C_Jaw_Instruction_EN_Rev_N (140588) (Updated).pdf

NORDBERG C SERIES JAW CRUSHERS INSTRUCTION MANUAL 140588-EN

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NORDBERG C SERIES JAW CRUSHERS

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0

This manual is valid for the Nordberg C Series Jaw Crushers manufactured by Metso. These crushers are high capacity jaw crushers, intented to be used in primary crushing applications.

Because of the continuous development of the product, the manufacturer reserves a right to alter the technical specifications written in this manual, without any advance information. In case of conflicts between different language versions, the English version of this manual is the original and prevails. Manufacturer: Metso Minerals, Inc., Tampere Works Lokomonkatu 3, P.O. Box 306 33101 Tampere Finland Phone: +358 204 84 142 Fax: +358-204-84 143

email: [email protected] www.metso.com Copyright © 2010 Metso. Printed in Tampere, Finland.

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Table of Contents NORDBERG C SERIES JAW CRUSHERS PREFACE 1.1 FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1.2 SAFETY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

SAFETY 2.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2.1.1 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 2.1.2 Operation safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 2.1.3 Maintenance safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 2.2 WARNING SIGNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 2.2.1 Warning sign codes and texts (ANSI). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 2.2.2 Warning sign codes and texts (ISO). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

GENERAL CRUSHER INFORMATION 3.1 CRUSHER TERMINOLOGY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3.2 CRUSHER COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 3.3 SPARE PARTS BOOK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 3.4 ORDERING PARTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 3.5 ESTIMATING CRUSHER CAPACITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 3.6 ESTIMATING CRUSHER PRODUCT GRADATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 3.7 CRUSHER SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 3.8 CRUSHER SETTING LIMITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 3.9 OPTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 3.9.1 Intermediate Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 3.9.2 Protection Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 3.9.3 Conveyor Belt Protector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 3.9.4 Hydraulic Setting Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 3.9.5 Automatic Lubrication Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Nordberg C Series Jaw Crushers

Table of Contents OPERATING INSTRUCTIONS 4.1 PREPARATIONS BEFORE STARTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4.2 STARTING THE CRUSHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4.3 STOPPING THE CRUSHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4.4 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 4.4.1 Oversized Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 4.4.2 Tramp Iron/Uncrushables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 4.4.3 Packing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 4.5 RE-STARTING A CRUSHER STALLED UNDER LOAD . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 4.6 CRUSHER SETTING ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 4.6.1 Mechanical wedge setting adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 4.6.2 Hydraulic wedge setting adjustment (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 4.6.3 Active setting control adjustment (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 4.7 TOGGLE PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 4.8 SPACER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 4.9 TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

MAINTENANCE 5.1 SPACER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 5.1.1 Spacer Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 5.1.2 Spacer Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 5.2 TOGGLE PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 5.2.1 Replacing the Toggle Plate And Toggle Seats (with wedge setting adjustment) . . . . . . 5-7 5.2.2 Replacing the Toggle Plate And Toggle Seats with Active Setting Control . . . . . . . . . . 5-9 5.3 LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 5.3.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 5.3.2 Grease Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 5.3.3 Eccentric Shaft Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 5.3.4 Eccentric Shaft Bearing Temperatures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 5.3.5 Jack-shaft Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17 5.3.6 Jack-shaft Bearing Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18 5.3.7 Thrust Bearing And Cap Nut Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18 5.3.8 Tension Cylinder Slide Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18 5.3.9 Electric Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18 5.3.10Toggle Seats And Toggle Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19 5.3.11Setting Adjustment Wedges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

Nordberg C Series Jaw Crushers

Table of Contents 5.4 INSTRUCTIONS FOR LIFTING A JAW CRUSHER WHEN REPLACING CRUSHER SUPPORT BRACKET DAMPERS . . . . . . . . . . . . . . . . . . . . . . . . . 5-20 5.5 HYDRAULIC POWER UNIT (OPTIONAL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22 5.5.1 Checking oil level and temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22 5.5.2 Changing oil and filter (Figure 5.11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22 5.5.3 Oil recommendation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24 5.5.4 Bleeding the hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25 5.6 PERIODICAL MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28 5.6.1 Daily maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28 5.6.2 Weekly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29 5.6.3 Monthly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30 5.6.4 Twice a Year. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30 5.6.5 Regularly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30 5.7 MAINTENANCE INTERVALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31 5.8 BOLT TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33

REPLACEMENT OF WEAR PARTS 6.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 6.2 JAW DIE SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 6.3 JAW DIE WORK HARDENING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 6.4 CHEEK PLATE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 6.4.1 Cheek Plate Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 6.4.2 Cheek Plate Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 6.5 CHANGING OR ROTATING THE JAW DIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 6.5.1 One piece jaw dies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 6.5.2 Two-piece jaw die removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17 6.5.3 Welding lifting lugs to the jaw die . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28 6.6 PITMAN EYE PROTECTION PLATE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31 6.7 FEED HOPPER LINER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31 6.8 TOGGLE PLATE SEAT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31

Nordberg C Series Jaw Crushers

Table of Contents APPENDIX A

1. 2. 3. 4. 5. 6. 7. 8. 9.

SAFETY, OPERATING AND MAINTENANCE INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . .A-1 Purpose of the jaw die lifting tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Storage of the jaw die lifting tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Safe use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Commissioning and operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2 The jaw die lifting tool verification before first use and in service . . . . . . . . . . . . . . . . . .A-2 Handling the load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3 Operating instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5

APPENDIX B

1. 2. 3. 4. 5. 6. 7. 8. 9.

SAFETY, OPERATING AND MAINTENANCE INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . .B-1 Purpose of the cheek plate lifting tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1 Storage of the cheek plate lifting tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1 Safe use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1 Commissioning and operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2 The cheek plate lifting tool verification before first use and in service . . . . . . . . . . . . . .B-2 Handling the load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3 Operating instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7

PREFACE

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1.1 FOREWORD

1.2 SAFETY

This instruction manual provides guidance for first time operators of the crusher as well as technical procedures as a reference for the experienced crusher operator. Read, study, and keep it for future reference.

BASIC RULES REGARDING SAFETY IN AND AROUND A CRUSHING PLANT ARE OUTLINED IN THE SECTION ENTITLED "SAFETY."

The instructions given are for the operation and basic maintenance procedures only, as this instruction book is not a repair manual. Should maintenance procedures not covered in this manual be required, contact Metso. Illustrations and instructions guide the operator through correct procedures for checking, operating and maintaining the crusher and its accessories. Operating techniques outlined in this manual are basic. Operating skills and additional techniques will develop through experience as the operator gains knowledge of the crusher and its capabilities.

OPERATOR SAFETY AND THE SAFETY OF OTHERS DEPEND UPON REASONABLE CARE AND JUDGEMENT IN THE OPERATION OF THIS CRUSHER. A CAREFUL OPERATOR IS GOOD INSURANCE AGAINST AN ACCIDENT. MOST ACCIDENTS, NO MATTER WHERE THEY OCCUR, ARE CAUSED BY FAILURE TO OBSERVE AND FOLLOW SIMPLE FUNDAMENTAL RULES OR PRECAUTIONS. FOR THIS REASON RECOGNIZING HAZARDS AND TAKING STEPS TO AVOID THEM CAN PREVENT MOST ACCIDENTS. REGARDLESS OF THE CARE USED IN THE DESIGN AND CONSTRUCTION OF THIS TYPE OF EQUIPMENT, THERE ARE CONDITIONS THAT CANNOT BE COMPLETELY SAFEGUARDED AGAINST WITHOUT INTERFERING WITH REASONABLE ACCESSIBILITY AND EFFICIENT OPERATION. WARNINGS ARE INCLUDED IN THIS INSTRUCTION MANUAL TO HIGHLIGHT THESE CONDITIONS.

Continuing improvement and advancement of product design may result in changes to your new machine that may not be included in this publication. As required, each publication is reviewed and revised to update and include appropriate changes in the later editions. The descriptions and specifications in this manual were in effect at the time this manual was approved for printing. Metso reserves the right to discontinue models at any time and to change specifications and designs, without notice and without incurring obligation. Whenever a question arises concerning your crusher, or this publication, please consult your Metso representative for the latest available information.

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SAFETY

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2.1 GENERAL The instructions of the safety guide, these safety instructions and other manuals and safety labels for the equipment must be read, understood and used by each person who works with this equipment.

2

This manual uses the alert symbol, with words such as DANGER, WARNING or CAUTION, to alert you and other Crushing Plant personnel of actions or conditions that pose a potential safety hazard, with an attending risk of personal injury (including death) or property damage. The machine also displays safety signs, labels and tags at appropriate points to show safety risks that may exist.

WARNING! In addition to these unit-specific safety instructions, the operators of this equipment must also read the safety guide with instructions for general operational safety.

DANGER

The following symbol is used in this manual and on the machine to call attention to instructions, which will help prevent machine related injuries.

WARNING

When you see this symbol on your machine or in this manual, be alert to the potential for personal injury.

CAUTION Sign

Figure 2.1 Alert Symbol

Description

Immediate hazards or unsafe practices DANGER that will result in severe personal injury or death. Hazards or unsafe practices that could WARNING result in severe personal injury or death Hazards or unsafe practices that could CAUTION result in minor personal injury or equipment damage Figure 2.2 Danger, warning, caution signs and their meaning

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CHAPTER 2 - SAFETY

Personal protective equipment and clothing such as foot protection, helmet, hearing protection, dust protective devices, safety glasses or other personal protective clothing and equipment should be worn at all times.

2.1.1 General safety instructions

WARNING! Before performing any maintenance or repair work, make sure that the crusher is stopped and locked out. LOCKOUT PROCEDURE of the Lokotrack installed crushers 1. Switch off engine 2. Remove the ignition key and keep it on person during lockout 3. Place appropriate maintenance warning signs (TAG OUT) LOCKOUT PROCEDURE of the electrical motor driven crushers 1. Switch off motor 2. Lock the main switch of the motor with a padlock or make sure in some other way that the engine cannot be started 3. Lock the main switch of the hydraulic adjustment power unit (if delivered) with padlock 4. Keep the keys on person during lockout 5. Place appropriate maintenance warning signs (TAG OUT).

Figure 2.3 Personal safety equipment

DANGER! When working outside service platforms, safety harnesses must be worn!

1. Ignoring the safety instructions or the warning signs increases the risk of the severe injury or death. 2. Nordberg C series jaw crushers has been designed for safe operation when used by professional staff in the operating situations included in this instruction manual. All other service and repair procedures must be performed by specially trained personnel or authorized Metso service staff. 3. The crushing plant and auxiliary equipment such as chutes, transfer stations, screens,

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etc. can create dust and, if not contained, the dust can escape into the air. Metso highly recommends that dust protective devices such as an appropriate respirator be worn by anyone exposed to airborne dust to prevent its inhalation. It is the responsibility of the Owner and Operator to determine the necessity and adequacy of protective devices and warnings, to provide them, and to ensure that they are used and followed!

2.1.2 Operation safety instructions 1. Never operate the crusher without proper covers and safety devices. If the covers or safety devices have not been purchased from Metso, a customer has to ensure that the covers and safety devices are according to law and regulations. 2. Before starting the crusher make sure that no one is near the crusher.

4. The noise level is dangerously high near the crusher. All personnel working near the crusher must wear hearing protection. The noise level is typically about 102-110 dB next to the crusher during crushing.

3. It is prohibited to stay in the danger area during the crushing process. The crushing material may be thrown into a few meters distance from the crusher. Always use helmet and safety glasses.

5. Keep the warning signs clean. Replace illegible and damaged signs before starting the crusher. Make sure that the warning signs are not hidden from sight when installing the crusher. If a part with a warning sign is replaced, make sure that the new part also has the required warning signs.

4. Do not look into the jaw cavity during crushing. Material may be thrown from the crusher during crushing and cause injuries. Always use a helmet and safety glasses. 5. Because the crusher is installed on rubber dampers, it moves during crushing. This movement causes a crushing danger. Never put your hands or feet between the moving parts and the structure of the crusher during crushing. The movement may be as much as ± 10mm. 6. Clearing a jammed cavity is extremely dangerous. Do not attempt to clear the cavity until the crusher has stopped completely.

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2.1.3 Maintenance safety instructions 1. The crusher does not stop immediately after the motor has been turned off. Make sure that the crusher has stopped completely before opening any covers, performing any maintenance, or adjusting the crusher. 2. Before performing any maintenance or repair work, make sure that the crusher is stopped and locked out. 3. The surfaces of the crusher may become hot during crushing. Hot surfaces can cause severe burn injuries. Make sure that the surfaces have cooled before performing any maintenance work. 4. Before changing any wear parts of the crusher, read chapter 6: Replacement of wear parts and appendixes A and B carefully. 5. Before lifting any wear parts, check the weight of the component and ensure that lifting equipment being used is adequate to lift the weight. In addition, familiarize yourself with all the special tools provided with the crusher specifically for replacing the wear parts. 6. Read the instructions regarding the lifting tools and replacing wear parts carefully before replacing any wear parts. Make sure that the parts are adequately supported before lifting. Never go under the suspended load. The lifting tools delivered with the crusher are designed to be used only with original Metso wear parts. 7. The spring of the mechanical setting adjustment may accumulate significant amount of energy. Follow the instructions strictly and be extremely accurate when adjusting the spring. Never release the protective plate. 8. The pressure accumulator of the hydraulical setting adjustment may be charged only by a professional. If the pressure accumulator is charged incorrectly, it may explode. Do not charge the accumulator yourself. Release the pressure from the hydraulic system according to instructions before any maintenance to the system.

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WARNING! Ensure that the crusher has stopped to the “rest position”. In other words there is no potential energy remaining in the flywheels. This can be determined from the position of the gib key. It should point down. (Figure 2.4) NOTE: If the gib key is not pointing down, start the crusher for a second.

Figure 2.4 At the “rest position” the gib key is pointing down

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2.2 WARNING SIGNS The warning signs attached to the equipment must always be kept readable and clean. Damaged or loose signs must be replaced at once before starting the crusher. Make sure that the warning signs are not covered during installation. If a part of the crusher attached a warning sign are replaced, always make sure that the warning signs needed are included in a new part.

IMPORTANT! There are two different sets of warning signs depending on the delivery country. You can check which set of warning signs is used on your machine from the side of the machine or the spare part manual.

Figure 2.5 The locations of the warning signs

The number and exact locations of the warning signs may vary according to options (for example, guards).

IMPORTANT!

The warning signs 1, 2, 3, and 4 are located on both sides of the crusher.

Warning signs 1, 2, 3 and 4 are not attached on crushers installed in Lokotracks or Nordwheelers.

The warning signs 3 are delivered only if the crusher delivery includes the drive guards. The warning sign 5 is delivered only with crushers that have a mechanical setting adjustment. The warning signs 6, 7, and 9 are delivered only with crushers that have a hydraulical setting adjustment.

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1

2

4

3

7

6

5

8 9

Figure 2.6 Warning signs (ANSI)

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2.2.1 Warning sign codes and texts (ANSI) 1. MM0229994 WARNING Read and understand instruction manual before using or maintaining this machine. Failure to follow operating instructions may result in death or serious injury. DANGER Lung disease hazard. Dust protection required. WARNING Risk of eye injury. Use of eye protection required. CAUTION Risk of head injury. Use of a helmet required. CAUTION Hazardous noise level. Use of ear protection required. 2. MM0229995 DANGER Moving parts can crush and cut. Do not insert tools in the crusher cavity when the motor is running. WARNING Material can fall out. do not stand in the vicinity of the crusher when the motor is running.

5. MM0229998 DANGER Spring in compression. Read and understand instruction manual before adjusting or servicing. Do NOT remove this protection plate. 6. MM0230002 WARNING Servicing while pressurized can cause severe injury. Lock out source and relieve pressure before servicing. 7. MM0230006 CAUTION Hot surface. Contact with skin may cause burns. Do not touch. 8. MM0230004 CAUTION Hot surface. Contact with skin may cause burns. Do not touch. 9. MM0230447 WARNING Pressurized device. Only authorized personnel should service this dev ice. See instruction manual for safety information.

3. MM0229997 WARNING Exposed moving parts can cause severe injury. Do not open drive guard before machine is completely stopped. 4. MM0229996 WARNING Exposed moving parts can cause severe injury. Do NOT operate this machine without proper guards.

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1

3 4

2

6

5

7

8

9

Figure 2.7 Warning signs (ISO)

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2.2.2 Warning sign codes and texts (ISO) 1. MM0250258 WARNING Read and understand instruction manual before using or maintaining this machine. Failure to follow operating instructions may result in death or serious injury. DANGER Lung disease hazard. Dust protection required. WARNING Risk of eye injury. Use of eye protection required. CAUTION Risk of head injury. Use of a helmet required. CAUTION Hazardous noise level. Use of ear protection required. 2. MM0250251 DANGER Moving parts can crush and cut. Do not insert tools in the crusher cavity when the motor is running. WARNING Material can fall out. do not stand in the vicinity of the crusher when the motor is running.

5. MM0250242 DANGER Spring in compression. Read and understand instruction manual before adjusting or servicing. Do NOT remove this protection plate. 6. MM0250241 WARNING Servicing while pressurized can cause severe injury. Lock out source and relieve pressure before servicing. 7. MM0250239 CAUTION Hot surface. Contact with skin may cause burns. Do not touch. 8. MM0251117 CAUTION Hot surface. Contact with skin may cause burns. Do not touch. 9. MM0250104 WARNING Pressurized device. Only authorized personnel should service this device. See instruction manual for safety information.

3. MM0250244 WARNING Exposed moving parts can cause severe injury. Do not open drive guard before machine is completely stopped. 4. MM0250244 WARNING Exposed moving parts can cause severe injury. Do NOT operate this machine without proper guards.

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CHAPTER

3

3.1 CRUSHER TERMINOLOGY Throughout this instruction manual, technical terms are used to describe the crusher, its components and its operation. These terms are defined herein with the intent of avoiding any confusion or misunderstanding.

Callout 1 2 3 4

Description Feed opening depth Moving jaw Stationary jaw Closed side setting (c.s.s)

Callout Description 5 Stroke 6 Nip angle 7 Feed opening width

Figure 3.1 Jaw crusher terminology

Feed: The raw material to be crushed, such as the rock type (limestone, basalt, granite, etc.) or man-made materials such as concrete and asphalt. The feed size is typically denoted in terms of a size distribution or based on an average top (maximum) size. Product size: The size of the material after it has been crushed. Similarly to the feed size, the product size is typically denoted in terms of a size

EN

distribution or based on an average top (maximum) size. Capacity: The output of the crusher in tons per hour. Feed Opening: The opening where the feed material is fed into the crusher. The feed opening has two dimensions: a width and a depth. The feed opening depth is a critical dimension because it dictates the maximum feed size a given jaw crusher model can accept.

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Maximum Recommended Feed Size: As a general guideline, the maximum average recommended feed size should be about 80% of the feed opening depth. Such measures will ensure that any bridging events resulting from oversized feed are kept to a minimum. A rock hammer is recommended for applications where the maximum feed size is regularly close to the feed opening depth.

Feed Opening

C80 C96 C100 C106 C110 C116 C3054 C125 C140 C145 C160 C200

mm 800 X 510 930 X 600 1000 X 760 1060 X 700 1100 X 850 1150 X 800 1380 X 760 1250 X 950 1400 X 1070 1400 X 1100 1600 X 1200 2000 X 1500

inch 20 X 32 24 X 37 30 X 40 28 X 42 34 X 44 32 X 45 30 X 54 37 X 49 42 X 55 43 X 55 47 X 63 59 X 79

Stroke: The difference between the maximum and minimum distances at the bottom of the fixed and moving jaws during one revolution of the eccentric shaft.

Maximum Rec. Feed Size mm 408 480 608 560 680 610 608 760 856 880 960 1200

inch 16 19 24 22 27 24 24 30 34 35 38 47

Table 3-1 Maximum recommended feed sizes

Nip Angle: The angle between the fixed and moving jaws. The nip angle is often referred to as the "bite" angle as well. Jaws: The members that perform the crushing are commonly referred to as jaws. The jaws consist of a stationary and moving jaw, and depending on the model each one of these may consist of either 1 or 2 pieces. Different jaw die profiles are available for different applications. Discharge Setting: The shortest distance between the bottom of the fixed and moving jaws as measured at the point where the jaws are at their closest relationship during their work cycle (i.e. the closed side setting, or c.s.s.). The method in which the setting is measured varies depending on the jaw die profile. These differences are explained in detail in the CRUSHER SETTING section.

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3.2 CRUSHER COMPONENTS

Callout 1 2 3 4 5 6 7 8 9 10 11

Description Front frame Upper wedge Filling wedge jaw die bolt Disc spring package Cheek plate, upper Fixed jaw, upper Moving jaw, upper Center wedges Cheek plate, lower Fixed jaw, lower

Callout 12 13 14 15 16 17 18 19 20 21 22

Description Moving jaw, lower Frame bolt Fixed wedge Pitman eye protection plate Flywheel Eccentric shaft Pitman bearing Pitman Frame connecting rods Side plate Toggle seat

Figure 3.2 Jaw crusher main components

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Active setting control adjustment

Mechanical wedge setting adjustment

Hydraulic wedge setting adjustment

Callout 1 2 3 4 5 6 7

Description Rear frame Adjustment wedges Spacer Toggle seat holder Toggle seat Locking nuts with thrust bearing Tension spring

Callout 8 9 10 11 12 13 14 15

Description Tension rod Toggle plate Piston rod Piston Pressure relief valve Pressure accumulator Tension cylinder Cylinder cover

Figure 3.3 Jaw crusher rear frame components

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3.5 ESTIMATING CRUSHER CAPACITY

3.3 SPARE PARTS BOOK A Spare Parts Book containing various assembly drawings pertaining to your crusher will be sent immediately after the crusher has been shipped. This book illustrates each and every part used in the assembly of the machine and is to be used when ordering spare or replacement parts.

3.4 ORDERING PARTS Metso endeavors to carry an ample supply of parts in stock to provide prompt and efficient service on all orders for repairs and replacements. To avoid delay and the possibility of incorrect parts being furnished, the following information should be given:

The capacity of the crusher depends on factors such as the type of feed (material type, size distribution, fracture characteristics, moisture content, etc.), type of operation (feed availability, feed arrangement) and discharge setting. To obtain an estimate of the capacity, refer to the following capacity table. These capacities are based on results obtained in actual practice with hard granite that has a bulk density of 1.6 t/m3 (100 lb/ft3), and are where the feed has been properly graded so that bridging does not take place. To obtain more accurate capacity estimates specific to your actual crushing application, contact your local Metso sales representative to request a computer simulation of your circuit's operating condition

1. Crusher size. 2. The serial number of the crusher which is stamped on the crusher nameplate. The serial number is also on the cover of the spare parts books. 3. Complete name and part code number as shown in the Spare Parts Book. 4. Exact quantity of each part ordered. 5. Complete shipping instructions. If your crusher Spare Parts Books have been lost, destroyed or misplaced, an additional set can be ordered. For proper operation, only genuine factory parts should be installed. These are guaranteed as to accuracy, workmanship and material. Using pirate parts may put your safety and that of your crusher at risk. Make sure you completely understand your crusher's Warranty conditions at all times.

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c.s.s. mm 40

in 1-5/8”

50 2” 60 2-3/8” 70 2-3/4” 80 3-1/8” 90 3-1/2” 100 4” 125 5” 150 6” 175 7” 200 8”

C80

C96

C100

C106

C116

C110

C125

C140

C145 C3054 C160

C200

Mtph Stph 63 72 80 90 97 107 114 125 131 143 148 161 165 185 207 232 250 280 292 327

Mtph Stph

Mtph Stph

Mtph Stph

Mtph Stph

Mtph Stph

Mtph Stph

Mtph Stph

Mtph Stph

Mtph Stph

Mtph Stph

150 165 171 187 192 209 213 238 265 296 317 355 369 413 421 471

168 185 190 208 213 232 235 263 291 325 346 388 402 450 458 513

185 204 207 227 230 250 252 282 308 344 363 407 419 469 475 531

190 209 212 232 235 256 257 287 313 350 368 412 424 475 480 537

520 581 596 666 672 751 748 836 824 921 900 1006 976 1091

760 849 853 953 946 1058 1039 1162 1132 1266 1225 1370

120 132 140 154 160 175 180 196 200 224 250 280 300 336 350 392

225 9” 250 10” 275 11” 300 12”

290 324 350 391 410 458 470 525 530 593 590 660 650 727

386 432 454 508 522 584 590 659 657 735 725 811

400 447 470 526 541 605 611 683 681 762 752 841 822 920

Mtph Stph

240 264 268 293 295 322 323 361 392 439 462 516 531 594 600 671

Table 3-2 Nominal jaw crusher capacities

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3.6 ESTIMATING CRUSHER PRODUCT GRADATION

These product gradations are based on results obtained in actual practice with hard granite. To obtain more accurate product gradation estimates, contact your local Metso sales representative to request a computer simulation of your circuit's operating conditions.

The crusher's product gradation depends on the same factors that affect capacity. The following figure gives an indication of the product gradation as a function of the closed side setting (c.s.s.).

1"

2"

4"

8"

16"

100

90 css

40 50

70

100 130 160 200 250

300

80

Percentage passing, weight %

70

60

50

40

30

20

10

0 1

10

100

1000

Product size

Figure 3.4 Crusher product gradation

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3.7 CRUSHER SETTING The Crusher setting is the most important Crusher parameter since it determines the Crusher's capacity as well as the top size of the Crusher product. It is therefore indispensable for everyone to understand how the Crusher setting is measured. The discharge setting is the shortest distance between the bottoms of the fixed and moving jaws during their work cycle. This distance is referred to as the closed side setting (c.s.s.), and it is a calculated distance as the Crusher setting is typically measured when the Crusher is at rest. The largest distance between the bottoms of the fixed and moving jaws is referred to as the open side setting (o.s.s.), and it is typically a distance that is directly measured when the Crusher is at rest.

The Crusher setting is measured in three different ways, first referring to the tooth groove (bottom) or crown (top) of the stationary jaw and then to the tooth groove (bottom) or crown (top) of the movable jaw. Thus, the setting is always measured from the Stationary (bottom or top) to the Movable jaw (bottom or top). The three alternatives are shown in Table 3-3. The measurement type depends on the profile as well as on the Crusher model. This information is also found in the Crusher Spare Parts Book.

Measurement Type 1 2 3

Reading Sequence (Jaws) Stationary Bottom Top Top

to to to to

Movable Top Top Bottom

Table 3-3 Measurement types

Figure 3.5 Crusher setting measurement

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For example, the setting of the C125, equipped with Quarry jaw dies, is measured from Top to Top (Type 2). However, with Standard jaw dies, the setting is measured from Bottom to Top (Type 1). IMPORTANT! The Crusher setting must always be measured in a straight line at the bottom of the crushing cavity. Measure the setting always from the least worn area.

Example Crusher: C140 Stroke: 42 mm (15/8” ) (Table 3-4) jaw die Profile: Quarry (top to top) O.S.S.: 230 mm (9") C.S.S.: 230 – 42 = 188 mm (9" – 1 5/8" = 7 3/8")

It is easiest to measure the setting when the Crusher is at rest with a device such as a block of wood of known dimensions (several blocks should be available if more than one setting is typically used). The distance measured this way is larger than the closed side setting (c.s.s.) because the pitman always stops at its lowest point. This value is close (±2mm/±0.08") to the open side setting (o.s.s.). As previously mentioned, the closed side setting is calculated by deducting the stroke from the open side setting (Table 3-4).

Model C80 C96 C100

Stroke mm Inch 24 1 32 1¼ 32 1¼

C106

34

13/8

C110

36

17/16

C116 C3054

37 32

1½ 1¼

C125

41

15/8

C140

41

15/8

C145

41

15/8

C160

41

15/8

C200

50

2

Table 3-4 Dimension (stroke) to be deducted from the open side setting (o.s.s.) to calculate the closed side setting (c.s.s.).

Dimension (stroke) to be deducted from the open side setting (o.s.s.) to calculate the closed side setting (c.s.s.).

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Figure 3.6 Measuring the setting

NOTE: The C.S.S does not have to be calculated if the user knows the Crusher setting limits in terms of the O.S.S. The C.S.S. is typically calculated because Crusher capacity is always denoted in terms of the C.S.S. only.

3.8 CRUSHER SETTING LIMITS All C-Series Crusher models have a maximum possible setting as well as a minimum allowed setting, and it is very important that the user understands why these are important to keep these in mind at all times. The maximum possible setting is simply the maximum setting that the Crusher is physically able to accommodate. Typically, such setting is indicated with new jaw dies, and the setting actually depends on the jaw die profile as well as on whether a spacer is being used or not. This

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information is always found in the Crusher Spare Parts Book. The minimum allowed setting (c.s.s. or o.s.s.) is the minimum setting at which the Crusher can be used when the Crusher is operated according to Metso ' recommendations. The minimum allowed setting is very important as it takes into account the design and operation limits of the Crusher. Not respecting these recommendations can lead to a poor utilization of the jaw dies (high scrap rate) as well as a shortened Crusher life. The minimum allowed setting varies depending on whether the application is a normal rock application (Normal), or a recycling application (Special), when materials such as concrete, asphalt and bricks are being crushed. Note that the minimum allowed setting does not depend on the jaw die profile (it is always the same for a specific Crusher model). See Table 3-5.

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Crusher model

C80 C96 C100 C106 C110 C116 C3054 C125 C140 C145 C160 C200

CSS Hard rock Soft Rock (>150 Mpa) ( 22 000 psi) (150 Mpa) ( 22 000 psi) (150 Mpa) ( 22 000 psi) (150 Mpa) ( 22 000 psi) (