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Trio Engineered Products, Inc.

• 12823 Schabarum Avenue • Irwindale, CA 91706 USA • Telephone 626-851-3966 • Fax 626-851-9526

OPERATOR INSTRUCTION MANUAL

Model TC-Series
Cone Crushers

Operation Instruction Manual- rev1


Copyright © 2012 Trio Engineered Products, Inc. All rights reserved.
All editorial content, information, software, photos, video, graphics, music, HTML, sounds or other
material (collectively, "Content") contained within are protected by U.S. copyright and international
treaties and may not be copied without the express permission of Trio Engineered Products, Inc., which
reserves all rights. All Content is copyrighted as a collective work under the U.S. copyright laws, and Trio
Engineered Products, Inc. owns a copyright in the selection, coordination, arrangement and enhancement
of such Content.
Re-use of any of our Content for any purpose other than stated commercial use is strictly prohibited. You
may not modify, publish, transmit, participate in the transfer or sale, create derivative works, or in any way
exploit, any of the Content, in whole or in part. You may not upload, post, reproduce or distribute content
protected by copyright, or other proprietary right, without obtaining permission of the copyright owner.
Operator Instruction Manual

To the Owner & Operator


We have tried to provide information that gives our customers a clear understanding of equipment
construction, function, capabilities and requirements. This information is based on the knowledge and
experience of qualified people at our company and in our field organization. Proper use of this information
provides users of our equipment with high efficiency, maximum service life and low maintenance costs.
That is why we strongly recommend that anyone using our equipment be familiar with this manual.
Information presented here should not be considered authoritative in every situation. Users will as a matter
of course encounter problems and circumstances that raise questions not anticipated here. Such questions
should be directed to their distributor or the manufacturer.
Anyone who uses this equipment for any purpose other than that for which it was intended assumes sole
responsibility for dangers encountered and injuries sustained as a result of such misuse.

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

(1) Read and heed all danger, warning, caution, and notice decals. Know what guards and protective
devices are included and see that each is installed and in operational condition. Additional guards and
protective devices may be required and must be installed by the user (owner) before operating.
(2) Never attempt to maintain, lubricate or adjust this equipment while it is running. Lock out and tag
out all energy sources before doing maintenance, cleaning, adjusting or repairing this equipment. Make it
impossible for anyone to start this machine while others are working on it or in it.
(3) Wear personal protective equipment such as hard hats, ear plugs, safety glasses and safety shoes
when operating this equipment. Do not wear loose clothing or long hair.
(4) Think safety and act safely. Stay alert at all times. Eliminate or neutralize potential hazards as soon
as you spot them. Never allow anyone to engage in horseplay when near this equipment.

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

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Operator Instruction Manual

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

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

The following warning applies to equipment supplied with diesel powered engines:

WARNING
Diesel engine exhaust and some of its constituents are known to the State of California to
cause cancer, birth defects, and other reproductive harm.

127,&(

Product Registration:
All equipment must be registered within 14 days of start-up to receive warranty coverage.
Registration information will only be accepted from the end-users of the equipment, however dealers can
register the equipment for the end-user provided the information registered is the end-user’s information.
In addition to this registration, all cone crushers, vertical shaft impact crushers, and all screens using
urethane media must have an application data sheet on file and approved by Trio.
After completion of the registration and application data sheet, if required, all submitted information will
be reviewed and a confirmation email sent to the email address provided to Trio.
Warranty will be fully enforced upon confirmation of payment and receipt of the above information.
Register online at: http://www.trioproducts.com/register/form
or call Trio at +1 626 851 3966.

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Operator Instruction Manual

Warranty Terms & Conditions


Seller warrants all new equipment manufactured or imported by Trio Engineered Products, Inc. (Trio) against defects
in material or workmanship attributed to the original machine manufacturing. No other warranties are expressed or
implied.
Warranty claims must be made through the dealer or agent responsible for the original equipment sale, as the
equipment will have been registered with them at the time of sale from Trio. Claims must be made within twelve (12)
months or 2,000 working hours, whichever occurs first, from the date of readiness for operation, but not more than
fifteen (15) months from the date of shipment from Trio. All parts claimed to be defective shall be returned to Trio,
freight prepaid, for inspection to determine that the said part or parts are defective.
If it is determined that the fault lies with Trio, Trio will ship a replacement part or parts at no cost, but freight charges
will be paid by customer. If it is determined that the fault does not lie with Trio, a replacement part or parts will be
shipped, freight collect, to the customer with the receipt of a purchase order from the dealer or agent. Trio will not be
responsible for freight costs associated with warranty claims.
When petitioning for a warranty item, the serial number of the equipment must be referenced. The serial number must
be clearly identifiable on the Trio nameplate on the equipment. This warranty is void if:
The serial number plate and/or other markings identifying the machine as Trio have been altered or removed.
The machine was not sold under the Trio brand name or another brand name approved by Trio.
Parts have been used other than those supplied by Trio.
Trio makes no warranty with respect to damages or defects in any product caused by improper installation, operation,
maintenance, and storage or caused by negligence or accident. In addition, any product repaired or altered in any way
as reasonably determined by Trio, that affects the performance or purpose for which the equipment was originally
manufactured, will not be covered under this warranty.
Under this warranty, the buyer will not be entitled to any labor charges involving the repair of the equipment involving
warranty items, unless authorized by Trio in writing.
Warranties of merchantability or of fitness for any particular purpose or arising from the course of dealing or usage of
trade are specifically excluded. Any affirmation of fact, description of goods, or sample or model referred to in this
agreement or elsewhere, whether or not the same relate to production or capability of the goods to perform, are not the
basis of this agreement, unless specifically made a party of the agreement in writing.
Under no circumstances will Trio be responsible for consequential or punitive damages of any nature, whether based
on contract or tort, including but not limited to lost profits, loss of production, delays or other expenses. Under no
circumstances shall the liability of Trio exceed the purchase price of the equipment furnished.
The laws of the state of California shall govern the warranty. The parties agree that exclusive jurisdiction for any claim
for breach of this warranty shall rest in the Los Angeles County Superior Court in the State of California.

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Operator Instruction Manual
Table of Contents

Copyright © 2012 Trio Engineered Products, Inc. All rights reserved. . . . . cover back page
To the Owner & Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a
Warranty Terms & Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . c

Section 1 - Introduction
About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 1
Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 1
Safety Alert Symbol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 1

Section 2 - Safety
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 1
Symbols and Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 1
Hazard Classification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 1
Safety Signs and Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 2
Safety Sign Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 2
Personal Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 3
Management Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 3
Operator Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 3
Work Area Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 4
Equipment & Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 4
Training and Knowledge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 4
What is Lockout & Tagout? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 5
When is Lockout & Tagout required? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 5
Who must apply a lock & tag? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 5
When can a lock and tag be removed? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 5
Who can remove a lock and tag? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 5

Section 3 - General Information


Cone Crusher Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 1
Serial Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 1
Countershaft Rotation Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 1
Cone Crusher Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 2
Cone External Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 2
Cone Internal Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 3
Cone Lubrication System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 4
Cone Crusher Gradation, Capacity & General Specification Charts . . . . . . . . . . . . . . . . .3 - 5
TC Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 6
Cone Crusher Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 8
Cone Crusher Weight & Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 8

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Section 4 - Set-Up & Installation


Crusher Receiving and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 1
Crusher Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 1
Level the Crusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 1
Lifting the Crusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 1
Positioning the Crusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 1
Crusher Frame Grouting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 2
Grouting to a Concrete Foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 2
Mounting Crusher on a Steel Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 3
Mounting Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 3
Crusher Auxiliary Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 4
Hydraulic Power Unit Description & Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 4
Lubrication System Unit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 5
Lubrication System Unit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 5
Countershaft Box Pressure Line Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 6
Lubrication System Unit Settings & Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 7
Test Safeties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 9
Return Oil Temperature Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 9
Return Oil Flow Switch (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 9
Lube Pressure Safety Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 10

Section 5 - Inspection & Lubrication


General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 1
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 1
Inspection Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 1
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 2
General Lubrication Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 2
Lubricating Oil and Hydraulic Oil Quantities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 2
Lubricant Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 2
Lubrication Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 4
Lubricating System Oil Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 5
Cone Crusher Daily Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 6

Section 6 - Start-Up & Operation


Start-Up & Operation Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 1
Initial Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 4

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Section 7 - Adjustments & Troubleshooting


Cone Crusher Crushing Chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 1
Crusher Setting Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 1
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 2
CRUSHER OVERHEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 2
CRUSHER THROWING OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 2
LOW OUTPUT (TONNAGE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 3
CRUSHER STALLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 3
ADJUSTMENT RING TILTED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 3
COUNTER SHAFT IS SEIZED OR BROKEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 4
BOWL STALLED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 4
LOOSE BOWL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 4
LOOSE SOCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 4
LOOSE BOWL LINER OR MANTLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 5
GEAR AND PINION TOOTH WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 5
EXCESSIVE VIBRATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 6
WEAR ON HEAD OR BOWL SEATING SURFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 6
GEAR AND PINION NOISY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 6
MAIN SHAFT BROKEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 6
DUST AND DIRT GETTING INTO LUBE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 7
HEAD SPIN HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 7

Appendix A - Torque Specs


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

Appendix B - V-Belt Drive Information


General Belt Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
General Belt Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Belt Drive Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Maintaining V-Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4
Tension-Deflection Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4
Belt Type Cross-Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6
Belt Idlers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6
Inside Idler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6
Backside Idler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6
Kiss Idler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6

CRSH-OI-0004ENG (NOV-2012) iii Model TC-Series Cone Crushers


Operator Instruction Manual
Table of Contents

Appendix C - Crushing Terminology


Glossary of Terms & Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Backlash: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Bridging: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Capacity: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Cavity: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Choke Feed: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Closed Circuit Crushing: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Closed Side Setting (CSS): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Crushing Chamber: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Discharge Opening: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Drive: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Drive Guard: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
Feed: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
Feed Opening: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
Feed Opening (Closed Side): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
Feed Opening (Open Side): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
Fines: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
Finished Product: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
Friable: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
Gradation: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
Grizzly: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
Liners: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
Minimum Discharge Setting: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
Open Circuit Crushing: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
Oversize: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
Parallel Zone: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
Plugging: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
Product Size: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
Reduction Ratio: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
Scalping: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
Top Size: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
Tramp Material: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
Yield: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3

CRSH-OI-0004ENG (NOV-2012) iv Model TC-Series Cone Crushers


Operator Instruction Manual
About This Manual

Section 1 - Introduction
DANGER
About This Manual
This book is an operation instruction manual for
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the owner or operator of the equipment described
within. This manual contains information
We strongly recommend that anyone working with necessary for proper and safe
this equipment become familiar with the manual, operation. Carefully read this
whether or not you have experience with similar manual before attempting to
equipment. operate. Failure to read and heed
instructions preceded by a safety-
This manual will help you understand how to alert symbol (Figure 1 - 2) can
install your equipment, prepare it for operation, cause death or severe personal
and perform normal operation and general injury as well as equipment and
maintenance tasks. environmental damage.

General maintenance tasks and utilization of Experience has shown it is to your advantage to
special tools refer to keep a copy of this manual where operators can
"Cone Standard Job Procedures" consult it as needed and to have a copy on file in
your office, so that shift leaders or supervisors can
Intended Use conveniently refer to it. Additional copies can be
The Cone Crusher described within is designed to ordered through your distributor.
crush rock, recycle concrete, and also a wide range This equipment is precisely engineered, highly
of other products and materials. Use of functional, and heavy-duty designed to provide
this machinery in any other way is years of excellent service performing to customer
prohibited and contrary to its intended use. specifications. We are proud to manufacture this
equipment for your use and profit. We also take
Safety Alert Symbol pride in the quality of our service and replacement
The safety alert symbol (Figure 1 - 1) is used to parts.
alert you to potential personal injury hazards. Only your Parts Catalog, identified with your
Obey all safety messages that follow this machine’s serial number, is an authoritative source
symbol to avoid possible injury or death. of part numbers and part descriptions for your
equipment.
Ongoing improvement of product design may in
the future result in changes to some parts. Use part
numbers, model numbers and serial numbers from
your Parts Catalog to communicate with your
distributor.

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CRSH-OI-0004ENG (NOV-2012) 1-1 Model TC-Series Cone Crushers


Operator Instruction Manual
About This Manual

This Page Intentionally Left Blank

CRSH-OI-0004ENG (NOV-2012) 1-2 Model TC-Series Cone Crushers


Operator Instruction Manual
Introduction

Section 2 - Safety Hazard Classification


A multi-tier hazard classification system is used to
Introduction communicate potential personal injury hazards.
The following signal words used with the safety
The Cone Crusher is designed to crush rock,
alert symbol indicate a specific level of severity of
recycle concrete, and also a wide range of other
the potential hazard (Figure 2 - 1). Signal words
products and materials. Use of this machinery in
used without the safety alert symbol relate to
any other way is prohibited and contrary to its
property damage and protection only. All are used
intended use.
as attention-getting devices throughout this
When our equipment is used for purposes other manual as well as on decals and labels fixed to the
than those for which it was designed, user assumes machinery to assist in potential hazard recognition
sole responsibility for any injuries or damage that and prevention.
may result from said misuse. We emphatically
recommend that this equipment be operated only DANGERLQGLFDWHVDQLPPLQHQWO\
DANGER KD]DUGRXV VLWXDWLRQ ZKLFK LI QRW
by personnel who are trained in its use. DYRLGHG ZLOO UHVXOW LQ GHDWK RU
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We make no guarantee, either expressly or by
implication, that this equipment meets all local or
WARNING LQGLFDWHVDSRWHQWLDOO\
federal safety regulations. It is the responsibility of WARNING KD]DUGRXV VLWXDWLRQ ZKLFK LI QRW
those individuals who own and/or operate this DYRLGHG FRXOG UHVXOW LQ GHDWK RU
equipment to verify that all safety regulations are VHULRXVLQMXU\
complied with before starting either this unit or
any associated equipment. CAUTION LQGLFDWHV D SRWHQWLDOO\
CAUTION KD]DUGRXV VLWXDWLRQ ZKLFK LI QRW
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Symbols and Standards PRGHUDWHLQMXU\

Important symbols and hazard classification CAUTION XVHGZLWKRXWWKHVDIHW\


standards relating to safe equipment operation are CAUTION DOHUW V\PERO LQGLFDWHV D
used throughout this manual. Make sure you read, SRWHQWLDOO\ KD]DUGRXV VLWXDWLRQ
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understand and follow all DANGER, WARNING LQSURSHUW\GDPDJH
and CAUTION decals on equipment.
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CRSH-OI-0004ENG (NOV-2012) 2-1 Model TC-Series Cone Crushers


Operator Instruction Manual
Symbols and Standards

Safety Signs and Icons


Beneath all safety regulations lies a set of 5HDGPDQXDO
common-sense rules. Everyone who works with or
near heavy equipment must be aware of those
rules. To foster and maintain such an awareness in 6DIHW\DOHUWV\PERO
our customers, safety signs are fixed on our
equipment.
Icons on our safety signs remind both workers and
supervisors of common hazards and procedures /RFNRXWSRZHUEHIRUHVHUYLFLQJ
PDFKLQH
that, in the course of a busy day, they might
otherwise forget. The language of the icons is
simple and direct (Figure 2 - 2). :HDUKHDULQJSURWHFWLRQZKHQ\RX¶UH
QHDUWKLVHTXLSPHQW
Safety Sign Maintenance
Replace any missing or damaged safety signs. :HDUH\HSURWHFWLRQZKHQ\RX¶UH
Keep operator safety in mind at all times. Use mild QHDUWKLVHTXLSPHQW
soap and water to clean safety signs. Do not use
solvent-based cleaners because they may damage :HDUUHVSLUDWRU\SURWHFWLRQZKHQ
the safety sign material. \RX¶UHQHDUWKLVHTXLSPHQW

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CRSH-OI-0004ENG (NOV-2012) 2-2 Model TC-Series Cone Crushers


Operator Instruction Manual
Personal Safety

Personal Safety • Replace guards, covers and shields when the


task for which you removed them is finished.
This equipment is designed with the safety of all
personnel in mind. Never attempt to change, • Block parts as necessary to prevent their
modify, eliminate or bypass any of the safety sudden movement while people are working
devices installed at the factory. Guards, covers and on the machine.
shields installed around moving parts at the factory • Never attempt to clear away jammed feed
are meant to prevent accidental injury to operators material, discharge material or other stoppage
and other personnel. Do not remove them. while the machine is running. Stop the
equipment, lock out and tag out before
DANGER touching this machine with your tools or your
hands.
Sometimes, at a customer’s • Wear proper personal protective equipment,
request, equipment is shipped including eye protection, hard hat and safety
without certain features such as a shoes, whenever you’re near this machine
drive sheave. In such cases it is the while it is running.
customer’s responsibility to guard
the machine properly. • Dress appropriately in every way. Never wear
loose clothes, long hair, coat tails, jewelry,
We recommend the following basic safety pockets full of tools or any other item that
practices: could get caught in moving parts.
• Know where your fellow workers are. Always
Management Responsibilities look around and inside this machine before
• Make sure that everyone working on or near starting it. Make sure nobody is in the way of
this equipment is familiar with safety moving parts or working on the machine.
precautions. Have a supervisor at the job site • Lift with your legs, not with your back. Keep
responsible for job safety. the weight close to your body. If the load is
• Give crew members specific safety more than 40 lbs., get someone to help you.
responsibilities and instruct them to report any • Never engage in horseplay when near this
unsafe conditions to their supervisor machine, or any other.

Operator Responsibilities • Report any defective machinery or equipment


and unsafe conditions or activity to your boss
• Read all danger, warning, caution and notice immediately.
signs.
• Don’t limit safety practices to the few rules
• Always lock out and tag out involved energy listed here. Think safety and act safely at all
sources before performing maintenance or times.
adjustments on this equipment. Make it
impossible for anyone to start this machine • Most of all, know your equipment. Understand
while others work on it or in it. the machinery, the conditions under which it
operates and what it is capable of doing.
• Never remove any guard, cover or shield when
this equipment is in motion.

CRSH-OI-0004ENG (NOV-2012) 2-3 Model TC-Series Cone Crushers


Operator Instruction Manual
Personal Safety

Work Area Safety Equipment & Tools


• Keep the work area as neat and clean as • Clean tools that are properly labeled and stored
practical. are safer tools. Keep your tools in good order.
• Keep all product safety signs clean, clear and • Keep drive belts and sheaves in good
current. condition. Frayed belts or cracked sheaves are
not only dangerous, they cost you downtime.
• Make sure all electrical equipment is properly
grounded. Wet spots near electrical current are • Always use mechanical assistance to lift heavy
especially dangerous. loads. Never overload a hoist, crane, jack or
other lifting device. Check lifting tackle
• Store hazardous materials in restricted access
regularly; replace it at the first sign of stretch,
areas and mark them clearly. Federal
fraying or other wear.
regulations require special labeling of certain
materials. • Keep your equipment clean, free of dirt and
grease, so that loose, cracked or broken parts
• Never start an engine in an enclosed space
are more easily spotted. Replace defective
without properly venting the exhaust.
parts as soon as they are discovered.
• Do not smoke or allow smoking near fuels and
solvents. Never strike a spark or use an open Training and Knowledge
flame near fuels and solvents.
Proper training and equipment knowledge is
• Store flammable fuels, solvents and gases in essential to the safe operation of this machine.
secure, well ventilated areas. Never allow Carefully read the entire manual before attempting
fumes to accumulate in the storage area. Use to operate. Keep this manual for future reference.
nonflammable solvents for cleaning parts and
equipment whenever possible.
WARNING
• Know where fire extinguishers and other fire-
suppression equipment are located. Learn how Do not operate this equipment until
to use them effectively. you have been trained in its
operation or maintenance. This
• Be alert and wary around any pressurized
equipment may only be operated or
system, hydraulic or pneumatic. High-pressure
maintained by trained personnel,
oils and gases are very dangerous.
who have demonstrated their
ability to do so safely.

CRSH-OI-0004ENG (NOV-2012) 2-4 Model TC-Series Cone Crushers


Operator Instruction Manual
What is Lockout & Tagout?

What is Lockout & Tagout? When can a lock and tag be removed?

Lockout & Tagout is a procedure that’s designed After performing these six steps:
to prevent the unexpected or accidental startup of 1) All safety guards are back in place.
equipment and to alert all workers whenever it is
unsafe to operate any piece of equipment. When 2) All work is complete and tools are put away.
used as intended, Lockout & Tagout also protects 3) All workers are notified that a lock is being
personnel from energy stored in devices such as removed.
springs, accumulators, batteries, hydraulic
systems, etc. 4) All workers are positioned safely for startup.
5) Controls are positioned for safe startup.
When is Lockout & Tagout required?
6) The machine is ready for safe operation.
• Any time anyone is maintaining, repairing,
lubricating, or, for whatever reason, working Who can remove a lock and tag?
on the equipment.
• Only the person who applied a lock and tag is
• When the equipment is broken or, for whatever permitted to remove them.
reason, unfit or unsafe to operate.
Lockout & Tagout rules laid out here are generic.
• While clearing blocked or jammed To get instructions for your particular workplace,
mechanisms. consult your employer’s lockout/tagout procedure.
• Whenever the equipment is left unattended.

Who must apply a lock & tag?


• Any person working on the equipment.
• Foreman or other person responsible for the
work being done.
• If several people are working on a machine at
the same time, each person must apply his or
her own lock and tag.

CRSH-OI-0004ENG (NOV-2012) 2-5 Model TC-Series Cone Crushers


Operator Instruction Manual
What is Lockout & Tagout?

This Page Intentionally Left Blank

CRSH-OI-0004ENG (NOV-2012) 2-6 Model TC-Series Cone Crushers


Operator Instruction Manual
Cone Crusher Description

Section 3 - General Information Serial Numbers


Crushers are assigned a serial number which is
Cone Crusher Description stamped on a plate on the machine.
The Cone Crusher is a high-capacity compression- Other components on the crusher may have
type crusher that fractures material along its separate serial numbers or identifying numbers.
natural fault lines.
Always give the model and serial number or
Product size is controlled by adjusting the distance identifying number of your crusher when ordering
between the bowl liner and mantle. The bowl liner parts or requesting information. If parts are
and mantle are commonly referred to as liners and required for the other certain components, you
make up the crushing chamber of the cone. These should supply that serial number or identifying
liners are replaceable and come in several different number as well as the crusher numbers.
profiles depending upon the type of material to be
crushed and customer preference.
Countershaft Rotation Direction
The crusher utilizes a hydraulic cylinder system
The TC-Series cone crushers are driven by a
which provides protection for the crusher as well
countershaft fitted with a belt drive sheave. The
as a simple method for release and clearing should
direction of rotation is counter clockwise as
an uncrushable object enter the crushing chamber.
viewed from the drive end of the countershaft. See
The Cone Crusher may be mounted or installed in (Figure 3 - 2).
static stationary, modular skid, as well as portable
wheel or mobile track plant applications. No
matter which type application the Cone Crusher is
used in, it must be level to operate properly.

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CRSH-OI-0004ENG (NOV-2012) 3-1 Model TC-Series Cone Crushers


Operator Instruction Manual
Cone Crusher Components

Cone Crusher Components To be certain your machine has the proper


components, check to ensure it was equipped as
Be familiar with the crusher’s components. ordered.
Each model/size cone crusher consists of similar
components, however certain models/sizes may Cone External Components
not have all the same components as other models/ See (Figure 3 - 3) for a side view of a typical cone
sizes. crusher’s external components.

5
6
4

3 7 8
9

10

11

1 - Crusher Main Frame 8 - Drive Motor


2 - Clamping Cylinders 9 - Electrical Controls & Power Unit
3 - Bowl Adjusting Gearbox & Motor (See separate Hydraulic Supplement Manual)
4 - Upper Frame Assembly 10- Crusher Lubrication System Unit
5 - Feed Hopper (See separate illustration for details)
6 - Adjustment Gear 11- Lubrication Oil Lines
7 - Countershaft Drive Sheave

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CRSH-OI-0004ENG (NOV-2012) 3-2 Model TC-Series Cone Crushers


Operator Instruction Manual
Cone Crusher Components

Cone Internal Components


See (Figure 3 - 4) for a cutaway view of a typical
cone crusher’s internal components.

12
13
14 15
11

16
10
17
9
18
8
19
7
20
6 21 22
23
5

4
3
24
2
1
25
26
1 - Crusher Main Frame 14- Torch Ring
2 - Outer Eccentric Bushing 15- Locking Cylinder
3 - Inner Eccentric Bushing 16- Lock Ring
4 - Frame Arm Guard 17- Seat with Liner
5 - Main Shaft 18- Socket Liner
6 - Cone Head 19- Socket
7 - Mantle 20- Eccentric with Gear
8 - Bowl Liner 21- Countershaft Box Guard
9 - Bowl 22- Countershaft Box
10- Adjustment Ring 23- Countershaft Flinger & Seal Assembly
11- Adjustment Gear 24- Countershaft
12- Feed Hopper 25- Bushings
13- Main Shaft Nut 26- Countershaft Pinion Gear

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CRSH-OI-0004ENG (NOV-2012) 3-3 Model TC-Series Cone Crushers


Operator Instruction Manual
Cone Crusher Components

Cone Lubrication System Components


See (Figure 3 - 5) for views of a typical cone
crusher’s lubrication system components.

13 14 15 16 17 18 19

12 2
A 11
Oil Cooler & Fan 10 3
Removed for Clarity 9
of End View 8
4
7 6 5
21 12 16 22 23
20

28

27

26

25 24
A
1 - Oil Reservoir 11- Ball Valves 21- Temperature Switch
2 - Oil Level/Temp. Gauge 12- Temperature Gauges 22- Oil Cooler Motor & Fan
3 - Pump 13- Flow Switch 23- Oil Cooler
4 - Motor Pump Coupling 14- Pressure Switch 24- Gate Valve & Gasket
5 - Coupling Guard 15- Pressure Gauge 25- Oil Filter/Strainer
6 - Pump Drive Motor 16- Adjustable Bypass Valve 26- Electric Junction Box
7 - Heater 17- Breather/Fill Cap 27- Return Oil Filter Basket
8 - Heater Housing 18- Filter 28- Electric Junction Box
9 - Temperature Gauge 19- Pressure Gauge
10- Temperature Switch 20- Temperature Switch

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CRSH-OI-0004ENG (NOV-2012) 3-4 Model TC-Series Cone Crushers


Operator Instruction Manual
Cone Crusher Gradation, Capacity & General Specification Charts

Cone Crusher Gradation, Capacity &


General Specification Charts
The following pages show charts for each model/
size cone crusher. These charts are general in
nature and should serve to give the operator an idea
for the crusher’s capabilities.

CRSH-OI-0004ENG (NOV-2012) 3-5 Model TC-Series Cone Crushers


Operator Instruction Manual
Cone Crusher Gradation, Capacity & General Specification Charts

TC Series
C
A

Product Range

MODEL A B C

mm mm mm

TC36 1,321 2,700 1,304

TC51 1,765 3,185 1,517

TC66 2,261 3,960 2,045

TC84X 2,490 4,650 1,375

Typical Physical Properties

MAX INSTALLATION MAX MAINTENANCE ROTATING


MODEL MACHINE WEIGHT RECOMMENDED POWER
WEIGHT PART WEIGHT SPEED
kg lbs kg lbs kg lbs kw hp rpm

TC36 12,000 26,455 5,000 11,023 <2,700 <5,952 75-90 100-125 585

TC51 22,500 49,604 9,200 20,283 <5,000 <11,023 160-200 200-250 625

TC66 43,500 95,901 19,000 41,888 <10,000 <22,046 225-250 300-350 550

TC84X 78,000 171,960 36,500 80,469 <17,000 <37,479 400-450 500-600 480-530

Capacity Chart (TPH)

CSS
MODEL CAVITY
6mm 10mm 13mm 16mm 19mm 25mm 32mm 38mm 51mm 64mm
TC36 Standard - 45-60 55-75 70-90 80-105 110-135 125-155 145-190 - -
Short Head 45-65 65-85 80-110 90-125 115-150 - - - - -
TC51 Standard - - 100-135 110-160 135-200 155-265 175-315 230-350 310-420 -
Short Head 70-100 90-130 115-190 140-230 175-260 200-300 - - - -
TC66 Standard - - - 160-210 175-240 250-340 290-410 320-495 380-570 480-770
Short Head 120-165 150-230 190-290 220-330 250-370 300-405 - - - -
1,200-
Standard - - - - 360-480 480-680 600-860 720-940 900-1,300
TC84X 1,500
Short Head 215-315 300-415 360-500 410-580 450-630 520-700 - - - -

Note: Indicated capacity is neither minimum or maximum values. Actual capacity will depend on eccentric speed, chamber selection, and feed parameters. For best
results, operating the cone crusher with a full crusher chamber is recommended. However, all TC series crushers accept reasonable variations in feed rates.

CRSH-OI-0004ENG (NOV-2012) 3-6 Model TC-Series Cone Crushers


Operator Instruction Manual
Cone Crusher Gradation, Capacity & General Specification Charts

TC Series

Typical Physical Properties

DISCHARGING
POWER OF
OPENING
MODEL CAVITY STANDARD HEAD SHORT HEAD ELECTRIC
ADJUSTMENT
MOTOR
RANGE
Minimum Minimum
Close feed Open feed Close feed Open feed Standard Short
discharging discharging
opening opening opening opening Head Head kW
opening opening
(mm) (mm) (mm) (mm) (mm) (mm)
(mm) (mm)

EC 25 160 178 - - - 25-38 -

C 13 138 158 6 61 76 13-38 6-19


TC36 75/90
M - - - 3 48 60 - 3-16

F 9 85 105 3 33 40 9-22 3-13

EC 25 255 281 16 106 128 25-50 16-25

C 19 225 251 10 84 105 19-50 10-20


TC51 160/200
M 16 200 221 6 72 90 16-38 6-16

F 13 108 135 3 50 60 13-30 3-16

EC 38 320 330 16 106 115 38-64 16-25

C 25 215 241 10 95 106 25-50 10-25


TC66 250
M 22 195 213 6 55 72 22-38 6-19

F 16 170 188 5 35 55 16-38 5-13

EC 38 399 427 16 152 203 38-64 16-25

C 32 331 367 13 127 178 32-64 13-25


TC84X 400
M 25 308 343 10 92 134 25-60 10-25

F 19 259 293 6 50 99 19-45 6-25

Note: E = Extra Coarse; C = Coarse; M = Medium; F = Fine


Details may vary due to product updates and/or customisation. Data for marketing use only. Please contact us for a solution designed to meet your unique needs.

CRSH-OI-0004ENG (NOV-2012) 3-7 Model TC-Series Cone Crushers


Operator Instruction Manual
Cone Crusher Specifications

Cone Crusher Specifications Cone Crusher Weight & Dimensions


Specifications for the cone crusher are found in the Weights and dimensions for the cone crusher are
serial specific parts manual. found in the serial specific parts manual.

CRSH-OI-0004ENG (NOV-2012) 3-8 Model TC-Series Cone Crushers


Operator Instruction Manual
Crusher Receiving and Inspection

Section 4 - Set-Up & Installation Lifting the Crusher


To lift the crusher, use machinery, lifting slings,
Crusher Receiving and Inspection and equipment of sufficient size to safely handle
the load. When hooking lifting slings to the
When the crusher is delivered, thoroughly check
crusher, always attach to the crusher frame. Never
for damage that might have occurred during
lift complete crusher by attaching to upper frame
transport. Do not set up the unit until the
assembly or feed hopper. If only upper frame
inspection is complete.
assembly is to be removed from crusher for
Note any damage on the shipper’s bill of lading maintenance or component replacement, fasten
and have the deliverer sign your description of any lifting slings and equipment to lifting lugs
problem(s). Keep a copy of the marked-up bill of provided on top of assembly. See (Figure 4 - 1)
lading for your files. Take photos if possible. File
a claim with the carrier within 30 days of receipt of
the equipment. Lifting Lugs(Holes)
Check loose parts, small parts boxes, and tools
against the packing list to ensure all items shipped
are present.

Crusher Installation
To operate correctly, the crusher must be installed
on a firm, level foundation. Make sure the
foundation and supporting structures are strong
enough to support the dynamic load of the
operating crusher and related equipment with
material moving through it. Lifting Lugs(Holes)

)LJXUH7\SLFDO&RQH&UXVKHU/LIWLQJ/XJV(Holes)
Level the Crusher
Wherever the crusher is installed, it must be Positioning the Crusher
mounted level. For stationary units, the supporting
Allow enough room around the crusher for
structure must be level when completed. For skid-
conveyors, loaders, and maintenance equipment
mounted, mobile, or portable plant units, the frame
and personnel. Allow enough clearance below
must be leveled. Use leveling jacks or suitable
crusher for discharge material conveyor and also
blocking as needed to bring the unit to a level
clearance above and around the unit for access to
position.
maintain, repair or replace components on the
crusher.

CRSH-OI-0004ENG (NOV-2012) 4-1 Model TC-Series Cone Crushers


Operator Instruction Manual
Crusher Frame Grouting

Crusher Frame Grouting


To install the crusher on a concrete foundation or to WARNING
grout a steel structure to a concrete slab, proceed as
follows: Always make sure the lifting
equipment is of sufficient capacity
Grouting to a Concrete Foundation to lift the required weights.

1) When using epoxy or concrete grout, place the 6) Using an overhead crane or other lifting
crusher on hardwood blocks positioned beneath device that is capable of lifting the total
each of the four (4) corners of the frame weight of the crusher, attach suitable steel
assembly. Wood is used because grout shrinks cable slings to the four (4) ribs near the lower
when it sets, and the wood will shrink with the corners of the main frame flange.
grout. See (Figure 4 - 2)
WARNING
2) The blocks should be able to support the
crusher approximately 1" to 1-1/2" (25 to The steel cables should be held
38mm) for epoxy grout and 2" to 2-1/2" (50 to apart by heavy-duty spreaders to
64mm) above the top of the concrete foundation prevent any shifting of the cables.
to allow for the proper thickness of concrete
grout. 7) Lower the crusher in position on the
foundation on top of the hardwood blocks.
3) The surface of the foundation, where the
grouting will be poured, should be left rough 8) Level the crusher by inserting steel shims
and be carefully cleaned before grouting. between the underside of the main frame
flange on top of the wood blocks.
4) When using concrete grout, this surface should
be thoroughly saturated with water and kept 9) Construct a form around the inside and outside of
wet to prevent any rapid absorption of water the main frame flange to contain the epoxy or
from the grout mix. However, remove any concrete during pouring. Use 1” x 4” (25 x
excess water from the top of the foundation 102mm) wood strips for the forms. Locate and
just prior to pouring the concrete grout. Use a fasten the 1" x 4" (25 x 102mm) wood strips, 1/2"
concrete grout mixture which contains a non- (13mm) from the outside of the main frame
shrink additive to minimize the shrinkage. flange. On the inside, place the forms against the
side of the foundation and the underside of the
5) Mix and pour the epoxy grout following the main frame flange. All forms must be thoroughly
instructions in the carton, paying particular waxed with several coats of ordinary paste wax.
attention to the temperature requirements. This will prevent the wood strips from sticking to
the grout. All joints and seams must be sealed
with tubes of silicone caulk to prevent leakage of
the grout during pouring.

CRSH-OI-0004ENG (NOV-2012) 4-2 Model TC-Series Cone Crushers


Operator Instruction Manual
Crusher Frame Grouting

10) To prevent air entrapment under the crusher,


pour the grout from one place at a time, 4 5
allowing the grout to cover an area of 3
approximately 2 feet (.6 meters) on either side
of the pouring spot. Then move to a position
where the previous pour flow has stopped and
pour again. Continue this procedure until
grouting is completed.

127,&( 2
1
Do not pour the grout into more
1 - Concrete Foundation
than one area at a time.
2 - Wood Forms
3 - Foundation Bolt
11) Epoxy or concrete grout should harden
4 - Outline of Crusher
sufficiently in 2 or 3 days to permit operation.
5 - Epoxy Grout - As it appears after
After the grouting has hardened, tighten the
forms removed.
crusher firmly to the foundation.
)LJXUH7\SLFDO&RQH&UXVKHU)UDPH*URXWLQJ

Mounting Crusher on a Steel Structure


When crusher is to be mounted directly onto a steel
structure, it is only necessary to level, shim and
firmly tighten the crusher to the structure.

Mounting Drive Motor


When mounting crusher drive motor, be sure it is
mounted on a similar mounting isolation platform
as the crusher. This will insure the drive motor
will not allow the drive belts to be slack under
load.

CRSH-OI-0004ENG (NOV-2012) 4-3 Model TC-Series Cone Crushers


Operator Instruction Manual
Crusher Auxiliary Equipment

Crusher Auxiliary Equipment


The crusher utilizes a system to provide hydraulic
power and controls (see separate Hydraulic
Supplement Manual) as well as a separate unit
which supplies lubricating oil to the crusher.
Make sure these units’ oil lines are properly
connected and tightened as well as the electrical
drive motor(s) are properly connected and run in
the correct direction.

Hydraulic Power Unit Description &


Installation
The full description and installation instructions Hydraulic Power
for this unit are found in the separate Hydraulic and Controls Unit
Supplement Manual provided with the crusher.
Generally, this unit should be placed as close to the
crusher as possible and clear of possible rock
impacts from the crusher. It also should be placed )LJXUH7\SLFDO+\GUDXOLF3RZHUDQG&RQWUROV8QLW
so the operator can view the crusher when standing
at the controls. Standard connecting hoses lengths
are around 6M (20 feet). See (Figure 4 - 3)

CRSH-OI-0004ENG (NOV-2012) 4-4 Model TC-Series Cone Crushers


Operator Instruction Manual
Crusher Auxiliary Equipment

Lubrication System Unit Description Lubrication System Unit Installation


The lubrication system consists of an oil reservoir, The lubrication system must be mounted below the
pump and motor, pump relief valve, filter, filter crusher’s drain line to prevent oil from being able
relief valve, oil cooler, lube pressure switch, to back up into the crusher and cause oil leaks or
immersion heater and high temperature switch. other problems.
Sensors are used at various locations in the circuit
The drain/return oil line must have a minimum
to monitor the oil temperature. Pressure gauges
pitch of 25mm (1 inch) for every 300mm (12
are used at various locations to monitor oil
inches) of run to provide proper oil drainage from
pressure as it flows through the entire circuit.
crusher. See (Figure 4 - 5)
See (Figure 4 - 4)
The drain/return oil line should be less than 5M
(16 feet). The bottom of the lube unit should be
greater than 1800mm (71 inches) to the crusher
mounting surface. See (Figure 4 - 5)

1
Lubrication System
Unit

4
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CRSH-OI-0004ENG (NOV-2012) 4-5 Model TC-Series Cone Crushers


Operator Instruction Manual
Crusher Auxiliary Equipment

Countershaft Box Pressure Line Connection


The lubrication system pressure lines must run to
the bottom center of the crusher as well as to the
top of the countershaft box housing to assure
proper lubrication oil circulation.
See (Figure 4 - 6)

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CRSH-OI-0004ENG (NOV-2012) 4-6 Model TC-Series Cone Crushers


Operator Instruction Manual
Crusher Auxiliary Equipment

Lubrication System Unit Settings & 6) Set cooling fan switch (if adjustable). Normal
Adjustment setting is 100°F (37.8°C) to 110°F (43°C).
See (Figure 4 - 8)
The lubrication system unit must be adjusted after
it is located and installed at the crusher site. The
following steps outline these settings and
adjustments:

1) Make sure proper amount and grade of oil are


in tank.

2) Open tank gate valve.

3) Check pump for proper rotation.

4) Check cooling fan for proper rotation (air


blows through the cooling fins).
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5) Set heater switch (if adjustable). Normal
setting is at 80°F (27°C). See (Figure 4 - 7)
7) Remove cover on bottom of return oil
temperature switch and set it to 130°F (55°C).
See (Figure 4 - 9)

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)LJXUH5HWXUQ2LO7HPSHUDWXUH6ZLWFK

CRSH-OI-0004ENG (NOV-2012) 4-7 Model TC-Series Cone Crushers


Operator Instruction Manual
Crusher Auxiliary Equipment

8) Check to make sure ball valves are turned to


allow oil to run through cooler. Table 4 - 1 Cone Crusher Lubrication System
See (Figure 4 - 10) Pressure Setting

MODEL PRESSURE
TC36 36,
TC51 36,
TC66 36,
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TC84
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KDYHEHWZHHQWKHOXEHOLQHDWWKHVNLGDQG
WKHFRXQWHUVKDIWER[RQFUXVKHU

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9DOYHV

9) Start lube system pump and allow the oil to


circulate until it has reached 60°F (16°C).
Adjust to correct pressure. See (Table 4 - 1)

127,&(
Once the cone has started and the oil heats
up, the pressure will need to be fine tuned.
The recommended pressure should be
maintained when cone temperature is
around 98°F (37°C) which means the
pressure may be slightly higher until cone
reaches that temperature.

CRSH-OI-0004ENG (NOV-2012) 4-8 Model TC-Series Cone Crushers


Operator Instruction Manual
Test Safeties

Test Safeties

Return Oil Temperature Switch

1) Start the cone when oil has reached 80°F


(27°C). The countershaft should rotate
counterclockwise.

2) Turn adjustment knob on return oil


temperature switch down below ambient
temperature. Cone should shut off after 15
seconds indicating the safety circuit is wired
correctly and functioning properly.

Return Oil Flow Switch (If Equipped)

1) Start the cone when oil has reached 80°F


(27°C). The countershaft should rotate
counterclockwise.

2) With a screwdriver, gently push the flap inside


the return line towards the flow of oil until
you hear the contacts actuate.
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See (Figure 4 - 11) Cone should shut down
indicating it is wired correctly and functioning
properly.

CRSH-OI-0004ENG (NOV-2012) 4-9 Model TC-Series Cone Crushers


Operator Instruction Manual
Test Safeties

Lube Pressure Safety Switch 3) Loosen jam nut on adjustment at the top of
switch.
1) Start the cone. It may be necessary to wait a
while if a soft start is set for a limited amount 4) Test the switch by turning the adjustment until
of starts. the lever on the inside travels to the top, thus
actuating the contacts. The cone should stop.
2) Remove cover of the pressure safety switch.
See (Figure 4 - 12) 5) Re-adjust the switch so the contacts actuate
when the cone is at 60 - 70% of the normal
operating pressure.
(Example - A cone calculated as needing
12 PSI at the gauge on the skid to operate
should be set to shut down when the
pressure is 7 - 8 PSI)

127,&(
The cone pressure is measured at the gauge
nearest to the cone. At no time should the
oil pressure at the countershaft be less
than 5 PSI.
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CRSH-OI-0004ENG (NOV-2012) 4 - 10 Model TC-Series Cone Crushers


Operator Instruction Manual
General

Section 5 - Inspection & Lubrication Inspection Procedures


The following are major steps in a daily inspection
General of your crusher:
To insure efficient operation, the crusher should be 1) Lockout & Tagout all power to crusher before
inspected, lubricated, and have necessary any lubrication or maintenance is performed.
maintenance adjustments and repairs made at
regular intervals.
DANGER
Inspection Failure to Lockout & Tagout will
Performing a daily inspection is a good way to result in death or severe personal
keep your crusher performing safely and injury.
efficiently. Utilizing the Daily Inspection Form at
the end of this section as a guide will help you 2) Look the complete crusher over carefully.
establish a maintenance routine, provide a When sure that everything is in good order
maintenance record, and help monitor the and safe, the crusher should be ready to
condition of the equipment. operate.

3) Remove the lock and tag.

4) Clear the area and prepare to start the crusher.

CRSH-OI-0004ENG (NOV-2012) 5-1 Model TC-Series Cone Crushers


Operator Instruction Manual
Lubrication

Lubrication Lubricating Oil and Hydraulic Oil Quantities


The table below shows the approximate quantities
General Lubrication Information of the respective lubricating and hydraulic units
The greatest single factor governing the life and for each model crusher.
efficiency of any piece of machinery, where
friction is encountered, is proper lubrication. Table 5 - 1 Lubricating Oil and Hydraulic Oil
Lubrication is critical to the Trio cone crusher. Quantities
The lubrication system provides oil to the crusher
components, protecting them from friction and Lubricating Oil Hydraulic Oil
Cone Qty. Qty.
heat. Not only does the lube oil prevent metal-to- Model
metal contact between internal components, it also Liters Gallons Liters Gallons
acts as a coolant by carrying heat to the reservoir TC36    
where it radiates out from the machine.
TC51    
Cleanliness in the handling of lubricants, fittings,
TC66    
grease guns, and the openings and plugs of
housings is of vital importance. Foreign TC84    
substances contaminate lubricant. Be sure all
fittings and openings are thoroughly cleaned Lubricant Specifications
before starting to inject lubricant. In using a grease Refer to (Table 5 - 2) as a guide for the proper
gun make sure the nozzle makes proper contact lubricants used on the crusher. If you do not have
with the cleaned fittings or openings and that the access to the brands shown, see your lubricant
nozzle has not been allowed to touch uncleaned distributor for an equivalent.
surfaces.
The table lists at what ambient temperature range
Never mix diffenent brands or types of lubricant to use a particular recommended lubricant
within the crusher. Always drain and flush out old specification. Contact Trio if questions arise
lubricant before changing to a different brand as concerning what specific lubricant should be used
chemical breakdown can occur in lubricant for your particular operating environment.
mixtures.

CRSH-OI-0004ENG (NOV-2012) 5-2 Model TC-Series Cone Crushers


Operator Instruction Manual
Lubrication

Table 5 - 2 Cone Crusher Lubricant Specifications


Ambient
Recommended Recommended
Lubricant Type Temperature Specification
Standard Lubricant Synthetic Lubricant
°C (°F)

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System Oil
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RSHUDWLQJHQYLURQPHQW

CRSH-OI-0004ENG (NOV-2012) 5-3 Model TC-Series Cone Crushers


Operator Instruction Manual
Lubrication

Lubrication Intervals
The cone crusher should use the specified
lubricants shown in (Table 5 - 2). See (Table 5 - 3)
for recommended lube intervals.

Table 5 - 3 Cone Crusher Lubrication Intervals


Location Crusher Lubrication System Oil
1 Lubricant Lubrication System EP Gear Oil
Interval Change every 2000 hours, if dirty
Location Hydraulic Power Unit, Tramp Release Cylinders and Locking Cylinders
2 Lubricant Hydraulic System Oil
Interval Change every 2000 hours, if dirty
Location Clevis Pins
Lubricant Grease
3
Interval 200 hours
Method Manual
Location Bowl and Head Surfaces that contact the backing material (Not on seating surfaces)
Lubricant Lubrication System EP Gear Oil
4
Interval Every liner change
Method Manual, brush
Location Bowl, Clamping Ring and Adjustment Ring Threads, (Unclamp bowl before greasing)
5 Lubricant Grease
Interval 40 hours; Every liner change
Method Manual, brush
Location Head and Locking Nut Threads
Lubricant Grease
6
Interval Every liner change
Method Manual, brush
Location Main Frame and Adjustment Ring Seating Surfaces
Lubricant Grease
7
Interval During Assembly
Method Manual, brush
Location Countershaft Box Inner Flange
Lubricant Grease
8
Interval During Assembly
Method Manual, brush
Location Socket Sealing Ring Chambers
Lubricant Grease
9
Interval Every liner change
Method Manual, hand pack
Location Bowl Adjusting Ring Gear Teeth and Pinion Teeth (On Hydraulic Drive Motor)
Lubricant Grease
10
Interval 200 hours
Method Manual, brush
Location Hydraulic Adjustment Mechanism Driver Ring Supports
Lubricant Silicone Spray
11
Interval 200 hours
Method Spray can
Location Main Frame Pins
Lubricant Grease
12
Interval Every Liner Change
Method Manual, brush

CRSH-OI-0004ENG (NOV-2012) 5-4 Model TC-Series Cone Crushers


Operator Instruction Manual
Lubricating System Oil Analysis

Lubricating System Oil Analysis


The following table shows oil contamination limits
to assist in determining whether the oil should be
changed or not. Lubrication system oil analysis is
also beneficial in that it can indicate to you if some
internal crusher components may be failing.
To have accurate analysis, it is recommended to
have a sample of the fresh oil you are using
analyzed to establish a baseline for that oil.

Table 5 - 4 Cone Lubricating System Contamination Limits


Acceptable High
Contaminant
Parts Per Million - PPM Parts Per Million - PPM

Copper (CU) %HORZ330 $ERYH330

Aluminum (Al) %HORZ330 $ERYH330

Iron (Fe) %HORZ330 $ERYH330

*Silica (Si) %HORZ330 $ERYH330

Chromium (Cr) %HORZ330 $ERYH330

Lead (Pb) %HORZ330 $ERYH330

Contamination Level
%HORZ $ERYH
(Total Solids)

Water %HORZ $ERYH

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DQGWKHRLOLVUDWHGXQVDWLVIDFWRU\

CRSH-OI-0004ENG (NOV-2012) 5-5 Model TC-Series Cone Crushers


Operator Instruction Manual
Cone Crusher Daily Log

Cone Crusher Daily Log

OPERATOR’S INITIALS:

DATE (MO/DAY/YR) :

TIME :

AMBIENT TEMP (ºF) :

Normal Values *
NO-LOAD CRUSHING
CLOSED SIDE SETTING (INS.) - 4 LOCATIONS

CHECKED FOR FREE PRODUCT DISCHARGE (YES/NO)

HEAD SPIN (RPM @ NO LOAD) 15 MAX

COAST DOWN TIME (SECONDS) >= 35 SECONDS

POWER DRAW (AMPS) AVERAGE CRUSHING

LOOSE BOLTS OR UNUSUAL NOISES (YES/NO)

LOOK / LISTEN / COMMENT

FEED / CHOKE FED (YES/NO)

FEED / EVEN DISTRIBUTION (YES/NO)


ANY Adjustment RING BOUNCE
0 - 5 SCALE WHERE: 0 = NONE AND 5 = CONTINUOUS
AIR BREATHER OBSTRUCTED (YES/NO)
OIL LEVEL (INCHES FROM BOTTOM OF SIGHT
POWER UNIT
HYDRAULIC

GAGE)
ANY OIL LEAKS (YES/NO)

OVER LOAD CYLINDER PRESSURE (PSI) 1900-2050 PSI

THREAD LOCKING CYLINDER PRESSURE (PSI) 2600-2800 PSI

AIR BREATHER OBSTRUCTED (YES/NO)


LUBE OIL LEVEL (INCHES FROM BOTTOM OF
SIGHT CAGE)
ANY OIL LEAKS (YES/NO)
LUBRICATION SYSTEM

CRUSHER INLET OIL TEMP >16 °C (60ºF)

CRUSHER OUTLET OIL TEMP <60°C (140ºF)

∆T = OUTLET OIL TEMP - INLET OIL TEMP


<= 3°C (5ºF)
OIL PRESSURE kPa (PSI) AT PUMP

CRUSHER OIL PRESSURE kPa (PSI)

BY-PASSING (% OF BY-PASS PIPE AREA)

OTHER OBSERVATIONS/COMMENTS :-

CRSH-OI-0004ENG (NOV-2012) 5-6 Model TC-Series Cone Crushers


Operator Instruction Manual
Start-Up & Operation Information

Section 6 - Start-Up & Operation 3) Start up all other components on the plant in
the proper sequence prescribed for your
particular plant system. If no prescribed
Start-Up & Operation Information
sequence is available, start with the last piece
The cone crusher is generally used as a component of equipment to discharge material and work
of an overall plant system. Specific equipment back toward the initial feed point until all
start-up procedures will depend on the particular components are operating empty.
plant and the material flow as well as the type of
controls used. Always refer to hydraulic power 4) Make sure crusher is running at the proper
unit supplement manual and controls schematics RPM for the material being crushed. See
and information received with your particular RPM charts elsewhere in this manual.
equipment for start-up and operation.
5) Note the head spin RPM and direction. When
The following steps should be used as a general material is introduced, the cone head should
guide to operation of the cone crusher: reverse its spin rotation.
1) Check the surrounding area to ensure no 6) Set the closed side setting (CSS) - A reduction
personnel are in a dangerous position prior to ratio of 6:1 for standard head and 4:1 for fine
start-up. head machines is recommended. 80% or more
of the feed material should fall within the ratio
WARNING unless ring bounce is detected. If ring bounce
is detected, it may be necessary to open the
CSS or reduce the feed size.
Always sound horn or other warning
device to warn others that you are about to 7) Begin material flow to the plant. Keep safety
start up the equipment. in mind.

2) If the crusher is part of a plant system, make 8) Record any observation about plant operating
sure it is started in proper sequence with other conditions in the plant log book.
components.

CLEARING THE CRUSHING CAVITY


SHOULD THE CRUSHER STOP UNDER LOAD ,NO ATTEMPT SHOULE BE MADE TO START THE CRUSHER
AGAIN UNTIL THE ENTIRE CRUSHING CAVITY HAS BEEN CLEARED.ATTEMPTING TO START THE
CRUSHER WITH THE CAVITY FULL OF MATERIAL MAY RESULT IN SERIOUS DAMAGE TO THE CRUSHER
AND CRUSHER MOTOR OR ENGINE.

CRSH-OI-0004ENG (NOV-2012) 6-1 Model TC-Series Cone Crushers


Some of the reasons a crusher stops under load are as follows:
• Crusher drive motor or engine stopped because of power failure or lack of fuel.
• Too much feed entering the crushing cavity causing the crusher to stall.
• Discharge conveyor stopped (allowing discharging material to back up and plug the crusher
from underneath).
• The gyrating crushing action of the head causes the material caught between the mantle and
bowl liner on the CLOSED SIDE to tip and raise the adjustment ring a small amount and stall the
crusher.
• ON OCCASION AN OVERSIZE PIECE OF "TRAMP IRON" CAN BECOME CAUGHT, OR
WEDGED BETWEEN THE CRUSHING MEMBERS AND CAUSE THE CRUSHER TO STALL

UNDER NO CIRCUMSTANCES ENTER THE CRUSHING CAVITY WHEN A PIECE OF


TRAMP IRON IS WEDGED BETWEEN THE BOWL LINER AND MANTLE.
To clear the crusher of plugged material, or to remove tramp iron wedged between the bowl
liner and mantle, ALWAYS USE THE HYDRAULIC CLEARING SYSTEM! Proceed as follows:

1. Stop the feed to the crusher.


2. Shut the power OFF to the crusher
motor or engine as quickly as possible.
LOCKOUTAND TAG THE MACHINERY.
3. Warn or inform personnel of what is
occurring.
4. Check the oil level in the sight gauge on
the side of theHydraulic Power Unit.
5. Be sure there is proper clearance above
and aroundthe crusher.
6. Check that the Hydraulic Power Unit is
ON.

7. Turn the CRUSHER CAVITY selector switch on the operator control cabinet to CLEAR. The six
(6) CLAMPING/CLEARING cylinder rods will EXTEND TO RAISE the adjustment ring to its
MAXIMUM HEIGHT of 5" (125 mm) OFF its seating surface on the main frame. In most cases, this
will allow the plugged material to fall through and clear the crushing cavity. If the cavity DOES NOT
CLEAR after the ring has been fully raised, insert the three (3) SAFETY BLOCKS provided with the
cavity clearing system, between the bottom of three (3) equally spaced clamping/clearing cylinders
and on top of the cylinder mounting ribs on the main frame flange (See Figure 10 - 7).

ONE OF THE MOST DANGEROUS OPERATIONS AROUND A CRUSHER IS THE REMOVAL


OF TRAMP IRON THAT HAS JAMMED IN THE CRUSHING CHAMBER. EXTREMELY SEVERE
INJURIES CAN OCCUR BY TRYING TO REMOVE TRAMP IRON.

ALWAYS USE THE HYDRAULIC CAVITY CLEARING SYSTEM TO REMOVE TRAMP


MATERIAL. DO NOT SIMPLY TRY TO LOOSEN THE TRAMP WITH A PRY BAR! SEVERE
PERSONAL INJURY COULD RESULT!

CRSH-OI-0004ENG (NOV-2012) 6 -2 Model TC-Series Cone Crushers


8. When the safety blocks have been properly installed, LOWER the adjustment ring so
that the clamping/clearing cylinders rest on top of the SAFETY BLOCKS!
9. Turn the CRUSHER CAVITY selector switch on the operator control cabinet to OFF.
10. With the adjustment ring in the raised position and the safety blocks properly installed,
jog the crusher by applying short spurts of power to the crusher drive motor or engine to clear
the crushing cavity.

DO NOT PLACE FEET OR HANDS ON THE CLAMPING/CLEARING CYLINDERS,


ACCUMULATORS, IN THE SPACE BETWEEN THE ADJUSTMENT RING AND MAIN
FRAME; OR ANY PART OF YOUR BODYBETWEEN THE CYLINDERS AND THE MAIN
FRAME LOWER FLANGE!

ALWAYS USE THE "SAFETY BLOCKS" WHEN THE ADJUSTMENT RING IS IN THE
RAISED POSITION AND MATERIAL IS BEING REMOVED FROM THE CRUSHING
CHAMBER! THESE SAFETY BLOCKS ARE USED TO PROTECT HANDS, ARMS,
EQUIPMENT, ETC. FROM BEING CAUGHT BETWEEN THE CRUSHING MEMBERS, IN
THE EVENT OF A HYDRAULIC FAILURE.

11. MAKE SURE THE ADJUSTMENT RING IS IN ITS RAISED POSITION AND THE
SAFETY BLOCKS ARE IN POSITION between the bottom of three (3) equally spaced
clamping/clearing cylinders and on top of the cylinder mounting ribs on the main frame
flange. Then stand on top of the adjustment ring and use a long pipe, wooden pole or a pry
bar to dislodge the compacted material in the crushing chamber until it falls out. BE
CAREFUL! (See Figure 10 - 7)

UNDER NO CIRCUMSTANCES SHOULD THE CRUSHER BE STARTED AND


CRUSHING RESUMED WITH THE ADJUSTMENT RING IN THE RAISED POSITION.
SERIOUS PERSONAL INJURY AND SEVERE DAMAGE TO THE CRUSHER COULD
RESULT!

12. Jog the crusher a few times as described in Step 10 and check for free head movement
in the crusher. DO NOT STAND ON OR NEAR CRUSHER DURING THE JOGGING
PROCEDURE.
13. If the head is still not free, repeat Steps 10 through 12, several times or as long as
material continues to discharge from the crushing cavity.
14. After the crushing cavity has been cleared, turn the CRUSHER CAVITY selector
switch on the operator control cabinet to CLEAR to "raise" the adjustment ring. THEN
REMOVE THE THREE (3) SAFETY BLOCKS.
15. Turn the CRUSHER CAVITY selector switch to CRUSH. The adjustment ring will now
LOWER and return to its seating surface on the main frame SEAT LINER. The adjustment
ring may lower with a SLIGHT TILT. This is normal!
16. Resume normal crushing.

CRSH-OI-0004ENG (NOV-2012) 6-3 Model TC-Series Cone Crushers


Operator Instruction Manual
Start-Up & Operation Information

Initial Break-In Use the following taken from the Delivery/


Commissioning Form as a guide and checklist:
A break-in period of operation is required at the
crusher initial start-up or after installation of new
bushings.

Initial Start-Up
OK Not OK OK Not OK
Crusher run no load for 2 hours minimum. Crusher run at 75% rated power for at least 4 hours.
Crusher running no load at ____________RPM. Power draw running at 75% is _________Amps.
Power draw running no load at _________Amps. Crusher lube oil temperature running at 75%.
_______________(Do not exceed 140°F. / 60°C.)
Crusher lube oil temperature running no load.
_______________(Do not exceed 140°F. / 60°C.) Crusher 75% power balance is good.
Crusher no load balance is good.
Crusher run at 50% rated power for at least 2 hours. After 8 Hours Initial Operation

Power draw running at 50% is _________Amps. Power draw running at 100% is _________Amps.

Crusher lube oil temperature running at 50%. Crusher lube oil temperature running at 100%.
_______________(Do not exceed 140°F. / 60°C.) _______________(Do not exceed 140°F. / 60°C.)
Crusher 50% power balance is good. Crusher 100% power balance is good.

Figure 6 - 1 Cone Crusher Break-In

CRSH-OI-0004ENG (NOV-2012) 6-4 Model TC-Series Cone Crushers


Operator Instruction Manual
Cone Crusher Crushing Chamber

Section 7 - Adjustments & Crusher Setting Adjustment


Troubleshooting The size of the crushed product required
determines the crusher setting. Also, as equipment
Cone Crusher Crushing Chamber is used, the crushing chamber wear parts must be
adjusted to keep the machinery operating
The cone crusher’s crushing chamber consists of
efficiently and properly.
the opening between the bowl liner and the cone
head mantle. See (Figure 7 - 1) The setting is changed by either lowering or
raising the bowl in the adjustment ring. By turning
the bowl assembly clockwise, it lowers the bowl
making the setting smaller. By turning the bowl
assembly counter-clockwise, it raises the bowl
1 making the setting larger.

2
6

5
3

4
1 - Bowl
2 - Bowl Liner
3 - Crusher Setting (Closed Side)
4 - Parallel Zone
5 - Mantle
6 - Cone Head

Figure 7 - 1 Cone Crusher Crushing Chamber

CRSH-OI-0004ENG (NOV-2012) 7-1 Model TC-Series Cone Crushers


Operator Instruction Manual
Troubleshooting

Troubleshooting

CRUSHER OVERHEATING
PROBABLE CAUSES COMMENTS/CORRECTIVE ACTIONS
Check for proper oil flow (GPM) in drain line, If required
Pump worn - not delivering enough oil.
change Pump.
Insufficient running clearances between main
shaft and inner eccentric bushing or eccentric Replace inner eccentric bushing or outer bushing.
and outer bushing.
Check pitch in drain line from crusher to oil tank (Minimum
pitch 1” per 12”) [25mm per 305mm].
Oil not draining properly.
Clean air breather on main frame countershaft box housing.
Check all drain holes and lines from the crusher for plugging.
Too much crushing in lower portion of crushing cavity causing
Improper crusher liners for application.
excessive power draw.
Hot or unusually hard feed causes crusher to Make sure water or air cooler is functioning effectively - keep
generate more heat. cooler clean!
Check for the proper oil level in tank.
Insufficient oil supply. Oil bypassing crusher. Check main relief valve for leakage,
due to wear, chips or stuck spring.
V-belts tensioned too tight. Re-tension V-belts.
Improper feed conditions often involved. Excessive amount of
Crusher pulling too much power. fines in feed, or crusher set too tight for application.
Large amount of tramp material in the feed causing overloads.
Do not set crusher setting below recommended minimum
Crusher set too tight.
discharge setting.
Lubrication hole in the main shaft plugged with Vertical hole in main shaft and interconnecting horizontal holes
dirt. in shaft must be cleaned using high pressure air.

CRUSHER THROWING OIL


PROBABLE CAUSES COMMENTS/CORRECTIVE ACTIONS
High head spin. See corrective actions for high head spin problem.
Socket liner is worn. Renew the parts.
Slabby feed trapped under feed plate and Reduce feed size.
cocking head.
Excessive countershaft speed (RPM) Check for correct countershaft speed (RPM).
Crusher not vented properly. Clean breather on main frame countershaft box housing.
Oil passages in socket liner are plugged, Dismantle and clean all socket liner oil drain holes and
preventing proper oil drainage. grooves.
Oil not draining properly. Check all drain holes and drain lines from the crusher for
plugging.

CRSH-OI-0004ENG (NOV-2012) 7-2 Model TC-Series Cone Crushers


Operator Instruction Manual
Troubleshooting

LOW OUTPUT (TONNAGE)


PROBABLE CAUSES COMMENTS/CORRECTIVE ACTIONS
Low operating speed (RPM). Check for correct countershaft speed (RPM).
Too much moisture in the feed, slowing the
Moisture should be less than 5%.
movement of the feed in the crushing cavity.
Extremely slabby feed causing bridging at the
Reduce feed size.
feed opening, at the top of the liners.
Large pieces of debris in the feed (wood, tree
roots, re-bar, etc.) slowing feed movement in Feed to crusher should be free of this type of material.
crushing cavity.
Too large of a feed top size. Reduce feed size.
Large amount of clay in the feed. Remove clay or sticky material from the feed.
Incorrect feed distribution, segregated feed
causes fines to be fed in one side of the Correct the feed arrangement.
crushing cavity.
Too many fines in feed. Incorrect or inadequate screening.
Torch cut the lip at the bottom of either liners to eliminate
Mantle or bowl liner “cupping” at the bottom.
restriction.

CRUSHER STALLING
PROBABLE CAUSES COMMENTS/CORRECTIVE ACTIONS
V-belts too loose. Re-tension V-belts.
Check power draw of crusher running empty and compare to
Electrical problems with drive motor. power draw of motor running free (without belts). If both
readings are close, have electrician check motor.
Build-up under crusher. Check foundation for ample discharge of crusher material.
Countershaft speed too low. Check for correct countershaft speed (RPM).
Feed level too high in crushing activity causing
Reduce amount of feed to crusher.
excessive power draw.
Incorrect feed opening (too small) in crushing
cavity. Most crushing being done at top of feed Check for correct selection of liners.
opening which increases power draw.
Closed-in outer bushing and/or inner eccentric Crusher must be disassembled to inspect condition of the
bushing, thereby reducing running clearances. bushings.
Electrical problems with the drive motor. Have the electrician check the motor.
Check for correct oil flow and viscosity. Check relief valve to
Oil pressure too low.
make sure it is not bypassing at the operating temperature.

ADJUSTMENT RING TILTED


PROBABLE CAUSES COMMENTS/CORRECTIVE ACTIONS
Uneven wear on main frame seat liners and/or Improper feed distribution in crushing cavity. Replace seat
adjustment ring seat. liners, and correctly feed crusher.
Continuous overload or improper liners causing Re-check for correct mantle and bowl liner combination,
adjustment ring to “pound” on main frame seat and/or reduce feed to crusher. Replace seat liners. Increase
liners and adjustment ring the setting.
seat.

CRSH-OI-0004ENG (NOV-2012) 7-3 Model TC-Series Cone Crushers


Operator Instruction Manual
Troubleshooting

COUNTER SHAFT IS SEIZED OR BROKEN


PROBABLE CAUSES COMMENTS/CORRECTIVE ACTIONS
V-Belts tensioned too tight. Re-tension V-Belts and check sheave alignment.
No lubrication or not enough lubrication to
Check the pipe/hose supplying oil to the ct. shaft box
countershaft bearings.
Bent countershaft. Usually shows up as
excessive vibration to end of countershaft or Replace countershaft.
“wobble” to crusher sheave.
Broken gear or pinion tooth. Replace gear or pinion.
Incorrect backlash and/or root clearance
Check for correct backlash and root clearance.
between gear and pinion.

BOWL STALLED
PROBABLE CAUSES COMMENTS/CORRECTIVE ACTIONS
Accumulation of dirt or rust between threads of Try the following steps in order:
adjustment ring, locking collar and bowl 1.Pour penetrating oil into threads.
because of:
· Hot incoming feed (slag)
2.Turn the BOWL ADJUSTMENT selector switch on the
operator control cabinet to the OFF position and run material
· Poor thread lubrication through crusher.
· Worn adjustment cap seal 3.Run short pieces of lumber through crusher (4”x4” or 4”x6”)
· Operating too long at one setting [102x102 or 102x152mm].

· Galled bowl, locking collar and/or 4.Throw small pieces of “SOFT” steel through crusher.
adjustment ring threads
· Broken threads
Insufficient oil pressure (PSI) to hydraulic motor See Power Unit troubleshooting guide to resolve the issue.
mounted on adjustment ring.

LOOSE BOWL
PROBABLE CAUSES COMMENTS/CORRECTIVE ACTIONS
Worn adjustment ring, locking collar and Re-machine 45º surface of threads to provide uniform pitch if
bowl threads. threads are not worn too badly. If threads are severely worn,
contact Trio for proper procedures for correcting the wear
areas.
Operating with hydraulic locking collar Pressurize the hydraulic locking collar cylinders to the proper
cylinders pressure being too low! pressure.
Too small of a crusher setting. Open crusher setting until bowl stops bouncing.
Operating with leaking hydraulic locking Replace locking cylinder assembly or assemblies.
cylinders.
Check that the hose between power unit and When power unit is operating, hose between power unit and
locking cylinders is properly connected. locking collar cylinders should feel somewhat “stiff”.

LOOSE SOCKET
PROBABLE CAUSES COMMENTS/CORRECTIVE ACTIONS
Loss of interference fit between the socket Restore the fit to the original value. If needed, rebuild the
and the mainframe. Socket bolts and dowels socket turn and machine oversize to match with the enlarged
sheared. mainframe bore.

CRSH-OI-0004ENG (NOV-2012) 7-4 Model TC-Series Cone Crushers


Operator Instruction Manual
Troubleshooting

LOOSE BOWL LINER OR MANTLE


PROBABLE CAUSES COMMENTS/CORRECTIVE ACTIONS
Mantle - locking nut does not self-tighten. Check for backing material poured too high and left in
contact with underside of locking nut.
Mantle - crusher countershaft rotating in Self-tightening feature of mantle will not work if countershaft
wrong direction. is rotating in wrong direction; correct direction is COUNTER
CLOCKWISE.
Locking nut bottoming on head. Insufficient clearance between bottom of locking nut and top
of head. Minimum clearance should be approximately 3/8”
(10mm).
Mantle or head seating surfaces worn or not Restore seating surfaces to factory dimensions.
machined correctly.
Insufficient backing clearance behind mantle Backing clearance should be at least 1/4” to 3/8” (6 to
and head. 10mm).
Mantle out-of-round. Maximum out-of-round condition should be 1/4" (6mm).
Mantle not centered on head, or mantle not Check with feeler gauge at bottom of mantle. Clearance
tight on head during initial installation. should be no more than 0.005” (0.127mm).
Mantle - operating crusher without feed for Maximum idle time should be 30 minutes.
too long of a time.
Mantle too thin. Wear not to exceed 2/3 of mantle thickness.
Old backing not completely removed before Remove all old backing to permit the new mantle to seat
installing new mantle. correctly on the head.
Bowl liner - broken “scallops” at top of liner. Badly worn bowl liner; thin section flexing.
Bowl liner too thin. Wear not to exceed 2/3 of bowl liner thickness.
Too much tramp iron or sticky material going Too much tramp iron or sticky material will cause adjustment
through the crusher. ring to jump or bounce excessively.
Bowl liner or bowl seating surfaces worn or Restore seating surfaces to factory dimensions.
not machined correctly.
Old backing not completely removed before Remove all old backing to permit the new bowl liner to seat
installing new bowl liner. correctly in the bowl.

GEAR AND PINION TOOTH WEAR


PROBABLE CAUSES COMMENTS/CORRECTIVE ACTIONS
Excessively dirty oil. Replace oil and clean oil tank.
Tooth wear profile too low. Worn thrust bearing plates. Raise eccentric assembly by
shimming under eccentric thrust bearing plate.
Tooth wear profile too high. Lower eccentric assembly by removing shims beneath the
eccentric thrust bearing plate.
Crusher overloaded. Usually shows up as bouncing adjustment ring. Reduce feed
to crusher and/or increase the setting.
Tooth wear profile on the ends of the teeth. Excessive wear on inner eccentric bushing and/or outer
eccentric bushing.

CRSH-OI-0004ENG (NOV-2012) 7-5 Model TC-Series Cone Crushers


Operator Instruction Manual
Troubleshooting

EXCESSIVE VIBRATIONS
PROBABLE CAUSES COMMENTS/CORRECTIVE ACTIONS
Weight change due to worn crusher parts. Excessively worn mantle, replace mantle.
Excessive head spin. Head moving with eccentric due to seized inner bushing.
Gear and pinion tooth root interference. Improper gear mesh, gear bottoming on pinion. Raise
eccentric assembly by shimming.
Bent countershaft. Replace countershaft.
Crusher sheave badly out of balance. Remove dirt build-up on rim of sheave.
If crusher is mounted on a portable plant, Check cribbing or soil conditions.
cribbing or soil conditions may be
inadequate.
Inadequate foundation and/or soil bearing Check foundation or soil conditions.
capacity.
Loose mantle. Remove mantle and re-install properly.
Countershaft speed (RPM) too high. Check for correct countershaft speed (RPM).

WEAR ON HEAD OR BOWL SEATING SURFACE


PROBABLE CAUSES COMMENTS/CORRECTIVE ACTIONS
Crusher operating with loose mantle or bowl Make sure crushing members are seated properly when
liner. assembling, and that the locking nut is tightened securely
against the torch ring and mantle BEFORE operation.
Crusher operating with excessively worn Thin section of crushing member flexes, accelerating wear
mantle or bowl liner. on head or bowl seating surfaces.
Wearing completely through mantle or bowl Thin section of crushing member flexes, accelerating wear
liner and crushing on head or bowl. on head or bowl seating surfaces.
Cracked mantle or bowl liner. Crushing member flexes, accelerating wear on head or bowl
seating surfaces.

GEAR AND PINION NOISY


PROBABLE CAUSES COMMENTS/CORRECTIVE ACTIONS
Incorrect backlash and/or root clearance. Recheck backlash and/or root clearance
Operating crusher with new gear and worn It is recommended that both the gear and pinion be replaced
pinion or worn gear and new pinion. at the same time

MAIN SHAFT BROKEN


PROBABLE CAUSES COMMENTS/CORRECTIVE ACTIONS
Frequent tramp iron passing through Install metal detection device.
crusher.
Crusher continually overloaded. Usually shows up as bouncing adjustment ring. Reduce feed
to crusher and/or increase the setting.

CRSH-OI-0004ENG (NOV-2012) 7-6 Model TC-Series Cone Crushers


Operator Instruction Manual
Troubleshooting

DUST AND DIRT GETTING INTO LUBE SYSTEM


PROBABLE CAUSES COMMENTS/CORRECTIVE ACTIONS
Oil filter housing cover not properly closed. Properly close Lube System oil filter housing cover.
Lube System tank cover not properly closed. Properly close Lube System tank cover.
No air breather on the main frame Install breather on the main frame countershaft box housing.
countershaft box housing.
Air breather on main frame countershaft box Replace air breather. To check, place a piece of paper over
housing not functioning properly. the breather piping, with the crusher running; the paper
should move in and out.
Crusher sheave swirling dust into the air Using hose, relocate air breather away from crusher sheave.
breather.
Dust and dirt falling into crusher when Cover socket and eccentric area with canvas tarpaulin or
crusher has been dismantled for servicing or polyethylene (plastic) sheeting when servicing crusher.
maintenance.
Floating ring and/or head wipers are Renew damaged or worn parts.
damaged or worn.
No seal (gasket) or bad seal between oil tank Replace tank seal.
and oil tank cover.
Floating ring is not supplied with proper Supply proper amounts of grease.
amount of grease.

HEAD SPIN HIGH


PROBABLE CAUSES COMMENTS/CORRECTIVE ACTIONS
Head wipers damaged. Renew damaged parts.
Ball of head contacting the inside portion of Scrape the socket liner spherical bearing surface so that the
socket liner thereby offering less resistance ball of the head makes contact on the outer surface of the
to spinning. socket liner.
Scored or burned inner eccentric bushing. Replace the bushing or polish out the scores, gouges or
burn marks.
Wrong lube oil. Check and replace with the correct oil.

CRSH-OI-0004ENG (NOV-2012) 7-7 Model TC-Series Cone Crushers


Operator Instruction Manual
Troubleshooting

This Page Intentionally Left Blank

CRSH-OI-0004ENG (NOV-2012) 7-8 Model TC-Series Cone Crushers


Operator Instruction Manual
Torque Charts

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

CRSH-OI-0004ENG (NOV-2012) A-1 Model TC-Series Cone Crushers


Operator Instruction Manual
Torque Charts

Standard Bolt Torque Chart


S.A.E Grade 2 S.A.E Grade 5 S.A.E Grade 8
dia. pitch Dry Lube Dry Lube Dry Lube
(in.) (thd/in.) (ft-lbs) N-M (ft-lbs) N-M (ft-lbs) N-M (ft-lbs) N-M (ft-lbs) N-M (ft-lbs) N-M
1/4 20 5 7 4 5 8 11 6 8 12 16 9 12
1/4 28 6 8 5 7 10 14 7 9 14 19 11 15
5/16 18 11 15 9 12 17 23 13 18 25 34 19 26
5/16 24 12 16 10 14 19 26 15 20 27 37 21 28
3/8 16 20 27 15 20 31 42 24 33 44 60 34 46
3/8 24 23 31 17 23 35 47 27 37 49 66 38 52
7/16 14 32 43 25 34 49 66 38 52 70 95 54 73
7/16 20 36 49 27 37 55 75 42 57 78 106 60 81
1/2 13 49 66 38 52 75 102 58 79 106 144 82 111
1/2 20 55 75 42 57 85 115 65 88 120 163 92 125
9/16 12 70 95 54 73 109 148 84 114 154 209 118 160
9/16 18 79 107 60 81 121 164 93 126 171 232 132 179
5/8 11 97 132 75 102 150 203 115 156 212 287 163 221
5/8 18 110 149 85 115 170 231 131 178 240 325 185 251
3/4 10 157 213 121 164 266 361 205 278 376 510 289 392
3/4 16 180 244 133 180 297 403 229 311 420 570 323 438
7/8 9 210 285 160 217 430 583 330 447 606 822 466 632
7/8 14 230 312 177 240 473 641 364 494 668 906 514 697
1 8 320 434 240 325 644 873 495 671 909 1233 699 948
1 14 340 461 255 346 704 955 542 735 995 1349 765 1037
1-1/8 7 350 475 270 366 794 1077 611 829 1288 1747 990 1342
1-1/8 12 395 536 305 414 891 1208 685 929 1445 1959 1111 1507
1-1/4 7 495 671 380 515 1120 1519 862 1169 1817 2464 1398 1896
1-1/4 12 550 746 425 576 1241 1683 954 1294 2012 2728 1548 2099
1-3/8 6 655 888 500 678 1469 1992 1130 1532 2382 3230 1832 2484
1-3/8 12 745 1010 570 773 1673 2269 1287 1745 2712 3677 2086 2829
1-1/2 6 865 1173 665 902 1949 2643 1500 2034 3161 4286 2432 3298
1-1/2 12 975 1322 750 1017 2194 2975 1687 2288 3557 4823 2736 3710
1-3/4 5 1370 1857 1055 1430 2286 3100 1758 2384 4988 6764 3837 5203
2 4.5 2060 2793 1585 2149 3438 4662 2644 3585 7500 10170 5769 7823
2-1/4 4.5 3015 4088 2320 3146 5027 6817 3867 5244 10969 14874 8438 11442
2-1/2 4 4125 5593 3170 4298 6875 9323 5288 7171 15000 20340 11538 15646
2-3/4 4 5590 7579 4300 5830 9321 12639 7170 9723 17794 24129 13688 18561
3 4 7385 10013 5680 7701 12313 16696 9472 12844 23507 31875 18082 24519
Table A - 1: Torque Values for Standard Hardware

CRSH-OI-0004ENG (NOV-2012) A-2 Model TC-Series Cone Crushers


Operator Instruction Manual
Torque Charts

Metric Bolt Torque Chart


Property Class = 8.8 Property Class = 10.9 Property Class = 12.9
dia pitch Dry Lube Dry Lube Dry Lube
(mm) (mm) (ft-lbs) N-M (ft-lbs) N-M (ft-lbs) N-M (ft-lbs) N-M (ft-lbs) N-M (ft-lbs) N-M
6 6.9 9.3 5.2 7 9.7 13.2 7.3 9.9 11.6 15.7 8.7 11.8
8 17.7 23.9 13.3 18 24.9 33.8 18.7 25.4 29.8 40.4 22.4 30.4
10 1.5 30 41 24 32 44 60 34 46 52 71 40 54
10 1.25 32 43 24 33 46 63 36 49 55 74 42 57
12 1.75 53 72 41 55 77 105 60 81 91 123 70 95
12 1.25 58 78 44 60 85 115 65 88 99 134 76 103
14 2 85 115 65 88 124 168 95 129 145 196 111 151
14 1.5 91 124 70 95 134 181 103 139 156 212 120 163
16 2 131 178 101 137 192 260 148 200 225 305 173 234
16 1.5 140 190 108 146 204 277 157 213 240 325 184 250
18 2.50 181 246 139 189 265 359 204 276 311 421 239 324
18 1.5 204 276 156 212 297 403 229 310 349 473 268 364
20 2.5 256 347 197 267 374 507 288 390 439 595 338 458
20 1.5 284 385 218 296 415 563 319 433 487 660 375 508
22 2.5 349 473 268 364 510 692 392 532 599 812 460 624
22 1.5 383 519 294 399 560 759 431 584 657 891 505 685
24 3 443 600 340 461 647 877 497 674 759 1029 583 791
24 2 482 654 371 503 705 956 543 736 828 1122 637 863
27 3 648 879 499 676 949 1286 729 989 1112 1508 856 1160
27 2 700 949 538 730 1023 1387 787 1067 1200 1627 923 1252
30 985 1335 741 1004 1389 1883 1044 1416 1665 2257 1252 1697
36 1716 2326 1290 1749 2419 3280 1819 2466 2900 3931 2180 2956
42 2753 3732 2070 2806 3882 5263 2919 3957 4652 6307 3498 4742
48 4156 5634 3124 4236 5860 7944 4406 5973 7023 9521 5280 7159
56 6662 9032 5009 6791 9393 12735 7063 9575 11259 15264 8465 11477
64 9954 13496 7484 10147 14035 19028 10553 14307 16822 22807 12648 17148
72 14410 19536 10835 14689 20319 27547 15277 20712 24353 33016 18310 24824
Table A - 2: Torque Values for Metric Hardware

CRSH-OI-0004ENG (NOV-2012) A-3 Model TC-Series Cone Crushers


Operator Instruction Manual
Torque Charts

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CRSH-OI-0004ENG (NOV-2012) A-4 Model TC-Series Cone Crushers


Operator Instruction Manual
General Belt Care

Appendix B - V-Belt Drive 5) Do not overtighten belts. Overtightening


Information shortens the useful life of belts and sheaves.
This can also cause premature bearing
failures. Ideal belt tension is the lowest at
General Belt Care which belts won’t slip under peak loads.
V-belts achieve more service life if kept clean and
dry. Rock dust and rust from metals are abrasive. 6) Periodically inspect v-belt drives for wear on
Oils and acids deteriorate belt material. Dust and belts or sheaves. See (Figure B - 1) and
moisture on belts can cause slippage. Dust buildup (Figure B - 2) Replace worn sheaves.
in sheaves can cause harmful vibration.
Belt dressing compounds are available and are Worn Worn Belt
sometimes used for various reasons. While they Sheave or Sheave Normal
may be used, belt dressing may actually shorten
belt life. Clean, well cared for belts are the best
way to care for belt problems. Daily cleaning of
belts and sheaves by blowing them off with
compressed air can increase their useful life.
Store un-used belts in a cool and dry environment
with no direct sunlight. Store on shelves or in
original containers. Do not allow belts to be bent
to diameters smaller that what is recommended for
the belt cross section.
Figure B - 1 Typical Belt & Sheave Wear
General Belt Recommendations

1) Keep belts and sheaves clean.

2) Avoid belt or sheave rubbing. Don’t let belts


or sheaves rub against a guard (or anything
else) while they are running.

3) Drive belts with motors mounted on


adjustable bases. This allows convenient and
proper installation of belts without prying on
belts.

4) Keep belts properly tightened. Most belt


stretch occurs in the first 30-40 hous of
operation. Check belt tension frequently Figure B - 2 Sheave Gauge Shows Wear
during this period.

CRSH-OI-0004ENG (NOV-2012) B-1 Model TC-Series Cone Crushers


Operator Instruction Manual
Belt Drive Troubleshooting

7) Keep belts straight. Don’t allow v-belts to run 8) If a drive uses multiple belts, use only
out of alignment. To run properly, sheaves matched belts. A matched set of belts lasts
must be parallel and grooves must be in line. longer and loading is evenly divided among
See (Figure B - 3) all the belts. Belts from different
manufacturers should not be mixed in a set
because material differences could reduce belt
life. Always replace belts in full sets.

9) Don’t overload belts. If the drive has 10


sheave grooves, use 10 belts. Using less than
the designed number puts stress on the
remaining ones. This can cause premature
failure.

Belt Drive Troubleshooting


Good maintenance practices should help you
experience minimal trouble with belts and
sheaves, however there may be times when
troubles are experienced. The following table can
be used as a troubleshooting tool.
Figure B - 3 Sheave Alignment

CRSH-OI-0004ENG (NOV-2012) B-2 Model TC-Series Cone Crushers


Operator Instruction Manual
Belt Drive Troubleshooting

Table B - 1 Belt Drive Troubleshooting

Trouble Cause Correction


Belt Slip (sidewalls glazed) Insufficient tension Replace belts; increase tension
Overloaded drive Find cause and correct
Drive squeals Arc of contact too short Increase distance between hubs
Heavy starting load Increase tension
Broken cord caused by prying Replace belt correctly
Overloaded drive Redesign drive
Impulse loads Apply proper tension

Misalignment Realign drive


Belts roll over
Worn sheave grooves Replace sheave
Flat idler sheave Align and reposition

Excessive vibration Check drive design, mounting


Consider banded belts
New belts installed with old Replace belts with matched set

Sheave grooves worn unevenly Replace sheaves


Mismatched belts
Improper groove angle

Shafts not parallel Align drive


Shock loads Apply proper tension

Heavy starting load Apply proper tension


Use compensator starting
Belt breaks
Belt pried over sheaves Replace belt correctly
Foreign object in drive Determine source of object,
design guard to correct problem
Sheave grooves worn Replace sheaves
Sheave diameter too small Redesign drive
Mismatched belts Replace with matched set
Drive overloaded Redesign drive
Belt wears prematurely
Belt slips Increase tension
Sheaves misaligned Align sheaves
Oil present Eliminate oil
Excessive heat present Ventilate drive

CRSH-OI-0004ENG (NOV-2012) B-3 Model TC-Series Cone Crushers


Operator Instruction Manual
Maintaining V-Belt Tension

Maintaining V-Belt Tension 1/64 inch per each inch of span length.
Example:
V-belt tension must be maintained to provide For a 100 inch span, the deflection would be
proper drive effectiveness. The following method 100/64, or approximately 1-1/2 inches.
of tensioning v-belts has been established as an
acceptable and preferred method. 4) Compare the force measurement to the
recommended ranges shown in (Table B - 2)
Tension-Deflection Method below for the appropriate belt cross section
type shown in.
1) Place a straightedge across the top of both
sheaves. See (Figure B - 4) 5) Tighten or loosen belt to bring it into the
recommended range.
2) Measure the span length.
6) When installing new belts, tighten them to
3) Using a spring scale at right angle to belt at “Initial Installation” tension. This tension will
1/2 of span length, apply a force to the scale drop during the run-in period.
on one of the belts enough to deflect the belt

1 4
2

9 5
8
6
1 - Straightedge 5 - Motor Drive Sheave
2 - Span Length 6 - V-belt
3 - 1/2 Span 7 - Spring Scale
4 - Deflection Measurement - 1/64 Inch for each 8 - Force Measurement
Inch of Span Length
9 - Driven Sheave

Figure B - 4 Tension-Deflection Diagram

CRSH-OI-0004ENG (NOV-2012) B-4 Model TC-Series Cone Crushers


Operator Instruction Manual
Maintaining V-Belt Tension

Table B - 2 Belt Deflection Forces


Recommended Belt Deflection Force (Pounds)

V-Belt Smallest Sheave Initial Retensioning


Cross Diameter Range Installation
Section (Inches) Maximum Minimum

- 3.0 3.6 3.1 2.4


3.1 - 4.0 4.2 3.6 2.8
A 4.1 - 5.0 5.2 4.6 3.5
5.1 - 6.1 5.3 4.1

- 4.6 7.3 6.4 4.9


4.7 - 5.6 8.7 7.5 5.8
B 5.7 - 7.0 9.3 8.1 6.2
7.1 - 10.0 8.8 6.8

- 7.0 12.5 10.7 8.2


7.1 - 9.0 15.0 13.0 10.0
C 9.1 - 12.0 18.0 16.3 12.5
12.1 - 19.5 16.9 13.0

12.0 - 13.0 25.5* 22.1 17.0


D 13.1 - 15.5 30.0* 26.0* 20.0
15.6 - 22.0 32.0* 28.0* 21.5

18.0 - 22.0 45.0* 39.0* 30.0*


E 22.1 - 52.5* 45.5* 35.0*

- 3.0 5.1 4.4 3.4


3.1 - 4.0 5.5 4.8 3.7
AX 4.1 - 5.0 6.0 5.2 4.0
5.1 - 6.7 5.9 4.5

- 4.6 10.0 8.7 6.7


4.7 - 5.6 11.0 9.5 7.3
BX 5.7 - 7.0 11.5 9.9 7.6
7.1 - 12.0 10.1 7.8

- 7.0 18.0 15.6 12.0


7.1 - 9.0 19.5 16.9 13.0
CX 9.1 - 12.0 20.0 17.6 13.5
12.1 - 21.0 18.2 14.0

2.65 - 3.35 4.6 4.0 3.1


3.65 - 4.50 5.5 4.8 3.7
3V 4.75 - 6.0 6.4 5.6 4.3
6.5 - 10.6 7.3 6.4 4.9

7.1 - 10.3 16.5 14.3 11.0


5V 10.9 - 11.8 19.5 16.9 13.0
12.5 - 16.0 21.0 18.2 14.0

12.5 - 16.0 39.0* 33.8* 26.0*


8V 17.0 - 20.0 45.0* 39.0* 30.0*
21.2 - 24.4 51.0* 44.2* 34.0*

2.2 - 2.5 4.8 4.2 3.2


2.65 - 4.75 5.7 4.9 3.8
3VX 5.0 - 6.5 7.2 6.2 4.8
6.9 - 8.7 7.5 5.8

- 5.5 15.0 13.0 10.0


5.9 - 8.0 19.0 16.9 13.0
5VX 8.5 - 10.9 21.0 18.2 14.0
11.8 - 22.0 19.5 15.0

* Note: For banded belts, multiply the force in table by


the number of belts in the band.

CRSH-OI-0004ENG (NOV-2012) B-5 Model TC-Series Cone Crushers


Operator Instruction Manual
Belt Type Cross-Sections

Belt Type Cross-Sections Backside Idler


A backside idler increases the arc of contact on
both sheaves. However, it forces a backward bend
in the v-belt that can contribute to premature
failure. The idler puts additional stress on the
bottom portion of the belt which will result in
bottom cracking. If a backside idler must be used,
the diameter should be at least 1 - 1/2 times the
diameter of the small sheave. It should also be
located as close as possible to the small sheave.

Figure B - 5 Belt Type Cross-Sections


Figure B - 7 Backside Idler
Belt Idlers
Kiss Idler
A properly designed v-belt drive does not require
and idler to deliver full horsepower if proper belt A kiss idler differs from the backside idler because
tension can be maintained. Idlers should be the kiss idler does not penetrate the belt span and
avoided if possible because it puts additional create a backward bend on the belt. A kiss idler
bending stress points on the belt. Due to drive does not contribute to premature belt failure. Use
design parameters, idlers are sometimes used. The of a kiss idler can help control belt vibration and
following are general descriptions of the types of whip on drives subject to shock and pulsating
idlers that may be used. loads. If a kiss idler is used, the diameter should
be at least 1 - 1/2 times the diameter of the small
Inside Idler sheave.

A v-grooved idler located on the inside of the belts


on the slack side of drive would be recommended
over a backside idler. The idler should be located
near the large sheave to minimize reduction of the
arc of contact on the small sheave. The diameter
should be equal to or larger than that of the small
Figure B - 8 Kiss Idler
sheave.

Figure B - 6 Inside Idler

CRSH-OI-0004ENG (NOV-2012) B-6 Model TC-Series Cone Crushers


Operator Instruction Manual
Glossary of Terms & Definitions

Appendix C - Crushing Terminology Closed Circuit Crushing:


The type of operation where uniformity of product
Glossary of Terms & Definitions size is important and the product is screened as it
is being discharged and the material that does not
The following list contains terms and definitions
pass through the screen is returned to the crusher.
commonly used throughout this manual as well as
in the rock-processing industry.
Closed Side Setting (CSS):
Backlash: The distance between the bottom of the crushing
members as measured at the point where the two
Total clearance between pinion teeth and gear
crushing members are at their closest relationship
teeth at pitch line.
during their gyrating cycle. This closed side
setting regulates product size.
Bridging:
Material wedged or covering the feed opening of Crushing Chamber:
the crusher and preventing entry of additional
The area of the crusher where crushing takes place.
material.
Discharge Opening:
Capacity:
The distance between the bottom of the crushing
The output of the crusher computed in tons per
members measured at the point where they are at
hour.
their farthest relationship during their gyrating
cycle. This opening permits rapid discharge of the
Cavity:
crushed material.
The internal contour formed by the two crushing
members. (Bowl liner and mantle). Drive:
Any device used to transmit rotating force from the
Choke Feed:
electric motor or diesel engine to the crusher
A condition when the feed material completely countershaft, v-belt or flexible coupling.
fills the crushing chamber.

CRSH-OI-0004ENG (NOV-2012) C-1 Model TC-Series Cone Crushers


Operator Instruction Manual
Glossary of Terms & Definitions

Drive Guard: Finished Product:


Safety enclosure for the drive with small opening The resultant material after it has been processed.
(opposite countershaft with cover) for tachometer.
Friable:
Feed:
Material that fractures easily.
The raw material which is to be crushed.
Gradation:
Feed Opening:
The range of sizes contained in a sample of rock.
The opening of the crusher where the material enters
the crushing chamber. Grizzly:
A heavy duty screening surface consisting of a series of
Feed Opening (Closed Side):
spaced bars, rails, or pipe members which may be
The smallest distance between the top of the crushing stationary or vibrating.
members as measured when the two crushing
members are at their closest relationship during Liners:
their gyrating cycle.
The bowl liner and mantle are the crushing
members and are commonly referred to as liners.
Feed Opening (Open Side):
The largest distance between the top of the Minimum Discharge Setting:
crushing members measured when the two
The smallest safe distance between the bottom of the
crushing members are at their farthest relationship
crushing members as measured when the two crushing
during their gyrating cycle. The feed opening
members are at their closest relationship during the
(open side) determines the maximum size of feed.
gyrating cycle.
Fines:
Open Circuit Crushing:
Material having particle size smaller than a
The type of operation where uniformity of product
specified screen opening. Fines are equal to or
size is not considered to be of prime importance and
smaller than closed side setting.
the feed is run through the crusher only once.

CRSH-OI-0004ENG (NOV-2012) C-2 Model TC-Series Cone Crushers


Operator Instruction Manual
Glossary of Terms & Definitions

Oversize: Reduction Ratio:


Material that will not pass through a specified screen Relationship of the top size of the feed material to the
opening. top size of the desired crushed product.

Parallel Zone: Scalping:


With the liners in their closest relationship during the Removing from crusher feed most of the
gyrating cycle, the lower portion of both the bowl liner undersize material.
and mantle, for some distance, will be parallel to each
other. This area is known as the parallel zone. Top Size:
The largest particle size in the feed or product.
Plugging:
Excessive fine material causes crusher to stall. Tramp Material:
Material in the crusher feed that contains wood, clay,
Product Size:
pieces of rubber belting, iron or steel, difficult (hard) to
The size of screened material after it has been crush material or oversize material, causing the crusher
crushed. to stall.

Yield:
Product at the desired size or sizes

CRSH-OI-0004ENG (NOV-2012) C-3 Model TC-Series Cone Crushers


Operator Instruction Manual
Glossary of Terms & Definitions

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CRSH-OI-0004ENG (NOV-2012) C-4 Model TC-Series Cone Crushers