Contents

Section I..........................................................General Manual

Generator Set Warning.............................................................................................................................................2
Start Up Speed Warning............................................................................................................................................3
Introduction...............................................................................................................................................................4
General Information..................................................................................................................................................5
Warranty Information. ..............................................................................................................................................7
Crusher Specifications. .............................................................................................................................................9
Mechanical Installation.......................................................................................................................................... 11
Electrical Installation Guidelines........................................................................................................................15
Interlock Control Panel.........................................................................................................................................22
Lid Operation and Maintenance..............................................................................................................................30
Feed Hopper Adjustment and Maintenance. ..........................................................................................................36
Routine Operation....................................................................................................................................................39
Lubrication Guidelines. ...........................................................................................................................................42
Belt Maintenance and Replacement.......................................................................................................................48
Anvil Rotation and Maintenance. ...........................................................................................................................54
Shoe Table Casting Maintenance. ..........................................................................................................................59
Table and Rotor Removal........................................................................................................................................68
Interior Crusher Maintenance. ..............................................................................................................................70
Pedestal Overhaul...................................................................................................................................................74
Electric Motor Replacement..................................................................................................................................83
Seasonal Maintenance.............................................................................................................................................85
Fastener Specifications...........................................................................................................................................87
Component and Assembly Diagrams.........................................................................................................................90

Section II...............................Component and Assembly Diagrams

Turbo 80 Anvil Ring Assembly
Turbo 80 Hub & Sheave Assembly
35” 6 Shoe Impeller Table HRPM
Turbo 80 Lid Assembly
Turbo 80 Lift Arm Assembly
Turbo 80 Lift Housing and Pump Assembly Electric
Interlock Panel ELE-365
Turbo 80 Motor Mount
Oil Tank Assembly
Turbo 80 Pedestal Assembly
Turbo 80 Pedestal Hoses and Fittings
Turbo 80 Tub Assembly

1
 Generator Set Warning

CAUTION
CONNECT
GROUND WIRE
BEFORE USING
In any generator set installation, the frame of the gen-
erator must be positively connected to an earth ground.
This connection is the first connection that is made at
the installation. This connection is the last connection
that should be removed. If the generator set is on flexible
mounting pads, the ground connection must be flexible
in order to avoid possible breakage in later operation.
Ground connection cable or straps should have at least
the current carrying capacity of the largest line lead to
the connected load. Joints in cables or straps must be
clean, free of electrical resistance, and protected from
possible oxidation. Bolted ground connection joints even-
tually oxidize. The joints are frequent sources of radio
frequency interference. (RFI). Joints that are silver sol-
dered and bolted are preferred. The generators with
a Wye Configuration usually have the neutral ground
when the generator is installed. Grounding the neutral is
for preventing damage to equipment.
2
 Start Up Speed Warning

WARNING!
To Prevent Catastrophic
Casting Failure:
At Crusher Start Up, the Rate
of Motor Acceleration From
Rest to Full Speed RPM MUST
take 30 Seconds or longer.

When starting up a CEMCO Vertical Shaft Impact

Crusher, the rate of motor acceleration from rest to
full speed RPM must take 30 seconds or longer. Any
shorter duration will cause damage to castings. Using a
Variable Frequency Drive (VFD) or a Soft Start is highly
recommended to control the start up speed. If this start
up procedure is not followed correctly the CEMCO, Inc.
warranty will be voided.

3
 Introduction
Section headings are in large bold type and appear
at the top of each page.
SECTION SUBHEADINGS ARE IN SMALL
BOLD CAPITALIZED TYPE
When a reference is made to another section heading
or section subheading, the referenced section title
is ITALICIZED AND CAPITALIZED.
Most procedures are introduced by a few short sen-
tences after the subheading followed by a detailed
list of numbered instructions. For simple operations,
a few sentences or a single paragraph adequately
describe the procedure and no numbered steps are
given.
Photographs are captioned and placed within the
section to which they relate.
Important information critical for safe crusher op-
eration is denoted by the “warning” symbol:
Always read the information and follow the instruc-
tions denoted by this symbol. Failure to do so could
lead to unsafe crusher operation and personal injury.
Some procedures warn against using what may be
considered common workshop practices. The “not
a good idea” symbol:
is usually followed by a statement that says “Do
not use certain tools, or methods in this procedure.”
This manual is divided into two main sections. The
GENERAL MANUAL covers installation, opera-
tion, and service information. The COMPONENT
AND ASSEMBLY DIAGRAMS contains illus-
trations that show part number and identification
information.
This manual is individualized for your specific
4
crusher. The exploded diagrams with part number
information correlate with your general crusher
configuration. You will notice that some parts have
the word “SPEC” instead of a part number. These
components are specific to your crusher. Detailed
ordering information for these components is in
the CRUSHER SPECIFICATIONS section. For
example, the drivetrain is designed to operate at
the optimum speed for each customer’s crushing
operation. Consequently, the drive sheaves and
sheave bushings can be different on the same model
crushers. To find the specific sheave and bushing
information for your crusher, refer to the CRUSHER
SPECIFICATIONS section. Whenever you see the
word “SPEC” in lieu of a part number, refer to the
CRUSHER SPECIFICATIONS section for detailed
component information.
ENCLOSURES
Depending on your crusher configuration, CEMCO
includes additional accompanying documentation
where applicable. We may pass along OEM informa-
tion or data sheets that came with some of the com-
ponents installed on your crusher. We also include
blank forms for photocopying and record keeping.
Electricians may prefer loose wiring diagrams rather
than carrying around an entire manual. Applicable
enclosures can be found in a pocket at the end of
this manual. Possible enclosures include.
Vibration sensor data sheet (Variable)
Flow meter data sheet
Oil switch data sheet-Oil level (temp)
Starter schematics
Oil pump motor wiring diagram (electric only)
Sheave/bushing data sheet
Motor data sheet (Variable)
Casting wear life table
Diesel engine manuals and schematics
Oil heater data sheet
Oil cooler data sheet
Turbo VSI Lubrication Record & recommended
lubricants
General Information
INTRODUCTION
This Service Manual contains operation instruc-
tions, lubrication and maintenance information, and
repair procedures for your CEMCO Turbo Impact
Crusher. Proper crusher maintenance and operation
maximizes profit.
Because all CEMCO crusher installations are unique
the photos and illustrations in this guide may not
exactly match your installation. Familiarize yourself
with your particular crusher and understand that the
photos and illustrations show typical components
and assemblies.
Consult your CEMCO dealer or the factory when-
ever a question arises regarding your Turbo Impact
Crusher. Your CEMCO dealer has the latest available
information pertaining to your crusher.
SAFETY
Safety is everybody’s business and is basically the
use of good common sense. These are general safety
guidelines. Each crusher installation is different. Be
aware of all the safety concerns particular to your
situation. Be attentive. Watch for hazards and cor-
rect them immediately. Use preventative measures.
in operation.
8. Before introducing feed material, read the flow
meters and verify that clean lubricating oil is
flowing through the pedestal and gearbox bear-
ings. Refer to the ROUTINE CRUSHER OP-
ERATION section for proper oil flow rate and
meter readings.
9. Allow diesel power units time to reach operating
temperature and oil pressure before crushing.
10. Never configure a crusher to exceed the
maximum rotor speed given in the CRUSHER
SPECIFICATIONS section.
11. All CEMCO crushers should rotate in the
counter-clockwise direction when looking
down on the pedestal from above.
12. Inspect the crusher every 4 hours. Never let
castings wear to a point where breakage could
occur.
13. Never allow tramp iron or other unbreakable
material to enter the crusher. MAGNETICAL-
LY PROTECT THE TURBO FEED USING
AN ELECTRONIC METAL DETECTOR OR
A PERMANENT MAGNETIC PULLEY.

Here are general guidelines for safe

crusher operation.
1. Always wear personal safety equipment including
a hard hat and safety glasses.
2. Read and understand all manuals before crusher
startup. Contact CEMCO regarding any questions
or concerns you may have.
3. Never operate a Turbo Impact Crusher with the
lid or inspection door open.
4. Never climb on or under the crusher while it is
Dangerous tramp iron and 3/4” x 2” bolt. A
in operation.
magnetic detection system should flag these.
5. Keep clear of belts, sheaves, crusher impellers,
and engine components.
6. Never operate crusher without belt and sheave
guards.
7. Stay a safe distance from the crusher while it is
5
 General Information
Harmless tramp iron: a 3/8” x 1-1/4” bolt and a 5/8”
nut. A magnetic detection system could pass these.
14. Never operate an out-of-balance crusher.
CEMCO crushers are simple machines, designed
for easy day-to-day maintenance. Monitor your
crusher closely, especially when it is new. Record
all completed maintenance. Educate all operators
and mechanics. Copy this manual and make it
available to them. (Additional copies are available
from CEMCO or your dealer.) If you maintain your
crusher properly, you may never have to make some
of the repairs outlined in this manual.
Here are general guidelines for
safe crusher maintenance and repair.
1. Always wear personal safety equipment including
a hard hat and safety glasses.
2. Always make sure power is locked in the “OFF”
position before inspecting, servicing, or repair-
ing crushers. This applies to electric and diesel
installations.
3. Use personal safety equipment when performing
crusher maintenance or repairs.
4. Do not hammer on castings.
5. Know the capacity of all hoists and cranes. Al-
ways use correct lifting tools. Examine all lifting
straps, chains, hooks and eyebolts before each
use. If any lifting devices are frayed, broken or
bent, discard them.
6
6. Follow OSHA/MSHA guidelines regarding com-
pressed air use.
7. Always use correct size eyebolts threaded into
the full hole depth for lifting.
8. Read through and familiarize yourself with an
entire service procedure before attempting it.
Have the correct tools and replacement parts
close at hand. MAKE SURE YOU HAVE THE
EQUIPMENT TO MAKE THE REPAIR.
9. When a repair dictates opening the oil or grease
system, always plug, cover, and protect exposed
hose fittings and openings. Reconnect only clean
fittings.
10. All electrical connections and components must
conform to all MSHA, OSHA, national, state,
and local safety codes and regulations.
11. Always use bolts and fasteners that are new or
excellent condition when replacing parts.
12. If you have questions or need parts, call the
factory (505)-864-1200.
REPLACEMENT PARTS
Use only Grade 8 fasteners. They are readily
available from most bolt suppliers. They are always
available from CEMCO.
A LWAY S U S E C E M C O W E A R C A S T
INGS. THEY ARE ENGINEERED
FOR FIT, WEAR LIFE AND SAFETY. NON
CEMCO CASTINGS ARE NOTORIOUS FOR
WEARING OUT PREMATURELY AND EX-
POSING THE ROTOR SURFACE AND FOR
BREAKAGE WHICH CAN CAUSE AN OUT
OF BALANCE CONDITION AND CRUSHER
DAMAGE..
CEMCO DOES NOT WARRANTY CRUSHER
OR ROTOR DAMAGE DUE TO NON CEMCO
CASTINGS THAT WEAR OUT PREMATURE-
LY OR BREAK.
Warranty Information
LIMITED WARRANTY AND DISCLAIMER OF IMPLIED WARRANTIES
CEMCO warrants that for one (1) year or 2000 hours of normal use from the date of delivery of the
Impact Crusher purchased hereunder, whichever comes first, the machinery and parts manufactured by CEMCO
will be free of defects in material and workmanship. CEMCO’s sole obligation and the User’s sole remedy
under this Warranty is repair of any part of the Equipment which CEMCO manufactured which CEMCO finds
is defective by reason of defects in material or workmanship within the one (1) years or 2000 hours of normal
use time period, whichever is less. Any repair performed under this Warranty shall be performed at CEMCO’s
shop or at a shop designated by CEMCO. User shall bear all incidental expenses of repair, including costs of
transportation and new parts.
CEMCO DISCLAIMS ANY IMPLIED WARRANTIES, INCLUDING THE WARRAN­TIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. In no event shall CEMCO
be liable for punitive, incidental or consequential damages to person or property, loss of use, loss of time,
inconvenience, equipment rental, loss of earnings or profits or any other loss. The warranty granted herein shall
be null and void in the event that the Equipment is altered by User, has been, in CEMCO’s judgment, subject to
negligence, improper maintenance, misuse (including exceeding specifications for feed size and/or maximum
speeds and feeding of non-crushable materials into the crusher), failure to replace worn parts as needed, or use
of wear parts other than those purchased from or approved by CEMCO. Any warranties on machinery and parts
not manufactured by CEMCO or warranties made by third parties regard­ing machinery and parts manufactured
by CEMCO are the responsibility of those manufacturers or third parties. CEMCO shall not be liable for any
warranty on parts and machinery of the Equipment except as expressly provided herein.
CEMCO shall have no liability or responsibility for any costs, losses or damages due to defective or failed
Product claims to the extent that the claims result from: (a) CEMCO’s compliance with Customer’s supplied
Specifications and/or manufacturing processes, (b) inadequate operating environment, accident, disaster, neglect,
abuse, or misuse, (c) design flaws or design parameters exceeding or violating component specifications,
(d) external or environmental factors after shipment from CEMCO, (e) follow-on handling, processing, or
manufacturing of Products after shipment of the Product from CEMCO, (f) repair, attempted repair, modification,
or alteration of the Product by a party other than CEMCO, and (g) defects related to components provided by
third party suppliers (including, but not limited to, motors, drives, gearboxes, electrical components, and wear
components) selected by Customer, which defects CEMCO could not reasonably detect, prevent or control, and
(h) Products for which Customer has not provided functional or other tests to adequately diagnose failures.

With respect to Equipment which is in whole or in part Used Equipment, the Equipment is sold “AS
IS, WHERE IS” and “WITH ALL FAULTS.”

EDITION March 1, 2011

7
 CEMCO, Inc.
RETURN OF GOODS POLICY
Merchandise may not be returned without CEMCO’s consent.
Return goods may not be used or damaged and must be
accompanied by CEMCO’s Return Goods Authorization number
(RGA#).

All returns are subject to a 15% charge to cover handling and

restocking costs.

Goods returned because of our error will be credited without

expense to you.

All returns are FOB CEMCO, Inc. Collect shipments arriving by

commercial carrier will be returned.

8
Crusher Specifications
INTRODUCTION CEMCO Serial Number Plate
Each CEMCO crusher is tailor made to customer
needs and specifications. The following specifica-
tion pages list information necessary for crusher and
component identification and parts ordering. The
service manual text and diagrams may refer you to
the specification pages for exact information about
your crusher. When the word “SPEC” is used in lieu
of a part number, refer to the specification pages for
the exact part number used in your crusher.
When you contact the factory or your sales rep-
resentative to order parts or ask questions, please
have your specifications on hand to facilitate un-
derstanding. Typical electric crusher (dual drive)
Each crusher includes serial numbers for the major
components. These numbers help CEMCO track
components and understand exactly how your
crusher is configured. The main serial number plate
is located on the frame usually on the endcap. On
some models the serial number plate may be at-
tached to side of the frame. The information on this
plate includes the Crusher Model, Crusher Serial
Number, SuperChipper™ Rotor or Impeller Table
description and the CEMCO job number.

Typical diesel drive crusher

Main crusher serial number plate location

9
 Crusher Specifications
TURBO CRUSHER WORKORDER - ELECTRIC MODEL - SINGLE DRIVE
UPDATE:
Order Date: 9/5/2017 Contact: Jorge Escobar
P.O. NO: Phone No. 786-732-0960
Dealer: Customer: Crushtech Equipment, Inc.
Shipping Address: 13571 SW 135th Ave. #208 San Miguel, El Salvador, Central Ame
Miami, FL 33186
Crusher Job Number:
Crusher Serial No. AEV-1017-180 Overall Assy. No: ORD28014
Crusher Model AEV-80
Scheduled Shipping Date: 10/5/2017 Actual Ship Date:

ELECTRIC MOTOR
Brand Name: TECO
Serial Number: ZB.AC16C090-4
Model Number: CD3004TR
Enclosure: TEFC
Frame Size: 449TZ MMW Part# MMW-38001
Horsepower: 300
R.P.M.: 1775
Full Load Amps: 334
Voltage: 460
Cycles: 60HZ
OIL SYSTEM
Electric Motor Brand: Marathon
Serial Number: 49
Model Number 56T17F15658A
Frame Size: 56C
Horsepower: 1
R.P.M.: 1725
Full Load Amps: 3.6-3.8/1.9
Voltage: 208-230/460
Cycles: 60
Oil Pump Brand: Eaton OIL S/N: 29142-1
Oil Pump Part Number: OIL-00033
Oil Pump Rotation: CLOCKWISE
Oil Filter Part Number: CSG-50-P10-A (NAPA 1551)
Oil Cooler / Heater: OIL-00058K
DRIVE INFORMATION
Motor Sheave: SHV-61400-8V Pedestal Sheave: SHV-61500-8V
6-8V 14" 6-8V 15"
Motor Bushing: BSH-F0306 Pedestal Bushing: BSH-J0400
F-3 3/8" J-4"
Qty. & Size Of Belts: 6 Belts BLT-81170 8V-1700
Pedestal Speed: 1636
CRUSHER CONFIGURATION
ANVIL RING ARK-80210 S/N 30373
Number Of Anvils: 21
Anvil Part Number: ANV-80000
IMPELLER TABLE STK-35-6 S/N 30313
Table Diameter: 35
Shoe Part Number: ISH-35600-K2
Number Of Shoes: 6
GENERAL INFORMATION
Part Number Pedestal Plate : PPL-80000
Hub : HUB-80000
Pedestal Kit : PDK-81000 S/N 30185
Top Seal Plate : TSP-80961
Bottom Seal Plate : BSP-81000
Shaft : SFT-81000
Inner Lid Lifter : LTW-54100
Outer Lid Lifter : LTW-54200
Vibration Switch: ELE-096
Oil Lube Panel S/N: 29524-1
NON STANDARD FEATURES WITH CRUSHER
OIL-00058K - Oil Cooler, 3 Phase, 480V, 1/4HP Forced Air

10
Mechanical Installation
INTRODUCTION
Installing a new CEMCOcrusher involves mounting
the crusher to a framework, installing the feed hop-
per, exit chutes, oil system, and supplying electricity
to the crusher and oil pump motors. This section
describes the mechanical installation guidelines
only. Electrical installation guidelines are discussed
in the next section.
At the end of this section is a listing of the miscel-
laneous components supplied with your crusher and
their purpose.
FRAME MOUNTING
Frame set on hard dirt

Failure to follow these crusher mount

ing guidelines could result in personal injury and
equipment damage. Use only Grade 8, unused fas-
teners for mounting a crusher to a frame.
CEMCO manufactures a wide array of crushing
configurations. For a stand alone electric drive
crusher, short pieces of square tubing are mounted
under each of the crusher mounting feet for ship-
ping. CEMCO may deliver a crusher with a mount-
ing frame but usually the frame is supplied by the
customer. The customer must mount the crusher to
the frame at the job site. Usually a frame mounted Skid mounted unit
on a concrete foundation is suitable. Skids are also
common. Occasionally, a frame with pads is simply
set upon hard soil.

Trailer mounted unit

Single drive crushers have five or seven mounting
feet. Dual drive crushers have between six and
Frame mounted on a concrete slab
ten. Most likely you received a general arrange-
ment drawing before your crusher was delivered.
11
 Mechanical Installation
The Ernst flow meter instructions specifically
prohibit the use of Loctite or liquid thread sealant at
the meter connections.

Crushers in series at a large mining operation

That drawing shows the precise hole locations for
the mounting feet. Remove the shipping feet from
the crusher and set it on the stand. Fasten the crusher
Oil hose connections at the crusher
to the stand with Grade 8, 1” diameter mounting
bolts at each mounting foot. It is acceptable to use
lockwashers. Torque these bolts to a minimum of
795 ft-lbs. (A Grade 8 bolt can safely be torqued to
900 ft-lbs with no lubrication).
Check and retorque the mounting bolts just prior to
operating the crusher for the first time and after the
first few hours of operation.
CEMCO does not recommend any vibration damp-
ing mounting schemes. If you intend to mount the
crusher in any manner other than the crusher’s steel
frame to a steel stand, please contact the factory.
OIL SYSTEM INSTALLATION
T he spare parts box contains two oil sys-
tem hoses, each 15 feet long, with fittings and oil
reservoir mounting hardware. The smaller diameter
hose is the supply line. The larger diameter hose is
the return line. These hoses link the crusher to the
oil tank. Mount the oil reservoir near the crusher and
below the pedestal to facilitate the gravity return. Oil hose connections at the oil tank
Remove any plugs or caps from the fittings and
Follow the ELECTRIC DRIVE START UP instruc-
hoses before installation. Avoid getting teflon tape
tions in the ROUTINE ELECTRIC DRIVE OPERA-
or any dirt or debris in the oil system components.
TION section. The oil level in the tank will drop the
first time oil is introduced into the system. It may
be necessary to add oil after this.

12
 Mechanical Installation
You may use the factory installed filter for the first
50 hours of use. The oil reservoir is shipped empty.
Oil and filter specifications and change intervals are
defined in the CRUSHER SPECIFICATIONS sec-
tion and discussed in detail in the LUBRICATION
GUIDELINES section.
DISCHARGE CHUTE INSTALLATION
The spare parts box contains a bag of cap screws,
flatwashers, nut, and lock washers for installing the
discharge chutes. Bolt the discharge chutes up to the
mating flange on the underside of the crusher.
Some customers choose not to use standard CEMCO
exit chutes. Non CEMCO chutes must have a large
enough opening and steep enough angle to prevent
material from backing up into the crusher. We are
willing to assist customers in nonstandard exit chute
design.

Enclosed feed hopper

CONNECTORS AND FASTENERS

Standard discharge chute ready for installation
FEED HOPPER INSTALLATION
The feed hopper is assembled and ready to go. It
simply needs to be inserted in the opening in the lid.
Check the square head feed hopper retainer bolts for
tightness. Once installed, verify that the feed tube
is at the correct height for the rotor. See the section
titled FEED HOPPER ADJUSTMENT AND MAIN-
TENANCE for details.
A box of small parts and components is included
with your crusher shipment. Below is a listing and
breakdown of the components and their purpose.
Discharge Chute Hardware
Turbo 35 12 - 3/8 x 3/4 CAP SCR, 24 FW, 12
NUT, 12 LW
Turbo 54 24 - 3/8 x 1 1/4 CAP SCR, 48 FW, 24
NUT, 24 LW
Turbo 70 24 - 3/8 x 1 1/4 CAP SCR, 48 FW, 24
NUT, 24 LW
Turbo 80 24 - 3/8 x 1 1/4 CAP SCR, 48 FW, 24
NUT, 24 LW
Turbo 96 24 - 3/8 x 1 1/4 CAP SCR, 48 FW, 24
NUT, 24 LW

13
 Mechanical Installation
Oil System Hoses
(1) 15 ft of 1/2 LOL hose with 1/2 LOC (swivel)
hose ends installed, high pressure line
(1) 15 ft of 3/4 LOL hose with 3/4 LOC (swivel)
hose ends installed, low pressure line

14
Electrical Installation Guidelines
INTRODUCTION
All wiring must comply with NEC or ASE
Electrical Code. CEMCO recommends only a
licensed electrician install and service electrical
systems on CEMCO products. Wiring schematics
and information in this section are suggestions.
CEMCO supplies the following standard electrical
components: Vibration switch, oil flow sensor unit,
oil level / temperature sensor unit and oil pump
motor. The optional components are included if
the customer specifies them in the initial purchase.
Optional components include:Oil heater, oil cooler
and hour meter. Because each plant is different,
the motor starters, hour meters, control panels and
buttons, and wiring supplies are supplied by the
customer. At the customer’s request, CEMCO can
recommend suitable components. The main crusher
motor(s) and the oil pump motor must each be on
their own circuit. CEMCO can also provide ladder
logic for the programming of PLC control systems.
The electric crusher motor(s) are three phase
industrial motors designed for across-the-line or
wye-delta starting with a suitable electrical starting
circuit. The customer must supply the starters and/or
the control system if not using the optional Variable
Fequency Drive (VFD) and/or interlock control
relay. If you are unsure about the proper starter or
need recommendations, please contact CEMCO.
The different electrical system components are
discussed below. Refer to the electrical schematics
in this section and at the back of this manual for
typical component wiring diagrams. (There may be
some duplication).
CRUSHER DRIVE MOTOR(S)
A steel faceplate on each electric motor defines
the pole wiring schematics for across the line and
wye-delta starting. CEMCO recommends Variable
Fequency Drive (VFD). A VFD has considerable
advantages over Solid State Soft Starters. Two
motors can be started as one, and the inrush current is
reduced in a manner that may alleviate high demand
charges on dual motors or single motor crushers.
If the custumer choses Solid State Soft Start it is
common to start one motor with a starter wired in a
”wye-delta” with a reduced voltage solid state electri
starting circut, and start the second motor across
the line after the first motor comes up to speed.
The electrical starting circuts need to be housed in
a control box located near the crusher. The starter
specifications must match the motor specifications.
All electrical wiring must be done to local code by
a licensed electrician.
CEMCO crushers are directional specific,
when starting up a new crusher or doing
any sort of electrical modification to motors on
and existing installation, ALWAYS CHECK THE
DIRECTION OF ROTATION. Failure to do so
will result in crusher damage and will void CEMCO
warranty.
Motor faceplate with wiring schematic
If power is produced on site with a generator
set, a reduced voltage auto transformer is a more
appropriate solution. If you choose to use a solid
state starter with a generator set, be sure to use surge
protection for the starter. When using a generator set
with a VFD you must first check with the generator
manufacturer for the correct kW needed to run a
VFD safely. An undersized generator can damage
a VFD, damage electrical crusher motors and void
warranty.
When starting up a CEMCO Vertical Shaft
Impact Crusher, the rate of motor acceleration from
rest to full speed RPM must take 30 seconds or
15
 Electrical Installation Guidelines
longer. Any shorter duration will cause damage to in the the INTERLOCK CONTROL PANEL section.
castings. Using a Variable Frequency Drive (VFD)
Connect it so a low oil flow condition will shut the
or a Soft Start is strongly encouraged to control
crusher motors off or prevent them from starting.
the start up speed. If this start up procedure is not
CEMCO recommends installing the oil flow sensor
followed correctly the CEMCO warranty may limit
in the NORMALLY OPEN position. The flow meter
or void the CEMCO warranty.
is adjusted at the factory. If necessary, it may be
OIL PUMP MOTOR adjusted in the field. The manufacturer’s adjustment
instructions are included as an enclosure with this
The oil pump motor is a simple 1 HP electric motor
manual. Check the meter function by varying flow
with a full load amperes of 1.9. It needs to be on a
through it and observing if the flow indicators are
separate circuit from the main crusher motors and
tracking. If not, there may be an obstruction around
must be activated before starting the crusher. The
the flow sensing element.
CEMCO Crusher comes with an optional interlock
controller (ELE-365) that provides a pre-lube timer Shut off flow to the meter and bleed off
that will start and run the lubrication system for 3 pressure prior to disassembly. The meter may
minutes to protect the bearings of the crusher on start also have to be purged if it is metering hazardous
up and a post lube timer that runs and shuts off the materials.
lubrication system for 6 minutes as the crusher coast
to stop. More detailed information can be found in
the the INTERLOCK CONTROL PANEL section.
Not using the recommended time delay circuts
for pre and post lubrication guidelines may limit
or void the CEMCO warranty.
HOUR METER
An hour meter is used for proper maintenance
and parts life monitoring. There are several hour
meter installation options including the oil pump
circuit, the crusher circuit, or even a feed or product
conveyor circuit. It is best to record the hours the
Inside the flow meter
crusher is actually crushing material. It is common
for the operator to turn on the oil pump and let Usually the switches are set at the factory as
it run for awhile before starting the crusher. It is indicated in the model code on the nameplate, or on
also common for the crusher to run awhile before an attached paper tag. To reset the switch point for
introducing feed material. Install the hour meter in common switch options, proceed as follows:
a circuit that will give the most accurate estimate
1. Remove the nameplate, window and gasket from
of actual crushing hours. An hour meter is included
the control box.
with the optional interlock controller (ELE-365).
2. The cam that actuates the switch is located just
Failure to use an hour meter may limit
under the pointer. The position of the cam dictates
or void the CEMCO warranty.
the flow rate at which the cam will trip the switch.
OIL FLOW SENSOR
3. Turn the pointer so that it points to the desired flow
The oil flow meter included with the oil tank rate on the scale. Against low spring forces you can
assembly should be used as a safety interlock device. do this by grasping the pointer itself and holding it
If the optional interlock controller (ELE-365) is in position while you adjust the cam.
being used, more detailed information can be found
16
 Electrical Installation Guidelines
4. While holding the pointer in the desired position,
depress the cam ring fully (approximately 1/16 inch)
and rotate it until the switch actuates (clicks). Release Failure to install the oil level/temperature
your downward pressure and the cam ring will lock at switch properly may limit or void CEMCO
that position. warranty.

5. If you can’t hear the switch click, you can determine

closure with an ohmmeter connected across the switch
terminals. Connect to the common and normally open
or normally close on the switch.
6. To check the setting, direct the pointer again to the
desired flow rate, noting where the switch actuates.
Make adjustments as necessary. If the bowl was
removed, place on guide roll pins and firmly tighten in
an X motion.
7. It’s much easier to set the switch point if you can do
it with actual flow present. Adjust the flow to the desired
point where you want a signal to occur and turn the cam
to actuate the switch as outlined above.
8. Replace window, nameplate and gasket before turning
on the electric power.
Note: It is recommended that all Teflon bowl seals be
replaced when the bowl is removed.
Oil Level-Temp Switch and Installation

OIL LEVEL and TEMPERATURE SWITCH

The oil tank assembly contains a float sensor to detect
a low oil level and temperature. The oil level switch
has two control wires and temperature switch has four
control wires. A certified electrician should connect the
switch so a low oil condition will shut the crusher motors
off and/or prevent them from starting. The temperature
switch has two temperature values. The low value is
86°F normally open, this temperature is used to start the
cooling system ( if an optional oil cooler is installed).
The second value is 176°F normally open, this is used
to alert the operator of potential heat issue or the need
for an oil cooler. See schematics in the encloses at the
back of this manual. If the optional interlock controller
(ELE-365) is installed, more detailed information can
be found in the the INTERLOCK CONTROL PANEL
section. VIBRATION SENSOR
CEMCO crushers include a vibration sensor,

17
 Electrical Installation Guidelines
refer to the VIBRATION SENSOR WIRING
(ELE-365) is installed, more detailed information
SCHEMATIC at the next page and at the end of
can be found in the the INTERLOCK CONTROL
this manual. The vibration sensor is a 3-1/2” x
PANEL section.
3-1/2” x 3” metal box mounted on one of the gus-
sets which support the lid lifting assembly. It is not
wired when the crusher arrives from the factory. Failure to install and set the vibration
switch voids warranty.

Vibration sensor mounted on crusher

Remove the vibration switch cover and run the
wires through the 1/2” NPT access port. Use a 12”
piece of flexible conduit between the vibration
switch and junction box to isolate the switch from
any conduit vibrations. The terminals are designed
for 24-14 AWG (0 .2-2.5 mm²)

The Vibration switch has two relays, the alarm

and the alert. The alarm shuts down the crusher if
the vibration is at or above the set magnitude, for
the set Time of threshold. This protects the crusher
from extreme damage and/or catastrophic failure.
The alert is set to a percentage of the alarm setting.

Example: if the alarm is set to 1 IPS for 2 seconds

and the alert is set to 50% of the 1 IPS and 50% of
2 seconds then it will indicate this by tripping the
relay at .5 IPS at duration of 1 second.
If the alert relay keeps tripping, this is a sign
that the crusher is not being fed consistently, or
surges of large material is making it’s way in to
the crusher, or the settings are not correct. Each
vibration switch must be tuned to the structure it
is attached to. If the optional interlock controller
Vibration sensor with cover removed
SCHEMATICS
CEMCO makes every effort to pass along schematics
and/or instructions from OEM suppliers of compo-
nents included with your crusher. Any additional
information can be found in the pocket at the back
of this manual on in an included envelope.

18
 Electrical Installation Guidelines
CRUSHER MOTOR STARTER SCHEMATIC
INCLUDING SAFETY SHUT-OFF SWITCHES

MOTOR
FUSES STARTER HEATERS CRUSHER
DRIVE MOTOR
L1

HIGH
L2 M1
VOLTAGE

L3

OIL OIL
START
FLOW LEVEL VIBRATION
LOW METER SWITCH SWITCH
VOLTAGE
NOT TO
EXCEED 110V. LINE 2 STOP M1 OL N
COIL
AUX
N.O. N.O. N.O.

A vibration switch is standard on all crushers and it must be wired in-line, on site, with oil flow meter and oil level switches
to prevent crusher from starting unless the oil pump is on,oil flow is apparent, the oil level is normal and vibration switch contact
is closed. PEDESTAL WARRANTY IS VOID IF SWITCHES ARE NOT IN PLACE.

OIL PUMP MOTOR STARTER SCHEMATIC

MOTOR
FUSES STARTER HEATERS OIL PUMP
MOTOR
L1
HIGH
VOLTAGE L2 M2

L3

START
LOW
VOLTAGE
NOT TO
EXCEED 110V. LINE 1 STOP M2 OL N
COIL
AUX

All wiring must be to NEC electrical code.

19
 Electrical Installation Guidelines

Standard Electric Schematic

PRESSURE GAUGE
80

60 100

600
400

40 800 120

200

20 1000 140

0
kpa
0 160
psi

OIL LEVEL GAUGE

¡F ¡C

220
100
200
90
180 80
160 70
140 60
120 50

100 40
30
80
20
60
10
40
0

FLOW METER
¨

FLOW METER
With Electrical Signal

FLOW DIRECTION
RATE

.5
1
2
3
4
5

GPM

3000 PSI MAX

OIL
LPM
RATE

12
16
20
4
8

FILTER

LOW OIL LEVEL

SWITCH(TEMP)

VIBRATION
SWITCH

PEDESTAL
Vibration
Switch

To Crusher Drive
Low Voltage
Motor Control Flow Meter To Crusher Drive
40
60

200
400
80

600
100

800 120

Pressure Gauge Low Voltage

Motor Control.
20 1000 140

0
kpa
0 160
psi

To Crusher Drive
FLOW METER
With Electrical Signal

FLOW DIRECTION
RATE

.5
1
2
3
4
5

GPM

3 0 0 0 P SI M A X
OIL
LPM
RATE

12
16
20
4
8

Low Voltage
Motor Control 1HP Pump Drive Motor
* Oil Level
Switch
(Temp)
¡F

220
200
180
¡C

100
90
80
To 230v/460v
Power Source
160 70
140 60
120 50

100 40
30
80
20
60
10
40
0

28 GALLON
RESERVOIR

PUMP

THE OIL TANK AND PUMP ASSEMBLY MUST BE INSTALLED

BELOW THE PEDESTAL TO FACILITATE A GRAVITY RETURN.
* Note: Oil Level has 2 Wires. Oil Level and Temp has 3 Wires

20
 Electrical Installation Guidelines
Electric Motor Grease
CEMCO VSI Crushers are equipped with either
diesel or electric motors. Electric motors must
be lubricated in order to perform properly and
to prolong motor life. Electric motors need to
have both the “drive end” and “opp drive end”
greased prior to initial start-up. Electric motors
also need to be greased periodically during
operation. On every electric motor there are I.D.
plates installed by the manufacturer. I.D. plates
give the specifications on which type of grease to
use, the re-lubrication period and the quantity of
grease required. CEMCO, Inc. provides one tube
of equivalent grease with each crusher shipped. Lubrication plate placed on motor by manufacturer.
This grease should be used for start-up lubrication
and customers must find a local vendor to supply
equivalent grease. Pictured below is a sample
I.D. plate. Customers need to refer to their
motor’s I.D. plates for their own electric motor’s
specifications.

CEMCO, Inc. provides a single tube of Chevron Black

Pearl EP NLGI 2 or equivelant with crushers equipped
with electric motors.

I.D. plates located on electric motor.

21
 Interlock Control Panel
Installation of all electrical devices should
be completed by licensed electricians and
all electrical connections should meet OSHA &
MSHA Regulations for local and federal codes.
LUBE OIL INTERLOCK PANEL
INTRODUCTION
motor getting energized. It also has a “post-lube
timer” that continues operation of the lube oil
system motor for six (6) plus minutes while the
crusher motor is powering down and slowing to a
stop. It also provides a properly sized starter for the
CEMCO oil system motor. Optional starters can
also be purchased for Oil heaters and/or Oil coolers
if they are needed.

VIBRATION SWITCH MODEL AND

OPERATION

ELE-365 Interlock Panel

The CEMCO, Inc. ELE-0365 interlock panel is a CEMCO standard IMI vibration switch
safety control system that provides protection for
the vital crusher components. There are a number The IMI vibration switch comes standard with all
of safety features that are equipped standard with CEMCO crushers. They are classified as three (3)
CEMCO VSI Crushers. When a safety element is inch per second (IPS) range of movement models.
activated or “tripped”, a corresponding function The vibration switch has an internal and an external
light on the lube oil panel (Vibration, Oil flow, reset button. The vibration switch operates on
Oil level) will turn off (or on) and the crusher will 120Vac power, it also has a 4-20mA output point to
shut down to prevent damage to the crusher and power to vibration display on the interlock panel.
its vital components.
The IMI vibration switch also has two relays that
The interlock panel also provides electrical “alert” and/or “alarm” the interlock panel based
connection points to attach all of the field wiring on vibration values from the vibration sensor. The
safety devices. This provides a single power “alert” relay will turn on a light on the lube oil panel
source for all the field devices such as the oil to warn the operator that an elevated amount of
system motor, oil flow meter, oil level switch, vibration is occurring with the crusher. The “alarm”
crusher vibration switch with warning relay relay will activate an electrical “shut down” mode
(Alert) and vibration shut down (Alarm). in the interlock panel to protect the crusher and
prevent any damage. Both the “alert and “alarm”
The interlock panel also includes both a “pre- relays need a120 Vac power source to operate
lube timer” that ensures lubrication to the crusher correctly. This power source can be provided by
pedestal for three (3) minutes prior to the crusher “jumping” the common power block to the “Alert”
22
Interlock Control Panel
and the “Alarm” relay connection points on the
vibration switch. The signal can then be connected
back to the interlock panel via terminals T-16 /
T-17.
Internal wiring for vibration switch
4-20mA DISPLAY
The 4-20mA display gives the user a numerical
value of the vibration that is occurring within
crusher.
4-20mA vibration display
This numerical value will allow the operator to
adjust the crusher vibration switch (Alert & Alarm)
to optimal settings for the crusher and structure
during operation. Adjustments need to be made
for different materials and locations. The user
can also record the vibration readings to trend
maintenance for replacement of wear parts on the
crusher. It can also be used to see if a warning
light was due to some surge of material going in to
the crusher, or if the warning is something worse
and the operator needs to shut down the plant to
see what the problem is.
ELE-365 Alert and Alarm Lights
The vibration display is connected in the vibration
switch by the use of shielded cable to the 4-20mA
terminal. The shielded cable needs to be run
in a separate conduit or raceway to prevent
Electromagnetic Interference (EMI) from other
electrical sources. In certain installations a filter or
“ferrite suppression cores” may be needed if the
display is not reading correctly due to the distance
from the vibration switch to the interlock panel
location. This will need to be determined at time
of installation.
Listed on the next table are a scale of mA to IPS
for a 3 IPS switch and a percentage of the IPS to
mA.
23
 Interlock Control Panel
The 4-20mA is a value of the IPS of vibration switch
ALERT AND ALARM CONNECTION
RELAYS
The vibration switch has two relays to warn (Alert)
and to shut down (Alarm) the crusher. The warning
relay (Alert) will turn on the orange “Vibration
Alert” light mounted on the interlock panel.
The shut down relay (Alarm) will turn on the red
“Vibration Alarm” light and disable the crusher.
The “Alert” relay needs to be connected terminal
T16 in the interlock panel. The “Alarm” relay
needs to be connected to terminal T17 in the
interlock panel.
alert and alarm relay diagram
24
DIP SWITCH & POTENTIOMETER
POSITIONING
The dip switches, located inside the vibration
switch in the lower area of the housing, need to
be placed the LAT, EN, EN & OFF (All down)
position.
all dip switches in the down position
The “alert” and “alarm” set points are adjusted
via the single turn potentiometers.
potentiometers for Alarm and Alert
The potentiometers are used to adjust the
vibration switch sensitivity and the time delay
(TD) allowed in that movement for the “alert”
and “alarm”. The alarm relay is set using the
first potentiometer labeled Alarm SP and the alert
relay is set with using the third potentiometer
labeled Alert SP. The alert relay trips when
the set percentage of the alarm value has
been reached. Time delays for both functions
are controlled using the second and fourth
potentiometers labeled Alarm TD & Alert TD
Example: The alarm is set for 1 IPS and the alert
is set for 50% for 10 seconds then the warning
- alert light will turn off at ½ IPS at 10 seconds
warning you that the crusher has met a value of
 Interlock Control Panel
vibration that should be inspected to protect the
crusher’s vital components.
If both criteria’s for alert and alarm are met at the them before starting the crusher up and doing more
same time, then both actions will occur. These
alerts can inform the operator that wear parts
need to be replaced due to wear, or tramp iron
could be entering the crusher, or there is a feed
material surge in the system.
VIBRATION SWITCH TEST AND RESET.
The vibration switch also has both a “test” and
“reset” button located in the right side of the case. LUBE OIL PANEL POWER SUPPLY
The top right is the reset and the bottom right
button is utilized to test the vibration switch.
There are three (3) LED lights in the vibration
switch case. The two upper left lights are the
“alert” and “alarm” the lower right lights is
power. Both the alert and the alarm lights should
be off unless the switch has been tripped or the
test button has been used.
TEST: The test button is utilized to verify that
the vibration switch is functioning correctly and
to simulate an alarm / alert trip. By pressing the
test button you will activate both alarm / alert
values at the same time simulating a “trip”.
RESET: The current vibration switches has
an external reset button. If the alarm or alert
values are activated the switch needs to be reset
at the crusher. This is so that the operator will go
and check the crusher for any problems and resolve
damage to the crusher or its components.
Older model (3IPS) vibration switches have an
internal reset button. The vibration switch must be
physically opened to access the rest button and reset
the vibration switch. If you utilize the test feature be
sure to reset the vibration switch before you attempt
to operate the crusher.
The ELE-354 oil lube panel has a 480Vac to 120Vac
transformer supplied in to the lube panel box to
power the field devices. The transformer uses a
FLM-6/10 time delay fuse.
The red terminal blocks are 120vac and white
terminal blocks are your neutral 120v power supply
for the field devices. There are also terminal blocks
for each phase of the 480 Vac to use for starting the
optional oil cooler and/or oil heater.
When wiring the field devices to the interlock
panel you will supply the devices power from
the red terminal blocks to the device and your
neutral/ control wire back to the corresponding field
terminal.
25
 Interlock Control Panel
Example: oil level switch takes a 120vac from the
red terminal block to one of the Blue wires. The
other blue wire will become #14 and you will run
a line back to Terminal-14 in the field terminals.
When the oil level is made the contact will close
signaling back to the relay.
TERMINAL LISTING
(Terminal 14) Oil Level, (Terminal 15) Oil Flow,
(Terminal 16) Vibration Alert (Terminal 17)
Vibration Alarm, (Terminal 18) Oil Cooler 86°F,
(Terminal 19) Oil Heater, and (Terminal 21) high
temp warning 178°F.
(Terminal 66-67) are for the Soft Start or a VFD
remote start control wires. ( if you have a V-Twin
crusher see dual drive wiring schematics, a DPDT
relay will need to be added to start both VFD’s )
VARIABLE FREQUENCY DRIVE (VFD) OR
SOFT START OPERATION
A VFD or soft start control is required to
correctly operate / start the VSI crusher motor.
The blue terminal blocks are controlling
connection points for use with a Variable
frequency drive (VFD) or a soft start to properly
control the crusher motor.
CEMCO can supply Danfoss VFD or World
Wide soft start Automation Drives. When using
a CEMCO supplied Danfoss VFD to start the
crusher motor, the lube oil panel control wires
labeled 66, 67 must be connected to terminal
12.18 of the VFD. This VFD wire connection is
required for the proper start / stop function and
operation of the crusher motor. If you chose to
26
supply your own brand of VFD or soft start refer
to the manufactures service manual for proper
electrical connection locations.
CEMCO crushers are directional specific, when
starting up a new crusher or doing any sort
of electrical modification to motors on and existing
installation, ALWAYS CHECK THE DIRECTION OF
ROTATION. Failure to do so will result in crusher
damage and will void CEMCO warranty.
V-TWIN CRUSHER DUAL DRIVE WIRING
SCHEMATICS
If you are using the interlock control box with a
dual drive V-Twin crusher, you will need to add a
DPDT relay to start both drives.
* See Schematics for suggested wiring. Each plant
and local code has its own specific requirements
that need to be accounted for. This is a suggested
schematic, Always refer to local codes and plant
requirements and always use licensed electricians. *
Dual drive wiring diagram
CEMCO recommends using DanFoss Drives, if
you choose to use a DanFoss Drive, the following
parameters will need to change to use the DanFoss
VFD relay. Go to Parameter 5-40 and change the
setting to “9 Alarm”. Do this on both drives. This
will shut down both drives and force the user to fix
the alarm from the tripped drive. {a copies of this
schematic is are in the back of this manual and in
the control box as well}. If using another brand
drive or soft start check with that manufacturer to
see how best to use its spare internal relay.
Interlock Control Panel

27
 Interlock Control Panel

28
Interlock Control Panel

29
 Lid Operation and Maintenance
INTRODUCTION 4. Operate the lid jack. Raise the lid until the feed
Lid liner castings protect the inside of the crusher tube liner clears the tub.
lid from the corrosive effects of the material being If you notice any resistance, STOP and
crushed. The adjustable feed hopper extends through look for any obstacles which may be causing
the lid to just above the rotor. The lid with its liners the resistance.
and feed hopper and whatever rock collects on top
of it comprises a significant amount of weight. A
hydraulic ram cylinder and hand pump are used to
raise and lower the lid. CEMCO offers an electric
hydraulic pump option. Camlocks around the lid
perimeter hold the lid secure during crushing. An
inspection door on the lids of some crushers provides
quick limited access.
OPENING THE LID
Always make sure the power is locked
in the “OFF” position before opening the
crusher lid or inspection door. Make sure there is
enough clearance for the lid and feed hopper. Never Electric hydraulic pump unit
open a crusher that is not secured to level base or
foundation. The weight of some lid/feed hopper 5. Simply push on the lid sideways to pivot it out
assemblies may be enough to tip the crusher if the of the way.
lid swings out too far. 6. Gently release the ram pump pressure and lower
1. Remove excessive rock and debris from the lid the lid onto a block, post, or obstacle. On a trailer
before opening. The bare lid is designed to remain mounted portable plant, rest the lid on the lid
level during opening and closing. support post.

2. Remove the detention pin from each camlock.

Lid resting on lid support post, portable unit

Unlatching camlock The lid must be supported when the

3. To unlatch the camlocks, lift out and up on the
camlock handles. Pivot the camlock eyebolt away
from the lid. Repeat for all the camlocks around
the lid perimeter.
30
crusher is open. Never perform maintenance on
or around the crusher if the lid is supported by hy-
draulic pressure only.
CLOSING THE LID
Lid Operation and Maintenance
5. Install the detention pins.
Keep all hands, fingers and obstacles
out of the way while closing the lid.
1. Rotate the lid so it is directly over the tub and
aligned with the lid lug that is opposite the lid
lifting mechanism.
2. Slowly unscrew the pressure relief screw to re-
lieve the pressure in the ram pump and lower the
lid into the proper operating position.

Camlock in lid slot Not seated properly

Lug aligned with lid slot

Camlock too loose (note gap), too tight

Note: If you have a model made earlier than 2000, then your
camlocks are fitted with the long hexagonal nuts on the end
instead of eye nuts . If you have T-Screws or IDR-12-EYE,
you may want to contact us if you would like to replace these.

Relieving ram pump pressure

3. Flip all the camlocks up into the lid slots.
4. Latch the camlocks. The force required to tighten
the camlock should be between 60 and 80 lbs.
If any camlock does not securely contact the
lid or is unusually difficult to latch, it may need
adjustment. To adjust a camlock, screw the eye
nut at the end of the camlock eyebolt clockwise
to tighten or counterclockwise to loosen.
31
 Lid Operation and Maintenance

Properly installed lid, Ready to crush!

Inspection door closed
USING THE INSPECTION DOOR
REPLACING LID LINERS
Always make sure the power is locked
Lid liners are the castings which protect the un-
in the “OFF” position before opening the
derside of the lid from wear. In most applications
inspection door. Never operate a crusher with the
lid liners will last a couple of years. Inspect the
inspection door open. Be sure to replace the in-
lid liners and plow bolts weekly and replace them
spection door with the safety bar securely installed
when any part of the liner is reduced to 1/8” thick
TO PREVENT THE DOOR FROM OPENING
or less. Always use new grade 8 plow bolts when
DURING OPERATION, OR FALLING INTO
replacing lid liners. EVEN THOUGH LID LIN-
CRUSHER.
ERS ARE CASTINGS, TORQUE LID LINER
The lids of larger crushers include an inspection PLOWBOLTS TO THE SPECIFICATION FOR
door for quick visual access to the tub. An operator MACHINED PARTS.
needs to check the clearance between the feed tube
In dry materials like a very dry sandstone, the plow
and rotor and inspect material packed in the rotor.
bolt heads may wear quicker than the casting they
To remove the inspection door, loosen the T-screws,
support. If they wear enough, the casting may fall off
slide out the safety bar, lift the door out of its portal
into the crusher. If the plow bolt heads show excess
and set aside. Replace the door when finished.
wear, replace them.

Inspection door open

Lid liners

32
Lid Operation and Maintenance
1. Raise the lid and support it. perfectly acceptable to remove the covers and rotate
the bushings in place. It is also acceptable to apply
2. Remove the nuts on top of the lid. The lid liners
lightweight oil to the pins before inserting them into
should fall off as the bolts are removed. If you
the urethane although this may not be necessary.
are replacing just the fasteners, replace them one
Do not immerse the bushings in solvent or allow
at a time to avoid removing the casting.
chemicals or cleaners to pool around the urethane. If
3. Install the new liners with new fasteners. the urethane comes in contact with a solvent, simply
wipe it with a clean rag.
4. Make sure there is still good lid clearance over
the crusher tub with the new castings. 1. Lower the lid and rest it on the tub.
2. Remove the bolts that hold the astralloy taper
pins to the bracket on the lid gusset.
ADDING HYDRAULIC JACK OIL
The lid lift hydraulic oil level should be checked at
least every six months or if the pump quits work-
ing. Decreasing pump performance is indicated by
more pump strokes (more time for an electric pump)
required to raise the lid. Drastically reduced perfor-
mance may indicate a hydraulic leak somewhere in
the system. Inspect all the hoses and fittings. Look
for evidence of leaks and make any necessary re-
pairs.
Follow these steps to add hydraulic oil
Use AGMA 1 ISO 46 or standard hydraulic jack oil.
Astralloy taper pins
1.Retract the cylinder. Overfilling is hazardous, fully
retract cylinder before adding oil. 3. Thread the bolts into the tapped holes on the taper
pins. Tighten the bolts evenly to dislodge the pin
2.Clean the area around filler cap. Remove the filler
and remove it.
cap and position the pump with the head down
and filler hole up. 4. Once both pins are removed, use the hydraulic
pump to raise the arm just enough to clear the lid.
3. Insert a clean funnel with a filter into the filler
hole.
4. Fill the pump with a high grade, approved hy-
draulic oil.
5. Place the pump on its base without the filler cap
installed and drain excess oil.
6. Test the sytem performance before putting the
crusher back into service.
REPLACING THE URETHANE BUSHINGS
CEMCO model 80 and model 96 crushers utilize ten
urethane bushings to dampen the vibration between
the crusher and the lid lift apparatus. Over time, the
urethane bushings may “wallow” to one side. It is
33
 Lid Operation and Maintenance

Raise the lift arm just enough to clear the lid
5. Remove and replace the urethane bushings.
Urethane bushings installed in the arm and base
8. Reinstall all the covers. Use 3/8 by 1 Cap screws
with lockwashers.
DURING CRUSHER OPERATION
There should be no pressure in the hydraulic system
during crusher operation. Any pressure in the system
will diminish the dampening effect of the urethane
bushings. It is important to inspect the entire lift
linkage after the crusher is operated. It is also a good
idea to check all the fasteners that hold the covers in
place at each pin location. Periodically remove the
covers and inspect the bushings. Models 80 and 96
have urethane bushings.

Urethane bushings installed in the lift arm tips

6. Lower the arm back down to the lid and install
the Astralloy taper pins back in their holes. For
final assembly, tap the taper pin with a brass drift
to seat it into the taper. Tighten the bolts to hold
the pins in place.
7. Remove the covers at the pin locations on the arm
and lift base to access the remaining bushings.
Sometimes the bushings are easy to remove. It
may be necessary to tap the pin out a few inches
on either side to remove and install the bushings.
Using a prybar, it is possible to raise the arm just
enough to remove the weight from the long rear
pivot pin. As long as there is no pressure in the
hydraulic system, it is easy to replace the bush-
ings at the upper and lower ram pin locations.

34
35
 Feed Hopper Adjustment and Maintenance
INTRODUCTION 1. Check the lid screws with a wrench, they should
be tight.
Feed hopper liners are trapezoid shaped plates which
protect the walls where feed material deflects into 2. On some crushers you can look through the ac-
the hopper. Attached to the feed hopper tube is a cess door to verify the feed tube liner is set to the
feed tube liner which directs the material into the correct depth and centered above the rotor.
SuperChipper™ tube flange or onto shoe table.
To maintain proper material flow as the feed tube
length decreases due to wear, the hopper is adjusted
lower. The feed tube liners need replacement when
the maximum adjustment is reached (the hopper is
as low as it can go).
REPLACING THE FEED HOPPER LINER
Replace the feed hopper liners when they wear
through and the hopper starts to appear behind
them. Simply remove the three cap screws, lift off
the plate, and replace it. Most likely the cap screws
will need replacement also.
Feed tube liner viewed through access door.
Center the feed tube liner inside a SuperChipper™
tube flange or above a shoe table feed disk by loos-
ening and tightening opposite lid screws
For SuperChipper™ Rotors, the feed tube should be
inserted to 1/2 inch below the top of the tube flange.
Reposition the feed tube when the liner wears to 1/2
inch above the top of the tube flange.

INITIAL
POSITION 1/2 IN.
Feed hopper liner
ADJUSTING THE FEED TUBE DEPTH
An upper feed tube collar clamps to the feed tube WORN
with three or four square head set screws with lock- 1/2" ABOVE
ing nuts (collar screws). A second set of screws and TUBE FLANGE
locking nuts (lid screws) guide the feed tube where
it penetrates the crusher lid. The end of the feed tube
must be set to the proper depth and concentric with
the tube flange on a SuperChipper™ rotor. To adjust
Feed tube placement within 1/2 inch of the top of
the feed tube depth for the Model 35:
the tube flange for SuperChipper™ Rotors
Collar screws and lid screws
For impeller shoe tables, the feed tube should be
inserted to 1/2 inch below the shoe tops. Reposition
the feed tube when the liner wears to 1/2 inch above
36 the shoe tops.
Feed Hopper Adjustment and Maintenance
REPLACING THE FEED TUBE LINER

1/2 IN. Never change the feed tube liner from

below the crusher lid. Always remove
the hopper and feed tube liner from above.
Change the feed tube liner on the ground or
in the shop.
The feed tube liner installs in the feed tube
through four J-shaped slots. Once installed,
1/2 IN. the tabs cut from the slots are tack welded
back in place with short, low penetration
welds. To remove the feed tube, grind off the
welds and remove the tabs. Insert the new feed
tube liner and tack weld the tabs back in place.
Feed tube placement for Impeller Shoe Tables
NEW STYLE FEED HOPPER
ADJUSTMENT FEED TUBE
TAB
CEMCO introduced a new feed hopper in 1997. It
adjusts up and down by turning a couple of large
ACME thread screws. Follow these instructions to
raise and lower the hopper.
FEED TUBE
1. Loosen the lid screws. LINER

2. Use the wrench provided to rotate the adjustment

screws. Turn the screws clockwise to lower the Tab mount feed tube liner
hopper and counterclockwise to raise the hopper.
If the hopper needs to move a large distance,
alternate between screws by giving one a turn
then the other a turn.
3. Secure the feed tube in position and center it in
the rotor by tightening the square head lid screws.

Tab removed Tab tacked in

place

New style hopper adjustment 37

 Feed Hopper Adjustment and Maintenance
EXAMPLES OF WHAT NOT TO DO
The feed tube or feed tube liner directs material
into the crusher rotor. Proper maintenance and
adjustment maximizes casting life and results in
more effective and efficient crushing.
Excess hopper liner wear or feed tube liner wear
may be the result of the material falling too far
before it enters the hopper. Sometimes breaking
the fall with chains or metal obstructions will
reduce hopper liner and feed tube liner wear.

This upper ramp was in the same rotor as the

tube flange pictured above.

Non square feed tube liner improperly directs

material into the rotor. This results in excess
tube flange and upper ramp liner wear.

The feed tube liner above caused excessive tube

flange wear. This tube flange lasted only 16
hours.

38
 Routine Operation
INTRODUCTION
These are the guidelines and instructions for normal
day-to-day crusher operation for a CEMCO electric
drive Turbo impact crusher.
ELECTRIC DRIVE PRE START
INSPECTION
Failure to follow these pre-start inspec
tion guidelines could result in personal injury
or crusher damage.
1. Check the oil tank level/temperature gauge. It is
simply a glass bulb with a thermometer inside.
The bulb should be full of oil. Tight camlock Loose camlock
7. Check the electric motor vent screens. They
should be clear to provide maximum air flow.

F C
8. Account for all personnel. Everyone should be a
220
100
safe distance from the crusher. Sound an all clear
start up signal.
200
90
180 80
160 70
140 60

9. A single stage manual pump is used for lid lifting.

120 50

100 40
30
80
20
60

10. An electric lid pump is optional.

10
40
0

ELECTRIC DRIVE START UP

1. Start the oil pump motor and let it run for 2-3
minutes. The oil pressure gauge should read 20
Full tank level psi or greater. It may read full scale immediately
at startup. The flow meter should indicate positive
2. Check the drive belt tension with belt tension tool
flow.
provided with crusher, refer to the belts section
of the manual for specifications.
3. Check the drive belt condition. The belts should
not have any nicks, tears or frayed areas.
4. Check the castings for wear to be sure none of
them have exceeded their maximum wear condi-
tion.
5. Check the lid camlocks to be sure they are seated
in the lid slot and secure.
6. Check the lid lift ram cylinder. It should be under
enough pressure to keep the lid lift linkage from
vibrating. If not, close the pump pressure relief
screw and give the pump a few strokes. Not re-
quired on nylon bushed lids. Full positive pedestal oil flow

39
 Routine Operation
3. When rotor rotation ceases, 5 to 6 minutes, shut
80
off the oil pump motor.
60 100

600
400

40 800 120

200

20 1000 140

0
kpa
0 160
psi

Normal pedestal oil pressure is generally between

10 and 70 psi, but can sometimes exceed that.
2. Turn on the main power to the crusher.
3. Introduce feed material. Do not exceed the feed
material size and feed rate listed in the CRUSHER
SPECIFICATIONS section.
4. Check for crusher vibration at start up and periodi-
cally during operation.
DURING CRUSHER OPERATION
While the crusher is operating, closely monitor the
gauges. This is especially important just after starting
up and during the first 100 hours of break-in operation.
Observe the following:
1. The oil pressure commonly remains between 10
and 70 psi, but can exceed that.
2. The flow meter should continue to indicate full
positive oil flow.
3. The oil temperature should not exceed 194°F (90C).
In high temperature enviroments, an oil cooler is
recommended.
4. Observe the crusher for signs of vibration. This
most likely indicates an unbalanced rotor.
ELECTRIC DRIVE SHUT DOWN
1. Stop the feed and wait for the crusher to finish
crushing.
2. Shut off the main power switch.

40
 Preventative Maintenance Form
This form is intended to be a training tool and can be modified by customer

SAFETY FIRST!

If energy lock out is necessary, Energy Lock Out Plan must be followed.

Site - Operation UNIT

PM INTERVAL DUE HRS
DUE AT: (HOURS) DATE

INTERVAL: Daily CIRCLE INTERVAL: 480-Hour 1440-Hour

O.K. Repair Priority O.K. Repair Priority
Inspect upstream magnet (if equipped) Repeat daily, 40-hour, and 250-hour
 ensure magnet is working properly PM service requirements
 ensure metal detector is working properly Pull oil sample from return line for analysis
Inspect drive V-belts * Change lube oil system oil
 for damage * With routine sampling and analysis showing pedestal oil
 for proper tension is retaining high quality, oil change intervals can extend
 for alignment to 1500hours maximum.
Check to ensure properly secured:
 inspection door CIRCLE INTERVAL: 760-Hour 1280-Hour 1760-Hour
 drive belt guard O.K. Repair Priority
Verify that all liners are tight Repeat daily, 40-hour, and 240-hour
 no bolts missing, damaged, or loose PM service requirements
Verify proper feed distribution
Inspect pedestal lube oil system
 for leaks and proper oil level
Tank capacity : 28 gallons
Verify proper oil level & flow
Grease pedestal (20 pumps min per shift) INTERVAL: 1000-Hour
O.K. Repair Priority
INTERVAL: 40-Hour (Weekly) Repeat daily, 40-hour, and 240-hour
O.K. Repair Priority PM service requirements
Inspect tub & lid liners for wear Pull oil sample from return line for analysis
Inspect motor cooling fins for buildup Change oil & filters
 clean fins as needed
Inspect Supperchipper for wear (if equipped)
Daily untill wear life is determined.

Inspect Impeller Table for wear (if equipped)

Daily untill wear life is determined. INTERVAL: 2000-Hour
O.K. Repair Priority
INTERVAL: 100-Hour Repeat daily, 40-hour, and 240-hour
Oil filter for lube oil system. PM service requirements
INTERVAL: 240-Hour Pull oil sample from return line for analysis
O.K. Repair Priority Change oil & filters
Repeat daily and 40-hour PM Inspect crusher thoroughly for wear
service requirements Replace as needed:
Verify RPM if possible.  pedestal, table, shoe or rotor,
Inspect drive and driven sheaves tub/crushing chamber, etc.
 inspect for wear and buildup Grease motors
Inspect mainframe crusher base bolts Check motor tag for grease schedule and amount.
Inspect feed tube for wear.
COMMENTS:

IMPORTANT: PLEASE NOTE!

When you are performing PMs, please remember that all PMs are built upon each other. For example, when you
are performing a 500-hour PM, you still must perform all preceding PMs (daily, 40-hour/weekly, etc.) and all
related service inspections and requirements first, ALONG WITH the 500-hour PM that is your current task.

Version 2a 04/23/2010 Vertical Shaft Impact Crusher Crusher Preventative Maint Checklist.xls

41
 Lubrication Guidelines
INTRODUCTION Tighten according to the instructions with the filter.
This section describes how to change the oil and RECOMMENDED FILTERS
grease the crusher pedestal.
Fram P7037
The pedestal oil filter should be changed every LHA SPE-15-10
100 hours of operation. The pedestal oil should be NAPA 1551
changed every 500 hours of operation. Use only WIX 51551
Chevron EP2 ISO 68 Gear Compound (oil) or equiv-
OIL CHANGE
alent and any of the recommended filters. CEMCO
recommends changing the oil while it is hot. Oil 1. Remove the oil drain plug and drain the oil. Fol-
system capacities vary between 30 and 40 gallons. low EPA recommendations for used oil.
The oil tank holds approximately 28 gallons.
2. Replace the drain plug.
Mounting the oil tank below the pedestal level fa-
3. The filler cap acts as a vent. Every 100 hours, it
cilitates a gravity return.
is a good idea to remove the filler cap and chain
at the split ring and immerse and rinse the cap in
solvent to clean the filter inside the cap.
Lock out power to the crusher while
changing the oil. Pedestal damage will occur 4. Add new oil until the oil level bulb on the tank
quickly if the bearings are not bathed in oil while reads full.
the crusher is running.
5. Replace the cap.
FILTER CHANGE
The oil filter is mounted on the oil tank assembly
next to the oil pressure gauge and flow meter.

Oil tank assembly, filter, and gauges

A hydraulic pump only pumps flow; it does

not pump pressure.
Simply remove the old filter and replace it with a
new filter. A standard filter wrench may be necessary.
Oil drain plug

42
Lubrication Guidelines
PEDESTAL GREASE
The upper pedestal seal should be greased daily for the prevention of contaminate material or water
from entering the upper shaft area. There is a grease zerk at the base of the crusher near where the
frame meets the tub. Apply an adequate amount of grease through zerk to ensure positive grease flow
through labyrinth seal. A positive grease flow is new grease flowing out and around the circumfrence
of the top of the pedestal below the hub. Visually check for fresh grease in this area prior to operation.
Use a grease that is waterproof, CEMCO recommends Chevron Delo EP-2 or equivalent.

Upper seal grease zerk

LUBRICATION RECORDS
The TURBO VSI LUBRICATION RECORD on the last page is a good format for keeping track of
lubrication. It also lists the recommended lubricants, filters and change intervals. Simply write down
the date and hour meter reading in the first two columns. The person performing the maintenance
should write his/her initials in the third column. The oil and filter change records include a row to
“carryover” information from the previous sheet. Write the starting date and ending date for the sheet
in the blanks provided in the lower right corner. Save all service records. A loose copy of this form for
you to photocopy is provided with the enclosures.

43
 Lubrication Guidelines
PEDESTAL SCHEMATIC
This cutaway schematic illustrates how oil and grease are delivered to the bearings and labyrinth seal re-
spectively to prevent contaminate material from entering the upper shaft area.

LABYRINTH
SEAL

OIL PASSAGE GREASE PASSAGE

44
Standard Oil System Schematic
INSTALL OIL TANK BE-
LOW OIL LEVEL LOW CRUSHER;
SWITCH(TEMP) MINIMUM: 2”
MAXIMUM: 10’

PRESSURE METER MOUNT REMOTE (DO

80

60 100

600
400

40 800 120

200

20 1000 140

0
kpa
0 160
psi

NOT MOUNT TO CRUSH-

¡F

220
200
180
160
140
120
100
¡C

100
90
80
70
60
50
40
30

OIL LEVEL GAUGE ER STAND AS VIBRA-

TION FROM CRUSHER IS
80
20
60
10
40
0

DETRIMENTAL TO PUMP
FLOW METER
¨

AND OIL TANK LIFE)

FLOW METER
With Electrical Signal

FLOW DIRECTION
RATE

.5
1
2
3
4
5

GPM

3000 PSI MAX

OIL
LPM
RATE

12
16
20
4
8

FILTER

PEDESTAL

80

60 100

600
400

40 800 120

200

20 1000 140

0
kpa
0 160
psi

FLOW METER
With Electrical Signal

PRESSURE
FLOW DIRECTION
RATE

.5
1
2
3
4
5

GPM

3000 PSI MAX

OIL
LPM
RATE

12
16
20
4
8

Oil Level
Switch RETURN
(Temp)
¡F ¡C

220
100
200
90
180 80
160 70
140 60
120 50

100 40
30
80
20
60
10
40
0

28 GALLON
RESERVOIR

PUMP

THE OIL TANK AND PUMP ASSEMBLY MUST BE INSTALLED

BELOW THE PEDESTAL TO FACILITATE A GRAVITY RETURN.
45
Recommended Lubrication & Service Schedule
* Labyrinth Seal must be greased daily during operation so that new grease is seen in the area between
the bottom of the hub and the top of the pedestal (20 pumps minimum).
* Oil Filter for main lube system: Change every 100 Hours
* Oil Change for main lube system: Change every 500 Hours (with routine sampling and analysis
showing pedestal oil is retaining high quality, oil change intervals can extend to 1500 hours)
* Micron Suction Filter OIL-00037 must be inspected and cleaned periodically.
* Refer to motor tag for grease schedule.
RECOMMENDED LUBRICANTS:
Labyrinth Seal Grease: Chevron Delo EP-2 NLGI, or equivalent.
Main Lubrication System Oil: Texaco Meropa 68, Exxon Spartan EP68, Mobil Gear 626, Dreyden EP
Gear Lube 2
Tank Capacity: 28 gallons
RECOMMENDED FILTERS:
LHA SPE-15-10, WIX 51551, NAPA 1551, FRAM P7037

ITEM FREQUENCY LUBE TYPE DATE INITIALS

Start Date:_________

End Date:__________
46
47
 Belt Maintenance and Replacement
INTRODUCTION
CEMCO crushers transmit power to the pedestal
through a V-belt drive. An opposing dual drive
crusher has two sets of belts, one for each electric
motor. A V-Twin arrangement has two sets of belts
on the same side of the tub. A diesel drive crusher
has a single set of belts from the gearbox. A properly
maintained set of belts may last a year or more. Nev-
ertheless, it is a good idea to have new drivebelts on
hand. The belt quantity and belt size for your crusher
are listed in the CRUSHER SPECIFICATIONS
section. CEMCO uses 5V and 8V belt designations.
Belts may be individual or “Powerband” style de-
pending on required horsepower transmission. See
your CRUSHER SPECIFICATIONS.
Dual drive belt arrangement
V-Twin belt arrangement
48
Worn belts are a safety hazard. Replace
worn belts before they break. Always lock out
power to the crusher before changing belts. Never
operate the crusher without all the belt guards in
place.
Never replace just one belt in a set. If you must
replace one belt, replace all the belts.
It is acceptable to replace only one powerband.
All belts are required to transmit the design torque
to the pedestal. Never operate a crusher that does
not have all the belts installed.
Changing belts is also a good time to check the
torque on the sheave mounting bolts. In some in-
stances, the significant heat generated by the friction
between the belts and the sheave may decrease the
torque on the sheave mounting bolts.
REPLACING BELTS (ELECTRIC DRIVE)
1. Lockout power to the crusher.
2. Remove the belt guards beneath the crusher and
set aside.
Loosening the motor mount bolts
3. Loosen the six motor mount bolts that hold the
motor sled to the frame.
4. Use the provided wrench to loosen the belt ten-
sion adjustment screw. Turn the screw until the
belts can be removed by hand. Remove the belts.
Belt Maintenance and Replacement
Loosening the belt tension adjustment screw
5. Install the replacement belts. It may be necessary
to loosen the belt tension adjustment screw even
more since new belts are not stretched out.
6. Tighten the tension adjustment screw until the
belts reach the proper tension.
7. Tighten the six motor mount bolts.
8. Replace the belt guards.
Properly installed belt guard
REPLACING BELTS (V-TWIN)
1. Lockout power to the crusher.
2. Remove the belt guards beneath the crusher and
set aside.
3. Loosen the six motor mount bolts that hold the
motor mount to the frame.
3a. V-Twin crushers use a 2 stage pump with a
“PUSH” and “PULL” capability.
4. Switch the lever on the hydraulic pump manifold
to “PULL.”
5. Pump the hydraulic hand pump to pull the mo-
tor sled towards the tub. Stop when the belts are
loose enough to remove from the sheaves.
6. Install the replacement belts. It may be necessary
to loosen the belt tension ram even more since
new belts are not stretched out.
7. Switch the lever on the hydraulic pump manifold
to “PUSH.”
8. Pump the hydraulic hand pump until the belts
reach the proper tension.
9. Tighten the six motor mount bolts.
10. Switch the lever on the hydraulic pump mani-
fold to the neutral position.
REPLACING BELTS (DIESEL DRIVE)
Replacing the belts on a diesel drive crusher mount-
ed on a trailer is similar but requires loosening six
motor mount bolts and six gearbox mount bolts and
sliding the entire engine and gearbox assembly on
the trailer. Photos are shown below.
Powerbands under a diesel drive portable plant
49
 Belt Maintenance and Replacement

Engine and gearbox mounting bolts

Belt tension adjustment screw

50
 Belt Maintenance and Replacement
How to Tension V-Belt Drives
General Method
Tension of the V-Belt is critical. A few simple rules about tensioning will satisfy most of you requirements.

1. The best tension for a V-belt drive is the lowest at 3. Check the drive tension periodically, thereafter.
which the belts will not slip under the higher load 4. Too much tension shortens belt and bearing life.
condition. 5. Keep belts and sheaves free from any foreign
2. Check the tension on a new drive frequently during material which may cause slip.
the first day of operation. 6. If a V-belt slips, tighten it.

Numerical Method
While designing a drive, it is well to specify data for use
in tensioning to drive. Many users of V-belt drives rely on
their experience and the above general rules for tension-
ing drives, but it has become common practice to actually
measure the tension in a drive. Numerical methods for
measuring tension have several advantages. For example,
they preventinexperienced personnel from drastically
overtensioning or undertensioning a drive, thus preventing
possible bearing or belt damage. Even with experienced
personnel, it helps the individual get a feel for the tension
needed in a particular drive. This is especially important
with modern drives, where each V-belt is rated for higher
horsepower than were previous belts. If a belt is to carry
more horsepower, it must be installed proportionally
tighter. Experience with older drives may lead to under-
tensioning of modern drives unless tension is measured
at least once to help get the feel for correct tension.
The procedure in numerically tensioning a drive is:
1. Determine the correct tension for the stopped
drive, called static tension, so that the tension
will be correct when the drive is operating.
2. Measure the static tension so that it can be set
at the correct value.

Tension Tester Method (Up to 30 lbs.)

1. Measure span length (t). belts should be tightened. If more than maximum
2. Position the lower of the two O-Rings using either of recommended deflection force, drive is tighter than
these methods: necessary.
a. On the scale reading “Deflection Inches”, set NOTE: There normally will be a rapid drop in tension
O-Ring to show a deflection equal to 1/64” per during the “run-in period” for V-belt drives. Check
inch of span length (t). tension frequently during the first day of operation.
b. On the scale reading “Inches of Span Length”,
set O-Ring to show a deflection equal to the
inches of measured span length (t).
3. At the center of span (t), apply force with Gates
Tension Tester perpendicular to the span, large enough
to deflect one belt of a multiple belt set on drive until
the bottom edge of the lower O-Ring is even with
tops of remaining belts. For drives with only one belt,
a straightedge across pulleys will assure accuracy of
positioning.
4. Find the amount of deflection force on upper scale of
Tension Tester. The Sliding Rubber O-Ring slides up
the scale as tool compresses and stays up for accurate
reading of pounds force. Read at the bottom edge of
ring (slide ring down before reusing).
5. Compare deflection force with range of forces
recommended. The Gates Rubber Company, Heavy Duty V-Belt Drive Design
1

If less than minimum recommended deflection force, Manual, Publication No. 14995-A, 1/95.

51
 Belt Maintenance and Replacement

52
 Sheaves should be
checked for wear every
time you change a belt
0

.0 0
DA

DA
7.0

º
38ºVER 7.00

38ºVER 7.00

-7
TU

TU
34

34
0-

.60
M

M
4.6
=O

=O

4
=

M=
UM

TU
T
DA

DA
DATUM=3.60-4.59 DATUM=3.60-4.59

32º 32º

Normal Sheave (Uniform Angle) Worn Sheave (Dished Out)

Indications of sheave wear include:

• Belts are turning over

• Belts wear out faster than normal
• Belts are “bottoming” out
• Belt dressing is used to quiet drive (not
enough tension or worn grooves.)
• Belts appear to be “Mismatched”

53
 Anvil Rotation and Maintenance
INTRODUCTION
CEMCO crusher and anvil ring combinations are
designed to provide the most desirable product
distribution possible. Adjusting the anvil ring up
and down positions the wear band in the anvils.
Optimum wear band adjustment increases anvil life.
Additionally, rotating the anvils 90 or 180 degrees
also increases life. If your input material or output
parameters change, it may be possible to change to
a different anvil/anvil ring combination. Increasing
or decreasing the distance material travels to impact
“fine tunes” the output size distribution.
This section describes anvil ring adjustment and 3 Position anvil ring bracket
anvil rotation guidelines. Inspect the anvil wear
frequently at first and record the service hours,
wear depth, and wear pattern. Once the wear rate is
documented, it is easy to implement an anvil rotation
and replacement schedule.
Always make sure power to the crusher
is locked off when servicing the anvil ring
or anvils.
ANVIL RING ADJUSTMENT
The anvil ring rests on three brackets around the tub
perimeter. The E-brackets have 2, 3, or 4 positions
depending on the crusher model. Lugs on the anvil
Anvil ring lug in E-bracket
ring rest in the brackets.
For initial crusher operation, position the anvil ring
to align the center of the anvils with the center of
the impeller shoes or SuperChipper™ ports.
Use extreme care when adjusting the
anvil ring. It is extremely heavy and a crane
is needed. Keep hands on the outside of the ring,
not under it.
Follow these steps to adjust the anvil ring.
1. Open the crusher lid and swing it completely out
of the way.
2. Remove the dust ring.
2 Position anvil ring bracket
3. Attach a three point chain or strap arrangement
to the anvil ring.
4. Slowly lift the anvil ring up no more than just a
few inches.
54
Anvil Rotation and Maintenance
5. Rotate the anvil ring by hand until the tabs are
directly above the new position.
6. Lower the anvil ring into the new position.
ANVIL ROTATION AND REPLACEMENT
Anvils with a square flange can be rotated four times
at 90 degrees. Anvils with a rectangular flange, tab
and pin arrangement, or tab and wedge pin arrange-
ment can be rotated 2 times at 180 degrees.

Tab and pin arrangement, 180° rotation

Square flange/shim arrangement, 90° rotation

Tab and wedge pin arrangement, 180° rotation

Rectangular flange/shim arrangement, 180°

rotation

Installing anvil pins

The anvil pins and anvil shims are usually tightly
wedged into the anvil bracket. Use whatever tools
are reasonably necessary to loosen and remove the
anvils.
55
 Anvil Rotation and Maintenance
Do not hammer on the anvils with a
steel hammer. A plastic dead blow mallet
works well. Small anvils can be lifted out and re-
moved by hand with the anvil ring still in the crusher.
For large anvils, it may be best to remove the anvil
ring from the crusher and set it on the ground upside
down to facilitate anvil removal. Replace or rotate
the anvils and reinstall the anvil ring in the crusher.
MODEL 80 ANVIL CLEARANCE
On a model 80 the clearance between anvils is so
close that the first anvil should remain loose while
the rest of the anvils are installed clockwise around
the ring. First and last anvils installed together
3. Place the last anvil in position and pivot the tab
throught the hole in the bracket. It may be neces-
sary to jockey the adjacent anvil so both anvils
can be seated into the brackets at the same time.
4. Drive the wedge pins into the tabs on the last two
anvils.

Tight clearance
1. Set the first anvil in position and loosely install
the wedge pin just enough to keep the anvil from
falling out of the bracket.
2. Install the remaining anvils clockwise around the
ring. Always install the wedge pin with the flat
side towards the bracket. Install the last anvil (Note the flat side against the
bracket)
ANVIL RING POSITIONING STRATEGY

Anvil wear patterns and rates vary widely with the
type of material and tonnage. The best anvil ring
placement and anvil rotation maximizes anvil life.
Monitor the anvil wear closely when your crusher is
new. This is the best way to develop a good rotation
and r replacement schedule.
The anvil ring also protects the tub. It has been
proven that tub life, with liners, is not more than
56 about 6 hours if the anvil ring is far enough off center
Anvil Rotation and Maintenance
to allow material to impact the tub wall.
In all cases, anvils should be replaced when the wear
depth reaches 3/4 of the total anvil thickness.

2x180° rotation on center

Wear depth, 3/4 of anvil thickness
Impeller shoe tables usually produce a narrower
wear band than SuperChipper rotors. In crushers
with impeller shoe tables, position the anvil ring
high or low so the wear pattern is slightly off center,
closer to the anvil edge than the anvil center line.
Rotate the anvils when the wear depth reaches 1/4
of the total anvil thickness.
ANVIL RING HARDFACE AND WEAR
PLATES
Some anvil rings have hardface welds at the anvil
bracket corners. Pay attention to the wear at the
hardface location. Add new hardface when the
underlying metal begins to appear. The anvil ring
does not need to be out of the crusher when adding
hardface. A good time to add hardface is when the
anvils need to be rotated or replaced.

4x90° rotation, off center

Anvil ring hardface
In crushers with SuperChipper rotors, position the
anvil ring so the wear pattern is as close to the anvil
centerline as possible. CEMCO does not recommend
anvil rotation when your crusher is equipped with a
SuperChipper rotor.

57
 Anvil Rotation and Maintenance
More recent model crushers have wear plates instead
of hardface welds. Either arrangement adequately
protects the anvil ring. Once the hardface is worn out,
wear plates may be installed. Likewise, hardface can
replace worn out wear plates.

Anvil brackets worn

Attach the wear plates to the anvil ring with tack

welds around the hole and at the edges where the
wear plates meet.
EXCESS WEAR EXAMPLES
The following photos show excess an-
vil wear or the results of excess anvil wear.
Consider them examples of what not to do. Un-
checked anvil wear results in expensive repairs or
part replacement.

Anvil worn through but caught in time to prevent

damage

58
 Shoe Table Casting Maintenance
INTRODUCTION
By design, the CEMCO impeller shoe tables are
clad in castings which wear during crushing. The
castings wear at different rates depending on their
location on the table, material feed rate, and rotor
speed. CEMCO recommends a wear monitoring plan
to maximize casting life. In a new crusher, closely
monitored casting wear is the key to developing a
cost effective scheduled rotation and replacement
strategy.
Always use proper lifting techniques. Four shoe the guidelines in this manual only. Do not reuse cast-
tables may be lifted at two points. Always use three ings if their individual weights differ by more than .05
lifting points for three and five shoe tables.
Using a casting after it has reached its
maximum wear condition creates a dangerous situation.
If the casting breaks, the sudden out-of-balance condi-
tion can ruin the entire pedestal assembly.
Use only Grade 8 fasteners when re-
placing castings.
Rotate and reuse castings according to
lbs (22.68 g)
This next section describes how to install new castings
on a bare impeller shoe table starting with the edge lin-
ers. For clarity, photos and illustrations in this section
show a shoe table out of the crusher body. Ordinarily,
castings are replaced with the table in the crusher.

Two point lift on a four shoe table

A shoe table’s high rotational speed makes it ex-

tremely susceptible to unbalanced conditions. Bare
shoe tables are balanced at the factory. A balanced
table operates smoothly and safely. When a shoe
table requires an even number of similar castings, the
castings are installed opposite each other in equally
weighted pairs. When it requires an odd number
of similar castings, all castings in a set weigh the
same. New castings from the factory are marked by
weight. A 12.73 indicates a 12 and 73/100 lb cast-
ing. ALWAYS INSTALL ROTOR CASTINGS IN
EQUAL WEIGHT PAIRS OR SETS.
CEMCO recommends that a scale be located at the
job site for weighing castings. It is useful for weigh-
ing partially worn castings and assembling complete
sets from odd castings.
Complete shoe table
The first paragraph in each subsection describes when
a casting needs to be replaced. Most castings have a
minimum allowable dimension. By monitoring the
minimum allowable dimension, a mechanic can deter-
mine when a casting should be reoriented or replaced.
Photos throughout this section illustrate the minimum
allowable dimension for individual castings.
This section is general to all CEMCO shoe tables. The
exploded diagram on the next page illustrates the ter-
minology and casting placement. Unless torque values
are given, refer to the TORQUE SPECIFICATIONS
section for general torque guidelines. Use the torque
values for castings.
59
 Shoe Table Casting Names

Feed Cone

Impeller Table Impeller

Liner Shoe

Backing
Spacer Plate

Shoe
Bracket

Edge
Liner

This diagram illustrates casting names and orientations. Refer to the assembly drawing for the exact com-
ponents and quantity used on your shoe table.
60
Shoe Table Casting Maintenance
CLEAN ALL MATING SURFACES BETWEEN
CASTINGS AND THE ROTOR. A SMALL ROCK
OR PEBBLE UNDER A CASTING OR BETWEEN
TWO CASTINGS MAY CAUSE A CASTING TO
BREAK WHEN THE BOLTS ARE TIGHTENED.
USE COMPRESSED AIR OR WATER TO RE-
MOVE DEBRIS FROM THE SHOE TABLE.
Rocks in key areas Rocks removed
EDGE LINERS
Edge liners need to be replaced when any portion
of the outside surface wears to 3/16” or less. If the
shoe table is out of the crusher, it is easiest to install
the edge liners with the table upside down. Position
the table right side up before installing the rest of
the castings.
Edge liners
Minimum edge liner thickness
1. Arrange the edge liners in evenly weighted
pairs from heaviest to lightest.
2. Distribute the edge liners around the rotor
perimeter with the matching pairs opposite each
other. Position the heaviest pair first. Position the
lightest pair adjacent to the heaviest pair. Position
the 2nd heaviest pair adjacent to the lightest pair.
Position the 2nd lightest pair adjacent to the 2nd
heaviest pair. Continue in this manner until all edge
liners are arranged around the rotor.
3. Apply anti sieze compound to the four end-
most threads on each bolt. Screw all the bolts into
the rotor but do not tighten.
4. Torque the bolts according to the torque table
at the beginning of this manual. Edge liners attached
to the rotor with three bolts need to have the middle
bolt tightened before the bolt on either side. Because
the torque on one bolt affects the torque on adjacent
bolts (in the same casting) it is important to recheck
the torque on all edge liner bolts when finished.
IMPELLER TABLE LINERS
Impeller table liners protect the bare shoe table
surface. They also ramp up just in front of the shoe
to help direct material. Impeller table liners need to
be installed before the impeller shoes. Replace table
liners when any portion of the wear pattern reaches
3/16” thick or less.
61
 Shoe Table Casting Maintenance
face is worn to 3/4” or less or cracking occurs along
the leading edge.

Install table top liners before impeller shoes

1. Clean the rotor surface and underside of the
table liners. Typical impeller shoe ready for replacement.
2. Lay the table liners in place. Many ripples indicate this shoe is crushing fine
material.
3. If applicable, fasten the lower table liners to the
rotor using flat head cap screws.
FEED DISK
On a shoe table, the feed disc needs to be set in posi-
tion before installing the impeller shoes. Some feed
discs are notched where the impeller shoes overlap.
The diagram at the bottom of this page illustrates the
proper orientation for a notched feed disc.

Typical impeller shoe ready for replacement.

Fewer ripples indicate larger material.

The impeller shoe overlaps the feed disc

IMPELLER SHOES
Replace impeller shoes when any part of the shoe
62
 Shoe Table Casting Maintenance
There are two types of impeller shoe mounts: 4. Clean off area around bracket and ramp liner,
flange mount (1) and fastener mount (2). and place new shoe into the bracket.

(1) A flange mount impeller shoe.

.Using a pinch bar to pry out a flange cast impel-
ler shoe.

(2) A fastener mounted shoe with bolt, lockwasher

and backing plate. Using a rubber mallet to loosen the impeller shoe.

FLANGE MOUNT IMPELLER SHOES

Flange mount impeller shoes have a flange cast onto
the impeller shoe. These are the most common and
simplest to install and replace.
Replacing flange mounted impeller shoes.

1. Use a pinch bar and pry upward and inward

2. Hit the the shoe with a rubber mallet to loosen it

from the bracket while prying inward.

3. After the impeller shoe and flange are free from Pull inward and up to remove shoe
the bracket, pull out and up. 63
 Shoe Table Casting Maintenance
NOTCHES ON CENTER FEED DISC
MUST BE IN PROPER POSITION FOR
SEATING THE IMPELLER SHOE.
EXTENSIVE DAMAGE WILL OCCUR
TO SHOE BRACKET IF IMPELLER SHOE
IS ALLOWED TO WEAR PAST 1/2" MIN.
THICKNESS AS SHOWN.

1/2" MIN.
THICKNESS

SHADED AREA MUST BE CLEAN FOR

PROPER SEATING OF IMPELLER SHOE.

1. Remove the old shoes by loosening the mounting

bolts from the back side of shoe bracket, then
push the worn shoes outward.
2. Inspect the mounting bolt, lockwasher and back-
ing plate (if applicable*). Replace them if they
are worn or stressed.
3. Remove sand and debris from all mating surfaces.
4. Set the new impeller shoe on the flat portion of
the table liner.

Flange mount impeller shoe table.

Fastener Mount Impeller Shoes

Fastener mount impeller shoes have a hole with he-
licoil threads instead of a flange. A 1-1/2” hex head
cap screw with a split lock washer and a steel plate
hold the impeller shoe in the bracket.

64 Fastener mount impeller shoe table

Shoe Table Casting Maintenance
Impeller shoe resting on flat liner
5. Seat the impeller shoe squarely into the bracket.
Impeller shoe seated in the bracket
6. Install the backing plates (If applicable*). Ap-
ply anti-seize compound to threads of each bolt.
Finger-tighten the mounting bolt. Be sure to
include the split lockwasher.
Finger-tighten the mounting bolt
7. Use a torque wrench and tighten the mounting
bolts to 75 ft-lbs, be sure split lockwasher is
seated flat against shoe mounting bracket.
Tighten mounting bolts with a torque wrench
Never tighten castings with a hammer
xDo not use a hammer or impact wrench to
tighten impeller shoe bolts.
* Newer models of shoe tables do not have a back-
ing plate, they are incorperated into the shoe
mounting bracket
65
 Shoe Table Casting Maintenance
SHOE BRACKET HARDFACING
Hardface welds protect the outside of the impeller
shoe brackets. Reapply the hardface when the old
welds are gone. The hardface duration depends upon
the material being crushed.

This table was destroyed when a piece of tramp

iron went through the crusher.

Hardface welds
The shoe table should be balanced to within .05
lbs. after hardfacing. If the welder uses the same
amount of welding rod on every shoe bracket, the
rotor will be very nearly balanced. Nevertheless it
is always a good idea to balance the shoe table after
applying weld.
EXAMPLES OF WHAT NOT TO DO
The crusher operator never changed the shoes on
this table. When the shoes wore away, the brackets
continued crushing material. The product size and
shape most likely changed as a result.

Failure to change edge liners and table top liners

will cause the shoe bracket base to wear away.
Notice the developing crack.

66
 SHOE TABLE CASTING CHANGE LOG
THROUGH PUT (TPH)
PRODUCT (TPH)
FEED SIZE
PRODUCT SIZE
PART QTY DATE/TIME DATE/TIME DATE/TIME TOTAL
CASTING QTY
NUMBER USED INSTALLED ROTATED REPLACED HOURS

PART QTY DATE/TIME DATE/TIME DATE/TIME TOTAL

CASTING QTY
NUMBER USED INSTALLED ROTATED REPLACED HOURS

PART QTY DATE/TIME DATE/TIME DATE/TIME TOTAL

CASTING QTY
NUMBER USED INSTALLED ROTATED REPLACED HOURS

PART QTY DATE/TIME DATE/TIME DATE/TIME TOTAL

CASTING QTY
NUMBER USED INSTALLED ROTATED REPLACED HOURS

67
 Table and Rotor Removal
DISASSEMBLY
Tables and rotors are mounted on a hub
and retained by cap screws with lock washers.
The table or rotor is located in the center of the
hub by a one eighth inch high shoulder. The hub
is retained on the main shaft by two large “AN”
type nuts. Do not remove these “AN” nuts. There
are dowel pins mounted in the top of the hub,
which fit into holes machined into the bottom
of the table or rotor. These dowel pins serve to
protect the attaching bolts from the natural shear
force generated during table or rotor rotation.
This method will allow the table or rotor to be
easily and safely removed. Do not use more
force than necessary to push and pull the table
or rotor away from the hub so that stored energy
does not cause loss of control of the table or rotor
and rigging.
Tables and rotors manufactured after July
2002 have “pusher holes” machined into the base
plate underneath the wear plates. Two ¾”x2 ½”
cap screws (not supplied) inserted into the “pusher
holes” will separate the table or rotor from the hub.
Clean threads then apply anti-seize to bolt threads
before inserting “pusher bolts”.

This diagram shows the rotor being removed with a crane

attached to the eyebolts, and bottle jacks in place. Place
two 1” x 4” cap screws through the bottom of the rotor into
Pusher bolts are 3/4” bolts that are used to push the table
the hub in the holes where the six cap screws were removed.
or rotor up off the hub. When they are screwed in even with
When the rotor comes off the hub, these screws prevent the
each other, removal is safer and easier.
rotor from popping off too far. This will prevent injuries
and damage to the crusher.

When removing a table or rotor, it must

be moved straight up off the dowel pins and hub
shoulder. Position a crane above the main shaft
and attach hooks or straps to the table or rotor. On
either side of the pedestal place two bottle jacks
so that they will be able to push the table or rotor
up off the dowel pins and hub shoulder. Placing
two 1” x 4” bolts through the rotor into the hub
(shown in diagram above) will prevent the rotor
from jumping up too far, preventing injury and
damage. Equally apply pressure to the bottom
of the table or rotor with both bottle jacks and at
Eyebolts attached to the rotor on opposite sides makes the
the same time pull up with the crane.
rotor easy to lift with a crane.
68
 Table and Rotor Removal

Lifting the rotor slowly with a crane connected to the eybolts.

ASSEMBLY

Thoroughly clean the hubs top surface. Insure

that shouldered area is clean and free of burrs. Check
that all dowel pins are at correct depth (appx.3/4”)
and that top radius on the pin is free of burrs. Clean
threaded holes in top of hub.

Clean bottom of table or rotor including the

inside diameter of bottom plate. Lower table or rotor
onto hub and align with dowel pins. Watch for debris
falling onto hub top surface while lowering table or
rotor. Install cap screws and lock washers through
table or rotor into hub. During the first tightening
sequence use a hand ratchet to tighten cap screws.
Always use “STAR” pattern to tighten table or rotor
mounting bolts. After hand tightening cap screws
place a welding rod or other suitable straight edge on
top of adjacent anvil, extending out over the outside
diameter of the table or rotor and manually rotate
table or rotor to check that it is set squarely on the
hub. After being sure that table or rotor is positioned
correctly on hub use a torque wrench to tighten cap
screws. Proper torque specification is in the service
manual. Check installation again with straight edge.
After installing a rotor, and before starting normal
feed, deposit a bucket of “fines” on the feed belt in
order to pack the rotor pockets. This insures that the
rotor will be balanced at start up. Start crusher, check
for vibration and check AMP meter. Start the feed
belt and check the crushers’ operating condition.
69
 Interior Crusher Maintenance
INTRODUCTION
Most surfaces inside the crusher tub and supporting
framework (channels) are subject to wear from the
material passing through the crusher and must be
protected. Tub liners protect the sides of the tub.
Channel liners protect the sides of the channels.
Because the channel liners are a few inches taller
than the channel they protect, material builds up on
top of the channel and protects it from erosion. The
installation and maintenance of the lid liners which
protect the inside of the lid is discussed in the LID
OPERATION AND MAINTENANCE section. A
pedestal shroud, while not a casting, causes material
to build up around the base of the pedestal housing
to protect it.
Tub liners
Channel liners, looking up from below
70
Pedestal shroud and channel liners
Interior castings wear at very different rates depend-
ing upon their location in the crusher, material hard-
ness, material feed rate, and even anvil ring position.
Whenever the crusher is open it is a good idea to
inspect the interior and make sure all the liners are
intact. Interior liners will last several months or even
years. Some may work for the life of the crusher.
Channel and tub liners are installed with plow bolts
inserted from the inside of the crusher facing out.
The rows of nuts and lock washers visible on the tub
exterior identify the location of the tub liners on the
inside. If any nuts on the outside are gone or a bolt
appears loose, investigate that location inside the
crusher and repair or replace the casting.
SPECIAL TORQUE CONSIDERATIONS
Always use new grade 8 plow bolts when replac-
ing tub liners and channel liners. EVEN THOUGH
TUB LINERS AND CHANNEL LINERS ARE
CASTINGS, TORQUE THE PLOWBOLTS TO
THE SPECIFICATION FOR MACHINED PARTS.
TUB LINERS
Replace tub liners when they break or when the
edges start to disintegrate and expose the tub wall.
CHANNEL LINERS
Replace channel liners when they break (very un-
common) or when the edges start to dintegrate and
expose the channel or when the upper lips are no
longer tall enough to contain material on top of the
channel.
Interior Crusher Maintenance
PEDESTAL SHROUD
Ordinarily the pedestal shroud does not need re-
placement. In some materials however, it may wear.
Replace the pedestal shroud when the pedestal
housing starts to become exposed due to lack of
material build-up.

This pedestal shroud was left in the crusher too

long.

These tub liners should have been replaced long

ago. Luckily the tub wall is still in good shape.

71
 Sheave Replacement
INTRODUCTION
The crusher drivetrain includes sheaves on the
pedestal shaft and on the electric motor shaft(s)
or diesel engine gearbox shaft. The sheave size is
determined at the factory based on the required
rotor rpm’s which yield the desired product
gradation. Ordinarily, sheaves should have long
life. However, pedestal disassembly and motor
replacement require sheave removal. Adjusting
the rotor speed requires changing either the ped-
estal or drive sheaves or both. Always make a
measurement to locate sheaves before removal.
Whenever possible, leave the bushing on the
shaft. If you must remove the bushing, measure
its location. If you are changing sheaves, as long
as the overall sheave height does not change,
the bushing location should not change and the
old bushing can be reused. A dramatic sheave
change may require a new bushing.
SHEAVE REMOVAL
This procedure is the same for all the pedes-
tal, electric motor, and diesel engine gearbox
sheaves.
Always lock out power to the crusher
before working on the drivetrain. It is easiest to
remove the pedestal sheave while the pedestal
is out of the crusher. Otherwise, be extremely
careful when removing the sheave, especially if
the pedestal is in the crusher. A strap or chain ar-
rangement should be used as a safety to catch the
sheave and bushing in the event they come off
the shaft sooner and more easily than expected.
1. Measure the sheave distance from the underside
of the crusher frame. You will need this measure-
ment when reinstalling the sheave.
2. Loosen all the bolts that attach the sheave to the
bushing and remove all but two of them.
72
Measuring the sheave location
3. Clean out the threaded removal holes in the
sheave.
4. Thread the sheave bolts into the removal holes.
Screw them in until they contact the bushing
behind the sheave. (A few drops of oil should
make them turn easier.) Continue to screw them
in evenly until the sheave breaks away from the
tapered bushing. This is where the force of the
falling sheave may cause the bushing to break
away from the shaft bringing the bushing and
sheave down together. USE A SAFETY CHAIN!
5. Assuming the bushing is still attached to the
shaft and the sheave is loose from the bushing,
unscrew the remaining bolts and carefully lower
the sheave away from the crusher.
6. If the sheave bushing needs to be removed, mea-
sure its location along the shaft and note it. You
will need this measurement when reinstalling the
sheave.
7. To remove the bushing, unscrew the set screw
that holds the bushing to the shaft key. Drive a
thin metal wedge into the bushing slot. It should
fall off the shaft. For stubborn bushings, use a
gear puller or dead blow hammer to remove the
bushing.
SHEAVE INSTALLATION
Use the standard mounting method as opposed
to the reverse mounting method.
Sheave Replacement
7. Repeat steps 5 and 6 until the torque on the sheave
mounting bolts does not change.
NOTE: The sheave diameter x circumference x
RPM : 12=ft./minute (D x þ x RPM : 12 =FPM).
Stock sheaves are given a static balance that is
satisfactory for rim speeds up to 6,500 feet per
minute. Sheaves with rim speeds above this limit
must be specially ordered.
Driving the sheave onto the bushing with a brass
drift, then reconfirm torque specifications
Bushing Torque Specifications:

CAP SCREW TORQUE

BUSHING SIZE
SIZE & THREAD FT/LBS

E 1 /2 - 1 3 60

F 9/16 - 12 75

J 5 / 8 - 11 135

M 3 /4 - 1 0 225
Standard mount bushing
1. If the bushing is on the shaft, skip steps 1 and 2. SHEAVE BREAK–IN
If you need to install the bushing, first open it up Recheck the torque on the sheave
by driving a wedge into the bushing sawcut.
mounting bolts after a few hours of opera-
2. Slide the bushing onto the shaft, flange end first, tion. In some instances, the significant heat gen-
to the desired location. Tighten the set screw in erated by the friction between the belts and the
the bushing against the shaft key and remove the sheave may decrease the torque on the sheave
wedge. The bushing should remain in place. mounting bolts.
3. Slide the sheave up over the bushing so the tapered This is especially important on small sheaves.
surfaces mate. Insert the sheave mounting bolts
Lock out power to the crusher, recheck the
through the drilled holes in the sheave and hand
tighten them into the tapped holes in the bushing.
torque and tighten the bolts if necessary. In the
future, if the belt guards are removed for other
4. Torque the bolts according to the bushing torque reasons, it is a good practice to inspect the drive-
table below. If this is a new bushing, torque the train and verify sheave torques.
bolts to the specification listed on the bushing
instruction sheet.
5. Use a brass drift and mallet to drive the sheave
onto the bushing. Position the drift on either side
of each mounting bolt and strike it with the mal-
let.
6. Retorque the bolts to the correct specification.
73
 Pedestal Overhaul
INTRODUCTION
A properly greased labyrinth seal will help prevent
dust and water damage to the pedestal bearing oil
supply and shaft seal area. Properly greased and
oiled pedestals rarely require an overhaul. Oil seep-
ing out from the upper or lower seals or sideways
shaft movement may be an indication that the ped-
estal needs a partial or complete overhaul.
found in some bearing catalogs.
SPECIAL TOOLS
Eyebolts for lifting
Hydraulic press with a pressure gauge and blocks
Table with a hole in it and a work stand to which the
pedestal housing can be bolted. A work stand that
rotates along a horizontal axis is ideal.
AN-NUT socket
Long Feeler gauges for checking RIC
Bearing Heater

Sideways shaft movement

If it is determined the pedestal needs a complete
rebuild, it should be removed from the crusher to
a clean work area. Refer to the parts manual for
specific part identification. Never replace only one
Some of the tools for a pedestal overhaul
bearing and never reuse a seal or O-ring. Some as-
sembly steps require heating the bearings or pedestal
housing to allow for part assembly with an interfer-
ence fit. Heated parts need sufficient time to cool so
they do not separate during subsequent assembly
steps; and before checking bearing tolerances (RIC).
Seal plate removal can be done by hand on a small
pedestal. Use lifting eyes and a hoist to remove the
seal plates on large pedestals.
Refer to the BELT MAINTENANCE AND RE-
PLACEMENT and SHEAVE REPLACEMENT
sections where appropriate.
Some knowledge of bearing clearances is needed to Pedestal work stand
properly diagnose and rebuild a pedestal. Specifi-
cally, the Radial Internal Clearance, or RIC must
be measured and compared to tabulated values. The
RIC and its measurements are standardized in the
bearing industry. Measurement procedures can be
74
Pedestal Overhaul
REPLACEMENT PARTS on the hub, carefully heat the hub and strike the
hub with an aluminum or brass block held against
Upper Dust Seal
the hub. Be careful not to damage the hub surface
Upper and Lower Oil Seals or lifting mechanism. The hub should separate
from the main shaft. Relieve the lift pressure and
Upper and Lower O-Rings
remove the lock nut and hub.
Alignment Tube O-Rings
Upper and Lower Bearings
AN Lockwashers

Carefully strike a block held against the hub

PRELIMINARY DISASSEMBLY AND
DIAGNOSIS
Replacement parts 1. Remove the six cap screws in the upper seal plate.
Use lifting eyes (if equipped with them) to raise
HUB REMOVAL
the seal plate off the pedestal housing.
1. Remove SuperChipper™ or impeller table from
Note: Recent model crushers have 2 set screws
the hub and set aside. Wash the crusher and ped-
in the seal plate. Tighten the set screws in equal
estal to remove dirt.
increments to separate the seal plate from the
2. Bend the lockwasher tab out of the slot in the pedestal housing. To install the lifting eyes, the
upper lock nut and use a blunt nosed drift and set screws must be completely removed and the
a heavy hammer to remove the locknut, then eyes are then threaded into the vacant holes.
remove the lockwasher.
Avoid scratching the seal surface. Do
3. Unthread the remaining locknut until it is even not pry the seal plate off the pedestal housing.
with the top of the shaft threads. Leave the lock-
nut in this position to prevent the hub from com-
ing off the shaft or damaging the threads when it
separates from the shaft.
4. Insert three lifting eyes into the hub and use a lift
or hoist to take the slack out of the chains and
exert an upward force on the hub.
5. If it is necessary, place bottle jacks under the hub
to help lift and remove hub from off of the ped-
estal shaft. Once the upward pressure is placed
75
Underside of the upper seal plate
 Pedestal Overhaul
2. Observe the underside of the seal plate. Look for
oil getting past the O-ring. Look for dirt in between
the seals.
3. Remove the upper dust and grease seal and the oil
seal O-ring from the seal plate. Check the rubber
on the seals and the O-ring for damage.
4. Inspect the mating surfaces between the upper seal
plate and pedestal housing for dirt outside the oil
seal O-ring, or any damage where the plates meet.
5. Inspect the shaft where the upper dust and grease
seal and oil seal rubber gaskets make contact. A
groove in the shaft indicates lack of oil or grease.
If this groove is deeper than .004”, the shaft needs
to be repaired or replaced.
Grooves in shaft caused by seals
PEDESTAL REMOVAL
If the pedestal needs rebuilding, it must be removed
from the crusher now. Otherwise, follow the PED-
ESTAL ASSEMBLY procedure to install the upper
seal plate with new seals.
1. Clean or wash the pedestal sheave. Remove ped-
estal shroud and remove material from the pedestal
bottom. Make sure the sheave bolt hole threads are
clean.
2. Remove the oil and grease lines from the pedestal
underside. Seal the loose hose ends to keep dirt
out.
76
Oil and grease connections at pedestal
3. Remove the bolts which secure the pedestal to the
crusher channel.
4. Install a lifting eyebolt in the end of pedestal shaft
and lift the assembly, including the drive sheave,
out of the crusher.
5. Wash the pedestal assembly to remove dirt and
foreign material from the sides or seal plates.
6. Bolt the pedestal assembly to a frame or table for
further disassembly.
COMPLETE PEDESTAL DISASSEMBLY
While all crusher drivetrains are unique, in
some cases the crusher may have a larger diameter
sheave than the hole in the crusher. Be extremely
careful when removing the sheave, especially if the
pedestal is in the crusher. A strap or chain arrange-
ment should be used as a safety to catch the sheave
and bushing in the event they should unexpectedly
slip off the shaft.
1. Measure the bushing distance from the end of the
pedestal shaft. You will need this measurement
when reinstalling the sheave / bushing.
2. Remove the sheave. (Refer to Sheave Replacement
section.)
3. Remove the sheave bushing.
4. Tap the key out of the shaft keyway.
5. Orient the pedestal assembly upside down in the
Pedestal Overhaul
work area for disassembly. fits. It should be clean and smooth.
6. Remove the lower seal plate cap screws and use
lifting eyes (if needed) to remove the seal plate
from the pedestal housing.
7. Remove the lower oil seal and O-ring from the
seal plate.
8. Inspect the seal plate and pedestal mating sur-
faces for damage.
9. Remove the lower bearing shaft lock nuts and
lockwasher. (Same procedure as #2 in Hub
Removal.)
10. Orient the pedestal upside down in a hydraulic
Measuring a bearing bore
press and push the main shaft out of the hous-
ing. Frequently the upper bearing will come CRUSHER MODEL
Upper Bore 35 54 70 80 96 128 160 175
out with the shaft. If the bearing remains in the Min (in) 5.9045 7.0842 8.4625 9.0530 12.5960 12.5960 12.5960 12.5960
housing, go ahead and remove the shaft and use 12
Max (in) 5.9050 7.0852 8.4635 9.0535 12.5965 12.5965 12.5965 12.5965

a (bearing) block or heat to remove the bearing Lower Bore

Min (in) 5.9052 7.4794 7.4805 9.4495 9.0534 9.0534 11.4162 11.4162
from the housing. Max (in) 5.9057 7.4805 7.4810 9.4500 9.0539 9.0539 11.4173 11.4173

11. If the upper bearing is still attached to the shaft, Shaft Diameter
Min (in) 3.3470 3.9375 4.7255 5.1190 5.9064 5.9064 5.9064 5.9064
remove it using heat or a hydraulic press. Max (in) 3.3475 3.9380 4.7260 5.1195 5.9069 5.9069 5.9069 5.9069

12. The lower bearing should easily separate from Pedestal and Bearing Bore Specifications
the pedestal housing. If it does not, gently tap it
out with a block of wood and a plastic or rubber PEDESTAL ASSEMBLY
mallet. 1. Heat the upper bearing to 50°F above the tem-
CLEAN AND INSPECT THE PEDESTAL perature of the shaft (be careful not to overheat the
ASSEMBLY bearing.)
1. Clean the shaft, seal plates, and pedestal housing 2. Screw a lifting eyebolt into the top of the shaft.
with solvent or similar cleaner. Lower the shaft into the bearing (Using some WD-
40 or other lubricant can help with inserting the
2. Clean out the oil and grease passages first with shaft.)
solvent and then with compressed air. It is usually
not necessary to remove any of the pipe plugs in (A table with a hole in it works well for this proce-
the lower seal plate mounting surface. If you do dure.) Allow the assembly to cool.
remove any plugs, clean them thoroughly and 3. First heat the entire pedestal evenly, then heat the
replace them below the machined surface using pedestal region which surrounds the upper bearing
pipe thread sealant. bore until the inside diameter just exceeds the Maxi-
3. Measure the upper and lower bearing bores in mum Upper Bore dimension given in the preceding
the pedestal housing and the shaft diameter at table.
the upper bearing area. They should meet the 4. Suspend the shaft and bearing above the upright
factory specifications listed in this manual. pedestal. Lubricate the outside of the bearing with
4. Inspect the shaft taper where the lower bearing WD-40 or a similar lubricant.
5. Lower the shaft/upper bearing assembly into the
77
 Pedestal Overhaul
• DANGER •
DO NOT WELD REPAIR A
PEDESTAL MAIN SHAFT!
bore. Seat the bearing in the bore by tapping it
lightly with a brass or plastic mallet. Allow the
assembly to cool slightly (5min), so the upper bore
can retain the bearing and shaft.
Lowering shaft/bearing into pedestal
6. Orient the pedestal assembly upside down so the
lower bearing bore is accessible.
7. Slide the tapered bore lower bearing (large end of
taper first) over the shaft. Tap the inside bearing
race with a brass drift or punch, securely seating
it against the tapered shaft section. Orient the
pedestal sideways.
8. Thread one of the lower bearing shaft lock nuts
with the flat side facing the bearing on the shaft.
This will prevent the bearing from slipping off the
shaft. At this point, the entire pedestal assembly
needs to cool down completely (overnight would
be best). Once the pedestal has cooled, tighten the
nut and check the tapered bore bearing RIC. As
the nut is tightened, the RIC decreases due to the
expansion of the inner race on the taper.
Do not overtighten. If you exceed the
minimum RIC, disassemble the pedestal and
start over.
78
9. Install the lockwasher with the concave side away
from the pedestal housing. The inner tooth slides
in the slot machined into shaft threads.
10. Thread on the remaining large lock nut with
the flat side away from the pedestal housing.
Manually tighten it with a hammer and punch,
or AN socket
11. Bend a tab on the lockwasher into one of the four
cutouts on the nut. This locks the nuts in place.
CHECK
Locknuts/lockwasher/bent tab
UPPER BEARING CLEARANCE
1. Leave the pedestal assembly in a horizontal
position.
2. Check the upper bearing Radial Internal Clearance
(RIC) by inserting a long feeler gauge between
the rollers and the outer race. With the shaft in
the horizontal position, the clearance must be
measured over both rows of rollers. Slide the
feeler gauge in a saw-like motion between the
roller and the outer race. The clearance should
be within the specifications listed below:
Maximum .0072 inches
Optimum .0055 inches
Minimum .0038 inches
3. If the clearance is too loose the pedestal housing or
shaft are out of tolerance and need to be replaced.
 Pedestal Overhaul
LOWER BEARING CLEARANCE
Here are the clearance specifications for the lower
bearings, according to the crusher model you have:
To find bearing bore (mm) on this chart, take last
two digits from the lower bearing part number and
multiply them by 5.
Example: A Turbo 35 pedestal lower bearing is
BRG-22314K. (14 x 5 = 70mm) Nominal bearing
bore mm for 70mm is between 65mm (over) and
80mm (incl).
From this example the Radial Internal Clearance
before mounting is .0037min .0047max. Use a long
blade feeler gauge set to get the actual measurement
of Radial Internal Clearance across both bearings.
Once the actual measurement is recorded, subtract
the Reduction Radial Internal Clearance min. &
max. to get a range of clearance.
Example: Actual measurement from feeler gauge
is .0040in.
(.0040in) - (.0016in (max))= .0024in (how loose)
(.0040in)-(.0020in(max))=.0020in (how tight)
INSTALL UPPER SEAL(S) AND SEAL PLATE
A grease seal and O-ring are installed in the up-
per seal plate. The grease seal provides a seal
between the seal plate and shaft. The O-ring
provides the seal between the seal plate and the
pedestal housing. Larger crushers also have a
dust seal which installs on top of the grease seal.
GREASE SEAL
SHAFT
TOP O-RING
SEAL
PLATE
Standard top seal plate arrangement
DUST SEAL
GREASE SEAL
SHAFT
TOP O-RING
SEAL
PLATE
Large crusher top seal plate arrangement
1. Some recent model crushers have 2 set screws in
the seal plate to separate it from the pedestal and
facilitate removal. If your crusher has these screws,
adjust them so the ends do not stick out beyond the
seal plate surface.
2. Orient the rubber lip so it will face downward when
installed and press the grease seal into the seal plate.
If necessary, gently tap the seal in place with a mallet
and wood block.
3. If your pedestal uses a dust seal, orient the rubber lip
upward when installed and press the dust seal into the
seal plate. If necessary, gently tap the seal in place
with a mallet and wood block.
4. Smear a small amount of grease into the groove in
the underside of the seal plate. Press the large O-ring
into this groove. The grease will hold it in place.
5. Replace the O-rings that fit over the alignment tubes
in the top of the pedestal housing.
6. Lubricate the rubber lips on the seals with assembly
grease. Align the oil and grease openings in the
seal plate over the alignment tubes in the pedestal
housing. Some pedestal assemblies have a seal plate
alignment dowel pin. Gently slide the seal plate (with
seals installed) over the shaft. Position it on top of
the pedestal housing in line with the dowel pin.
79
 Pedestal Overhaul
3. Replace the O-rings that fit over the alignment
tubes in the bottom of the pedestal housing if
needed.
4. Lubricate the rubber lip on the seal with assem-
bly grease and slide the seal plate (with the seal
installed) over the shaft. Avoid the keyway in
the shaft which could cut the rubber seal. Gently
position the seal plate on the pedestal housing
and align the mounting holes.

Aligned oil and grease openings and alignment

dowel in the upper seal plate
8. Install the seal plate bolts. Tighten the bolts in a
crosswise pattern according to the torque guidelines.
INSTALL THE LOWER SEAL AND SEAL
PLATE

O-RING GREASE SEAL

SHAFT
BOTTOM
SEAL
PLATE
Standard bottom seal plate arrangement
O-RING GREASE SEAL
SHAFT
BOTTOM
DUST SEAL
SEAL
PLATE
Bottom seal plate with a dust seal installed.
1. Orient the rubber lip towards the lower bearing and
press the seal into the lower seal plate. If necessary,
gently tap the seal in place with a mallet and wood
block. The Turbo 54 and Turbo 70 pedestals also
have a dust seal which installs on top of the grease
seal. The installation of the second seal is similar
to the Upper Seal Plate seal installation.
2. Smear grease into the groove in the underside of the
seal plate. Press the large O-ring into this groove.
The grease will hold it in place.
Installing the lower seal plate
5. Install and torque the seal plate bolts. Tighten
the bolts in a cross-like pattern according to
the torque guidelines for machined parts in this
manual.
6. Plug the oil and grease holes in the underside of
the pedestal to keep dust out until the pedestal
is installed back in the crusher.
INSTALL THE SHEAVE
1. Install the bushing key into the keyway in the
shaft.
2. Slide the bushing onto the shaft. Align it with
the mark or measurement you made during the
COMPLETE PEDESTAL DISASSEMBLY.
Lock the bushing onto the shaft key with the
set screw.
3. Place the sheave over the bushing. Finger
tighten the bolts which hold the sheave to the
bushing. Alternately tighten the bolts in a pat-
tern until they reach the torque specified in the

80
Pedestal Overhaul
table below. the tub bottom. Realign oil & grease lines.

Lower rebuilt pedestal into crusher

3. Apply a locking compound to the bolts according
NOTE: The sheave diameter x circumference x RPM to the manufacturers instructions.
: 12=ft./minute (D x þ x RPM : 12 =FPM). Stock Do not use red Loc-tite or lock washers.
sheaves are given a static balance that is satisfac- CEMCO recommends Loctite #242 Anoeribic
tory for rim speeds up to 6,500 feet per minute. Thread Locker and SAE flat washers.
Sheaves with rim speeds above this limit must be
specially ordered. 4. Install the bolts which hold the pedestal housing to
the crusher. Torque them according to the TORQUE
INSTALL THE PEDESTAL INTO THE CRUSHER SPECIFICATIONS guidelines.
1. Clean out the pedestal plate bolt holes and the ma-
chined lip with a wire brush and solvent. Clean the
bolts with solvent as well. Air dry both the holes
and the bolts.

Apply locking compound

5. Remove the covers from the oil and grease hoses.
Remove the plugs from the ports in the underside
of the pedestal housing. Inspect all the openings
Clean holes in pedestal plate . and remove any dirt or debris. Carefully reinstall
Lift the rebuilt pedestal with a lifting eye and lower the fittings and the hoses onto the pedestal.
it into the crusher. Be extremely careful. Have a 6. Follow the BELT INSTALLATION and INITIAL
person help guide the sheave through the hole in CRUSHER START-UP procedures outlined in this
81
 Pedestal Overhaul
service manual.
INSTALL THE HUB
1. Install the hub key into the keyway in the shaft.
2. Heat the hub to 50°F above the temperature of
the shaft and slip over the tapered shaft end.
3. Thread the first lock nut on, flat side down against
the hub. Tighten the locknut with a blunt-nose
drift and a heavy hammer until it is firmly locked
in place. Install the lockwasher, concave away
from the hub. The lock tab fits in the slot in the
shaft threads. Thread on the second locknut with
the flat side up away from hub. Tighten the lock-
nut with a blunt-nose drift and a heavy hammer
until it is firmly locked in place, similar to the
first lock nut.
4. Bend a tab on the lockwasher into one of the four
cutouts on the outer nut. This locks the nuts in
place.
5. Use the pedestal grease zerk to fill labyrinth seal
with grease. If it is a new or rebuilt pedestal, it
may take up to 2 tubes of grease to fill it up.

82
Electric Motor Replacement
INTRODUCTION
This section offers tips and guidelines for electric
motor selection and replacement. A properly main-
tained electric motor should last for several years.
Occasionally, electric motors must be replaced or
serviced. Sending a damaged motor to an authorized
repair facility may be the best option. Severely
damaged motors may need to be replaced. Contact
CEMCO directly to learn about electric motor
availability options, authorized repair centers and
specific issues regarding electric motors from dif-
ferent manufacturers.
CEMCO installs TECO or TOSHIBA electric mo-
tors on all factory crushers. TECO and TOSHIBA
have approved our application and installation.
When we receive motors from TECO or TOSHIBA,
the installation instructions are inside the electrical
junction box which is located on the side of the
motor. CEMCO crushers shipped from the factory
should contain these instructions in the junction box
as well as a wiring diagram. If you did not receive
them, contact CEMCO directly and we will send
or fax them to you. Follow the instructions during
wiring and motor installation. They also provide
useful information and guidelines for taking a motor
out of service or placing a motor back into service.
Nearly all industrial grade electric induction motors
may be installed so the motor rotates clockwise or
counterclockwise. The rotational direction has no
effect on the motor performance. The rotational
direction is critical however when installed on a
CEMCO VSI. If the motor is wired incorrectly and
rotates in the wrong direction, the VSI pedestal will
rotate in the wrong direction as well. Unfortunately,
this happens far too much. If caught quickly, little
or no damage occurs to the crusher. In a worst case
situation, the crusher is allowed to run backwards
unabated. Rock traveling across a shoe table or
through a rotor causes wear at unprotected locations
on the table or rotor body. If enough parent material
is removed, a casting may breakaway from the rotor,
resulting in a severe out-of-balance and unsafe situ-
ation. A severely out-of-balance rotor will ruin the
pedestal if the crusher is not shut off immediately.
CEMCO VSI pedestals and accompa-
nying electric drive motors should always
rotate in a counter clockwise direction as viewed
from above. Always verify the motor rotation at
seasonal start-up and whenever the electric motor
has been serviced or replaced. NEVER operate a
CEMCO VSI if the pedestal is rotating in the wrong
direction.
MOTOR SELECTION
CEMCO uses IEEE and NEMA standardized electric
motors on their crushers. When selecting a motor,
choose one with comparable voltage, horsepower,
NEMA frame size and shaft dimensions to the motor
it is replacing. Specify heavy duty service and that
the motor is designed to run in an upright or down-
shaft orientation. (Most industrial electrical motors
require internal bearing modifications to operate in
a vertical orientation.) If applicable, specify if the
motor must be explosion proof. The hole spacing
in the motor mounting plate is determined by the
electric motor frame size. If you install a different
size motor, you will probably need to drill new holes
in the motor frame.
MOTOR AND FRAME REMOVAL
This is the recomended procedure for replacing an
electric motor. In nearly all situatuions, it is easiest
and safest to remove the motor mounting frame
from the crusher before removing the motor from
the frame.
1. Loosen the fasteners that prevent the mounting
frame from sliding on the crusher frame.
2.Relieve the tension on the belts by loos-
ening the belt tension screw (single motor frame) or
activating the double acting ram (V-Twin).
3.Remove the belts from the drive sheaves.
4.Remove the fasteners that hold the mounting frame
to the crusher frame.
5.Attach lifting chains or straps to the motor mount
frame lifting eyes or through the motor mount
frame side gussets.
Never lift the motor mount frame by
the motor mount hood. 83
 Electric Motor Replacement
6.Lift the motor and motor mount togther and set
them off to the side for further disassembly.
MOTOR REMOVAL
1. Remove the fasteners that attach the motor mount
hood to the motor mount frame.
2. Lay the motor and frame assembly on its back.
Be sure to set it up on blocks so the fasteners that
attach the motor are accessible.
3. Remove the sheave. Follow the instructions in
the SHEAVE REPLACEMENT section of the
service manual. (If you plan to use the same
sheave arrangement, take some measurements to
help install the sheave in the same location along
the shaft of the new motor.)
4. Loosen and remove the motor fasteners.
5. Install screw eyes into the holes in the motor
housing.
6. Lift the motor off the mounting frame.
Installation of Turbo 110 motors using special
motor lifting device shown below. Optionally
available from CEMCO INC.
Special Motor Lift on Turbo 110
84
REASSEMBLY
1. Measure the hole pattern on the replacement mo-
tor and check it against the hole pattern on the
motor mount. If they are not the same, drill new
holes in the motor mount.
2 With the frame laying on its back and on blocks,
fasten the motor to the frame. CEMCO recom-
mends using all new fasteners. Always use Grade
8 or better cap screws and nuts. Never compress
a lockwasher against a rough finish casting. Bolt
length may vary depending on the mounting foot
thickness of the motor frame. If there is enough
clearance between the motor housing and the
mounting feet, install the bolts with the head on
the motor side and nut on the frame side.
3. Torque the fasteners to the torque listed in the
Torque Specifications section of the CEMCO
Service Manual.
4. Follow the instructions in the SHEAVE RE-
PLACEMENT section of the service manual and
install the sheave.
5. Set the frame and motor upright, taking extra care
not to drag the shaft or sheave on the ground.
6. Set the frame on the crusher, align the holes in the
motor mount frame with the slots in the crusher
tub. Fingertighten the nuts onto the fasteners.
7. Loop the belts back onto the sheave.
8. Tighten the belts (Follow the guidelines in the
Belt Maintenance and Replacement section of
the Service Manual).
Seasonal Maintenance
INTRODUCTION
This sections lists the steps necessary to keep your
VSI in good condition if you plan to shut down for
a period of time or during the cold weather season.
Preventative maintenance at the end of the season
goes a long way towards smooth start-up in the
future.
Removing all material from the crusher tub and
internal chamber will prevent moisture build-up
and possible corrosion or freeze-thaw damage in
the crusher.
Obviously, storing the crusher in a building or shed
is optimal but usually not practical. At the very
least, cover all openings where the elements could
penetrate into the crusher, oil system or diesel en-
gine. Make sure the motor hood (bolted to the motor
mount for electric motors) is secure.
During the shut down, note any parts or castings
which need service or replacement. The off-season
is a good time to recast rotors, order and install new
parts, reweigh, inventory, and stock up on wear parts
and prepare for a smooth transition when crushing
resumes.
END OF SEASON SHUT DOWN
1. Replace the oil in the system and install a new
filter.
2. Run the crusher for a few minutes to circulate
the new oil. Add more oil if necessary. This helps
prevent condensation in the oil system.
3. Lockout and tag the crusher.
4. Remove & invert feed hopper.
5. Clear the crusher and discharge chutes of all the
material. Clean rotors, anvils, rock shelves and any
place else where water may collect. This prevents
material from freezing and packing and retards cor-
rosion due to moist material.
6. Close the lid and secure the camlocks.
7. Cover the lid tube opening. Ordinarily, placing a
tarp over the lid tube is not a good idea. Usually it
collects water which eventually finds its way into the
crusher tub. A board or a piece of plate works best.
8. Relieve any pressure in the hydraulic lid
lift system. If the crusher has an electric hydraulic
pump, remove it and store it indoors. If the crusher
has a hand operated pump, remove it, cap the hose
ends, and store the pump indoors. If it is not possible
to remove the pump, relieve the pressure and cover
it to protect it from the elements.
9. It is not necessary to loosen belts. However it
is a good idea to sufficiently grease the belt adjust-
ment screw.
10. Cover with plastic and tape shut the oil filler
cap. Tarp the oil tank.
11. Notify personnel that the crusher is shut down
for the season.
12. During the shut down season, check on the
crusher periodically to make sure all the tarps are
still in place and openings secured.
END OF SEASON SHUT DOWN -
PORTABLE PLANT
1. Replace the oil in the pedestal oil system and
install a new filter.
2. Replace the oil in the gearbox oil system.
3. Run the crusher for a few minutes to circulate
the new oil. Add more oil if necessary. This helps
prevent condensation in the oil system.
4. Change the oil and filter in the diesel engine.
5. Flush the diesel engine coolant system and fill
it with the proper mixture of antifreeze and water.
6. Lockout the clutch and lock out and tagout the
conveyor and dust collection system.
7. Remove the batteries and install onto another
piece of equipment or store indoors where the tem-
perature fluctuations are at a minimum.
8. Remove & invert feed hopper.
9. Clear the crusher and discharge chutes of all the
material. Clean rotors, anvils, rock shelves, con-
veyors and any place else where water may collect.
This prevents material from freezing and packing
85
 Seasonal Maintenance
and retards corrosion due to moist material. 3. Check the oil level in all systems. Look for signs
of moisture or condensation. Ideally, it is best to
10. Close the lid and secure the camlocks.
analyze a sample of the oil. If there is water in any
11. Cover the lid tube opening. Ordinarily, placing of the oil systems, change the corresponding oil
a tarp over the lid tube is not a good idea. Usually it and filter.
collects water which eventually finds its way into the
4. Fill labyrinth seal with spec grease.
crusher tub. A board or a piece of plate works best.
12. Relieve any pressure in the hydraulic lid lift sys- INITIAL STARTUP CHECKLIST
tem. If the crusher has an electric hydraulic pump, With each new crusher, CEMCO includes an Initial
remove it and store it indoors. If the crusher has a Startup Checklist. If you purchased your crusher
hand operated pump, remove it, cap the hose ends, new, you were asked to complete the checklist and
and store the pump indoors. If it is not possible to send it to CEMCO to keep on file. A copy of the
remove the pump, relieve the pressure and cover it checklist is included here. Use this same checklist
to protect it from the elements. when restarting the crusher after it has been shut
13. It is not necessary to loosen belts. However it down for more than a month.
is a good idea to sufficiently grease the belt adjust-
ment screw.
14. Cover with plastic and tape shut the oil filler cap.
15. Cover the exhaust openings on the muffler.
16. Lower the air intake stack, store inside or under
the plant, away from the elements. Secure and seal
off the air intake opening.
17. Notify personnel that the crusher is shut down
for the season.
18. During the shut down season, check on the
crusher periodically to make sure all the tarps are
still in place and openings secured.

BEGINNING OF SEASON START UP

1. Remove all tarps and covers.
2. Install hydraulic pumps and any other compo-
nents which were removed for seasonal shut down.

86
Fastener Specifications
GENERAL FASTENER INFORMATION EXCEPTIONS
CEMCO Inc., specifies Unified National Coarse, Metric fasteners are Metric Grade 10.9.
Grade 8 or better fasteners for nearly all crusher
Additional exceptions are noted within the manual
assemblies. Replacement fasteners, including wash-
text.
ers and lockwsahers must meet these specifications.
Common Grade 8 Hex Head Cap Screws have six DEFINITIONS
radial lines on the head. The grade for less common
The diagram below includes most of the fasteners
fasteners may not be as easily identifiable. Order
mentioned, a description for each and the abbrevia-
CEMCO fasteners and you can be sure they meet
tions used by CEMCO for parts lists and diagrams.
Grade 8 specifications.
If you get your fasteners elsewhere,
make sure you are getting Grade 8 quality
or better.

Hex Head Socket Head 12 Point Square Head

Cap Screw Cap Screw Cap Screw Cup Point
Set Screw
CAP SCR SOC HD CAP SCR 12 PT CAP SCR SQ HD SET SCR

Plow Bolt Flat Head Cup Point

Cap Screw Set Screw

PL BLT FL HD CAP SCR SOC HD SET SCR

87
 Fastener Specifications
SOCKET AND WRENCH SIZES REQUIRED FOR STANDARD HEX HEAD BOLT SIZES

BOLT DIAMETER (INCHES) SOCKET or WRENCH SIZE (INCHES)

1/4 7/16
5/16 1/2
3/8 9/16
7/16 5/8
1/2 3/4
9/16 13/16 for Bolt or 7/8 for Nut
5/8 15/16
3/4 1-1/8
7/8 1-5/16
1 1-1/2
1-1/8 1-11/16
1-1/4 1-7/8
1-1/2 2-1/4

88
Torque Specifications
TORQUE GUIDELINES oil and grease and 15% for anti-seize compound.
When torquing a group of bolts, tighten them down GENERAL TORQUE VALUES FOR BOLTS
together, turning each bolt a turn or a half turn, and AND NUTS
following a logical pattern or sequence which usu-
The following chart lists the recommended torque
ally means tightening bolts across from one another.
values for standard thread nuts and bolts used on
When a bolt reaches the specified torque, the bolt
CEMCO crushers. Note the lower torque values
next to it may become loose. Double-check adjacent
recommended for fastening castings. Exceptions
bolts for consistency. Do not overtorque.
are noted in the service manual.
LUBRICANTS
Lubricants reduce the required torque values. CEM-
CO does not recommend using lubricants except
where anti-seize compound is required. A good rule
of thumb is to reduce the torque values by 10% for
BOLT DIAMETER CASTINGS
Torque Torque
(in-TPI) (mm) (ft-lbs) (N-m)
1/4-20 6.35 10 14
3/8-16 9.53 25 34
1/2-13 12.70 75 102
9/16-12 14.29 85 113
5/8-11 15.88 90 123
3/4-10 19.05 100 136
7/8-9 22.23 100 136
1-8 25.40 250 339
1-1/4-7 31.75 250 339
1-1/2-6 38.10* 250* 339*
*As tight as possible, not to exceed these values

FEED DISC BOLTS (IF REQUIRED) SHOULD NOT BE TORQUED TO THE ABOVE
LISTED VALUES. ALL FEED DISC BOLTS SHOULD ONLY BE TORQUED TO 50 ft-lbs
MAX. IMPELLER SHOES (IF REQUIRED) SHOULD ONLY BE TORQUED TO 75 ft-lbs.

COMMON TORQUE PATTERNS

5
1 4
1 2
2
1
6 2 8 6
1
2 3
3
4 3
3 5 7
3 Hole Pattern 3 Hole Pattern 6 Hole Pattern 8 Hole Pattern

89
 Component and Assembly Diagrams
INTRODUCTION DIAGRAMS use the following abbreviations for
fasteners.
The following pages contain assembly diagrams
with corresponding part name and number listings. CAP SCRHex Head Cap Screw
This manual is individualized for your specific
SOC HD CAP SCRSocket Head Cap Screw
crusher. The exploded diagrams with part number
information correlate with your general crusher 12 PT CAP SCR12 Point Cap Screw
configuration. You will notice that some parts have
SQ HD SET SCRSquare Head Cup Point Set Screw
the word “SPEC” instead of a part number. These
components are specific to your crusher. Detailed PL BLTPlow Bolt
ordering information for these components is in
FL HD CAP SCRFlat Head Cap Screw
the CRUSHER SPECIFICATIONS section. For
example, the drivetrain is designed to operate at SOC HD SET SCRCup Point Set Screw
the optimum speed for each customer’s crushing
All fasteners listed in the Parts Manual
operation. Consequently, the drive sheaves and
are Grade 8 unless noted otherwise. Use only
sheave bushings can be different on the same model
fasteners designated Grade 8 or better. Contact
crushers. To find the specific sheave and bushing
CEMCO directly if you are having difficulty locating
information for your crusher, refer to the CRUSHER
Grade 8 fasteners.
SPECIFICATIONS section. Whenever you see the
word “SPEC” in lieu of a part number, refer to the
CRUSHER SPECIFICATIONS section for detailed
component information.
The FASTENER SPECIFICATIONS section con-
tains illustrations and descriptions of the fasteners
used. The COMPONENT AND ASSEMBLY

90
Turbo 80 Anvil Rings
Assembly
Turbo 80 Anvil Rings

ARW-80000

HYD-HOS12
(Anvil Ring Seal)

ANV-80009

ANV-80000

ANV-WP001

ARW-80190
ARW-80200
ARW-80210

111109
Turbo 80 Anvil Rings
ARK-80190 80 Crusher 19 Anvil Ring Complete 1
ARK-80200 80 Crusher 20 Anvil Ring Complete 1
ARK-80210 80 Crusher 21 Anvil Ring Complete 1
Item # Old Item # Description Quantity
ANV-80000 C-6402 Anvil - Model 80 Crusher 19, 20 or 21
ANV-80009 C-6401 Anvil Wedge 80 19, 20 or 21
ANV-WP001 Anvil Bracket Wear Plate, 3 x 8 19, 20 or 21
ARW-80000 80 Anvil Cap Ring Weldment 1
HYD-HOS12 #12 (3/4) LOLAPLUS, 300 psi Hydrauli 210"
ARW-80190 80-19 Anvil Ring Weldment 1
ARW-80200 80-20 Anvil Ring Weldment 1
ARW-80210 80-21 Anvil Ring Weldment 1

Crusher may be configured with 19,20 or 21 anvils.

The specification sheet or work order identifies the anvil quantity for each crusher.
Hardface welds may be used in lieu of wear plates.
*The anvil ring seal and seal weldment is not used in the following configurations:
ARW-80190 1 80 - 19 Anvil Ring Weldment
ARW-80200 1 80 - 20 Anvil Ring Weldment

**If your crusher is equipped with a 35" 4 port Superchipper, then your anvil ring
kit number will change to ARK-80214, and will be configured with the following components:
ANV-83540 Anvil 80 for 35-4 Port S/C-Tall 19, 20 or 21
ARW-80004 80 Anvil Cap Ring/4 PT ShortWeldment 1

ANV-80009 Anvil Wedge must be Installed with the straight edge to ARW.
Turbo 80 Hub & Sheave
Assembly
Turbo 80 Hub & Sheave Assembly
RET-AN24

RET-AW24

UNC-11622 RET-AN24
UNC-LW-16 PIN-50508

Hub must be heated to 500 above

ambient temp, prior to mounting HUB-80000
on to the shaft.

UNC-11632
KEY-11214

SAE-FW-16

PDK-81000

KEY-SPEC

SPEC0002

SPEC0003

SPEC0004

031606
Turbo 80 Hub & Sheave Assembly
HUB-80000 8204 Hub 80 96 (with PIN's) 1
Item # Old Item # Description Quantity
KEY-SPEC Key 1
KEY-11214 Key 3/4" x 1-3/4" (54,70,80 Hub) 1
PDK-81000 8209 Pedestal Assembly T80 1
PIN-50508 Hardened Dowel Pin, 3/4 x 2, 54-175 3
RET-AN24 Retaining Nut AN24 2
RET-AW24 Retaining Washer W24 1
SPEC0002 Bushing 1
SPEC0003 Sheave 1
SPEC0004 Sheave Cap Screw w/LW 3

Fasteners
Item # Old Item # Description Quantity
UNC-11622 1 x 2-3/4 HCS 6
UNC-11632 1 x 4 HCS 12
UNC-LW-16 1 L/W 6
SAE-FW-16 1 F/W SAE Flat Washer 12

All fasteners must be rated Grade 8 or better.

KEY-SPEC may be replaced to accommodate certain sheave/bushing combinations.
The sheave, bushing and associated fasteners depend on the drivetrain arrangement.
Consult the specifications for the individual crusher.
Use six UNC-11622 (1x2-3/4 CAP SCR) with six UNC-LW-16 (1 Lock Washer) to install
the rotor or table to the hub.
35” 6 Shoe Impeller Table
Assembly
 35” 6 Shoe Impeller Table Assembly

The Maximum RPM for this table is 1700.

ISH-35600-K2

UNC-21210

ITL-35601-K2

UNC-11216

MMF-12FW

*FDT-35600-K2

STW-35-6

EDG-35390

UNC-LW-14

UNC-11416

070909
35” 6 Shoe Impeller Table Assembly

STK-35-6 35" 6 Shoe Table Complete 1 $ 7,786.44

Item # Old Item # Description Quantity List Price
ISH-35600-K2 Impeller Shoe 35"/6 shoe 6 $ 127.35
ITL-35601-K2 Impeller Liner 35 Table/32 Shoes (9/ 6 $ 71.59
MMF-12FW Flat Washer Special-O.D. 1.98" 1 $ 18.64
FDT-35600-K2 Feed Disc 35"/6 shoe T80 table 1 $ 274.42
STW-35-6 Shoe Table 35" 6 Shoe Bare 1 $ 5,578.42
EDG-35390 C-7326 Edge Liner 35SC 39SC 35ST 2 16 $ 44.00

Fasteners
Item # Old Item # Description Quantity List Price
UNC-21210 3/4 x 1-1/4 FHSCS 12 $ 2.44
UNC-11216 3/4 x 2 HCS 1 $ 3.14
UNC-LW-14 7/8 L/W 32 $ 1.55
UNC-11416 7/8 x 2 HCS 32 $ 2.65

All fasteners must be rated Grade 8 or better.

The Maximum RPM for this table is 1700.
Fasteners to bolt table to hub:
UNC-11622 6 1 x 2-3/4 C.S.
UNC-LW-16 6 1” Lockwashers

*Due to the unique design of this impeller table, the

feed disk (FDT-35600-K2) needs to be removed first
when replacing impeller shoes (ISH-35600-K2). The
feed disk will also be installed last after new impeller
shoes are installed.

070909
Turbo 80 Lid Assembly
 Turbo 80 Lid Assembly

FHL-80000

FTL-80001

HPW-80000

UNC-10810
UNC-LW-08
UNC-NUT-08

PIP-112ST-21N

FTL-80000

HAK-80001
HAW-80100
HAK-80001
MMF-24AN
HAW-80200
UNC-JNUT-16
UNC-51632
OLL-70800
UNC-40616
UNC-FW-06
UNC-LW-06
UNC-NUT-06
LDW-80000

ILL-80000
UNC-40616
UNC-FW-06
UNC-LW-06
UNC-NUT-06 IDW-80000

OLL-70800
MMF-12IDR

IDW-54-96

060515
Turbo 80 Lid Assembly

Item # Old item # Description Quantity

FHL-80000 80 Feed Hopper Liner 2
FTL-80000 C-6503A Feed Tube Liner 80 1
HAW-80200 80 Lower Hopper Adjuster Weldment 1
HAW-80100 80 Upper Hopper Adjuster Weldment 1
HAK-80001 Hopper Adjustment Screw Kit 2
HPW-80000 6501 80 Hopper Weldment 1
MMF-12IDR 3/4" Eyebolt 3/4" Eyebolt Insp Door Retainer - Pa 1
IDW-80000 6604 80 Inspection Door Weldment 1
IDW-54-96 54,70,80,96 Safety Bar 1
ILL-80000 C-6504 Inner Lid Liner 80 4
LDW-80000 6605 80 Lid Weldment w/vibration control 1
OLL-70800 C-7502 Outer Lid Liner 70 80 8
PIP-112ST-21N 14 Schedule STD Pipe x 21" Feed Pipe 1
FTL-80001 T80 Upper Feed Tube Liner 20" (polyu 1
Fasteners
Item # Old item # Description Quantity
MMF-24AN 1-1/2 x 4 TPI Heavy Hex ACME NUT 2
UNC-10810 1/2 x 1-1/4 HCS 6
UNC-40616 7503 3/8 x 2 PB 68
UNC-51632 1 x 4 SQST CP 6
UNC-FW-06 3/8 Flat Washer F/W USS 68
UNC-JNUT-16 1 Jamb Nut HJN 6
UNC-LW-06 3/8 L/W 68
UNC-LW-08 1/2 L/W 6
UNC-NUT-06 3/8 Nut FHN 68
UNC-NUT-08 1/2 Nut FHN 6

All fasteners must meet Grade 8 specifications.

*HAK-80000, Hopper Adjustment Kit consists of:
HAW-80100 1 80 Upper Hopper Adjuster Weldment
HAW-80200 1 80 Lower Hopper Adjuster Weldment
HAK-80001 2 80 Adjustment Screw Kit
MMF-24AN 2 1-1/2 x 4 TPI Heavy Hex ACME NUT
**HPK-80000 80 Feed Hopper Kit consists of:
HPW-80000 1 80 Hopper Weldment
FHL-80000 2 80 Feed Hopper Liner
FTL-80000 1 Feed Tube Liner 80
PIP-112ST-21N 1 14 Schedule STD Pipe x 21" Feed Pipe
UNC-10810 6 1/2 x 1-1/4 HCS
UNC-LW-08 6 1/2 L/W
UNC-NUT-08 6 1/2 Nut FHN
FTL-80001 1 T80 Upper Feed Tube Liner 20" (polyu

060515
Turbo 80 Lift Arm
Assembly
 Turbo 80 Lift Arm Assembly
Lid Weldment
(See Lid Assembly)

UNC-10608
UNC-FW-06
UNC-LW-06

ARM-20003
ARM-30001

PIN-31801
UNC-10610
UNC-LW-06

ARM-30001
PIN-33801 ARM-30801
ARM-30902 LTW-80301
UNC-10608
UNC-LW-06 UNC-30806

HYD-REB25

HYD-RAM02

HYD-REP25

PIN-32801
ARM-30001
ARM-30901 LTW-80101
UNC-10608
UNC-LW-06
PIN-34801
ARM-30001
ARM-30902
UNC-10608
UNC-LW-06 BRG-62152

BRG-62122
UNC-11016 RET-R0350
UNC-FW-10
UNC-LW-10
UNC-NUT-10
UNC-11020
LTW-54200 UNC-FW-10
UNC-LW-10
UNC-NUT-10

UNC-11012

080108
Turbo 80 Lift Arm Assembly
Item # Old Item # Description Quantity
ARM-20003 80 Arm Cover(use ARM-20002) 1
ARM-30001 38641 Donut Urethane 10
ARM-30801 38644 Upper Ram Pin Urethane Spacer 80 Vib 2
ARM-30901 50653 Lower Ram Pin Cover 80 96XHD Vibrati 2
ARM-30902 50649 Pivot and Upper Ram Pin Cover 80 96X 4
BRG-62122 Ball Bearing Lower Lift Shaft 1
BRG-62152 Ball Bearing Upper Lift Shaft 1
HYD-RAM02 RC-254 (25 TON) RAM 1
HYD-REB25 Base Clevis w/(2) 1/2 x 3/4 SOC HD C 1
HYD-REP25 Plunger Clevis 1
LTW-54200 54 70 80 Lift Housing Weldment 1
LTW-80101 80 Lift Shaft Weldment w/Vibration C 1
LTW-80301 80 Lift Arm Weldment w/Vibration Con 1
PIN-31801 50669 Lid Tube Pin 80/96XHD Vibration Arm 2
PIN-32801 50665 Lower Ram Pin 80 96XHD Vibration Arm 1
PIN-33801 50679 Upper Ram Pin 80 Vibration Arm Astra 1
PIN-34801 50681 Pivot Pin 80 Vibration Arm Astralloy 1

Fasteners
Item # Old Item # Description Quantity
RET-R0350 2-3/16 x .083 Steel External Retaini 1
UNC-10608 9000 CAP SC3/8 x 1 HCS 16
UNC-10610 9003 CAP SC3/8 x 1-1/4 HCS 4
UNC-11012 5/8 x 1-1/2 HCS 3
UNC-11016 5/8 x 2 HCS 3
UNC-11020 5/8 x 2-1/2 HCS 6
UNC-FW-10 5/8 Flat Washer F/W USS 9
UNC-LW-10 5/8 L/W 9
UNC-NUT-10 5/8 Nut FHN 9
UNC-FW-06 3/8 Flat Washer F/W USS 4
UNC-LW-06 3/8 L/W 20
UNC-30806 1/2 x 3/4 SHCS 2
All fasteners must meet Grade 8 specifications.
HYD-REB25 Fasteners are included with the clevis.
ARM-30801 Upper Ram Pin Spacer fits inside the arm
between the clevis and the donut welded on the inside
of the arm.
It is designed to keep the clevis centered on the pin.

The LTA-80000 kit contains the following Components:

BRG-62122 Ball Bearing Lower Lift Shaft 1
BRG-62152 Ball Bearing Upper Lift Shaft 1
LTW-80101 80 Lift Shaft Weldment w/Vibration C 1
LTW-54200 54 70 80 Lift Housing Weldment 1
RET-R0350 2-3/16 x .083 Steel External Retaini 1
Turbo 80 Lift Housing and Pump
Assembly
Turbo 80 Lift Housing and Pump Assembly

UNC-11016
LTW-54200

UNC-11020

HYD-PUM05

HYD-NIP02
HYD-QCK02 UNC-11012
HYD-HOS02
HYD-PLG01

UNC-FW-10
UNC-LW-10
UNC-NUT-10

UNC-FW-10
UNC-LW-10
UNC-NUT-10

HYD-ELB12

HYD-HOS01

HYD-QCK03

HYD-CAP01

101912
Turbo 80 Lift Housing and Pump Assembly

Item # Old Item # Description Quantity

HYD-ELB12 1315030 3/8 FNPT x 3/8 FNPT x 90í 1
HYD-HOS01 6C2AT x 66MPX Both Ends x 40" OAL (5 1
HYD-HOS02 6C2AT x 66MPX Both Ends x 70" OAL (5 1
HYD-NIP02 1278506 3/8 Close Nipple 1
HYD-PUM05 P-55 OTC Manual Lid Lift Pump 1
HYD-QCK02 5601-0606 3/8 FNPT Female Quick Connect 1
HYD-QCK03 5602-0606 3/8 FNPT Male Quick Connect 1
LTW-54200 54 70 80 Lift Housing Weldment 1

Fasteners
Item # Old Item # Description Quantity
HYD-CAP01 5657-6 3/8 Buna Dust Cap 4
HYD-PLG01 5659-6 3/8 Buna Dust Plug 4
UNC-11012 5/8 x 1-1/2 HCS 3
UNC-11016 5/8 x 2 HCS 3
UNC-11020 5/8 x 2-1/2 HCS 6
UNC-FW-10 5/8 Flat Washer F/W USS 9
UNC-LW-10 5/8 L/W 9
UNC-NUT-10 5/8 Nut FHN 9

All fasteners must meet Grade 8 specifications.

Electric Lube Oil Interlock Panel

ELE-349
ELE-356 ELE-328
ELE-325
VIBRATION VIBRATION
READY TO RUN POWER ON
DISPLAY ALERT

ELE-364
ORANGE GREEN RED
ELE-327
ELE-326
OIL HIGH TEMP VIBRATION
TANK LEVEL GOOD LUBE OIL FLOW
ALERT ALARM

ELE-328
ELE-327 RED GREEN GREEN GREEN ELE-325
ELE-326

ELE-328
ELE-325
LUBE OIL PUMP CRUSHER
START STOP START STOP
ELE-328
ELE-325

ELE-330

RGENCY S
ELE-327 E ELE-346
EM

TO

ELE-326
P

RED

PUSH

ELE-301 ELE-329
 Electric Lube Oil Interlock Panel

ELE-364

ELE-324

ELE-330 ELE-330

ELE-324
ELE-346

ELE-329
 Electric Lube Oil Interlock Panel

ELE-302

ELE-303

ELE-366

L1 NL I1 I2 I3 I4 I5 I6 I7 I8 1N I9 I10I 11 I12

ELE-305

Q7 Q8

ELE-345
Q1 Q2 Q3 Q4 Q5 Q6

ELE-367 ELE-315
ELE-315
COMMON NEUTRAL SPARE FIELD DEVICES (Optional for Oil
Heater or Oil
Cooler)

PUMP COOLER HEATER

ELE-317

ELE-320
ELE-316
ELE-317 (Optional for Oil
Heater or Oil
ELE-319 Cooler)

ELE-317 ELE-316
Electric Lube Oil Interlock Panel
ELE-365 Electrical Lube Oil Smart Relay Pane
Item # old item # Description Quantity
ELE-301 Enclosure Box - 20" x 20" x 6-1/2" 1
ELE-302 Enclosure Mounting Back Panel (for E 1
ELE-303 Control transformer w/ primary fuse 1
ELE-304 480V Breaker 1
ELE-315 12amp 120V Contactor 1
ELE-316 Overload Relay 1
ELE-317 BGE 35amp Terminal Block 4
ELE-318 35amp Terminal Block 1
ELE-319 Blue Terminal Block 2
ELE-320 35amp Red Terminal Block 5
ELE-321 Yellow Terminal Barrier 3
ELE-324 Light Base - screw portion for bulbs 8
ELE-325 Green dome lense 4
ELE-326 Red Domed Lens - TWTD INC 3
ELE-327 120V LED Red Lamp 3
ELE-328 120V LED Green Lamp 4
ELE-329 Hour Meter 1
ELE-330 Push/Pull (PB) Switch 2
ELE-345 FLM-6/10 Fuse 1
ELE-346 E-Stop 1-NO-1-NC 1
ELE-349 Amber Domed Lens 1
ELE-356 IDEC Amber LED Lamp 1
ELE-364 4-20mA Digital Vibration Reader/Indi 1
ELE-366 IDEC smart relay base module 1
ELE-367 IDEC smart relay expansion module 1
Electric Lube Oil Interlock Panel
L1 L2 L3 GND To VFD &
CB size as Motor
needed

Optional VFD/
Soft Start

CB size as
Earth Ground 95
needed
to M1
L1 T1
T1 M1
L2 T2
to M1 VSI CRUSHER T-35
L3 T3 To VT-128 M1
T3 480VAC
ELE-365
CB Main

Control Board Terminals Block

66 24+
480V 12
15 AMP Star
67 t
18

E-Stop 24+
13
I5
37

VFD – M1
DanFoss

Q1-2
Oil Pump Motor
M2

T
3
T
Q1-1 2
Optional
T

X-2
1

Oil Cooler
Fan M3
T
3
T
2

T-19
T T

Optional
1 1

X-2
Oil Heater
M4
T
3
T
2

T-18
T
1

H X
4 2
H
3 240/480 x 120 VAC
H Hammond HPS Transformer
L1 L2 L3 2
H X
1 1

120 120 VAC X-1

VAC X-2
X-1 X-2
L
L

N N

Lube Pump
I1 Lube Star Q1
I1 Q1-1 Q1-2

66 67
I2 Lube Stop Crusher Run
I2 Q2
Q2-1 Q2-2
S4

I3 Crusher Start Ready run

I3 Q3
S3

I4 Crusher Stop Oil Level

I4 Q4
S5
I5 E-Stop
I5 Oil Flow
EQ1
S6
I6 Oil Level
I6 Vibration Alarm
T14 EQ2
S7 I7 Flow Meter
I7
T15
Vibration Alert
S8 I8 Vibration Alert
EQ3
I8
T16
Oil High Temp
EQ4
I9 Vibration Alarm
EI1
T17
I10 Oil High Temp 176 Deg
EI2
T21
S9
Oil Low Temp 86 Deg

T18
S10

Connect 66 & 67 to
DANFOSS 12 & 18 for
start command
Smart Relay Oil Lube Panel
T66 T67
Q2-1 Q2-2 ELE-365
8-10-16
Turbo 80, 449TZ Motor Mount
 Turbo 80, 449TZ Motor Mount

MMW-44901
UNC-11018
UNC-LW-10
UNC-NUT-10

UNC-10810
UNC-LW-08
MMW-25400

MMK-54960

MMW-38001

SPEC

449TZ Motor
UNC-11424

UNC-FW-14
UNC-LW-14
UNC-NUT-14
SPEC

SPEC0006

SPEC0002

SPEC0007

062507
Turbo 80, 449TZ Motor Mount
Item # Old item # Description Quantity
MMK-54960 Belt Tension Screw Kit, 5496XHD 1
MMW-25400 713 54-96 Adjustment Wrench Weldment 1
MMW-38001 80D620 80 447/449TZ 200/250 HP Motor Mount 1
MMW-44901 800621-1 449TZ Hood 1
SPEC0006 Motor Shaft and Key 1
SPEC0007 Motor Sheave 1
SPEC0002 Bushing 1
Fasteners
Item # Old item # Description Quantity
UNC-10810 1/2 x 1-1/4 HCS 8
UNC-11018 5/8 x 2-1/4 HCS 4
UNC-11228 3/4 x 3-1/2 HCS 4
UNC-11424 7/8 x 3 HCS 6
UNC-FW-08 1/2 Flat Washer F/W USS 4
UNC-FW-14 7/8 Flat Washer F/W USS 6
UNC-LW-08 1/2 L/W 8
UNC-LW-10 5/8 L/W 4
UNC-LW-12 3/4 L/W 4
UNC-LW-14 7/8 L/W 6
UNC-NUT-10 5/8 Nut FHN 4
UNC-NUT-12 3/4 Nut FHN 4
UNC-NUT-14 7/8 Nut FHN 6

All fasteners must meet Grade 8 specifications.

The motor sheave and bushing depend on the
crusher configuration. The specification sheet
or work order identifies the specific drivetrain
items.
449TZ motors are typically 150, 200 or 250
horsepower

062507
Oil System Assembly
(OIL-90004)
Oil Tank Assemblies (OIL-90004)
TOOL-012
UNC-LW-06 OIL-00031-1
UNC-FW-06 OIL-00020
UNC-NUT-06 HYD-BUS10
HYD-TEE05
HYD-NIP06 UNC-10406
UNC-LW-04
OIL-00028
HYD-ELB24 HYD-CAP02
HYD-STR24
BKP-NIP14 OIL-00025
OIL-00014
HYD-NIP07
MTR-00120-17M1
ELE-00077
OIL-00034 w/cover & seal
OIL-00038 BKP-BSH39
BKP-NIP04
HYD-STR44 BKP-BSH37
HYD-BUS10
HYD-STR02
HYD-CAP03
OIL-00002
OIL-00032-1 HYD-ELB11
BKP-HOS01
HYD-STR02
BKP-NIP17
UNC-30610 BKP-CUP02
UNC-LW-06
OIL-00059
HYD-HOS44
OIL-00035
HYD-NIP06
OIL-00036
OIL-00033
HYD-ELB46
UNC-30610
UNC-LW-06 HYD-TEE05
BKP-ELB23
HYD-NIP08
HYD-STR45
HYD-VAL06
BKP-NIP10
HYD-STR43
OIL-00037

BKP-ELB23
OIL-00057

UNC-10616
UNC-FW-06 OIL-00005

BKP-PLG11
BKP-PLG04
Oil Tank Assemblies (OIL-90004)
OIL-90004 1HP Lube Oil System w/reservoir &fil 1
Item # old item # Description Quantity
BKP-BSH37 1" x 1/2"x 1/2" BI Double Tap NPT 1
BKP-BSH39 3/4" M x 1/2" F Galvaniazed Reducer 1
BKP-CUP02 30213 1/4 Pipe Coupling 1
BKP-ELB23 1" Street MNPT x 1" FNPT Street Elb 2
BKP-HOS01 3/4" x 24" OAL Black Pipe cut at 45 1
BKP-NIP04 30411 1/2 Close Nipple 1
BKP-NIP10 1" x 9-1/2" Threaded Pipe Nipple 1
BKP-NIP14 1/2 x 6 OAL Nipple 1
BKP-NIP17 1/4" Schd 40 Blk Pipe 6" Oil Level S 1
BKP-PLG04 1/2 Pipe Plug 1
BKP-PLG11 2" Square Head Plug Cored Black 1
ELE-077 1/2" LL Conduit Body w/ Cover & Sea 1
HYD-BUS10 1280757 1/2 MNPT x 1/4 FNPT Reducer Bush 2
HYD-CAP02 1/2 JIC Plastic Dust Cap 1
HYD-CAP03 3/4 JIC Plastic Dust Cap 1
HYD-ELB11 219858 3/4 MJIC x 3/4 MNPT x 90í 1
HYD-ELB24 69253 1/2MNPT x 1/2FNPT 90 Street 1
HYD-ELB46 2024-8-8S 1/2" MNPT x 1/2" MJIC 90 short 1
HYD-HOS44 22" 8M3K Hose with 8FJX - 8FJX fitt 1
HYD-NIP06 #8 MNPT x #8 MNPT 2
HYD-NIP07 #12 MNPT x #8 MNPT 1
HYD-NIP08 #8 MNPT x #6 MNPT 1
HYD-STR02 184304 1/2 JIC x 1/2 NPT Straight 2
HYD-STR24 184308 3/4 MNPT x 1/2 JIC Male Connector 1
HYD-STR43 #10 MORB x #8 FNPT Adapter 1
HYD-STR44 #8 FJIC x #8 FNPT Adapter 1
HYD-STR45 #16 MORB x #16 FNPT Adapter 1
HYD-TEE05 2090-8-8S 1/2" Female NPT Tee 2
HYD-VAL06 65 psi Check Va 65 psi Check Valve (Vickers) 1
MTR-00120-17M Oil System, 1HP, 460/208-230V, 1725 1
OIL-00002 Filler Cap Assembly 1
OIL-00005 Oil Level Sightglass w/ Screws (w/Te 1
OIL-00014 Oil Filter 0080 MA 010 P 1
OIL-00020 160 psi Pressure Gauge 213.53 2-1/2 1
OIL-00025 Filter Base, Top Mount 1
OIL-00028 335AL 0 0.5 1.4 Ernst Flow Meter 1/2NPT - Use on Oi 1
OIL-00031-1 Cover Plate Rock Protector 1
OIL-00032-1 Cover Plate Top with Holes 1
OIL-00033 PUMP 287x70020 1
OIL-00034 HUB L-075 X 5/8 STD 3/16 X 3/32 KW 1
OIL-00035 SPIDER L-075/AL-075 SOX 1
OIL-00036 HUB L-075 X 3/4 STD 3/16 X 3/32 KW 1
OIL-00037 10 1 100 RV-3 Suction Filter / Tank Strainer 1
OIL-00038 Pump/Motor Mount 6028 1
OIL-00057 Oil Tank Gasket for Cover Plate Top 1
OIL-00059 Temp/Float Switch 86F - 176F 1/4" N 1
TOOL-012 Lifting Eye 3/8" 4

Fasteners
Item # Old Item # Description Quantity
UNC-10406 1/4 x 3/4 HCS 2
UNC-30610 3/8 x 1-1/4 SHCS 6
UNC-10616 3/8 x 2 HCS 4
UNC-FW-04 1/4 Flat Washer F/W USS 2
UNC-FW-06 3/8 Flat Washer F/W USS 6
UNC-LW-04 1/4 L/W 2
UNC-LW-06 3/8 L/W 8
UNC-NUT-06 3/8 Nut FHN 2
Turbo 80 V-Twintm

Pedestal Assembly
(Single & V-Twin)
Turbo 80 Pedestal Assembly (Single&V-Twin Post2000)
SEL-60028 UNC-30812
UNC-60608

TSP-80961

SEL-568273

*RET-AN24

*RET-AW24 SFT-81000

*RET-AN24

* These parts are required for mounting

the hub onto the pedestal shaft and are
part of the complete pedestal kit.
BRG-23226C
MMC-13501
SEL-568012

PIN-50302

PED-80000

BRG-22322K

RET-AN22

RET-AW22

RET-AN22

SEL-568273

BSP-81000

SEL-417511 UNC-LW-08
UNC-10812
081806
Turbo 80 Pedestal Assembly (Single&V-Twin Post2000)
PDK-81000 8209 Pedestal Assembly 80 V TWIN 1
Item # Old item # Description Quantity
BRG-23226C Spherical Roller Bearing (NON TAPERE 1
BRG-22322K Spherical Roller Bearing Tapered 1
BSP-81000 Bottom Seal Plate 80 V-Twin 1
MMC-13501 50013/105 Alignment Tube 35-96 (not XHD) 2
PED-80000 8109 Pedestal housing 80 96 (add PLG) 1
PIN-50302 Hardened Dowel Pin, 1/4 x 3/8, 35 Pe 1
RET-AN22 Retaining Nut AN22 2
RET-AW22 Retaining Washer W22 1
SEL-417511 NAT 417511 T80 V-Twin Lower Seal 1
SEL-568012 106/8104 O-Ring Alignment Tube 568-012 2
SEL-568273 8106 & 8114 O-Ring Upper and Lower 80 568-273 2
SEL-60028 8101 CR60028 80/96 Upper Seal 1
SFT-81000 81000 SHAFT TURBO 80 V-TWIN MAINSHAFT 1
TSP-80961 8103 Top Seal Plate 80 96 1
Fasteners
Item # Old item # Description Quantity
UNC-10812 1/2 x 1-1/2 HCS 6
UNC-30812 1/2 X 1-1/2 SHCS (TSP bolts) 6
UNC-60608 3/8 x 1 SSS CP 2
UNC-LW-08 1/2 L/W 6

All fasteners must be rated Grade 8 or better.

UNC-60608 facilitates separating the seal plate from the pedestal housing.

These components are required to mount the hub on to the pedestal shaft.
The complete pedestal kit contains these components.
RET-AN24 Retaining Nut AN24 2
RET-AW24 Retaining Washer W24 1
Model 80 Pedestal
Hoses and Fittings
Assembly
Model 80 Pedestal Hoses and Fittings

HYD-HOS10
HYD-CMP02
HYD-HOS11

HYD-INV02
HYD-HOS09
HYD-INV03
HYD-ZRK01

HYD-STR02 HYD-HOS08
HYD-STR04 HYD-HOS12

HYD-ELB11 HYD-CAP03 HYD-ELB02

HYD-ELB09 HYD-CAP02 HYD-ELB05
P

P
Pressure hose from the oil pump
R
Return hose to the oil tank

010102
Model 80 Pedestal Hoses and Fittings
Item # Old Item # Description Quantity
HYD-CAP02 1/2 JIC Plastic Dust Cap 1
HYD-CAP03 3/4 JIC Plastic Dust Cap 1
HYD-CMP02 Stauff Clamp Double 1 3/4 3
HYD-ELB02 218998 1/2 MJIC x 3/8 MNPT x 45í 1
HYD-ELB05 219126 3/4 MJIC x 3/4 MNPT x 45í 1
HYD-ELB09 218270 1/2 MJIC x 1/2 MNPT x 90í 2
HYD-ELB11 218396 3/4 MJIC x 3/4 MNPT x 90í 2
HYD-HOS08 #8 (1/2") LOLAPLUS, 300 psi Hydrauli 1
HYD-HOS09 1/4 Grease Line, 51 Long 1
HYD-HOS10 8LOC8RFJSX 1/2 LOC-8 Female JIC Hose Stem 2
HYD-HOS11 12LOC12RFJX 3/4 LOC-12 Female JIC Hose Stem 2
HYD-HOS12 #12 (3/4) LOLAPLUS, 300 psi Hydrauli 1
HYD-INV02 352X4 WTHRHEAD 1/4 Invert Flare x 1/8 NPT 45í Elbow 1
HYD-INV03 402X4 WTHRHEAD 1/4 Invert Flare x 1/8 NPT 90í Elbow 1
HYD-STR02 182842 1/2 JIC x 1/2 NPT Straight 1
HYD-STR04 182968 3/4 JIC x 3/4 NPT Straight 1
HYD-ZRK01 1/8 MNPT Straight Grease Zerk 1

Oil system must be located below the level of the crusher pedestal to facilitate a gravity return.
HYD-CAP02 Dust Cap is installed on the oil supply elbow fitting (HYD-ELB09) for transport.
HYD-CAP03 Dust Cap is installed on the oil return elbow fitting (HYD-ELB11) for transport.
Turbo 80 Tub Assembly
Turbo 80 Tub Assembly

RLS-06

UNC-11012
UNC-LW-10 PSW-80000

MMF-12EYE
UTL-80000-K2
MMF-12680 UNC-40818
UNC-FW-08
ZCS-35960P UNC-LW-08
UNC-11240 UNC-NUT-08
UNC-NUT-12

PIN-50312

TCW-80000

UNC-41020

TSL-80000
BOS-24000

UNC-LW-10
UNC-NUT-10

CHA-80000
UNC-40814 LTL-80000
UNC-FW-08 UNC-40818
UNC-LW-08 UNC-FW-08
UNC-NUT-08 UNC-LW-08
UNC-NUT-08
102803
Turbo 80 Tub Assembly

TCW-80000 80 Tub & Channel Weldment 15" Channe 1

Item # Old Item # Description Quantity
BOS-24000 C-314-B Boss Medium 2-15/16 OD 4
CHA-80000 C-6417 Center Channel Liner 80 12
LTL-80000 C-6414 Lower Tub Liner 80 16
PIN-50312 7420 3/8 x 3 Detention Pins with split ri 6
PSW-80000 8212 80/96 Pedestal Shroud Weldment 1
RLS-06 Rubber Lid Seal 3/4" (T80=300" T16 213
TSL-80000 C-6423 Tub Support Liner 80 2
UTL-80000-K2 C-6404 Upper Tub Liner 80 24
ZCS-35960P C-411 Camlock Casting - Painted 6
Fasteners
Item # Old Item # Description Quantity
MMF-12680 3/4 x 8-3/4 Lid Lock Eyebolt not pai 6
MMF-12EYE 3/4" Lid Eye nut 6
UNC-11012 5/8 x 1-1/2 HCS 4
UNC-11240 3/4 x 5 HCS 6
UNC-40814 1/2 x 1-3/4 PB 24
UNC-40818 1/2 x 2-1/4 PB 80
UNC-41020 5/8 x 2-1/2 PB 4
UNC-FW-08 1/2 Flat Washer F/W USS 104
UNC-LW-08 1/2 L/W 104
UNC-LW-10 5/8 L/W 4
UNC-NUT-08 1/2 Nut FHN 104
UNC-NUT-10 5/8 Nut FHN 4
UNC-NUT-12 3/4 Nut FHN 12

All fasteners must be rated Grade 8 or better.

Crusher Mounting Bolts are supplied by the customer. They must be 1 inch Grade 8 bolts.