Cedarapids Operation & Maintenance Manual Jaws
May 3, 2017 | Author: Nery Castellanos | Category: N/A
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Operation & Maintenance Manual
JAW CRUSHERS Bolted Bearing Blocks Pull-Type Bearing Sleeves
A Terex Company 22783 (8/02)
A Terex Company
To the Owner & Operator: We have tried to provide information that gives our customers a clear understanding of equipment construction, function, capabilities and requirements. This information is based on the knowledge and experience of qualified people at our company and in our field organization. Proper use of this information rewards users of our equipment with high efficiency, maximum service life and low maintenance costs. That is why we strongly recommend that anyone using our equipment be familiar with this manual. Information presented here should not be considered authoritative in every situation. Users will as a matter of course encounter problems and circumstances that raise questions not anticipated here. Such questions should be directed to their distributor or the factory. Anyone who uses this equipment for any purpose other than that for which it was intended assumes sole responsibility for dangers encountered and injuries sustained as a result of such misuse.
DANGER Federal, state and local safety regulations aim to protect both people and property from accident, injury and harmful exposure. When complied with, such regulations are often effective. Hazards to personnel and property are further reduced when this equipment is used in accordance with all operation and maintenance instructions. Generally: (1) Read and heed all danger, warning, caution, and notice decals. Know what guards and protective devices are included and see that each is installed and in operational condition. Additional guards and protective devices may be required and must be installed by the user (owner) before operating. (2) Never attempt to maintain, lubricate or adjust this equipment while it is running. Lock out and tag out all energy sources before doing maintenance, cleaning, adjusting or repairing this equipment. Make it impossible for anyone to start this machine while others are working on it or in it. (3) Wear personal protective equipment such as hard hats, ear plugs, safety glasses and safety shoes when operating this equipment. Do not wear loose clothing or long hair. (4) Think safety and act safely. Stay alert at all times. Eliminate or neutralize potential hazards as soon as you spot them. Never allow anyone to engage in horseplay when near this equipment.
DANGER Failure to take these precautions will result in death or severe personal injury.
22783 (8/02)
Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers
A Terex Company
The following warning applies to equipment supplied with lead-acid batteries:
WARNING Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling.
22783 (8/02)
Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers
A Terex Company
22783 (8/02)
Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers
Table of Contents
Section 1 - Introduction About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 1
Section 2 - Safety General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 1 Decal Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 3 Personal Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 4 Lockout & Tagout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 5
Section 3 - General Jaw Crusher Information Crusher Description & Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 1 General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 2 Operating Principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 2 Crusher Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 2 Left/Right Side Designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 2 Crusher Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 3 Lifting Crusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 4 Direction of Flywheel Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 4 Crusher Drive Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 4 Maximum & Minimum Crusher Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 5 Capacity of Crusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 5 Crusher Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 6
Section 4 - Set-up & Operation Mounting & Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 1 Mounting Crusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 1 Mounting Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 1 Flywheel Counterweight Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 1 Guarding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 3 Prior To Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 3 Starting Crusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 3 Cold Weather Startup Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 3 During Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 4 Oil Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 4 Stopping Crusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 4 Feeding The Crusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 5 Material Feed Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 5 Clay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 5 Adjusting Closed Side Setting (CSS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 6
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Table of Contents
Section 5 - Lubrication & Maintenance General Lubrication Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 1 Capped Grease Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 2 Grease Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 2 Lubricating Stored Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 3 Bearing Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 3 Grease Lube Labyrinth Seal Crushers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 3 Labyrinth Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 3 Daily Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 3 Changing Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 5 Grease Lube Annular/Labyrinth Seal Crushers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 6 Annular/Labyrinth Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 6 Daily Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 6 Changing Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 7 Oil Lube Annular/Labyrinth Seal Crusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 9 System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 9 Low Oil Flow Alarm System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 11 Annular/Labyrinth Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 12 Daily Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 12 Periodic Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 14 Oil Heater (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 16 Cycle Timer (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 16 Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 18 Maintenance Benchmark Check Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 19 Periodic Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 20
Section 6 - Electrical Standard Drive Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 1
Section 7 - Troubleshooting Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 1 Crusher Not Operating At Rated Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 1 Bearings Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 1 Excessive Jaw Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 2 Difficult to Adjust Closed Side Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 2
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Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers
Table of Contents
Appendix A - Torque Specs Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A - 1 Standard Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A - 1 Metric Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A - 1 Standard Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A - 2 Metric Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A - 3
Appendix B - General Belt Drive Care General Belt Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintaining V-Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Check Belt Tension with Mechanical Tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Belt Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Idlers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inside Idler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Back-Side Idler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kiss Idler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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B-1 B-2 B-4 B-6 B-7 B-7 B-7 B-7
Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers
Table of Contents
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Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers
Introduction
About This Manual
Section 1 - Introduction
Experience has shown it is to your advantage to keep a copy of this manual where operators can consult it as needed and to have a copy on file in your office, so that shift leaders or supervisors can conveniently refer to it. Additional copies can be ordered through your distributor.
About This Manual This book is an operation and maintenance manual for the owner or operator of the equipment described within. We strongly recommend that anyone working with this equipment become familiar with the manual, whether or not you have experience with similar equipment. This manual will help you understand how to install your equipment, prepare it for operation, and perform normal operation and maintenance tasks.
DANGER This manual contains information necessary for proper and safe operation. Carefully read this manual before attempting to operate. Failure to read and heed instructions preceded by a safetyalert symbol can cause death or severe personal injury as well as equipment and environmental damage.
22783 (8/02)
This equipment is precisely engineered, highly functional, and heavy-duty designed to provide years of excellent service performing to customer specifications. We are proud to manufacture this equipment for your use and profit. We also take pride in the quality of our service and replacement parts. This manual, however, is not a parts catalog and should not be used to order parts. Only your Parts Book, identified with your machine’s serial number, is an authoritative source of part numbers and part descriptions for your equipment. Ongoing improvement of product design may in the future result in changes to some parts. Use part numbers, model numbers and serial numbers from your Parts Book to communicate with your distributor.
1-1
Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers
Introduction
About This Manual
22783 (8/02)
1-2
Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers
Safety
General Safety
Section 2 - Safety
Hazard Classification
General Safety This equipment is designed expressly for processing rock and recycling concrete and asphalt. When our equipment is used for purposes other than those for which it was designed, user assumes sole responsibility for any injuries or damage that may result from said misuse. There are many hazards involved in rock processing and in the use of rock-processing equipment. That is why we emphatically recommend that this equipment be operated only by personnel who are trained in its use.
A multi-tier hazard classification system is used to communicate potential personal injury hazards. The following signal words used with the safety alert symbol indicate a specific level of severity of the potential hazard (Figure 2 - 2). Signal words used without the safety alert symbol relate to property damage and protection only. All are used as attention-getting devices throughout this manual as well as on decals and labels fixed to the machinery to assist in potential hazard recognition and prevention.
We make no guarantee, either expressly or by implication, that this equipment meets all local or federal safety regulations. It is the responsibility of those individuals who own and/or operate this machine to verify that all safety regulations are complied with before starting either this unit or any associated equipment.
DANGER
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
WARNING
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.
Safety Alert Symbol The safety alert symbol (Figure 2 - 1) is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.
CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage.
NOTICE
NOTICE indicates information or a company policy that relates directly or indirectly to the safety or protection of property.
Figure 2 - 2 Hazard Classification
Figure 2 - 1 Safety Alert Symbol
22783 (8/02)
CAUTION
2-1
Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers
Safety
General Safety
Decals and Icons Beneath all safety regulations lies a set of commonsense rules. Everyone who works with or near heavy equipment must be aware of those rules. To foster and maintain such an awareness in our customers, safety decals are fixed on our equipment. Icons on our safety decals remind both workers and supervisors of common hazards and procedures that, in the course of a busy day, they might otherwise forget. The language of the icons is simple and direct (Figure 2 - 3).
Place guards around all moving parts on this machine. Never start the machine if those guards are broken or missing. Keep hands, feet, clothes and hair away from moving belts and sheaves.
Wear hearing protection when you’re near this equipment.
Wear respiratory protection when near this equipment. Rock dust is hard on your lungs. Rock chips sometimes come flying out of equipment. Wear goggles or safety glasses near this equipment.
Falling rock is a hazard around any rock-processing operation. Wear your hard hat.
Lockout & Tagout. Equipment may be energized. Lockout and tagout all energy sources prior to performing maintenance or adjustments.
Read all the manuals that shipped with your equipment. Maintenance is done more easily and safely when you know what you’re doing.
Figure 2 - 3 Safety Pictograms Explained
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Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers
Safety
Decal Location
Decal Location
1-16
1-15
04494-104-01
04418-542
1-16
04494-104-01
1-15
04418-542
STAMP SERIAL NO. IN PARENT METAL (SEE P/L 01376EAS)
DANGER
DANGER
ENTANGLEMENT HAZARD
ENTANGLEMENT HAZARD
04490-031
T PELIGRO
EQUIPMEN LOCKED OUT
Keep all guards in place. DANGER
EQUIPMEN LOCKED OUT
Death or serious injury will result.
DANGER
DANGER
LOCKED OUT
DANGER
PELIGRO
T
Keep all guards in place. SWITCH OFF and LOCKOUT & TAGOUT equipment before opening or removing guards. 04490-031
1-8
Do not reach into unguarded machine, you can be pulled in.
NOTE: WIRE TIE DECAL AROUND GROOVED FLYWHEEL. (SEE P/L 05077SBK, DECAL P/N 04490-026).
Death or serious injury will result.
LOCKED OUT
Do not reach into unguarded machine, you can be pulled in.
1-8
SWITCH OFF and LOCKOUT & TAGOUT equipment before opening or removing guards. 04490-031
04490-031
CAUTION EQUIPMENT DAMAGE HAZARD
CAUTION
May cause damage to motor or crusher. Keep crusher pulley free of dust and dirt buildup to avoid shaking of machine.
EQUIPMENT DAMAGE HAZARD
04492-005b
May cause damage to motor or crusher. Keep crusher pulley free of dust and dirt buildup to avoid shaking of machine.
04492-005
1-11
04492-005b
04492-005
1-11 Roller Bearing Crusher Grease Lubrication Jaw, Impact Breaker, Hammermill
Lubricant:
Lithium base, extreme pressure type, grade 1 grease.
Caution:
Over lubrication will result in elevated operating temperatures.
STAMP SERIAL NO. IN PARENT METAL (SEE P/L 01376EAS)
Brand Names: Chevron Dura-Lith EP1 Exxon Lidok EP1 Mobil Mobilux EP1
Shell Alvania EP1 Texaco Multifak EP1
Bearings & Seals: Grease must extrude from the seals at all times to produce an effective dust & moisture seal. Greasing intervals must be established to maintain this visible grease slick. Safety
Refer to Operation & Maintenance Manual for detailed lubrication instructions.
DANGER
04494-100-01a
04494-100-01
04418-955d
Made In United States of America
1-14
OR Roller Bearing Crusher Circulating Oil System
Built under one or more of the following patents:
Great Britain:
Do not reach into unguarded machine, you can be pulled in. Death or serious injury will result. Keep all guards in place.
Safety
Refer to Operation & Maintenance Manual for detailed lubrication instructions.
4493-023
New Zealand: 04494-100-04a
Wear proper eye personal protective equipment.
*
04494-100-04
222,991 - 228,746 - 212,988
Wear proper hearing personal protection equipment.
May cause difficulty in breathing. Wear proper respiratory personal protective equipment.
Read all manuals prior to operation. DO NOT OPERATE equipment if you do not understand the information in the manuals. Consult your supervisor, the owner, or the manufacturer. 04490-103-01
534,673 - 534,674 - 534,675 - 548,832 - 552,227 - 557,149 - 557,477 - 569,405 579,784 - 615,281
1-3 1-4
Other Patents Pending.
04493-023 07073-015
1-10
04490-103-01
DANGER
NOTICE
WARNING
ENTANGLEMENT HAZARD
FALLING MATERIAL May cause death, or severe personal injury. Wear proper head personal protective equipment.
Do not reach into unguarded machine, you can be pulled in. Death or serious injury will result.
FLYING MATERIAL May cause loss or degradation of eye sight.
Keep all guards in place.
Wear proper eye personal protective equipment.
HEARING HAZARD May cause loss or degradation of hearing over a period of time. Wear proper hearing personal protection equipment.
RESPIRATORY HAZARD May cause difficulty in breathing. Wear proper respiratory personal protective equipment.
MENT D EQUIP LOCKE OUT
NOTES: 1. ASSEMBLY IS FOR ALL JAW CRUSHERS. DECAL LOCATIONS AS SHOWN, OR AS CLOSE AS POSSIBLE. 2. ITEMS MARKED * ARE ON PARTS LIST 03042ED (JAW OIL LUBE EMBLEMS).
PELIGRO
Equipment may be energized. Lockout and Tagout all energy sources prior to performing maintenance or adjustments.
DANGER
LOCKOUT & TAGOUT
READ MANUALS DANGER
D
May cause loss or degradation of hearing over a period of time.
RESPIRATORY HAZARD
DANGER
HEARING HAZARD
OUT
Wear proper head personal protective equipment.
MENT D EQUIP LOCKE OUT
May cause death, or severe personal injury.
May cause loss or degradation of eye sight.
Australia:
1-19
NOTICE
WARNING FALLING MATERIAL
FLYING MATERIAL
PELIGRO
ENTANGLEMENT HAZARD
DATE OF MANUFACTURE
2213398 - 2127500
DANGER
CEDAR RAPIDS, IOWA U.S.A.
MODEL NUMBER
9010205
D
DANGER
A Terex Company SERIAL NUMBER
France:
Lubricant: Lithium base, extreme pressure type, grade 2 grease. Grease must extrude from the seals at all times to produce an effective dust & moisture seal. Greasing intervals must be established to maintain this visible grease slick.
DANGER
Seals:
Canada:
OUT
United States: 4,454,994 - 4,477,031 - 4,571,112 - 4,699,326 - 4,717,084 - 4,773,604 - 4,896,838 4,919,348 - 4,919,349 - 4,925,114 - 5,083,714 - 5,111,569 - 5,005,772 - 5,004,169 5,996,916 - 5,312,053 - 5,350,125 - 5,718,390 - 5,875,981 - 5,927,623 - 5,718,391 5,799,886 - 5,803,382 - 5,944,265 - 5,971,306 - 5,810,268 - 6,070,819 - 6,070,820 6,089,481 - 6,126,101 - 6,149,086 - 6,155,507 - 6,161,650 - 6,189,820
1,282,391 - 1,313,170 - 2,015,298 - 2,015,299 - 2,112,946.
LOCKE
Lubricant: Extreme pressure lubricating oil. Fill supply tank with recommended lubricant.
DANGER
04418-955
Crushing & Screening Patents
Pitman & Side Bearings:
Brand Names: Ambient Temperature Guide - (Above 32˚f) [Below 32˚f] Chevron Gear Compound EP (220) [150] Exxon Spartan EP (220) [150] Shell Omala EP (220) [150] Texaco Meropa (220) [150] Mobil Mobilgear (630) [629] Every 1000 hours or seasonally, drain the supply tank and fill with flushing oil. Proceed with flushing operation. See specific instructions in Operations Manual.
LOCKE
1-19
LOCKOUT & TAGOUT Equipment may be energized. Lockout and Tagout all energy sources prior to performing maintenance or adjustments.
READ MANUALS DANGER
Read all manuals prior to operation. DO NOT OPERATE equipment if you do not understand the information in the manuals. Consult your supervisor, the owner, or the manufacturer. 04490-103-01
1-10
04490-103-01
A Terex Company 04418-031y
1-17
22783 (8/02)
04418-031
2-3
Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers
Safety
Personal Safety
Personal Safety
•
Never attempt to clear away jammed feed material, discharge material or other stoppage while the machine is running. Stop the equipment, lock out and tag out before touching this machine with your tools or your hands.
•
Wear proper personal protective equipment, including eye protection, hard hat and safety shoes, whenever you’re near this machine while it is running.
•
Dress appropriately in every way. Never wear loose clothes, long hair, coat tails, jewelry, pockets full of tools or any other item that could get caught in moving parts.
•
Know where your fellow workers are. Always look around and inside this machine before starting it. Make sure nobody is in the way of moving parts or working on the machine.
•
Make sure that everyone working on or near this equipment is familiar with safety precautions. We recommend the following basic safety practices:
Lift with your legs, not with your back. Keep the weight close to your body. If the load is more than 40 lbs., get someone to help you.
•
Never engage in horseplay when near this machine, or any other.
•
Read all danger, warning, caution and notice signs.
•
•
Always lock out and tag out involved energy sources before performing maintenance or adjustments on this equipment. Make it impossible for anyone to start this machine while others work on it or in it.
Report any defective machinery or equipment and unsafe conditions or activity to your boss immediately.
•
Don’t limit safety practices to the few rules listed here. Think safety and act safely at all times.
•
Most of all, know your equipment. Understand the machinery, the conditions under which it operates and what it is capable of doing.
This equipment is designed with the safety of all personnel in mind. Never attempt to change, modify, eliminate or bypass any of the safety devices installed at the factory. Guards, covers and shields installed around moving parts at the factory are meant to prevent accidental injury to operators and other personnel. Do not remove them.
DANGER Sometimes, at a customer’s request, equipment is shipped without certain features such as a drive sheave. When this occurs, we attach a warning decal to alert installers that the related guard or other safety feature is missing. In such cases it is the customer’s responsibility to guard the machine properly.
•
Never remove any guard, cover or shield when this equipment is in motion.
•
Replace guards, covers and shields when the task for which you removed them is finished.
•
Block parts as necessary to prevent their sudden movement while people are working on the machine.
22783 (8/02)
2-4
Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers
Safety
Lockout & Tagout
Work Area Safety •
Keep the work area as neat and clean as practical.
•
Keep all product safety signs clean, clear and current.
•
Make sure all electrical equipment is properly grounded. Wet spots near electrical current are especially dangerous.
•
Store hazardous materials in restricted access areas and mark them clearly. Federal regulations require special labeling of certain materials.
Always use mechanical assistance to lift heavy loads. Never overload a hoist, crane, jack or other lifting device. Check lifting tackle regularly; replace it at the first sign of stretch, fraying or other wear.
•
Keep your equipment clean, free of dirt and grease, so that loose, cracked or broken parts are more easily spotted. Replace defective parts as soon as they are discovered.
Lockout & Tagout Code of Federal Regulations number 1910.147 requires that employers establish and follow a Lockout & Tagout procedure and train their employees in that procedure before any employee can operate, service or maintain any piece of power equipment.
Never start an engine in an enclosed space without properly venting the exhaust.
•
Do not smoke or allow smoking near fuels and solvents. Never strike a spark or use an open flame near fuels and solvents.
•
Store flammable fuels, solvents and gases in secure, well ventilated areas. Never allow fumes to accumulate in the storage area. Use nonflammable solvents for cleaning parts and equipment whenever possible.
•
Know where fire extinguishers and other firesuppression equipment are located. Learn how to use them effectively. Be alert and wary around any pressurized system, hydraulic or pneumatic. High-pressure oils and gases are very dangerous.
To promote safety in its use, we ship a Lockout & Tagout Kit with the equipment. The kit and its contents are illustrated in (Figure 2 - 4).
u t
o
c k
L o
FED ER AL
-
t
g o u
a
T
Keep drive belts and sheaves in good condition. Frayed belts or cracked sheaves are not only dangerous, they cost you downtime.
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Clean tools that are properly labeled and stored are safer tools. Keep your tools in good order.
it
it
K
•
per
tO
No
Employers are required to make periodic inspections to see that their Lockout & Tagout procedures are being followed, and they must monitor and update their program on an ongoing basis. Employees are responsible for seeing that equipment is locked out and tagged out in accordance with the employer’s policy.
Equipment & Tools •
!
ate
Do
•
•
•
Figure 2 - 4 Lockout & Tagout Kit 22783 (8/02)
2-5
Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers
Safety
Lockout & Tagout
What is Lockout & Tagout?
Who must apply a lock & tag?
Lockout & Tagout is a procedure that’s designed to prevent absolutely the unexpected or accidental startup of equipment and to alert all workers whenever it is unsafe to operate any piece of equipment. When used as intended, Lockout & Tagout also protects personnel from energy stored in devices such as springs, accumulators, batteries, hydraulic systems, etc.
•
Any person working on the equipment.
•
Foreman or other person responsible for the work being done.
•
If several people are working on a machine at the same time, each person must apply his or her own lock and tag.
When can a lock and tag be removed? How to Lockout & Tagout
After performing these six steps:
•
Install one or more locks to hold the master switch lever in the OFF position.
1) All safety guards are back in place.
If the switch is keyed, turn the key to the OFF position and remove the key.
3) All workers are notified that a lock is being removed.
•
Disconnect the batteries.
5) Controls are positioned for safe startup.
•
Regardless of which lockout method is used, place one or more tags on machine control panels, access doors and electrical panels.
6) The machine is ready for safe operation.
•
2) All work is complete and tools are put away.
4) All workers are positioned safely for startup.
•
When is Lockout & Tagout required? •
Any time anyone is maintaining, repairing, lubricating, or, for whatever reason, working on the equipment.
•
When the equipment is broken or, for whatever reason, unfit or unsafe to operate.
•
Whenever the equipment is left unattended.
22783 (8/02)
Who can remove a lock and tag? Only the person who applied a lock and tag is permitted to remove them.
Lockout & Tagout rules laid out here are generic. To get instructions for your particular workplace, consult your employer’s lockout/tagout procedure.
2-6
Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers
General Jaw Crusher Information
Crusher Description & Information
Section 3 - General Jaw Crusher Information 1
Crusher Description & Information
2
3
4
5
6
7
18
17
16
15
14 1 - Pitman 2 - Pitman bearing 3 - Side bearing 4 - Eccentric shaft 5 - Key plate 6 - Base
13
12
11
10
7 - Stationary jaw 8 - Movable jaw 9 - Toggle seat 10 - Toggle plate 11 - Toggle seat base 12 - Hydraulic ram
9
8 13 - Tension spring 14 - Tension spring collar 15 - Hand pump 16 - Tension rods 17 - Shims 18 - Shim cover
Figure 3 - 1 Jaw Crusher Parts
22783 (8/02)
3-1
Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers
General Jaw Crusher Information
Crusher Description & Information
General Description Cedarapids roller bearing jaw crushers are used both as primary and secondary crushers depending on the size of the material to be crushed. They will break rock down to the size specified in one operation or to a size that can be further reduced by a secondary crusher such as a rollercone or a smaller jaw crusher. These crushers are made of welded type construction and can be used in either a stationary or portable plant. The jaw crusher consists of two readily separable subassemblies; the base assembly and the shaft and pitman assembly. Refer to Figure 3 - 1. The base assembly consists of the crusher base, stationary jaw, key plates and adjusting mechanism. The shaft and pitman assembly is composed of the moving parts of the crusher; the eccentric shaft, pitman, movable jaw, side and pitman bearings, side bearing housings, all bearing seals and spacers and the two flywheels.
diminishes between the top and the bottom of the movable jaw, producing a long primary crushing stroke at the top of the jaw and a short stroke for crushing to a more uniform size at the bottom. Crusher Sizes Jaw crusher size refers to the opening at the top of the crusher. This opening is rectangular and is measured from the top of the movable jaw (A) to the top of the stationary jaw (B), and from side key plates (C) to opposite side key plate (D) (Figure 3 2). For example: a Model 3042 jaw crusher has an intake opening of 30 inches (762 mm) between jaws (A) to (B) and 42 inches (1067 mm) between key plates (C) to (D). The dimensions will vary slightly due to the casting tolerances of jaws and key plates. B
Operating Principle
D
The stationary jaw is wedged in place in the base by the key plates and the movable jaw, which is attached to the pitman. The pitman is mounted on roller bearings on the eccentric portion of the crusher shaft, the concentric ends of which are mounted in housed roller bearings rigidly attached to the crusher base. The lower end of the pitman is hinged on one end of the toggle plate; the other end of the toggle plate oscillates in a groove in the toggle bearing wedge, which is attached to the crusher base. The replaceable cast iron toggle plate serves as a fuse or safety device in the crusher, as it will break when uncrushable material such as a shovel tooth passes between the jaws. Due to the eccentric shaft and the toggle plate, a combination crushing and downward motion is imparted to the pitman and movable jaw as the shaft is revolved. The horizontal length of the crushing motion gradually 22783 (8/02)
C
A
LEFT SIDE
RIGHT SIDE
Figure 3 - 2 Jaw Crusher Opening
Left/Right Side Designation Right and left side of crusher are determined when standing facing the tension springs (Figure 3 - 2).
3-2
Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers
General Jaw Crusher Information
Crusher Description & Information
Crusher Weights The approximate weights listed in Table 3 - 1 are based on clean new standard components. Weights may vary and listed weights should be considered only an approximation.
Model
Complete Crusher (Base, Pitman Assy, & Flywheels)
Pitman Assembly (Pitman Assy & Flywheels)
Flywheel Only (Each)
lbs
kg
lbs
kg
lbs
kg
1016
5,306
2,406
2,844
1,293
690
314
1024
8,255
3,752
4,817
2,190
1,275
580
1036
12,551
5,705
7,449
3,386
1,223
556
1236
13,978
6,354
8,007
3,640
1,250
568
1242
19,521
8,873
12,120
5,509
2,098
954
1248
24,300
11,045
14,374
6,534
2,175
989
1524
12,305
5,593
6,771
3,078
1,215
552
1636
21,003
9,547
11,895
54,07
2,075
943
1642
33,998
15,454
19,642
8,928
2,741
1,246
1648
32,406
14,730
16,988
7,722
2,684
1,220
1824
12,426
5,648
6,771
3,078
1,215
552
1836
21,280
9,673
12,105
5,502
2,126
966
2236
24,903
11,320
14,266
6,485
2,785
1,266
2248
43,094
19,588
25,746
11,703
3,700
1,682
2436
46,737
21,244
22,861
10,391
3,462
1,574
2438
26,017
11,826
14,501
6,591
2,873
1,306
2540
45,000
20,455
18,950
8,614
4,200
1,909
2542
42,095
19,134
21,832
9,924
3,584
1,629
2742
48,520
22,055
25,842
11,746
4,194
1,906
3042
48,520
22,055
25,842
11,746
4,194
1,906
3054
52,740
23,973
27,525
12,511
4,194
1,906
3242
57,137
25,971
28,755
13,070
4,028
1,831
3648
79,653
36,206
39,524
17,965
5,560
2,527
3660
107,664
48,938
58,478
26,581
5,595
2,543
4242
58,838
26,745
28,755
13,070
4,028
1,831
4248
104,567
47,530
52,827
24,012
5,595
2,543
5460
196,258
89,208
102,715
46,689
10,570
4,805
5748
117,000
53,182
52,827
24,012
5,595
2,543
Table 3 - 1 Approximate Crusher and Component Weights
22783 (8/02)
3-3
Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers
General Jaw Crusher Information
Crusher Description & Information
Lifting Crusher
Crusher Drive Speed
To lift crusher, always fasten chain or cable to crusher base. Never lift complete crusher with cables attached to flywheels or pitman. If only pitman, shaft and bearing assembly is to be removed from crusher base, fasten chain or cable to lifting lugs provided on top of pitman housing.
The correct speed of the crusher will be stamped into the crusher base (Figure 3 - 3). Correct speed is one of the basic requirements to obtain maximum capacities with minimum wear.
Direction of Flywheel Rotation The overhead eccentric force feed jaw crusher are designed to have the shaft assembly with flywheel rotate downward and toward the crushing chamber. Standing on the left side of the crusher, the flywheels will be rotating in a counterclockwise direction (Figure 3 - 3). Right and left hand are determined when facing the tension spring.
Always maintain speed of the crusher according to the factory recommendations. Crushers are designed to run at a certain speed with a specific flywheel and counterweight configuration. Changing speed will change the flywheel and counterweight requirements. Consult factory if operating speed will vary more than +/- 25 rpm from the speed marked on the crusher.
CAUTION Operating with incorrect speeds and flywheels can increase compaction in the crusher and lead to premature shaft and bearing failure.
SPEED
Figure 3 - 3 Direction of Flywheel Rotation
22783 (8/02)
3-4
Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers
General Jaw Crusher Information
Crusher Description & Information
Maximum & Minimum Crusher Settings
Capacity of Crusher
Cedarapids has established limits for the discharge opening of each crusher. For safe and efficient operation, the following maximum and minimum openings should govern crushing extremes. Refer to Table 3 - 2.
Crusher capacity is measure both by the size of material that can be fed into the crusher and throughput of the crusher. In general, the maximum feed size for jaw crushers is 80% of the jaw opening in sand and gravel applications and 90% of the jaw opening in quarry applications. For example, a 3042 crusher with a jaw opening of 30” by 42” will have a maximum feed size of 24” by 33.6” in sand and gravel applications and 27” by 37.8” in quarry applications. These are general guidelines and may vary in certain applications.
Minimum
Maximum
Size inches
mm
inches
mm
1016
3/4
19
3 1/2
89
1020
3/4
19
3 1/2
89
1024
3/4
19
3 1/2
89
1036
1 1/2
38
3 1/2
89
1236
1 1/2
38
5
127
1242
1 1/2
38
5
127
1248
1 1/2
38
5
127
1524
1 1/2
38
5
127
1636
1 1/2
38
5
127
1642
1 1/2
38
5
127
1648
1 1/2
38
5
127
1824
1 1/2
38
5
127
1836
1 1/2
38
5
127
2236
2 1/2
64
6
152
2248
2 1/2
64
6
152
2436
2 1/2
64
6
152
2438
4 1/2
114
8
203
2542
3 1/2
89
10
254
2742
3 1/2
89
10
254
3042
4
102
13
330
3054
3 1/2
89
13
330
3242
4
102
13
330
3648
4
102
13
330
3660
4
102
13
330
4242
14
356
23
584
4248
4
102
13
330
5460
6
152
20
508
5748
19
483
28
711
Crusher throughput capacities are based on average conditions and will vary widely with different types of rock and stone, uniformity of feed and moisture content of material being crushed. Crusher throughput and gradation information is available by contacting your Cedarapids distributor.
Table 3 - 2 Closed Stroke Setting Limits
22783 (8/02)
3-5
Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers
General Jaw Crusher Information
Crusher Description & Information
Crusher Dimensions
F
C E
D
A B
H
G
Tension Spring Location on 1016 & 1020
Model
1016
1020
1024
1036
1236
1242
1248
1524
1636
1642
1648
1824
1836
2236
A
40 1015
48 1220
45 1145
48 1220
48 1220
56 1420
59 1500
55 1395
61 1550
71 1800
66 1675
56 1420
64 1625
65 1650
B
– –
– –
– –
– –
– –
– –
– –
– –
– –
73 1855
– –
– –
– –
– –
C
41 1040
46 1170
46 1170
46 1170
51 1295
55 1395
56 1420
57 1445
63 1600
76 1930
70 1780
57 1445
63 1600
77 1955
D
24 610
28 710
28 710
28 710
32 810
33 840
35 890
36 915
41 1040
46 1170
41 1040
36 915
41 1040
48 1220
E
26 660
28 710
28 710
28 710
33 840
34 865
35 890
39 990
42 1065
48 1220
42 1065
39 990
42 1065
49 1245
F
58 1470
72 1830
72 1830
81 2055
81 2055
98 2490
104 2640
67 1700
92 2335
99 2515
94 2385
77 1955
92 2335
92 2335
G
22 560
26 660
27 685
41 1040
41 1040
47 1195
53 1345
27 685
41 1040
47 1195
53 1345
27 685
41 1040
43 1090
H
14 355
14 355
21 535
18 455
19 480
20 510
19 480
18 455
16 405
20 510
16 405
19 480
16 405
17 430
Model
2248
2436
2438
2542
2742
3042
3054
3242
3648
3660
4242
4248
5748
5460
A
79 2005
88 2235
67 1700
82 2080
88 2235
88 2235
88 2235
93 2360
107 2715
118 2995
103 2615
123 3125
138 3505
149 3785
B
81 2055
91 2310
– –
85 2160
88 2235
91 2311
91 2311
99 2515
113 2870
– –
109 2770
126 3200
141 3580
152 3860
C
83 2110
89 2260
77 1955
93 2360
92 2337
92 2337
92 2337
105 2665
120 3050
125 3175
105 2665
137 3480
137 3480
172 4370
D
52 1320
61 1550
50 1270
63 1600
62 1575
62 1575
63 1600
75 1905
82 2080
86 2185
75 1905
96 2440
96 2440
127 3225
E
54 1370
61 1550
49 1245
65 1650
64 1626
64 1626
64 1626
77 1955
84 2135
88 2235
77 1955
101 2565
101 2565
130 3300
F
99 2515
94 2385
92 2335
95 2415
99 2515
99 2515
110 2795
99 2515
101 2565
119 3025
99 2515
120 3050
120 3050
140 3555
G
53 1345
43 1090
43 1090
45 1145
47 1195
47 1195
69 1755
47 1195
52 1320
78 1980
47 1195
55 1395
55 1395
67 1700
H
16 405
17 430
18 455
19 480
17 430
17 430
20 510
22 560
20 510
28 711
22 56 0
20 510
20 510
18 455
Figure 3 - 4 Crusher Dimensions to nearest inch and mm 22783 (8/02)
3-6
Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers
Set-up & Operation
Mounting & Set-up
Section 4 - Set-up & Operation
The crusher must be perfectly level across the length of the shaft (side-to-side) to maintain even load on all the bearings and ensure proper lubrication of the bearings.
Mounting & Set-up The jaw crusher may be installed on a portable plant or as a component for installation in a stationary plant or customer supplied portable plant. Mounting a jaw crusher requires careful planning to ensure: •
mounting structure is capable of supporting the weight and forces generated by an operating jaw crusher.
•
adequate clearance has been left around the crusher to allow safe operation without interference.
Mounting Clearance Adequate clearances must be maintained above the crusher for feeding material into it as well as facilitate maintenance of the crusher. Likewise, adequate clearance must be below the crusher to allow for material to exit the crusher without buildup. Flywheel Counterweight Installation
•
crusher flywheel and drive are appropriately guarded to prevent access during operation.
•
provisions are made allowing the power source to be locked out and tagged out.
•
guard rails and walkways are installed where necessary.
•
a means of feeding material to the crusher and removing crushed material from under the crusher are provided.
Normal flywheel counterweight location when the crusher is at rest, is indexed approximately 30° toward the crushing chamber from top dead center (12 o’clock) position. It is very important that counterweights on one flywheel be directly across from the counterweights on the other flywheel. (Figure 4 - 1) Incorrect flywheel counterweight positioning will cause the crusher to vibrate excessively. Flywheel with Counterweights
Mounting Crusher All foundations and crusher supports must be designed by a qualified engineer to meet local code requirements. Information needed to design the crusher foundation or support may be obtained from Cedarapids. When installing crusher in a stationary plant, place on an adequately designed foundation. There must be ample clearance maintained between crusher discharge and receiving conveyor for the material to discharge without rubbing end of pitman. Consideration for overhead clearance must also be made should removal of the pitman become necessary. 22783 (8/02)
4-1
Figure 4 - 1 Flywheel Counterweight Installation
Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers
Set-up & Operation
Mounting Crusher
Guarding It is the responsibility of the equipment owner and operators to ensure that adequate guarding is designed and built. The following are situations that should be considered when installing a jaw crusher. Each installation is unique with special hazards that must be considered and guarded. The entire installation should be reviewed by a qualified safety engineer before operation begins. •
The drive system from the drive shaft on the power unit to the flywheels on the crusher should be guarded to prevent access during operation. This includes the v-belts and both flywheels.
•
The power unit must provide a means to disengage the power source and install a lock and hasp to prevent accidental starting of the crusher. This could include accidental starting of the engine if a wrench falls onto the starter or start switch.
•
The area between the crusher and feeder should be guarded to prevent access during operation.
•
Any conveyor, feeder or other equipment that is overhead or accessible by workers while the crusher is operating must be guarded to prevent any worker from contacting moving parts. This equipment must also be guarded to prevent material from dropping off the equipment and hitting a worker.
•
Guarding, handrails and walkways must be designed and operated in compliance with all current applicable OSHA, MSHA, National Electric Code (NEC), federal, state, and local regulations.
22783 (8/02)
4-2
Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers
Set-up & Operation
Operation
Operation
B) Control valves regulate the oil flow to the bearings. Flow to each bearing is controlled independently.
Prior To Starting Perform all daily and periodic lubrication and maintenance tasks listed in Section 5.
C) Fully open all valves. Brass indicators in the flow indicator tubes will rise to their highest points in the tubes.
WARNING
D) Allow the crusher to run until the oil is warmed up.
Shut down, lock out and tag out all drives, power sources, and electric power panels prior to performing any maintenance.
E) Partially close the valves until all the indicators are at the same level.
Starting Crusher
4) Start or engage crusher drive.
Grease Lube Systems
5) Allow the crusher to run empty for a few minutes.
1) Start or engage crusher drive. 6) Start under-crusher conveyor. 2) Allow the crusher to run empty for a few minutes until the lubricant is warmed up.
7) Start feeder.
3) Start under-crusher conveyor.
Cold Weather Startup Notes
4) Start feeder. Oil Lube Systems
•
Allow the crusher extra time to run empty to ensure the lubricant is warmed.
•
If the crusher is hard to start, change to lighter lubricant. Refer to lubrication instructions for more information.
1) If the crusher is equipped with the optional oil lubrication system with oil reservoir heaters, turn on heaters and allow oil to warm to operating temperature. 2) If the crusher is equipped with the optional oil lubrication system with optional cycle timer, switch the Day-Night switch to Day. 3) If the crusher is equipped with the optional oil lubrication system operate as follows. A) Start oil lubrication pump.
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4-3
Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers
Set-up & Operation
Operation
During Operation
Stopping Crusher
Throughout the daily operating period the operator should check for unusual sounds or other signs of abnormal operation that warn of future trouble if not promptly corrected. •
•
•
Check crusher bearings for the appearance of overheating. Do not operate crusher if bearings overheat until the cause is determined and corrected. Ensure tension springs are tight enough to keep the toggle plate from clattering when the crusher is running empty. After changing the crusher discharge opening or replacing the toggle plate listen for a clattering or pounding noise, indicating the tension springs are too loose. Adjust tension springs before resuming operation.
1) Stop the feed to the crusher. 2) Allow the material in crusher to be fully crushed and empty out the crushing chamber. 3) Shut off the power to the crusher drive. 4) Shut off the power to the under-crusher conveyor.
Observe the stationary jaw for slight up and down movement. If such movement is visible, tighten the key plates. If crusher is operated with loose key plates, the resulting movement of the stationary jaw will cause unnecessary wear on the jaw and base as well as reduce the capacity of the crusher.
CAUTION Avoid stopping the crusher when the jaws are full of material. Restarting the loaded crusher produces an excessive load on the power unit and an extreme pull on the belts. A plugged crusher should be at least partially emptied by hand before restarting.
Oil Lubrication System •
Periodically check the level of the flow indicators. If the level falls in any of the tubes, it could be a sign of bearing problems or clogged filters.
•
The filter gauge shows the pressure in the feed line to the filter. Readings will vary with ambient temperature, type of lubricant, operating temperature, etc.
•
The suction gauge will normally show little or no reading.
22783 (8/02)
4-4
Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers
Set-up & Operation
Feeding The Crusher
Feeding The Crusher The most efficient operation of the crusher results when the crushing chamber is kept full of material and when a uniform method of feeding is used. The crusher should be kept full of material however, material should not be allowed to build up above the tops of the jaws.
In general, the maximum feed size for jaw crushers is 80% of the jaw opening in sand and gravel applications and 90% of the jaw opening in quarry applications. For example, a 3042 crusher with a jaw opening of 30” by 42” will have a maximum feed size of 24” by 33.6” in sand and gravel applications and 27” by 37.8” in quarry applications. These are general guidelines and may vary in certain applications.
CAUTION DANGER
Allowing material to build up to the pitman during crushing could damage the pitman. Do not allow material to build up higher than the tops of the jaw dies.
Do not use explosives in crusher chamber. The crushing chamber is not designed to withstand the forces generated by explosives. Explosives can cause premature failure of bearings and breakage of the pitman, eccentric shaft and base.
Material Feed Size Material typically found in sand and gravel operations has rounded corners. Shot material typically found in quarry operations tends to be more cubical with square corners. Rounded material requires a smaller nip angle so the jaws can grab and crush the material. Material that is not grabbed by the jaws will slide up and down as the jaws open and close. This wears the jaws without producing product. This material should be removed from the crusher and broken up before attempting to crush again. A rock breaker can be installed that will allow material to be broken up in the crusher or feeder.
CAUTION Always turn off the crusher and feeder before using a rock breaker.
WARNING Running the crusher with oversized or uncrushable material sliding on the top of the pitman can damage the pitman. Shut down and remove oversized material. Clay Clay tends to build up in the corrugations of the jaw. This reduces jaw capacity and could damage the crusher. When crushing material containing clay, the crusher should be stopped periodically and clay should be cleaned from the jaw corrugations. Material containing heavy clay should be scalped to remove clay before feeding into the jaw crusher.
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4-5
Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers
Set-up & Operation
Adjusting Closed Side Setting (CSS)
Adjusting Closed Side Setting (CSS) The crusher discharge opening governs the size of finished material produced by the crusher.The size of the crusher discharge opening is changed by adding or removing shims from behind the toggle seat base. The opening is reduced by moving the base toggle seat forward with the hydraulic mechanism and shimming behind the seat. Refer to Figure 4 - 3. Adjust as follows:
2) Some crushers are equipped with toggle plate base wedges which lock the toggle plate base during operation. This prevents any rocking movement of the base during operation, reducing wear on the toggle seat insert and on the end of the toggle plate. If your crusher is equipped with toggle plate base wedges, perform the following steps. Refer to Figure 4 - 2.
Slot (for loosening wedge)
5) Attach hydraulic pump to ram(s).
Toggle Plate Base
6) Make a wooden spacer similar to that shown in Figure 4 - 3, to the exact thickness of the correct discharge opening. When lumber of proper width or thickness is not available, make up a lamination, including plywood, hard fibre board, or metal to obtain the correct thickness. Spacer must be wide enough to bridge between several jaw plate tips as shown in Figure 4 - 3. This is especially important when the desired setting is close to the minimum closed side setting of the crusher. Adding a handle to spacer block will make it easier to properly position at the bottom of the jaws.
Support
Figure 4 - 2 Toggle Plate Base Wedge
A) When the crusher opening is to be adjusted, loosen the four wedge tightening locknuts (2 per side) at the sides of the crusher base. Loosen 1/2 inch. 22783 (8/02)
3) Loosen tension spring nuts so that shim pack can be adjusted. 4) Install hydraulic rams to push toggle seat forward. Some crushers have two mounts near the bottom of the crusher used to adjust the crusher and a single mount around the midpoint of the pitman used to push the pitman forward when installing a toggle plate. Always install the rams in the lower holes when adjusting the closed side setting. Refer to Figure 4 - 3.
1) When the crushing chamber is completely empty, stop the jaw crusher drive and lock out the power source.
Wedge
B) Insert a bar through the hole in each side of the crusher base side plate and through a slot in each of the support angles, to contact the wedges. Hit the bar with a sledge until wedge is loose and the toggle plate base is free to move.
7) Rotate and hold the flywheel so that the eccentric shaft closes the jaws as much as possible. Using a ratcheting cable puller (come-along) will make it easier to rotate and hold the flywheel in the desired position.
4-6
Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers
Set-up & Operation
Adjusting Closed Side Setting (CSS)
8) Hold the wood spacer as shown in Figure 4 - 3 so that it is centered in the crushing chamber and extends below the jaws.
DANGER Never run the crusher while holding anything in the crushing chamber. Doing so could result in serious injury or death.
11) Tighten all wedge bolt locknuts. This draws the support angles up tight against the ends of the toggle seat to prevent any movement. After the next day of crusher operation, retighten all wedge bolt locknuts. 12) Remove hydraulic pump and rams from crusher.
WARNING Failure to remove hydraulic rams before operating crusher could result in serious personal injury and/or damage to the equipment.
9) To change jaw opening, A) Close valve on hydraulic pump. B) Pump up rams to push toggle plate base forward relieving pressure on shims. C) If decreasing closed side setting, pump hydraulic pump until jaw is tight against wood spacer.
WARNING A failure of the hydraulic system while adding or removing shims from the shim pack could result in serious personal injury. Keep hands and fingers clear of shims when adjusting crusher. Use a tool to pull shims out of shim pack. D) Add shims as needed to achieve desired jaw spacing. E) To increase closed side setting, force jaw forward, remove several shims and proceed with step C. 10) Tighten tension spring nuts to restore holding force on toggle plate.
22783 (8/02)
4-7
Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers
Set-up & Operation
Adjusting Closed Side Setting (CSS)
Racheting Cable Puller
Pitman Eccentric Rotated To Minimum Jaw Opening
Hydraulic Ram Toggle Plate Change Position
Shims Hydraulic Ram Adjusting CSS Position Toggle Plate Base
Handle
Toggle Plate Base Wedge
Tension Spring Nuts
Laminated Spacer Same Thickness As Desired CSS
Spacer Must Span Several Corrugations Figure 4 - 3 Setting closed side setting
22783 (8/02)
4-8
Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers
Lubrication & Maintenance
General Lubrication Information
Section 5 - Lubrication & Maintenance
Side Bearing
General Lubrication Information
Seal
Cedarapids has built crushers using three possible lubrication/seal configurations. It is important to know which type of seal and lubrication your crusher uses. The three configurations are: 1) Grease lubrication with a labyrinth seal (Figure 5 - 1). 2) Grease lubrication with an annular/labyrinth seal (Figure 5 - 2). 3) Oil lubrication with an annular/labyrinth seal (Figure 5 - 2). The differences between these configurations will be explained in depth later in this section. Most current production jaw crushers use the annular/ labyrinth seal configuration with grease or oil lubrication.
Figure 5 - 2 Annular/labyrinth seal grease or oil design
WARNING Side Bearing
Never attempt to lubricate or maintain the crusher until flywheels are stopped and drive is locked out.
Seal
The greatest single factor governing the life and efficiency of any piece of machinery, where friction is encountered, is proper and intelligent lubrication. While it is generally known that insufficient lubrication will enable friction to reduce the efficiency and service life of key parts, it is also true that the presence of too large a quantity of grease in a bearing housing usually results in high operating temperatures and subsequent loss of efficiency.
Figure 5 - 1 Labyrinth seal grease lube design
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5-1
Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers
Lubrication & Maintenance
General Lubrication Information
Cleanliness in the handling of lubricants, fittings, grease guns and the openings and plugs of housings is of vital importance. Foreign substances contaminate lubricant. Be sure that all fittings and openings are thoroughly cleaned of all foreign substances before starting to inject lubricant. In using the grease gun always see that the gun makes proper contact with the cleaned fittings and that the nozzle has not been allowed to touch unclean surfaces.
Grease Capacities Table 5 - 1 lists amount of grease required to completely drain and refill each bearing housing with grease. Add 20% to the quantity listed when refilling after overhauling the crusher.
NOTICE Never mix different types of lubricant within the crusher. Always drain and flush out old lubricant before changing to a different brand, as chemical breakdown can occur in lubricant mixtures. Capped Grease Fittings A special type grease fitting with screw-on metal cap is used on all crushers. This type of fitting not only makes complete protection of the grease entrance point possible, the tight fitting cap also prevents grease from being squeezed back out of the crusher by internal pressure. Always keep the metal cap screwed down tight after each greasing (Figure 5 - 3). Install Cap After Greasing
Side Bearing (each)
Pitman Bearings
lbs
kg
lbs
kg
1016
2
0.9
4
1.8
1020
2
0.9
5
2.3
1024
2
0.9
8
3.6
1036
2
0.9
14
6.4
1236
2
0.9
18
8.2
1242
4
1.8
27
12.3
1248
4
1.8
32
14.5
1524
3
1.4
8
3.6
1536
6
2.7
25
11.4
1636
6
2.7
25
11.4
1642
10
4.5
48
21.8
1648
9
4.1
38
17.3
1824
3
1.4
8
3.6
1836
6
2.7
25
11.4
2236
4
1.8
23
10.5
2248
8
3.6
55
25.0
2436
12
5.5
29
13.2
2442
7
3.2
33
15.0
2540
7
3.2
33
15.0
2640
10
4.5
48
21.8
2742
10
4.5
47
21.4
3040
10
4.5
48
21.8
3042
10
4.5
48
21.8
3054
10
4.5
48
21.8
3242
10
4.5
48
21.8
3648
12
5.5
64
29.1
4242
10
4.5
48
21.8
4248
9
4.1
51
23.2
5460
31
14.1
158
71.8
5748
9
4.1
51
23.2
Table 5 - 1 Crusher grease capacities
Figure 5 - 3 Typical capped grease fitting 22783 (8/02)
Crusher Size
5-2
Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers
Lubrication & Maintenance
Grease Lube Labyrinth Seal Crushers
Grease Lube Labyrinth Seal Crushers
Lubricating Stored Equipment Idle equipment whether new or used; must be turned over at least every 30 days either by power or hand to redistribute the lubricant. Rotating the bearing assemblies periodically redistributes lubricant on all surfaces of the bearing. Failure to rotate bearings when crusher is idle will permit lubricant to drain to the bottom of the bearing assembly. Moisture from condensation could collect and set up a chemical reaction in the bearing assemblies know as corrosive staining. These stained areas are a positive point for premature bearing failures, as flaking will start at these points when the equipment is put back into operation.
Labyrinth Seals Labyrinth seals are designed with a series of interlocking passages that block dirt from getting into the bearings (Figure 5 - 4). As the crusher runs, grease works its way through the labyrinth passages pushing dirt out of the seal. This causes a film of grease to constantly build up around the outside of the seal. This film helps keep dirt and moisture out of the seal and should be allowed to build up. Grease film forms outside of seal.
Bearing Temperature Normal operating bearing temperature should be 100° to 150°F (38° to 66°C) but in warm climates may reach 180° to 200°F (82° to 93°C). Excessive heat in the bearings may indicate the presence of foreign material between the fixed and rotating seals, and it is recommended that grease be injected into the bearings through the lubrication fittings to force the foreign material out and reduce heat generation. The reduction of temperature in the bearing will be slow because heat will continue to exist until the internal pressure inside the housing forces out the excess lubricant. If the crusher stops, back up the shaft assembly one-half a revolution to see if foreign material has been expelled. Repeat process until shaft assembly turns over easily; if the grease seals do not break loose,” then a complete overhaul is the only solution.
22783 (8/02)
Figure 5 - 4 Labyrinth seal
Daily Lubrication Grease should be added to one grease fitting on each side bearing and one on the center of the pitman (Figure 5 - 5). If the bearing is properly lubricated, a fresh film of grease will be present around the edge of the inner and outer seals of each bearing. As the bearings and grease seals become worn, more lubricant will be extruded from the seals. More frequent greasing may be required to maintain a film of grease around the outside of the seals.
5-3
Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers
Lubrication & Maintenance
Grease Lube Labyrinth Seal Crushers Lubricate with a lithium base, extreme pressure, Grade 1 grease.
Typical brand names are: Chevron Dura-Lith EP1, Exxon Lidok EP1, Mobil Mobilux EP1, Shell Alvania EP1, Texaco Multifak EP1.
1
2 4
Side Bearing 1 Pitman Bearing
3
4 2 1 - Pitman grease fitting 2 - Pitman magnetic drain plug
3 - Side bearing grease fitting 4 - Side bearing magnetic drain plug
Figure 5 - 5 Grease lubrication points
22783 (8/02)
5-4
Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers
Lubrication & Maintenance
Grease Lube Labyrinth Seal Crushers Changing Lubricant
CAUTION
Under normal conditions, it is recommended that grease be changed every 1000 hours of actual crushing or once each year, whichever occurs first.
Failure to thoroughly clean drain plugs and fittings before installation could cause grease contamination. Grease must be kept clean to prevent damage to bearings.
1) Before changing lubricant, run crusher long enough to heat the existing lubricant to a consistency that allows it to flow freely. 2) Clean area around drain plugs and grease fittings then remove plugs and fittings to drain free flowing lubricant. Refer to Figure 5 - 5. 3) Replace drain plugs and inject flushing oil in each bearing to fill pitman barrel and base housing to top of fill hole. An extreme pressure 150 viscosity, Grade 46 flushing oil should be used. 4) Replace the grease fittings. 5) Run the crusher empty for at least 10 minutes. 6) Stop unit and remove drain plugs to drain flushing oil.
NOTICE Running crusher slowly while draining flushing oil will expedite the draining. 7) Thoroughly clean and replace the magnetic drain plugs and inject a recommended grease in each bearing. 8) Replace and tighten the grease fittings and fitting caps.
22783 (8/02)
9) Refill bearing housing with grease. In determining the amount of grease to be used be governed by the fact that a pint of grease weighs slightly less than one pound. It is recommended in a complete overhaul, that 20% more lubricant be added in both of the side bearings and in the pitman. When starting a new crusher for the first time, or after an overhaul, apply a liberal amount of gear lube to the area between the pitman and side bearing seals. Apply oil until grease inside bearing begins to extrude from the grease seals. This precautionary measure insures lubrication until the actual lubricating system begins to function. A crusher which has been idle for a period of time and exposed to the weather should receive the same consideration. At the end of a season’s operation it is recommended that the lubricant be drained, flushed and new lubricant be injected into the housing. The crusher should be operated without load for approximately one hour to permit new lubricant to be evenly distributed in the bearing assembly and housing. New lubricant in the housing would tend to eliminate the possibility of corrosive reactions which might be evident if worked” and oxidized” lubricant is allowed to remain in the housing when the crusher is not in use for long periods of time.
5-5
Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers
Lubrication & Maintenance
Grease Lube Annular/Labyrinth Seal Crushers
Grease Lube Annular/Labyrinth Seal Crushers Annular/Labyrinth Seals Annular/labyrinth seals are designed with a series of annular rings and a labyrinth passage (Figure 5 6). Clean grease is pumped into the seal fitting on the outer side bearing seal. All other seals are lubricated with grease that works into the seal from the bearing. As the crusher runs, grease works its way through the labyrinth passage pushing dirt out of the seal. This causes a film of grease to constantly build up around the outside of the seal. This film helps keep dirt and moisture out of the seal and should be allowed to build up. Grease also works its way into the annular rings where it creates a barrier to dirt and moisture entering the bearing.
lubricated, a fresh film of grease will be present around the edge of the inner and outer seals of each bearing. As the bearings and grease seals become worn, more lubricant will be extruded from the seals. More frequent greasing may be required to maintain a film of grease around the outside of the seals. Lubricate with a lithium base, extreme pressure, Grade 1 grease. Typical brand names are: Chevron Dura-Lith EP1, Exxon Lidok EP1, Mobil Mobilux EP1, Shell Alvania EP1, Texaco Multifak EP1.
Grease film forms outside of seal. Labyrinth
Annular Rings Figure 5 - 6 Annular/labyrinth seal
Daily Lubrication Grease should be added to one grease fitting on each of the four bearings and one on each outer side bearing seal (Figure 5 - 7). If the bearing is properly 22783 (8/02)
5-6
Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers
Lubrication & Maintenance
Grease Lube Annular/Labyrinth Seal Crushers
2 4
1
3
Pitman Bearing
5
Side Bearing
4 2 1 - Pitman bearing grease fitting 2 - Pitman magnetic drain plug 3 - Side bearing grease fitting
4 - Side bearing magnetic drain plug 5 - Side bearing outer seal grease fitting
Figure 5 - 7 Grease lubrication points
Changing Lubricant Under normal conditions, it is recommended that grease be changed every 1000 hours of actual crushing or once each year, whichever occurs first.
22783 (8/02)
1) Before changing lubricant, run crusher long enough to heat the existing lubricant to a consistency that allows it to flow freely. 2) Clean area around drain plugs and grease fittings then remove plugs and fittings to drain free flowing lubricant. Refer to Figure 5 - 7.
5-7
Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers
Lubrication & Maintenance
Grease Lube Annular/Labyrinth Seal Crushers 3) Replace drain plugs and inject flushing oil in each bearing to fill pitman barrel and base housing to top of fill hole. An extreme pressure 150 viscosity, Grade 46 flushing oil should be used. 4) Replace the grease fittings. 5) Run the crusher empty for at least 10 minutes. 6) Stop unit and remove drain plugs to drain flushing oil.
NOTICE Running crusher slowly while draining flushing oil will expedite the draining. 7) Thoroughly clean and replace the magnetic drain plugs and inject a recommended grease in each bearing.
When starting a new crusher for the first time, or after an overhaul, apply a liberal amount of gear lube to the area between the pitman and side bearing seals. Apply oil until grease inside bearing begins to extrude from the grease seals. This precautionary measure insures lubrication until the actual lubricating system begins to function. A crusher which has been idle for a period of time and exposed to the weather should receive the same consideration. At the end of a season’s operation it is recommended that the lubricant be drained, flushed and new lubricant be injected into the housing. The crusher should be operated without load for approximately one hour to permit new lubricant to be evenly distributed in the bearing assembly and housing. New lubricant in the housing would tend to eliminate the possibility of corrosive reactions which might be evident if worked” and oxidized” lubricant is allowed to remain in the housing when the crusher is not in use for long periods of time.
8) Replace and tighten the grease fittings and fitting caps.
CAUTION Failure to thoroughly clean drain plugs and fittings before installation could cause grease contamination. Grease must be kept clean to prevent damage to bearings. 9) Refill bearing housing with grease. In determining the amount of grease to be used be governed by the fact that a pint of grease weighs slightly less than one pound. It is recommended in a complete overhaul, that 20% more lubricant be added in both of the side bearings and in the pitman.
22783 (8/02)
5-8
Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers
Lubrication & Maintenance
Oil Lube Crusher
Annular/Labyrinth
Seal
Oil Lube Annular/Labyrinth Seal Crusher
reservoir. The flow indicators must be checked periodically during operation to ensure that flow to any of the bearings has not stopped.
System Overview
A low oil flow alarm system will sound if low oil flow is detected on one or more of the bearing supply lines. If the feeder control is connected to the oil flow system as recommended, the feeder will shut down.
The oil lubrication system is standard on the 5460 and optional on most other crusher models. Refer to Figure 5 - 8. It is recommended for use on larger crushers or when the crusher will be operated in cold environments. Oil is drawn from the reservoir by the oil pump. The oil pump is normally driven by an electric motor. An optional flywheel driven oil pump is available although, electric drive is usually preferred. The electric driven lube system can be started before engaging the crusher. This ensures lubrication of the bearings the moment the crusher is started. The reservoir size is dependent upon the crusher size. Capacities will vary by crusher size. The reservoir is set lower that the bearings so that oil flows by gravity from the bearings to the reservoir.
Some crushers were built with a stand pipe on the oil outlet at the bottom of each bearing cavity. This Stand pipe retained a small amount of oil in each cavity to ensure the bearings remained lubricated in case of lube pump failure. Use of the Stand pipes is no longer recommended on crushers equipped with electric motor driven pumps. If your crusher is equipped with electric pump drive and STAND pipes, the STAND pipes should be removed when the crusher is disassembled.
For operation in cold environments, an optional reservoir heater and cycle timer are available. The heaters are thermostatically controlled to maintain the oil at a working temperature. A cycle timer can be used to periodically start and stop the electrically driven oil pump when the crusher is not running. This ensures that oil in the lines and bearing cavities is circulated back to be warmed in the reservoir. Oil is strained between the reservoir and pump and filtered between the pump and bearings. A vacuum gage is mounted on the strainer. A pressure gauge is mounted on the filter. Oil from the filter runs through the flow control valves and indicator. Oil flow to each bearing is individually controlled and monitored. From the flow indicator, the oil flows into the top of each bearing and flows by gravity through the bearing. Oil collects at the bottom of each of the bearing cavities and returns by gravity to the 22783 (8/02)
5-9
Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers
Lubrication & Maintenance
Oil Lube Crusher
8
7
Annular/Labyrinth
Seal
7
6
9 10
5
17 16 4 15 3 3
4
2 11 1 12 14
1 - Breather/filler cap 2 - Suction vacuum gauge 3 - Side bearing drain lines 4 - Pitman bearing drain lines 5 - Electric motor/pump 6 - System pressure gauge
13
7 - Bearing supply lines 8 - Flow indicators/controls 9 - Low flow alarm horn 10 - Lube system junction box 11 - Reservoir 12 - Reservoir sight gauge
13 - Reservoir drain 14 - Oil heaters (optional) 15 - Suction strainer 16 - Bypass line 17 - Filter
Figure 5 - 8 Electric drive oil Lube system
22783 (8/02)
5 - 10
Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers
Lubrication & Maintenance
Oil Lube Crusher
Annular/Labyrinth
Seal
Low Oil Flow Alarm System The low oil flow alarm system will sound when the flow of oil to the bearings drops below minimum setting. If the electrical system is wired according to the schematic in Figure 5 - 9, the feeder will shut down when the low oil flow alarm is activated.
Figure 5 - 9 Low oil flow alarm system schematic
22783 (8/02)
5 - 11
Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers
Lubrication & Maintenance
Oil Lube Crusher Annular/Labyrinth Seals Annular/labyrinth seals are designed with a series of annular rings and a labyrinth passage (Figure 5 10). Clean grease is pumped into the seal fitting. As the crusher runs, grease works its way through the labyrinth passage pushing dirt out of the seal. This causes a film of grease to constantly build up around the outside of the seal. This film helps keep dirt and moisture out of the seal and should be allowed to build up. Grease also works its way into the annular rings where it creates a barrier to dirt and moisture entering the bearing. Grease stored in the annular rings also prevents oil in the bearings from leaking out of the seal.
Annular/Labyrinth
Seal
Oil leaking from the seals indicates that more frequent greasing of the seals is required. Lubricate seals with a lithium base, extreme pressure, Grade 2 grease. The oil level in the reservoir should be checked daily before operation begins. Oil level is checked at the sight gauge on the side of the oil reservoir. Refer to Table 5 - 2 when selecting the proper lubrication oil.
Grease film forms outside of seal. Labyrinth
Annular Rings Figure 5 - 10 Annular/Labyrinth seal
Daily Lubrication Grease should be added to each of the six seal fittings (Figure 5 - 11). If the seal is properly lubricated, a fresh film of grease will be present around the edge of the inner and outer seals of each bearing. As the seals become worn, more lubricant will be extruded from the seals. More frequent greasing may be required to maintain a film of grease around the outside of the seals. 22783 (8/02)
5 - 12
Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers
Lubrication & Maintenance
Oil Lube Crusher
Annular/Labyrinth
Seal
2 4
5
1 Pitman Bearing
3 5
Side Bearing
4 2 1 - Pitman bearing inlet line 2 - Pitman drain line 3 - Side bearing inlet line
4 - Side bearing drain line 5 - Seal grease fittings Figure 5 - 11 Grease lubrication points
22783 (8/02)
5 - 13
Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers
Lubrication & Maintenance
Oil Lube Crusher Periodic Lubrication Lubricating oil should be changed every 1000 hours of crusher operation or once each year, whichever occurs first. 1) The oil should be changed after the crusher has been run and the oil is at operating temperature.
Annular/Labyrinth
Seal
13) Refill the reservoir with the appropriate oil listed in Table 5 - 2. Selecting the proper oil viscosity is critical to maintaining lubrication of the bearings. Thinner oils have less lubricating ability. Thicker oils may not flow freely at lower temperatures which could cause insufficient oil to be delivered to the bearings. Regardless of which oil is used, the temperature of the oil returning from the bearings (operating temperature) must not exceed the Maximum Operating Temperature listed in Table 5 - 2.
2) Stop the crusher and clean area around drain plugs, fill plugs, and reservoir. 3) Drain the reservoir by removing the drain plug in the bottom of the reservoir. Since the oil in the bearing cavities drains by gravity back to the reservoir, draining the reservoir removes most of the oil from the crusher.
CAUTION Failure to use oil of proper viscosity could result in insufficient bearing lubrication. This could lead to premature bearing failure.
4) Remove the screen from suction strainer and clean it. 5) Reinstall the screen and drain plugs.
CAUTION
6) Add at least 10 gallons of flushing oil to the supply reservoir.
Do not allow the crusher to operate when the temperature of the oil returning from the bearings exceeds the temperature listed in Table 5 - 2. Failure to follow this warning could cause premature bearing failure.
7) Run the crusher empty for at least 10 minutes. 8) Stop the crusher. 9) Drain the flushing oil from the reservoir. If it appears extremely dirty, repeat the flushing with fresh flushing oil to remove more of the contaminants until the drained flushing oil appears sufficiently clean. 10) Remove the screen from suction strainer once again and clean it. 11) Reinstall the screen. 12) Remove and replace the filter element.
22783 (8/02)
5 - 14
Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers
Lubrication & Maintenance
Oil Lube Crusher
Annular/Labyrinth
Seal
Brand
Ambient Temp 32°F (0°C) or above
Ambient Temp 32°F (0°C) to 0°F (-18°C)
Ambient Temp below 0°F (--18°C)
Chevron Gear Compound EP
220
150
Exxon Spartan EP
220
150
68
Shell Omala EP
220
150
68
Mobil Mobilgear
630
629
68
Texaco Meropa
220
150
68
Maximum Operating Temperature (Returning from bearings)
190°F (88°C)
170°F (77°C)
130°F (54°C)
Table 5 - 2 Recommended oil viscosities/brands
22783 (8/02)
5 - 15
Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers
Lubrication & Maintenance
Oil Lube Crusher Oil Heater (optional) For operation in cold weather, an optional oil heater system is available. Immersion heaters mounted in the tank maintain oil at a thermostatically controlled temperature. Set the temperature of the thermostat no higher than the Maximum Operating Temperature listed in Table 5 - 2. When using the oil heaters, the temperature of the oil returning from the bearings to the reservoir should be monitored to ensure that the operating temperature does not exceed maximum operating temperature for the viscosity of oil being used. This
Annular/Labyrinth
Seal
is especially important when using the lower viscosity oils since their maximum operating temperature is low.
CAUTION Do not heat oil by applying a torch flame directly to the reservoir. Extreme heating could burn the oil and reduce the oils ability to lubricate. The optional oil heaters should be installed according to the schematic in Figure 5 - 12.
120 VAC by customer 30 Amp Service
30 Amp 104
100
102
Heater Power OFF 104
Heater #1
105
1000 W
ON OFF 104
Heater #2
106
1000 W
ON
Figure 5 - 12 Oil heater electrical schematic
Cycle Timer (optional) When operating in cold weather with the optional oil heater system, an optional cycle timer can be used to warm the crusher and oil when not operating. The cycle timer can be set to run the lubrication pump for short periods of time when the crusher is not in operation. With the heaters 22783 (8/02)
running, the warm oil in the reservoir will be passed through the bearings and hoses to prevent oil in these areas from gelling. The cycle timer should be installed and wired as shown in the typical wiring schematic shown in Figure 5 - 13.
5 - 16
Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers
Lubrication & Maintenance
Oil Lube Crusher The timer can be set to cycle time from 0.6 seconds to 24 hours. By changing dip switch settings, the time range of the timer dials is changed. The Off timer controls the amount of time that the lube pump will shut off. The On timer controls the length of time that the lube pump will be running. Setting the dip switches to the setting shown in Figure 5 - 13 will give the Off timer a range of 1145 minutes. The On time will have a range of 1.5 -
Annular/Labyrinth
Seal
5.5 minutes. Other time ranges can be selected by changing the dip switch settings according to the chart on the side of the timer. For normal operation the Day-Night switch should be in the Day position which will allow the lube pump to run continuously when started. When the Day-Night switch is in the Night position the lube pump will run on the timed cycle set by the timer dials.
Timer Dials
Timer Dip Switches
Figure 5 - 13 Lube pump cycle timer
22783 (8/02)
5 - 17
Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers
Lubrication & Maintenance
Periodic Maintenance
Periodic Maintenance Maintenance Benchmark Checklist The maintenance benchmark checklist can be a useful tool to determine if bearings or components are operating outside of normal operating ranges. Refer to Table 5 - 3. When the crusher is first put into service and at operating temperature, record the following in the “Benchmark” column. •
Bearing Temperature
•
Electrical Component Temperature
•
Full Load Amps and Voltages
•
Belt Tension
Each month the readings should be taken again and recorded in the appropriate column. Always remember to use the same measuring procedure. If a reading varies significantly from previous or benchmark readings, investigate the cause.
22783 (8/02)
5 - 18
Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers
Lubrication & Maintenance
Maintenance Sheet
Benchmark
Check
December
November
October
September
August
July
June
May
April
March
February
January
Benchmark
Maintenance Benchmark Check Sheet
I) Temperatures A. Bearings 1. Drive Side 2. Non Drive Side 3. Drive Side Pitman 4. Non Drive Side Pitman 5. Jack Shaft/Outboard Bearing B. Electrical Components 1. Starters 2. Breakers 3. Motor 4. Plug II) Electrical Checks A. Full Load Amps 1. At Motor 2. Below Starter 3. Top of Starter 4. Below Breaker 5. Above Breaker B. Voltage (each leg) 1. L1 2. L2 3. L3 III) Belt Tension A. Drive Belts B. Oil Pump Drive
Table 5 - 3 Maintenance Benchmark Check Sheet
22783 (8/02)
5 - 19
Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers
Lubrication & Maintenance
Maintenance Sheet Periodic Inspections 1) Check and tighten all fastening and mounting bolts, cap screws and set screws. 2) Inspect the stationary and movable jaws for wear. To maintain efficient operation the jaws should be turned when the corrugations at the lower end are worn almost smooth, or replaced after both ends are worn. The stationary jaw will generally require turning or replacing more often than the movable jaw.
Benchmark
Check
5) The toggle plate needs no care other than lubrication and replacement when natural wear reduces the balls on both ends. When the balls have worn 1 inch (25.4 mm) on each end or half the original ball, replace toggle plate. Do this before excessive wear occurs to toggle seat insert in pitman and the base toggle seat. Be sure the toggle plate is located as centrally in position as possible in relation to the toggle seat insert in the pitman.
WARNING Failure to replace jaws when corrugations are worn smooth, or running crusher until concave sections are worn in jaws will reduce capacity of crusher. Also, jaws not changed when recommended will cause compaction of material in crushing chamber and could result in premature bearing failure, excessive breakage of toggle plates or shaft or base breakage. 3) Inspect the key plates, especially the lower sections, for wear. Replace when worn through. Tighten both of the key plates. 4) Check and tighten the movable jaw wedge to prevent the movable jaw from becoming loose and causing wear or damage to the pitman.
22783 (8/02)
5 - 20
Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers
Electrical
Standard Drive Electrical
Section 6 - Electrical Standard Drive Electrical No drive electrical controls are provided as standard with the crusher. It is usually controlled from the main power panel. Check with the supplier of the electrical system for specific information.
22783 (8/02)
6-1
Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers
Electrical
Standard Drive Electrical
22783 (8/02)
6-2
Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers
Troubleshooting
Troubleshooting
Section 7 - Troubleshooting
The following are some of the most common causes of bearing overheating:
Troubleshooting
1) Improper lubricant level. Too much lubricant will not allow for proper circulation and air space inside housing. Fill only to correct levels.
Crusher Not Operating At Rated Capacity 1) Pitman shaft direction of rotation incorrect.
2) Insufficient, dirty or improper lubricant.
2) Stationary jaw loose.
3) Operating at a speed faster than recommended.
3) Speed incorrect.
4) Crusher out of level. This will cause lubricant to flow away from the high bearing. Make sure crusher is level.
4) Jaws excessively worn. 5) Attempting to feed raw material larger than crushing chamber.
5) Side bearing outer seal and flinger not turning with shaft.
6) Incorrect toggle plate for size of crusher discharge opening.
6) Insufficient radial clearance between side bearing outer seal and end cap.
7) Lack of raw material or erratic feeding of crusher.
7) Toggle plate improperly seated.
8) Insufficient power or v-belt slippage.
8) Bearing(s) damaged and/or failing.
Bearings Overheating
9) Movable jaw rubbing on base or key plates.
The bearings normally operate at 100° to 150°F (38° to 66°C) but in warm climates may reach 180° to 200°F (82° to 93°C). Under these conditions and within these limits the bearings are not overheating. However, if a bearing maintains 212°F (100°C) or higher, it is considered to be overheating. The cause should be found and corrected.
10) Bent pitman shaft. 11) Seals Rubbing.
Temperature should be checked on housing closest to the bearing or on the end plate nearest the bearing.
22783 (8/02)
7-1
Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers
Troubleshooting
Troubleshooting
Excessive Jaw Wear 1) Stationary jaw loose. 2) Closing crusher below minimum recommended discharge opening. 3) Operating faster than recommended. 4) Not using genuine Cedarapids jaws. 5) Very abrasive material. Difficult to Adjust Closed Side Setting 1) Tension spring not released. 2) Support angles on base not loose. 3) Toggle seat loose and “peened” into base.
22783 (8/02)
7-2
Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers
Torque Specs
Torque Charts
Appendix A - Torque Specs Torque Charts The following pages contain charts for use as guides when tightening bolts and nuts. These specifications should be followed unless specific torques are given elsewhere in this manual. Standard Torque Chart Table A - 1 is a list of recommended torque values for standard bolts. Use this torque chart to avoid overstressing standard nuts and bolts used on the equipment. These specifications should be followed unless specific torques are given. The equipment uses Grades 2, 5, and 8. The maximum torque values are based on 75% of the specified minimum proof strength of the bolt steel in order to provide a safety factor. The term “lube” applies to cadmium plating and/or application of thread lubricants. Hardened washers should always be used, regardless of whether standard nuts or lock nuts are employed. Metric Torque Chart Table A - 2 is a list of torque values recommended for metric bolts. The maximum torque values are based on 75% of the specified minimum proof strength. The term “lube” includes the application of thread lubricants, cadmium plating and the use of hardened washers regardless of whether standard or lock nuts are used.
22783 (8/02)
A- 1
Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers
Torque Specs
Torque Charts
Standard Torque Chart S.A.E Grade 2 dia. pitch (inches) (thread/in.) 1/4
20
Torque (ft-lbs) Dry
Lube
Clamp Load (lbs)
5
4
S.A.E Grade 5 Torque (ft-lbs)
S.A.E Grade 8
Dry
Lube
Clamp Load (lbs)
2020
12
9
2860
Dry
Lube
Clamp Load (lbs)
1310
8
6
Torque (ft-lbs)
1/4
28
6
5
1500
10
7
2320
14
11
3270
5/16
18
11
9
2160
17
13
3340
25
19
4710
5/16
24
12
10
2390
19
15
3690
27
21
5220
3/8
16
20
15
3190
31
24
4940
44
34
6970
3/8
24
23
17
3620
35
27
5590
49
38
7900
7/16
14
32
25
4380
49
38
6770
70
54
9560
7/16
20
36
27
4890
55
42
7560
78
60
10680
1/2
13
49
38
5850
75
58
9040
106
82
12770
1/2
20
55
42
6590
85
65
10190
120
92
14390
9/16
12
70
54
7500
109
84
11600
150
115
16380
9/16
18
79
60
8370
121
93
12940
170
130
18270
5/8
11
97
75
9320
150
115
14400
210
160
20340
5/8
18
110
85
10560
170
130
16320
240
180
23040
3/4
10
170
130
13770
265
200
21290
375
285
30060
3/4
16
190
145
15380
295
225
23770
415
320
33570
7/8
9
165
125
11430
425
330
29450
605
465
41580
7/8
14
180
140
12590
470
360
32440
665
510
45810
1
8
245
190
14990
640
495
38630
905
695
54540
1
14
270
210
16400
700
540
42260
990
765
59670
1-1/8
7
350
270
18880
790
610
42340
1285
990
68670
1-1/8
12
395
305
21180
890
685
47500
1440
1110
77040
1-1/4
7
495
380
23980
1120
860
53770
1815
1395
87210
1-1/4
12
550
425
26550
1240
950
59550
2010
1545
96570
1-3/8
6
655
500
28580
1465
1130
64100
2380
1830
103950
1-3/8
12
745
570
32540
1670
1285
72980
2710
2085
118350
1-1/2
6
865
665
34770
1945
1495
77970
3160
2430
126450
1-1/2
12
975
750
39120
2190
1685
87740
3555
2735
142290
1-3/4
5
1370
1055
47020
2285
1755
78370
4985
3835
170990
2
4.5
2060
1585
61870
3435
2640
103120
7500
5765
225000
2-1/4
4.5
3015
2320
80430
5025
3865
134060
10960
8435
292500
2-1/2
4
4125
3170
99000
6875
5285
165000
15000
11530
360000
2-3/4
4
5590
4300
122010
9320
7165
203360
17790
13680
388230
3
4
7385
5680
147750
12310
9470
246260
23500
18080
470130
Table A - 1: Torque Values for Standard Hardware
22783 (8/02)
A- 2
Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers
Torque Specs
Torque Charts
Metric Torque Chart Property Class = 8.8 Dry dia pitch (mm) (mm) (ft-lbs) N-M
Property Class = 10.9
Lube
Dry
Property Class = 12.9
Lube
Dry
Lube
(ft-lbs)
N-M
(ft-lbs)
N-M
(ft-lbs)
N-M
(ft-lbs)
N-M
(ft-lbs)
N-M
10
1.5
37
50
29
39
53
72
41
56
62
84
48
65
10
1.25
39
53
30
41
56
76
43
58
66
89
51
69
12
1.75
65
88
50
68
93
126
71
96
109
148
83
113
12
1.25
71
96
55
75
101
137
78
106
119
161
91
123
14
2
104
141
80
108
148
201
114
155
173
235
133
180
14
1.5
112
152
86
117
160
217
123
167
187
254
144
195
16
2
161
218
124
168
230
312
177
240
269
365
207
280
16
1.5
172
233
132
179
246
334
189
256
287
389
221
300
18
2.50
230
312
177
240
318
431
245
332
372
504
286
388
18
1.5
258
350
199
270
357
484
275
348
418
567
321
435
20
2.5
325
441
250
339
450
610
346
469
525
712
404
548
20
1.5
360
488
277
376
499
677
384
521
583
791
448
607
22
2.5
443
601
341
462
613
831
471
639
716
971
551
747
22
1.5
486
659
374
507
673
913
518
702
786
1066
605
820
24
3
562
762
432
586
777
1054
598
811
908
1231
698
946
24
2
612
830
471
639
847
1149
652
884
990
1342
762
1033
27
3
823
1116
633
858
1139
1544
876
1188
1331
1805
1024
1389
27
2
889
1205
683
926
1229
1667
945
1281
1436
1947
1105
1498
Table A - 2: Torque Values for Metric Hardware
22783 (8/02)
A- 3
Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers
Torque Specs
Torque Charts
22783 (8/02)
A- 4
Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers
General Belt Drive Care
General Belt Information
Appendix B - General Belt Drive Care General Belt Information You get more service from V-belts if you keep them clean and dry. Rock dust and rust from metals are abrasive. Oils and acids deteriorate belt material. Dust buildup in sheaves causes harmful vibration. On belts, dust or water causes slippage. For maintenance purposes, so-called belt dressing compounds are worse than worthless. Most belt dressings actually shorten belt life. Clean, well cared for belts are the best answer to problems that belt dressings are meant for but do not solve. Daily cleaning of belts and sheaves by blowing them off with compressed air increases their useful life and saves you money.
5) Periodically inspect the V-belt drive for wear (Figure B - 2) and for proper sheave alignment (Figure B - 1). 6) Do not overtighten belts. Overtightening shortens useful life of belts and sheaves and also places undue strain on shafts which, in turn, causes premature bearing failure. Ideal belt tension is lowest at which belts won't slip under peak load.
OK
1) Keep belts and sheaves clean. 2) Avoid belt or sheave rubbing. Don't let belts or sheaves rub against the guard (or anything else) while they’re running. 3) Drive your belts with motors mounted on adjustable bases. Mount drive motors on a slotted base, so you can shorten the distance from motor to driven sheave when you need to do so. This allows convenient and proper installation of belts. Prying on belts with tools cracks and prematurely breaks them. With belts already lightly seated in their grooves, you can tighten the belts correctly by moving the motor and rolling the sheaves at the same time. 4) Keep belts tight. Most belt stretch occurs in the first 30-40 hours of operation after new belts are installed. Check belt tension frequently during this period. Slack belts cause slipping and excessive wear. They cost you money by delivering less power and causing more frequent replacement.
22783 (8/02)
OK
Figure B - 1: Align Sheaves
7) Keep belts straight (Figure B - 1). Don't allow V-belts to run out of alignment. To run properly, sheaves must be parallel and grooves must be in line. 8) Use only matched belts. A matched set of belts lasts longer because loading is evenly divided among all the belts.
B- 1
Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers
General Belt Drive Care
Maintaining V-Belt Tension
Belts often wear at the sides, so their crosssectional area decreases. They stretch with use and age. New belts ride higher in sheave grooves. They travel faster and take higher tension than worn belts. If its center cord breaks, a belt stretches and won't carry its load. Putting one or two new belts on a partially used set very soon wears and stretches the new ones until they are in poor condition. Their cost is wasted.
5) If belts are not tight enough, loosen drive motor mount bolts and adjust take-up bolts to tighten belts. Retighten motor mount bolts to hold tension. Worn Sheave
Worn Belt or Sheave
Just Right
Belts from different manufacturers should not be mixed in a set because of slight material and quality differences that could reduce the life of all the belts. Always replace belts in full sets. 9) Don't overload. If the sheave has 10 grooves, use 10 belts. Using less than the designed number of drive belts puts too much strain on remaining ones. They will break down quickly and cause you downtime.
Figure B - 2: Belt & Sheave Wear
10) Replace worn sheaves. Worn sheaves reduce belt life. If the sheave is worn enough that belts touch bottom in the grooves, belts soon start to slip and burn. If your maintenance program takes all of those things into account, your troubles with belts and sheaves will be minimal. Still, you’re bound to experience some problem, sooner or later. When you do, use Table B - 1 as a diagnostic tool.
Maintaining V-Belt Tension Figure B - 3: Sheave Gauge Shows Wear
1) Check drive belt tension daily. Check condition of belts and sheaves (Figure B - 2). 2) If belts are worn, replace with a matched set. 3) Use a sheave gauge (Figure B - 3) to look for steps worn in sheave grooves. Steps are a measure of sheave wear. Belts must not bottom out in grooves. 4) If sheaves are worn excessively, replace them.
22783 (8/02)
B- 2
Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers
General Belt Drive Care
Maintaining V-Belt Tension
Trouble
Cause
Correction
Belts slip (sidewalls glazed)
Insufficient tension
Replace belts; increase tension
Drive squeals.
Overloaded drive. Arc of contact too short. Heavy starting load.
Find cause and correct. Increase distance between hubs. Increase tension.
Rock gets into drive. Broken cord caused by prying. Overloaded drive. Impulse Loads.
Replace belt correctly. Redesign drive. Apply proper tension.
Belt rolls over.
Mismatched belts
Excessive vibration.
Check drive design, mounting. Consider banded belts.
New belts installed with old.
Replace belts with matched set.
Sheave grooves worn unevenly. Improper groove angle.
Replace sheaves.
Shafts not parallel.
Align drive.
Shock loads.
Apply proper tension.
Heavy starting load.
Apply proper tension. Use compensator starting.
Belt pried over sheaves. Foreign object in drive.
Replace belt correctly. Determine source of object, design guard to correct problem.
Sheave grooves worn. Sheave diameter too small. Mismatched belts. Drive overloaded. Belt slips. Sheaves misaligned. Oil present. Excess heat present.
Replace sheaves. Redesign drive. Replace with matched set. Redesign drive. Increase tension. Align sheaves. Eliminate oil. Ventilate drive.
Belt breaks
Belt wears prematurely.
Realign drive. Replace sheave. Align and reposition.
Misalignment. Worn sheave grooves. Flat idler sheave.
Table B - 1: Belt-Drive Diagnostics
22783 (8/02)
B- 3
Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers
General Belt Drive Care
Check Belt Tension with Mechanical Tester
Each 1/64" mark equals 1" of belt span (Centimeters on Opposite Side)
Each Mark Equals 1 Pound Pressure (Kilograms on Opposite Side)
Large O-ring
Small O-ring
Figure B - 4: Belt Tension Tester (Cedarapids P/N 45500-036-08)
Small O-ring
Bottom of Straightedge or Top of Adjacent Belt
Span "t"
Deflection to be 1/64" Per Inch Span
Large O-ring
Figure B - 5: Using the Belt Tension Tester
Check Belt Tension with Mechanical Tester 1) Measure span length "T" (Figure B - 5). 2) Position large O-ring on tester at 1/64 inch (0.397 mm) for each inch of belt span. Set small O-ring at zero (Figure B - 5). Example: For belt span of 48 inches (1.219 m), setting would be 48/64 inch (3/4 inch, or 19.05 mm). 3) At center of belt span, push yellow tipped plunger until bottom of large O-ring is level with top of adjacent belt (Figure B - 5). If there is no adjacent belt, lay straight edge between sheaves for reference.
22783 (8/02)
4) Remove tester and read belt deflection force, in pounds, at small O-ring. Compare this figure with values given in tables that follow. If required force is within limits shown in table for that particular belt, drive tension should be satisfactory. If required force is outside these limits, drive should be retensioned. 5) When installing new belts, tension may relieve during run-in. After drive is operated for several days, tension should be checked and adjusted to recommended tension values.
B- 4
Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers
22783 (8/02)
B- 5 D
CX
B, BX
A, AX
Cross Section
5.4 4.7
1000 - 2500 2501 - 4000
5.0 - 7.0
11.5 9.4 14.1 12.5 24.9 21.2 30.4 25.6
500 - 1740 1741 - 3000 500 - 1740 1741 - 3000 200 - 850 851 - 1500 200 - 850 851 - 1500
7.0 - 9.0 9.5 - 16.0 12.0 - 16.0 18.0 - 20.0
45.2 38.0
37.0 31.3
21.0 18.5
17.0 13.8
9.4 8.9
15.9 14.6
14.7 11.9
8.5 7.3
Table B - 3: Belt Deflection Force
6.3 6.0
860 - 2500 2501 - 4000
7.1 7.1
7.9 6.7
860 - 2500 2501 - 4000
5.7 5.1
5.0 4.3
4.1 3.4
4.9 4.2
5.8 - 8.6
4.4 - 5.6
8.0 7.0
6.8 5.7
5.5 4.2
860 - 2500 2501 - 4000 5.3 4.5
4.5 3.8
1000 - 2500 2501 - 4000
3.8 - 4.8
3.4 - 4.2
3.7 2.8
1000 - 2500 2501 - 4000
3.0 - 3.6
23.52 1.6
21.8 21.6
12.6 10.9
10.5 9.1
7.2 6.2
9.4 7.6
7.4 6.4
6.1 5.0
New Belt
Used Belt
New Belt
Used Belt
RPM Range
Smallest Sheave Diameter Range
Cogged Torque-Flex & Machined Edge Torque Team Belts
Uncogged Hy-T Belts & Uncogged Hy-T Torque Team Belts
Belt Deflection Force (Pounds)
8V
5V, 5VX
3V, 3VX
Cross Section
39.6 35.3
59.2 52.7
49.3 39.9
23.4 21.8
18.9 16.7
7.3 6.6
5.1 4.4
New Belt
17.1 16.8
14.8 13.7
10.2 8.8 5.6
5.3 4.9
4.2 3.8
3.3 2.9
Used Belt
25.5 25.0
22.1 20.1
15.2 13.2 8.5
7.9 7.3
6.2 5.6
4.9 4.3
New Belt
Cogged Hy-T Wedge Belts & Hy-T Wedge Machine Edge Torque Team
Table B - 2: Belt Deflection Force
200 - 850 851 - 1500
33.0 26.8
200 - 850 851 - 1500 12.5 - 17.0 18.0 - 22.4
15.5 14.6
12.7 11.2
4.9 4.4
3.6 3.0
Used Belt
500 - 1740 1741 - 3000
500 - 1740 1741 - 3000
500 - 1749 1750 - 3000 3001 - 4000
1000 - 2500 2501 - 4000
1000 - 2500 2501 - 4000
1000 - 2500 2501 - 4000
RPM Range
11.8 - 16.0
7.1 - 10.9
4.4 - 6.7
4.12 - 6.90
2.65 - 3.65
2.2 - 2.4
Smallest Sheave Diameter Range
Uncogged HyT Wedge Belts & Uncogged Hy-T Wedge Torque Team
Belt Deflection Force (Pounds)
General Belt Drive Care
Check Belt Tension with Mechanical Tester
Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers
General Belt Drive Care
Belt Guards
Belt Guards
3V
1.0”
.62”
.38” .31”
5V
V-belt drive guards promote both cleanliness and safety. Screened, meshed or grilled guards are best because they allow air to circulate and heat to escape.
.54”
8V
.88”
.50”
A
.31”
.66”
B
.41”
.88”
C
.53”
1.25”
D
.75”
1.5”
E
.91”
Figure B - 6: Belt Types in Cross-Section
22783 (8/02)
B- 6
Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers
General Belt Drive Care
Idlers
Idlers A properly designed V-belt drive does not require an idler to deliver full rated horsepower if proper belt tension can be maintained. Idlers should be avoided if possible because an idler puts an additional bending stress point on the belt. This reduces the belt’s horsepower rating and its life expectancy. The smaller the idler, the greater the stress and the more belt life is reduced.
Driver Driven
Inside Idler A V-grooved idler located on the inside of the belts on the slack side of the drive is recommended over a back-side idler. The idler should be located near the large sheave to minimize reduction of the arc of contact across the small sheave. The diameter of the V-idler pulley should be equal to or larger than that of the small sheave.
Kiss Idler A kiss idler differs from the back-side idler because the kiss idler does not penetrate the belt span and create a back-bend on the belt. Consequently, the kiss idler does not contribute to premature belt failure. Use of a kiss idler can help control belt vibration and whip on drives subject to shock and pulsating loads. Kiss idlers can be used in single-belt drives where joined belts are not applicable. If a kiss idler is used, diameter of the flat pulley should be at least 1-1/2 times (1.5x) greater than the diameter of the small sheave.
Driver Driven
Back-Side Idler A back-side idler increases the arc of contact on both sheaves. However, it forces a backward bend in the V-belt that contributes to premature belt failure. The idler puts additional stress on the bottom portion of the belt which will result in bottom cracking. If a back-side idler must be used, the diameter of the flat idler pulley should be at least 1-1/2 times (1.5x) the diameter of the small sheave. A back-side idler should be located as close as possible to the small sheave.
22783 (8/02)
B- 7
Driver Driven
Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers
General Belt Drive Care
Idlers
NOTES:
22783 (8/02)
B- 8
Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers
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