Jaw Crusher

Operation, Maintenance and Repair

TITLE

MODELS
2036 2250 2540 3042
3055 3648 4448 5060 5566

ISSUE DATE: 04/08 (Rev. 5) TP387

SAFETY
Be sure to read and fully understand the precautions shown on the inside front cover of this manual before
operating or servicing your Telsmith product. Also refer to Chapter 1 for important safety information.
 ! WARNING
Failure to follow the safety precautions shown below may result
in serious personal injury or death!

• Never attempt to work on quarry equipment while it is in operation. Always stop the machinery, lockout power
and tag controls:
1. Before performing any lubrication, maintenance, adjustment, or repairs.

2. Before removing spilled materials.

3. Before clearing jams or working inside the machinery.

4. If any unusual noises or sudden changes in operation are noticed.

• Stay clear of feed and discharge areas and other places where falling rock is present. Keep away from loading
vehicles. Wear and use personal protective equipment in accordance with all applicable health and safety
regulations. Safety goggles, hard hat, ear plugs and steel-toed shoes are mandatory when working near
machinery. Wear and use additional personal protective equipment as required.

• Stay clear of springs and other pinch points. Never reach in-between vibrating equipment and its support
structure. Keep a safe distance from all moving components.
• Never attempt to enter the crushing chamber when tramp iron or other uncrushable objects are wedged inside.
These materials are under tremendous pressure and may be propelled upward through the feed opening at any
time. On crushers not equipped with hydraulic clearing, use a pole, hook, grappling device, or breaker bar to
safely dislodge uncrushable objects.
• Do not make equipment modifications that will result in a safety hazard or create a dangerous situation. Never
remove or disable safety devices. Maintain all machinery in accordance with manufacturer’s instructions and
maintenance schedules.
• Read the operator’s manual for the equipment that you operate. Be sure that you fully understand all phases of
operation for each machine. A careful and well-trained operator is the best insurance against an accident.
• Refer to Chapter 1, Safety, for important quarry safety information. If your copy is missing, replacement
copies may be obtained from your local Telsmith Dealer or the Telsmith Parts Department.
• All rotating power products are potentially dangerous and must be properly guarded. Placement of guards and
other safety equipment is the user’s responsibility. Such equipment must be installed wherever appropriate and
maintained as required.
• It is the purchaser’s responsibility to ensure that quarry equipment is installed and used in a safe and lawful
manner. All machinery must be operated in compliance with applicable health and safety laws and general
standards of reasonable care.
 Foreword
INTRODUCTION ORDERING REPLACEMENT PARTS
The information, drawings, and pictures provided in this Bill of materials and drawings have been provided with this
manual will help you to achieve optimum performance from manual. Refer to these documents when ordering Telsmith
your Telsmith, Inc. product. It contains safety, operation, parts. If your drawings or BOMs have been lost or damaged,
maintenance, service, and repair information on the machine new copies are available from your local approved Telsmith
to assist you in your operation. Distributor or the Telsmith Parts Department.
Please note that some features shown in this manual may not To ensure that you receive the correct parts for your machine,
be present on your machine. Some equipment described may always include the model number and serial number when
be optional at extra cost, or available only on selected ordering.
models.
The data and instructions contained in this manual are based MODEL and SERIAL NUMBER PLATE
on the latest information at the time of publication. Telsmith's Model and serial numbers are located on a data plate attached
policy of continuous improvem ents, features and to the right side plate. Always lockout power and tag
specifications are subject to change without notice. controls before reading data plate!
Actual dimensions, weights, and clearances may be different
than shown, due to fabrication variables, custom engineering SERVICE BULLETINS
or optional equipment. Telsmith periodically issues service bulletins to inform
customers of the latest repair and maintenance procedures.
HOW TO CONTACT TELSMITH INC. Service bulletins may have been included separately with this
manual. Always read and understand all service bulletins
Use the following information when you wish to contact
before starting any maintenance or service work.
Telsmith:
• General: Phone (262) 242-6600 SAFETY
FAX (262) 242-5812
All quarry personnel operating or servicing the machine must
• Parts: Phone (800) 688-6601 read and fully understand the information included in
FAX (262) 242-7861 Chapter 1, Safety of this manual.
• Written: Telsmith, Inc.
10910 N. Industrial Drive ILLUSTRATIONS
P.O. Box 539 This manual contains some illustrations in which guards,
Mequon, WI 53092-0539 access panels and other safety equipment have been removed
U.S.A. for instructional purposes or to provide greater clarity.
• Send all e-mail to: However, to prevent serious personal injury or death, always
parts@telsmith.com be sure all such equipment is installed before operating the
product.
REQUESTING SERVICE ASSISTANCE
If service assistance is required or you have questions about
INSTALLATION & ASSEMBLY DRAWINGS
maintenance or repair procedures in this manual, please Installation and assembly drawings (blueprints) are provided
contact your local approved Telsmith Distributor. If with all new Telsmith products. These drawings are normally
additional assistance is necessary, contact the Telsmith included with the technical manuals but may be shipped
Service Department. separately for some orders.
Service technicians are available by telephone from 8:00 a.m. The drawings include specifications, dimensions and other
to 4:30 p.m. CST, Monday through Friday, except holidays. information for use during installation and assembly
To ensure faster response, always have your machine’s model procedures. Contact your local Telsmith dealer or the
and serial numbers ready when calling. Telsmith Service Department if you have any questions about
information contained on the drawings.
If the drawings are lost, replacement copies may be ordered
from your local Telsmith dealer or the Telsmith Parts
Department.

04/08 3
Foreword Foreword
Telsmith Jaw Crushers Model 2036 - 5566

CONTACTS
TELSMITH PARTS DEPARTMENT CONTACTS

Name:
Phone (Office):
Phone (Cell):
FAX:

Name:
Phone (Office):
Phone (Cell):
FAX:

TELSMITH SERVICE DEPARTMENT CONTACTS

Name:
Phone (Office):
Phone (Cell):
FAX:

TELSMITH APPROVED DISTRIBUTOR CONTACTS

Name:
Phone (Office):
Phone (Cell):
FAX:

OTHER CONTACTS

Name:
Phone (Office):
Phone (Cell):
FAX:

Name:
Phone (Office):
Phone (Cell):
FAX:

4 04/08
 Operation and Maintenance Safety
Telsmith Model 3258 Jaw Crusher
TABLE OF CONTENTS
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

EQUIPMENT DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

RECOMMENDED TOOLS, TEST EQUIPMENT & SPARE PARTS . . . . . . . 4

INSTALLATION and ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 5

START-UP and OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 6

PERIODIC MAINTENANCE, ADJUSTMENTS & LUBRICATION . . . . . . . . 7

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
7F
MAINTENANCE & REPAIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

ECCENTRIC SHAFT OVERHAUL (2036, 2540 & 3042) . . . . . . . . . . . . . 10

ECCENTRIC SHAFT OVERHAUL (3055, 3648, 4448, 5060 & 5566) . . . . . . 11

STORAGE & SHIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

04/08 (Rev. 5) i
 Foreword Operation and Maintenance
Telsmith Model 3258 Jaw Crusher
TABLE OF CONTENTS
(Continued)
APPENDICES
1
APPENDIX A - CONVERSION TABLES . . . . . . . . . . . . . . . . . . . . . . . A-1
APPENDIX B - TORQUE TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
APPENDIX C - GLOSSARY OF TERMS . . . . . . . . . . . . . . . . . . . . . . . C-1
APPENDIX D - TORQUE NUT TENSIONER INFORMATION . . . . . . . . . . . . D-1
APPENDIX E - GREASE LUBE SYSTEM OPERATION & MAINTENANCE . . . . E-1

ii 04/08 (Rev. 5)
 TABLE OF CONTENTS 1
CHAPTER 1
Safety
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--1
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--1
MAINTENANCE AND INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--1
PRECAUTIONARY STATEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--1
Note and Important Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--1
Caution, Warning and Danger Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--1
JAW CRUSHER SAFETY SUMMARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--3
CLEARING OF CRUSHER OR FEED SYSTEM JAMS . . . . . . . . . . . . . . . . . . . . . . . . . . 1--3
DISCHARGE OPENING ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--3
GENERAL JAW CRUSHER SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 1--3
BEFORE STARTING JAW CRUSHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--3
AFTER STARTING JAW CRUSHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--4
GENERAL QUARRY SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--4
KNOW YOUR MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--4
WEAR PROPER PROTECTION EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--4
OBSERVE PERSONAL SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--5
KEEP EQUIPMENT AND SITE CLEAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--5
EQUIPMENT INSTALLATION GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--5
Foundations And Supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--5
Electrical Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--5
PROPER HOISTING AND HANDLING OF EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . 1--6
Wire Ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--6
Connecting Or Clamping Wire Ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--6
Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--6
Fiber Or Synthetic Slings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--6
MAINTENANCE AND REPAIR SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--7
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--7
HYDRAULIC SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--7
WELDING ON MACHINERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--7
HAZARDOUS MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--7
DISPOSAL OF EXCESS FUELS, LUBRICANTS AND LIQUIDS . . . . . . . . . . . . . . . . . . 1--8
CAUTION AND WARNING SIGNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--8
T
Telsmith Jaw Crushers
Models 2036 thru 5566
INTRODUCTION
SAFETY PRECAUTIONS
Safety is basically common sense. There are standard
safety rules, but each situation has its own peculiarities
which cannot always be covered by rules. Therefore,
always watch for possible safety hazards and correct
any deficiencies promptly.
Lack of attention to the WARNING, CAUTION and
DANGER statements in this manual can result in
accidents, personal injury, reduced efficiency, and loss
of life. Refer to Figure 1.1 for examples of the
precautionary statements used throughout this manual.
! WARNING!!!
It is the responsibility of the equipment owner
and operator to exercise safety practices and
procedures in the operation of machinery. This
responsibility includes placement of guards
and other safety equipment, instruction to
operators and other personnel in contact with
the machinery, and operation in compliance
with applicable health and safety laws and
general standards of reasonable care.
A careful operator is the best insurance against an
accident. The complete observance of the following
precautions will prevent many serious injuries.
1. Be sure all personnel operating or servicing the
crusher read and fully understand the contents of this
manual, including the safety information discussed in
this chapter. Be sure all personnel read and
thoroughly understand the manuals for all other
machinery which they operate and maintain.
2. Be sure that all personnel working around processing
machinery read and fully understand the Telsmith
Quarry Equipment Safety Guide furnished with your
machine. If your copy of the Telsmith Quarry
Equipment Safety Guide is missing or incomplete,
new copies are available from your dealer, or from
the Telsmith Technical Publications Department.
3. Never make any checks, adjustments, or repairs of
any kind while machinery is in operation.
4. Make sure all guards and other protective devices
are in place, secured, and not damaged. Never
tamper with safety devices or warning systems.
MAINTENANCE INSPECTIONS
This chapter contains some references to maintenance
inspection procedures. While maintenance is not
typically a safety concern, machinery that is maintained
and in proper working condition will minimize the
occurrence of emergency situations which could
become a safety hazard.
REV 4
(7/01)
Safety
1
Maintenance inspections and routine maintenance,
such as lubrication, can often be conducted when you
perform your safety inspections. Regular maintenance
inspections will help you establish a proper service
routine, and will help increase the efficiency of your
operation.
PRECAUTIONARY STATEMENTS
Throughout this manual, the use of the following
precautionary statements has been emphasized.
These statements are based on five different levels of
concern.
• NOTE
• IMPORTANT
• CAUTION
• WARNING
• DANGER
Refer to Figure 1.1 for examples of typical precautionary
statements used in this manual.
Note and Important Statements
The NOTE and IMPORTANT statements are advisory
statements relating to equipment maintenance,
operation and general service procedures. They are
used to draw attention to procedures and practices.
A NOTE is a basic statement of procedures. An
IMPORTANT is used to draw attention to a procedure
that needs to be followed to prevent machine damage.
Caution, Warning and Danger Statements
These statements are intended to notify workers of
dangerous areas or situations. All of these notices are
preceded by the SAFETY ALERT SYMBOL. The
SAFETY ALERT SYMBOL is meant to draw attention to
a dangerous situation.
Be sure to read and follow all instructions whenever the
SAFETY ALERT SYMBOL is present. Failure to follow
the instructions could result in SERIOUS PERSONAL
INJURY or DEATH.
The CAUTION statement involves safe operating
procedures. If the procedure associated with a
CAUTION statement is ignored, personal injury may
result.
The WARNING statement involves procedures which
are potentially hazardous. Failure to follow a WARNING
statement could result in SERIOUS INJURY or DEATH.
The DANGER statement involves procedures which are
the most hazardous if not properly performed. Failure to
follow the instructions associated with a DANGER
statement will likely result in SERIOUS INJURY or
DEATH.
1--1
 Telsmith Jaw Crushers
Safety Models 2036 thru 5566

SAMPLE PRECAUTIONARY STATEMENTS

! DANGER!!! ! WARNING!!!
Never walk onto bridged materials. The bridge Lock out power and tag controls before
may break free at any time. servicing oil lubrication system. Alert all
personnel that crusher is being serviced.

! CAUTION!!!
Operating the crusher above or below the
speed recommended in Table 3.3 will result in
reduced efficiency and increased wear.

NOTE: After startup, speed should be measured IMPORTANT: Bearings must be lubricated after
at the flywheels and checked under load with a every 8 hours of operation. Refer to Chapter 7 for
tachometer. Speed variations of ± 3% are allow- more information.
able and will not affect the operation of the crusher.

Figure 1.1 Sample Precautionary Statements

1--2
Telsmith Jaw Crushers
Models 2036 thru 5566
JAW CRUSHER SAFETY SUMMARY
CLEARING OF CRUSHER OR FEED
SYSTEM JAMS
See “Clearing Obstructions” in Chapter 6 if removal of
uncrushable objects is necessary. Read and
understand the entire procedure and all precautionary
statements before working on crusher.
! DANGER!!!
Uncrushable object jams are extremely
dangerous. These objects are under
tremendous pressure and can dislodge or
fracture at any time.
! DANGER!!!
Never attempt to reach into or enter the
crushing chamber. After locking out power and
tagging controls use a pole, hook, grappling
device or breaker bar to dislodge the
uncrushable object. The force of the crusher
can propel the uncrushable object with
tremendous power and can cause severe injury.
DISCHARGE OPENING ADJUSTMENT
See “Discharge Opening Adjustment” in Chapter 7 if
adjustment of discharge opening is necessary. Read
and thoroughly understand the entire procedure and all
precautionary statements before working on crusher.
GENERAL JAW CRUSHER SAFETY
PRECAUTIONS
• Disconnect, lock out and tag the main power source
to the crusher drive motor and feeding equipment
before attempting any maintenance repairs or
adjustments.
• Avoid looking into the crushing chamber while
crusher is operating unless absolutely necessary.
• If you must look into the crushing chamber while the
crusher is operating, take appropriate precautions to
protect yourself from flying rock. Always wear
hard-hat, protective gloves, and approved full face
shield. Also be sure that all feed guarding is installed.
• Avoid stopping crusher with material inside the
crushing chamber. Always allow all material to
discharge before shutting off the drive motor.
• If it is necessary to enter the crushing chamber, make
sure the power has been locked out, the controls
have been tagged and the drive pulley has been
secured. Also make sure that the sheaves are
positioned so that their counterweights are located at
the top.
REV 4
(7/01)
Safety
1
• Do not place timber or any other blocking device
between the swing jaw and the stationary jaw to hold
the swing jaw open during maintenance. Due to the
angled faces of the jaws, the blocking device could
unexpectedly dislodge, causing severe injury or
death. Always hold the swing jaw in place by securing
the drive pulley.
• Observe all local, state, and federal regulations
pertaining to burning torches, ladders, crane
facilities, lifting slings, operator platforms, use of
pressurized hydraulic tools and protection of eyes
and hearing.
• Federal and local safety codes may require the use
of special guards, safety shutdown devices, etc.
Compliance with such laws is the owner’s/
management’s responsibility. Upon request,
Telsmith will supply safety-related items to meet
such codes at extra cost.
• Never arc weld on any part of the crusher unless the
actual part being welded is grounded directly to the
welding machine. Arcing through roller bearings will
permanently damage them. Any field welding
performed on the crusher or eccentric shaft without
written authorization from Telsmith will be at the
responsibility of the operator.
• Never adjust pressure relief valves to obtain higher
pressures.
BEFORE STARTING JAW CRUSHER:
• Read and understand this entire manual, including
the safety material in this chapter.
• Read and understand the Telsmith Quarry
Equipment Safety Guide. If your copy of the Guide is
missing or incomplete, replacement copies are
available from your Telsmith dealer, or from the
Telsmith Technical Publications Department.
• Perform all checks and lubricate crusher as
described in Chapter 7.
• Make sure all guards and other protective devices
are in place, secured and not damaged.
• Check that all safety devices are properly connected
and operational. Never tamper with safety devices.
• Check that all platforms and walkways are clear of
any spilled materials, such as rocks, sand, oil or
grease.
• Inspect all drive belts and pulleys for improper
alignment, incorrect tension or signs of wear. See
“V-Belt Maintenance” in Chapter 7.
• Make sure lubrication system oil tank is filled with
high quality oil of proper type and viscosity. Add oil if
required. See Chapter 7 for oil specifications.
1--3
 Telsmith Jaw Crushers
Safety Models 2036 thru 5566
• Make sure discharge opening is not smaller than the GENERAL QUARRY SAFETY
recommended minimum discharge opening.
PRECAUTIONS
• Start oil lubrication system and circulate warmed oil
for about 15 minutes before starting crusher KNOW YOUR MACHINE
(oil-lubricated crushers only). Never begin crushing
until the temperature of the lubricating oil is at least • Study the operator’s manuals of all machinery that
70° F. you operate. Become familiar with the controls,
functions, and settings of each machine. Fully
• After adjusting discharge opening, always ensure understand all phases of each machine’s operation.
that the toggle beam is tight against the shims and
backing blocks. On 3042 and smaller models, be • Make sure that you completely understand all
sure clamping screws are tight. start-up procedures.

• Never reverse the direction of rotation of the • In the event of an accident, make sure that you know
flywheel. Crusher flywheel must rotate toward the the proper emergency shut-down procedures for the
receiving opening of the crusher. equipment you operate.

• Make sure no personnel are standing beside, under, • Before daily equipment startup, make sure that all
inside, or on the crusher. Many serious accidents can routine maintenance has been performed. Refer to
happen if the plant is started while personnel are Chapter 7 for jaw crusher periodic maintenance
standing in a dangerous position. procedures.

• Warn all personnel before you start the crusher. • Before servicing any equipment, lock out all power
supplies and tag controls to notify others that service
AFTER STARTING JAW CRUSHER: work is being performed.
IMPORTANT: Except as noted, perform all checks • Contact the Safety Officer at your facility to receive
without material feeding. the latest safety guidelines published by the
Occupational, Safety and Health Administration
• Never attempt to clear or adjust crusher while it is (OSHA) and the Mine Safety and Health
running. Administration (MSHA).
• Do not stand on crusher during operation.
WEAR PROPER PROTECTION
• Listen for loose tension rod springs. If necessary, EQUIPMENT
tighten springs until toggle does not “knock”. Never
stand directly behind tension rod springs when Crushing rock can be a dangerous process. To reduce
adjusting tension. the risk of injury or death, observe the following
precautions:
• Visually inspect the crusher for oil leaks, worn hoses
and loose parts. • Always wear proper protection for hearing and eyes
whenever outside of an approved operator’s
• Check that all controls operate properly and that all enclosure.
gauges show normal readings. Shut down crusher
immediately if any improper temperature or pressure • Use respirators in dusty locations.
readings are observed. • Wear steel-toe safety boots, hard-hats and heavy
• Check that alarms and other safety devices are duty gloves.
functioning properly.
• Visually observe flow of oil through sight glasses on
oil system reservoir.
• Listen for any unusual noises.
• Check that the machine’s feed and discharge areas
are in proper condition.
• Start the machine’s production flow and again
inspect the feed and discharge areas to make sure
that they are fully functional.

1--4 REV 4
(7/01)
Telsmith Jaw Crushers
Models 2036 thru 5566
OBSERVE PERSONAL SAFETY
PRECAUTIONS
• Never wear watches, jewelry or loose clothing when
working on or around rotating power equipment such
as conveyor belts, drive belts, or pulleys. Do not have
loose, long hair. These items can become caught or
tangled in the equipment, resulting in severe
personal injury or death.
• Before you assemble, operate, clean, lubricate or
adjust machinery, be sure to read and understand all
procedures as listed in this manual.
• At the start of each shift, it is the operator’s
responsibility to inspect the machinery. See the “Jaw
Crusher Safety Summary” elsewhere in this chapter
for additional information.
• If any problems are noted, make sure that they are
repaired by a qualified technician before crushing
begins. If repairs are required, always lock out the
power supply and tag the controls.
• Make sure that all personnel know:
* Where first aid equipment is stored.
* Where emergency phone numbers are listed.
* How to report accidents. Report all accidents
immediately!
KEEP EQUIPMENT AND SITE CLEAN
• Make sure that walkways, platforms and ramps are
kept free of spilled materials at all times. Small pieces
of material can cause falls and injuries.
• Be especially careful whenever using wet walkways,
platforms, or ramps. Rock dust and wet metal can
become extremely slippery.
• Keep the areas around control panels, power supply
panels and lubrication systems free of spilled
material and obstructions. Free access must be
maintained at all times. In the event of an emergency,
quick access to controls could prevent injury or
death.
EQUIPMENT INSTALLATION GUIDELINES
Foundations And Supports
Proper foundation and support structures are very
important for the safe and efficient operation of all
Telsmith equipment.
Follow all Telsmith supplied engineering drawings and
specifications when constructing the base pads for
permanent plants. If any questions arise about
foundation requirements or modifications necessary for
your installation, contact the Telsmith Service
Department for further information.
Safety
1
Crushing machinery needs a firm foundation on which to
operate. This does not need to be a poured pad, but it
cannot be on unstable ground. When selecting the
location make sure that the entire area is as level as
possible.
All support structures that are designed in the field to
support any Telsmith equipment must meet Telsmith’s
engineering requirements. It is recommended that you
submit your installation plans to the Telsmith Service
Department for approval.
Electrical Considerations
! WARNING!!!
When installing any electrical equipment, make
sure to follow the manufacturer’s instructions
completely. failure to do so could lead to a
dangerous electrical shock hazard. Make sure
that all electrically powered equipment has
been properly grounded.
• Layout the power lines, especially those for portable
plants, to minimize contact with standing ground
water.
• Do not allow the power lines to be placed in an area
where they will be driven over by quarry equipment
or transport vehicles.
• If it is necessary to cross a traffic area with an
electrical cable, be sure to protect the cable with
properly rated bridging.
• Inspect power cables and connections daily for signs
of wear, cracked insulation, and worn or damaged
connectors. Repair or replace as required.
• If auxiliary control panels or power supply panels are
being installed, make sure that these can be securely
locked out. This type of panel is mandatory.
• Adequate overhead clearance must be maintained
from overhead power lines or other obstructions,
particularly when planning to use stacking conveyers
for stockpiles.
• Make sure that electrical power supplies are located
in an area that will be safe from accidental contact
during crushing operations.
1--5

Safety
! WARNING!!!
All Telsmith equipment has been designed with
the proper size of electrical components. Any
modifications to the power supplies or
equipment on Telsmith machinery must be
approved in writing by the Telsmith service
department. Be sure to follow all electrical
specifications when installing power supplies.
PROPER HOISTING AND HANDLING OF
EQUIPMENT
Wire Ropes
Wire ropes require careful use, handling, and
maintenance to ensure long life and safe operation.
Always observe the following precautions:
• Be sure that the correct wire rope is being used for
the application.
• Be sure that the ropes are inspected regularly
following the manufacturer’s guidelines.
• Avoid sudden loading in cold weather.
• Never use frozen wire ropes.
• Use suitable padding to protect wire rope from sharp
corners or edges.
• Avoid dragging the rope from under loads or over
obstacles.
• Never use a wire rope that has been cut, badly
kinked, frayed or crushed.
• Avoid reverse bends.
• Be sure that the rope ends are properly sized.
• Use thimbles in eye fittings at all times.
• Watch for local wear. Reposition or shorten rope to
remove worn section from the area of lifting tension.
• Follow the manufacturer’s instructions for lubrication
if the wire ropes are used for lifting procedures.
Connecting Or Clamping Wire Ropes
When connecting or clamping wire ropes, use one of the
following:
• Clamp and thimble connections combine both the
clamp and thimble in one unit. Clamp and thimble
connections are capable of supporting 80% rated
wire rope load.
• Cable clips are the most common way to secure a
rope to a piece of equipment or to make an eye. The
cable clip or “Crosby Clip” is made of a U-bolt and
saddle. If this type of clip is used to make an eye, the
use of a properly sized thimble is mandatory. If not,
the cable may kink, forming a permanent weak spot.
IMPORTANT: Refer to wire rope supplier for proper
installation of cable clips. Improperly installed cable
clips can cause damage and premature failure.
1--6
Telsmith Jaw Crushers
Models 2036 thru 5566
Chains
Chains require careful use, handling and maintenance
to ensure long life and safe operation.
• Make sure that the correct size chain is being used
for the application.
• Make sure that the chains are inspected regularly
following the manufacturer’s guidelines
• Avoid sudden or shock loading (DO NOT jerk load
upright).
• Use suitable padding to protect the chain from sharp
corners or edges.
• Avoid dragging the chain from under loads or over
obstacles.
• Use the proper fittings at all times.
• Watch for local wear. Reposition or shorten chain to
move worn section from the area of tension.
• Inspect links to determine the amount of wear. Refer
to manufacturer’s specifications for wear tolerance
ranges.
• Make sure that all connections between chain
sections are completed with properly sized hardware
and lifting hooks.
! CAUTION!!!
Always follow proper rigging procedures as
provided by the chain manufacturer. The angle
of rigging may decrease the rated lifting
capacity.
Fiber Or Synthetic Slings
Slings require careful use, handling and maintenance to
ensure long life and safe operation.
• Make sure that the sling is rated or coded for the hitch
or application.
• Make sure that the slings are inspected regularly
following the manufacturer’s guidelines.
• Do not use synthetic slings in temperatures
exceeding 180° Fahrenheit.
• Slings may be safely used in a temperature range of
20° to 180° Fahrenheit without decreasing load
limits. For temperatures beyond this range or for
wet/frozen slings, follow manufacturer’s instructions
for load reductions.
• Avoid sudden or shock loading (DO NOT jerk load
upright).
• Use suitable padding to protect the sling from sharp
corners or edges.
• Avoid dragging the sling from under loads or over
obstacles.
• Use the proper fittings at all times.
REV 4
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Telsmith Jaw Crushers
Models 2036 thru 5566
• Watch for local wear. Reposition or shorten sling to
eliminate worn section.
• Inspect connection links to determine the amount of
wear. Refer to manufacturer’s specifications for wear
tolerance ranges.
MAINTENANCE AND REPAIR
SAFETY
! WARNING!!!
Whenever machines are maintained, either on
the daily service cycle or for other repairs, make
sure that all controls are tagged and that the
electrical system has been locked out.
ELECTRICAL SYSTEM
• Always read, understand, and follow appropriate
electrical system troubleshooting, maintenance and
repair instructions in machinery manuals.
• Allow only trained and licensed electricians to service
electrical equipment.
• Whenever troubleshooting or repairing the electrical
system, work with the power locked out, if possible.
• If it is not possible to service the equipment with the
power locked out tag all controls and alert all
personnel. See Figure 1.2.
Figure 1.2 Tagged Controls
REV 4
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Safety
1
HYDRAULIC SYSTEMS
• Whenever service work is to be performed on any
hydraulic system, make sure that all system
pressure has been relieved. Make sure that all
controls and the power supply have been locked out
and tagged before beginning any service procedure.
After the power has been shut off, cycle control
levers in all directions to relieve system pressure.
• Never have your face near, or stand directly in front
of a hydraulic line when cracking a fitting. Always
assume that the line has pressure.
• Always clean up any spilled hydraulic fluid,
particularly on an elevated metal work platform or
walkway. Spilled hydraulic fluid is extremely slippery.
• The adjustments and settings of all hydraulic
systems must be done according to the procedures
outlined in this manual.
WELDING ON MACHINERY
• While all welding should be performed in a properly
ventilated area, special concern should be exercised
when welding chromium, manganese, cadmium,
copper, cobalt, lead and nickel, as these materials
are considered to be potentially carcinogenic.
• Be sure there is adequate ventilation when welding
inside the jaw crusher.
• Always follow all standard safety procedures if
welding is necessary. Make sure that all systems are
shut down, power is locked out, and controls are
tagged.
• Do not weld near flammable liquids or hydraulic oils.
• Do not weld lifting eyes or hooks to manganese steel
castings. If necessary, use a stainless steel or
manganese weld rod. Use extreme caution to keep
personnel clear of castings being lifted or supported
by these devices.
• Never ground the welder so that the electrical power
will flow through bearings, hydraulic components or
electrical equipment.
HAZARDOUS MATERIALS
• To avoid potential health hazards, persons in regular
contact with hydraulic oils must be aware of the
importance of thorough hygiene, and the proper
methods for handling mineral oils.
• Mineral-based hydraulic oils act as solvents on the
natural oils of the skin. Frequent and prolonged skin
contact can cause dermatitis or severe irritation.
1--7

Safety
• Always wear suitable protective clothing when
handling hydraulic oil.
• Be sure protective clothing and proper wash-up
facilities are available to all personnel that may come
in contact with mineral based hydraulic fluids.
• Always dispose of rags or paper towels in the correct
and safe fashion.
DISPOSAL OF EXCESS FUELS,
LUBRICANTS AND LIQUIDS
• It is the responsibility of the machine users to
properly dispose of unused fuels, used lubricating
oils, used hydraulic oils, and other toxic materials,
DO NOT dump these materials in an un-approved
manner.
Figure 1.3 Jaw Crusher Caution and Warning Signs (Typical)
1--8
Telsmith Jaw Crushers
Models 2036 thru 5566
CAUTION AND WARNING SIGNS
Telsmith machinery is posted with CAUTION and
WARNING signs. These signs provide user information
and warnings about potentially dangerous situations
and areas on the machine.
Follow all safety instructions posted on the machine,
and make sure that all signs and notices are in good
condition and are attached in the proper locations as
shown in Figure 1.3. Note that it is often necessary to
add additional WARNING and CAUTION signs on field
installations to provide adequate coverage and visibility.
Order additional signs as required, from the Telsmith
Parts Department or your local dealer.
REV 1
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 TABLE OF CONTENTS
CHAPTER 2
2
General Information
EQUIPMENT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--1
MAJOR FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--1
DIFFERENCES BETWEEN MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--1
PERFORMANCE CHARACTERISTICS AND SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . 2--1
LOCATION AND DESCRIPTION OF MAJOR COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . 2--3
HYDRAULIC ADJUSTMENT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--5
PRINCIPLES OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--7
T
Telsmith Jaw Crushers
Models 2036 thru 5566
EQUIPMENT DESCRIPTION
Telsmith jaw crushers reduce run--of--mine ore or stone
to smaller sizes for further processing. The larger
models are designed for primary reduction in metal and
non--metallic mines, and in large commercial quarries.
The smaller models are designed for gravel plant
primary reduction.
All Telsmith jaw crushers feature the single toggle,
overhead eccentric roller bearing design. Capacities
range from 45 tons per hour to 1950 tons per hour,
depending on model, discharge opening and material
being crushed.
MAJOR FEATURES
• Single wall main frame of stress--relieved steel
withstands high crushing pressures.
• Patented hydraulic adjusting system allows changes
in discharge opening from outside the crusher.
• Open back design for easy access during
maintenance.
• Power oil lubrication system (optional) helps prolong
bearing life.
• Reversible manganese jaw dies provide longer wear.
• Two--piece main frame on larger crushers facilitates
handling and installation.
• Special thrust mechanism helps extend bearing life.
Front
Right Side
Figure 2.1 Machine Orientation
REV 4
(7/01)
General Information
DIFFERENCES BETWEEN MODELS
Major configurational differences between the crushers
described in this manual are as follows:
2
• The 4448, 5060 and 5566 feature two piece frames.
The 2036, 2250, 2540, 3042, 3055 and 3648 feature
one piece frames.
• The 3055, 3648, 4448, 5060 and 5566 feature
Telsmith’s patented wedge lock system for securing
the toggle beam. The 2036, 2250, 2540 and 3042
use bolts to secure the toggle beam.
• A manual hand pump for the adjusting system is
standard on all models. An electrically powered
pump for the adjusting system is optional on the
3055, 3648, 4448, 5060 and 5566.
• An air-to-oil cooler is included on the 4448, 5060 and
5566 equipped with the optional power oil lubrication
system. The air-to-oil cooler is not available on other
models.
• Spherical bearings are used on the 3055, 3648,
4448, 5060 and 5566. a combination of radial and
spherical bearings are used on the 2036, 2250, 2540
and 3042.
PERFORMANCE CHARACTERISTICS
AND SPECIFICATIONS
Refer to Chapter 3 for performance charts,
specifications and other data.
Left Side
Rear
2--1
 Telsmith Jaw Crushers
General Information Models 2036 thru 5566

Figure 2.2 Major Components of Jaw Crusher

2--2
Telsmith Jaw Crushers
Models 2036 thru 5566
LOCATION AND DESCRIPTION OF MAJOR COMPONENTS
Item Component
A Swing Jaw
B Main Frame
C Cheek Plates
D Stationary Jaw Die
E Swing Jaw Die
F Toggle Plate
G Tension Rod Assembly
H Oil Lubrication System
(optional)
I Auxiliary Hydraulic Cylinder
(optional)
J Main Frame Bearing
K Swing Jaw Bearing
L Eccentric Shaft
M Flywheel Sheave
N Thrust Bracket
O Thrust Shaft
P Flywheel Pulley
Table 2.1 Major Components of Jaw Crusher
General Information
Description
2
Moving weldment that crushes rocks against stationary jaw. Fits inside
main frame. Supported by eccentric shaft.
Major weldment that forms the crushing chamber.
Replaceable manganese wear surfaces bolted to inner sides of crusher
frame.
Replaceable manganese wear surface located inside front of crusher.
Provides a breaking surface for swing jaw.
Replaceable manganese wear surface bolted to front of swing jaw.
Supports lower part of swing jaw and controls its movement. Designed
to bend or fracture upon overload, preventing further damage to crush-
er.
Provides tension that holds swing jaw against toggle plate.
Provides oil lubrication for swing jaw and main frame bearings.
Hydraulic cylinder used to position swing jaw during toggle replace-
ment.
Rotational surface between eccentric shaft and main frame.
Rotational surface between eccentric shaft and swing jaw.
A shaft machined with a portion of its axis off--center to create the
swinging (crushing) motion of the swing jaw.
Drives eccentric shaft (through V-belts).
Contacts thrust shaft during crusher operation. Helps prevent side
forces from damaging bearings.
Absorbs side motion of swing jaw and helps prevent damage to bear-
ings.
Helps maintain crusher speed as load conditions change.
2--3
 Telsmith Jaw Crushers
General Information Models 2036 thru 5566

A C D
B

ADJUSTMENT MECHANISM
(2036, 2250, 2540 & 3042) F
B H
I
E

G
F

J
ADJUSTMENT MECHANISM
(3055, 3648, 4448, 5060 & 5566)

K L

HAND HYDRAULIC PUMP ELECTRIC HYDRAULIC PUMP

(Standard All Models) (Optional 3055, 3648, 4448, 5060 & 5566)
Figure 2.3 Hydraulic Adjustment System

2--4 REV 4
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Telsmith Jaw Crushers
Models 2036 thru 5566
HYDRAULIC ADJUSTMENT SYSTEM
Item Component
A Set Screw
B Shims
C Shim Retainer Pin
D Clamping Screws
E Hydraulic Cylinder
F Toggle Beam
G Backing Block
H Wedge Lock Bolt
I Toggle Beam Wedge
J Wedge Lock Plate
and Lock Plate Shoe
K Hand Hydraulic Pump
L Electric Hydraulic Pump
Table 2.2 Hydraulic Adjustment System
REV 4
(7/01)
General Information
Description
2
Secures shim retainer pin (2036, 2250, 2540 and 3042 only).
Used to maintain toggle beam position. Install as required to achieve
desired discharge opening.
Keeps shims in place (2036, 2250, 2540 and 3042 only).
Secures toggle beam during crusher operation (2036, 2250, 2540 and
3042 only).
Moves toggle beam backward or forward. Used to adjust discharge
opening.
Controls size of crusher discharge opening.
Supports toggle.
Provides flat load bearing surface for shims.
Keeps toggle beam wedges tight and holds shims in place (3055,
3648, 4448, 5060 and 5566 only).
Locks toggle beam in place. Eliminates need for clamping screws
(3055, 3648, 4448, 5060 and 5566 only).
Locks toggle beam in place by pushing toggle beam wedge against
toggle beam.
Provides hydraulic pressure for adjusting system hydraulic cylinders.
Standard on all models.
Provides hydraulic pressure for adjusting system hydraulic cylinders.
Replaces hand pump. Optional on 3055, 3648, 4448, 5060 and 5566.
2--5

General Information
Figure 2.4 Oil Lubrication System
Item Component
A Pressure Relief Valve
B Oil Pump and Motor
C Oil Tank
D Air--to--Oil Cooler Switch
E Air--to--Oil Cooler
F Temperature Gauge
G Oil Filter
H Pressure Gauge
I Alarm Panel
Table 2.3 Oil Lubrication System
2--6
Telsmith Jaw Crushers
Models 2036 thru 5566
A
B
H C
F
D
Description
Safety feature that returns oil to tank if pressure exceeds
approximately 12 PSI.
Electric pump provides pressure for oil lubrication system.
Supplies oil for lubrication system. Holds either 12 or 24 gallons,
depending on crusher model.
Activates air-to-oil cooler fan whenever oil temperature exceeds 120
degrees F. (oil lubricated 4448, 5060 and 5566 only).
Fan-forced cooler maintains safe oil temperature (oil lubricated 4448,
5060 and 5566 only).
Indicates lubrication system oil temperature.
Traps and removes impurities from oil. Includes replaceable filter
element and by--pass indictor.
Indicates lubrication system oil pressure.
Activates alarm if oil temperature exceeds 140 degrees F or if oil
pressure falls below 2 PSI.
REV 4
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Telsmith Jaw Crushers
Models 2036 thru 5566 General Information

2
FLYWHEEL
SWING STATIONARY
JAW JAW DIE

TOGGLE
BEAM
SWING
JAW DIE
TENSION
SPRING

TENSION
ROD TOGGLE DISCHARGE
PLATE OPENING

Figure 2.5 Jaw Crusher Operation

PRINCIPLES OF OPERATION
Jaw crushers process quarry material by compressing it
between two surfaces, one moving and one fixed.
The swing jaw is the moving surface. It is attached to a
rotating eccentric shaft. The stationary jaw is the fixed
surface. It is an integral part of the crusher frame. Both
surfaces are lined with manganese jaw dies. The jaw
dies may be replaced or reversed when worn.
During crusher operation, the toggle plate controls
movement of the lower part of the swing jaw. To prevent
serious damage, the toggle plate is also designed to
bend or break if uncrushable objects enter the crushing
chamber.
Quarry material is loaded from the top of the crusher and
falls through the crushing chamber. As the swing jaw
opens and closes, it compresses and crushes this
material against the stationary jaw. Crushed material
then drops through the bottom of the crusher.
The minimum size of the opening at the bottom of the
jaws is called the “discharge opening”. It may be
adjusted by adding or subtracting shims (not shown)
between the toggle beam and the crusher frame. This
adjustment is necessary to compensate for jaw die wear
and to suit different types of crushing requirements.

REV 1 2--7
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 Telsmith Jaw Crushers
General Information Models 2036 thru 5566

2--8 REV 4
(7/01)
 TABLE OF CONTENTS
CHAPTER 3
Equipment Data
3
DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--1
CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--2
SCREEN ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--3
HORSEPOWER AND RPM SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--4
WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--5
POWER AND UTILITY SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--5

NOTE: SEE CHAPTER 7 FOR OIL AND GREASE SPECIFICATIONS

T
Telsmith Jaw Crushers
Models 2036 thru 5566 Equipment Data

DIMENSIONS

Dim. 2036 2250 2540 3042 3055 3648 4448 5060 5566

A 431/4″ 503/8″ 453/8″ 481/8″ 555/8″ 5315/16″ 5615/16″ 72″ 75″

B 431/4″ 503/8″ 453/8″ 481/8″ 555/8″ 5315/16″ 5615/16″ 72″ 75″
C 54″ 711/4″ 611/4″ 661/4″ 773/4″ 71″ 751/2″ 90″ 96″
D 25″ 27″ 27″ 30″ 27″ 33″ 36″ 39″ 39″
E 813/ 4″ 87″ 89″ 1061/ 2″ 1031/ 2″ 1273/ 4″ 1605/ 8″ 1681/ 4″ 1801/4″
F 18″ 15″ 26″ 24″ 25″ 27″ 20″ 20″ 20″
G 181/ 2″ 231/ 2″ 21″ 30″ 29″ 341/ 4″ 38″ 44″ 44″
H 521/ 2″ 59″ 60″ 72″ 701/ 4″ 813/ 4″ 88″ 1011/ 2″ 1061/2″
I 71″ 82 1/2″ 81″ 102″ 991/4″ 116″ 126″ 1451/2″ 1501/2″
J 11″ 141/2″ 12″ 15″ 15″ 171/4″ 16″ 20″ 20″
K 503/ 4″ 54″ 56″ 66″ 66″ 831/ 4″ 1121/ 2″ 117″ 1411/4″
L 22″ 295/8″ 245/8″ 26″ 297/8″ 30″ 30″ 361/2″ 391/4″

Table 3.1 Dimensions

REV 4 3--1
(7/01)
 Telsmith Jaw Crushers
Equipment Data Models 2036 thru 5566

CAPACITIES Some material produced by the crusher will be larger

To achieve the capacities shown in Table 3.2., all feed
should be smaller than the feed opening of the crusher in
at least one dimension. Required horsepower is
dictated by the size of the finished product, crusher
capacity and hardness of rock or ore.
The capacities shown are in tons (2000 lbs.) and are
based on crushing limestone weighing approximately
2600 lbs. per cubic yard and having a specific gravity of
2.6.
than the given discharge opening. All crushers produce
some oversize material. The amount of oversize will
vary with the character of the rock. For close settings, all
undersize material should be removed from the feed so
as to eliminate packing and excessive wear on the jaw
dies. Wet, sticky feeds will tend to reduce crusher
capacities.
“♦” indicates a discharge opening at which crusher
cannot be economically or safely operated.

Discharge
Opening** 2036 2250 2540 3042 3055 3648 4448 5060 5566
3/
4″ 45--85 ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦
1″ 52--95 170--250 ♦ ♦ ♦ ♦ ♦ ♦ ♦
11/4″ 58--105 175--266 ♦ ♦ ♦ ♦ ♦ ♦ ♦
11/2″ 64--115 180--283 ♦ ♦ ♦ ♦ ♦ ♦ ♦
2″ 75--135 210--315 ♦ ♦ ♦ ♦ ♦ ♦ ♦
21/2″ 85--155 230--343 133--217 150--230 ♦ ♦ ♦ ♦ ♦
3″ 96--174 250--370 148--237 167--252 ♦ ♦ ♦ ♦ ♦
31/2″ 108--192 270--405 160--259 183--273 283--430 ♦ ♦ ♦ ♦
4″ 146--210* 290--440 178--282 197--319 300--460 290--435 ♦ ♦ ♦
5″ 165--250* 330--475 206--334 230--342 350--530 328--492 384--580 ♦ ♦
6″ ♦ ♦ 234--389* 270--405* 390--600 362--547 443--655 548--785 ♦
7″ ♦ ♦ 266--444* 310--505* 430--670 408--620 500--750 570--850 670--995

8″ ♦ ♦ ♦ ♦ ♦ 438--660 540--810 625--940 720--1080

9″ ♦ ♦ ♦ ♦ ♦ ♦ 580--870 680--1015 785--1175

10″ ♦ ♦ ♦ ♦ ♦ ♦ 620--930 745--1120 857--1282

11″ ♦ ♦ ♦ ♦ ♦ ♦ 660--980 840--1190 938--1410

12″ ♦ ♦ ♦ ♦ ♦ ♦ 700--1030 925--1260 1045--1565

13″ ♦ ♦ ♦ ♦ ♦ ♦ ♦ 995--1330 1170--1750

14″ ♦ ♦ ♦ ♦ ♦ ♦ ♦ 1065--1400 1310--1950

* Capacity with short toggle. ** Discharge opening is measured as PEAK to PEAK with jaws in closed position.

Table 3.2 Crusher Capacity/Tons Per Hour

3--2 REV 4
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Telsmith Jaw Crushers
Models 2036 thru 5566 Equipment Data

SCREEN ANALYSIS

Figure 3.1 Screen Analysis (3/4″--4″ opening)

Figure 3.2 Screen Analysis (5″--16″ opening)

REV 4 3--3
(7/01)
 Telsmith Jaw Crushers
Equipment Data Models 2036 thru 5566

HORSEPOWER AND RPM
SPECIFICATIONS
All horsepower recommendations shown in Table 3.3.
are based on electric horsepower.
Horsepower for diesel engines is rated differently from
horsepower for electric motors. If you wish to power your
crusher with a diesel engine, check with the engine
manufacturer to determine the equivalent diesel
horsepower at the recommended speed (RPM) shown
for your crusher in Table 3.3. If necessary, contact the
Telsmith Service Department for assistance.
Actual horsepower and speed required may vary with
the size of product being produced, the capacity
required, and the hardness of the rock or ore being
processed. Contact the Telsmith Service Department
before attempting to operate your crusher at a different
RPM or horsepower than specified in Table 3.3.
IMPORTANT: Operating the crusher at other than the
recommended horsepower and RPM could void
warranty and may result in serious damage to crusher.
Any changes in horsepower or RPM require written
approval from the Telsmith Service Department.

Model 2036 2250 2540 3042 3055 3648 4448 5060 5566
Horsepower
Required 100 125 125 150 150 200 200 300 350
RPM 265 260 260 255 280 230 225 225 225
* Crusher speed can vary +/-- 3% from the speed listed
Table 3.3 Horsepower and RPM Specifications

IMPORTANT: Horsepower and speed

requirements shown above are typical
but may be different for some crushers
due to custom engineering or design
variables. Refer to the installation and
assembly drawings provided with your
crusher for complete V--belt drive data.

3--4 REV 4
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Telsmith Jaw Crushers
Models 2036 thru 5566 Equipment Data

WEIGHTS †
Model
2036 2250 2540 3042 3055 3648 4448 5060 5566
Component
Entire
Crusher 27,400 41,500 35,515 53,200 58,000 76,800 116,200 173,400 217,000

Swing Jaw
Die

Stationary
Jaw Die
1500

1,500
2,800

2,800
2,050

2,050
3,000

3,000
4,656

4,040
4,850

4,850
6,700

6,300
9,700

1,0900
12,300

13,100
3
Cheek Plate 220 (R) 250 (R) 300 (R) 360 (R) 360 (R) 550 (R) 1,010 (R) 1,500 (R) 1,750 (R)
(Upper) 220 (L) 250 (L) 300 (L) 360 (L) 360 (L) 550 (L) 1,010 (L) 1,500 (L) 1,750 (L)

Cheek Plate 220 (R) 220 (R) 220 (R) 300 (R) 300 (R) 420 (R) 650 (R) 1,050 (R) 1,400 (R)
(Lower) 220 (L) 220 (L) 220 (L) 300 (L) 300 (L) 420 (L) 650 (L) 1,050 (L) 1,400 (L)

Swing Jaw &

Shaft Assy.* 7,400 10,800 12,000 20,200 27,801 25,100 33,700 50,350 70,300

Flywheel
Sheave 2,260 2,300 2,250 2,000 2,250 4,400 4,350 9,100 9,100

Flywheel
Pulley 2,300 2,250 2,250 2,700 2,250 4,400 4,350 11,000 10,900

Toggle 200 350 350 600 741 1,000 900 1,570 2,100

Main Frame 8,700 13,550 12,500 22,000 17,252 31,800 26,000 35,000 40,800
(Upper) (Upper) (Upper)

26,000 35,700 40,000

(Lower) (Lower) (Lower)

Toggle Beam 1,900 2,450 1,700 2,800 3,510 4,550 4,850 7,150 9,850

Eccentric
Shaft 1,130 1,920 1,600 2,400 2,739 3,570 4,380 8,350 8,850

* Includes: shaft assembly, swing jaw, and swing jaw die. Does not include flywheel and flywheel sheave.
† Approximate weights. Actual weights may vary by ± 10%.
Table 3.4 Crusher Component Weights (in pounds)

POWER AND UTILITY

SPECIFICATIONS
Power and utility specifications vary by machine. Refer
to the electrical schematics furnished with your crusher.
If the electrical schematics are missing or incomplete,
contact the Telsmith Service Department for
replacement schematics.
When installing electrical equipment be sure to
understand and follow the electrical schematics
completely. Failure to do so could cause a dangerous
electrical shock hazard.

REV 4 3--5
(7/01)
 Telsmith Jaw Crushers
Equipment Data Models 2036 thru 5566

3--6
 TABLE OF CONTENTS
CHAPTER 4
Recommended Tools, Test Equipment
And Spare Parts

RECOMMENDED TOOLS AND TEST EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TOOLS SUPPLIED WITH CRUSHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4--1
4--1
4
RECOMMENDED SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--1
T
Telsmith Jaw Crushers Recommended Tools,
Models 2036 thru 5566 Test Equipment and Spare Parts

RECOMMENDED TOOLS AND TEST TOOLS SUPPLIED WITH CRUSHER

EQUIPMENT
Below is a general list of common tools and test
equipment required to service your jaw crusher. You
may already have some of these items in your shop.
Additional tools and test equipment may be needed
depending on the maintenance task being performed. If
additional guidance regarding tools or test equipment is
required, contact the Telsmith Service Department.
• Chain puller (6000 lb. capacity)
Various tools have been supplied with your crusher. For
a description of these tools, refer to the parts catalog.
RECOMMENDED SPARE PARTS
Below is a general list of spare parts recommended for
Telsmith jaw crushers. Refer to the parts catalog for the
specific spare parts recommended for your crusher.
• One set of V--belts
• One set of jaw dies

4
• Impact wrenches (Sizes required vary by crusher)
• One set of jaw die bolts
• Set of sockets and breaker bars, minimum 3/4″ drive
• One toggle
with sockets up to 31/2″ (Sizes required vary by
crusher) • One set of thrust shaft ends (bronze)
• Hammers (Various types and sizes) • One oil filter element (oil--lubricated crushers only)
• Impact wrench, 3/4″ drive minimum, 1″ preferred
• Grease gun
• Cables, slings, and chains
• Crane or hoist of adequate capacity (Refer to
Chapter 3 for component and sub--assembly
weights).
• Amp probe (For testing electrical currents)
• Spring tension gauge (To check belt tension)

REV 1 4--1
(8/94)
Telsmith Jaw Crushers Recommended Tools,
Models 2036 thru 5566 Test Equipment and Spare Parts

4--2 REV 4
(7/01)
 TABLE OF CONTENTS
CHAPTER 5
Installation And Assembly
SHIPPING, RECEIVING AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--1
HOW SHIPPED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--1
INSPECTION AND UNLOADING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--1
GENERAL INSTALLATION GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--1
FOUNDATIONS AND SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLEARANCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FEEDING EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5--1
5--1
5--1
5
CHUTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--1
ELECTRICAL CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--2
ASSEMBLY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--2
BEFORE YOU BEGIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--2
MAIN FRAME ASSEMBLY
(4448, 5060 AND 5566 ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--2
SWING JAW INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--3
THRUST SHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--5
FLYWHEEL PULLEY / SHEAVE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--6
TOGGLE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--6
TENSION ROD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--7
T
Telsmith Jaw Crushers
Models 2036 thru 5566
SHIPPING, RECEIVING AND
INSPECTION
HOW SHIPPED
For domestic shipment, the smaller jaw crushers are
usually shipped as completely assembled units.
However, they may be disassembled into
sub-assemblies for export and when special shipping
and handling restrictions apply.
The larger jaw crushers are usually shipped in
sub-assemblies.
Because of these differences, some assembly
procedures described in this chapter may not be
necessary for your crusher.
INSPECTION AND UNLOADING
When unloading crusher, inspect all parts for possible
damage that may have occurred during transit.
Check the bill of lading against the parts received. If any
parts are missing or damaged, bring them to the
attention of the respective carrier. Process all claims
immediately. Be sure all claims are in writing.
Refer to Chapter 3 for weights of major components and
sub-assemblies.
! WARNING!!!
Always make sure that cranes, hoists, chains,
and other lifting devices are of adequate rated
capacity. Always follow appropriate safety
precautions when lifting and handling crusher
components. Failure to observe these
precautions could result in equipment damage,
personal injury or death.
GENERAL INSTALLATION
GUIDELINES
FOUNDATIONS AND SUPPORT
The jaw crusher must be mounted on a substantial
foundation. Refer to the foundation drawing provided
with your crusher for additional information. After the
crusher is placed on the foundation, it must be leveled
transversely in relation to the eccentric shaft.
Note: If the foundation drawing for your crusher is
missing or damaged, contact the Telsmith Service
Department for a replacement drawing.
Sub-soil conditions of the crusher foundation should be
investigated by test boring. Core samples may reveal
underground layers of loose sand and gravel or
underground water problems. Where fill of any kind has
been used, the foundation must extend through the fill to
a solid sub-surface. The sub-surface must be of
Installation and Assembly
adequate load bearing ability to support the combined
weight of the crusher and the foundation.
Grout between the frame and the foundation to ensure a
proper bearing surface. If the crusher is mounted on
steel beams, add the proper amount of steel shims or
Smithbond to level the crusher and ensure a perfect
bearing surface. If you have questions regarding
foundation requirements or special modifications
required for your installation, contact your dealer or the
Telsmith Service Department.
CLEARANCES
See Chapter 3 for the external dimensions of your
crusher.
When planning the foundation, make sure that sufficient
5
clearance is provided beneath the crusher for the lower
portion of the swing jaw and for the tension rod
assemblies.
Openings in the foundation must be made large enough
to provide adequate room for servicing the crusher and
for removing spillage.
Allow adequate clearance for the installation of the feed
hopper to the crusher. The feed hopper should be
constructed so that the portion which extends over the
crusher can be unbolted and removed.
FEEDING EQUIPMENT
Regardless of the size of the plant or type of equipment
used, proper feeding equipment of adequate size is
essential for efficient plant performance. When
installing the feeding equipment, always install a
suitable hopper over the crusher entrance. Provisions to
mount a standard hopper have been provided in the
basic design of the crusher. If required, special hopper
designs are available from Telsmith as optional
equipment.
Adequate surge storage facilities must also be provided
in the material flow line to ensure full capacity and a
uniform load condition to the crusher. Mechanical
feeders (with adjustable flow regulation) located
between the crusher and surge storage can be used to
regulate the feed rate to the crusher. An even, constant
feed rate will help ensure a maximum product of proper
size.
CHUTES
Stone chutes should be designed to minimize wear as
much as possible. Crushed stone can be very abrasive
and whenever possible the chutes should be
constructed in the form of boxes so that stone runs on
stone. The chutes may be lined with sectional material
such as manganese strips or spring steel bars so that it
will not be necessary to replace a whole box when wear
develops.
5--1

Installation and Assembly
Study flowability of material being processed before
determining the plant layout. Flat bottom boxes built
under the crusher as discharge chutes must be low
enough so that crushed material, when piled to the
angle of repose or rest, will not reach the lower portion of
the swing jaw and tension rod assemblies.
! CAUTION!!!
Serious damage may occur to the crusher if a
back--up occurs in the discharge chute and the
free flow of material is restricted.
ELECTRICAL CONSIDERATIONS
Adequate overhead clearance must be maintained from
overhead power lines. Make sure that electrical power
supplies are located in an area that will be safe from
accidental contact during crushing operations.
ASSEMBLY INSTRUCTIONS
BEFORE YOU BEGIN
Prior to assembly, make sure protective coating applied
to all machined surfaces (for shipment) has been
completely removed. Make sure all parts are clean and
free from grit and dirt, especially oil passages and
hoses. Any machined surfaces and threads that were
damaged during shipment must be restored to their
Upper Frame
Jam Nut
Hex Nut
Lower Frame
Frame Bolt
Figure 5.1 Assembling Main Frame
5--2
Telsmith Jaw Crushers
Models 2036 thru 5566
proper condition before assembly can begin. After
cleaning, a coating of light oil should be applied to all
machined surfaces. This will ensure ease of assembly.
MAIN FRAME ASSEMBLY
(4448, 5060 AND 5566 ONLY)
IMPORTANT: When assembling the upper and lower
halves of the main frame, make sure the mating
surfaces are completely free of dirt, grit, nicks and
bumps. Make sure alignment pins are in-place and
undamaged.
IMPORTANT: See Chapter 3 for component weights.
1. Install and level lower half of main frame.
2. Using suitable lifting devices of adequate capacity,
install upper half of main frame on top of lower half.
Make sure alignment pins engage holes in upper
half.
3. Secure main frame halves with frame bolts, hex nuts,
and jam nuts.
4. Check joint between main frame halves with a feeler
gauge. Joint must be free of gaps.
5. Install stationary jaw die. Refer to “Stationary Jaw
Die Replacement” in Chapter 9 and perform the
steps that apply.
Telsmith Jaw Crushers
Models 2036 thru 5566
SWING JAW INSTALLATION
If the swing jaw was shipped separately from the
main frame, perform the following steps:
1. Place four hardwood timbers inside the main
frame toward the rear of crusher.
NOTE: Arrange timbers so that lower portion of
swing jaw will move towards front of crushing
chamber when jaw is lowered into main frame.
IMPORTANT: See Chapter 3 for swing jaw weights.
2. Support the swing jaw assembly in a wire rope
sling as shown in Figure 5.2. Install blocking as
shown.
Blocking
Attach
Guide
Rope
HERE
Figure 5.2 Swing Jaw in Sling
3. Attach a guide rope to the lower end of the swing
jaw. Use the rope to control jaw movement during
steps 4 through 7.
4. Hoist swing jaw assembly over the main frame,
with the front of swing jaw facing stationary jaw
die. Lower jaw until bearing mountings are
suspended over openings in crusher frame.
Installation and Assembly
NOTE: The main frame bearing mountings are
keyed in position with steel keys. Key #1 prevents
bearing mountings from rotating in the main frame.
Key #2 restricts the lateral movement of the swing
jaw. Key #1 is installed during step 7. Key #2 is welded
to crusher frame.
Bearing Cap
Key #2
Key #1 Bearing
Mounting
5
Main Frame
Key #1 Key #2
Figure 5.3 Key and Keyway Locations
5. Rotate bearing mountings until keyways for keys
(#1) are in alignment with the corresponding
keyways on crusher frame openings.
6. Position swing jaw so that keys (#2) on frame are in
alignment with the corresponding keyways on
bearing mountings.
NOTE: As jaw is lowered during step 7, have
assistants install keys (#1). Rotate bearing
mountings and reposition jaw as required so that all
keyways and keys are precisely aligned.
7. Slowly lower swing jaw until bearing mountings
are seated in crusher frame openings. As jaw is
lowered, check that thrust brackets do not contact
thrust shaft housings (in crusher frame).
8. Install bearing caps and shims (if present) on
studs.
5--3
 Telsmith Jaw Crushers
Installation and Assembly Models 2036 thru 5566
IMPORTANT: Bearing caps must be replaced on the
same side and in the exact same position from which
they were removed from shipment. Observe match Jam
Nut
marks on bearing caps and crusher frame.
IMPORTANT: On some crushers, shims must be Shim
installed between the bearing caps and the frame. Hex
Shims (shipped separately) are tagged to identify their Nut
location. Failure to install these shims as directed may
result in premature bearing failure.
9. Secure bearing caps with hex and jam nuts. Bearing
Cap

Figure 5.4 Installing Bearing Caps

5--4
Telsmith Jaw Crushers
Models 2036 thru 5566 Installation and Assembly

THRUST SHAFT INSTALLATION 4. Install grease fitting parts.

NOTE: Most crushers are shipped with thrust shafts
pre--installed. Follow steps 1 through 6 only if thrust
shafts were removed for shipping. Refer to Figure 5.5.
1. Center swing jaw assembly so clearance is equal on
both sides between the main frame bearing
mountings and swing jaw retaining rings.
2. Slide thrust shaft and shim through hole on side of
crusher. Observe match marks (stamped on parts) to
be sure that parts are installed on the correct side.
3. Secure thrust washer with screws and lock washers.
5. Measure clearance between thrust shaft and thrust
bracket. Clearance should be approximately 0.025″
at each side. The combined clearance of both sides
should be 0.050″.
IMPORTANT: If clearances measured in step 5 are
incorrect, check that the swing jaw is centered (see step
1). If clearances are still incorrect after centering jaw,
contact the Telsmith Service Department for assistance.
6. Tighten setscrews and lubricate thrust shafts. Refer
to Chapter 7 for grease specifications.

Thrust

5
Shaft
Thrust
End
Bracket

Center the swing jaw assembly 0.025” Clearance

before checking clearances! Required At Each Side

Figure 5.5 Installing Thrust Shaft (all models except 3055)

Note: See page 7--11 for Model 3055 thrust shaft

installation and adjustment procedures.

REV 4
(7/01) 5--5
 Telsmith Jaw Crushers
Installation and Assembly Models 2036 thru 5566

FLYWHEEL PULLEY/ SHEAVE TOGGLE INSTALLATION

INSTALLATION
1. Align flywheel pulley keyway with eccentric shaft
keyway and install flywheel pulley on eccentric shaft.
IMPORTANT: Before lifting flywheel pulley or sheave
see Chapter 3 for weights.
2. Install key. Drive key into place with hammer.
3. Install hub bolts and secure with hex nut and jam nut.
4. Secure shaft washer with lockplate and bolts or
washers and bolts. (See Figure 5.6).
5. Repeat above procedure for flywheel sheave.
The toggle protects the crusher from damage caused by
tramp iron and other non-crushable materials. It is
designed to bend or break when tramp iron or other
un-crushable objects pass between the jaws.
NOTE: The swing jaw must be moved forward before
the toggle can be installed.
1. If the crusher is equipped with the optional auxiliary
cylinder, install the cylinder between the swing jaw
and rear of crusher as shown in Figure 5.7. Attach the
auxiliary cylinder to the hydraulic hand pump. Use
the pump to extend the cylinder and move the swing
jaw forward.

FLYWHEEL PULLEY
Hub Bolt Sheave Swing Jaw
Bolt
† Washer
Key

* Lock
Plate

Eccentric Hex Nut Shaft Washer

Shaft Jam Nut

* 3648, 4448, 5060 & 5566 only

† 2036, 2250, 2540, 3042 & 3055 only
FLYWHEEL SHEAVE Auxiliary
Cylinder
Shaft Hub Bolt Pulley
Washer Key

† Washer Figure 5.7 Auxiliary Cylinder Installation

2. If the crusher is not equipped with the optional
Bolt
auxiliary cylinder, use a hand--winch to move swing
jaw forward.
3. Suspend hoist from cross member at top of crusher
* Lock frame.
Plate Eccentric Shaft
Hex Nut
IMPORTANT: Refer to Chapter 3 for toggle weights.
Jam Nut
* 3648, 4448, 5060 & 5566 only 4. Lower sling through center ribs of toggle and secure
† 2036, 2250, 2540, 3042 & 3055 only toggle to sling.
Figure 5.6 Flywheel Pulley/Sheave

5--6
Telsmith Jaw Crushers
Models 2036 thru 5566 Installation and Assembly

Toggle Seat Clamp TENSION ROD ASSEMBLY

NOTE: 2036, 2540 and 2250 models have one tension
rod. 3042 and larger models have two tension rods.
Toggle
1. Slide bare tension rod through tension spring bracket
(bolted to bottom of toggle beam).
2. Position tension rod between eyes on bottom of
swing jaw. Install tension rod pin through swing jaw
eyes and secure with cotter pins.
IMPORTANT: A grease fitting is located at the eye end
of the tension rod. This fitting provides lubrication to the
Toggle Beam tension rod bushing and should be directed downward
(w/seat) so that it accessible from beneath the crusher.
Ribs
3. Slide tension rod sleeve over threaded end of tension
Toggle Seat rod and seat two cast lugs into mounting blocks on
(attached to swing jaw) tension spring bracket.
Figure 5.8 Toggle Assembly 4. Install spring, spring washers, and two hex nuts on
tension rod end.

5. Slowly raise toggle into position.
IMPORTANT: The canvas protecting apron must be
lifted slightly so that when the toggle is seated in the
toggle seat of the swing jaw, it forms a “U” with the top
edge of the toggle.
6. Slowly release swing jaw allowing it to move towards
back of crusher. Line up toggle and toggle seat as
swing jaw is moved toward back of crusher.
IMPORTANT: The toggle must be positioned
between the two toggle seat clamps (bolted to toggle
beam). The toggle must be fully seated in both toggle
seats.
5
! CAUTION!!!
Never stand directly behind tension rod spring
when tightening nuts. Spring could accidentally
release, causing serious injury.
5. Tighten nuts until spring is compressed approximately
11/4″.
6. Apply grease to fittings on tension rod and tension
rod sleeve. Refer to Chapter 7 for grease
specifications.
IMPORTANT: After crusher is in operation, readjust
nuts if necessary, to prevent toggle from “bumping”.

Hex Nut
Tension Spring
Bracket
Spring Washer

Jam Nut
Washer

Screw
Tension Rod
Tension Rod
Spring Sleeve Cotter Pin

Cast Lugs
Tension Rod Pin

Figure 5.9 Tension Rod Assembly

5--7
 Telsmith Jaw Crushers
Installation and Assembly Models 2036 thru 5566

REV 4
5--8 (7/01)
 TABLE OF CONTENTS
CHAPTER 6
Start--Up and Operation
FLYWHEEL SPEED AND DIRECTION OF ROTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--1
V BELTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--1
GREASE LUBRICATED BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--1
OIL LUBRICATION SYSTEM (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--1
ALARM SYSTEM (Oil--lubricated crushers only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--4
TENSION RODS AND THRUST SHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--4
HYDRAULIC ADJUSTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISCHARGE SETTING ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6--4
6--4 6
ELECTRICAL HOOK--UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--4
OIL PUMP INTERLOCK (Oil--lubricated crushers only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--5
DIESEL ENGINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--5
INITIAL START--UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--5
CRUSHER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--8
DAILY START--UP AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--8
FEED REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--8
CLEARING OBSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--8
COLD WEATHER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--9

REV 1
(7/01)
T
Telsmith Jaw Crushers
Models 2036 thru 5566 Start--Up and Operation

FLYWHEEL SPEED AND ! WARNING!!!

DIRECTION OF ROTATION
Install all flywheel and V--belt guards after
• Arrange the belt drive so that the tops of the flywheels installing belts. Failure to install guards could
turn toward the receiving opening of the crusher. result in serious personal injury or death.

GREASE LUBRICATED BEARINGS

Bearings on grease lubricated crushers are lubricated
prior to shipment and require no lubrication before initial
start-up.
IMPORTANT: Bearings must be lubricated after every
8 hours of operation.

OIL LUBRICATION SYSTEM

(Optional)
• Be sure all oil system hoses are connected to crusher
as shown in Figures 6.3 and 6.4.
• On oil-lubricated 4448, 5060 and 5566 models only,

6
check that air--to--oil cooler hoses are connected as
shown in Figure 6.5. Also check that electrical wiring
for air--to--oil cooler temperature switch is connected
as shown in the electrical schematics provided with
your crusher.
• Be sure that alarm system pressure and temperature
Figure 6.1 Flywheel Rotation sensors are connected as shown in Figure 6.6.
• Check sight gauge on side of oil tank for proper oil
• Be sure electric motor or diesel engine is of sufficient
level. Add oil if required. See Chapter 7 for oil
power to maintain the crusher’s recommended
specifications.
speed while under load. Refer to Chapter 3 for the
recommended horsepower and RPM for your
crusher.

IMPORTANT: Operating the crusher above or below

the speed recommended in Chapter 3 will result in
reduced efficiency and increased wear.
Oil Level (Full)
• After start-up, speed should be measured at the
flywheels and checked under load with a tachometer.
Speed variations of ± 3% are allowable and will not
Add Oil
affect the operation of the crusher.

V--BELTS
• Be sure flywheel sheave and flywheel pulley are
securely attached to the eccentric shaft and free of
damage. Flywheels must not “wobble” when shaft is
rotated.
• Before installing belts, be sure motor sheave and
flywheel sheave are properly aligned. Misalignment
will cause excessive wear and may cause belts to slip
off sheaves during operation.
• Be sure belt tensioner mechanism (under motor) is Figure 6.2 Sight Gauge
tight enough to maintain proper belt tension.
• Proper belt tension is very important. Refer to • After power is connected, check that pump turns in
Chapter 7 for detailed belt installation, adjustment direction of arrow on pump motor.
and maintenance procedures. NOTE: See Chapter 7 for oil lubrication system
maintenance instructions.

REV 1 6--1
(8/94)
 Telsmith Jaw Crushers
Start--Up and Operation Models 2036 thru 5566

2250, 2540
& 5060 only

Figure 6.3 Oil Lubrication System Connections (Oil--lubricated crushers, all except 3055)

Figure 6.4 Oil Lubrication System Connections (Oil--lubricated 3055 only)

6--2 REV 1
(8/94)
Telsmith Jaw Crushers
Models 2036 thru 5566 Start--Up and Operation

Oil Tank

Oil Return
Hose Air-to-Oil
Cooler Switch

Air-to-Oil
Cooler

OUT
Oil Intake
To OUT port of Hose

6
air--to--oil cooler To IN port of IN
air--to--oil cooler

Figure 6.5 Air-to-Oil Cooler Connections (Oil lubricated 4448, 5060 & 5566 only)

NOTE: See Figure 6.7 for alarm

system wiring schematic
Alarm Panel

Oil Pressure Line

Oil Temperature
Line

Oil Tank

Figure 6.6 Alarm System Connections (Oil--lubricated crushers only)

REV 1 6--3
(8/94)

Start--Up and Operation
ALARM SYSTEM
(Oil--lubricated crushers only)
An alarm system is included with all oil--lubricated
crushers. It is activated under the following conditions:
• If oil pressure falls below 2 PSI
• If oil temperature exceeds 140° F
A warning horn sounds whenever the alarm is activated.
The warning horn is located on the front cover of the
alarm panel. A “HORN TEST” push--button is provided
to check operation of the warning horn.
Note:
• Alarm temperature switch set to 140°F.
• Alarm pressure switch set to 2 PSI.
Figure 6.7 Alarm System Wiring Schematic
TENSION RODS AND THRUST
SHAFTS
Apply grease to fittings on tension rods and thrust shafts
before start-up. See Chapter 7 for grease point locations
and grease specifications.
HYDRAULIC ADJUSTING SYSTEM
NOTE: A hand pump is standard. An electric pump is
optional.
• Check adjusting system oil level and add oil if
required. Refer to Chapter 7 for oil specifications.
• On crushers equipped with electric pump only: After
power is connected, apply power to pump and check
that pump turns in direction of arrow on pump motor.
6--4
Telsmith Jaw Crushers
Models 2036 thru 5566
Your crusher’s alarm system may also be equipped with
a warning light (optional equipment) to visually alert
quarry personnel when the alarm is activated.
Important: The alarm system does not stop the crusher
drive motor. To prevent bearing damage, always
disconnect power to drive motor whenever the warning
horn sounds! Determine cause (low oil pressure, high oil
temperature, loose electrical connections, etc.) and
make required repairs before restarting crusher.
See Figure 6.6 for alarm panel temperature and
pressure connections. See Figure 6.7 for alarm system
wiring schematic.
DISCHARGE SETTING
ADJUSTMENT
Adjust discharge setting before start-up. See Chapter 7
for discharge setting adjustment procedures.
ELECTRICAL HOOK--UP
Power and utility specifications vary by machine. Refer
to the electrical schematics provided with your crusher.
If the electrical schematics are missing or incomplete,
contact the Telsmith Service Department for
replacement schematics.
! WARNING!!!
When connecting or installing any electrical
equipment, be sure to follow the electrical
schematics completely. Failure to do so could
create a dangerous electrical shock hazard.
REV 4
(7/01)
Telsmith Jaw Crushers
Models 2036 thru 5566
Figure 6.8 Oil Pump Wiring Schematic
OIL PUMP INTERLOCK
(Oil--lubricated crushers only)
Before start--up, be sure that the oil pump is properly
interlocked with the crusher drive motor. Make the
following checks:
• Be sure oil pump is ON whenever crusher drive motor
is ON.
• Be sure that when oil pump stops, crusher drive
motor also stops.
Important: The crusher bearings require a continuous
flow of oil during operation. If crusher is started with the
oil pump OFF, rapid damage to bearings will result! Such
damage is not covered under warranty.
Refer to Figure 6.8 for oil pump wiring schematic. If
further assistance is required, please contact your local
Telsmith Distributor of the Telsmith Service Department.
DIESEL ENGINE OPERATION
On diesel--powered crushers, refer to the engine
manufacturer’s instructions for engine operation and
pre--start procedures. Also see power--take--off
manufacturer’s instructions. Contact your dealer or the
Telsmith Service Department if additional information is
required.
IMPORTANT: All crushers equipped with a diesel
engine and the oil lubrication system must have an
engine shut--down device wired to the alarm panel.
Failure to install and connect the shut--down device may
result in serious damage to crusher.
REV 2
(2/95)
Start--Up and Operation
INITIAL START--UP
6
An initial start-up checklist is included in the documents
provided with you crusher. The checklist must be
completed during the initial start-up and mailed to
Telsmith within 7 days.
A duplicate copy of the initial start-up checklist appears
in Figure 6.9 of this manual.
The initial start-up checklist is divided into three
sections.
• Section I covers pre--start-up inspections that must
be performed before the crusher is started for the first
time.
• Section II covers inspections that must be
performed after the crusher is started for the first
time.
• Section III covers inspections that must be
performed after aggregate materials are processed
through the crusher for the first time.
During initial start-up, perform all checks and
inspections in the order shown on the initial start-up
checklist. Do not skip any steps. If necessary, stop
crusher and make any necessary adjustments. Mark
each check box with an “X” after performing each step.
! WARNING!!!
Read and understand all safety information in
Chapter 1, including the Jaw Crusher Safety
Summary on pages 1--3 and 1--4 before starting
crusher. Failure to follow these safety
instructions during initial start-up may result in
serious personal injury or death.
6--5
 Start-Up and Operation Telsmith Jaw Crushers
Models 2036 thru 5566

Mail to: Important:

Telsmith, Inc. Mail Signed Checklist
Attn: Service Department within 7 days of start-up
P.O. Box 539 to maintain warranty.
Mequon, WI. USA
INITIAL START-UP CHECKLIST
Telsmith D-Series Jaw Crushers
Customer Information: SECTION 1- Pre Start-Up Checks cont.

Customer Name / Address ALARM SYSTEM (Grease Lubricated Unit)

Low grease level in reservoir sounds alarm horn
High grease pressure sounds alarm horn
Pressing “Horn Test” sounds alarm
Dealer Name / Address
OIL LUBRICATION SYSTEM (If equipped)
Proper Type and Grade of Oil.
Current Brand/Type/Weight _______________
Checklist completed by:
Proper oil level
Date Oil piping correct
Screen Size Air-to-oil cooler installed properly (if equipped)
No. of Decks Oil heating element installed properly (if equipped)

6 Serial Number

Customer Signature :
Oil pump electrically interlocked to crusher drive
motor
GREASE LUBRICATION SYSTEM (If equipped)
Timer switches correctly set for your model crusher
SECTION 1- Pre-Start-Up Checks
Lockout power to crusher drive motor before beginning inspection Grease pump run manually to pre-load bearings
FOUNDATION Grease reservoir refilled after initial manual run
Crusher grouted or shimmed level ADJUSTING SYSTEM (DISCHARGE OPENING)
Anchor bolts tight
Oil reservoir
CHUTES AND HOPPERS Proper oil type (name and grade ___________ )
Adequate size and clearance of feed chute
Hoses connected properly
Adequate size and clearance of discharge chute
Shims equal on both sides
Feed chute properly located
Electric pump operates properly (if equipped)
V-BELT DRIVE
CRUSHER DRIVE MOTOR
All sheaves tight on shafts
Motor starter equipped with proper size overload
All bolts tight
heaters
All sheaves aligned Motor wired for proper voltage (voltage _____ A.C.)
Proper V-belt tension Ammeter operates correctly and accurately (if
All guards in place equipped)

ALARM SYSTEM (Oil Lubricated Unit)

Low oil pressure sounds alarm horn
High temperature sounds alarm horn
Pressing “Horn Test” sounds alarm horn
Alarm horn sounds until oil flow starts
SECTION 2 - Initial Start-Up
Run crusher without material feed during initial start-up
OIL LUBRICATION SYSTEM (If Equipped)
Oil pressure at start up on gauge is _____ PSI
Oil showing steady flow through site gauges

6–6 04/08 (Rev 5)

Telsmith Jaw Crushers Start-Up and Operation
Models 2036 thru 5566

INITIAL START-UP CHECKLIST

Telsmith D-Series Jaw Crushers
Continued

SECTION 2- Initial Start-Up (cont.) SECTION 4- FIRST DAY CHECK LIST

OIL LUBRICATION SYSTEM (If Equipped)
Ambient temperature __________o
Oil filter indicator in safe zone
Air-to-oil cooler thermostat turns fan on/off
Crusher equipped with oil lubrication only
OIL PRESSURE
@ Start-up ____ @ 2 hrs. _____ @ 4 hrs. ____
@ 6 hrs. _____ @ 8 hrs. ____

Oil heater thermostat turns heating element on/off OIL TEMPERATURE

CRUSHER DRIVE @ Start-up ____ @ 2 hrs. _____ @ 4 hrs. ____
Crusher rotates in proper direction @ 6 hrs. _____ @ 8 hrs. ____

Actual flywheel RPM is _____ w/crusher empty OIL COOLERS and HEATERS
Cooler(s) operating
Electric motor draws ____ amps no load
Heater(s) operating
DIESEL ENGINE (If equipped)
Coolant temperature OK
SECTION 5 - GENERAL
Oil pressure and temperature OK
ELECTRIC MOTOR DATA
Power take-off operates properly
Manufactured by: __________
Engine rpm _____ with crusher running empty
Engine manufacturer’s manual read by all personnel
Horsepower: _______ RPM: _______
Full load amp rating__________
6
DIESEL ENGINE DATA
SECTION 3- MATERIAL INTRODUCTION Manufactured by ___________
MATERIAL FEED Size _______ Horsepower _________
Feed distributes evenly into crushing chamber MATERIAL BEING CRUSHED AT STARTUP
Feed rate at approx. 50% capacity for first 8 hours. Common Name of material _______________
Feed free of clay and fines
Sieve analysis of feed ______________
OIL LUBRICATION SYSTEM (If equipped) Sieve analysis of product -
Oil pressure and temperature remain within limits (attach separate sheet)
Oil return remains adequate Crusher set at _________ discharge opening
Compressive strength of material _________
CRUSHER DRIVE
Electric motor draws ____ amps no load Silica content of material _____________

Electric motor rpm under load ______ COMMENTS

Diesel engine gauges within limits _____________________________________

Diesel RPM remains constant (within 5%) _____________________________________

Mail to: Important:

Telsmith, Inc. Mail Signed Checklist
Attn: Service Department within 7 days of start-up
to maintain warranty.
P.O. Box 539
Mequon, WI
U.S.A.

04/08 (Rev 5) 6–7


Start--Up and Operation
CRUSHER OPERATION
DAILY START--UP AND OPERATION
Refer to the following sections of the Jaw Crusher Safety
Summary before starting and operating your crusher:
• “General Jaw Crusher Safety Precautions”
(page 1--3)
• “Before Starting Jaw Crusher” (page 1--3)
• “After Starting Jaw Crusher” (page 1--4)
Perform all checks and inspections as required. Make
any necessary adjustments or repairs. Be sure power
to crusher drive system and feeding equipment is
tagged and locked out before making adjustments
or repairs.
FEED REQUIREMENTS
The primary jaw crusher feed should be sized to a top
dimension well within the effective receiving opening
dimension of the crusher, and fed to rated capacity at the
maximum particle size that is readily nipped. Pieces that
cannot be handled by the crusher without bridging
should be broken by other methods or set aside.
The feed to the crusher must not contain an excessive
amount of fine material. For this reason feeds usually
require scalping ahead of the jaw crusher. Scalping
devices distribute and scalp the large lumps of material
to the crusher, while undersize material is bypassed
around the crusher. This increases the crusher’s
capacity because only material of the proper size is fed
to it. Crusher maintenance and power requirements are
reduced because packing caused by fines in the feed is
eliminated.
Peak efficiency is achieved when the maximum size of
material being fed to the crusher is 20 percent smaller
than the full rated receiving opening dimension, and well
graded to the closed side setting of the discharge
dimension.
6--8
Telsmith Jaw Crushers
Models 2036 thru 5566
Proper feeding equipment of adequate size is essential
for efficient plant operation. A suitable hopper should be
installed over the crusher entrance. Provisions for
mounting a standard hopper have been provided in the
basic design of the crusher. Special hopper designs are
available upon request from Telsmith.
Adequate surge storage facilities must also be provided
in the flow line to assure full capacity and a uniform load
condition to the crusher. Mechanical feeders with
adjustable flow regulation (installed between the
crusher and surge storage) may be used to regulate the
feed to the crusher.
The feed should be regulated so that the crushing
chamber is always about 2/3 full. An even, constant feed
will increase crushing efficiency and prolong jaw die life.
CLEARING OBSTRUCTIONS
Use the following procedure to remove jammed objects
that have become lodged inside the crushing chamber.
1. Lockout/tagout power to the crusher drive, to the oil
lubrication system, and to all feed and discharge
devices. Refer to Chapter 1 for complete
lockout/tagout procedures.
2. If the crusher is powered by a diesel engine,
lockout/tagout engine controls, disconnect the
batteries and shut--off the fuel supply.
3. Lockout/tagout power to the adjusting system
electric pump (if equipped).
4. Remove the V--belt drive guard to provide access to
the flywheel sheave.
5. Block the flywheel sheave to prevent the eccentric
shaft and swing jaw from moving while clearing
procedures are in progress.
REV 4
(7/01)
Telsmith Jaw Crushers
Models 2036 thru 5566 Start--Up and Operation

6. Read and understand all of the following warning

statements before continuing with chamber clearing
procedures.

! WARNING!!!
Be certain that power is completely locked--out
before beginning chamber clearing procedures.
Rock Hook
! WARNING!!!
Use extreme caution when attempting to
dislodge or remove jammed objects. These
objects are under tremendous pressure and can
dislodge or fracture at any time.

! WARNING!!!
Always use a pole, rock hook, breaker bar or
grappling device to safely dislodge objects
jammed inside the crushing chamber. To
prevent serious personal injury, do not attempt
to remove or dislodge jammed objects by hand. Figure 6.10 Removing Uncrushable Objects
with Rock Hook

6
! WARNING!!!
COLD WEATHER OPERATION
Never use dynamite or other explosives to clear
jammed objects. Material ejected from crusher • On grease lubricated crushers, use a lighter grease if
chamber could strike persons working in the starting becomes difficult in cold weather. Refer to
area, resulting in serious personal injury or Chapter 7 for grease specifications.
death. • A heavy concentration of old grease can also cause
difficult cold weather starting for grease lubricated
! WARNING!!! crushers. If necessary, disassemble bearings and
clean out old grease. Refer to eccentric shaft
If it becomes necessary to enter the crushing overhaul procedures in Chapters 10 thru 11.
chamber, use a safety belt, lifeline, body
• Some oil lubricated crushers are equipped with an oil
harness and/or lanyard. Never attempt to walk
immersion heater. Use the oil immersion heater to
on jammed or bridged material. The material
pre--heat the oil to at least 70° F before starting oil
could break free at any time.
system and crusher.
• To ensure adequate oil temperature, be sure oil
! WARNING!!! immersion heater thermostat is set at 70° F or above.
Do not place timbers or any other blocking • Never operate an oil lubricated crusher if the oil
devices inside the crushing chamber to hold the temperature drops below 70° F.
swing jaw open. The blocking could crack or
become dislodged. Serious personal injury
could result.
7. Remove as much loose material from the top of the
crushing chamber as possible. When the
uncrushable object becomes accessible, try to
loosen it with a pole, rock hook or breaker bar. If
necessary, use a grappling device to remove the
uncrushable object through the feed opening.
8.After clearing is completed, remove any objects, loose
material or debris from the crusher discharge area.
9. Remove the blocking from the flywheel sheave.
Reinstall the V--belt drive guard.

REV 4 6--9
(7/01)
 Telsmith Jaw Crushers
Start--Up and Operation Models 2036 thru 5566

6--10 REV 4
(7/01)
 TABLE OF CONTENTS
CHAPTER 7
Periodic Maintenance, Adjustments &
Lubrication
GENERAL MAINTENANCE GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--1
PERIODIC MAINTENANCE CHECKS AND SERVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--1
HYDRAULIC ADJUSTING SYSTEM MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--7
GENERAL MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--7
CHECKING OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--7
Hand Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--7
Electric Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--7
AUXILIARY HYDRAULIC CYLINDER MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--7

7
OIL LUBRICATION SYSTEM MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--8
Checking Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--8
Draining and Refilling Oil Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--8
Air--to--Oil Cooler Maintenance (Oil lubricated 4448, 5060
and 5566 models only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--8
V--BELT MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--9
GENERAL MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--9
V--BELT REPLACEMENT AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--9
THRUST SHAFT CLEARANCE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--10
DISCHARGE OPENING ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--12
MEASURING THE DISCHARGE OPENING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--12
DISCHARGE OPENING ADJUSTMENT (2036, 2250, 2540 & 3042) . . . . . . . . . . . . . . 7--12
DISCHARGE OPENING ADJUSTMENT (3055, 3648, 4448, 5060 & 5566) . . . . . . . . 7--13
T
Telsmith Jaw Crushers
Models 2036 thru 5566 Periodic Maintenance, Adjustments & Lubrication

GENERAL MAINTENANCE PERIODIC MAINTENANCE CHECKS

GUIDELINES
• Dirt and spilled material: Serious problems, such
as cracked welds and leaks, may be hidden from
view. Remove dirt or spilled materials when making
inspections. Always clear the work area of any
obstructions or debris.
• Bolts, nuts, screws and other fasteners: Check all
fasteners and replace if bent, worn or broken.
Tighten any loose fasteners.
• Hydraulic hoses and lines: Look for signs of leaks
and tighten any loose fittings. Replace any worn
hoses or fittings. Be sure that hoses are not pinched,
bent or rubbing.
• Electric wires and connectors: Check for loose or
broken connectors and damaged insulation around
wires. Make repairs as required. Always lock out
power and tag controls to prevent electric shock
hazard.
• Welds: Look for chipped paint, rust, or gaps where
AND SERVICES
• Refer to Table 7.1 for periodic maintenance,
adjustment and lubrication procedures.
• Refer to Table 7.2 for lubrication points and oil fill
locations.
• Refer to Tables 7.3, 7.4 and 7.5 for lubricant
specifications.
Always perform the procedures in Table 7.1 in the same
order as shown. Never skip any procedures that apply.
Failure to perform procedures at the specified intervals
may result in reduced efficiency, premature wear and
component failure.
IMPORTANT: Before performing any procedures in
Table 7.1, read and understand all safety information in
Chapter 1, including Jaw Crusher Safety Summary on
pages 1--3 and 1--4.
! WARNING!!!
Unless otherwise noted, perform all procedures
in Table 7.1 with power locked out and controls

7
parts are welded together. Repair any cracked welds tagged. Always secure drive pulley if it is
necessary to enter the crushing chamber. Alert
immediately. Always follow general safety
all personnel that crusher is being serviced.
precautions in “Welding on Machinery” section of
Chapter 1 whenever any welding is necessary on
crusher.

INTERVAL CHECK, SERVICE OR LUBRICATE AS DESCRIBED

Before starting crusher Start oil system and check
for oil return in
all four site glasses.
(Oil--lubricated crushers only)

4 hours after initial startup Check tightness of flywheel bolts. Tighten as required. See Appendix B for
correct torque.
Every 4 hours Apply grease to thrust shafts. See Table 7.2, Item A
Every 4 hours Apply grease to tension rod sleeves and tension rod pins. See Table 7.2, Item E
Every 8 hours Apply grease to main frame and swing jaw bearings. See Table 7.2, Items B
and C. (Grease--lubricated crushers only)
Table 7.1 Periodic Maintenance Checks and Services

REV 4 7--1
(7/01)
 Telsmith Jaw Crushers
Periodic Maintenance, Adjustments & Lubrication Models 2036 thru 5566

INTERVAL CHECK, SERVICE OR LUBRICATE AS DESCRIBED

Daily Check that clamping screws on toggle beam Clamping
are tight. (2036, 2250, 2540 & 3042 only) Screws

Daily Check tightness of swing jaw die wedge(s) and bolts.

Daily Check lubrication system oil level
and add oil if necessary.
See Table 7--2, Item D.
(Oil lubricated crushers only) Oil Level
(Full)
Add
Oil

Daily Test alarm system by pushing “Horn Test”

push--button. Alarm horn should sound
when button is pushed.
(Oil lubricated crushers only)
Horn--Test
Push--button

Daily Check for unusual noise and vibration while crusher is running.
Daily Check oil filter indicator.
Replace oil filter
element if necessary. Indicator
(Oil lubricated crushers only)

Daily Check oil pressure gauge. Pressure

should be 8 to 10 PSI when oil is HOT.
(Oil lubricated crushers only)
Oil
Pressure
Gauge

Weekly Check that all nuts, bolts and other fasteners are tight.
Weekly Check jaw dies and cheek plates for cracks, looseness or wear.
Weekly Check that the swing jaw “T” key is secure (if equipped)
Weekly Check toggle for wear or cracks.
Weekly Check discharge opening setting.

Table 7.1 Periodic Maintenance Checks and Services (cont.)

7--2 REV 4
(7/01)
Telsmith Jaw Crushers
Models 2036 thru 5566 Periodic Maintenance, Adjustments & Lubrication

INTERVAL CHECK, SERVICE OR LUBRICATE AS DESCRIBED

Weekly Check clearance between thrust
shaft tips and thrust brackets.

Clearance should be approximately

0.025″ on each side. Combined clearance
of both sides should be 0.050″--0.100″. Add
shims or adjust thrust rods as required until
clearance is correct.
0.025″ Clearance
NOTE: On 3055 only, clearance should be
approximately 0.031″ on each side. Combined
clearance of both sides should be 0.062″--0.100″.
Weekly Check thrust shaft tips for wear. Replace if worn more than 1/2″ (usable thick-
ness under 0.010″).
Weekly Inspect feed hopper for wear & damage.
Weekly Check V--Belts for wear, damage and/or improper alignment. Also check V--
Belt tension.
Weekly Check for worn or leaking hydraulic fittings and hoses. Tighten and/or repair
components as required.
Monthly Check tightness of flywheel bolts. Tighten as required. See Appendix B for
correct torque.
Monthly Remove dirt from core and fan
of air--to--oil cooler (crushers

7
equipped with air--to--oil cooler only)

Every 6 months or 600 hours
Yearly
Before adjusting discharge
setting
Before adjusting discharge
setting
Before using auxiliary hydrau-
lic cylinder
Whenever jaw dies are
changed
Table 7.1 Periodic Maintenance Checks and Services (cont.)
Drain and clean--out lubrication system oil tank. Replace filter element. Refill
tank with proper oil. Refer to Table 7.2, Item D (Oil--lubricated crushers only).
Disconnect air--to--oil cooler. Circulate suitable degreasing agent through cool-
er core to remove sludge from internal surfaces (models equipped with air--to--
oil cooler only)
Apply grease to toggle wedge fittings. Refer to Table 7.2, Item H (3055, 3648,
4448, 5060 and 5566 only).
Check oil level of adjusting system pump and add oil as required. Check for
leaks of oil level is low. Refer to Table 7.2, Items F & G.
Check oil level of adjusting system pump and add oil as required. Check for
leaks if oil level is low. Refer to Table 7.2, Item G.
Inspect jaw die support ribs for wear.

REV 1 7--3
(8/94)
 Telsmith Jaw Crushers
Periodic Maintenance, Adjustments & Lubrication Models 2036 thru 5566

Fitting

Fitting

Fitting
B
A

Fill Cap
Fittings
H

Fill Cap

D
Fitting

Fill Cap
F
F
&
G

Fitting
E

ITEM ADD OIL OR APPLY GREASE TO: OIL/GREASE AMOUNT OF OIL/

SPECIFICATIONS GREASE REQUIRED
A Thrust Shafts Two fittings, one on each side of crusher. Refer to Table 7.5 as required*
B Swing Jaw Bearings Two fittings at rear of swing jaw, one on each side (grease Refer to Table 7.5 as required*
lubricated crushers only).
C Main Frame Bearings Two fittings, one on each side of crusher (grease lubricated Refer to Table 7.5 as required*
crushers only).
D Oil Lubrication System Cap on top of tank. Refer to Table 7.3 12 Gals (3648 & smaller)
24 Gals (4448 & larger)
E Tension Rods Two fittings per tension rod, lower rear of crusher. One fitting Refer to Table 7.5 as required*
on each tension rod sleeve and one fitting on each tension
rod end.

F Hydraulic Adjusting System Cap on pump body (hand pump). Cap on top of reservoir Refer to Table 7.4 1 to 4 gallons †
(electric pump).
G Auxiliary Cylinder Cap on pump body. Refer to Table 7.4 1 to 2 gallons †
H Toggle Beam Wedges (3055, 3648, Four fittings, two on each side of crusher. Refer to Table 7.5 as required*
4448, 5060, 5566 only)
* NOTE: The amount of grease required per application may vary. However, 4 to 6 shots of grease per fitting is generally sufficient.
† Appropriate amount of oil needed to fill entire system.

Table 7.2 Location Of Grease Fittings and Oil Fill Points

7--4 REV 4
(7/01)
Telsmith Jaw Crushers
Models 2036 thru 5566 Periodic Maintenance, Adjustments & Lubrication

AMBIENT TEMPERATURE

SPECIFICATION Below 40_F (4.5_C) Above 40_F (4.5_C)

Viscosity ISO Grade C--100 C--150
Viscosity AGMA Grade # 250.04 3 EP 4 EP
Viscosity SUS @ 100_F 469--575 709--871
Viscosity SUS @ 210_F 61--67 74--82
Viscosity Index 95+ 95+
Timken OK Load (Lbs.) 60+ 60+
Extreme Pressure Agent (EP) Yes Yes
Rust and Oxidation Agent Yes Yes
Anti--Foaming Agent Yes Yes
Copper Strip Corrosion Test Pass Pass
D Oil must not be corrosive to metals generally used in bearings, gears, shaftings, pumps and housings.
D Oil must have the least possible effect on rubber seals, synthetic seals, packings and hoses.

Table 7.3 Lubrication System Oil Specifications

SPECIFICATION REQUIREMENT (All Temperatures)

Viscosity Grade ISO 68

7
Viscosity at 210_F 53--57 SUS
Viscosity at 100_F 317 SUS
Viscosity Index 95 Min.
API Gravity 29 Min.
Pour Point, degrees F --10_ to +10_
Flash Point, degrees F 400_ to 425_
Anti--Wear Agent Yes
Anti--Foaming Agent Yes
Rust and Oxidation Inhibitor Yes

Table 7.4 Hydraulic Adjusting System/Auxiliary Cylinder Oil Specifications

(Hand Pump & Electric Pump)

REV 2 7--5
(2/95)
 Telsmith Jaw Crushers
Periodic Maintenance, Adjustments & Lubrication Models 2036 thru 5566

AMBIENT TEMPERATURE

SPECIFICATION Below 40_F (4.5_C) Above 40_F (4.5_C)

NLGI Grade Number -- 2
Worked Penetration at 77_F 295 285
(60 Strokes)
Worked Penetration at 77_F 325 300
(100,000 Strokes)
Dropping Point, _F 500 365
ASTM Corrosion Test, 14 Days Pass Pass
Wheel Bearing Test at 275_F Pass Pass
Timken Test, Pounds Pass 50 lbs. 50 lbs.
The above greases must contain an extreme pressure (EP) agent that is not harmful to bronze, brass or lead. For satisfactory lubrication,
greases must be absolutely free from any ingredients which could cause corrosion, and from gritty material which could produce wear.
Greases should also be uniform in texture, consistency, structure, stability, flow characteristics and lubricating characteristics.

Table 7.5 Grease Specifications

7--6
Telsmith Jaw Crushers
Models 2036 thru 5566 Periodic Maintenance, Adjustments & Lubrication

HYDRAULIC ADJUSTING SYSTEM Electric Pump

MAINTENANCE 1. Move control valve back and forth between EXTEND
and RETRACT several times to relieve system
GENERAL MAINTENANCE pressure.
• Be sure all replacement hydraulic connections, 2. Remove fill cap and check oil level.
hoses, and fittings are rated for high pressure.
• Be sure all connections are fully tightened. Seal all Control Valve
pipe connections with high quality pipe thread sealer.
• Do not over-tighten connections. All connections Fill Cap
should be snug and leak free.
• Be sure hydraulic hoses are connected to the correct
inlet and outlet ports on the pump and hydraulic
cylinders.

! WARNING!!!
Lock out power and tag controls for crusher
drive motor and feeding equipment before
performing any maintenance or repairs. Always
secure drive pulley if it is necessary to enter the
crushing chamber. Alert all personnel that Retract Extend
crusher is being serviced.

CHECKING OIL LEVEL

Hand Pump
1. Move control valve back and forth between EXTEND
and RETRACT several times to relieve system
pressure.
2. Remove fill cap and check oil level.
NOTE: The hydraulic oil should be level with mark on
dipstick inside oil fill cap. If oil level is low, check system
for leaks.
Fill Cap
Figure 7.2 Electric Hydraulic Pump
Neutral
7
NOTE: The hydraulic oil should be level with fill cap
opening. If level is low, check for leaks.
3. Add hydraulic oil as necessary. Refer to Table 7.4 for
oil specifications.
AUXILIARY HYDRAULIC CYLINDER
MAINTENANCE
Check oil level and inspect system for leaks. Follow
same instructions as for hydraulic adjusting system.
Refer to “General Maintenance” and “Checking Oil
Level” above.

Retract Extend
Oil Level
Neutral
Control Valve Control Valve

Figure 7.1 Hand Pump

3. Add hydraulic oil as necessary. Refer to Table 7.4 for
oil specifications.

7--7

Periodic Maintenance, Adjustments & Lubrication
OIL LUBRICATION SYSTEM
MAINTENANCE
! WARNING!!!
Lock out power and tag controls before
servicing oil lubrication system. Alert all
personnel that crusher is being serviced.
! CAUTION!!!
Hot oil can cause serious burns. Check oil
temperature gauge and be sure that oil is cool
before performing any oil system maintenance.
Checking Oil Level
1. Check oil level at sight gauge located on oil tank.
Sight
Gauge
Oil Level (Full)
Add Oil
Figure 7.3 Sight Gauge
2. Remove fill cap and add oil as needed. Refer to
Table 7.3 for oil specifications.
3. Install and tighten fill cap.
Draining and Refilling Oil Tank
1. Remove drain plug from oil tank and drain oil into
suitable container.
2. Remove and discard oil filter element. Replace with
new filter element. (Do not attempt to clean and
re--use old filter element).
3. Reinstall and tighten drain cap.
4. Remove fill cap from oil tank and add lubricating oil.
NOTE: The area around the fill cap and the container
from which the new oil is poured must be thoroughly
clean to prevent contamination. Never add oil from a
dirty container.
5. Install and tighten oil fill cap.
7--8
Telsmith Jaw Crushers
Models 2036 thru 5566
Air--to--Oil Cooler Maintenance (Oil
lubricated 4448, 5060 and 5566 models
only)
• Consult motor manufacturer for lubrication
instructions. Clean motor ventilation openings as
needed.
• Remove dirt and grease from the cooler housing, fan
motor, and fan guard as required. Sand and repaint
any rusty or corroded surfaces.
• Remove accumulated dust and dirt from exterior of
core by carefully brushing fins and tubes. Use an air
hose to clean hard--to--reach areas.
• If core is greasy, remove fan motor and apply a mild
alkaline solution or a nonflammable degreasing
solution to the fins and tubes. Follow with a hot water
rinse and dry thoroughly. A low pressure steam hose
may also be used for rinsing.
• To remove sludge from internal surfaces, disconnect
piping and circulate a suitable degreasing agent or
flushing oil through the core.
• Clean fan blades as required by conditions. Use a
stiff brush or an air nozzle for loose dirt. Use a
nonflammable solvent with brush to remove solid
deposits.
• Periodically check for excessive vibration resulting
from fan imbalance or loose components.
• Check that wiring is properly connected between
air--to--oil cooler and temperature switch. Replace
any damaged or broken wires.
NOTE: Be careful not to damage or bend fan blades
during cleaning or maintenance. Bent fan blades may
cause excessive vibration and motor bearing failure.
Figure 7.4 Air--to--Oil Cooler
Telsmith Jaw Crushers
Models 2036 thru 5566 Periodic Maintenance, Adjustments & Lubrication
V--BELT MAINTENANCE
GENERAL MAINTENANCE
• Replace any V--Belts that are frayed, loose or
damaged. For best results, always use a matched
set of new belts of the same number.
• Always allow proper ventilation around belts. High
temperatures will result in reduced belt life.
• Be sure guards and shrouds are properly positioned
and that they are not contacting belts.
• Be sure that sheaves are aligned and that V--Belt
tension is properly adjusted. Replace any sheaves
that “wobble”.
• Check belt tension weekly and adjust if necessary.
• Keep belts free of dirt, oil and other quarry materials.
Use a cleaning solution approved for V--Belts. Do not
use belt dressing.
NOTE: A buildup of very fine quarry material on the
flywheel and V--belt sheaves can cause excessive
vibration of the crusher drive components. When
servicing belts, check for this built--up material and
remove if present.
V--BELT REPLACEMENT AND
ADJUSTMENT
! WARNING!!!
Lock out power and tag controls for crusher
drive motor and feeding equipment before per-
forming any maintenance or repairs. Always se-
cure drive pulley if it is necessary to enter the
crushing chamber. Alert all personnel that
crusher is being serviced.
1. Remove drive guards as required.
2. Loosen motor mounting nuts. Turn bolt on belt
tensioner assembly until tension is removed from
belt.
REV 1
(8/94)
3. Remove old belts.
4. Thoroughly clean crusher sheave and motor
sheave. Remove any burrs or rust from sheave
grooves.
5. Check alignment between sheaves. Make sure
shafts are parallel and that belt path is free of
obstructions.
NOTE: Check sheave alignment by placing a straight
edge or tight cord across the sheave faces so that it
touches all four points of contact. A misalignment of
more than one--half of one degree (one eighth inch in
one foot) will adversely affect belt life.
6. Place a new matched set of belts between motor and
flywheel sheaves. Make sure belts rest squarely in
sheave grooves.
7. Turn bolts on belt tensioner assembly until correct
tension is applied to belts. Tighten motor mounting
nuts.
NOTE: The V--Belts should be adjusted tight enough to
prevent excessive vibration, but they must not be
tightened to the point where the motor shaft will be under
strain. Adjust for the lowest tension at which the belts will
7
not slip when starting. TOO MUCH TENSION
SHORTENS BELT AND BEARING LIFE.
8. To check V--Belt adjustment, apply a force on one of
the belts midway between the crusher sheave and
the motor sheave. The deflection of the belt at that
point should be equal to the thickness of the
adjacent V--Belt.
9. Install drive guards that were removed in Step 1.
IMPORTANT: Recheck tension of new V--Belts
several times during first 50 hours of operation and
make adjustments as required.
7--9
 Telsmith Jaw Crushers
Periodic Maintenance, Adjustments & Lubrication Models 2036 thru 5566

THRUST SHAFT CLEARANCE 3. Remove thrust washers.

ADJUSTMENT (All Models Except
3055)
! WARNING!!!
Lock out power and tag controls for crusher
drive motor and feeding equipment before
performing any maintenance or repairs. Always
secure drive pulley if it is necessary to enter the
crushing chamber. Alert all personnel that
crusher is being serviced.
1. Measure clearance between thrust shaft ends and
thrust brackets. There should be approximately
0.025″ clearance between the thrust shaft end and
the thrust bracket on each side. The combined
clearance of both sides should not exceed 0.100″ or
be less than 0.050″. If combined clearance is not
within limits, follow steps 2 through 7.
2. Remove grease fitting parts. Loosen outer and inner
set screws.
4. Move swing jaw from side--to--side until it is centered
in the frame and clearance between main frame
bearing mountings is equal on both sides.
5. Insert shims as required to achieve 0.025″ clearance
on each side. Replace thrust shaft end if total
thickness of shims required (per side) is greater than
1/ ″.
2
NOTE: If the swing jaw usually runs towards one side,
additional shims may be required on that side only.
6. Install thrust washers. Measure clearance between
thrust shaft ends and thrust brackets. Clearance
should be approximately 0.025″ at each thrust shaft
end. The combined clearance of both sides should
not be less than 0.050″.
7. Tighten set screws and lubricate thrust shafts. Refer
to Table 7.5 for grease specifications.

Thrust
Shaft
Thrust
End
Bracket

Center the swing jaw assembly 0.025” Clearance

before checking clearances! Required At Each Side

Figure 7.5 Thrust Shaft Clearance Adjustment (all models except 3055)

7--10 REV 1
(8/94)
Telsmith Jaw Crushers
Models 2036 thru 5566 Periodic Maintenance, Adjustments & Lubrication

THRUST SHAFT CLEARANCE 4. Move swing jaw from side--to--side until it is centered
in the frame and clearance between main frame
ADJUSTMENT (3055 ONLY) bearing mountings is equal on both sides.

! WARNING!!! 5. Turn thrust rods until clearance is approximately

Lock out power and tag controls for crusher
drive motor and feeding equipment before
performing any maintenance or repairs. Always
secure drive pulley if it is necessary to enter the
crushing chamber. Alert all personnel that
crusher is being serviced.
1. Measure clearance between thrust shaft ends and
thrust brackets. There should be approximately
0.031″ clearance between the thrust shaft end and
the thrust bracket on each side. The combined
clearance for both sides should not exceed 0.100″ or
be less than 0.062″. If combined clearance is not
within limits, follow steps 2 through 7.
2. Remove grease hoses at swivel fittings.
3. Loosen hex nuts and unscrew thrust rods. Push
thrust shafts completely inside frame so that they will
not touch thrust brackets during step 4.
0.031 at each thrust bracket. Combined clearance of
both sides should not be less than 0.062″. If the
swing jaw usually runs towards one side, clearance
adjustment may be required on that side only.
6. Measure thrust rod length on both sides. If thrust rod
length has decreased by more than 1/2″ since thrust
shaft end was new, then thrust shaft end is worn and
must be replaced. After replacing thrust shaft end,
repeat step 5 and measure thrust rod length again.
Always record this measurement in your service log
for future reference.
7. Tighten hex nuts and reattach grease hoses.
Lubricate thrust shafts. Refer to Table 7.5 for grease
specifications.

0.031”

7
Clearance Thrust
Bracket
Thrust
Rod

Thrust
Measure Shaft End
Length
Center the swing jaw assembly
before checking clearances!

Grease
Thrust Hose
Shaft End

Thrust
Rod
Thrust
Shaft
Thrust
Hex Washer
Nut
Swivel
Fitting

Figure 7.6 Thrust Shaft Clearance Adjustment (3055 only)

REV 3 7--11
(9/95)
 Telsmith Jaw Crushers
Periodic Maintenance, Adjustments & Lubrication Models 2036 thru 5566

DISCHARGE OPENING DISCHARGE OPENING ADJUSTMENT

ADJUSTMENT (2036, 2250, 2540 & 3042)
1. Lockout power to the crusher and to all feed and
! WARNING!!! discharge devices.

Lock out power and tag controls for crusher
drive motor and feeding equipment before
performing any maintenance or repairs. Always
secure drive pulley if it is necessary to enter the
crushing chamber. Alert all personnel that
crusher is being serviced.
Never attempt to measure or adjust discharge
opening while crusher is running. Be sure
crushing cavity is empty of all material.
2. Loosen clamping screws.
3. Move control valve to the RETRACT position. Move
pump handle several times until hydraulic cylinders
retract and toggle beam moves away from shims.
4. Loosen shim retainer set screws and remove shim
retainer pins.
5. Install or remove shims as required to obtain desired
discharge opening.

MEASURING THE DISCHARGE OPENING Clamping

Set Screws
Hydraulic
Measure the discharge setting as described in the Cylinder Screws
following steps.
1. Lockout power to the crusher and to all feed and
discharge devices.
2. Visually check that the crushing chamber is
complete empty. Be sure that the swng jaw is in the
“at rest” position.
3. From beneath the crusher, measure the PEAK to
PEAK distance between the stationary jaw die and
the swing jaw die. Make measurements in at least
five different places across the entire width of the
discharge opening. See Figure 7.7.
4. Subtract 1/2 inch (13 mm) from the shortest Shims
measurement made in step 3. This dimension is the
Retainer Pin
approximate discharge setting of the crusher.
Figure 7.8 Adjusting Mechanism
Swing Jaw

Discharge
Opening
Stationary Jaw Die
(peak to peak)
Note: Subtract 1/2 inch from the
discharge opening to determine
the approximate discharge setting.

Figure 7.7 Discharge Setting Measurement

7--12 REV 4
(7/01)
Telsmith Jaw Crushers
Models 2036 thru 5566 Periodic Maintenance, Adjustments & Lubrication

IMPORTANT: Do not exceed the maximum or 2. Loosen the inner and outer wedge lock bolts about
minimum discharge opening recommended for your 1/ inches.
2
crusher. Refer to Chapter 3 for recommended discharge
openings. 3. Open both ball valves.

IMPORTANT: Always install the same number and 4. Move control valve to the RETRACT position.
thickness of shims on each side to ensure proper toggle
beam alignment. When tight, toggle beam must be Inner Wedge
positioned at right angle to side plates of crusher frame. Lock Bolt

6. Install shim retainer pins and tighten shim retainer

set screws.
7. Move control valve to the EXTEND position.
8. Move pump handle several times to extend hydraulic
cylinders. Extend cylinders until toggle beam is tight
against shims.

Inside crusher frame

Fill Cap Pump Handle One on each side

Wedge Lock Wedge

Plate
Outer Wedge

7
Lock Bolt

Retract Extend

Neutral Control Valve

Figure 7.9 Hand Pump Shims

Toggle Beam
Hydraulic
9. Move control valve to the NEUTRAL position. Cylinder
10.Tighten clamping screws.
Figure 7.10 Wedge Lock Adjusting Mechanism
DISCHARGE OPENING ADJUSTMENT
(3055, 3648, 4448, 5060 & 5566)
1. Lockout power to the crusher and to all feed and
discharge devices.

REV 4 7--13
(7/01)

Periodic Maintenance, Adjustments & Lubrication
5. ON HAND PUMP MODELS ONLY, move pump
handle until cylinders begin to retract. As the
cylinders retract, the hinged wedge lock plate will
rotate slightly and move forward, freeing the toggle
beam and toggle wedge from the LOCKED position.
Control Valve
Ball Valve
Pressure
Gauge
Ball Valve
Retract Extend
Neutral
Figure 7.11 Hand Pump
6. ON ELECTRIC PUMP MODELS ONLY, move power
switch to the ON position. Run pump until cylinders
begin to retract. As the cylinders retract, the hinged
wedge lock plate will rotate slightly and move
forward, freeing the toggle beam and toggle wedge
from the LOCKED position. Turn switch to the OFF
position when the cylinders are fully retracted.
NOTE: If one toggle wedge comes loose and the other
remains tight, close ball valve on side with loose toggle
wedge. This will divert hydraulic pressure to the other
side.
7--14
Telsmith Jaw Crushers
Models 2036 thru 5566
7. Install or remove shims as required to obtain desired
discharge opening.
IMPORTANT: Do not exceed the maximum or
minimum opening recommended for your crusher.
Refer to Table 3--2 in Chapter 3 for recommended
discharge openings.
IMPORTANT: Always install the same number and
thickness of shims on each side to ensure proper toggle
beam alignment. When tight, toggle beam must be
positioned at right angle to side plates of crusher frame.
8. Move directional control valve to the EXTEND
position.
9. ON HAND PUMP MODELS ONLY, move pump
handle several times to extend hydraulic cylinders.
Extend cylinders until toggle beam is tight against
shims and pressure gauge reads approximately
3500 PSI.
10.ON ELECTRIC PUMP MODELS ONLY, move power
switch to the ON position to extend cylinders. Extend
cylinders until toggle beam is tight against shims
and pressure gauge reads approximately 3500 PSI.
Power
Switch
Control Valve Pressure
Gauge
Ball Valve
Retract Extend
Neutral Ball Valve
Figure 7.12 Electric Hydraulic Pump
11. Tighten nuts on all four wedge lock bolts
12.Move control valve to the NEUTRAL position.
REV 4
(7/01)
 TABLE OF CONTENTS
CHAPTER 8
Troubleshooting
JAW CRUSHER MECHANICAL TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--1
LUBRICATION SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--4
HYDRAULIC ADJUSTMENT SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . 8--7

8
T
Telsmith Jaw Crushers
Models 2036 thru 5566 Troubleshooting

JAW CRUSHER MECHANICAL TROUBLESHOOTING

beside or under the crusher. Stay a safe distance
! WARNING!!!
from the crusher when observing crusher operation
Failure to follow the precautions below may or listening for noises.
result in serious injury or death!
• Troubleshooting procedures may reveal problems
that need immediate attention. Always tag and
• During troubleshooting, be sure to observe all safety
lockout crusher drive controls before performing any
precautions as described in Chapter 1 of this
adjustments, maintenance or repairs. Be sure
manual. Alert all personnel that the crusher is being
pressure is relieved in all hydraulic and air systems.
inspected.
Alert all personnel that the crusher is being serviced.
• If it is necessary to run the crusher during
• Allow only trained electricians to troubleshoot
troubleshooting, be sure no one is standing on,
electrical components.

SYMPTOM POSSIBLE CAUSE REMEDY

1. Crusher will not start
2. Crusher stops under load
a. Incorrect wiring Check wiring diagram.
b. No power Check power source.
c. Defective motor Check motor. Replace motor if
defective.
d. Crushing chamber full Clear crushing chamber. See
Chapter 6.
e. Oil pump not on Check wiring diagram.
a. Excessive amp draw Possible voltage drop. Check
power source.
b. Excessive fines in feed Remove fines from feed.
c. Uncrushable object in crushing
chamber
d. Damaged or worn bearings
Clear crushing chamber.

Replace bearings.
8
e. Discharge opening too close Adjust discharge opening to within
specifications. See Chapter 7.
3. Crusher shakes a. Wrong number of counter- Add or remove counterweights as
weights on sheaves required.
b. Flywheels inside--out Remount flywheels with shallow
side toward chamber.
4. Knocking sounds a. Loose toggle Check tension springs. Tighten as
required. See Chapter 7.
b. Loose die bolts Check die bolts for looseness.
Tighten as required.
5. Squeaking sounds Dirt in toggle seats Remove dirt.
6. Rattling sounds Loose bolts Check all bolts for looseness.
Tighten as required.

Table 8.1 Mechanical Troubleshooting

REV 4 8--1
(7/01)
Telsmith Jaw Crushers
Models 2036 thru 5566
SYMPTOM
7. Crusher loses RPM
8. Swing jaw runs to one side
9. Toggle runs to one side
10. Low production
11. Broken toggle
Table 8.1 Mechanical Troubleshooting (continued)
8--2
POSSIBLE CAUSE
a. Excessive fines in crushing
chamber
b. Low voltage
c. Loose or worn drive belts
d. Worn drive pulleys
a. Crusher not level
b. Feed directed to one side
c. Shim quantity and/or size not
the same on both sides
d. Toggle worn on one end
e. Unequal tension applied to ten-
sion rod springs (crushers with
two tension rods only)
f. Thrust rod ends worn
Unequal tension applied to tension
rod springs (crushers with two ten-
sion rods only)
a. Close discharge opening
b. Crusher rotation incorrect
a. Uncrushable object in crushing
chamber
b. Material build up in discharge
area
c. Excessive fines in feed causing
build up in bottom of crusher
d. Improper clearance between
thrust shafts and brackets
e. Worn thrust shaft ends
f. Tension rod assemblies out of
adjustment
Troubleshooting
REMEDY
Check feed and remove fines.
Check power source.
Adjust tension and replace belts as
required. See Chapter 7.
Replace drive pulleys.
Level crusher.
Redirect feed to center of crusher.
Add or remove shims as required.
See Chapter 7.
Replace toggle and seats.
Tighten or loosen tension nuts so
that spring pressure is equal for
both tension rods.
Replace thrust end rods as re-
quired. See Chapter 7.
Tighten or loosen tension nuts so
that spring pressure is equal for
both tension rods.
Check for proper discharge open-
ing. See Chapter 7.
Check for proper rotation. Tops of
crusher flywheels must turn
towards crushing chamber.
Clear crushing chamber. See
Chapter 6.
Clear discharge area. See Chapter
6.
Clear crushing chamber. See
Chapter 6.
Adjust thrust shaft clearance. See
Chapter 7.
Replace thrust shaft ends.
Adjust tension rod assemblies. See
“Tension Rod Assembly” procedure
in Chapter 5.
REV 4
(7/01)
Telsmith Jaw Crushers
Models 2036 thru 5566
SYMPTOM
12. Broken Jaw die bolts
13. Broken tension rod
14. Movement of Main Frame
Bearing mountings.
15. Overheated bearings
Table 8.1 Mechanical Troubleshooting (continued)
REV 4
(7/01)
POSSIBLE CAUSE
a. Jaw die bolts loose
b. Fabric washers missing or in-
correctly installed
a. Pivot pins worn
b. Tension rod sleeves worn
c. Toggle worn
Cap studs loose or broken
a. Lubrication system failure
b. Wrong lubricant
c. Discharge setting less than
minimum
d. Shim quantity and/or size not
the same on both sides
e. Flywheel speed too high
f. Worn thrust shaft ends
g. Too much grease (Grease Lu-
bricated Crushers Only)
h. Too little grease (Grease Lubri-
cated Crushers Only)
i. Swing jaw assembly not cen-
tered between main frame
(pulled to one side)
j. Oil not returning (oil trapped or
churning)
Troubleshooting
REMEDY
Tighten bolts.
Check that fabric washers are
correctly installed on bolts. See the
parts catalog for location of fabric
washers.
Replace pivot pins. Be sure to
apply grease.
Replace tension rod sleeves. Be
sure to apply grease.
Replace toggle.
Tighten or replace cap studs.
See Table 8.2 “Lubrication System
Troubleshooting”.
See Chapter 7 for lubricant
specifications.
Adjust discharge setting to within
specifications. See Chapter 7.
Remove and/or replace shims,
making sure both sides are equal.
See Chapter 7.
Adjust speed to within acceptable
limits. See Chapter 3.
Replace thrust shaft ends. See
Chapter 7.
Drain excess grease from bearings.
8
Apply grease to grease fittings.
See Chapter 7.
Realign swing jaw and check for
wear on thrust shafts. Replace
thrust shaft ends if worn.
Readjust thrust shaft clearances.
Check return hoses for low spots.
8--3
Telsmith Jaw Crushers
Models 2036 thru 5566 Troubleshooting

LUBRICATION SYSTEM TROUBLESHOOTING

! WARNING!!!
Failure to follow the precautions below may
result in serious injury or death!
• During troubleshooting, be sure to observe all safety
precautions as described in Chapter 1 of this
manual. Alert all personnel that the crusher is being
inspected.
• If it is necessary to run the crusher during
troubleshooting, be sure no one is standing on,
beside or under the crusher. Stay a safe distance
from the crusher when observing crusher operation
or listening for noises.
• Troubleshooting procedures may reveal problems
that need immediate attention. Always tag and
lockout crusher drive controls before performing any
adjustments, maintenance or repairs. Be sure
pressure is relieved in all hydraulic and air systems.
Alert all personnel that the crusher is being serviced.
• Allow only trained electricians to troubleshoot
electrical components.

SYMPTOM POSSIBLE CAUSE REMEDY

1. Oil pump motor does not oper-
ate.
2. Alarm system bell rings
continuously
3. No flow in return sight gauges
4. Oil leaks between swing jaw
and main frame
5. Oil leaks from outside of main
frame bearing
a. No power
b. Incorrect wiring
c. Defective motor
a. Low or no oil pressure
b. High oil temperature
a. Return oil line(s) plugged
b. Low oil pressure
Seals worn or damaged
a. Excessive pressure
b. Blocked or sagging oil return
line
Check power source.
Check wiring diagram.
Check motor. Replace if defective.
• Check bypass valve. Replace if
defective.
• Check feed lines and orifices for
obstructions. Clean and replace
as required.
• Check for proper pump rotation.
Reverse motor leads, if
necessary.
• Check for leaking oil lines.
Replace as required.
• Go to #6 in this section for
additional troubleshooting
procedures.
Clean and replace return oil line(s)
as required.
Check oil pressure. See #10 in this
section.
Replace seals.
Adjust bypass valve. Pressure
should be 8--10 PSI when oil is
HOT.
Clean, straighten or replace oil
return line.

Table 8.2 Lubrication System Troubleshooting

8--4
Telsmith Jaw Crushers
Models 2036 thru 5566 Troubleshooting

SYMPTOM POSSIBLE CAUSE REMEDY

6. High oil temperatures
7. Noisy pump
a. Low oil level Check oil level and add oil as
necessary. See Chapter 7.
b. Oil dirty Change oil. Refer to Chapter 7 for
oil specifications.
c. Oil viscosity too high Drain system and refill with proper
oil. See Chapter 7.
d. Clogged air to oil cooler (if Clean oil cooler passages.
equipped)
e. Excessive discharge pressure Adjust bypass valve.
Pressure should be 8--10 PSI when
oil is HOT.
f. Bearing(s) damaged or worn Replace bearing(s).
a. Low oil level Check oil level and add oil as
required. See Chapter 7.
b. Clogged or restricted oil hoses/ Blow out hoses/piping.
piping
c. Leaking hoses/piping Inspect and replace hoses/piping
as necessary.
d. Cold oil Warm lubricant with immersion
heater.
e. Loose or worn pump parts Replace pump.
f. Improper oil See lubrication oil specifications in
Chapter 7.
g. Dirty filter Replace filter element as

8
necessary. See Chapter 7.
h. Pump rotating in wrong direc- Make sure pump is rotating in
tion direction indicated by arrow on
pump body. Reverse electrical
leads, if necessary.
i. Pump is running too fast Replace pump motor.

Table 8.2 Lubrication System Troubleshooting (continued)

REV 3 8--5
(9/95)
Telsmith Jaw Crushers
Models 2036 thru 5566
SYMPTOM
8. Leakage around pump
9. No pressure in system
10. Low pressure in system
11. Erratic or sluggish oil flow
12. Sluggish oil flow at startup
Table 8.2 Lubrication System Troubleshooting (continued)
8--6
Troubleshooting
POSSIBLE CAUSE REMEDY
Worn/damaged gasket or seal Determine origin of leak and check
for loose bolts and other mounting
hardware. If leak continues after
hardware is tightened, replace
defective gasket or seal.
a. Pump rotating in the wrong di- Make sure pump is rotating in
rection direction indicated by arrow on
pump body. Change drive direction
if necessary.
b. Clogged intake Check and clear line from oil
reservoir to pump.
c. Low oil level Add oil as needed. See Chapter 7.
d. Leak in suction line to pump Locate leak and repair line.
e. Pump is dry Prime pump with oil.
f. Loose and/or damaged hose or Inspect all hoses and fittings for
fittings leakage. Tighten, repair or replace
as needed.
a. Bypass valve setting too low Adjust bypass valve. Pressure
should be 8--10 PSI when oil is
HOT.
b. Bypass valve stuck open Replace bypass valve.
c. Dirty oil Change oil. See Chapter 7.
d. Broken/worn pump parts Replace pump.
Relief valve or oil pump sticking of Drain and flush entire system.
binding Refill system with proper oil. See
Chapter 7.
Oil is cold Warm oil with immersion heater.
Telsmith Jaw Crushers
Models 2036 thru 5566 Troubleshooting

HYDRAULIC ADJUSTMENT SYSTEM TROUBLESHOOTING

! WARNING!!!
Failure to follow the precautions below may
result in serious injury or death!
• During troubleshooting, be sure to observe all safety
precautions as described in Chapter 1 of this
manual. Alert all personnel that the crusher is being
inspected.
• If it is necessary to run the crusher during
troubleshooting, be sure no one is standing on,
beside or under the crusher. Stay a safe distance
from the crusher when observing crusher operation
or listening for noises.
• Troubleshooting procedures may reveal problems
that need immediate attention. Always tag and
lockout crusher drive controls before performing any
adjustments, maintenance or repairs. Be sure
pressure is relieved in all hydraulic and air systems.
Alert all personnel that the crusher is being serviced.
• Allow only trained electricians to troubleshoot
electrical components.

SYMPTOM POSSIBLE CAUSE REMEDY

1. Cylinder will not extend
a. Pump release valve in the
“Retract” position
b. In--line ball valve not open
c. No oil in pump
d. Air bound
e. Fittings not fully tightened
f. Blocked hydraulic hose
g. Pump not operating
Turn valve to “Extend” position.
Open ball valve.
Add oil to pump. See Chapter 7.
Bleed air from system. See
Chapter 7.
Check for leakage and tighten
fittings as necessary.
Remove and clean hydraulic hoses.
HAND PUMP: Replace pump.

2. Cylinder will not fully extend a. Low oil level in pump

3. Cylinder jerks as it extends
b. Air trapped in cylinder
c. Air in hydraulic system
a. Leaking connection
b. Restricted hydraulic hose or fit-
ting
c. Internal leakage in pump
ELECTRIC PUMP: Check power
supply. Replace pump if necessary.
Add oil to pump. See Chapter 7.
8
Remove air from system. See
Chapter 7.
Remove air from system. See
Chapter 7.
Tighten connection.
Clean hose or fitting.
Replace pump.

Table 8.3 Hydraulic Adjustment System Troubleshooting

8--7
Telsmith Jaw Crushers
Models 2036 thru 5566
SYMPTOM
4. Cylinder extends slowly
5. Cylinder advances but will not
hold pressure
6. Cylinder leaks oil
7. Cylinder will not retract or re-
tracts slower than normal
8. Cylinder will not fully retract
Table 8.3 Hydraulic Adjustment System Troubleshooting (continued)
8--8
Troubleshooting
POSSIBLE CAUSE REMEDY
a. Leakage at cylinder seals Replace cylinder.
b. Leaking connection Tighten or replace connection
c. Leakage in pump Replace pump.
a. Worn or damaged seals Replace cylinder.
b. Loose connection Tighten connection.
a. Pump release valve in “Extend” Turn valve to “Retract” position.
position.
b. Inline ball valve not open Open ball valve.
c. Blocked hydraulic hose Clear hydraulic hose.
d. Internal leakage in cylinder Replace cylinder.
a. Pump reservoir overfilled Adjust oil level. See Chapter 7.
b. Partially blocked hydraulic hose Clear hydraulic hose.
c. Internal leakage in cylinder Replace cylinder.
a. Pump reservoir overfilled Adjust oil level.
b. Partially blocked hydraulic hose Clear hydraulic hose.
c. Internal leakage in cylinder Replace cylinder.
 TABLE OF CONTENTS
CHAPTER 9
Maintenance and Repair
STATIONARY JAW DIE REPLACEMENT (All models except 2250) . . . . . . . . . . . . . . . . . 9--1
STATIONARY JAW DIE REPLACEMENT (2250 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--2
SWING JAW DIE REPLACEMENT (All models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--3
CHEEK PLATE REPLACEMENT (All models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--4
FLYWHEEL PULLEY/SHEAVE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--5
TENSION ROD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--5
TOGGLE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--6
SWING JAW REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--6

9
T
Telsmith Jaw Crushers
Models 2036 thru 5566 Maintenance and Repair

STATIONARY JAW DIE

REPLACEMENT
(All models except 2250) Jaw Die Bolt
Stationary Jaw Die
! WARNING!!!
Lock out power and tag controls for crusher Lifting Hook Pocket
drive motor and feeding equipment before Jaw Die Key
performing any maintenance or repairs. Always (Do not remove unless Jaw
secure drive pulley if it is necessary to enter the Die is worn or broken)
crushing chamber. Alert all personnel that
crusher is being serviced.
Jam Nut
IMPORTANT: Use figure 9.1 as a guide only. Refer to Hex Nut
the parts catalog provided with your crusher for the Steel Washer
exact location and quantity of nuts, bolts and other Fabric Washer
attaching hardware. Also see Chapter 3 for jaw die
weights.
1. Loosen (but do not remove) nuts on lowest row of
jaw die bolts.
2. Remove nuts and washers from upper row(s) of jaw
die bolts. Remove upper row(s) of jaw die bolts.
3. Carefully pry top of jaw die from crusher frame.
Insert lifting hook in pocket and support die with
hoist.
4. Remove nuts and washers from lowest row of jaw
die bolts. Remove bolts.
IMPORTANT: Mating surfaces must make solid
contact. Always remove any dirt before replacing or
reversing die. Clean all surfaces as required. Inspect
keys and replace if worn or broken.

9
Jaw Die Haedware
5. Lift die from crusher frame. Rotate die 180_ (if (Do not remove unless Jaw
opposite end is not worn) or place new die on lifting Die is worn or broken)
hook. Lower die into position, making sure that
keyways on back of die are aligned with keys on
crusher frame. Be sure that corrugations of
stationary jaw and swing jaw are ”aligned” as shown Figure 9.1 Stationary Jaw Die Replacement (all
in Figure 9.2. models)
IMPORTANT: Install new fabric washers during steps 6
Swing Jaw Die
and 7. Do not reuse old fabric washers. Refer to the
parts catalog for quantity and arrangement of washers.
6. Position die on crusher frame. Install lowest row of
jaw die bolts. Loosely secure bolts with washers
and nuts.
7. Remove lifting hook and install upper row(s) of jaw
die bolts. Loosely secure bolts with washers and
nuts. Jaw Opening
(align peaks Stationary Jaw Die
8. Tighten all nuts by striking end of wrench with with valleys
sledgehammer.
Figure 9.2 Jaw Die Alignemt

REV 4 9--1
(7/01)
 Telsmith Jaw Crushers
Maintenance and Repair Models 2036 thru 5566

STATIONARY JAW DIE
REPLACEMENT (2250 ONLY)
! WARNING!!!
Lock out power and tag controls for crusher
drive motor and feeding equipment before
performing any maintenance or repairs. Always
secure drive pulley if it is necessary to enter the
crushing chamber. Alert all personnel that
crusher is being serviced.
IMPORTANT: Use Figure 9.3 as a guide only. Refer to
the parts catalog provided with your crusher for the
exact location and quantity of nuts, bolts and other
attaching hardware. Also see Chapter 3 for jaw die
weights.
1. Remove nuts and washers from bolts securing
upper wedges. Remove bolts and upper wedges.
2. Loosen (but do not remove) nuts on bolts securing
lower wedges. Carefully pry top of jaw die from
crusher frame. Insert lifting hook in pocket and
support die with hoist.
3. Remove nuts and washers from bolts securing
lower wedges. Remove bolts and lower wedges.
IMPORTANT: Mating surfaces must make solid
contact. Always remove any dirt before replacing or
reversing die. Clean all surfaces as required. Inspect
keys and replace if worn or broken.
4. Lift die from swing jaw. Rotate die 180_ (if opposite
end is not worn) or place new die on lifting hook.
Lower die into position, making sure that keyways
on back of die are aligned with keys on crusher
frame. Be sure that corrugations of stationary jaw
and swing jaw are ”aligned” as shown in Figure 9.4

Swing Jaw Die

Stationary Jaw Die

Jam
Nut
Bolts
Jaw Opening
Jaw
(align peaks Stationary Jaw Die
Die with valleys
Key

Wedge Figure 9.4 Jaw Die Alignement

Pockets
IMPORTANT: When installing wedges in steps 5 and 6,
Jam Nut be sure that the wedge ends are keyed into wedge
pockets on sides of jaw die.
5. Install lower wedges. Loosely secure with bolts,
washers and nuts.
6. Remove lifting hook and carefully place top of jaw
die against crusher frame. Install upper wedges
and secure with bolts, washers and nuts.
7. Tighten all nuts by striking end of wrench with
sledgehammer.

Jaw Die Key Hardware

(Do Not remove unless
key is worn or broken)

Figure 9.3 Stationary Jaw Die Replacement

(2250 only)

9--2 REV 4
(7/01)
Telsmith Jaw Crushers
Models 2036 thru 5566
SWING JAW DIE REPLACEMENT
(All Models)
! WARNING!!!
Lock out power and tag controls for crusher
drive motor and feeding equipment before
performing any maintenance or repairs. Always
secure drive pulley if it is necessary to enter the
crushing chamber. Alert all personnel that
crusher is being serviced.
IMPORTANT: Use Figure 9.5 as a guide only. Refer to
the parts catalog provided with your crusher for the
exact location and quantity of nuts, bolts, washers and
other attaching hardware. Also see Chapter 3 for jaw die
weights.
1. Remove nuts, washers, wedge bolts and wedges.
2. 3648, 4448, 5060 & 5566 ONLY: Remove “T” key.
3. 2036, 2250, 2540, 3042 & 3648 ONLY: Carefully
pry top of die from swing jaw. Insert lifting hook in
pocket and support die with hoist.
Fabric Washer
Fabric Washer
Figure 9.5 Swing Jaw Die Removal
REV 1
(8/94)
Maintenance and Repair
4. 3055, 4448, 5060 & 5566 ONLY: Remove upper
and lower jaw die bolts.
a. Remove nuts, washers and upper jaw die bolts.
b. Loosen (but do not remove) nuts and washers
on lower jaw die bolts.
c. Carefully pry top of die from swing jaw and
insert lifting hook in pocket. Support die with
hoist.
d. Remove nuts, washers and lower jaw die bolts.
IMPORTANT: Mating surfaces must make solid
contact. Always remove any dirt before replacing or
reversing die. Clean all surfaces as required.
5. Lift die from swing jaw. Rotate die 180_ (if opposite
end is not worn) or place new die on lifting hook.
Align die with swing jaw, making sure die is properly
seated over centering key and supported by ledge.
6. 2036, 2250, 2540, 3042 & 3648 ONLY: Remove
lifting hook from pocket. Carefully place top of die
against swing jaw.
”T” Key
9
Jaw Die Bolt
9--3

Maintenance and Repair
IMPORTANT: Install new fabric washers during steps 7
through 9. Do not reuse old fabric washers. Refer to the
parts catalog for quantity and arrangement of washers
7. 3055, 4448, 5060 & 5566 ONLY: Install upper and
lower jaw die bolts.
a. Install lower jaw die bolts. Loosely install
washers and nuts on bolt ends.
b. Remove lifting hook from pocket. Carefully
place top of die against swing jaw.
c. Install upper jaw die bolts. Secure with washers
and nuts.
8. 3648, 4448, 5060 & 5566 ONLY: Install “T” key.
9. Position wedges at top of die and install wedge
bolts. Secure wedge bolts with washers and nuts.
10. Tighten all nuts by striking end of wrench with
sledgehammer.
CHEEK PLATE REPLACEMENT
(All Models)
! WARNING!!!
Lock out power and tag controls for crusher
drive motor and feeding equipment before
performing any maintenance or repairs. Always
secure drive pulley if it is necessary to enter the
crushing chamber. Alert all personnel that
crusher is being serviced.
IMPORTANT: Use Figure 9.6 as a guide only. Refer to
the parts catalog provided with your crusher for the
exact location and quantity of nuts, bolts and other
attaching hardware. Refer to Chapter 3 for cheek plate
weights.
1. Completely remove bolts, nuts and washers from
one bolt hole at top of cheek plate.
2. Loosen (but do not remove) nuts on other bolts to
provide room for lifting hook. Insert lifting hook
through open bolt hole.
3. Support cheek plate with hoist and remove all
remaining bolts, nuts and washers.
9--4
Telsmith Jaw Crushers
Models 2036 thru 5566
IMPORTANT: Mating surfaces must make solid
contact. Before replacing or exchanging cheek plates,
always remove any dirt and clean surfaces as required.
4. Lift cheek plate from crusher and place new (or
exchanged) check plate on hook. Align cheek plate
with bolt holes on crusher frame.
IMPORTANT: Fabric washers are used on some
models. Install new fabric washers during steps 5 and 6.
Do not reuse old fabric washers. Refer to the parts
catalog for quantity and arrangement of fabric washers.
Bolt
Cheek
Fabric Washer Plates
Steel
Washer
Jam
Nut
Hex
Nut
Figure 9.6 Cheek Plate Replacement
5. Slide bolts through open holes of cheek plate and
crusher frame. Loosely install bolts and washers on
bolt ends.
6. Remove lifting hook and install remaining bolt.
Secure bolt with washers and nuts.
7. Tighten all nuts by striking end of wrench with
sledgehammer.
Telsmith Jaw Crushers
Models 2036 thru 5566 Maintenance and Repair

FLYWHEEL PULLEY/SHEAVE 3. Remove nuts and hub bolts from flywheel sheave
hub. Remove flywheel sheave and key from
REMOVAL eccentric shaft.

! WARNING!!! NOTE: If flywheel and/or flywheel sheave cannot be

Lock out power and tag controls for crusher
drive motor and feeding equipment before
performing any maintenance or repairs. Always
secure drive pulley if it is necessary to enter the
crushing chamber. Alert all personnel that
crusher is being serviced.
! WARNING!!!
See Chapter 3 for weight of flywheels. Failure to
use suitable lifting device of adequate capacity
may result in equipment damage, personal
injury or death.
1. Remove bolts, washers or lockplates, and shaft
washers frame both ends of eccentric shaft.
2. Remove nuts and hub bolts from flywheel hub.
Remove flywheel pulley and key from eccentric
shaft.
removed by hand, use a wedge to expand the split hub.
NOTE: Refer to Chapter 5, ”Installation and Assembly”
for flywheel pulley/sheave installation procedure.
TENSION ROD REMOVAL
! WARNING!!!
Lock out power and tag controls for crusher
drive motor and feeding equipment before
performing any maintenance or repairs. Always
secure drive pulley if it is necessary to enter the
crushing chamber. Alert all personnel that
crusher is being serviced.
Spring Washer
Spring

FLYWHEEL PULLEY Jam Cast Lugs

Hub Bolt Sheave Nut
Bolt Hex
Key Nut
† Washer Tension Spring
Bracket
Tension Rod
Sleeve

Tension Rod

* Lock
Plate
Washer
Screw
Cotter Pin
9
Shaft Washer
Hex Nut Tension Rod Pin
Eccentric Shaft Jam Nut
FLYWHEEL SHEAVE Figure 9.8 Tension Rod Removal
Shaft Hub Bolt Pulley
Washer Key ! CAUTION!!!
Never stand directly behind tension rod spring
† Washer when removing nuts. Spring could accidentally
release, causing serious injury.
Bolt 1. Remove hex nut, jam nut, spring washer and spring
from tension rod assembly.
2. Remove tension rod sleeve.
3. Remove two cotter pins, tension rod pin and tension
* Lock rod.
Plate Eccentric Shaft
Hex Nut NOTE: Refer to Chapter 5, “Installation and Assembly”
Jam Nut for flywheel pulley/sheave installation procedure.
* 3648, 4448, 5060 & 5566 only
† 2036, 2250, 2540, 3042 & 3055 only
Figure 9.7 Flywheel Pulley / Sheave Removal
9--5

Maintenance and Repair
TOGGLE REMOVAL
! WARNING!!!
Lock out power and tag controls for crusher
drive motor and feeding equipment before
performing any maintenance or repairs. Always
secure drive pulley if it is necessary to enter the
crushing chamber. Alert all personnel that
crusher is being serviced.
! WARNING!!!
See Chapter 3 for weight of toggle. Failure to
use suitable lifting device of adequate capacity
may result in equipment damage, personal
injury or death.
1. Suspend hoist from cross member at top of crusher
frame.
2. Lower sling through center ribs of toggle and secure
toggle to sling.
Figure 9.9 Toggle Removal
! CAUTION!!!
Use extreme caution when removing the toggle
from the crusher. Personal injury can occur to
people under the crusher if the toggle is
accidentally dislodged from hoist and allowed
to fall.
3. With toggle adequately supported, guide swing jaw
assembly forward towards front of crusher. Lower
toggle through bottom of crusher.
9--6
Telsmith Jaw Crushers
Models 2036 thru 5566
4. Place four wooden timbers inside rear of main
frame. The wooden timbers will hold the lower
portion of the swing jaw assembly in place when
swing jaw is released during Step 5.
5. Slowly release swing jaw assembly, allowing it to
rest against wooden timbers.
SWING JAW REMOVAL
! WARNING!!!
Lock out power and tag controls for crusher
drive motor and feeding equipment before
performing any maintenance or repairs. Always
secure drive pulley if it is necessary to enter the
crushing chamber. Alert all personnel that
crusher is being serviced.
! WARNING!!!
See Chapter 3 for weight of swing jaw. Failure to
use suitable lifting device of adequate capacity
may result in equipment damage, personal
injury or death.
1. On oil lubricated crushers, remove oil feed and
return hoses from swing jaw. Cap hoses to prevent
contaminants from entering oil system.
2. Mark bearing caps for proper reassembly. Remove
jam nuts and hex nuts from bearing cap studs.
3. Thread eye bolt into each bearing cap and remove
bearing cap from main frame bearing cap studs.
Figure 9.10 Removing Bearing Caps
Telsmith Jaw Crushers
Models 2036 thru 5566 Maintenance and Repair
IMPORTANT: Note shim locations and quantities when
removing bearing caps. Shims must be reinstalled in
their original locations.
4. Secure swing jaw to hoist with wire rope sling.
5. Attach a guide rope to the lower end of the swing
jaw. Use the rope to help control swing jaw
movement during Steps 6 and 7.
6. Lift entire swing jaw assembly from crusher.

Figure 9.11 Hoisting Swing Jaw

9
7. Lower swing jaw onto blocking with jaw die facing
up.
NOTE: Refer to Chapter 5, “Installation and Assembly”
for swing jaw installation procedure.

REV 1 9--7
(8/94)
 Telsmith Jaw Crushers
Maintenance and Repair Models 2036 thru 5566

9--8 REV 4
(7/01)
 TABLE OF CONTENTS
CHAPTER 10
Eccentric Shaft Overhaul
(2036, 2540 & 3042)
ECCENTRIC SHAFT OVERHAUL --
GENERAL INSTRUCTIONS (2036, 2540 & 3042) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10--1
MAIN FRAME THRUST BEARING -- REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10--3
MAIN FRAME EXPANSION BEARING -- REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10--9
SWING JAW BEARINGS -- REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10--15
SWING JAW BEARINGS -- INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10--21
MAIN FRAME THRUST BEARING -- INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10--31
MAIN FRAME EXPANSION BEARING -- INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10--39
MAIN FRAME BEARINGS -- FINAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10--47

10
T
Telsmith Jaw Crushers Eccentric Shaft Overhaul Procedures
Models 2036 thru 5566 (2036, 2540 & 3042)

ECCENTRIC SHAFT OVERHAUL -- GENERAL INSTRUCTIONS (2036, 2540 &

3042)
WORK SAFELY AND USE COMMON NOTE: This chapter includes general removal,
SENSE disassembly, assembly and installation procedures.
The procedures for your crusher may be different due to
• Read Chapter 1 for important safety information. model variations, custom engineering or product
• Follow all precautionary statements (DANGER, improvements. Refer to the parts catalog for a
WARNING, CAUTION, IMPORTANT & NOTE) description of the actual components used on your
included within the eccentric shaft overhaul crusher.
procedures.
• Be sure all lifting devices and supports are of INSPECT COMPONENTS BEFORE
adequate rated capacity. See Chapter 3 for swing jaw ASSEMBLY
and eccentric shaft assembly weights.
• Do a visual check of all components. Be sure they are
• Keep cleaning solvents and other combustibles clean, not cracked, and free of nicks or burrs.
away from heat and open flame.
• Check clearances and dimensions as instructed in
• Be careful when handling hot parts. To prevent burns the eccentric shaft repair procedures.
and other injuries, wear appropriate eye and hand
protection. • Replace any excessively worn or damaged parts.
• Be careful when handling dry ice. Always use gloves HANDLE BEARINGS WITH CARE
to prevent burns. • Use clean tools in clean surroundings.
• Keep work area clean and tools organized. Be sure • Use clean solvents and flushing oils.
you have adequate space for the job.
• Remove any dirt from swing jaw before exposing
• If you need service advice, contact your dealer or the bearings. Clean inside of swing jaw bore before
Telsmith Service Department. replacing bearings.
HAVE TOOLS AND SUPPLIES READY • Handle bearings with clean, dry hands.
• Cleaning solvent • Use only clean, lint--free rags.
• Flushing oil • Install new bearings as removed from packaging
• Grease without washing. Do not remove bearings from
packaging until ready to use.
• Pipe sealant
• Wash used bearings in a tank of clean solvent. Clean
• Silicone sealant capable of withstanding bearings as required after soaking in solvent. Hand
temperatures of 200° F (93° C) or higher. wash bearings and blow them dry with filtered,
• Clean rags moisture--free compressed air. Dip bearings in oil
• Oil bath immediately after drying to prevent rust.
• Source of dry ice
Feeler gauge and micrometer

10
•
• Saw horses or other suitable supports of adequate ! WARNING!!!
capacity. See Chapter 3 for eccentric shaft and swing
jaw weights. Always wear eye protection and face shield
when using compressed air. Do not spin the
• Recommended shop tools. Refer to Chapter 4. bearings by hand or by air pressure after the
• Fabricated tools used for main frame thrust bearing bearing surfaces have dried.
removal and main frame expansion bearing removal
(see overhaul procedures for fabrication KEEP COMPONENTS FROM THRUST
instructions). AND EXPANSION ENDS SEPARATE
REFER TO THE PARTS CATALOG AS Keep all parts from the thrust and expansion ends of the
REQUIRED shaft separate. They must be installed on the same side
For an exploded view of the eccentric shaft assembly, from which they were removed. Identify and mark all
components during removal and disassembly. Note that
please refer to the parts catalog furnished with your
ends of shaft are stamped “THR” and “EXP” for
crusher. If your parts catalog is missing, please contact
identification.
your dealer or the Telsmith Parts Department for a
replacement copy.

10--1
 Eccentric Shaft Overhaul Procedures Telsmith Jaw Crushers
(2036, 2540 & 3042) Models 2036 thru 5566

10--2
Telsmith Jaw Crushers Eccentric Shaft Overhaul Procedures
Models 2036 thru 5566 (2036, 2540 & 3042)

MAIN FRAME THRUST BEARING -- REMOVAL (2036, 2540 & 3042)

BEFORE YOU BEGIN

1. Read General Instructions section at the be-
ginning of this chapter.
2. Remove swing jaw assembly from crusher
frame. See “Swing Jaw Removal” procedure
on Chapter 9.
3. Place swing jaw assembly on suitable sup-
ports with wear surface facing down.

REMOVE OUTER SPACER

1. Remove key.
2. Carefully remove outer spacer from shaft.

10

REV 4 10--3
(7/01)
 Eccentric Shaft Overhaul Procedures Telsmith Jaw Crushers
(2036, 2540 & 3042) Models 2036 thru 5566

REMOVE RETAINING RING

IMPORTANT: Place match marks on retaining ring
and bearing housing for use during reassembly. Re-
taining ring must be installed and aligned exactly in
the same position as removed.
1. Remove lubrication system fittings (as required).
2. Remove bolts and washers from retaining ring.
3. Remove retaining ring from mounting. Slide re-
taining ring off shaft.

10--4 REV 4
(7/01)
Telsmith Jaw Crushers Eccentric Shaft Overhaul Procedures
Models 2036 thru 5566 (2036, 2540 & 3042)

REMOVE BEARING AND MOUNTING

ASSEMBLY
1. Remove tube from bearing mounting.
2. Remove slotted head pipe plug from shaft and re-
place with grease fitting.
3. Support bearing and mounting assembly with hoist
and chain.
4. Attach grease gun to fitting. Pump grease gun until
pressure causes inner race of bearing to loosen on
the shaft.
5. While continuing to maintain pressure, quickly
slide the bearing and mounting assembly off the
shaft as far as possible (beyond the shaft oil
groove).
6. If necessary use wheel puller to remove bearing
completely off shaft. Place wheel puller on mount-
ing using the groove around its circumference.
Evenly heat the inner bearing race from behind the
mounting, being careful not to heat shaft at the
same time.
IMPORTANT: If bearing appears re--usable, con-
tinually douse inner bearing race with oil during step 6
to prevent permanent damage to bearing.
NOTE: If bearing cannot be removed using the pro-
cedure in steps 1 through 6 above, go on to the next
procedure.

10

REV 4 10--5
(7/01)
 Eccentric Shaft Overhaul Procedures Telsmith Jaw Crushers
(2036, 2540 & 3042) Models 2036 thru 5566

REMOVE BEARING AND MOUNTING

ASSEMBLY (ALTERNATE METHOD)
NOTE: Follow the steps below only if bearing cannot
be removed using the previous removal procedure.
1. Fabricate removal tool as shown at right.
2. Insert 30 ton hydraulic jack between shaft end and
plate. Attach hose of at least 20 feet long (6 meters)
between pump and jack.

! WARNING!!!
Nuts and other parts may break and be ejected
with tremendous force during step 3. To prevent
serious injury, stand at least 20 feet (6 meters)
from the bearing removal tool. Always wear eye
protection. Never allow any personnel to stand
under, beside, or behind the removal tool while
pressure is applied.

3. Slowly apply pressure to hydraulic jack until bear-

ing is unseated and begins to move off shaft. Con-
tinue until jack reaches near the end of its travel.
4. Remove pressure from jack. Reposition plate and
tighten nuts.
5. Repeat steps 3 and 4 until bearing is at end of
shaft. Remove removal tool from bearing mount-
ing.
6. Support bearing with hoist and chains. Using
crowbar and hammer, apply pressure to inner
race until bearing slides completely off shaft.

10--6
Telsmith Jaw Crushers Eccentric Shaft Overhaul Procedures
Models 2036 thru 5566 (2036, 2540 & 3042)

INSPECT BEARING AND MOUNTING

ASSEMBLY
Do visual inspection of bearing components. Check
for:
• Obvious wear
• Excessive corrosion
• Spalling
• Pitting
• Damage from improper removal
If not worn or damaged, wrap bearing and mounting
assembly in waterproof paper. Store in a dry, clean
place until needed for reassembly.

IF NECESSARY, REMOVE BEARING

FROM HOUSING
Metal Metal
1. Remove slotted head pipe plugs from side of Plate Bar
mounting and replace with grease fittings.
2. Attach grease gun to fitting A. Pump grease gun
until pressure causes outer race of bearing to Nut
loosen in the bore of mounting.
3. Fabricate removal tool parts as shown at right.
While continuing to pump grease gun, tighten nut
to apply pressure on plate. This will unseat bear-
ing from housing.
Bolt
4. Attach grease gun to fitting B and repeat step 3 un-
til bearing is partially removed.
5. After bearing is partially removed, use hammer,
hydraulic jack or arbor press to apply additional
pressure against plate. Continue until bearing is
completely removed from mounting.
NOTE: If a hammer is used in step 5, rotate the
blows around the circumference of bearing outer
A
B
10
race to prevent bearing from cocking or binding.

TO COMPLETE ECCENTRIC SHAFT

OVERHAUL:
1. Remove main frame expansion bearing. Refer to
procedure on page 10--9.
2. Remove swing jaw bearings and eccentric shaft.
Refer to procedure on page 10--15.

10--7
 Eccentric Shaft Overhaul Procedures Telsmith Jaw Crushers
(2036, 2540 & 3042) Models 2036 thru 5566

10--8
Telsmith Jaw Crushers Eccentric Shaft Overhaul Procedures
Models 2036 thru 5566 (2036, 2540 & 3042)

MAIN FRAME EXPANSION BEARING -- REMOVAL (2036, 2540 & 3042)

BEFORE YOU BEGIN Main Frame Expansion Bearing

1. Read General Instructions section at the begin-
ning of this chapter.
2. Remove swing jaw assembly from crusher frame.
Refer to “Swing Jaw Removal” procedure in
Chapter 9.
3. Place swing jaw assembly on suitable supports
with wear surface facing down.

REMOVE OUTER SPACER

1. Remove key.
2. Carefully remove outer spacer.

10

REV 4 10--9
(7/01)
 Eccentric Shaft Overhaul Procedures Telsmith Jaw Crushers
(2036, 2540 & 3042) Models 2036 thru 5566

REMOVE RETAINING RING

IMPORTANT: Place match marks on retaining ring
and bearing housing for use during reassembly. Re-
taining ring must be installed and aligned exactly in
the same position as removed.
1. Remove lubrication system fittings (as required).
2. Remove bolts and washers from retaining ring.
3. Remove retaining ring from mounting. Slide retain-
ing ring off shaft.

REMOVE BEARING AND MOUNTING

ASSEMBLY
1. Remove tube from bearing mounting.
2. Remove end ring.
3. Support bearing and mounting assembly with
hoist and chain.

10--10 REV 4
(7/01)
Telsmith Jaw Crushers Eccentric Shaft Overhaul Procedures
Models 2036 thru 5566 (2036, 2540 & 3042)

REMOVE BEARING AND MOUNTING

ASSEMBLY (CONTINUED)
4. Carefully slide bearing mounting, outer race and
roller cage off of shaft as an assembly.
NOTE: Inner race of bearing will remain on shaft dur-
ing step 4.

REMOVE INNER RACE FROM SHAFT

1. Remove slotted head pipe plug from shaft and re-
place with grease fitting.
2. Attach grease gun to fitting. Pump grease gun until
pressure causes visible leakage between the in-
ner race and the shaft.
3. While continuing to pump grease gun, have assis-
tant force a sharp, wedge--shaped tool between
the inner race and the spacer behind it. Push race
out far enough so that gear puller fingers will have
enough room in step 4.
4. Continue to pump grease gun while using gear
puller to complete inner race removal. If neces-
sary, evenly heat the race to ease removal. Be
careful not to heat shaft at same time.

10

REV 4 10--11
(7/01)
 Eccentric Shaft Overhaul Procedures Telsmith Jaw Crushers
(2036, 2540 & 3042) Models 2036 thru 5566

REMOVE OUTER RACE FROM MOUNT-

ING
1. Remove slotted head pipe plugs from mounting
and replace with grease fittings.
2. Install pipe plugs in holes on outer race.
3. Attach grease gun to fittings. Pump grease gun
until pressure causes visible leakage between
outer race and mounting.
4. Force a sharp wedge--shaped tool behind the lip
of the outer race. Move race out of mounting far
enough so that rod ends can be inserted in step 5.
5. Fabricate removal tool as shown at right. Mounting Grease
Fittings
6. With assistant continuously pumping grease gun,
tighten both nuts evenly until flanged rod ends pull
outer race partially through mounting.
7. Remove fabricated tool. Turn mounting over and
tap outer race with wood block and hammer until
race is completely removed from mounting.

10--12 REV 4
(7/01)
Telsmith Jaw Crushers Eccentric Shaft Overhaul Procedures
Models 2036 thru 5566 (2036, 2540 & 3042)

INSPECT MAIN FRAME EXPANSION

BEARING (outer race, roller cage & in-
ner race)
Do visual inspection of bearing components. Check
for:
• Obvious wear
• Excessive corrosion
• Spalling
• Pitting
• Damage from improper removal
If not worn or damaged, wrap bearing components in
waterproof paper. Store in a dry, clean place until
needed for reassembly.

TO COMPLETE ECCENTRIC SHAFT

OVERHAUL:
• Remove swing jaw bearings and eccentric shaft.
Refer to procedure on page 10--15.

10

10--13
 Eccentric Shaft Overhaul Procedures Telsmith Jaw Crushers
(2036, 2540 & 3042) Models 2036 thru 5566

10--14
Telsmith Jaw Crushers Eccentric Shaft Overhaul Procedures
Models 2036 thru 5566 (2036, 2540 & 3042)

SWING JAW BEARINGS -- REMOVAL (2036, 2540 & 3042)

BEFORE YOU BEGIN

1. Read General Instructions section at the begin-
ning of this chapter.
2. Remove main frame bearing and mounting as-
sembly from thrust end of eccentric shaft. Refer to
section beginning on page 10--3.
3. Remove main frame bearing and mounting as-
sembly from expansion end of eccentric shaft. Re-
fer to section beginning on page 10--9.
4. Remove inner race of main frame expansion
bearing. Refer to procedure on page 10--11.
5. Place swing jaw on suitable supports with wear
surface side facing down.
IMPORTANT: Keep parts on expansion and thrust
sides separate. They must be installed on the same
side as removed. To ensure correct reassembly,
place reference marks on parts during disassembly.

10

10--15
 Eccentric Shaft Overhaul Procedures Telsmith Jaw Crushers
(2036, 2540 & 3042) Models 2036 thru 5566

REMOVE SPACERS
1. Apply a coat of clean oil to eccentric shaft surface.
2. Remove main frame bearing inner spacers and
keys.
3. Remove swing jaw bearing spacers and keys.
IMPORTANT: Do not lose keys. Identify them for
use during reassembly.

Swing Jaw Bearing Spacer

Key

10--16 REV 4
(7/01)
Telsmith Jaw Crushers Eccentric Shaft Overhaul Procedures
Models 2036 thru 5566 (2036, 2540 & 3042)

REMOVE RETAINING RINGS

! WARNING!!!
Molten babbitt is hot and can cause serious
burns. Always wear face shield, gloves and
protective clothing whenever working with
molten babbitt.

IMPORTANT: Place match marks on the swing jaw

and the retaining rings for use during reassembly.
Retaining rings must be installed and aligned exactly
in the same position as removed.
1. Use heating torch to melt and remove babbitt from
around retaining ring bolt holes.
2. Remove capscrews and washers from retaining
ring.
3. Remove retaining rings from jaw.

10

REV 4 10--17
(7/01)
 Eccentric Shaft Overhaul Procedures Telsmith Jaw Crushers
(2036, 2540 & 3042) Models 2036 thru 5566

REMOVE BEARING END RINGS

AND ROLLER CAGES
1. Support both ends of eccentric shaft with
hoist and chains.
NOTE: Reposition hoist and chains as re-
quired to move shaft during steps 2
through 4.
2. Slowly move shaft until roller cage on one
side is exposed. Slide roller cage off in-
ner race.
NOTE: End ring will slide off shaft shoulder
as roller cage is removed.
End Ring
3. Repeat step 2 for other side.
4. Place hardwood blocking under eccen-
tric shaft. Cover hardwood blocking with
clean rags.
5. Lower hoist and allow eccentric shaft to
rest on blocking. Remove chains.
6. Remove end rings and roller cages from
shaft.
Roller Cage

10--18 REV 4
(7/01)
Telsmith Jaw Crushers Eccentric Shaft Overhaul Procedures
Models 2036 thru 5566 (2036, 2540 & 3042)

REMOVE ECCENTRIC SHAFT FROM

JAW
NOTE: During installation, shaft must be positioned
through bore in the same way as removed. Place ref-
erence marks on jaw and shaft for use during reas-
sembly.
1. Attach hoist and chains to shaft.
2. Lift shaft and remove blocking.
3. Carefully guide eccentric shaft through swing jaw
bore and remove. Reposition hoist and chains as
necessary. Do not allow shaft to contact bore.
4. Carefully lower shaft onto suitable supports.

REMOVE INNER RACES FROM ECCEN-

TRIC SHAFT Chain
1. Suspend shaft vertically using eye bolt screwed
into tapped hole at end.
2. Apply a thick coating of grease to the race closest
to the ground.
3. Carefully heat the race with a heating or welding
torch. To prevent damage, continuously turn shaft
and apply additional grease to race while heating
IMPORTANT: Do not apply heat to an ungreased
race surface. Do not use a cutting torch to apply heat.
4. When expanded by the heat, race should drop off. Inner
Light blows with a hardwood block and hammer Races Eccentric
Shaft
may be necessary to completely remove race.
5. Reverse shaft and repeat steps 1 through 4 for
race on other end.
10

REV 4 10--19
(7/01)
 Eccentric Shaft Overhaul Procedures Telsmith Jaw Crushers
(2036, 2540 & 3042) Models 2036 thru 5566

REMOVE OUTER RACES FROM JAW Install

BORE Plugs Here
1. Install plugs in threaded holes on outer race.
2. On oil--lubricated crushers only, temporarily install
grease fitting (This fitting is already installed on
grease--lubricated crushers).
3. Attach grease gun to grease fitting. Pump grease
gun until leakage between outer race and swing
jaw is observed.
NOTE: To ease outer race removal, have assistant
continue to pump grease gun during step 4.
4. Use a hammer and long brass rod to completely
remove outer race. During removal, alternately in- Install
sert brass rod into the two pockets behind the race Grease
(spaced 180_ apart). This will help prevent the Fitting
race from becoming cocked or stuck. Here

5. Remove plugs installed in step 1.

INSPECT BEARING COMPONENTS

(outer races, roller cages & inner races)
Do visual inspection of bearing components. Check
for:
• Obvious wear
• Excessive corrosion
• Spalling
• Pitting
• Damage from improper removal
If not worn or damaged, wrap bearing components in
waterproof paper. Keep components from each side
separate. Store bearing cages in a dry, clean place
until needed for reassembly.

10--20
Telsmith Jaw Crushers Eccentric Shaft Overhaul Procedures
Models 2036 thru 5566 (2036, 2540 & 3042)

SWING JAW BEARINGS -- INSTALLATION (2036, 2540, & 3042)

BEFORE YOU BEGIN

1. Read General Instructions section at the begin-
ning of this chapter.
2. Place swing jaw on suitable supports with wear
surface side facing down.
IMPORTANT: Keep parts on expansion and thrust
sides separate. They must be installed on the same
side as removed. Observe reference marks placed
on parts during disassembly.

INSTALL OUTER RACE

1. Place swing jaw on suitable supports with wear
surface side facing down.
2. Be sure jaw bore is free of grease, dirt, nicks and
burrs.
3. Apply a light coat of oil to jaw bore.

! WARNING!!!
Be careful when handling dry ice. Never allow
dry ice to contact skin. Always use gloves to
prevent burns.

4. Using dry ice or freezer, chill outer race for approxi-

mately 1 hour.
5. Carefully press chilled outer race into bore. Be
sure race is tight against shoulder of bore.
IMPORTANT: Be sure race is not cocked in bore.
6. Check clearance between outer race and jaw bore
shoulder with a feeler gauge. There should not be
10
any clearance at this point.

Use Feeler Gage

REV 4 10--21
(7/01)
 Eccentric Shaft Overhaul Procedures Telsmith Jaw Crushers
(2036, 2540 & 3042) Models 2036 thru 5566

INSTALL INNER RACE

1. Place swing jaw on suitable supports in horizontal
position.
2. Clean surface of shaft. Be sure it is free of grease,
dirt, nicks and burrs.
3. Heat inner race to between 175--195°F
(79--80°C) using an oil bath.
IMPORTANT: During heating, suspend inner race
on a cable or in a basket so that it does not contact
the bottom of the container. Direct heat may perma-
nently damage the inner race.
IMPORTANT: Do not allow oil temperature to ex-
ceed 200°F (93°C). Temperatures above 200°F may
permanently damage race.
IMPORTANT: Each inner race has an extended lip
on one side. Lip must be toward center of shaft dur-
ing step 4.
4. Carefully slide heated inner race into place on
shaft. Be sure lip is fully seated against shoulder
of eccentric shaft.
5. Place blocking against inner race and secure with
bolts. Allow race to cool with blocking in place.
6. Remove blocking. Check clearance between in-
ner race lip and eccentric shaft shoulder with a
feeler gauge. There should not be any clearance
at this point.

10--22 REV 4
(7/01)
Telsmith Jaw Crushers Eccentric Shaft Overhaul Procedures
Models 2036 thru 5566 (2036, 2540 & 3042)

POSITION ECCENTRIC SHAFT

THROUGH JAW BORE
IMPORTANT: Expansion and thrust ends of shaft
must be positioned through bore in the same way as
removed. Observe reference marks placed on jaw
and shaft during removal.
1. Attach hoist and chains to shaft.
NOTE: Reposition hoist and chains as required to
move shaft during steps 2 through 4. Do not allow
shaft to contact bore.
2. Carefully guide eccentric shaft into swing jaw
bore.
3. Place hardwood blocking under eccentric shaft.
Cover blocking with clean rags.
4. Lower hoist and allow eccentric shaft to rest on
blocking. Remove chains.

10

REV 4 10--23
(7/01)
 Eccentric Shaft Overhaul Procedures Telsmith Jaw Crushers
(2036, 2540 & 3042) Models 2036 thru 5566

INSTALL ROLLER CAGES AND END

RINGS
1. Place roller cages loosely on eccentric shaft.
2. Support both ends of eccentric shaft with hoist and
chains.
3. Lift shaft slightly. Remove rags and blocking from
under shaft.
4. Be sure inner races are free of nicks, burrs, dirt and
grease.
5. Apply a light coat of oil to inner races.
NOTE: Move shaft from side--to--side as required to
ease roller cage installation in step 6. Roller cages
are a loose fit over inner races.
6. Slide roller cages over inner races until seated.
7. Center shaft in bore. Remove chains.
8. Install bearing end rings. Be sure they are fully
seated in groove between shaft shoulder and roll-
er cage.

10--24 REV 4
(7/01)
Telsmith Jaw Crushers Eccentric Shaft Overhaul Procedures
Models 2036 thru 5566 (2036, 2540 & 3042)

INSTALL ROLLER CAGES AND END

RINGS (cont.)
9. Check clearance between top rollers and outer
race. Refer to table for allowable clearances.

Crusher Model Clearance between top roller

& outer race after installation
(min./max. in inches)

2036 0.0081/0.0121
2540 0.0073/0.0119
3042 0.0077/0.0121

10

REV 4 10--25
(7/01)
 Eccentric Shaft Overhaul Procedures Telsmith Jaw Crushers
(2036, 2540 & 3042) Models 2036 thru 5566

LUBRICATE BEARINGS
(Grease lubricated crushers only)
1. Install grease fitting in jaw.
2. Pump grease into bearing while rotating shaft. Fill
all pockets between rollers.

INSTALL NEW OIL SEAL

1. Remove and discard old oil seal.
2. Start new seal into groove by finger pressure, then
tap evenly all around until seal is seated and flush
with retaining ring face. Seal lip must be toward
swing jaw when retaining ring is installed.
NOTE: To prevent seal damage, tap only on outer
edge of seal.

Swing Jaw

Seal Lip must be toward swing jaw

10--26 REV 4
(7/01)
Telsmith Jaw Crushers Eccentric Shaft Overhaul Procedures
Models 2036 thru 5566 (2036, 2540 & 3042)

INSTALL RETAINING RINGS

1. Be sure retaining rings and jaw bore faces are free
of nicks, burrs, dirt and grease.
2. Apply sealant to face of swing jaw bore
NOTE: Use only high quality silicone--type sealant
that will withstand temperatures of 200°F (93°C) with-
out deterioration.
IMPORTANT: During step 3, the lubrication port in
jaw bore must line up with the corresponding cut--out
in retaining ring. Observe match marks placed on
bore and retaining rings during removal.
3. Align retaining ring with jaw bore face. Secure re-
taining ring with capscrews and washers.

10

REV 4 10--27
(7/01)
 Eccentric Shaft Overhaul Procedures Telsmith Jaw Crushers
(2036, 2540 & 3042) Models 2036 thru 5566

INSTALL SPACERS
1. Install key and swing jaw bear-
ing spacer.
2. Apply grease in groove.
3. Apply a light coat of oil to eccen-
tric shaft surface.
4. Install key and inner main frame
bearing spacer.
Swing Jaw
Bearing Spacer
Key

10--28 REV 4
(7/01)
Telsmith Jaw Crushers Eccentric Shaft Overhaul Procedures
Models 2036 thru 5566 (2036, 2540 & 3042)

FILL BOLT HOLES WITH MOLTEN

BABBITT
! WARNING!!!
Molten babbitt is hot and can cause serious
burns. Always wear face shield, gloves and
protective clothing whenever working with
molten babbitt. Always wear face shield when
removing and sanding excess babbitt in steps 3
and 4.
1. Fill bolt holes with molten babbitt. Use funnel or
other suitable tool to direct flow of babbitt towards
holes.
2. Leave funnel in place for a few seconds until bab-
bitt cools.
3. Remove all excess babbitt with file or scraper.
4. Sand babbitt until flush with retaining ring face.
5. Remove any babbitt that has dripped on eccentric
shaft.

10

REV 4 10--29
(7/01)
 Eccentric Shaft Overhaul Procedures Telsmith Jaw Crushers
(2036, 2540 & 3042) Models 2036 thru 5566

TO COMPLETE ECCENTRIC SHAFT

INSTALLATION:
1. Install main frame thrust bearing. Refer to section
beginning on page 10--31.
2. Install main frame expansion bearing. Refer to
section beginning on page 10--39.
3. Complete final assembly procedures for main
frame bearings. Refer to section beginning on
page 10--47.

10--30
Telsmith Jaw Crushers Eccentric Shaft Overhaul Procedures
Models 2036 thru 5566 (2036, 2540 & 3042)

MAIN FRAME THRUST BEARING -- INSTALLATION (2036, 2540 & 3042)

BEFORE YOU BEGIN Install thrust bearing on this side

1. Read General Instructions section at the begin-
ning of this chapter.
2. Place swing jaw on suitable supports with wear
surface side facing down.

INSPECT MOUNTING AND REMOVE

OIL SEAL
1. Place mounting on suitable supports with oil seal
side facing down. Check for cracks and obvious
wear.
2. Measure run--out of mounting bore. If bore is out--
of--round more than 0.005 inch, replace or re-
condition mounting.
3. Reposition mounting so that oil seal side is facing
up. Remove and discard oil seal.
NOTE: Do not replace with new oil seal yet. New
seal will be installed later.

10

REV 4 10--31
(7/01)
 Eccentric Shaft Overhaul Procedures Telsmith Jaw Crushers
(2036, 2540 & 3042) Models 2036 thru 5566

ASSEMBLE THRUST BEARING AND

MOUNTING
1. Apply a light coat of oil to mounting bore.

! WARNING!!!
Be careful when handling dry ice. Never allow
dry ice to contact skin. Always use gloves to
prevent burns.

2. Chill bearing with dry ice for approximately 1 hour.

3. Carefully press thrust bearing into mounting.
IMPORTANT: Apply pressure against outer race of
bearing only. Be sure bearing is not cocked in mount-
ing.
4. Check clearance between outer race and mount-
ing shoulder with a feeler gauge. There should be
no clearance at this point.

Check with feeler gauge

10--32 REV 4
(7/01)
Telsmith Jaw Crushers Eccentric Shaft Overhaul Procedures
Models 2036 thru 5566 (2036, 2540 & 3042)

INSTALL BEARING AND MOUNTING

ASSEMBLY
1. Clean surface of shaft. Be sure it is free of grease
and dirt. Remove any nicks and burrs with a grind-
er or emery cloth.
2. Apply a light coat of oil to shaft.
3. Heat bearing and mounting assembly to between
175--195°F (70--90°C) using an oil bath. Bring oil
up to temperature slowly so that oil has adequate
time to warm entire bearing.
IMPORTANT: During heating, suspend bearing
and mounting assembly on a cable or in a basket so
that it does not contact the bottom of the container. Di-
rect heat may permanently damage the bearing.
IMPORTANT: Do not allow oil temperature to ex-
ceed 200°F (93°C). Temperatures above 200°F
(93°C) may permanently damage bearing.
NOTE: Steps 4 through 7 must be done quickly to
prevent bearing from cooling and seizing on shaft be-
fore it is fully installed. Read and understand all steps
to ensure that there will be no delays once bearing is
removed from oil bath.
4. Lift bearing and mounting assembly from oil bath.
Using an assistant to hold bearing in place, install
oil seal. Do this as quickly as possible.

Seal lip must be

toward bearing
10

REV 4 10--33
(7/01)
 Eccentric Shaft Overhaul Procedures Telsmith Jaw Crushers
(2036, 2540 & 3042) Models 2036 thru 5566

INSTALL BEARING AND MOUNTING

ASSEMBLY (cont.)
5. Carefully slide heated bearing and mounting as-
sembly onto shaft. Be sure race is fully seated
against shoulder of main frame bearing inner
spacer.
6. Place blocking against inner race of bearing and
secure with bolts. allow race to cool with blocking
in place.
7. Remove blocking. Check clearance between bot-
tom rollers and outer race with a feeler gauge. See
table for allowable clearances.

Crusher Model Clearance between bottom roller

& outer race after installation
(min./max. in inches)

2036 0.0042/0.0080
2540 0.0032/0.0072
3042 0.0034/0.0098

10--34 REV 4
(7/01)
Telsmith Jaw Crushers Eccentric Shaft Overhaul Procedures
Models 2036 thru 5566 (2036, 2540 & 3042)

LUBRICATE BEARING
(grease lubricated crushers only)
1. Install grease fitting.
2. Pump grease into bearing while rotating shaft. Fill
all pockets between rollers.

INSTALL RETAINING RING

1. Apply pipe sealant to threads of tube and install.
Important: Be sure pipe sealant does not plug
tube. Wipe off any excess sealant.
2. Apply silicone sealant to mating surfaces of
mounting and retaining ring.
NOTE: In step 2, use only high quality silicone seal-
ant that will withstand temperatures of 200°F (93°C)
without deterioration.
3. Align retaining ring with bearing mounting face.
Lubrication port in mounting must line up with the
corresponding cut--out in the retaining ring. To en-
sure correct assembly, observe match marks
made during removal.
4. Secure retaining ring with capscrews and
washers.

10

REV 4 10--35
(7/01)
 Eccentric Shaft Overhaul Procedures Telsmith Jaw Crushers
(2036, 2540 & 3042) Models 2036 thru 5566

INSTALL OUTER SPACER

1. Apply grease to both grooves.
2. Apply a light coat of oil to shaft.
3. Carefully slide outer spacer onto shaft.
4. Install key.

10--36 REV 4
(7/01)
Telsmith Jaw Crushers Eccentric Shaft Overhaul Procedures
Models 2036 thru 5566 (2036, 2540 & 3042)

INSTALL PLUGS AND LUBRICATION

FITTINGS AS REQUIRED
IMPORTANT: Apply pipe sealant to threads of all
plugs and fittings as installed. Wipe off any excess
pipe sealant.
1. Install lubrication system fittings (as required).
2. Install plug in hole on shaft.
NOTE: Step 3 is necessary only if a new bearing
mounting was installed. New plugs are shipped loose
with new bearing mountings. See old bearing mount-
ing for location of plugs.
3. Install plugs in open holes of new bearing mount-
ing (as required).

10

REV 4 10--37
(7/01)
 Eccentric Shaft Overhaul Procedures Telsmith Jaw Crushers
(2036, 2540 & 3042) Models 2036 thru 5566

TO COMPLETE ECCENTRIC SHAFT

INSTALLATION
1. Install main frame expansion bearing. See sec-
tion beginning on page 10--39.
2. Complete final assembly procedures for main
frame bearings. See section beginning on page
10--47.

10--38
Telsmith Jaw Crushers Eccentric Shaft Overhaul Procedures
Models 2036 thru 5566 (2036, 2540 & 3042)

MAIN FRAME EXPANSION BEARING -- INSTALLATION (2036, 2540 & 3042)

BEFORE YOU BEGIN Install expansion bearing

on this side
1. Read General Instructions section at the begin-
ning of this chapter.
2. Place swing jaw on suitable supports with wear
surface side facing down.
IMPORTANT: Keep parts on expansion and thrust
sides separate. They must be installed on the same
side as removed. Observe reference marks placed
on parts during disassembly.

INSTALL INNER RACE

1. Clean surface of shaft. Be sure it is free of grease,
dirt, nicks, and burrs.
2. Heat inner race to between 175--195°F (79--90°C)
using an oil bath.
IMPORTANT: During heating, suspend inner race
on a cable or in a basket so that it does not contact the
bottom of the container. Direct heat may permanently
damage the inner race.
IMPORTANT: Do not allow oil temperature to ex-
ceed 200°F (93°F). Temperatures above 200°F may
permanently damage race.
3. Carefully slide heated inner race into place on
shaft. Be sure race is fully seated against inner
main frame bearing spacer.
4. Place blocking against inner race and secure with
bolts. Allow race to cool with blocking in place.
5. Remove blocking. Check clearance between in-
10
ner race and eccentric shaft shoulder with a feeler
gauge. There should not be any clearance at this
point.
6. Clean surface of inner race. Be sure it is free of oil,
dirt, nicks and burrs.
Check with Feeler
Gauge

REV 4 10--39
(7/01)
 Eccentric Shaft Overhaul Procedures Telsmith Jaw Crushers
(2036, 2540 & 3042) Models 2036 thru 5566

INSPECT HOUSING AND INSTALL NEW

OIL SEAL
1. Check run--out of mounting bore. If bore is out--of--
round by more than 0.005 inch, replace with new
mounting.
2. Inspect surfaces. Remove any burrs or imperfec-
tions.
3. Remove and discard old oil seal. Replace with
new seal.

Seal lip
must face
toward
bearing

INSTALL OUTER RACE

1. Apply a light coat of clean oil on inner surface of
mounting.

! WARNING!!!
Be careful when handling dry ice. Never allow
dry ice to contact skin. Always use gloves to
prevent burns.

2. Chill outer race with dry ice for approximately 1

hour.
3. Carefully press outer race into mounting.
IMPORTANT: Apply pressure against outer race
only. Be sure race is not cocked in mounting.
4. Check clearance between outer race and mount-
ing shoulder with a feeler gauge. There should not
be any clearance at this point.

Check with feeler gauge

10--40 REV 4
(7/01)
Telsmith Jaw Crushers Eccentric Shaft Overhaul Procedures
Models 2036 thru 5566 (2036, 2540 & 3042)

INSTALL BEARING AND HOUSING AS-

SEMBLY
1. Wipe outer race surface and apply a coating of
clean oil.
2. Place bearing roller cage inside mounting.
3. Apply a coating of clean oil to the inner race.
4. Carefully slide roller cage and housing on shaft as
an assembly. Be sure that labyrinth grooves of
mounting and main frame bearing inner spacer
are engaged.

10

REV 4 10--41
(7/01)
 Eccentric Shaft Overhaul Procedures Telsmith Jaw Crushers
(2036, 2540 & 3042) Models 2036 thru 5566

INSTALL END RING

1. Install end ring.
2. Check clearance at bottom of bearing between in-
ner race and bearing rollers with a feeler gauge.
See table for allowable clearances.

Crusher Model Clearance between bottom roller

& outer race after installation
(min./max. in inches)

2036 0.0059/0.0101
2540 0.0082/0.0142
3042 0.0089/0.0129

LUBRICATE BEARING
(grease lubricated crushers only)
1. Install grease fitting.
2. Pump grease into bearing while rotating shaft. Fill
all pockets between rollers.

10--42 REV 4
(7/01)
Telsmith Jaw Crushers Eccentric Shaft Overhaul Procedures
Models 2036 thru 5566 (2036, 2540 & 3042)

INSTALL RETAINING RING

1. Apply silicone sealant to mating surfaces of
mounting and retaining ring.
NOTE: In step 1, use only high quality silicone seal-
ant that will withstand temperatures of 200°F (93°F)
without deterioration.
2. Apply pipe sealant to threads of tube and install
IMPORTANT: Be sure pipe sealant does not plug
tube. Wipe off any excess sealant.
3. Align retaining ring with bearing mounting face.
Lubrication port in mounting must line up with the
corresponding cut--out in the retaining ring. To en-
sure correct assembly, observe match marks
made during removal.
4. Secure retaining ring with capscrews and wash-
ers.

Tube

10

REV 4 10--43
(7/01)
 Eccentric Shaft Overhaul Procedures Telsmith Jaw Crushers
(2036, 2540 & 3042) Models 2036 thru 5566

INSTALL OUTER SPACER

1. Apply grease to both grooves.
2. Apply a light coat of oil to shaft.
3. Install outer spacer onto shaft.
4. Install key.

10--44 REV 4
(7/01)
Telsmith Jaw Crushers Eccentric Shaft Overhaul Procedures
Models 2036 thru 5566 (2036, 2540 & 3042)

INSTALL PLUGS AND LUBRICATION

FITTINGS AS REQUIRED
IMPORTANT: Apply pipe sealant to threads of all
plugs and fittings as installed. Wipe off any excess
pipe sealant.
1. Install lubrication system fittings (as required).
2. Install plug in hole on shaft.
NOTE: Step 3 is necessary only if a new bearing
mounting was installed. New plugs are shipped loose
with new bearing mountings. See old bearing mount-
ing for location of plugs.
3. Install plugs in open holes of new bearing mount-
ing (as required).

10

REV 4 10--45
(7/01)
 Eccentric Shaft Overhaul Procedures Telsmith Jaw Crushers
(2036, 2540 & 3042) Models 2036 thru 5566

TO COMPLETE ECCENTRIC SHAFT

INSTALLATION:
Complete final assembly procedures for main
frame bearings. See section beginning on page
10--47.

10--46
Telsmith Jaw Crushers Eccentric Shaft Overhaul Procedures
Models 2036 thru 5566 (2036, 2540 & 3042)

MAIN FRAME BEARINGS -- FINAL ASSEMBLY (2036, 2540 & 3042)

INSTALL SHIMS AND MEASURE

CLEARANCE
1. Fabricate four metal shims. See table below for
thickness.

Crusher Model Required shim thickness

(each side) Thrust
2036 side
2450 1/8″ thick
3042

2. Have assistants hold shims in place between the

swing jaw bearing retaining rings and the main Expansion
frame bearing mountings. side
3. Install blocking on expansion end as shown. Tight-
en bolts until shims on both sides are snug against
bearing mountings and retaining rings.
IMPORTANT: If gap on one or both sides is larger
(install on
than shims, do the following checks: both thrust
• Check that blocking material is fully tightened. and expansion
sides)
• Check that main frame thrust bearing is fully (install on
seated on shaft and not cocked or binding. expansion
• Check that main frame expansion bearing is fully side only)
seated on shaft and not cocked or binding.

! CAUTION!!!
Failure to meet the correct dimensions on both
sides will result in “T” key alignment problems
and/or premature bearing wear. Never attempt
to reposition “T” keys on frame to compensate
for too large a gap on either side of shaft.
10

REV 1 10--47
(8/94)
 Eccentric Shaft Overhaul Procedures Telsmith Jaw Crushers
(2036, 2540 & 3042) Models 2036 thru 5566

INSTALL SWING JAW IN FRAME

1. Perform “Swing Jaw Installation” procedure in
Chapter 5. Leave shims in place until “T” keys
are aligned and seated in grooves of bearing
housings.
NOTE: Check for “T” key wear before installing
swing jaw. If necessary, tack weld new “T” keys to
frame and check alignment by lowering swing jaw.
Be sure to do final weld of new “T” keys before
completely installing swing jaw.
2. Perform “Toggle Installation” procedure. See
Chapter 5.
3. Perform “Tension Rod Assembly” procedure.
See Chapter 5.
4. Perform “Flywheel Pulley/Sheave Installation”
procedure. See Chapter 5.
5. Perform “Thrust Shaft Clearance Adjustment”
procedure. See Chapter 7.
6. Perform pre--start--up assembly procedures in
Chapter 6 as required.
7. Refer to start--up procedures in Chapter 1. Run
crusher without load and check for any obvious
problems. Listen for any unusual noises.

10--48
 TABLE OF CONTENTS
CHAPTER 11
Eccentric Shaft Overhaul
(3055, 3648, 4448, 5060 & 5566)
ECCENTRIC SHAFT OVERHAUL -- GENERAL INSTRUCTIONS . . . . . . . . . . . . . . . . . 11--1
MAIN FRAME BEARINGS -- REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11--3
TO COMPLETE ECCENTRIC SHAFT OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11--8
SWING JAW BEARING -- REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11--9
SWING JAW BEARINGS -- INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11--15
MAIN FRAME BEARINGS -- INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11--25
MAIN FRAME BEARINGS -- FINAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11--39

11
T
Telsmith Jaw Crushers Eccentric Shaft Overhaul Procedures
Models 2036 thru 5566 (3055, 3648, 4448, 5060 & 5566)

ECCENTRIC SHAFT OVERHAUL -- GENERAL INSTRUCTIONS (3055, 3648,

4448, 5060 & 5566)
WORK SAFELY AND USE COMMON
SENSE NOTE: This chapter includes general removal,
disassembly, assembly and installation procedures.
• Read Chapter 1 for important safety information. The procedures for your crusher may be different due to
• Follow all precautionary statements (DANGER, model variations, custom engineering or product
WARNING, CAUTION, IMPORTANT & NOTE) improvements. Refer to the parts catalog for a
included within the eccentric shaft overhaul description of the actual components used on your
procedures. crusher.
• Be sure all lifting devices and supports are of
adequate rated capacity. See Chapter 3 for swing jaw INSPECT COMPONENTS BEFORE
and eccentric shaft assembly weights. ASSEMBLY
• Keep cleaning solvents and other combustibles • Do a visual check of all components. Be sure they are
away from heat and open flame. clean, not cracked, and free of nicks or burrs.
• Be careful when handling hot parts. To prevent burns • Check clearances and dimensions as instructed in
and other injuries, wear appropriate eye and hand the overhaul procedures.
protection.
• Replace any excessively worn or damaged parts.
• Be careful when handling dry ice. Always use gloves
to prevent burns. HANDLE BEARINGS WITH CARE
• Keep work area clean and tools organized. Be sure • Use clean tools in clean surroundings.
you have adequate space for the job. • Use clean solvents and flushing oils.
• If you need service advice, contact your dealer or the • Remove any dirt from exterior of swing jaw before
Telsmith Service Department. exposing bearings. Clean inside of swing jaw bore
HAVE TOOLS AND SUPPLIES READY before installing swing jaw bearings.
• Cleaning solvent • Handle bearings with clean, dry hands.
• Flushing oil • Use only clean, lint--free rags.
• Grease • Install new bearings as removed from packaging
without washing. Do not remove bearings from
• Pipe sealant packaging until ready to use.
• Silicone sealant capable of withstanding • Wash used bearings in a tank of clean solvent. Clean
temperatures of 200°F (93°C) or higher. bearings as required after soaking in solvent. Hand
• Service--removable thread locking compound wash bearings and blow them dry with filtered,
• Clean rags moisture--free compressed air. Dip bearings in oil
• Oil bath immediately after drying to prevent rust.
• Source of dry ice
• Feeler gauge and micrometer ! WARNING!!!
• Saw horses or other suitable supports of adequate Always wear eye protection and face shield
capacity. See Chapter 3 for eccentric shaft and swing when using compressed air. Do not spin the
jaw weights.

11
bearings by hand or by air pressure after the
• Recommended shop tools (refer to Chapter 4) bearing surfaces have dried.
• Fabricated tools used for main frame thrust bearing
removal and main frame expansion bearing removal KEEP COMPONENTS ON THRUST AND
(see overhaul procedures for fabrication EXPANSION ENDS SEPARATE
instructions).
Keep all parts on thrust and expansion ends of the shaft
REFER TO THE PARTS CATALOG AS separate. They must be installed on the same side from
REQUIRED which they were removed. Identify and mark all
components during removal and disassembly. Note that
For an exploded view of the eccentric shaft assembly, ends of shaft are stamped “THR” and “EXP” for
please refer to the parts catalog provided with your identification.
crusher. If your parts catalog is missing, please contact
your dealer or the Telsmith Parts Department for a
replacement copy.

11--1
 Eccentric Shaft Overhaul Procedures Telsmith Jaw Crushers
(3055, 3648, 4448, 5060 & 5566) Models 2036 thru 5566

11--2
Telsmith Jaw Crushers Eccentric Shaft Overhaul Procedures
Models 2036 thru 5566 (3055, 3648, 4448, 5060 & 5566)

MAIN FRAME BEARINGS -- REMOVAL (3055, 3648, 4448, 5060 & 5566)

BEFORE YOU BEGIN

1. Read General Instructions section at the begin-
ning of this chapter.
2. Place swing jaw on suitable supports with wear
surface side facing down.

NOTE: Removal and disassembly procedures are

the same for both thrust and expansion sides.

IMPORTANT: Keep parts on expansion and

thrust sides separate. They must be installed on the
same side as removed. To ensure correct reas-
sembly, place reference marks on parts during dis-
assembly.

11

11--3
 Eccentric Shaft Overhaul Procedures Telsmith Jaw Crushers
(3055, 3648, 4448, 5060 & 5566) Models 2036 thru 5566

REMOVE RETAINING RING AND

OUTER SPACER
1. Remove lubrication system fittings (as re-
quired).
IMPORTANT: Place match marks on retaining ring
and bearing mounting for use during reassembly.
Retaining ring must be installed and aligned exactly
in the same position as removed.
2. Remove capscrews and washers.
3. Remove retaining ring from mounting. Slide re-
taining ring off shaft.
4. Remove key and slide outer spacer off shaft.

11--4 REV 4
(7/01)
Telsmith Jaw Crushers Eccentric Shaft Overhaul Procedures
Models 2036 thru 5566 (3055, 3648, 4448, 5060 & 5566)

REMOVE BEARING AND MOUNTING

ASSEMBLY
1. Remove slotted head pipe plug and replace with
grease fitting.
2. Support bearing and mounting assembly with
hoist and chain (not shown).
3. Attach grease gun to fitting. Pump grease gun
until pressure causes inner race of bearing to
loosen on the shaft.
4. While continuing to maintain pressure, quickly
slide the bearing and mounting assembly off the
shaft as far as possible (beyond the shaft oil
groove).
5. If necessary use wheel puller to remove bearing
completely off shaft. Place wheel puller on
mounting using the groove around its circumfer-
ence. Evenly heat the inner bearing race from
behind the mounting, being careful not to heat
shaft at the same time.
IMPORTANT: If bearing appears re--usable, contin-
ually douse inner bearing race with oil during step 5
to prevent permanent damage to bearing.
NOTE: If bearing cannot be removed using the pro-
cedure in steps 1 through 5 above, go on to the next
procedure.

11

REV 4 11--5
(7/01)
 Eccentric Shaft Overhaul Procedures Telsmith Jaw Crushers
(3055, 3648, 4448, 5060 & 5566) Models 2036 thru 5566

REMOVE BEARING AND MOUNTING

ASSEMBLY (ALTERNATE METHOD)
NOTE: Follow the steps below only if bearing cannot
be removed using the previous removal procedure.
1. Fabricate removal tool as shown at right.
2. Insert 30 ton hydraulic jack between shaft end
and plate. Attach hose of at least 20 feet long (6
meters) between pump and jack.

! WARNING!!!
Nuts and other parts may break and be
ejected with tremendous force during step 3.
To prevent serious injury, stand at least 20
feet (6 meters) from the bearing removal tool.
Always wear eye protection. Never allow any
personnel to stand under, beside, or behind
the removal tool while pressure is applied.
3. Slowly apply pressure to hydraulic jack until bear-
ing is unseated and begins to move off shaft. Con-
tinue until jack reaches near the end of its travel.
4. Remove pressure from jack. Reposition plate and
tighten nuts.
5. Repeat steps 3 and 4 until bearing is at end of
shaft. Remove removal tool from bearing mount-
ing.
6. Support bearing with hoist and chains. Using
crowbar and hammer, apply pressure to inner
race until bearing slides completely off shaft.

11--6
Telsmith Jaw Crushers Eccentric Shaft Overhaul Procedures
Models 2036 thru 5566 (3055, 3648, 4448, 5060 & 5566)

INSPECT BEARING AND MOUNTING

ASSEMBLY
Do visual inspection of bearing components.
Check for:
• Obvious wear
• Excessive corrosion
• Spalling
• Pitting
• Damage from improper removal
If not worn or damaged, wrap bearing and mounting
assembly in waterproof paper. Store in a dry, clean
place until needed for reassembly.

IF NECESSARY, REMOVE BEARING

FROM MOUNTING
1. 3055, 3648 and 4448 only: Remove capscrews
from inner retaining ring. Separate inner retaining
ring from mounting and remove inner spacer.
2. Remove slotted head pipe plugs from side of
mounting and replace with grease fittings.
3. Attach grease gun to fitting A. Pump grease gun
until pressure causes outer race of bearing to
loosen in the bore of mounting.
IMPORTANT: Bearing is an interference fit in
mounting. During step 4, be sure bearing does not
become cocked in mounting.
3055, 3648 & 4448 only
4. Fabricate removal tool parts as shown at right.
While continuing to pump grease gun, tighten nut
to apply pressure on plate. This will unseat bear-
A B
ing from mounting.
5. Attach grease gun to fitting B and repeat Step 4
until bearing is partially removed.
Metal
6. After bearing is partially removed, use hammer, Bar
hydraulic jack or arbor press to apply additional
pressure against plate. Continue until bearing is
completely removed from mounting.
Bolt 11
NOTE: If a hammer is used in step 6, rotate the blows Nut
around the circumference of bearing outer race to Metal
prevent bearing from cocking or binding. Plate

11--7
 Eccentric Shaft Overhaul Procedures Telsmith Jaw Crushers
(3055, 3648, 4448, 5060 & 5566) Models 2036 thru 5566

TO COMPLETE ECCENTRIC
SHAFT OVERHAUL:
1. Repeat steps in this section for main frame
bearing on other side.
2. Remove swing jaw bearings and eccentric
shaft. See procedure on page 11--9.

11--8
Telsmith Jaw Crushers Eccentric Shaft Overhaul Procedures
Models 2036 thru 5566 (3055, 3648, 4448, 5060 & 5566)

SWING JAW BEARING -- REMOVAL (3055, 3648, 4448, 5060 & 5566)

BEFORE YOU BEGIN:

1. Read General Instructions section at the begin-
ning of this chapter
2. Remove main frame bearing and mounting as-
semblies from both sides of shaft. Refer to sec-
tion beginning on page 11--3.
3. Place swing jaw on suitable supports with wear
surface side facing down.
NOTE: Removal and disassembly procedures are
the same for both thrust and expansion sides.
IMPORTANT: Keep parts on expansion and thrust
sides separate. They must be installed on the
same side as removed. To ensure correct reas-
sembly, place reference marks on parts during dis-
assembly.

11

11--9
 Eccentric Shaft Overhaul Procedures Telsmith Jaw Crushers
(3055, 3648, 4448, 5060 & 5566) Models 2036 thru 5566

REMOVE MAIN--SWING JAW SPACERS

1. Use crowbar and capscrew to unseat spacer.
2. Slide main--swing jaw spacer off shaft.
3. Remove key.

Key

11--10 REV 4
(7/01)
Telsmith Jaw Crushers Eccentric Shaft Overhaul Procedures
Models 2036 thru 5566 (3055, 3648, 4448, 5060 & 5566)

REMOVE RETAINING RINGS

(3055, 3648 & 4448 ONLY)
IMPORTANT: Place match marks on the swing
jaw and the retaining ring for use during reassembly.
Retaining ring must be installed and aligned exactly
in the same position as removed.
1. Remove capscrews and washers from retaining
ring.
2. Remove retaining ring from jaw bore face. Slide
retaining ring off shaft.

REMOVE RETAINING RINGS

(5060 & 5566 ONLY)

! WARNING!!!
Molten babbitt is hot and can cause serious
burns. Always wear face shield, gloves and
protective clothing whenever working with
molten babbitt.
IMPORTANT: Place match marks on the swing
jaw and the retaining rings for use during reassemb-

11
ly. Retaining rings must be installed and aligned ex-
actly in the same position as removed.
1. Use heating torch to melt and remove babbitt
from around retaining ring bolt holes.
2. Remove bolts and washers from retaining ring.
Slide retaining ring off shaft.

REV 4 11--11
(7/01)
 Eccentric Shaft Overhaul Procedures Telsmith Jaw Crushers
(3055, 3648, 4448, 5060 & 5566) Models 2036 thru 5566

REMOVE SWING JAW INNER SPACERS

(All models except 5566)
1. Slide inner spacer off shaft.
2. 5060 only: Remove key (not shown).

REMOVE ECCENTRIC SHAFT AND

BEARINGS AS AN ASSEMBLY
NOTE: When reinstalled, shaft must be positioned
through jaw bore in the same way as removed. Place
reference marks on jaw and shaft for use during reas-
sembly.
1. Attach hoist and chains to shaft.
2. Support shaft with hoist and chains.
IMPORTANT: Bearings are a slip fit in the swing jaw
bore. However, shaft must remain level as it is re-
moved to prevent binding between bearings and jaw
bore.
3. Carefully guide eccentric shaft and bearings
through swing jaw bore and remove.
NOTE: Reposition hoist and chains as necessary. If
needed, attach hand winch at one end to help pull
shaft through bore.
4. Carefully lower shaft onto suitable supports.

11--12 REV 4
(7/01)
Telsmith Jaw Crushers Eccentric Shaft Overhaul Procedures
Models 2036 thru 5566 (3055, 3648, 4448, 5060 & 5566)

REMOVE BEARINGS FROM

ECCENTRIC SHAFT
1. Suspend shaft vertically using eye bolt screwed
into tapped hole at end.
2. Apply a thick coating of grease to the bearing clos-
est to the ground.
3. Carefully heat the inner race of bearing with a heat-
ing or welding torch. To prevent damage, continu-
ously turn shaft and apply additional grease to race
while heating.
IMPORTANT: Do not apply heat to an ungreased sur-
face. Do not use a cutting torch to apply heat.
4. When expanded by the heat, bearing should drop
off. Light blows with a hardwood block and hammer
may be necessary to completely remove bearing.
5. Reverse shaft and repeat steps 1 through 4 for
bearing on other end.

INSPECT BEARINGS
Do visual inspection of bearings. Check for:
• Obvious wear
• Excessive corrosion
• Spalling
• Pitting
• Damage from improper removal
If not worn or damaged, wrap bearing components in
waterproof paper. Keep components from each side
separate. Store bearing cages in a dry, clean place
until needed for reassembly.

REMOVE SHAFT SPACERS

(3055, 4448, 5060 & 5566 ONLY)
If not removed with bearing, slide shaft spacer off of
shaft.
11

REV 4 11--13
(7/01)
 Eccentric Shaft Overhaul Procedures Telsmith Jaw Crushers
(3055, 3648, 4448, 5060 & 5566) Models 2036 thru 5566

11--14
Telsmith Jaw Crushers Eccentric Shaft Overhaul Procedures
Models 2036 thru 5566 (3055, 3648, 4448, 5060 & 5566)

SWING JAW BEARINGS -- INSTALLATION (3055, 3648, 4448, 5060 & 5566)
BEFORE YOU BEGIN
1. Read General Instructions section at the begin-
ning of this chapter.
2. Place swing jaw on suitable supports with wear
surface side facing down.
NOTE: Assembly and installation procedures are
the same for both thrust and expansion sides.
IMPORTANT: Keep parts on expansion and thrust
sides separate. They must be installed on the same
side as removed. Observe reference marks placed
on parts during disassembly.

INSPECT JAW BORES

1. Be sure jaw bores are free of grease, dirt, nicks
and burrs. File or grind any areas that might inter-
fere when shaft and bearings are installed.
2. Check that bores are not out--of--round.

INSTALL SHAFT SPACERS

11
(3055, 4448, 5060 & 5566 ONLY)
Slide spacer onto shaft until seated against
shoulder.

REV 4 11--15
(7/01)
 Eccentric Shaft Overhaul Procedures Telsmith Jaw Crushers
(3055, 3648, 4448, 5060 & 5566) Models 2036 thru 5566

INSTALL BEARINGS ON SHAFT

1. Place shaft on suitable supports.
2. Clean surface of shaft. Be sure it is free of grease,
dirt, nicks and burrs.

NOTE: Do steps 3 through 6 for both sides of shaft.

Heat and install bearings one at a time.
3. Heat bearing to between 175--195°F (79--80°C)
using an oil bath.

IMPORTANT: During heating, suspend bearing on a

cable or in a basket so that it does not contact the
bottom of the container. Direct heat may permanent-
ly damage the bearing.

IMPORTANT: Do not allow oil temperature to ex-

ceed 200°F (93°C). Temperatures above 200°F may
permanently damage bearing.

NOTE: The following steps must be done quickly to

prevent bearing from cooling and seizing on shaft
before it is fully installed. Read and understand all
steps to ensure that there will be no delays once
bearing is removed from oil bath.
4. Carefully slide heated bearing onto shaft. Be
sure inner race of bearing is fully seated against
shaft spacer (all models except 3648) or shaft
shoulder (3648 only).
5. Place blocking against bearing inner race and
secure with bolts. Tighten bolts and allow bearing
to cool with blocking in place.
6. Remove blocking. Check clearance between in-
ner race and shaft spacer ( or between inner race
and eccentric shaft shoulder on 3648 only) with a
feeler gauge. There should not be any clearance
at this point.

11--16 REV 4
(7/01)
Telsmith Jaw Crushers Eccentric Shaft Overhaul Procedures
Models 2036 thru 5566 (3055, 3648, 4448, 5060 & 5566)

POSITION ECCENTRIC SHAFT

THROUGH JAW BORE
IMPORTANT: Expansion and thrust ends of shaft
must be positioned through bore in the same way as
removed. Observe reference marks placed on jaw
and shaft during removal.
1. Attach hoist and chains to shaft.
2. Apply a coat of clean oil to jaw bore.
3. Apply a coat of clean oil to bearing outer races.

NOTE: Reposition hoist and chains as required to

move during step 4. Bearings are a slip fit in swing
jaw. Attach hand winch at one end to help pull shaft
through bore.
4. Carefully guide eccentric shaft and bearings into
jaw bore. Adjust hoist as required so that bearing
outer races are aligned with jaw bore.

11

REV 4 11--17
(7/01)
 Eccentric Shaft Overhaul Procedures Telsmith Jaw Crushers
(3055, 3648, 4448, 5060 & 5566) Models 2036 thru 5566

POSITION ECCENTRIC SHAFT

THROUGH JAW BORE (cont.)
5. Center the eccentric shaft so that it extends an
equal amount on both sides of the swing jaw.
6. Check clearance between top roller and outer race
of each bearing. Refer to table below for allowable
clearances.
Crusher Model Clearance between top roller
& outer race after installation
(min./max. in inches)
3055 0.0059/0.0117
3648 0.0076/0.0140
4448 0.0070/0.0139
5060 0.0146/0.0197
5566 0.0146/0.0197

11--18 REV 4
(7/01)
Telsmith Jaw Crushers Eccentric Shaft Overhaul Procedures
Models 2036 thru 5566 (3055, 3648, 4448, 5060 & 5566)

LUBRICATE BEARINGS
(Grease lubricated crushers only)
1. Install grease fitting in jaw.
2. Pump grease into bearing while rotating shaft.
Fill all pockets between rollers.

INSTALL SWING JAW INNER SPACERS

(all models except 5566)
NOTE: The swing jaw inner spacer fits between the
swing jaw bearing and the retaining ring. It is not
present on 5566 models.
1. Slide spacer on shaft until it is against the swing
jaw bearing inner race.
2. 5060 only: Install key (not shown).

INSTALL NEW OIL SEALS TO

RETAINING RINGS
1. Remove and discard old oil seal.
2. Start new seal into groove by finger pressure,
then tap evenly all around until seal is seated and
flush with retaining ring face. Seal lip must be to-
ward swing jaw when retaining ring is installed.

NOTE: To prevent seal damage, tap only on outer

11
edge of seal.

Swing Jaw

Seal lip must be toward swing jaw

REV 4 11--19
(7/01)
 Eccentric Shaft Overhaul Procedures Telsmith Jaw Crushers
(3055, 3648, 4448, 5060 & 5566) Models 2036 thru 5566

INSTALL RETAINING RINGS

1. Be sure retaining rings and jaw bore faces are
free of nicks, burrs, dirt and grease.
2. Apply grease to groove of spacer (all except
5566).
3. Apply silicone sealant to face of swing jaw bore.
NOTE: Use only high quality silicone--type sealant
that will withstand temperatures of 200°F (93°C)
without deterioration.

11--20 REV 4
(7/01)
Telsmith Jaw Crushers Eccentric Shaft Overhaul Procedures
Models 2036 thru 5566 (3055, 3648, 4448, 5060 & 5566)

INSTALL RETAINING RINGS (cont.)

NOTE: For all models except 5060 and 5566, apply
service removable thread locking compound to
capscrews as installed in step 4. Do not apply com-
pound to capscrews of 5060 and 5566.
IMPORTANT: During step 4, the lubrication port in
jaw bore must line up with the corresponding cut--out
in retaining ring. Observe match marks placed on
bore and retaining rings during removal. Be sure in-
side flange of retaining ring is fully seated into the
bore.
4. Align retaining ring with jaw bore face. Secure re-
taining ring with capscrews and washers.

11

REV 4 11--21
(7/01)
 Eccentric Shaft Overhaul Procedures Telsmith Jaw Crushers
(3055, 3648, 4448, 5060 & 5566) Models 2036 thru 5566

FILL BOLT HOLES WITH MOLTEN

BABBITT (5060 & 5566 only)
! WARNING!!!
Molten babbitt is hot and can cause serious
burns. Always wear face shield, gloves and
protective clothing whenever working with
molten babbitt. Always wear face shield
when removing and sanding excess babbitt
in steps 3 and 4.

1. Fill bolt holes with molten babbitt. Use funnel or

other suitable tool to direct flow of babbitt towards
holes.
2. Leave funnel in place for a few seconds until bab-
bitt cools.
3. Remove all excess babbitt with file or scraper.
4. Sand babbitt until flush with retaining ring face.
5. Remove any babbitt that has dripped on eccentric
shaft.

11--22 REV 4
(7/01)
Telsmith Jaw Crushers Eccentric Shaft Overhaul Procedures
Models 2036 thru 5566 (3055, 3648, 4448, 5060 & 5566)

INSTALL MAIN--SWING JAW BEARING

SPACER
1. Apply a coat of clean oil to eccentric shaft.
2. Install key and spacer.

Key

TO COMPLETE ECCENTRIC SHAFT

INSTALLATION:
11
1. Install main frame bearings. See section begin-
ning on page 11--25.
2. Complete final assembly procedures for main
frame bearings. See section beginning on
page 11--39.

REV 4 11--23
(7/01)
 Eccentric Shaft Overhaul Procedures Telsmith Jaw Crushers
(3055, 3648, 4448, 5060 & 5566) Models 2036 thru 5566

11--24
Telsmith Jaw Crushers Eccentric Shaft Overhaul Procedures
Models 2036 thru 5566 (3055, 3648, 4448, 5060 & 5566)

MAIN FRAME BEARINGS--INSTALLATION (3055, 3648, 4448, 5060 & 5566)

BEFORE YOU BEGIN

1. Read General Instructions section at the begin-
ning of this chapter.
2. Place swing jaw on suitable supports with wear
surface facing down.
NOTE: Assembly and installation procedures are
the same for both thrust and expansion sides.
IMPORTANT: Keep parts on expansion and thrust
sides separate. They must be installed on the same
side as removed. Observe reference marks placed
on parts during disassembly.

INSPECT MOUNTING
1. Place mounting on suitable supports. Check for
cracks and obvious wear. Remove any high spots
that might interfere with bearing installation.
2. Measure run--out of mounting bore. If bore is out--
of--round more than 0.005 inch, replace or re-
condition mounting.

11

REV 4 11--25
(7/01)
 Eccentric Shaft Overhaul Procedures Telsmith Jaw Crushers
(3055, 3648, 4448, 5060 & 5566) Models 2036 thru 5566

ASSEMBLE BEARING AND MOUNTING

(3055, 3648 & 4448 only)
1. Secure inner retaining ring to mounting with caps-
crews.
NOTE: Inner retaining ring will prevent chilled bear-
ing from falling through mounting in step 6. It will also
provide an even supporting surface until bearing
warms and expands. Because inner retaining ring
will be removed from mounting in step 6, do not tight-
en capscrews or apply sealant.
2. Turn mounting over so that inner retaining ring is
on bottom and other side of mounting is facing up.
3. Apply a light coat of clean oil to mounting bore.

! WARNING!!!

Be careful when handling dry ice. Never allow

dry ice to contact skin. Always use gloves to
prevent burns.

4. Chill bearing with dry ice for approximately 1

hour.
5. Carefully lower chilled bearing into mounting.
IMPORTANT: Bearing is an interference fit in
mounting. Apply pressure against outer race of
bearing only. Be sure bearing is not cocked in
mounting.
6. After bearing has warmed, turn bearing on its
end and remove inner retaining ring and caps-
crews.

11--26 REV 4
(7/01)
Telsmith Jaw Crushers Eccentric Shaft Overhaul Procedures
Models 2036 thru 5566 (3055, 3648, 4448, 5060 & 5566)

ASSEMBLE BEARING AND MOUNTING

(5060 and 5566 only)
1. Apply a light coat of oil to mounting bore.

! WARNING!!!
Be careful when handling dry ice. Never allow
dry ice to contact skin. Always use gloves to
prevent burns.
2. Chill bearing with dry ice for approximately 1 hour.
3. Carefully press thrust bearing into mounting.
IMPORTANT: Bearing is an interference fit in
mounting. Apply pressure against outer race of bear-
ing only. Be sure bearing is not cocked in mounting.
4. Check clearance between outer race and mount-
ing shoulder with a feeler gauge. There should not
be any clearance at this point.

INSTALL NEW OIL SEAL TO INNER

RETAINING RING (3055, 3648 & 4448
only)
1. Remove and discard old oil seal.
2. Start new seal into groove by finger pressure,
then tap evenly all around until seal is seated and
flush with retaining ring face. Seal lip must face
away from swing jaw when inner retaining ring is
installed on shaft.
NOTE: To prevent seal damage, tap only on outer
edge of seal. 11

Swing Jaw

Seal lip must face away from swing jaw

REV 4 11--27
(7/01)
 Eccentric Shaft Overhaul Procedures Telsmith Jaw Crushers
(3055, 3648, 4448, 5060 & 5566) Models 2036 thru 5566

INSTALL INNER RETAINING RING AND

INNER SPACER (3055, 3648 & 4448
only)
IMPORTANT: Dimensions of the inner retaining
rings are different for the thrust and expansion sides.
Retaining rings must be installed on the correct
sides. They cannot be interchanged.
1. Apply a coat of clean oil to main--swing jaw
spacer.
2. Slide inner retaining ring on shaft and position
over main--swing jaw spacer.
3. Apply grease to groove.
4. Install inner spacer.

11--28 REV 4
(7/01)
Telsmith Jaw Crushers Eccentric Shaft Overhaul Procedures
Models 2036 thru 5566 (3055, 3648, 4448, 5060 & 5566)

INSTALL BEARING AND MOUNTING

ASSEMBLY (3055, 3648 & 4448 only)
1. Clean surface of shaft. Be sure it is free of grease
and dirt. Remove any nicks and burrs with a grind-
er or emery cloth.
2. Apply a light coat of oil to shaft.
3. To prevent bearing from dropping out of mounting
during heating, temporarily install bolt and flat-
washers through one of the threaded holes on
mounting face (swing jaw side).
4. Heat bearing and mounting assembly to between
175--195°F (70--90°C) using an oil bath. Bring oil
up to temperature slowly so that oil has adequate
time to warm entire bearing.
IMPORTANT: During heating, suspend bearing
and mounting assembly on a cable or in a basket so
that it does not contact the bottom of the container. Di-
rect heat may permanently damage the bearing.
IMPORTANT: Do not allow oil temperature to ex-
ceed 200°F (93°C). Temperatures above 200°F
(93°C) may permanently damage bearing.
NOTE: Steps 5 through 7 must be done quickly to
prevent bearing from cooling and seizing on shaft be-
fore it is fully installed. Read and understand all steps
to ensure that there will be no delays once bearing is
removed from oil bath.
5. Lift bearing and mounting assembly from oil bath.
Slide bearing and mounting assembly partially on
shaft. Have assistant remove bolt and washers
that were installed in step 3.
6. Carefully slide heated bearing and mounting as-
sembly completely onto shaft. Be sure inner race
of bearing is fully seated against main--swing jaw
spacer.
7. Place blocking against inner race of bearing and
secure with bolts. Allow race to cool with blocking
in place.
11

REV 4 11--29
(7/01)
 Eccentric Shaft Overhaul Procedures Telsmith Jaw Crushers
(3055, 3648, 4448, 5060 & 5566) Models 2036 thru 5566

INSTALL BEARING AND MOUNTING

ASSEMBLY (5060 & 5566 ONLY)
1. Position mounting so that oil seal side is facing up.
Remove and discard old oil seal. Do not replace
with new oil seal yet. New seal will be installed in
step 5.
2. Clean surface of shaft. Be sure it is free of grease
and dirt. Remove any nicks and burrs with a grind-
er or emery cloth.
3. Apply a light coat of oil to shaft.
4. Heat bearing and mounting assembly to between
175--195°F (70--90°C) using an oil bath. Bring oil
up to temperature slowly so that oil has adequate
time to warm entire bearing
IMPORTANT: During heating, suspend bearing
and mounting assembly on a cable or in a basket so
that it does not contact the bottom of the container. Di-
rect heat may permanently damage the bearing.
IMPORTANT: Do not allow oil temperature to ex-
ceed 200°F (93°C). Temperatures above 200°F
(93°C) may permanently damage bearing.
NOTE: The following steps must be done quickly to
prevent bearing from cooling and seizing on shaft be-
fore it is fully installed. Read and understand all steps
to ensure that there will be no delays once bearing is
removed from oil bath.
5. Lift bearing and mounting assembly from oil bath.
Using an assistant to hold bearing in place, install
new oil seal. Do this as quickly as possible. Be
sure seal is evenly seated and that seal lip is
pointed toward bearing.

Seal lip
must face
toward
bearing

6. Carefully slide heated bearing and mounting as-

sembly onto shaft. Be sure race is fully seated
against main--swing jaw spacer.
7. Place blocking against inner race of bearing and
secure with bolts. allow race to cool with blocking
in place. Remove blocking after bearing has
cooled.

11--30 REV 4
(7/01)
Telsmith Jaw Crushers Eccentric Shaft Overhaul Procedures
Models 2036 thru 5566 (3055, 3648, 4448, 5060 & 5566)

SECURE INNER RETAINING RING TO

BEARING MOUNTING (3055, 3648 &
4448 only)
1. Apply silicone sealant to gap between mounting
and inner retaining ring.
NOTE: In step 1, use only high quality silicone seal-
ant that will withstand temperatures of 200°F (93°C)
without deterioration.
2. Align bolt holes of inner retaining ring and bearing
mounting face. Lubrication port in mounting must
line up with the corresponding cut--out in the re-
taining ring. To ensure correct assembly, observe
match marks made during removal.
3. Secure retaining ring to mounting with capscrews
and washers. Apply service--removable thread
locking compound to threads of capscrews as
installed. Tap on end of wrench with mallet until
capscrews are tight.
4. Remove excess silicone sealant.

11

REV 4 11--31
(7/01)
 Eccentric Shaft Overhaul Procedures Telsmith Jaw Crushers
(3055, 3648, 4448, 5060 & 5566) Models 2036 thru 5566

CHECK BEARING CLEARANCE

Check clearance between bottom roller and outer
race with a feeler gauge. See table for allowable clear-
ances.

Crusher Model Clearance between bottom roller

& outer race after installation
(min./max. in inches)
3055 0.0034/0.0098
3648 0.0064/0.0134
4448 0.0059/0.0134
5060 0.0091/0.0151
5566 0.0091/0.0151

Lubricate bearing (Grease lubricated

crushers only)
1. Install grease fitting.
2. Pump grease into bearing while rotating shaft. Fill
all pockets between rollers.

11--32 REV 4
(7/01)
Telsmith Jaw Crushers Eccentric Shaft Overhaul Procedures
Models 2036 thru 5566 (3055, 3648, 4448, 5060 & 5566)

INSTALL OUTER SPACER

1. Apply a coat of clean oil to shaft.
2. Align keyways and slide outer spacer on shaft.
Tap evenly with mallet until seated against in-
ner race of bearing.
3. Install key.

11

REV 4 11--33
(7/01)
 Eccentric Shaft Overhaul Procedures Telsmith Jaw Crushers
(3055, 3648, 4448, 5060 & 5566) Models 2036 thru 5566

INSTALL NEW OIL SEAL TO OUTER

RETAINING RING
1. Remove and discard old oil seal.
2. Start new seal into groove by finger pressure,
then tap evenly all around until seal is seated
and flush with retaining ring face.
Oil--lubricated crushers only: Seal lip must face
towards main frame bearing when retaining ring is
installed.
Grease--lubricated crushers only: Seal lip must
face towards flywheel when retaining ring is
installed.
NOTE: To prevent seal damage, tap only on outer
edge of seal.

Oil--lubricated
Crushers only
(Seal Lip towards
Bearing)

Grease--lubricated
Crushers only
(Seal Lip towards
Flywheel)

11--34 REV 4
(7/01)
Telsmith Jaw Crushers Eccentric Shaft Overhaul Procedures
Models 2036 thru 5566 (3055, 3648, 4448, 5060 & 5566)

INSTALL OUTER RETAINING RING

1. Apply silicone sealant to mating surfaces of bear-
ing mounting and retaining ring.
NOTE: In step 1, use only high quality silicone seal-
ant that will withstand temperatures of 200°F (93°C)
without deterioration.
2. Apply grease to groove of outer retaining ring.
3. Apply coat of clean oil to outer spacer and to lip of
oil seal.
4. Align retaining ring with bearing mounting face.
Lubrication port in bearing mounting must line up
with the corresponding cut--out in the retaining
ring. To ensure correct assembly, observe match
marks made during removal.

11

REV 4 11--35
(7/01)
 Eccentric Shaft Overhaul Procedures Telsmith Jaw Crushers
(3055, 3648, 4448, 5060 & 5566) Models 2036 thru 5566

INSTALL OUTER RETAINING RING

(cont.)
5. Carefully slide retaining ring onto shaft and over
outer spacer. Make sure that seal lip edge is not
twisted.
6. Secure retaining ring with capscrews and wash-
ers. Apply service--removable thread locking
compound to capscrews as installed. Tap on end
of wrench with mallet until capscrews are tight.

11--36 REV 4
(7/01)
Telsmith Jaw Crushers Eccentric Shaft Overhaul Procedures
Models 2036 thru 5566 (3055, 3648, 4448, 5060 & 5566)

INSTALL PLUGS AND LUBRICATION

FITTINGS AS REQUIRED.
IMPORTANT: Apply pipe sealant to threads of all
plugs and fittings as installed. Wipe off any excess
pipe sealant.
1. Install plug in hole on shaft.
2. Install lubrication system fittings (as required).
3. Install plugs in open holes of new bearing mount-
ing (as required).
NOTE: Step 3 is necessary only if a new bearing
mounting was installed. New plugs are shipped loose
with new bearing mountings. See old bearing mount-
ing for location of plugs.

11

REV 4 11--37
(7/01)
 Eccentric Shaft Overhaul Procedures Telsmith Jaw Crushers
(3055, 3648, 4448, 5060 & 5566) Models 2036 thru 5566

INSTALL PLUGS AND LUBRICATION

FITTINGS AS REQUIRED. (cont.)
4. 4448, 5060 & 5566 only: Install breather.

TO COMPLETE ECCENTRIC SHAFT

OVERHAUL
1. Install main frame bearing on other side (if re-
moved).
2. Complete final assembly procedures for main
frame bearings. See section beginning on page
11--39.

11--38 REV 4
(7/01)
Telsmith Jaw Crushers Eccentric Shaft Overhaul Procedures
Models 2036 thru 5566 (3055, 3648, 4448, 5060 & 5566)

MAIN FRAME BEARINGS -- FINAL ASSEMBLY (3055, 3648, 4448, 5060 & 5566)

INSTALL SHIMS AND MEASURE

CLEARANCE
1. Fabricate four metal shims. See table below for
thickness.
Thrust
Crusher Model Required shim thickness side
(each shim)
3055 1/2″ thick
3648 1/4″ thick
4448 1/8″ thick
5060 1/8″ thick Expansion
5566 1/8″ thick side

2. Have assistants hold shims in place between the

swing jaw bearing retaining rings and the main
frame bearing mountings.
3. Install blocking on expansion end as shown. (install on
Tighten bolts until shims on both sides are snug both thrust
against bearing mountings. and expansion
sides)
IMPORTANT: If gap on one or both sides is larger (install on
than shims, do the following checks: expansion
side only)
• Check that blocking material is fully tightened.
• Check that main frame thrust bearing is fully
seated on shaft and not cocked or binding.
• Check that main frame expansion bearing is fully
seated on shaft and not cocked or binding.

! CAUTION!!!
Failure to meet the correct dimensions on both
sides will result in “T” key alignment problems
and/or premature bearing wear. Never attempt
to reposition “T” keys on frame to compensate
for too large a gap on either side of shaft.

11

REV 1 11--39
(8/94)
 Eccentric Shaft Overhaul Procedures Telsmith Jaw Crushers
(3055, 3648, 4448, 5060 & 5566) Models 2036 thru 5566

INSTALL SWING JAW IN FRAME

1. Perform “Swing Jaw Installation” procedure in
Chapter 5. Leave shims in place until “T” keys
are aligned and seated in grooves of bearing
housings.
NOTE: Check for “T” key wear before installing
swing jaw. If necessary, tack weld new “T” keys to
frame and check alignment by lowering swing jaw.
Be sure to do final weld of new “T” keys before
completely installing swing jaw.
2. Perform “Toggle Installation” procedure. See
Chapter 5.
3. Perform “Tension Rod Assembly” procedure.
See Chapter 5.
4. Perform “Flywheel Pulley/Sheave Installation”
procedure. See Chapter 5.
5. Perform “Thrust Shaft Clearance Adjustment”
procedure. See Chapter 7.
6. Perform pre--start--up assembly procedures in
Chapter 6 as required.
7. Refer to start--up procedures in Chapter 1. Run
crusher without load and check for any obvious
problems. Listen for any unusual noises.

11--40
 TABLE OF CONTENTS
CHAPTER 12
Storage & Shipment
CRUSHER STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12--1
BEFORE STORING CRUSHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12--1
DURING STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12--1
RETURNING CRUSHER TO SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12--1
PREPARATION FOR SHIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12--1

12
T
Telsmith Jaw Crushers
Models 2036 thru 5566
CRUSHER STORAGE
BEFORE STORING CRUSHER
Perform the following steps before storing the crusher
for 6 months or longer.
• Add oil preservative to lubrication system tank. Run
oil pump for at least 5 minutes to circulate oil
preservative through bearings (oil lubricated
crushers only).
• Apply grease to bearing lubrication fittings (crushers
without oil lubrication system only).
• Cover all machined surfaces with protective coating.
Be sure to apply protective coating to any exposed
threads, including tension rod threads.
• Relieve tension on tension rod springs by loosening
adjusting nuts.
• Relieve tension on drive belts.
DURING STORAGE
• Once a month, manually rotate flywheels back and
forth.
• Once a month, start lubrication system oil pump and
run for 5 minutes (oil lubricated crushers only).
RETURNING CRUSHER TO SERVICE
Before start--up, perform the following steps:
• Drain oil from lubrication system tank and refill with
fresh oil. Refer to Chapter 7 for oil specifications.
• Apply grease to tension rods and tension rod
sleeves. Refer to Chapter 7 for grease specifications.
• Apply grease to bearings (grease lubricated crushers
only), Refer to Chapter 7 for grease specifications.
• Tighten tension rod springs.
• Tighten V--belts. Refer to Chapter 7 for V--belt
tensioning procedure.
• Make sure discharge setting is adjusted to produce
desired end product. Refer to Chapter 7 for discharge
setting measurement and adjustment procedures.
• Follow initial start-up procedures in Chapter 6.
Storage & Shipment
PREPARATION FOR SHIPMENT
NOTE: Level of disassembly required for shipping will
vary depending on shipping route. Check state and local
laws for maximum weight, height and width restrictions.
Laws may differ from state to state. Obtain any
necessary permits or waivers.
• Crushers with one piece frames can often be shipped
fully assembled. Remove components only if
necessary. See Chapter 9 “Maintenance and Repair”
for component removal and disassembly
procedures.
• Before shipping crushers with two piece frames,
separate main frame halves and all other major
components. Secure all components to wooden
skids. Refer to Chapter 9 for component disassembly
procedures.
• As removed, place all hardware and small
components in marked containers.
• Be sure lifting devices used during disassembly,
loading, unloading, and assembly procedures are
not overloaded. Refer to Chapter 3 for individual
component weights.
• Coat all unpainted surfaces with protective coating.
Be sure to apply protective coating to any exposed
threads, including tension rod threads.
• If flywheels have been removed for shipping, provide
blocking at both ends of eccentric shaft to prevent
main frame retaining rings from falling off.
• Be sure all sub--systems (hydraulic adjust, oil
lubrication systems, air/oil cooler etc.) are secured
and all hoses/fittings are capped.
12
12--1
Telsmith Jaw Crushers
Models 2036 thru 5566 Storage and Shipment

12--2 REV 4
(7/01)
Telsmith Jaw Crushers
Models 2036 thru 5566 Appendix A

CONVERSION TABLES
LINEAR MEASURE SQUARE MEASURE
To Convert Into Multiply By To Convert Into Multiply By
Inches Centimeters 2.54 Sq. Inches Sq. Centimeters 6.452
Feet Meters 0.3048 Sq. Miles Sq. Kilometers 2.59
Centimeters Inches 0.3937 Sq. Centimeters Sq. Inches 0.15499
Millimeters Inches .0394 Sq. Meters Sq. Inches 1549.9
Meters Inches 39.37 Sq. Meters Sq. Feet 10.763
Meters Feet 3.2808
CUBIC MEASURE WEIGHT
To Convert INTO Multiply By To Convert Into Multiply By

Cu. Inches Kilograms Pounds 2.2046

Cu. Centimeters 16.387 Pounds Kilograms 0.4536
Cu. Feet Cu. Meters 0.0283
Cu. Centimeters Pounds/Sq. Kilograms/Sq. 0.0703
Cu. Inches 0.06102 Inch Centimeter
Cu. Meters Cu. Inches 610233779.0
Cu. Meters Pounds/Sq. Kilograms/Sq. 4.8824
Cu. Feet 35.314 Foot Meter

DEGREES FAHRENHEIT TO DEGREES CENTIGRADE

F C F C F C F C F C
--30 --34.44 +20 --6.67 +55 +12.78 +90 +32.22 +225 +107.22
--28 --33.33 21 --6.11 56 13.33 91 32.78 230 110.00
--26 --32.22 22 --5.56 57 13.89 92 33.33 235 112.78
--24 --31.11 23 --5.00 58 14.44 93 33.89 240 115.56
--22 --30.00 24 --4.44 59 15.00 94 34.44 245 118.33
--20 --28.89 25 --.3.89 60 15.56 95 35.00 250 121.11
--18 --27.78 26 --3.33 61 16.11 96 35.56 255 123.89
--16 --26.67 27 --2.78 62 16.67 97 36.11 260 126.67
--14 --25.56 28 --2.22 63 17.22 98 36.67 265 129.44
--12 --24.44 29 --1.67 64 17.78 99 37.22 270 132.22
--10 --23.33 30 --1.11 65 18.33 100 37.78 275 135.00
--8 --22.22 31 --0.56 66 18.89 105 40.55 280 137.78
--6 --21.11 32 0.00 67 19.44 110 43.33 285 140.55
--4 --20.00 33 +0.56 68 20.00 115 46.11 290 143.33
--2 --18.89 34 1.11 69 20.56 120 48.89 295 146.11
0 --17.78 35 1.67 70 21.11 125 51.67 300 148.89
+1 --17.22 36 2.22 71 21.67 130 54.44 305 151.67
2 --16.67 37 2.78 72 22.22 135 57.22 310 154.44
3 --16.11 38 3.33 73 22.78 140 60.00 315 157.22
4 --15.56 39 3.89 74 23.33 145 62.78 320 160.00
5 --15.00 40 4.44 75 23.89 150 65.56 325 162.78
6 --14.44 41 5.00 76 24.44 155 68.33 330 165.56
7 --13.89 42 5.56 77 25.00 160 71.11 335 168.33
8 --13.33 43 6.11 78 25.56 165 73.89 340 171.11
9 --12.78 44 6.67 79 26.11 170 76.67 345 173.89
10 --12.22 45 7.22 80 26.67 175 79.44 350 176.67
11 --11.67 46 7.78 81 27.22 180 82.22 355 179.44
12 --11.11 47 8.33 82 27.78 185 85.00 360 182.22
13 --10.56 48 8.89 83 28.33 190 87.78 365 185.00
14 --10.00 49 9.44 84 28.89 195 90.55 370 187.78
15 --9.44 50 10.00 85 29.44 200 93.33 375 190.55
16 --8.89 51 10.56 86 30.00 205 96.11 380 193.33
17 --8.33 52 11.11 87 30.56 210 98.89 385 196.11
18 --7.78 53 11.67 88 31.11 215 101.67 390 198.89
19 --7.22 54 12.22 89 31.67 220 104.44 395 201.67

A--1
 Telsmith Jaw Crushers
Appendix A Models 2036 thru 5566

A--2 REV 4
(7/01)
Telsmith Jaw Crushers
Models 2036 thru 5566 Appendix B

Torque Tables

REV 4 B--1
(7/01)
 Telsmith Jaw Crushers
Appendix B Models 2036 thru 5566

Torque Tables
(continued)

B--2 REV 4
(7/01)
 Telsmith Jaw Crushers
Models 2036 thru 5566
Glossary of Terms
ANGLE OF NIP -- Acute angle formed by stationary and
swing jaw.
BEARING--JAW -- A crusher component which allows
rotation of the shaft on which it is mounted. Basic types
are roller and sleeve (plain).
BEARING CAP -- A type of bearing seal. Also the top
portion of a split bearing housing.
CLOSED SIDE SETTING -- Distance between jaw dies
measured at their bottom with the jaw in the closed
position. Measurement of distance is taken from peak of
corrugation to valley of opposing corrugation on jaw die
surfaces.
COUNTERWEIGHT -- Weights placed on flywheels to
balance the crusher.
CRUSHING CHAMBER--JAW -- The area confined by
the stationary and swing jaw dies and the cheek plates in
which crushing takes place.
DISCHARGE OPENING--JAW -- The area between the
jaw dies and the cheek plates at the bottom of the
crushing chamber.
DOUBLE TOGGLE JAW CRUSHER -- Has two shafts
and two toggles. The swing jaw is pivoted at the top and
actuated at the bottom.
ECCENTRIC SHAFT -- Shaft machined with a portion of
the axis off--center to impart a crushing motion to the
swing jaw.
FEED OPENING -- The inlet opening of the crusher
confined by the jaw dies and the cheek plates.
HAND OF DRIVE -- Right or left on which drive is
located.
HYDRAULIC ADJUSTMENT SYSTEM -- Hydraulic
pump which locates the swing jaw to assist in the
addition or removal of shims whims when changing
discharge settings.
JAW DIES (JAW PLATES) -- Replaceable crushing
surfaces with different types of configurations on the
surface.
JAW DIE WEDGES -- Bolted wedges used to tighten
and secure jaw dies.
Appendix C
MAIN FRAME -- Major casting or weldment that
supports the crushing members.
MOTOR BASE -- Slide base to maintain proper V--belt
tension.
OPEN SIDE SETTING -- Distance between jaw dies
measured at their bottom with the jaw in the open
position. Measurement of distance is taken from peak of
corrugation to valley of opposing corrugation on jaw die
surfaces.
OVERHEAD ECCENTRIC -- Eccentric shaft and
bearing mechanism located at the top of the swing jaw
assembly to impart crushing motion to the machine.
ROLLER BEARING -- Common types used in jaw
crushers are spherical, taper, and cylindrical roller
bearings.
SHIM--ADJUSTING -- Steel spacer plates to locate and
hold swing jaw in the desired discharge position.
SLIPPAGE -- Action that occurs when the angle of the
nip is too great, thus retarding acceptable flow rate of the
material to be crushed.
SPEED -- RPM of the eccentric shaft and crusher
flywheel.
STROKE -- Amount of movement of the swing jaw which
is controlled by the amount of eccentricity of the
eccentric shaft and the toggle system.
SWING JAW ASSEMBLY -- Consists of jaw, shaft and
bearings.
SWING (MOVABLE) JAW DIES -- Manganese crushing
surface mounted on the swing jaw.
TENSION ROD SPRING ASSEMBLY -- Designed to
maintain a tight contact between the swing jaw, toggle
plate and main frame.
TOGGLE OR TOGGLE PLATE -- A spacing member
located between frame and swing jaw which may also
act as a protective member.
TOGGLE SEAT -- A bearing surface, usually a
replaceable insert, designed to take the wear due to
toggle movement.
C--1
 Telsmith Jaw Crushers
Appendix C Models 2036 thru 5566

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 Appendix E
CENTRAL GREASE LUBE SYSTEM
OPERATION and MAINTENANCE

CONTENTS

Page

CENTRAL GREASE LUBE SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . E-2

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-2
Installing Feed Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-2
Grease Pump Feed Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . E-2
Crusher Feed Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-3
E
Alarm Installation & Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-4
Time Delay Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-5

ALARM PANEL SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-6

GREASE FILL AND STARTUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-8

Initial Fill and Startup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-8

PERIODIC MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-9

AUTOMATIC GREASE SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . E-9

Troubleshooting Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-10

04/08 E–1
 CENTRAL GREASE LUBE SYSTEM OPERATION and MAINTENANCE Operation and Maintenance
Telsmith Jaw Crusher Models 2036 - 5566

CENTRAL GREASE LUBE SYSTEM

OPERATION
Model 2044/2540/3042/3055/3258/3648/3858/4448/5060
and 5566 Jaw Crushers that are not equipped with an Oil
Lubrication System will be delivered with either a manual or
an automatic central grease lubrication system. The
automatic grease lubrication system (Fig. E-1) has a timer
E
controlled grease pump that delivers lubrication to the swing
D
jaw and main frame bearings, the tension rod eyes, the
tension rod sleeves and the thrust shafts on a preset schedule.
The automatic system features a grease reservoir that must be
filled periodically. Grease is delivered to the bearings and
fittings in the typical range of 400 to 1000 PSI (depending on
temperature and grease type). If pressure exceeds 2800 PSI
due to a malfunction in the manifold or a blockage in a line, C
the pressure switch will turn on the alarm horn on the cover
of the control panel after a five second delay (TR-1 Relay). If
the high pressure condition continues, a second time delay
relay (TR-2) will shut the crusher drive motor off after 50
seconds. This 50 second delay after the alarm sounds allows
the crusher chamber to clear material before the drive motor B
shuts off. If pressure in the grease system reaches 3000 PSI,
a relief valve will vent grease back to the grease reservoir to
prevent damage to the system. The pressure switch resets
E when pressure in the system drops back below 2600 PSI.
The automatic grease system mounts on the left side of the
A
crusher on a separate bracket (E, Fig. E-1). Typically the
automatic grease system will be delivered completely
mounted with all lines plumbed and the grease reservoir
filled. If your jaw crusher is delivered with the swing jaw
removed, it will be necessary to remove caps from the lines Figure E–1. Automatic Grease Lube System
and install the lines at the crusher termination points when the Components
jaw has been installed. A. Crusher B. Grease Pump
C. Grease Reservoir D. Control Panel
When the lines have been installed and the grease reservoir E. Mounting Bracket
has been filled, it will be necessary to have a 24V power
supply wired to the control panel.
INSTALLATION
Initalization of the grease pump will require installing any
lines that are delivered loose and capped, adding grease to the
reservoir (if necessary), supplying 24V power to the alarm
panel and setting the timer switches that control the pump
timer On/Off duration.
Installing Feed Lines
Grease Pump Feed Line
If the grease line from the grease reservoir to the feed block
has not been installed, connect the line observing the
following guidelines:
• Check all threaded fittings before assembly to make
certain all pipe ends and fittings are free of burrs and chips.

E–2 04/08 (Rev. 5)

Operation and Maintenance CENTRAL GREASE LUBE SYSTEM OPERATION and MAINTENANCE
Telsmith Jaw Crusher Models 2036 - 5566

Check the interior of the lines for dirt or debris, flush as

necessary.
B
• Install the feed line from the grease pump fitting (Fig. E-2)
to the manifold fitting on the crusher (Fig. E-2).
• Use pipe sealing compound on the threaded fittings and
make certain all fittings are tight.

A A

E
C
E
B

A
C A
E B B
E D
C C

Figure E–2. Pump Feed Line Installation D D

A. Grease Block Input Line B. Pump Feed Line Connector E

Connector E
C. Fill Port Quick Coupler D. Relief Valve Assembly
E. Relief Valve Cartridge

Figure E–3. Feed Line Installation Points (3648 Model

Crusher Feed Line Installation
Crusher Shown)
If the feed lines have not been installed at the swing jaw, A. Swing Jaw Bearing Line (2) B. Main Frame Bearing Line (2)
tension rods and thrust shafts (Fig. E-3), install them at this C. Thrust Shaft Line (2) D. Tension Rod Sleeve Line (2)
time. E. Tension Rod Eye Line (2)

Check the lines for dirt or debris, flush as necessary.

Use pipe sealing compound on the threaded fittings and make
certain all fittings are tight.

04/08 (Rev. 5) E–3

 CENTRAL GREASE LUBE SYSTEM OPERATION and MAINTENANCE Operation and Maintenance
Telsmith Jaw Crusher Models 2036 - 5566

Alarm Installation & Operation

The alarm mounted in the automatic grease system control
panel door (Fig. E-5) is an integral part of the lubrication All “OFF” Switches OFF OFF TIME ON TIME
Equals 15 Minutes IN MINUTES IN MINUTES
system. It is activated by one or more of the following All “ON” Switches OFF 60 240
conditions: Equals 30 Seconds 30 120 1 2 4 8 7

• High feed line system pressure. A 5 second time delay ON

(TR-1) prevents the alarm from sounding due to brief OFF
fluctuations in system pressure. 8
• Low grease level in the reservoir. If grease level drops to
a preset level, a low level switch in the tank will activate 10
1 6
the alarm horn.
Make incoming 24V electrical power connections to the
grease system alarm panel at this time. Refer to Figures E-8
and E-9. 2+ 2 3- 3

1A 2A
! WARNING!!!
DANGER
Always lock out power and tag controls before
making any electrical connections. Failure to
Figure E–4. Timer Switches
observe this precaution may result in serious
personal injury or death.
Timer Switch Settings (3648 Settings Highlighted)
! WARNING!!!
DANGER
E Switch Number
OFF
Switch Number
ON
Failure to properly install and connect electrical TIME TIME
equipment may result in a dangerous electrical 30 60 120 240 1 2 4 8

shock hazard. All connections must be made in Off Off Off Off 15 min Off Off Off Off 30
accordance with the National Electrical Code and sec.
any applicable local codes. Be sure all electrical
On Off Off Off 30 min On Off Off Off 1 min
work is done by a trained and licensed electrician.
Off On Off Off 60 min Off On Off Off 2 Min
Check that the grease pump on/off timer settings are correctly
set (Fig. E-4 & Table E-1) for your model. The switch settings On On Off Off 90 min On On Off Off 3 Min

for a 3648 crusher are highlighted in the example. The Off Off On Off 120 min Off Off On Off 4 Min
switches for setting the timer are located under a cover at the
On Off On Off 150 min On Off On Off 5 Min
front of the grease unit reservoir. Remove the four screws and
pull the cover off to access the switches. Off On On Off 180 min Off On On Off 6 Min

On On On Off 210 min On On On Off 7 Min

Table E-1. Timer Settings Off Off Off On 240 min Off Off Off On 8 min

On Off Off On 270 min On Off Off On 9 min

Jaw Model On Time Off Time
Off On Off On 300 min Off On Off On 10 min
2044/2540 210 Sec 90 Min
On On Off On 330 min On On Off On 11 min
3042/3055/3258/3648 480 Sec 90 Min
Off Off On On 360 min Off Off On On 12 min
3858/4448 480 Sec 60 Min
On Off On On 390 min On Off On On 13 min
5060/5566 480 Sec 30 Min
Off On On On 420 min Off On On On 14 min

On On On On 450 min On On On On 15 min

When the grease system alarm panel is fully wired, power up
the unit and test the alarm horn by pressing the horn test
switch on the alarm panel cover (Fig. E-5).

E–4 04/08 (Rev. 5)

Operation and Maintenance CENTRAL GREASE LUBE SYSTEM OPERATION and MAINTENANCE
Telsmith Jaw Crusher Models 2036 - 5566

IMPORTANT: If the alarm sounds immediately when

power is connected to the alarm panel, this may be an
indication that the grease reservoir is not filled. If the
reservoir has not been filled, do so at this time
introducing the specified grease for the prevailing
temperatures through the front grease loading coupler
or by removing the top cover. The alarm should silence
A
when the reservoir fills approximately 1/4 full.

6
B

TR1
=;

DISABLE Figure E–6. Time Delay Relay TR1

HORN TEST INTERLOCKS

A. Set dial to “85%” B. Set dial to “6”

Time Delay Relay TR-2 which sets a 50 second delay on high

pressure related crusher shutdown, should be checked for
correct settings. If the TR-2 relay is displaying 85% on the E
upper dial, and 60 in the lower readout (Fig. E-7), it is
correctly adjusted. The 50 second delay figure is established
by setting the upper at 85% of 60 seconds which yields a 50
second delay.

Figure E–5. Alarm Panel

Time Delay Relays A

Time Delay Relay TR-1 sets a 5 second delay on the system

high pressure alarm to prevent momentary pressure 60
B
fluctuations from triggering the alarm. If the TR-1 relay is
displaying 85% on the upper dial, and 6 in the lower readout
(Fig. E-6), it is correctly adjusted. The 5 second delay figure
is established by setting the upper dial at 85% of 6 seconds TR2
=;
which yields a 5 second delay.

Figure E–7. Time Delay Relay TR2

A. Set dial to “85%” B. Set dial to “60”

04/08 (Rev. 5) E–5

 CENTRAL GREASE LUBE SYSTEM OPERATION and MAINTENANCE Operation and Maintenance
Telsmith Jaw Crusher Models 2036 - 5566

Alarm Electrical Schematic

(Customer Supplied)
24V DC -
+

CONTROL PANEL
2-1A

LUBE LOW PRESSURE

2-1 BROWN BLUE 2-2
1 3
CRA
2-3 WHT BLACK 2-4
2 4

CRP-1 CRA-1 TR1

2-5 2-6 2-2 OFF DELAY
SET AT 5 SEC

TR-1 TR2
2-1 2-7

HORN TEST HORN

2-8 2-9 2-2 OFF DELAY
SET AT 50 SEC

CRP-3 CRX
2-1 2-10

DISABLE INTERLOCKS

E 2-1 CRP-2

2-11

CRX-1 CRP
2-13 2-12 2-2
MS1-2

CRUSHER AUX
(Customer
Supplied)
2-11 2-2 2-13

Cable Supplied
Leveling With
Grease Lube System

Manual Run 2+ 3 6 ON-BOARD

Switch TIMER
WHT BLK RED
Low Level
Switch Interlock Examples
TRI-LUBE HD

2-14 2-15
NOTES
Terminal located in jaw grease lubrication panel
all switches shall be grounded at a single point.
Leveling
Supplied by Telsmith
2-16 2-17
Quick Disconnect

Figure E–8. Alarm Schematic

E–6 04/08 (Rev. 5)

Operation and Maintenance CENTRAL GREASE LUBE SYSTEM OPERATION and MAINTENANCE
Telsmith Jaw Crusher Models 2036 - 5566

ALARM PANEL COMPONENTS

24 VDC A

C
HORN DISABLE
B TEST INTERLOCKS

F H

E
D
E G

CRA CRP CRX

TR1 TR2

CB1

K
J

Figure E–9. Alarm Panel Components

A. Horn B. Horn Test Button C. Disable Interlocks Test Button D. CRA Relay
E. CRP Relay F. CRX Relay G. TR1 Timer (Set at 5 Sec.) H. TR2 Timer (Set at 50 Sec.)
I. CB1 Circuit Breaker J. Terminal Strip K. Ground Block

04/08 (Rev. 5) E–7

 CENTRAL GREASE LUBE SYSTEM OPERATION and MAINTENANCE Operation and Maintenance
Telsmith Jaw Crusher Models 2036 - 5566

GREASE FILL AND STARTUP

Initial Fill and Purge
When the alarm panel is fully wired, it may be necessary to
fill the grease reservoir before 24 VDC is applied to the panel.
If the unit was delivered dry, fill the reservoir as follows:
1. Use the fill inlet quick coupler (C, Fig. E-2) on the front
of the reservoir and a pressure grease unit to fill the reservoir
with the correct grease for your operational temperature
range (Table E-2). If a pressure grease fill unit is not
available, the unit can also be filled manually by removing A
the three nuts securing the top cover and loading the grease
reservoir manually from the top. Approximately 20 lbs (9 Kg)
B
of grease will be required for an initial fill of the reservoir.

Figure E–10. Manual Pump Switch Location

A. Manual Switch B. Pump Body
Table E-2. Grease Requirements
5. Run the pump until grease begins to flow from the two
Ambient lines that were removed.
Temperature Standard Synthetic
Type
o Lubricant Lubricant 6. Refill the grease reservoir and re-install the swing jaw and
F (oC)
tension rod eye lines that were removed in Step 2.
Below NLGI 00 Mobilith 7. Run the pump manually for several more minutes to fully
40o (4o) with EP SHC 007
E Additives load the bearings.
Below NLGI 02 Mobil Mobilith 8. After the crusher has run for one shift, remove the drain
100oF with EP Delvac SHC 460 plugs at the swing jaw (Fig. E-11) and main frame bearings
Additives Xtreme
(38oC) and check that grease is visible and/or weeps from the holes.
Above NLGI 02 Mobilith Grease should also be visible at the tension rod eyes and
100oF with EP SHC 460 sleeves.
Additives
(38oC)

2. Remove one swing jaw bearing line at the inlet fitting and
one tension rod eye line at the inlet fitting (Fig. E-3). This will
allow you to check for grease flow as the system fills.
3. Activate the DISABLE INTERLOCKS switch (Fig. E-5)
on the alarm panel cover.
4. Locate the manual pump switch on the back of the grease
pump body (Fig. E-10). This is a momentary toggle switch
with a rubber boot. While continuing to depress the
DISABLE INTERLOCKS switch, activate and hold the
toggle switch to run the grease pump.

B A B

Figure E–11. Jaw Grease Drainage Points (Flywheel

Removed For Clarity/ Model 3648 Shown)
A. Swing Jaw Drain Plug B. Main Frame Bearing Drain Plug
(2 Places) (2 Places)

E–8 04/08 (Rev. 5)

Operation and Maintenance CENTRAL GREASE LUBE SYSTEM OPERATION and MAINTENANCE
Telsmith Jaw Crusher Models 2036 - 5566

PERIODIC MAINTENANCE • Check for visible leaks at hoses, manifolds and fittings. As
required, tighten or replace fittings and hoses to eliminate
The automatic grease system should be checked on a daily leaks.
basis for the following:
• Be sure proper voltage is connected to the grease pump
1. Check the grease level in the reservoir. Running the and alarm. Be sure polarity is correct.
system with the reservoir less than half full could result in
nuisance alarm trips. Monitor the system grease usage and • Check that grease system On/Off intervals are correctly set
establish a fill schedule that will help eliminate low level for your model crusher.
alarm trips. • If electrical problems are suspected, have a licensed
2. Monitor the pressure gauge on startup. System pressure electrician inspect and troubleshoot all related electrical
should run in the 400 PSI to 1000 PSI range after the crusher circuits and components.
warms. Continuous pressure above 2000 PSI can indicate
blockages in the system or incorrect viscosity grease for the Troubleshooting Chart
ambient temperatures. Refer to Table E-1. Refer to Table E-3 for the automatic grease system
troubleshooting chart. Also refer to other chapters in your
Periodic Grease Purge Procedure manual as noted.
On an every other month basis remove the drain plugs at the
main frame and swing jaw bearings to allow excess grease to
vent. Run the crusher for 15 minutes with the drain plugs
removed to allow old grease to drain. Clean up all drainage
and install the plugs.
If bearing temperatures rise noticeably between grease
purges, this may indicate excess grease buildup. Drainage
intervals may need to be shortened to accommodate excess
grease buildup or grease system on/off intervals may need to
E
be changed.

AUTOMATIC GREASE SYSTEM

TROUBLESHOOTING

! WARNING!!!
DANGER
Never attempt to clean or repair the automatic
grease system pump motor while it is in
operation. Always lockout/tagout power to the
control consoles before starting any service
work.
• Lockout/tagout power to the automatic grease system
control panel before inspecting, cleaning or repairing the
automatic grease unit. (Refer to Chapter 1 for complete
lockout/tagout procedures).

Preliminary Checks & Inspections

Make the following checks and inspections before
performing any lubrication system troubleshooting
procedures:
• Check that grease level is correct. Add correct type of
grease if low. Refer to Table E-2.

04/08 (Rev. 5) E–9

 CENTRAL GREASE LUBE SYSTEM OPERATION and MAINTENANCE
Table E-3: Automatic Central Grease Lube System Troubleshooting
SYMPTOMS
Grease is not pumping from
reservoir (Grease In
reservoir).
E when a high pressure condition does
Grease is pumping from
reservoir at correctly timed
intervals, but no grease or
insufficient grease is
reaching some components.
Grease is not being
delivered to bearings at the
correct time or in the correct
amount.
E–10
Operation and Maintenance
Telsmith Jaw Crusher Models 2036 - 5566
POSSIBLE CAUSE
Pump motor not running.
Grease outlet fitting plugged
or damaged.
Grease is bypassing back to
the reservoir through the relief
valve loop although a high
pressure condition is not
indicated.
Vacuum condition in reservoir
is hindering grease flow.
Grease diverter manifold on
crusher frame has blocked
ports or is defective.
Grease is too thick for
ambient temperatures
On-Board timer on/off settings
are not set correctly.
CORRECTIVE ACTION
Attempt to manually activate the pump
using the Disable Interlocks Switch and the
Manual Pump Motor switch
If the pump will not run using the manual
switch, check for incoming power to the
control panel, Circuit Breaker CB-1, and the
motor.
If 24V power is present at the motor, motor
may be defective or rotating power paddle
is jammed or broken off shaft. Replace
motor or paddle as required.
Remove outlet hose at fitting on reservoir
body and check for debris or damage.
Remove relief valve and clean. If this
doesn’t cure problem, replace relief valve.
If a new relief valve does not cure the
condition, check that pressure switch is not
defective and is failing to sound the alarm
actually exist.
Reservoir vent is defective. Attempt to
pump grease with cover removed. If grease
flows with cover removed, replace vent.
Remove input lines from the bearings
receiving insufficient grease at the diverter
manifold. If no debris or blockage is present
in the ports, replace the diverter manifold.
Clean out grease reservoir and reload with
grease of the proper consistency and type.
Refer to Table E-1.
Refer to Figure E-4 for correct timer switch
settings. Change as needed.
If the timer switch settings are set correctly
and the condition continues, replace the
pump on-board timer.
04/08 (Rev. 5)
Operation and Maintenance
Telsmith Jaw Crusher Models 2036 - 5566
Table E-3: Automatic Central Grease Lube System Troubleshooting
SYMPTOMS
Low Level switch in the
grease reservoir is
triggering an alarm when
the reservoir is full.
Relief valve is triggering
alarm and shutting down
crusher when a high
pressure condition (2800
PSI) is not indicated.
Grease reservoir will not fill,
or will not fill fully when
grease is injected through
quick disconnect fill fitting.
Crusher bearings indicating
over temperature condition
with grease system
operating correctly.
04/08 (Rev. 5)
CENTRAL GREASE LUBE SYSTEM OPERATION and MAINTENANCE
POSSIBLE CAUSE
Grease low level switch is
stuck shut.
Air pocket(s) in grease.
Relief valve is defective
Pressure gauge is defective
and not correctly registering
current pressure situation.
Quick disconnect fill fitting is
plugged or defective.
Reservoir vent is blocked
preventing grease from filling
to top of reservoir.
Overpressure condition due
to old grease buildup.
Grease being delivered to
bearings is not of the proper
type or viscosity for high
ambient temperatures.
CORRECTIVE ACTION
Remove switch and clean. If this does not
cure the problem, replace the switch.
If the low level switch continues to create
nuisance alarms with a new switch
installed, air pockets may be forming in the
grease. Check grease consistency and the
operation of the power paddle. Replace
grease with a new load of the correct
viscosity for the ambient temperature.
Replace power paddle if damaged, loose
on shaft or broken.
Replace relief valve.
Replace pressure gauge and locate source
of high pressure (If high pressure does
exist).
Attempt to clear fill fitting with compressed
air. If blockage will not clear, replace fitting.
Clean or replace reservoir vent.
E
Remove both main frame and crusher
bearing vent plugs. Run crusher for at least
fifteen minutes allowing grease to drain.
Refer to Table E-2 and change grease if
necessary.
E–11
 CENTRAL GREASE LUBE SYSTEM OPERATION and MAINTENANCE Operation and Maintenance
Telsmith Jaw Crusher Models 2036 - 5566

NOTES

E–12 04/08 (Rev. 5)