester and read belt deflection force, in pounds, at small O-ring. Compare this figure with values given in tables that follow. If required force is within limits shown in table for that particular belt, drive tension should be satisfactory. If required force is outside these limits, drive should be retensioned. 5) When installing new belts, tension may relieve during run-in. After drive is operated for several days, tension should be checked and adjusted to recommended tension values.

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Belt Deflection Force (Pounds) Belt Deflection Force (Pounds) Smallest Sheave Diameter Range RPM Range Cross Section Smallest Sheave Diameter Range RPM Range Used Belt 3.0 - 3.6 3.8 - 4.8 2.2 - 2.4 3V, 3VX 4.12 - 6.90 2.65 - 3.65 5.0 - 7.0 3.4 - 4.2 4.4 - 5.6 5.8 - 8.6 7.0 - 9.0 9.5 - 16.0 12.0 - 16.0 18.0 - 20.0 200 - 850 851 - 1500 30.4 25.6 45.2 38.0 200 - 850 851 - 1500 24.9 21.2 37.0 31.3 500 - 1740 1741 - 3000 14.1 12.5 21.0 18.5 15.9 14.6 23.52 1.6 8V 18.0 - 22.4 500 - 1740 1741 - 3000 11.5 9.4 17.0 13.8 14.7 11.9 21.8 21.6 860 - 2500 2501 - 4000 6.3 6.0 9.4 8.9 8.5 7.3 12.6 10.9 5V, 5VX 860 - 2500 2501 - 4000 5.3 4.5 7.9 6.7 7.1 7.1 10.5 9.1 4.4 - 6.7 860 - 2500 2501 - 4000 4.9 4.2 7.2 6.2 1000 - 2500 2501 - 4000 5.4 4.7 8.0 7.0 5.7 5.1 9.4 7.6 1000 - 2500 2501 - 4000 4.5 3.8 6.8 5.7 5.0 4.3 7.4 6.4 1000 - 2500 2501 - 4000 1000 - 2500 2501 - 4000 1000 - 2500 2501 - 4000 500 - 1749 1750 - 3000 3001 - 4000 7.1 - 10.9 11.8 - 16.0 12.5 - 17.0 500 - 1740 1741 - 3000 500 - 1740 1741 - 3000 200 - 850 851 - 1500 200 - 850 851 - 1500 12.7 11.2 15.5 14.6 33.0 26.8 39.6 35.3 18.9 16.7 23.4 21.8 49.3 39.9 59.2 52.7 3.6 3.0 4.9 4.4 5.1 4.4 7.3 6.6 1000 - 2500 2501 - 4000 3.7 2.8 5.5 4.2 4.1 3.4 6.1 5.0 Used Belt New Belt Used Belt New Belt Uncogged HyT Wedge Belts & Uncogged Hy-T Wedge Torque Team New Belt Uncogged Hy-T Belts & Uncogged Hy-T Torque Team Belts Cogged Torque-Flex & Machined Edge Torque Team Belts Cogged Hy-T Wedge Belts & Hy-T Wedge Machine Edge Torque Team Used Belt 3.3 2.9 4.2 3.8 5.3 4.9 10.2 8.8 5.6 14.8 13.7 17.1 16.8 New Belt 4.9 4.3 6.2 5.6 7.9 7.3 15.2 13.2 8.5 22.1 20.1 25.5 25.0

General Belt Drive Care

Cross Section

A, AX

B- 5

B, BX

CX

Check Belt Tension with Mechanical Tester

Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers

Table B - 3: Belt Deflection Force

Table B - 2: Belt Deflection Force

General Belt Drive Care

Belt Guards

Belt Guards
.38 .62 .31 1.0 .54

3V

5V

8V

V-belt drive guards promote both cleanliness and safety. Screened, meshed or grilled guards are best because they allow air to circulate and heat to escape.
.88

.50

A
.66

.31

B
.88

.41

C
1.25

.53

.75

1.5

.91

Figure B - 6: Belt Types in Cross-Section

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Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers

General Belt Drive Care

Idlers

Idlers
A properly designed V-belt drive does not require an idler to deliver full rated horsepower if proper belt tension can be maintained. Idlers should be avoided if possible because an idler puts an additional bending stress point on the belt. This reduces the belts horsepower rating and its life expectancy. The smaller the idler, the greater the stress and the more belt life is reduced. Inside Idler A V-grooved idler located on the inside of the belts on the slack side of the drive is recommended over a back-side idler. The idler should be located near the large sheave to minimize reduction of the arc of contact across the small sheave. The diameter of the V-idler pulley should be equal to or larger than that of the small sheave. Kiss Idler A kiss idler differs from the back-side idler because the kiss idler does not penetrate the belt span and create a back-bend on the belt. Consequently, the kiss idler does not contribute to premature belt failure. Use of a kiss idler can help control belt vibration and whip on drives subject to shock and pulsating loads. Kiss idlers can be used in single-belt drives where joined belts are not applicable. If a kiss idler is used, diameter of the flat pulley should be at least 1-1/2 times (1.5x) greater than the diameter of the small sheave.
Driven

Driver Driven

Driver

Back-Side Idler A back-side idler increases the arc of contact on both sheaves. However, it forces a backward bend in the V-belt that contributes to premature belt failure. The idler puts additional stress on the bottom portion of the belt which will result in bottom cracking. If a back-side idler must be used, the diameter of the flat idler pulley should be at least 1-1/2 times (1.5x) the diameter of the small sheave. A back-side idler should be located as close as possible to the small sheave.
Driver Driven

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Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers

General Belt Drive Care

Idlers

NOTES:

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Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers