Cone Crusher

instruction manual

1
FOREWORD

This book is an Instruction Manual for the new operator and a refresher for the experienced one. Read
— study — and keep it handy.

Illustrations and instructions guide the operator through correct procedures for checking, starting and
operating the Crusher and accessories.
Operating techniques outlined in the book are basic. Operating skills and additional techniques will
develop as the operator gains knowledge of the Crusher and its capabilities.
Continuing improvement and advancement of product design may result in changes to your new
machine which may not be included in this publication, however each publication is reviewed and
revised, as required, to up-date and include appropriate changes in the later editions.
The description and specifications in this manual were in effect at the time this manual was approved
for printing. Vanguard reserves the right to discontinue models at any time, and to change
specifications or design, without notice and without incurring obligation.
Whenever a question arises regarding your Crusher, or this publication, please consult your Vanguard
representative for the latest available information.

SAFETY
BASIC RULES REGARDING SAFETY IN AND AROUND A CRUSHING PLANT ARE OUTLINED IN SECTION 0,
ENTITLED “SAFETY.”

OPERATOR SAFETY AND THE SAFETY OF OTHERS DEPENDS 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 MOST
ACCIDENTS CAN BE PREVENTED BY RECOGNIZING HAZARDS AND TAKING STEPS TO AVOID
THEM BEFORE AN ACCIDENT OCCURS.

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.
 TABLE OF CONTENTS

SAFETY ...................................................................................................................................... SECTION 0

GENERAL CRUSHER INFORMATION .................................................................................. SECTION 1

GENERAL INSTALLATION INFORMATION ........................................................................ SECTION 2

OPERATING. INSTRUCTIONS ................................................................................................ SECTION 3

LUBRICATING SYSTEM .......................................................................................................... SECTION 4

HYDRAULIC CLAMPING AND ADJUSTMENT MECHANISMS ........................................ SECTION 5

HYDRAULIC CLEARING SYSTEM ........................................................................................ SECTION 6

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 SECTION 0

SAFETY

PERSONNEL SAFETY ....................... ........ ........................................................... 1

DO YOU KNOW YOUR EMPLOYER'S SAFETY PROGRAM? . . 1

ARE YOU DRESSED PROPERLY FOR THE JOB? ............................................ 1

DO YOU UNDERSTAND YOUR MACHINERY? . . . . . . . . . 2

DO YOU HAVE KNOWLEDGE OF WORKING AREAS? .................................. 2

ARE YOU PREPARED FOR EMERGENCIES? .......................................... ....... . 2

BEFORE STARTING CHECK ........... .................................................................................. 3

START UP SAFELY . ................ ........................................................................... 3

REPORT A DEFECTIVE MACHINE ................................................................... 3

STOPPING SAFELY ............................................................................................................ 4

TIPS FOR SAFE MAINTENANCE .............................................................. ..... . 4

READ AND UNDERSTAND ................................................................................ 4

WARNING TAGS ........................................................ ...... .. ............................... 4

LOCKOUT ELECTRICAL SERVICE . . ...................... ........................................ 4

CLOTHING - SAFE PRACTICE ............................................ ...... .................. ...... 4

ALCOHOLIC BEVERAGES AND MEDICATION ............................................. 5

WORK AREA ..................................... .... .............................................................. 5

EQUIPMENT ........................... ...... ................................................. ...... . . . . 5

FIRE HAZARDS • • • • ........................................................................ ...... . . . 6

PRESSURIZED SYSTEMS - HYDRAULIC OR AIR . . . . . . . 6

USE QUALITY PARTS . . . . ....................................................................... ....... . 6

REPORT NECESSARY REPAIRS ............. ..................................................... ...... 6

4
 PLANT SAFETY------------------------------------------------------------------------------- 7
DRIVE GUARDS .................................................................................................................. 7

OPERATORS PLATFORM .................................................................................................... 7

ELECTRICAL LOCKOUT ................................................................................................... 7

CRANES ................................................................................................................................. 8

MOBIL CRANES .................................................................................................................... 8

WELDING EQUIPMENT ...................................................................................................... 8

CONVEYOR BELTS ............................................................................................................ 9

PORTABLE PLANTS .......................................................................................................... 9

CRUSHING PLANT nNOISEn ................................................................................................ 9

NORDBAK VERSUS ZINC ................................................................................................... 9

SPRING RING ASSEMBLIES ............................................................................................. 10

CLEARING A CRUSHER .................................................................................................... 10

TRAMP IRON REMOVAL .................................................................................................. 10

GENERAL MAINTENANCE WORK------------------------------------------------------- 11

SECTION 0
SAFETY

C-1138 0-1
PERSONNEL SAFETY work area hazards exist, and to discuss them with his
supervisor. A common understanding should be
reached by all personnel to assure safe performance in
This portion of the instruction manual is intended to operating the equipment.
illustrate only basic safety procedures. Additional
precautions may be necessary for the safe operation of a The operator is the key to safe job performance and
Crusher. The information contained in this manual is should study these safety tips to be aware of basic
not intended to replace safety codes, insurance safety precautions to help prevent serious injury and
requirements, federal, state and local laws, rules and damage to property.
regulations.
SAFETY of the operator and maintenance personnel is STOP ACCIDENTS BEFORE THEY STOP YOU!
of prime concern. These paragraphs are presented as a
helpful guide to construction equipment personnel, and
shows some of the daily work problems which they
may encounter.
In order to alert you, the user, and those entrusted as
It is the responsibility of the operator to know what operators and maintenance personnel, dangerous or
specific requirements, precautions and hazardous operations are shown
WARNING
The safest machine must still be operated with care and
with knowledge of its performance capabilities. The
most comprehensive safety program must still be
followed.
Remember that on any job, YOU are the key to safety.
Good safety practices not only protect the men around
you, they are your own best protection. Study this
manual and any manufacturer’s operator’s manuals
covering your specific equipment. Read all warning
and caution instructions. Practice safe operation.
INSIST THAT YOUR FELLOW WORKERS DO,
TOO. BE ALERT TO POSSIBLE HAZARDS
BEFORE THEY CAUSE TROUBLE, AND
REMEMBER............. SAFETY IS UP TO YOU!!!
DO YOU KNOW YOUR EMPLOYER'S SAFETY
PROGRAM?
Company safety records show that the greatest
percentage of accidents are caused by disregard of
simple safety rules. Know-observe!-the overall
program • • • and consult your supervisor for specific
Know instructions when starting a job.
which
ARE YOU DRESSED PROPERLY FOR THE
JOB?
You may need any number of special items - safety hat,
safety shoes, safety glasses, goggles, heavy gloves, ear
protective devices, etc.,- for your own protection. Find
out what items are required and wear them!

0-2 C-870
READ THE MANUAL furnished with your equipment area as possible:Be a good housekeeper . . . keep the
to learn its operating and maintenance characteristics, floor clean, free of oil, grease, rags, cables, chains,
capacities and limitations. Learn the location and buckets, rocks and other hazards. Keep loose parts in a
function of ALL controls, indicators, warning devices tool box. Use only non-flammable solutions for
and caution instructions. Learn to recognize the cleaning.
machine’s warning and safety devices. They will alert
you to conditions such as LOW PRESSURE or HIGH the weight limitations for any floors on you will
TEMPERATURE that may make it hazardous to operate.
continue operating.
Know the clearances in the work area. A little time
spent checking side and overhead clearances, including
power lines, can save a lot of trouble later.
DO YOU HAVE KNOWLEDGE OF WORKING
AREAS? Be careful of dust, smoke or fog, which may obscure
your vision.
Learn -- beforehand -- as much about your working

C-871
 Loose clothing can catch in moving parts. Keep sleeves 9. CHECK the Crusher thoroughly for visual defects,
buttoned, jackets belted, and wear your special safety such as leaks, worn hoses or loose parts.
equipment. Keep warm without restricting your
movement. Wrist watches and rings can be dangerous. 10. INSPECT your machine according to the
Keep your pockets free of objects which may fall out. operator’s manual and your supervisor’s
DO YOU UNDERSTAND YOUR instructions.
MACHINERY?
11. BEFORE STARTING walk completely around
ARE YOU PREPARED FOR EMERGENCIES? your machine. Make sure there is no one next to,
under, or on the machine. Warn any personnel
Plan ahead -- stay alert -- operate sensibly - - and you nearby that you are starting up.
will avoid both having and causing personal injury and
accidental equipment damage. If a careless moment REPORT ANY DEFECTS TO YOUR
does cause an emergency -- react quickly with the tools SUPERVISOR.FOLLOW the recommended
and skills at hand. Know the location of and how to use starting procedure as outlined in Section 11,
a fire extinguisher and a first aid kit. OPERATING INSTRUCTIONS.
1. AFTER Crusher has been started, check all
Know where to get prompt assistance. gauges and instruments to be sure that everything
is operating properly.
An emergency calls for fast action.
2. SHUT DOWN immediately if any improper
DON'T STOP YOUR SAFETY PROGRAM WITH THESE readings are observed.
GENERAL RULES. BE EQUALLY .CONSCIOUS THAT
SPECIFIC WORKING CONDITIONS - A N D YOUR 3. TEST all controls for proper functioning.
PARTICULAR EQUIPMENT -CAN REQUIRE ADDITIONAL
PRECAUTIONS. 4. LISTEN for and report any unusual noises.
BEFORE STARTING CHECK
5. RE-CHECK alarms or other warning and safety
Equipment not properly prepared for operation is devices.
unsafe equipment. Run a careful check at the beginning
of your shift. If you find something that needs attention, 6. DO NOT stand on the adjustment ring while the
THINK TWICE before deciding to "let it go this time”. Crusher is running.
Even minor mechanical defects can lead to personal
injury and accidents. 7. DO NOT lean or place your hands on or against
the spring clusters while the Crusher is in
1. DO NOT allow unauthorized personnel to operate operation.
the Crusher!
8. DO NOT take a chance with a defective machine.
2. MAKE SURE all guards and other protective REPORT IT TO YOUR SUPERVISOR.
devices are in place, secured and not damaged.
3. CHECK fluid, systems: Are they at the correct REPORT A DEFECTIVE MACHINE
level, and completely leak free?
Inspect your machine daily . . . check for loose, worn or
4. CHECK every drain cock, valve, and fitting to be damaged parts. Report or correct any unsafe conditions
sure it is in place and secure. immediately . . . and do not operate the machine until
they have been corrected.
5. LOSS of pressure from low fluid levels may lead
to serious hydraulic failures. Even a minor defect can become serious ... report any
machine defects to your supervisor.
6. CRUSHER SEIZURE from lack of oil is a
problem that may cause accidents.
STOPPING SAFELY
7. NEVER adjust pressure relief valves to get higher
operating pressures. The manufacturer’ Be sure Crusher is stopped before... cleaning, servicing,
recommended pressures give the safest lubricating • . . checking belt tension .• .removing
performance with the longest life. housing covers . • .working on hydraulic system . . .
making repairs • • • or attempting to clear a plugged
8. NEVER tamper with safety devices. cavity. MAKE NO CHECKS, ADJUSTMENTS OR

0-2 C-872
START UP SAFELY 1 CHECK equipment for TIPS FOR SAFE MAINTENANCE

warning tags. Perform Maintenance With Care 0—3

 REPAIRS OF ANY KIND WHILE CRUSHER IS IN cleaning fluid, oil or brake fluid. THESE
OPERATION. MATERIALS CAN DAMAGE YOUR EYES.
READ AND UNDERSTAND
3 WEAR A RESPIRATOR when required.
1 Instruction manual furnished with the Crusher,
especially Section 11, OPERATING 4 WEAR SAFETY GLASSES when drilling,
INSTRUCTIONS. grinding or hammering metal.

2 Instructions for inspection and maintenance 5 KEEP YOUR POCKETS FREE of objects which
located at the rear of Section 11, OPERATING can fall out and into machinery.
INSTRUCTIONS.
6 WEAR HARD HAT AND SAFETY SHOES,
3 Warning and caution plates provided on the when required.
machine.
7 WEAR GLOVES to protect your hands when
4 Warning and caution notes in the instruction changing cables.
manual.
8 WEAR SAFETY GLASSES AND
5 Lubrication guides for periodic servicing also at PROTECTIVE CLOTHING when using high
the rear of Section 11. pressure air.
9 WEAR GOGGLES AND PROTECTIVE
WARNING TAGS CLOTHING when handling molten metals; zinc,
babbitt, lead, etc.
Before working inside a Crusher, be sure to tag and
lockout the electrical controls so no one else will start it. 10 WEAR EAR PROTECTIVE DEVICES when
required or REDUCE exposure time as required.
Attach warning tags to prevent accidents:

1 If Crusher is unsafe for operation ALCOHOLIC BEVERAGES AND MEDICATION

2 If controls are being serviced A. DO NOT use alcoholic beverages before coming
to work or while on the job.
3 If machine is being repaired
B. BEWARE of medicines, tranquilizers or other
drugs which can make you sleepy or less alert.
LOCKOUT ELECTRICAL SERVICE

1 Always lockout all electrical controls before

performing any type of maintenance work on the WORK AREA
Crusher.
1 PROMOTE GOOD HOUSEKEEPING, keep the
2 When servicing the electrical power unit on those floor clean and dry, free of debris and tools. Oily
Crushers equipped with hydraulic clamping and and wet floors, steps and hand rails are slippery.
adjustment mechanisms, lockout the electrical In winter watch out for ice and snow. Wet spots,
service to the power unit as depressing especially near electrical equipment, are
the ’’STOP’’ button will only stop the motor. dangerous.

3 Provide each maintenance man with his own 2 DO NOT let material lay and build up on or
personal padlock and ONE key. around the Crusher.
3 STORE dangerous fluids in a suitable place
CLOTHING - SAFE PRACTICE --away from unauthorized personnel. ALLOW
NO SMOKING IN THE AREA!
1 KEEP HANDS AND CLOTHING AWAY
FROM MOVING PARTS. Do not take chances
by wearing loose sleeves, floppy ties, watches and
rings.
2 WEAR EYE PROTECTION when handling fuel,
C-873
 4 NEVER start a diesel or gasoline engine within an connections for wear.
enclosed area unless there is adequate ventilation. 6 DO NOT let greasy, oily rags accumulate in a
Exhaust fumes can kill! poorly ventilated area. Store oily rags and other
combustible material in a safe place.

EQUIPMENT 7 NEVER use an open flame to check fuel, battery

electrolyte, or coolant levels . . • or to look for
1 Use the proper tools; handle tools and heavy parts hydraulic leaks anywhere on the equipment. Use
sensibly. a flashlight!

2 Keep all tools and equipment free of dirt, oil and 8 KNOW where fire extinguishers are kept -- and
grease. Do not drop or toss them. how they operate -- and for what type of fire.
Check regularly -- at least monthly -- to be sure it
3 Use hoisting equipment for heavy lifting. Save is in the working area.
your back.
4 Lower parts, do not drop them.
PRESSURIZED SYSTEMS - HYDRAULIC OR AIR
5 To prevent slipping, wipe hand levers and knobs
clean of oil or grease. 1. Relieve ALL pressure before opening or
removing any hydraulic or air pressure lines,
6 Do not use sheaves with cracked rims or spokes. valves, fittings, etc.

7 Check for missing, cracked or frayed V-belts. 2. Check for worn hoses or damaged lines?

8 Check for broken, defective or missing parts and 3. High pressure oil can be dangerous.
replace them. Keep equipment clean and free of
dirt and oil so you can spot loose or defective parts.
USE QUALITY PARTS
9 When using cables to move a load, be sure cables
are of adequate size and replace any worn, badly A replacement part for any item should always be of
frayed, broken or kinked ones. Check end comparable SIZE, TYPE AND QUALITY -as the part
being discarded.

C-874 0-5
 PLANT SAFETY ELECTRICAL LOCKOUT

FIRE HAZARDS that the sheave could explode and cause severe injury or
even death.
1 DO NOT smoke while refueling -- or when
handling fuel containers. Since the speed of the Crusher is quite important for
proper operation, most V-belt drive guards usually have
2 SHUT OFF engine when refueling -- and use a small opening immediately opposite the center of the
extra caution if engine is hot. crusher drive shaft so that a tachometer can be inserted
to occasionally check the speed of the countershaft. This
3 WHEN pouring fuel into the tank, ground the
opening should be covered with an access door or hatch.
funnel or spout against the filler neck to avoid
static electric spark.
4 DO NOT use gasoline or diesel fuel for OPERATORS PLATFORM
cleaning parts. Good commercial,
nonflammable solvents are preferred. Since periodic inspection and maintenance must be
performed on each Crusher, IT IS IMPORTANT THAT
5 DO NOT smoke while using cleaning
SOME TYPE OF PLATFORM BE ERECTED AT A
LEVEL CONVENIENT FOR THE MAINTENANCE
solvents. MEN WHO MUST INSPECT AND WORK ON THE
REPORT NECESSARY REPAIRS CRUSHER. A good operators platform constructed
of ,Tsolidn floor plate should have hand railings, toe
If your daily check uncovers any item that needs plates and wire mesh or expanded metal between the
attention -- repair, replacement or adjustment platform and the top of the hand railing to prevent tools
—REPORT it NOW!The most minor defect could result from dropping off the platform and hitting someone
in more serious trouble -- IF THE MACHINE IS working below. Do not fasten the operators platform to
OPERATED. the adjustment ring as the entire adjustment ring raises
or lifts very quickly when tramp iron passes through the
Only perform the work you!re authorized to do. Do not Crusher.
attempt repairs you do not understand. THE ELECTRICAL POWER SOURCE FOR THE
CRUSHING EQUIPMENT SHOULD BE LOCKED
Only work on equipment you thoroughly understand --A OUT WHENEVER ANYONE IS WORKING ON IT.
pressure-loaded part, if carelessly released, could injure Each maintenance man who normally works on a
anyone in its path. Crusher should be provided with his own personal
padlock with only one key. When he works on any
assembly of the Crusher, he should use this padlock to
Remember you are entrusted with the operation and lock out the electrical controls for the Crusher. It is most
maintenance of a highly valuable piece of equipment. important that only one key be provided for the lock and
TREAT IT AS SUCH! that key must be in the pocket of the person who is
REMEMBER SAFETY IS UP TO YOU!The working on the Crusher. If more than one person works
safety procedures mentioned here do not eliminate all on the Crusher, each should have his own lock and key
safety hazards found in the area of crushing plants. at separate lockout stations for the controls of the
However, they do highlight some of the procedures Crusher. Accidental start-up of crushing equipment with
which have been found through long experience to men in the immediate area can be responsible for many
improve safety conditions around Crushers, and accidents on what was supposedly a "clear” machine.
crushing plants. Nordberg will welcome inquiries
regarding other suggested safety procedures for use
around their Crushers and related equipment. CRANES
DRIVE GUARDS
Crushers, like any other type of mechanical equipment,
Proper safety precautions start with the initial require normal periodic maintenance if the operator is to
installation of the Crusher. Crushers are driven either by get the most for his money from the use of the machine.
V-belts or by direct couplings to motors. THE BELT One of the most flagrant crusher safety violations is the
DRIVE OR COUPLING SHOULD HAVE A use of inadequate and unsafe lifting equipment.
PROTECTIVE GUARD AROUND IT. Although a Crusher is not a finely tuned piece of
equipment such as an automobile engine, the internal
Crusher sheaves in particular are designed for maximum parts of a Crusher should be assembled and
rim speeds. If these speeds are exceeded it is possible disassembled with crane facilities that have the

C-875 0-7
capability of gently and slowly lifting and lowering the
various parts that make up a Crusher. WHEN USING A
CRANE, ALWAYS OPERATE WITHIN THE
RATED CAPACITY OF THE CRANE. THE SAFE
RATED CAPACITY INCLUDES WEIGHT OF
HOOK, BLOCK AND ANY MATERIALS
HANDLING DEVICES SUCH AS CABLES, SLINGS,
SPREADER BARS ETC. SUBTRACT THE WEIGHT
OF ALL THESE TO FIND THE TRUE WEIGHT OF
THE LOAD THAT CAN BE HANDLED SAFELY.
Chain falls should be considered only as a last resort to
assemble and disassemble a Crusher. When it comes to
safety, the best should be used.

MOBILE CRANES

WHEN USING A MOBILE CRANE, ALWAYS

OPERATE WITHIN THE RATED CAPACITY OF
THE MACHINE TO AVOID BUCKLING THE
BOOM OR TIPPING, Safe ratings are based on
operating the crane on firm, level ground; outriggers
should be properly extended

C-876
 PLANT SAFETY ELECTRICAL LOCKOUT

and/or lowered whenever possible. Avoid fast swings, unsupported portion of the trailer beams stop vibrating
hoists or sudden braking; these can cause overloads. Do or until vibrations are reduced to a minimum. NEVER
not handle large, heavy loads in strong winds. leave your trailer in a low spot where rains may wash out
your footing. PERIODICALLY RECHECK TRAILER
When moving your crane, check bridges before crossing, FOOTING FOR STABILITY.
make sure they will support the weight of the machine.
Check clearances under bridges, for overhead electrical When moving your trailer, check bridges before
lines or any overhead obstruction. crossing, make sure they will support the weight of the
machine. Check clearances under bridges, for overhead
Check your hitcher, be sure he’s clear before starting lift. lines, or any overhead obstruction. NEVER TRAVEL
Make certain he securely attaches the load. WITH NEAR-CAPACITY LOADS, CHECK LOCAL
LAWS, ESPECIALLY ON WEIGHT LIMITATIONS.
When traveling on the highway make sure all headlights,
WELDING EQUIPMENT clearance lights and tail lights are on. Use proper traffic
warning flags and signs.
One of the most frequently used tools around the
Crusher is the cutting torch. Crushers which are
equipped with hydraulic components should have these CRUSHING PLANT nNOISE”
components depressurized and adequately covered with
flame-proof material so that sparks, weld spatter, etc., Crushing equipment by its very nature is noisy, and the
cannot reach these areas. Ruptured high pressure auxiliary equipment found in and around crushing
hydraulic lines will quickly vaporize the hydraulic fluid equipment such as chutes, transfer stations, screens, etc.,
as it reaches the atmosphere. This vaporized fluid can can at times be noisier than the Crusher itself. EAR
quickly become a mass of flames, resulting in severe PROTECTIVE DEVICES MAY BE REQUIRED IF
burns for personnel in the immediate area. ALL NOISE LEVELS ARE HIGHER THAN THOSE
MAINTENANCE PERSONNEL WHO NORMALLY ALLOWED BY LAW. If ear protective devices are
USE TORCH CUTTING EQUIPMENT SHOULD BE undesireable consideration should be given to reducing
ADVISED IF THERE ARE HYDRAULIC the amount of noise exposure that an operator or
COMPONENTS IN THE IMMEDIATE AREA IN maintenance man may be subjected to, in other words
WHICH THEY ARE WORKING. Then adequate shorter working hours.
precautions be made to avoid contact with these
components. Rubber lined hoses are not immune to the Although alteration of the machinery to change its noise
torch cutting equipment which is used in normal plant characteristics may be economically impossible, many
maintenance procedures. operators have found that the installation of a relatively
inexpensive operator^ station can improve noise
conditions. The operator can see the equipment in
CONVEYOR BELTS operation and still be protected from the noise through
the installation of acoustical tile, double windows, air
DO NOT USE CONVEYOR BELTS AS WALKWAYS. conditioning equipment, etc. These working conditions
Conveyor belts leading to and from the Crusher should will normally result in a more efficient operation and
be provided with walkways alongside the conveyor. reduce potential injuries from noise.
Always provide hand rails along the conveyor belt
walkway as an added safety precaution. Many plant operators are finding that an operator^ tower
erected at an elevation above most of the equipment
PORTABLE PLANTS provides both safety features for the operator and
increased efficiency in plant operation.
If your crushing plant consists of portable equipment,
that is crushing and screening equipment mounted on
trailers, trailer footing or cribbing is extremely important
for safe operation. Check your footing. Your machine
should be on as solid and level a footing as possible.
Use heavy timber mats as needed. Trailers must be
raised so that trailer wheels do not touch the ground.
Place screw jacks at each corner of the trailer or as near
the corner as possible. All four jacks must be an equal
distance from each end. Adjust each jack until the
C-877 0-7
 NORDBAK VERSUS ZINC by inserting a high pressure water hose into the crushing
chamber and washing away the material which has
All Crushers require some type of backing when jammed itself into the cavity. In machines which are
replacing the crushing members. Recent crushing a relatively coarse material, some operators
developments of epoxy resins such as NORDBAK have found that a long handled pruning saw can be used
Backing Compound have all but eliminated the to ’’saw awayff the material which is jamming the
possibility of workmen being accidentally burned Crusher.
due to molten zinc either spilling or exploding when
it comes in contact with wet surfaces. THE In some cases, hydraulic jacks have been used on the
ENORMOUS DEGREE OF CONVENIENCE AS outside of the Crusher to overcome the spring load
WELL AS THE HIGH SAFETY FACTOR holding the jammed material in place in the crushing
INVOLVED WHEN USING PLASTIC cavity. Excessive loading from a hydraulic jack on the
BACKING AGENTS HAS MADE THE USE OF external parts of a Crusher can cause severe stresses
MOLTEN ZINC FOR CRUSHER LINER within the Crusher and initiate cracks in some of the
BACKING OBSOLETE! more expensive assemblies.

When epoxy backings are used, care should also be

taken when removing the liners with a cutting torch. TRAMP IRON REMOVAL
THE AREA SHOULD BE WELL VENTILATED
BECAUSE EPOXY FUMES CAN CAUSE Without question, the MOST DANGEROUS
NAUSEA OR POSSIBLE EYE OR SKIN OPERATION around a Crusher is the REMOVAL OF
IRRITATION. TRAMP IRON which has jammed in the crushing
chamber. Extremely severe injuries, can occur trying to
remove tramp iron. ABSOLUTELY NO WORK
SHOULD BE DONE IN TRYING TO REMOVE
SPRING RING ASSEMBLIES TRAMP IRON LODGED IN THE CRUSHING
CAVITY WITHOUT FIRST READING
For those Crushers which use springs as a means of THOROUGHLY THE PARAGRAPH TRAMP IRON
REMOVAL IN SECTION 11.
protecting the Crusher from tramp iron overload, it
is recommended that the hydraulic jacks used to
assemble and disassemble spring clusters be tightly
secured to the Crusher itself by means of a chain or
cable. IF PROPERLY SECURED, ANY GENERAL MAINTENANCE WORK
UNEXPECTED AND SUDDEN MOVEMENTS
WILL NOT CAUSE THE JACKS TO BE A certain amount of work must be done in the immediate
FORCEFULLY EJECTED TOWARD THE area of the Crusher during the normal course of
PERSONNEL WORKING ON THE CRUSHER. It operations on a day-to-day basis. The following are
is also recommended to wrap a cable around the some of the do’s and don’ts to be followed as part of
springs themselves to keep them from being ejected normal crusher operating procedures,
away from the Crusher.
1 DO NOT perform maintenance on moving
machinery. This includes such items as adding
lubricating oil or greasing parts of the Crusher
CLEARING A CRUSHER while it is in operation.

There are many unforeseen events such as power 2 DO NOT put hands or feet on the spring clusters
failures, sudden surge of materials, etc., which can which protect the Crusher from tramp iron
cause a Crusher to become plugged with material and overloads while the Crusher is in operation.
stall. UNPLUGGING THE CRUSHER CAN
BECOME A VERY SERIOUS POTENTIAL 3 DO check the manufacturer’s recommendations
SOURCE OF ACCIDENTS. In many instances, the for periodic maintenance procedures. These
only way in which the Crusher can be restarted is to maintenance procedures are
literally dig the material out of the crushing cavity by
hand. Sometimes, however, alternate methods may be
used which make clearing the machine both easier
and safer.
In those machines which are crushing relatively fine
material, a plugged Crusher can sometimes be cleared

c-i406 0-9
 designed to not only avoid damage to the equipment but also avoid harm to the operator as well.

4 DO avoid spillage around the Crusher. Crushers seem to attract odd size pieces of rock, gravel, etc. Plant
operators should make it a habit to keep the area immediately adjacent to the Crusher free from this type of
spillage which could cause unsuspecting personnel to trip and fall.
NEVER look into the crushing cavity while the Crusher is in operation without protection from possible flying material.
Section 1
GENERAL CRUSHER INFORMATION

INTRODUCTION ............................................................................... 13
CRUSHER SIZES ............................................................................ 13

INITIAL INSPECTION ................................................................... 13

INFORMATION FURNISHED ........................................................ 13

REPAIR PARTS ............................................................................... 14
CRUSHER TERMINOLOGY .......................................................... 14
ESTIMATING CRUSHER CAPACITY .......................................... 15
SELECTION OF PROPER LINERS ............................................... 16
SECTION 1

GENERAL CRUSHER INFORMATION

INTRODUCTION

This Instruction Book has been prepared to assist you, the user, and those entrusted as operators, in the installation, operation, and maintenance of the
Symons cone crushers, Standard and Short Head.

The information contained herein will serve to acquaint you with the construction of the Crusher and as an aid in gaining the general knowledge
necessary for efficient operation and maintenance.

Each Crusher is completely assembled and test run prior to shipment, however, certain safeguards must be taken during use. These precautions are
defined in the following instructions, and will help to prevent the problems that arise because of improper operation or maintenance.

It is strongly recommended that the contents of this book be read, understood and put in practice prior to installation and during operation of the
Crusher.

CRUSHER SIZES

These instructions, in general, cover all sizes of Symons cone crushers； which are the 2 Ft., 3 Ft., 4-1/4 Ft., 5100, 5-1/2 Ft. and 7 Ft. sizes.

INITIAL INSPECTION
It is recommended that as soon as possible after receipt of the Crusher, a careful check be made for any possible damage which might have been
incurred during transit. A careful check should also be made to be sure that nothing has been lost and that all items on the Bill of Lading, Freight Bill
or Manifest can be accounted for. If any shortages or damages are discovered, these should immediately be brought to the attention of the respective
carrier so that necessary claims can be processed without any undue delay.

C-1317 1一1
 INFORMATION FURNISHED

The following drawings and data for your particular Crusher will be found in a separate book
entitled INSTALLATION DRAWINGS.

1 Foundation Drawing.

2 Oil Piping Drawings for the Crusher and lubricating system.

3 Water Piping Drawings when the water seal is furnished.

4 Drawings and Auxiliary Bulletins when the hydraulic clamping and adjustment mechanism is furnished.

5 All other drawings or informational data that might be required for your specific installation.

A Parts Manual containing the various assembly drawings pertaining to your Crusher will be sent under separate cover at a later date； usually
immediately after the Crusher has been shipped. This manual illustrates and identifies each and every part used in the assembly of the machine and is
to be used when ordering spare or replacement parts.

REPAIR PARTS
Vanguard 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:
1 Crusher Size and Type (Standard or Short Head).
2 The Serial Number of the Crusher which is stamped on the crusher name plate as well as on the cover of the Parts
Manual.Exact quantity of each part ordered.
3 Complete name and part code number as shown in the Parts Manual.

4 Complete shipping instructions. Advise whether shipment is desired by Mail, Express, Surface or Air Freight.

If your crusher Parts Manuals have been lost, destroyed or misplaced, an additional set will be supplied without charge upon
application.

For proper operation, only genuine factory parts should be installed. These are guaranteed as to accuracy, workmanship and
material.CRUSHER TERMINOLOGY

Throughout this manual certain terms will be used in describing the Crusher and its operation. In order that there will be no
possibility of confusion or mi sunder standing, these terms are defined as to their usage in the manual.
FEED OPENING (Open Side): The largest distance between the top of the crushing members as measured when the two
crushing members are at their farthest relationship during their gyrating cycle. The feed opening (open side) determines the
maximum size of feed.

1-2 C-1370
 DISCHARGE SETTING: The distance between the bottom of the crushing members as measured at the point where
the two crushing members are at their closest relationship during their gyrating cycle. This discharge setting regulates product
size.
MINIMUM DISCHARGE SETTING: The smallest permissible distance between the bottom of the crushing members as
measured when the two crushing members are at their closest relationship during the gyrating cycle.

DISCHARGE OPENING: The distance between the bottom of the crushing members as measured at the point where the
two crushing members are at their farthest relationship during their gyrating cycle. This wide opening permits rapid
discharge of the crushed material.

1-3
FEED： The raw material that is to be crushed. enhance crusher capacity and performance.

LINERS: The bowl liner and mantle are the crushing 1 Proper selection of crushing chamber for material
members and are commonly referred to as liners. to be crushed.

CAVITY ： The internal contour formed by the two 2 A feed grading containing proper distribution of
crushing members. the particle sizes.

PARALLEL ZONE: With the liners in their closest 3 Controlled feed rate.
relationship during the gyrating cycle, the lower portion
of both the bowl liner and mantle, for some distance, 4 Proper feed distribution 360° around the crushing
will be parallel to each other. This area is known as the chamber.
parallel zone.
5 Discharge conveyor sized to carry maximum
crusher capacity.
FEED OPENING (Closed Side): The smallest distance
between the top of the crushing members as measured 6 Properly sized scalping and closed circuit screens.
when the two crushing members are at their closest
relationship during their gyrating cycle. 7 Automation controls.
PRODUCT SIZE: The size of the screened material
after it has been crushed. 8 Adequate crusher discharge area.

The following factors will detract from crusher capacity

CAPACITY ： The output of the Crusher computed in and performance.
tons per hour.
1 Sticky material in crusher feed.

OPEN CIRCUIT OPERATION: The type of operation 2 Fines in crusher feed (smaller than crusher setting)
where precise uniformity of product size is not exceeding 10% of crusher capacity.
considered to be of prime importance and the feed is run
through the Crusher but once. 3 Excessive feed moisture.

4 Feed segregation in crushing cavity

CLOSED CIRCUIT OPERATION: The type of
operation where precise uniformity of product size is 5 Improper feed distribution around circumference of
important and the product is screened as it is being crushing cavity.
discharged and the material which does not pass
through the screen is returned to the 6 Lack of feed control.
Crusher.ESTIMATING CRUSHER CAPACITY 7 Inefficient use of recommended connected
Cone crusher capacity charts have been developed for horsepower.
use as an application tool to properly utilize the
machine’s capabilities. Symons Cone Crushers have 8 Insufficient conveyor capacity.
three separate and distinct capacities (see the tables
STANDARD CONE CRUSHER CAPACITIES or 9 Insufficient scalper and closed circuit screen
SHORT HEAD CONE CRUSHER CAPACITIES). capacities.
The difference between these is the point in the circuit at
which the measure is taken in either open circuit or 10 Insufficient crusher discharge area.
closed circuit operation. The crusher is one component
of the circuit. As such, its performance is in part 11 Extremely hard or tough material.
dependent on the proper selection and operation of
feeders, conveyors, screens, supporting structure, 12 Operation of crusher at less than recommended full
electric motors, drive components and surge bins. load countershaft speed.
Where used, attention to the following factors will

1-4 C-1370
Capacities shown on these tables are neither maximum To operate continuously with liners having a crushing
nor minimum and are based on results secured in actual cavity unsuited to the operation, results in
practice. The figures shown apply to short tons of uneconomical wear of the liners' poor crushing
material weighing 100 pounds per cubic foot and are efficiency and, in some instances, abuse to the
based on a properly graded feed. Crusher.

The capacities shown in the tables are based on results

obtained from thousands of installations worldwide,
crushing the broadest range of ores, rocks and minerals
to determine effect of individual conditions.

SELECTION OF PROPER LINERS

Through extensive research and study, Vanguard has

developed a varied line of crushing members covering a
wide range of feed and product sizes. Since there are so
many variable conditions and types of operation to be
considered, it would be difficult to list each type of liner
that would be best suited for each individual condition
and type of operation.
If for any reason, it is felt that unsatisfactory wear life
was obtained from the original liners, it is suggested that
the bowl liner and mantle be cut open so that the contour
of the bowl liner and mantle can be traced onto a sheet
of paper and the traced contours sent to the factory, in
order that the exact concentration of wear can be
determined.
Another bowl liner and mantle can then be
recommended which will have a different contour at
these wear points-
In order to properly answer any inquiry, it is important
that the following information be included：
1 Size of Feed.

2 Type of Feed.

3 Product Size Desired.

1-5
 Section) 2

GENERAL INSTALLATION INFORMATION

FOUNDATION ......................................................................................................................... 2-1

CRUSHER CLEARANCE DIMENSIONS .............................................................................. 2-1

CRUSHER AND SUB-ASSEMBLY WEIGHTS ..................................................................... 2-1

FEED ARRANGEMENT .......................................................................................................... 2-2

DISCHARGE ARRANGEMENT ............................................................................................. 2-3

TYPE OF DRIVE ...................................................................................................................... 2-4

INITIAL INSTALLATION OF V-BELT DRIVE .................................................................... 2-5

TENSIONING THE V-BELT DRIVE ...................................................................................... 2-5

V-BELT PRECAUTIONS ......................................................................................................... 2-8

INITIAL ALIGNMENT OF FLEXIBLE COUPLING ............................................................. 2-9

CRUSHER MOTOR ................................................................................................................ 2-11

PIPELINE INFORMATION ................................................................................................... 2-11

GENERAL ASSEMBLY AND DISASSEMBLY INFORMATION ..................................... 2-11

GENERAL MAINTENANCE INFORMATION .................................................................... 2-12

MINIMUM RECOMMENDED SPARE PARTS LIST .......................................................... 2-12

SPECIAL TOOLS ................................................................................................................... 2-13

PROTECTING THE CRUSHER AGAINSTRUST CORROSION ....................................... 2-13

 SECTION 2

GENERAL INSTALLATION INFORMATION

C-1407 2-1
FOUNDATION The feed platform can be adjusted vertically by turning the
feed adjustment nuts which support the platform. On the 7
The foundation drawing which is furnished will, in most Ft. Crushers, the feed platform is a rigid structure without
instances, govern the installation of the Crusher. The feed spout, and is furnished on the large machines due to the
foundation should conform wherever possible, to the size type of feed and the wide variation of feeding equipment
and type of construction recommended on the drawing. A available for these Crushers. A properly constructed feed
TYPICAL FOUNDATION ARRANGEMENT is shown at box mounted on top of the feed platform provides a
the beginning of this section. A solid level foundation of backstop for the feed as it comes from the chute so that the
proper proportion and durability is of utmost importance to feed will rebound and fall vertically through the feed spout.
the successful operation of the Crusher. The feed will then drop onto the feed plate in a more
uniform manner. The feed box, when correctly fed in
conjunction with the feed distributing plate on the Crusher,
CRUSHER CLEARANCE DIMENSIONS will help to assure a uniform distribution of thoroughly
A well planned installation is an absolute necessity for the mixed feed around the entire crushing cavity. Segregation of
ultimate success of the Crusher. One of the major fine and coarse material should be kept to a minimum to
considerations to be given the construction of the foundation achieve maximum liner wear. For best results on the
is crusher clearances. Sufficient head room should be “Standard” Crushers the feed should be regulated so that the
provided above the Crusher for the removal of the main crushing cavity is not entirely filled and that the feed does
shaft and bowl assemblies. Enough room should be not build up under the feed plate. On the “Short Head”
provided at the side of the foundation for the removal of the Crushers the feed should be regulated so that there is a
countershaft box assembly. Consideration should also be build-up of material below the feed plate and above the
given to the additional clearance required for the feeding crushing cavity. This bridge of material should extend
arrangement, such as; chuting, feed hopper and other around the entire cavity and serve as a limiting means to
auxiliary equipment. Adequate clearance should also be prevent overfeeding. With this type of feeding, a greater
provided for the discharge compartment, conveyor and output can be realized with a product of a finer and more
related equipment. In order to accurately determine crusher uniform size and also a substantial reduction in power
clearances, refer to the table CLEARANCE DIMENSIONS consumption. A feed box is not furnished with the Crusher,
as well as the foundation drawing. since the type of feed will determine how the feed box is to
be constructed and of what material.

WHENEVER POSSIBLE, IT IS ADVISABLE TO PLACE

CRUSHER & SUB-ASSEMBLY WEIGHTS A SCREEN AHEAD OF THE CRUSHER TO REMOVE
FINE OR STICKY MATERIAL FROM THE FEED
Another factor to be considered when designing the PRIOR TO CRUSHING. THIS WILL ELIMINATE
foundation and also a factor to be considered when planning PACKING, EXCESSIVE SPRING ACTION AND
overhead lifting equipment is crusher weights. An overhead INEFFICIENT OPERAION. A METAL DETECTOR CAN
crane, a rubber or track mounted mobile crane, a chain hoist ALSO BE INSTALLED TO REMOVE METALLIC
or other suitable equipment must be provided for handling OBJECTS, SUCH AS TRAMP IRON WHICH WOULD
heavy crusher components during erection or during the CAUSE SPRING ACTION.
replacement of the crushing members or other worn parts. Here the incoming material passes through one side of
Size requirements for hoisting equipment including cables, the feed opening, causing uneven distribution.
slings and hooks can be calculated by referring to the table
CRUSHER AND SUB-ASSEMBLY WEIGHTS. This table
gives the complete crusher weight as well as the weights of Results of uneven distribution:
sub-assemblies that require frequent handling.FEED
ARRANGEMENT 12. Reduced capacity.
The maximum efficiency which can be obtained from the 13. Oversize product.
Crusher is directly dependent on the feed arrangement. The 14. Excessive spring action.
Crusher can only reach maximum efficiency if the feed is 15. Maximum bearing pressure.
supplied in the correct amount and is evenly distributed 16. Maximum power consumption.
around the entire crushing cavity. By carefully checking the
foundation drawing and crusher clearance dimensions,
certain precautions can be taken regarding the installation of
the feed equipment. The construction should permit the easy
removal of this equipment when servicing the Crusher. The
feed arrangement, therefore, deserves a great deal of thought
in the planning prior to its eventual construction.

Each Crusher can be furnished with a feed platform and

spout which should be used whenever conditions permit.

2-2
 CORRECT METHOD OF FEED
Here the incoming material falls on the feed plate 9. Maximum capacity.
properly. 10. Uniform product.
11. Minimum spring action.
Results of even distribution: 12. Minimum bearing pressures.
13. Minimum power consumption.

FEED ARRANGEMENT
The feeding equipment must be of adequate size so as to If a chute is to be used, the slope of the chute must be more
maintain maximum feed conditions to the Crusher. than 45° with the horizontal and,

The correct and incorrect method of feed and feed box

construction are shown in the illustration FEED
ARRANGEMENT.

DISCHARGE ARRANGEMENT
Since the discharge arrangement varies with each
installation, a discharge compartment or chute is not
furnished with the Crusher. The construction should,
however, follow the recommendations as shown on the
foundation drawing. Either metal or wood may be used for
the discharge compartment. An inspection door should be
provided in the compartment so that the inside of the
compartment is readily accessible for cleaning or inspection.
A shelf or ledge should be constructed within the discharge
compartment. The shelf will provide a ’’dead bed’’ of
crushed material on which the fallingmaterial will hit. The
shelf will absorb much of the impact before the material falls
onto the conveying equipment, adding considerable life to
such equipment.

C-658 23
-
if material is very sticky, the angle of inclination should be 8V belts or banded belts. See the illustration BELT CROSS
increased. SECTIONS.

There should be sufficient clearance, as shown on the The narrower 3V, 5V, 8V belts are designed for
foundation drawing, between the main frame cap and the compactness of drive, drive economy and reduced overhung
bottom of the discharge compartment and between the load. Banded belts are single belts unitized with a common
discharge opening or chute and the conveying belt or cover to prevent belt whip or turnover. Banded belts fit all
elevator. Adequate clearance at these points will prevent standard sheaves, however, banded belts should be limited
material from clogging the discharge area and causing it to to only 2 or 3 individual belts banded together.
build up under the head and interfere with the operation of
the Crusher. This will insure a free unimpeded discharge of
crushed material. Should the motor sheave be located directly ABOVE the
countershaft or within 30° of the crusher vertical centerline,
the factory must be informed as to the position of the drive
sheave, so that the OUTER countershaft bushing can be
properly installed.
TYPE OF DRIVE
The standard recommendation for driving the Crusher is Power may be furnished by either an electric motor or diesel
through a V-belt drive. The V-belt drive is particularly engine.
desirable because of, first its feature \^iich prevents Crusher
shock loads from being transferred to the crusher motor and, The Crusher may also be direct driven, that is, coupling
secondly, its ability to carry surge loads without a resultant connected to a driving motor or engine.
loss in crusher speed.
Any problems related to the crusher drive should be
The V-belt drive can consist of either conventional ABCDE submitted to the factory for suggestions.
section belts, narrow 3V, 5V,

BANDED BELTS

BELT CROSS SECTIONS

C-659
 INITIAL INSTALLATION OF TENSIONING THE V-BELT
V-BELT DRIVE DRIVE
For the initial installation or when reassembling the V-belt Tensioning the drive is a term used when force is applied to
drive, proceed as follows: the V-belt by some method to provide the wedging action
between the V-belt and the sheave. This wedging action
9 Clean all oil, grease or rust from the sheave grooves. provides the ability for a V-belt to transmit power from the
motor sheave to the crusher sheave.
10 Make certain that the sheaves are correctly aligned and
that the shafts are parallel. Various methods of tensioning V-belts have been
established. Two simplified methods will be described in the
11 Never force belts onto sheaves. Always shorten the following paragraphs; Tension- Deflection and Percent (%)
center distance until belts can be slipped on easily. To of Elongation. Either of these two methods, if followed
determine the minimum allowances for shortening or closely, will provide belt tension such that the drive will
lengthening the center distance between sheaves, see operate satisfactorily. Each has certain advantages for a
the table V-BELT INSTALLATION AND TAKE-UP given type of belt.
ALLOWANCES.
For tensioning the drive using the TENSION-
12 Always use a matched set of belts and use new belts of DEFLECTION method, proceed as follows:
the same manufacture. Never mix worn and new belts.
4 Place a straight edge across the top of both sheaves.
See the illustration TENSION- DEFLECTION
TIGHT SIDE METHOD.

5 Measure the span length.

6 Using a spring scale at right angles to the center of the

span length, apply a force to the scale great enough to
deflect one of the belts 1/64” per EACH inch of span
length.

7 The force should approximate the forces shown in the

table DEFLECTION FORCES for a properly
tensioned drive.

EXAMPLE

V-belt section = Standard nD’’ Belt

Span length (Center Distance) = 62”

Deflection Force (From Table) = 20 to 30 pounds

Deflection = 62’’ Span Length x 1/64’’ =

62/64” or 3l/32Tf
DETERMINING SLACK SIDE

13 Place belts on sheaves and run the drive for a few

minutes. Then tension the drive until only a slight bow
or sag appears on the slack side of the belts when the
drive
is running. An example of tight side and slack side is
shown in the illustration DETERMINING SLACK
SIDE. The slack side depends both on motor position
and rotation of Crusher.

C-859 2-5
2-6 C-661
 After calculating a center distance from a standard of the narrower width of the sheaves, which results in
pitch length make provision that the centers can be less overhung load.
moved closer together by the amount shown in the
following table to facilitate installing the belts without
injury. Also, the centers should be adjustable over the
WHEN PROPERLY TENSIONED, A 3V, 5V， 8V
calculated distance by an amount as shown in last BELT MAY NOT FEEL AS TIGHT AS ONE
column of the table because of manufacturing tolerance MIGHT EXPECT FROM THE TENSION THEY
and possible stretch and wear of belt. CARRY. THEREFORE, IT IS ADVISABLE TO
CONVENTIONAL
r,
ABCDE" V-BELTS USE A SPRING SCALE TO CHECK BELT
TENSION ON THESE BELTS.
V-BELT INSTALLATION AND
TAKE-UP ALLOWANCES
Therefore on a NEW installation with
For tensioning the drive using the PERCENT (%) OF
anD” section belt and a span length ELONGATION method, proceed as follows. This
of 62’’，the belt should deflect 31/32" particular method of tensioning V-belt drives was
with a spring force of 20 to 30 developed primarily for tensioning banded belts.
pounds for a properly tensioned
drive. 4 Remove the slack from the belts.
1.At the'end of 2 - 4 hours of operation, the drive should be
retensioned to approximately the maximum force. 5 Next, wrap a 50 Ft. steel tape around the outside
circumference of the belt and measure to the nearest
2.After 24-48 hours, it is well to check the drive to see if the l/8M. Record this length. See the illustration
force on the belts is between the minimum and maximum PERCENT OF ELONGATION METHOD.
force shown on the table DEFLECTION FORCES.
Retension if necessary. Either excessively low or high
tension will affect the life and operation of a V-belt.

Because of the higher horsepower rating of 3V, 5V, 8V

belts, each belt will be required to operate at a higher
tension than belts used on a conventional V-belt drive.
The total tension, however, will be no higher than that
required by a conventional drive. In fact, the bearing
load will be less than that for a conventional V-belt
drive because

C-860 2-7
TAPE READING Belt
Multiplier Percent
Section*

A .010 1.0

B .009 0.9

C .008 0.8

D .007 0.7

E .006 0.6
Refer to TENSION-
3V DEFLECTION METHOD

5V .009 0.9

8V .009 0.9
* Standard or banded belts

CRUSHER SHEAVE ELONGATION FACTORS

PERCENT OF ELONGATION METHOD

2-8 C-861
 6 Multiply this recorded length by a percent of elongation factor which is shown in the table ELONGATION FACTORS
and add this amount to the initial measurement.

7 Elongate the belt to this new reading.

EXAMPLE

V-belt section = Standard or banded ”D” belt

Initial tape reading = 120”

Elongation factor (From Table) = .007
(Multiplier) which is 0.7% (Percent)

New length reading = 120” initial readingx • 007 elongation factor = 120M initial reading + •840 = 120.8” or 120-7/8”

Therefore on an installation with a "Bisection belt and an outside circumference measurement of 120n, the motor
sheave should be moved away from the crusher sheave until the steel tape reads 120-7/8” for a properly tensioned
drive.
8 Periodic belt tension checks must be made and if retensioning becomes necessary, the tensioning process just
described should be repeated.
It must be pointed out that the TENSION-DE- FLECTION METHOD is the preferred method of tensioning V-belts.
Usually the first sign that indicates retension- is necessary, is belt slippage. This slippage 1 show up in loss of power and
speed at the crusher sheave and in a high rate of belt and sheave groove wear. These conditions are usually accompanied by
belt ’’squeal’’ and also a heating up of belts and sheaves. These conditions are readily apparent and can be detected by simply
looking, listening and feeling.

V-BELT PRECAUTIONS
Some of the do’s and don’ts in connection with proper V-belt drive operation are as follows:

11 DO - Check belt tension frequently during the first few days of run-in operation. When the belts have had time to
become seated in the sheave groove, re-tension the belts. New belts have a certain amount of initial stretch and will
require additional tensioning.

12 DONTT - Overtighten belts as too much tension shortens both belt and bearing life. Maintain uniform tension. Idle belts
should appear snug or tight; in motion, they have a slight sag on the slack side,

13 DO - Keep drives well ventilated as heat build-up over 140o Fahrenheit causes belt life to become shortened. The sides
of the belt guard must be designed to allow for adequate circulation of air. Either perforated plate or expanded metal is
ideal for this type of application.
 14 DONfT - Allow any oil or grease to come in contact with the belts as excessive oil causes the rubber to swell and the
belts to fail prematurely.

15 DO - Make V-belt drive general inspections on a periodic basis. The following points should be checked at each
inspection.

C. Loss of crusher speed - check tension.

D. Unequal stretch - check for internal breaks.

E. Excessive elongation - check for overload.

F. Belt softening or swelling ■ check for oil or grease.

G. Belt hardening and cracking - check for excessive heat.

INITIAL ALIGNMENT OF FLEXIBLE COUPLING

For the initial installation or when reassembling the flexible coupling on a direct drive arrangement it is always desirable to
align the couplings as accurately as possible for the longest coupling life and minimum vibration. After the coupling halves
have been properly installed on the shafts, bring the two halves together and proceed to align the coupling as follows:
5 Check the gap and angular alignment by measuring the distance between the coupling halves, at four places, 90° apart,
around the circumference of the coupling. See the illustration COUPLING ALIGNMENT. To measure the gap, use a
feeler gauge or an inside calipers or a dial indicator with a magnetic base. Coupling halves must be aligned so that all four
measured dimensions DO NOT vary more than 0.015 inches.

If any of the four measured dimensions varies more than the 0.015 inch it would indicate excessive angular
misalignment.

6 Check parallel alignment by laying a straight edge across the outside diameter of the coupling halves, at four places, 90°
apart, around the circumference of the coupling. See the illustration COUPLING ALIGNMENT. Align so that the
straight edge rests squarely on both coupling halves. Check with a feeler gauge or with a dial indicator. Parallel
misalignment should NOT exceed 0,015 inches.

7 Gap, angular and parallel alignment are important whenever using a flexible coupling to drive a Crusher.

8 A safety set collar must be installed on the crusher countershaft to provide the proper countershaft end float or running
clearance. Refer to the instructions DIRECT DRIVE in Section 4, for the proper installation of a safety set collar.

CHECK WITH FEELER GAUGE FOR PROPER

PARALLEL ALIGNMENT ON OTHER COUPLING
HALF AT THIS POINT - CHECK AT 90° INTERVALS

COUPLING (CRUSHER COUNTERSHAFT)

 CORRECT PARALLEL ALIGNMENTCORRECT GAP 0.015" MAXIMUM
AND ANGULAR ALIGNMENT
INCORRECT GAP AND
ANGULAR ALIGNMENT ANGULAR

COUPLING ALIGNMENT
2-10 C-1037

INCORRECT PARALLEL ALIGNMENTCRUSHER

MOTOR
The electrical driving motor is to be a squirrel cage induction
motor; continuous rated, with normal starting torque
(approximately 125 percent) and normal breakdown torque
(approximately 200 percent) with ± 10 percent acceptable
voltage variance.

Abrasive resistant insulation and stator thermostats (an

internal protective device) are suggested. The motor can
either be open dripproof or totally enclosed fan cooled.

To maintain continuous service of the recommended

operating horsepower level shown on the foundation
drawing, an electric motor with a 1.15 service factor is
required. If a service factor of 1.0 is used, the horsepower
rating appearing on the motor's nameplate should be the motor, that the motor shaft extension and bearings are
approximately 15 percent higher than the recommended adequately sized for a direct drive application. The motor
operating horsepower. However, the crusher power draw is shaft diameter must be able to withstand peak torque.
to be held to the horsepower shown on the foundation
drawing. All horsepower ratings referred to on foundation drawings
are based on electric horsepower. Therefore, when using a
If a V-belt drive is used, care should be taken when ordering diesel engine as the driving unit, the engine manufacturer
the motor that the motor bearings are adequately sized for the must be contacted in order to find out what diesel
overhung sheave weight and belt pull. The motor must also
have 360 。 radial belt pull capacity. Motor shaft diameter horsepower is equivalent to the electric horsepower at the
must be able to withstand peak torque and simultaneous speed (RPM) shown on the foundation drawing.
bending due to belt pull and sheave weight. The shaft should PIPELINE INFORMATION
be of sufficient length to accommodate the entire length of The LUBRICATING SYSTEM, Section 10, describes in
the motor sheave bushing or hub as well as provide clearance detail the proper type of oil, its temperature and regulation,
between the motor housing and the rim of the sheave. as well as the equipment that is used or could be used in the
Crusher lubricating system. It should be noted that the
With the V-belt drive, slide rails under the motor are required lubricating system for the Crusher is designed for 125 PSI
to provide allowance for V-belt take-up due to belt stretch MAXIMUM operating pressure.
and for belt installation.
Consult piping drawings furnished to show the pipe and pipe
fittings supplied with the Crusher and any other lubricating
If a direct drive is used, care should be taken when ordering equipment. Pipeline layout will vary to suit local conditions.
C-1038 2-11
Two influencing factors should be considered in the layout GENERAL MAINTENANCE INFORMATION
of both feed and drain lines; the pipeline should be as short
When performing any maintenance work on the Crusher, the
and as direct as possible, without dead pockets or other flow
following general precautions should be observed:
obstructions and the drain line should have a minimum pitch
of lf，for every 12” of pipe used.
10 When removing parts with machined or bearing
It is necessary that all piping be checked for internal surfaces which may rust, they should be well oiled or
cleanliness, that all chips and cuttings at threaded ends be covered with a rust preventative, if they are to be kept
removed to safeguard the oil pump. out of the Crusher for any length of time.
Unions should be installed in suitable locations to facilitate
11 Use additional caution when handling any parts which
removal of any of the lubricating equipment：oil pump, filter,
have bearing surfaces or a machined surface that has
cooler, etc.
close tolerances.
All piping connections should be checked for leaks. It is very
important that the oil suction line between the pump and tank 12 When disassembling any parts with bearing or
be absolutely tight, since any leakage in this line will be machined surfaces, protect these surfaces from coming
reflected in the lowering of pump efficiency, that is, oil in contact with the ground by using wooden blocking.
capacity and oil pressure will be considerably lower and may
endanger the crusher lubrication. Leakage in the suction line 13 Bronze liners or bushings should be handled with
is especially dangerous since it does not reveal itself by an oil extreme care. Excessive ramming or pounding on this
leakage as would be the case in the oil pressure line. soft material may cause warping or springing of such
parts.
Attention should be given as to the direction of rotation of 14 Clean thoroughly and oil, all machined parts before
the crusher countershaft, as it is important that suction and installing them in the Crusher. Do not replace a
feed lines be connected properly to the crusher driven bearing surface without coating it with oil.
integral pump. For the correct arrangement of the integral
pump piping consult the piping drawings furnished. 15 When assembling two mating parts that require either
a press or sliding fit, coat the contacting surfaces with
a light coating of oil. This will act as a lubricant and
GENERAL ASSEMBLY AND prevent rusting in place. When pressing the main shaft
DISASSEMBLY INFORMATION into the head or the pinion onto the countershaft use a
white lead and oil mixture.
Symons cone crushers are shipped either as a complete unit
or in sub-assemblies, depending on crusher size. For 16 Inner and outer eccentric bushings are to be stored
domestic shipment, the smaller size Crushers are usually vertically, stored in any other position could cause the
shipped as a complete unit, ready to be set on the foundation. bushings to become out-of-round or elliptical. Great
In some instances these smaller machines will be dismantled difficulty could consequently be encountered when
into installing them in the Crusher. In some instances
sub-assemblies for export shipment or for domestic installation would be impossible.
shipment where shipping or handling restrictions so demand.
The larger size Crushers are, in most instances dismantled 17 All bowl, adjustment ring, main shaft, main shaft nut,
for shipment. locking collar, locking nut and locking nut cover
thread surfaces are to be rubbed with a cloth
In succeeding sections detailed instructions will be given impregnated with powdered molybdenum disulfide
covering the assembly and disassembly of the various and then coated with grease or oil. Again, should this
crusher components. Starting with the main frame, the powder be unobtainable, grease applied liberally is a
remaining components are discussed in their normal
assembly sequence. Whether the Crusher is shipped as a good substitute.
complete assembled unit or whether it is completely
dismantled, the Crusher can be assembled by referring to MINIMUM RECOMMENDED
those sections which apply to the Crusher depending on the SPARE PARTS LIST
extent of dismantling. The following is a list of the minimum spare parts which
should be on hand at all times to insure a minimum of down
Before installing any of these crusher parts, check that the time.
protective coating applied to all machined surfaces for
shipment has been removed, and that all parts are clean and 4. Bowl liner.
free from grit and dirt, especially oil passages and pipes.
5. Mantle.
All machined surfaces and threads that may have possibly
been damaged in shipment must be restored to the proper 6. Integral oil pump (if so equipped).
condition before assembly. After cleaning, lightly oil all
bearing surfaces and machined surfaces of mating parts.
2-12 C-1039
 example copper and aluminum, results in the formation of a
7. Step bearing plate shims (1 Set). tight oxide film that protects the surfaces from further
corrosion. On the other hand, rust on iron or steel is porous
8. Socket sealing ring springs (1 Set), so that water and oxygen can still get at the underlying
surface. Therefore, rusting continues and penetrates deeper
9. Socket sealing ring spring housings (1 Set). into the metal.
SPRINGS AND HOUSINGS ARE USED ONLY ON
CRUSHERS EQUIPPED WITH THE STANDARD Rust is dangerous and expensive. Rusting causes industry
HEAD SEALING ARRANGEMENT several billions of dollars annually. In many plants rusting is
the major cause of:

It is to be understood that this list contains only the minimum Downtime

compliment of spare parts and if the crusher installation is Lost Production
either in a remote location or consists of several Crushers, Wasted Production
this list should be expanded. Therefore, consult the factory High Maintenance Costs
for a suggested list of spare parts for your particular Early Replacement of Equipment
operation.
Rusting also creates:
Before storing any spare parts, check that the protective
coating applied before shipment is still intact. Safety Hazards to Personnel

Finally, when replacing any bushings, bearings or major This cost can be greatly reduced:
parts and when the Crusher is being started for the first time, Through a rust prevention program Through proper use
it is advisable to ’’run the parts in’’. Refer to the information of rust preventives
described in the paragraph entitled BREAK- IN
PROCEDURE in Section 11. To protect your Crusher from rust corrosion during seasonal
shut down or for foreign shipment or for outdoor storage
(winter or summer), the following protective measures are
SPECIAL TOOLS recommended:

Only tools which are not readily available through

commercial supply houses can be fur- nished with your 6 Remove the bowl and main shaft assemblies and fill
Crusher. the entire eccentric bore with a rust preventive
lubricating oil until the oil is level with the top of the
These tools consist of all the eyebolts necessary for handling socket liner.
the equipment; a few special wrenches; cables for turning
and adjusting the bowl; a mandrel for pouring backing; and Make sure that all piping and the breather hole in the
special capscrews for installing and removing the side of the countershaft box are sealed with pipe plugs
countershaft box. to assure that the entire inside of the Crusher can be
filled.
All of the tools are painted the same color as the Crusher for
immediate identification and shipped in a separate box.
Use a lubricating oil which has a rust- preventive blend
The illustration SPECIAL TOOLS shows the type of tools that is designed for the protection of internal parts of
usually furnished, but will vary slightly with each size of enclosed assemblies such as engines, compressors,
Crusher. pumps, gear sets, and hydraulic assemblies. The rust
preventives function by displacing water from metal
surfaces, by forming strong water-resistant films on the
PROTECTING THE CRUSHER AGAINST RUST surfaces, and by absorbing water in the system into a
CORROSION water-in-oil emulsion. These products provide as much
as 30 to 40 times the protection against rust as
Rusting is a specific type of corrosion that occurs on iron and high-quality lubricating oils that have not been
steel surfaces when both water and oxygen are present. especially formulated to prevent rust.
Rusting can occur even if the amount of water present is only
a very thin film that may not even be visible. In fact, rusting
of iron and steel in humid atmospheres is a common
experience. Since air, the normal source of oxygen, usually
contains some moisture, and ordinary water contains
dissolved air, the elements required for rusting are
practically always present. Corrosion of some metals, for
2-13
SPECIAL TOOLS
2-14 C-1409
 In most applications, the residual rust- preventive film left by these products need not be flushed away or otherwise
removed when the Crusher is to be filled with lubricating oil and put into normal service.

Generally, one (1) barrel (55 U.S. gallons) is sufficient to coat a Crusher. The viscosity of the oil should be in the
150 to 300 SSU at 100° Fahrenheit range.

7 Fill the countershaft box with oil through the 1/2n tapped hole in the top of the box casting. Some leaking will occur
from the end of the countershaft box, this is normal.

8 Turn the main shaft assembly upside down and fill the lubricating hole in the bottom of the shaft until the oil flows
out of the hole in the head, then drain. Brush or spray a light-bodied petroleum solvent containing a substantial
amount of a polar rust-preventive additive having strong attraction for metal surfaces, on the entire main shaft and
underside of the head.

The additive should have excellent ability to wet metal surfaces in the presence of water; as a result it strongly
resists displacement from the surface by water. The solvent should evaporate quickly and leave a thin, transparent,
greasy film. The material should be suitable for light and moderate service, for example, protected outdoor storage.
It should be applied at plant operating temperature by any convenient means (brushing, rolling, spraying) and the
film need not be removed when the Crusher is placed in operation.

9 Brush or spray this same greasy solution on the bowl and adjustment ring threads. Then cover the threads with a
liberal amount of a lithium base grease NLGINo. 1 containing 5-10% of molybdenum disulfide.

10 Pack the socket sealing ring (standard seal only) with this same grease, making sure the wipers are completely
covered. If the Crusher has a water sealing arrangement, fill the water chamber with the same oil as used in the rest
of the Crusher.

11 If the Crusher is equipped with a hydraulic clamping and adjustment mechanism, fill the oil tank on the power unit
with a similar rust preventive oil but having a viscosity of 150 SSU at 100° Fahrenheit, 25 U.S.
gallons are required for the entire hydraulic system. Make sure the oil is compatible with such a hydraulic system
where neoprene, polyurethane, bronze, nickel, chrome, steel and iron is used.

The hydraulic clamping and adjustment system must be operated to assure that the power unit, lock posts and rams
have been thoroughly coated with the rust preventive.

12 After the Crusher has been completely filled with the special rust preventive oil, the Crusher is to be drained before
placing it in storage, as the remaining film is all that is required for adequate rust protection.

DO NOT USE THIS OIL TO OPERATE THE CRUSHER AS IT IS DESIGNED ONLY FOR RUST
PREVENTION.

13 Then re-assemble the bowl and main shaft assemblies into the Crusher and cover the entire adjustment cap and bowl
hopper with a sheet of 8 mil BLACK polyethylene to prevent water from seeping into the Crusher and corroding the
bowl and adjustment ring threads. This sheeting is available in 20 ft. by 100 ft. rolls. Black is recommended as
transparent sheeting will deteriorate four^ (4) times faster than black. The end of the countershaft box and
countershaft should also be covered. Steel strapping or banding is an ideal method of holding the polyethylene
sheeting in place.

IF THE ABOVE RECOMMENDATIONS ARE FOLLOWED, A CRUSHER STORED OUTDOORS SHOULD HAVE
6-12 MONTHS OF RUST PROTECTION.
2-23 C-1039
Where it is necessary that the Crusher be shipped or stored dismantled, the various sub- assemblies must be protected more
thoroughly, as the previously described procedures are for metal surfaces that are NOT directly exposed to the elements; sun,
wind, rain, snow, etc.

The following protective measures are recommended in those instances where a Crusher must be shipped or stored
dismantled and the various sub-assemblies exposed to the elements:

5 Cover the entire top of the socket liner, the adjustment ring, and end of the counter-shaft box with the black
polyethylene sheeting to protect the inside of the Crusher after the Crusher itself was prepared as previously described
with a rust preventive oil. The sheeting must be adequately braced to prevent sagging.
6 Spray or paint the machined surfaces of the various sub-assemblies; bowl, main shaft and head, etc. with a specially
processed asphaltic material that is made fluid by means of a petroleum solvent. It is a medium-body, black liquid that can
be applied at room temperature by any convenient method. The solvent evaporates and leaves a hard strong dry
acid-resistant film. This coating provides long-time protection under severe conditions such as
unprotected outdoor storage and presence of corrosive fumes. It is especially suitable for unpainted external surfaces. The
treated parts will withstand considerable scuffing and moderately rough handling, but they should be protected against severe
physical damage, since the hard, dry film is not self-repairing. The film is somewhat similar to paint and although
semi-permanent can be removed even after prolonged aging by vigorous rubbing with solvent soaked rags.

FOR THOSE PARTS STORED OUTDOORS UNPROTECTED, THE ABOVE RECOMMENDATIONS SHOULD
PROVIDE 24 MONTHS OF PROTECTION AGAINST RUST CORROSION.

Section 3
OPERATING INSTRUCTIONS

CHECK LIST FOR STARTING NEW CRUSHER

PREPARATIONS BEFORE STARTING ................................................................................. 11-1

COUNTERSHAFT SPEED ....................................................................................................... 11-1

COUNTERSHAFT ROTATION ............................................................................................... 11-2

STARTING THE CRUSHER .................................................................................................... 11-3

BREAK-IN PROCEDURE ........................................................................................................ 11-3

SETTING THE CRUSHER ....................................................................................................... 11-3

ADJUSTING THE BOWL ........................................................................................................ 11-4

MINIMUM SETTING ............................................................................................................. 11-11

CHECKING THE CRUSHER SETTING ............................................................................... 11-11

THREAD LUBRICATION ...................................................................................................... 11-12

TURNING THE BOWL .......................................................................................................... 11-12

DETERMINING LINER WEAR ............................................................................................. 11-14

2-24 C-1039
 CLEARING THE CRUSHER ................................................................................................. 11-15

TRAMP IRON REMOVAL ..................................................................................................... 11-20

FACTORY OVERHAUL ........................................................................................................ 11-24

INSPECTION PERIODS ......................................................................................................... 11-24

TYPICAL CRUSHER PROBLEMS ........................................................................................ 11-27

LUBRICATION CHART FOR STANDARD SYMONS CONE CRUSHER ....................... 11-50

LUBRICATION CHART FOR SHORT HEAD SYMONS CONE CRUSHER.... 11-53

OIL LUBRICATION CHART ................................................................................................... 11-56

GREASE LUBRICATION CHART .......................................................................................... 11-57

OPERATOR’S DAILY CRUSHER LOG ................................................................................. 11-58

CHECK LIST FOR STARTING NEW

PRIOR TO ACTUAL STARTING OF CRUSHER

1. Wooden shipping wedges have been removed from between mantle and bowl liner

2. Crusher setting has been checked at---------------------------------------- ”

3. V-Belt drive tension and alignment

4. Relationship of countershaft bushing oil groove and drive location

5. Countershaft end float (l/32M to l/l6Tf)

6. Grouting and fastening of Crusher to foundation

7. Foundation design has ample discharge area for material to fall free and prevent build-up from below

8. Lubricating system:

a) Drain line pitch is ample (Minimum ln per 12”)

b) Brand name and type of oil in oil tank;

Specify name and type

c) Piping has been installed per factory drawings

d) Auxiliaries such as filter, cooler, immersion heater, pressure switch, temperature switch, flow switch, have been installed properly

e) Alarm system (Pressure Switch, Temperature Switch,

Flow Switch) has been electrically connected according to Wiring Diagram No as shown in Section 10

f) Location of relief valve and piping is correct

2-25 C-1039
 CRUSHER
g) Pump is rotating in correct direction

h) Independent oil pump gear reducer lubricant (if furnished) SATIS

FACTORY
i) Pump has been primed (if Integral Pump)

□ □□□□□
j) Piping connections are correct on pump

k) Filters have been vented (if furnished)

l) Countershaft box and oil tank air breathers have been installed properly

9. Sealing ring is free and floating (if Standard Seal)

10. Motorized feeder gear reducer lubricant (if furnished)

11. Recommended grease was forced into all adjustment ring

grease fittings

12. Hydraulics (if furnished)

a) Brand name and type of oil in power unit oil tank Specify name and type

□□□□□□□ □□□

2-26 C-1039
 b) All hoses from power unit to Crusher have been properly bled

c) At least one adjustment has been made to assure that bowl adjustment rams and lock posts are operating properly

d) Bowl lock arm engages notch in adjustment cap properly and has been installed to prevent undesired rotation during crushing

e) Hose from power unit to lock posts has ample MPlayn when bowl is rotated

f) Air filter-lubricator is full of oil and in proper working condition (if Air Power Unit)

JOG CRUSHER

1. Countershaft rotates in proper direction START CRUSHER

1. Crusher was run no load until drain line temperature was at least 70° F.

2. Crusher is running at______________________ RPM

3. Crusher head spin (running no load) is_____________________________________ RPM

4. Crusher has been checked for oil leaks from below Crusher

5. Power draw running empty is_________________________ Amps

□ □□□□□ □□□□□
6.

□□□□□ □□□□□□
Alarm system (Pressure Switch, Temperature Switch, Flow Switch) has been checked

7. Pitch of water drain line (if Water Seal) (Minimum l/2” per 12，，)

8. Water flow from water chamber is_____________________ GPM (if Water Seal)

9. Crusher was run at 50% of full power for at least two hours

10. Relief valve stopped returning oil to tank at_________________________________ 0F.

11. Feed distribution in crushing cavity AFTER SIX HOUR INITIAL OPERATION
1. Temperature differential between oil feed line and oil drain
line was______________ °F.

2. Customer has been advised of any recommended changes to his installation

PORTABLE PLANTS

1. Cribbing has been installed properly

2. If rubber mounts are used, Crusher is free to move without interference

SECTION 3

OPERATING INSTRUCTIONS
PREPARATIONS BEFORE STARTING LUBRICATING SYSTEM, Section 10.

Good inspection habits will do much to insure years of successful

2 Start the independently motor driven oil pump (if so equipped).
Remove the inspection cover in the oil tank cover and check the oil
operation of the Crusher. Do not rely on memory alone to regulate drain line inside the tank to be certain the oil is circulating. Under
required periodic maintenance, keep an accurate written record. normal operating conditions, the oil flowing out of the drain line
Regularly performing prestart and maintenance inspections will pay off should at least half fill the pipe.
in the way of eliminating costly down time and prolonging the life of the
Crusher. Before starting the Crusher perform the following operations: 3 If the Crusher is equipped with a crusher driven integral pump,
the pump must be primed and the countershaft box filled with oil
before starting the Crusher. Remove the pipe plug from the tee at
1 Check that the correct lubricating oil is being used and that the the pump and prime the pump by pouring in a quantity of oil. This
lubricating system has been installed as described in
2-27 C-1039

C-109
1 1H
is only necessary during initial start up or starting after an 4 Remove the wooden wedges which are driven in between the
extended shutdown. The check valve at the oil tank will maintain crushing members for shipping purposes.
prime under ordinary operating conditions.
5 Check the end float, the countershaft must be free to move axially
Fill the countershaft box with oil by disconnecting the flexible oil in and out l/32fT. See MOUNTING CRUSHER SHEAVE in
Section 4.
hose at the top of the countershaft box and filling the box with
lubricating oil. Reconnect the hose and securely tighten the 6 Make a final inspection of the Crusher to be certain that no tools
connection. Filling the box with oil is necessary to properly or mechanical obstructions are on the Crusher, that all joints and
lubricate the countershaft bushings with this type of oil pump upon fasteners are properly tightened, that no leaks are apparent, and
that there is no other reason why the Crusher should not be
initial start-up.
started.

7 Rotate the countershaft by hand to check that the mantle is not

striking the bowl liner and that there are no other mechanical
difficulties. Should the mantle strike the bowl liner, refer to the
instructions under ADJUSTING THE BOWL, later in this
section.

8 After all the previous steps have been checked, start the Crusher
as instructed under the paragraph STARTING THE CRUSHER.

COUNTERSHAFT SPEED

The correct speed or revolutions per minute (RPM) is most important for
the proper crushing action. The speed for all sizes of Crushers is shown in
the table COUNTERSHAFT SPEED. The sheave sizes recommended for
driving the Crusher are designed for full load running, therefore, the
countershaft speed will be somewhat higher when running under no load.
Experience has shown that by operating the Crusher at the correct
countershaft speed, maximum output of material can be achieved in
conjunction with a uniformly shaped product.

2-28 C-1039
 5100 AND
CRUSHER SIZE 2 FT. 3 FT. 4 FT. 4-1/4 FT. 5-1/2 FT. 7 FT.

Revolutions Per Minute (RPM) 575 580 485 485 485 435
Full Load
COUNTERSHAFT SPEED

The speed of the crusher countershaft determines the amount of material

and also the number of blows a particle will receive in passing through the All 4 Ft” 5100,4-1/4 Ft and 5-1/2 Ft SHORT HEAD Crushers
crushing cavity. If the Crusher cannot be operated at the correct RPM, a that use a standard main shaft (threaded at the top) are
slightly higher RPM is preferred (within 5 percent (%) of the correct equipped for COUNTERCLOCKWISE rotation of the
RPM) since if the speed of the crusher countershaft is reduced much countershaft Under SPECIAL conditions these Crushers can
below the recommended RPM the crushing performance would be be equipped to rotate CLOCKWISE, as described in the
adversely affected by over choking the crushing chamber and causing the instructions shown below for a STANDARD Crusher.
Crusher to stall.

EXAMPLE: A crusher countershaft with a

recommended speed of 485 RPM could be driven at
any speed between 485 and 510 RPM (485 RPM
+5%, - 0%) without affecting crushing
performance.
There are certain applications where a higher than normal RPM has been
recommended to improve particle size and/or shape without loss of
tonnage through the Crusher. This higher RPM is usually used in If the rotation on a STANDARD Crusher is changed from
conjunction with a special "reduced throw" eccentric. In such counterclockwise to clockwise, such as with a diesel drive, a special lock-
applications, consult the factory for the correct countershaft speed. washer must be assembled in the main shaft nut as described in the article
REPLACING MANTLE in Section 7 as the main shaft and main shaft
COUNTERSHAFT ROTATION nut have right hand threads. This locks the main shaft nut to the main

All STANDARD Crushers are equipped for COUNTERCLOCKWISE shaft and prevents loosening of the assembly but eliminates the

rotation of the countershaft and all SHORT HEAD Crushers are self-tightening feature. When using an electric drive motor on a

equipped for CLOCKWISE rotation of the countershaft. Direction of STANDARD Crusher, the motor should be wired to give the Crusher

rotation is as viewed from the drive end of the countershaft and should counterclockwise rotation.

not be reversed. Direction is important as the self-tightening main shaft

If the rotation on a SHORT HEAD Crusher is changed from clockwise to
nut or locking nut automatically keeps the mantle tight against the head,
counterclockwise, three parts must also be changed. They are the locking
relying on the correct rotation of the countershaft to provide this
collar, locking nut, and locking nut cover. These parts must all have right
self-tightening feature.
hand threads instead of the left hand threads that are used for clockwise
Under SPECIAL conditions STANDARD Crushers can be equipped to
rotation. This change will still retain the self-tightening feature; however,
rotate clockwise and SHORT HEAD Crushers, counterclockwise.
replacement parts with right hand threads may be very difficult to obtain,
as they are not normally stocked. It is NOT recommended to change
rotation on a SHORT HEAD Crusher.

Also, in the case of the crusher driven integral pump, the proper direction
of rotation is very important, refer to INTEGRAL OIL PUMP in Section
10.

If a change in rotation is made on a Crusher with a crusher driven

integral oil pump, the inlet and outlet piping must also be reversed.
BREAK-IN PROCEDURE

STARTING THE CRUSHER

2-29 C-1039
 The Crusher is driven by an engine or an electric motor. Starting the Crusher merely
amounts to starting the engine or motor according to the manufacturers1 instruction. Do
not introduce any feed to the Crusher during starting. To start the Crusher, proceed as
follows :
1 Start the engine or motor.
2 If the Crusher is equipped with an integral pump which only functions when the
Crusher is operating, check to be certain there is oil coming from the drain line in the
oil tank. If the pump is operating properly, the oil should flow out of the drain line into
the oil tank almost immediately after starting and is readily visible by removing the
inspection cover in the oil tank cover.
3 Check the rotation of the countershaft.
4 Check the speed of the countershaft.
DO NOT ALLOW THE CRUSHER TO OPERATE LONGER THAN TWO MINUTES IF
NO OIL HAS APPEARED AT THE DRAIN LINE INSIDE THE OIL TANK, AS SERIOUS
DAMAGE CAN RESULT TO THE CRUSHER. NORMALLY, OIL FLOWING OUT OF
THE DRAIN LINE SHOULD BE OF SUFFICIENT VOLUME AS TO HALF FILL THE
PIPE. LACK OF OIL FLOW CAN BE CAUSED BY SEVERAL CONDITIONS;
INSUFFICIENT OIL IN THE
LUBRICATING SYSTEM, OIL PUMP
FAILURE, LOSS OF PRIME ON THE
PUMP, OBSTRUCTIONS IN THE
FEED LINE OR AN INCORRECT
SETTING OF THE RELIEF VALVE.
REFER TO LUBRICATING SYSTEM.
SECTION IQ.

SETTING THE CRUSHER

5.16
11-
3
2-30 C-1039
Although the Crusher was test run at the factory, it is advisable after initial start-up or
starting after installation of new bearings, to permit the Crusher to run without a load or at
reduced load for several hours. This will permit a general running-in of the Crusher and
an assurance that all parts are functioning properly as well as being thoroughly
lubricated. It is also advisable to check the oil temperature more closely during this time.
Refer to the paragraph on OIL TEMPERATURE in Section 10.

SETTING THE CRUSHER

The crusher setting is dependent on the size of product required. In most instances the
bowl should be set so that the opening between the crushing members on the closed
side, measures a distance slightly less than the maximum size of product desired. In
addition to resetting the bowl when changing the size of the product, it is also necessary
to adjust the bowl to compensate for wear on the crushing members.
THE INITIAL SETTING AS DETERMINED BY THE SIZE OF THE PRODUCT DESIRED IS NOT AN
ABSOLUTE GUARANTEE THAT THIS IS THE BEST SETTING FOR MAXIMUM PRODUCTION. THIS
DEPENDS AT TIMES ON THE CHARACTERISTICS OF THE MATERIAL TO BE CRUSHED, ON THE
POWER DRAW OF THE CRUSHER MOTOR OR ENGINE OR ON ADJUSTMENT RING ACTION.

The setting of the Crusher is changed by either lowering or raising the bowl in the adjustment ring, by turning
the bowl assembly clockwise to lower and counterclockwise to raise. Lowering the bowl decreases the setting,
raising the bowl increases the setting.

ADJUSTING THE BOWL

ADJUSTING THE BOWL (Windlass and Adjustment Cap Screw Arrangement). This arrangement, normally
furnished on the 2 Ft., 3 Ft., 4 Ft., 5100 and 4-1/4 Ft. Crushers, uses windlasses located on the adjustment ring to
provide the mechanical advantage to turn the bowl and the adjustment cap screws to raise the bowl into the
crushing position. To adjust the bowl with the windlass and adjustment cap screw arrangement, proceed as
follows:

1 Loosen the adjustment cap screws sufficiently to allow the bowl to be turned into the ring to the desired
setting. A special wrench is provided for this purpose or a heavy duty air wrench and socket can be used.
2 Connect the windlass cable to the windlass and to the adjustment cap collar as shown in the illustration
WINDLASS AND ADJUSTMENT CAP SCREW ARRANGEMENT. Attach the cables to the proper
side of the adjustment cap to obtain the desired rotation.
3 Pry out the lock link pins and swing the lock links out of the way. Turn the
windlasses with the large cast wrenches. If necessary, pipe extensions can be
used on the wrench handles for added leverage. Turning the windlasses will wind
the cable around the windlass and turn the bowl in the adjustment ring. The pawl,
which is spring loaded, ratchets against the notches in the windlass, thereby
keeping the cable from unwinding when the wrench pressure is relaxed. Repeat
this procedure until the bowl assembly reaches the desired setting.
4 Swing the lock links in place against the adjustment cap and insert the lock link pin
through the lock link and into one of the locking holes in the adjustment cap collar. It
may be necessary to slightly rotate the adjustment cap in either direction to align the
holes in the lock link and the collar.
5 Tighten the adjustment cap screws. Do not tighten the screws in a consecutive
2-31 C-1039
 order, but alternate 180 degrees so that an even rise of the bowl assembly will be
made. This will raise the bowl into the crushing position and prevent the bowl from
rotating. See the illustration BOWL THREAD ENGAGEMENT WITH ADJUSTMENT
RING (Crushing Position). Sledge the cap screws tight, using a pipe extension on
the wrench handles if necessary, to insure maximum tightness. It is important that
these screws are absolutely tight to prevent any movement what-so- ever in the
bowl threads.
6 Check the screws for tightness after the Crusher has been in operation for several
hours and retighten, if necessary.

FAILURE TO ADEQUATELY TIGHTEN THE ADJUSTMENT CAP SCREWS COULD CAUSE THE
BOWL TO LOOSEN AND POSSIBLY BREAK THE ADJUSTMENT CAP SCREWS OR THE BOWL
AND ADJUSTMENT RING THREADS COULD WEAR EXCESSIVELY.

TURNING THE BOWL USING AN OVERHEAD CRANE

If an overhead crane, or some other lifting means is available, turning the bowl within the
adjustment ring requires somewhat more skill but less effort. To turn the bowl assembly
using a crane, proceed as follows:
1 Rig suitable lifting cables from the crane C-1245

2-32 C-1039
WINDLASS AND ADJUSTMENT CAP SCREW ARRANGEMENT
11-5
C-779
 keys. This will prevent the keys from
flying all the way out. The keys should
then be tapped out and removed by
hand. See the illustration WINDLASS
AND DUCKWORTH ADJUSTMENT
ARRANGEMENT.
2 Remove the three adjustment lock
post washers.
3 Adjust the bowl to the desired setting
using the windlass or overhead crane
as described in previous instructions.
4 Swing the lock links in place against
the adjustment cap and insert the lock
link pin through the lock link and into
one of the locking holes in the
adjustment cap collar. It may be
CRUSHING RELEASED FLOATING necessary to slightly rotate the cap in
POSITION OR TURNING POSITION either direction to align the holes in the
POSITION lock link and the collar.
BOWL THREAD ENGAGEMENT 5 Replace the three lock post washers,
WITH ADJUSTMENT RING with the rubber washer in between the
metal washers.
to the adjustment cap hooks and lift the entire bowl
assembly a very slight amount. By lifting the bowl 6 Turn the lock post down until it bottoms
ever so slightly, the bowl will float in the adjustment on the adjustment ring then back off
ring threads as shown in the illustration BOWL approximately 1-1/2 turns to allow
THREAD ENGAGEMENT WITH ADJUSTMENT clearance between the bottom of the
RING (Floating Position). post and the top of the adjustment
ring.
2 With the bowl suspended in the floating position,
7 Insert the tapered keys into the lock
two men can walk the bowl down or up within the post and using a sledge hammer,
adjustment ring to the desired setting. With each drive them securely in place to raise
quarter turn of the bowl, lower or raise the
the bowl into the crushing position and
prevent the bowl from rotating. Do not
assembly so that the bowl remains free in the sledge the keys in a consecutive order,
adjustment ring. but alternate 180 degrees so that an
even rise of the bowl assembly will be
made. It is important that the keys are
ADJUSTING THE BOWL (Windlass and Duckworth absolutely tight to prevent any
Adjustment Arrangement) movement what-so-ever in the bowl
threads. A clear ringing sound when
On the 3 Ft., 4 Ft., 5100 and4-1/4 Ft. Crushers, equipped sledging the keys is evidence that the
with a Duckworth arrangement for raising the bowl into the keys are tightly in place.
crushing position, proceed as follows：
8 Install the cotter pins in each key.
9 Check the keys for tightness after the
Crusher has been in operation for
several hours and resledge, if
necessary.

11-6 C-124G
 Remove the tapered keys by sledging. FAILURE TO TIGHTEN THE TAPERED
Do not remove the cotter pins inserted KEYS SUFFICIENTLY COULD CAUSE THE
through the keys until after the initial BOWL AND ADJUSTMENT RING THREADS
loading has been eliminated from the TO WEAR EXCESSIVELY.

WINDLASS AND DUCKWORTH ADJUSTMENT ARRANGEMENT

11-7
C-781
 COTTER PIN、 PER KEY

ADJUSTMENT 、
CAP SEAL

RUBBER
BOWL ADJUSTMENT
HOPPER LOCK POST
WASHER

STEEL
ADJUSTMENT
RUBBER SEAL LOCK POST
WASHERS
ADJUSTMENT
"ADJUSTMENT
BOWL HOPPER LOCK POST
CAP

APPROXIMATELY 1/2”
CLEARANCE IS
REQUIRED

ADJUSTMENT
RING

■"ADJUSTMENT CAP

-ADJUSTMENT CAP COLLAR

ANCHOR SHACKLE

ADJUSTMENT RING

WINDLASS CABLE

WINDLASS

11-8 C-1247
ADJUSTING THE BOWL (Adjustment Sheave and bending the washer.
Duckworth Adjustment Arrangement) 8 Insert the tapered keys into the lock post and
using a sledge hammer drive them securely in
This arrangement which is furnished on the 5-1/2 Ft. place to raise the bowl into the crushing position
and 7 Ft. machines uses a swivel casting and a sheave and prevent the bowl from rotating. Do not
located on either of two bosses on the adjustment ring sledge the keys in a consecutive order, but
to turn the bowl and the Duckworth arrangement to alternate 180 degrees so that an even rise of the
raise the bowl into the crushing position. To adjust the bowl assembly will be made. It is important that
bowl with the adjustment sheave and Duckworth the keys are absolutely tight to prevent any
adjustment arrangement, proceed as follows: movement what-so-ever in the bowl threads. A
clear ringing sound when sledging the keys is
1 Remove the tapered keys by sledging. Do not evidence that the keys are tightly in place.
remove the cotter pins inserted through the keys
until after the initial loading has been eliminated 9 Install the cotter pins in each key.
from the keys. This will prevent the keys from
flying all the way out. The keys should then be 10 Check the keys for tightness after the
tapped out and removed by hand. Crusher has been in operation for
several hours and resledge, if
2 Remove a few of the adjustment lock post necessary.
washers.
3 Connect the swivel cable to the adjustment cap
collar and around the sheave as shown in the FAILURE TO TIGHTEN THE TAPERED
illustration ADJUSTMENT SHEAVE AND KEYS SUFFICIENTLY COULD CAUSE THE
DUCKWORTH ADJUSTMENT BOWL AND ADJUSTMENT RING
ARRANGEMENT. Attach the cable to the proper THREADS TO WEAR EXCESSIVELY.
side of the adjustment cap to obtain the desired
rotation.
ADJUSTING THE BOWL (Hydraulic Adjustment
Arrangement)
4 Connect the opposite end of the cable
to an overhead crane (10 ton capacity), Another arrangement, for rotating and clamping the
if available, or by a block and tackle bowl, which provides all the conveniences of effortless
arrangement connected to a truck or
tractor. remote control, is the hydraulic adjustment
arrangement. This system, although optional, is
5 Swing the lock links out of the way and available on the 4 Ft., 5100, 4-1/4 Ft., 5-1/2 Ft. and 7 Ft.
rotate the bowl by pulling on the cable Crushers and can be installed on new machines as well
with a crane, truck or tractor. Turn the as existing machines now in operation. All the
bowl assembly to the desired setting. adjustments are made from a power unit, either
6 Swing the lock links in place against electrically or air operated. Positive clamping of the
the adjustment cap and insert the lock bowl assembly is automatically maintained by
link pin through the lock link and into hydraulic cylinders which replace the standard lock
one of the locking holes in the posts or adjustment cap screws.
adjustment cap collar. It may be
necessary to slightly rotate the cap in A lever on the power unit releases clamping pressure
either direction to align the holes in the on the hydraulic lock posts while adjustments are being
lock link and the collar. made, and when the lever is returned to the clamp
7 Remove or add the correct amount of position, pressure is automatically re-applied.
washers to each lock post so that when Hydraulic adjustment rams rotate the bowl to the
the tapered key is driven into place it desired setting by engaging notches on the adjustment
will protrude an equal amount on each cap driver ring. A spring loaded ratchet type bowl lock
side of the post. Always reassemble automatically engages these notches after each
the washers so that a heavy washer at retraction of the bowl adjustment rams and positively
least one inch thick is on top to support holds the setting until another change in setting is
the pressure of the tapered key without
WINDLASS AND DUCKWORTH ADJUSTMENT ARRANGEMENT
11-9
C-781
necessary. Installation, operation

11-10 C-1247
C-783
ADJUSTMENT SHEAVE AND DUCKWORTH ADJUSTMENT ARRANGEMENT
11-11
11-12 C-784
and maintenance of the hydraulic components are
completely described in Section 12. See the Recom-
illustration HYDRAULIC ADJUSTMENT CRUSHER mended
SIZE Type of Cavity Minimum
ARRANGEMENT. Discharge
Setting
SINCE CLAMPING PRESSURE IS UNIFORM
AND AUTOMATICALLY SUSTAINED, NO 2 Ft. Fine 1/4
PERIODIC INSPECTIONS FOR BOWL Standard Coarse 3/8
LOOSENESS ARE NECESSARY AND THE Extra Coarse 1/2
POSSIBILITY OF DAMAGE CAUSED BY 3 Ft. Fine 3/8
BOWL MOVEMENT DURING OPERATION Standard Medium 1/2
HAS BEEN ELIMINATED. Extra Coarse 1
Fine 3/8
MINIMUM SETTING 4 Ft. Medium 1/2
Standard Coarse 3/4
Under no circumstances should the Crusher be set Extra Coarse 1
closer than the recommended minimum setting for
that particular size of Crusher. Operating with less 5100 and Fine 1/2
than the recommended minimum setting causes 4-1/4 Ft Medium 5/8
excessive spring action and produces an Standard Coarse 3/4
unsatisfactory product. This also places an undue Extra Coarse
strain on the Crusher, resulting in added Fine 5/8
maintenance expense. The table RECOMMENDED 5-1/2 Ft. Medium 7/8
MINIMUM DISCHARGE SETTING shows the Standard Coarse 1
minimum discharge settings for the various sizes of Extra Coarse 1-1/2
Crushers. These settings are in keeping with Fine 3/4
maximum production and satisfactory Crusher 7 Ft. Medium
performance. Standard Coarse 1-1/4
Extra Coarse 1-1/2
CHECKING THE CRUSHER SETTING
Check the crusher setting by fastening a piece of 2 Ft. Fine 1/8
lead to the end of a strong, flexible wire and Short Head Coarse 3/16
inserting the lead slowly downward into the 3 Ft Fine 1/8
crushing cavity with the Crusher running empty. Short Head Medium 1/8
Make sure that the lead passes through the Coarse 1/4
PARALLEL ZONE of the crushing members. In the
same motion, quickly withdraw the lead and Fine 3/16
measure the thickness, this will give the setting of 4 Ft. Medium 5/16
Short Head Coarse 1/2
the Crusher. If necessary, reset the bowl assembly to Extra Coarse 5/8
the desired closed side setting. Do not use zinc to
check the crusher setting as zinc will not compress Fine 1/8
5100 and Medium 1/4
easily. Using zinc may cause the adjustment ring to 4-1/4 Ft. 5/16
lift slightly and give an incorrect measurement. Coarse
Short Head Extra Coarse 5/8
Fine 3/16
5-1/2 Ft. Medium 1/4
To determine if the crusher setting is the same all Short Head Coarse 3/8
around the crushing cavity, it is suggested that a Extra Coarse 1/2
piece of lead be inserted into the crushing cavity at Fine 3/16
four different locations, each 90° apart. Comparing 7 Ft. Medium 3/8
the four thicknesses will show at a glance if the Short Head Coarse 1/2
adjustment ring is setting level on top of the main Extra Coarse 5/8
frame or if the adjustment ring is tipped due to wear RECOMMENDED MINIMUM DISCHARGE
on one side of the Crusher because of improper feed SETTING
distribution. See the illustration FEED (All Dimensions In Inches)
ARRANGEMENT in Section 2 for the correct
method of feed.
Operating with a tipped adjustment ring can reduce
tonnage through the Crusher considerably and cause
excessive spring action.

C-1620 13-11
 THREAD LUBRICATION If the SINGLE cable pull was used to turn the bowl
assembly into the adjustment ring, the bowl tends to tip
As the bowl is the adjusting member of the Crusher, it in the adjustment ring threads. This tipping creates point
contact between the outside diameter of the bowl threads
is very important to lubricate the threads on the bowl and the flat surfaces of the adjustment ring threads in the
and adjustment ring periodically to insure free direction of pull, especially if the pull is not horizontal.
movement of the bowl within the adjustment ring. When the bowl is pulled ,!off center，，and tipping occurs,
thread galling or tearing can take place. This damage is
Grease fittings evenly distributed around the side or normally limited to the first thread on the bowl and
top of the adjustment ring are provided to enable adjustment ring and appears on the flat surfaces of the
lubrication of the threads while the bowl is in threads. The metal shavings created by the tearing of the
lead thread can damage the remaining threads as this
engagement with the adjustment ring. See the debris is carried along with the thread as the bowl is
illustration GREASE FITTINGS. turned into the adjustment ring. Similar thread damage
may occur when removing the bowl in this manner •
Grease should be forced into these fittings when the
bowl is both in the crushing position and the released If thread galling or tearing has occurred, the following
position. Establish a regular maintenance schedule for alternate methods of installing and removing the bowl
forcing grease into these fittings. Use a lithium base assembly will minimize thread damage.
grease such as NLGI No. 1 or equivalent, preferably
mixed with 5 - 10% (by volume) of molybdenum 1 Turn the bowl, using an overhead crane or some
disulfide powder. When crushing hot materials; other lifting means to "float” the bowl in the
clinkers, slag, etc., a high temperature grease, adjustment ring threads as shown in the illustration
preferably mixed with the same 5 - 10% (by volume) of BOWL THREAD ENGAGEMENT WITH
molybdenum disulfide powder should be used. This ADJUSTMENT RING. With the bowl suspended
powder mixed with lubricating oil has also been found in the floating position, two men can walk the bowl
satisfactory for such high temperature applications. down or up within the adjustment ring to the
desired setting. With each quarter turn of the bowl,
lower or raise the assembly so that the bowl
remains free in the adjustment ring. Turn the bowl
assembly at least two full revolutions using this
method.
2 Use a DOUBLE cable pull to turn the bowl
assembly in or out.
3 If the Crusher is equipped with hydraulic clamping
and adjustment use the bowl
ustment rams to turn the bowl until least two
full revolutions of the bowl are made.

After the bowl assembly has been turned into the

adjustment ring at least two revolutions, the SINGLE
cable pull can be used to turn the bowl in the rest of the
If difficulty in turning the bowl is encountered it is way. Make sure the bowl assembly is pulled slowly
probably due to galling or tearing of the thread (approximately ONE revolution per minute). Reverse
surfaces on either the bowl or the adjustment ring or the procedure when removing the bowl.
both. Such thread damage normally occurs during the Considerable force might possibly have to be exerted in
initial assembly of the bowl in the adjustment ring order to ffbreakft the bowl loose in the adjustment ring.
when Asing a SINGLE cable connected to the One or a combination
adjustment cap to npullM the bowl to the desired setting.
The bowl, when turned in this manner, is usually
rotated by pulling on the cable with a truck, tractor or
front end loader.

1H2 C-1241
 The following suggestions will do much to eliminate the
of any of the following faulty operating conditions could possibility of even experiencing a bowl that is difficult to
cause the bowl to become difficult to turn within the turn in the adjustment ring.
adjustment ring.
1 Periodically release the bowl from its crushing
1 Crushing hot materials; slag, clinkers, etc., using position and rotate the bowl back and forth.
unsuitable thread lubricant.
2 Add grease in the grease fittings located around the
2 Not lubricating the bowl and adjustment ring side or top of the adjustment ring while the bowl is
threads at recommended periodic intervals. in the adjustment ring. Establish a regular
maintenance schedule for servicing these grease
3 Worn or improperly installed adjustment cap seal. fittings. Use a grease as recommended in the
See the illustration BOWL SEALS. THREAD LUBRICATION paragraph found in
this section.
^ Worn or improperly installed dust collar seal. See the
illustration BOWL SEALS. 3 At the time of initial installation or whenever the
bowl is removed, clean the threads and coat them
5 Operating the Crusher at the same setting for too with the lubricant recommended in ASSEMBLY
long a period of time. INSTRUCTIONS in Section 8 prior to reassembly.

6 Locating the Crusher where it is exposed to the 4 Check the bowl seals occasionally for wear.
elements, particularly rain, without adequate
protection. If the bowl does become stuck in the adjustment ring and
ADJUSTMENT RING BOWL HOPPER the bowl cannot be rotated by ordinary means, proceed
as follows:
1 While the Crusher is operating, feed a quantity of
material into the Crusher with the bowl in the
released position.
2 Pour penetrating oil or antifreeze around the entire
circumference of the bowl threads and force these
same solutions through the grease fittings on the
adjustment ring. The penetrating oil or antifreeze
will loosen

BOWL SEALS

ITIAL LOCKING POSITION ADJUST- LOCK LINK IN

MARKON ADJUSTMENT CAP MENT COLLAR IS KACH
USED TO BE FOUR POSITION IS
FOR CONNECTED
TO THK

POSITION LOCKING POSITION

LOCKING POSITIONS
POSITION 11-13
C-1242
 3 During regular operation, keep an
any packed dirt that may have filtered accurate record on the exact number of
into the thread clearances and also locking positions used on this initial set
loosen any rust that may have formed. of liners, starting with the first locking
position and recording each locking
3 Using the windlass or swivel position until the liners have worn out.
arrangement, try turning the bowl by
applying as much force as possible.
AS NO TWO CRUSHING
If this procedure does not get OPERATIONS ARE IDENTICAL AND
immediate results, let the Crusher BECAUSE OF THE WIDE RANGE OF
stand for several hours while LINER STYLES AND THICKNESSES
periodically applying penetrating oil or AVAILABLE AND CASTING
antifreeze around the threads, then VARIATIONS, IT WOULD BE
repeat the previous steps. IMPOSSIBLE TO PREDICT IN
ADVANCE HOW MANY LOCKING
DETERMINING LINER WEAR POSITIONS A PARTICULAR SET OF
The following information will be extremely LINERS WILL HAVE TO GO
THROUGH BEFORE THEY ARE
helpful when trying to determine when the WORN OUT.
liners have worn to a point where
replacement is necessary. An accurate
4 After the liners have worn out, but
record can be kept to show the degree of before moving the bowl within the
liner wear without stopping operations. On adjustment ring, paint a short horizontal
the INITIAL set of liners, keep a record of line on the bowl hopper just above the
liner wear as follows: adjustment cap seal.

1 After the crusher setting has been 5 Install the new liners and by keeping a
reached, swing the lock links inward record of the locking positions, the
until they engage the adjustment cap degree of liner wear can be determined
collar. The cap must be rotated slightly by comparison with the number of
in either direction until a hole in the lock locking positions that were required
link aligns with a hole in the adjustment when the initial set of liners was worn
cap collar. Fasten the lock link to the out. The mark painted on the bowl
collar with the lock link pin. hopper will also show when the liners
are approaching the wear limit as the
2 Place an identifying mark on the hopper moves downward with each
adjustment cap at one of the lock link change in setting. Follow this
pins. This will indicate the INITIAL procedure several times to establish a
locking position. Locking positions are fairly accurate average as no two sets
shown in the illustration LOCKING of liners will wear exactly alike. As an
POSITIONS. Rotating the same hole in aid to the operator, the number of
the adjustment cap collar to the next locking positions available per each
hole in the lock link will bring the bowl revolution of the bowl as well as the
into a new locking position and gives a change in vertical height are shown in
very fine vertical adjustment of the the table VERTICAL TRAVEL OF
bowl. BOWL.

5100 and
2 Ft. 3 Ft. 4 Ft. 5-1/2 Ft. 7 Ft.
4-1/4 Ft.
CRUSHER SIZE
Pitch of Bowl Thread 1-1/2" 2" 2" 2"
2?t 2n
Number of Locking Positions
Available
24 24 24 24 32 64
In One Complete Revolution
of Bowl

All dimensions in inches

VERTICAL TRAVEL OF BOWL
 5100 and 7 Ft. 7 Ft.
4 Ft. 5-1/2 Ft.
4-1/4 Ft. Heavy Duty Extra Heavy Duty
CRUSHER SIZE
Pitch of Bowl Thread 2n 2n 2" 2，T
2M
Number of Locking Positions
Available
48 48 48 48 32
In One Complete Revolution
of Bowl
Vertical Travel of Bowl Per
3/64" 3/64" 3/64" 3/64" 1/16"
Locking Position
All dimensions in inches

VERTICAL TRAVEL OF BOWL USING HYDRAULIC ADJUSTMENT

IF YOUR PARTICULAR OPERATION DOES NOT in serious damage to the Crusher and crusher motor.
CALL FOR SUCH FINE VERTICAL ADJUSTMENT
Some of the reasons a Crusher stops under load are as
OF THE LINER, NOT ALL THE LOCKING follows; for example, Crusher drive motor or engine
POSITIONS POSSIBLE WOULD NEED BE USED. stopped because of power failure or lack of fuel, too
THEREFORE, MARK ONE OF THE HOLES IN THE much feed entering the crushing cavity causing the
LOCK LINK AND USE ONLY THIS HOLE FOR Crusher to stall, discharge conveyor stopped allowing
LOCKING THE LINK TO THE ADJUSTMENT CAP discharging material to back up and plug the Crusher or
a piece of tramp iron becoming caught in the crushing
EACH AND EVERY TIME YOU ADJUST THE cavity.
BOWL SETTING. THIS WILL ALLOW AN
ACCURATE RECORD TO BE KEPT WITHOUT The gyrating crushing action of the head could possibly
USING ALL THE LOCK LINK HOLES. cause the material caught between the crushing
members on the closed side to tip and raise the
adjustment ring a small amount. This caught material
wedges very tightly between the bowl liner and mantle
DETERMINING LINER WEAR USING because of the compression of the spring clusters in that
HYDRAULIC ADJUSTMENT. Liner wear can be area. See the illustrations CLEARING THE
recorded when using the hydraulic means of CRUSHER.
adjustment in much the same manner as previously ON OCCASION AN OVERSIZE PIECE OF TRAMP
described. To determine liner wear with the hydraulic IRON CAN BECOME CAUGHT, IMBEDDED OR
adjustment, record the number of strokes or extensions WEDGED BETWEEN THE CRUSHING MEMBERS
made by the bowl adjustment rams on the INITIAL set AND CAUSE THE CRUSHER TO STALL. IF
of liners. Each ram extension rotates the adjustment cap TRAMP IRON IS SUSPECTED AS THE REASON
THAT THE CRUSHER STALLED, READ
one notch on the driver ring, resulting in a change in the THOROUGHLY THE PARAGRAPHS TRAMP
crusher setting. On the next set of liners compare the IRON REMOVAL LOCATED IN THIS SECTION.
number of strokes to determine the degree of liner wear.
The number of locking positions available per each One of the MOST DANGEROUS OPERATIONS
revolution of the bowl as well as the change in vertical around a Crusher is the REMOVAL OF TRAMP IRON
height is shown in the table VERTICAL TRAVEL OF which has jammed in the crushing chamber. Extremely
BOWL USING HYDRAULIC ADJUSTMENT. severe injuries can occur by trying to remove tramp
iron in an incorrect manner. ABSOLUTELY NO
WORK SHOULD BE DONE IN TRYING TO
REMOVE TRAMP IRON LODGED IN THE
CRUSHING CAVITY WITHOUT FIRST READING
CLEARING THE CRUSHER THOROUGHLY THE PARAGRAPHS IN TRAMP
Should the Crusher stop under load, no attempt should IRON REMOVAL.
be made to start the Crusher again until the entire
crushing cavity has been cleared. Attempting to start
the Crusher with the cavity full of material may result

C-1483 11-15
 ON A STANDARD CRUSHER THE
INCOMING FEED USUALLY FILLS
THE ENTIRE CRUSHING CAVITY
WHEN THE CRUSHER
STOPS UNDER LOAD

ADJUSTMENT RING
RAISED SLIGHTLY
IN THIS AREA
?SER MATERIAL ON
ITHIS SIDE OF CRUSHING
CAVITY

BOWL LINER

ADJUSTMENT RING

SPRINGS
COMPRESSED ON CLOSED
THIS SIDE
SIDE
MATERIAL TIGHTLY
WEDGED BETWEEN
BOWL LINER AND
MANTLE ON CLOSED SIDE

CLEARING THE CRUSHER (STANDARD)

1M6
C-1484

11- 18 C-1492
 material, a curved saw with a long handle, such
ON A SHORT HEAD CRUSHER as a pruning saw, can be used to literally “saw”
THE INCOMING FEED USUALLY away the wedged material.
REMAINS IN ONLY 1/2 OF
THE CRUSHING CAVITY WHEN There are many unforeseen events which can cause a
THE CRUSHER STOPS Crusher to become plugged with material and stall.
UNDER LOAD UNPLUGGING THE CRUSHER CAN BECOME A
CLEARING THE CRUSHER (SHORT HEAD) VERY SERIOUS POTENTIAL SOURCE OF
ACCIDENTS. In many instances, the only way in
C-14 11-17 To manually which the Crusher can be restarted is to literally dig the
85 material out of the crushing cavity.
WARNING
WHEN CLEARING THE CRUSHER IN
ADJUSTMENT THIS MANNER, DO NOT PLACE FEET
OR HANDS ON THE SPRING
CLUSTERS OR IN THE SPACE
RING RAISED BETWEEN THE ADJUSTMENT RING
AND MAIN FRAME OR ANY PART OF
YOUR BODY BETWEEN THE LOWER
SLIGHTLY IN SPRING SEGMENTS AND THE MAIN
FRAME F L A N G E . S E R I O U S
P E R S O N A L INJURY CAN RESULT.
THIS AREA
clear the Crusher of material wedged
between the bowl liner and mantle,
proceed as follows:
1 Shut the power OFF to the crusher motor and
LOCK OUT the motor.
An arrangement for hydraulically clearing the Crusher
2 Clean out all loose material in the crushing cavity. is available on the 4 Ft., 5100, 4-1/4 Ft., 5-1/2 Ft. and 7
Always use extreme care when cleaning out the Ft. Crushers. This hydraulic clearing system will
crushing cavity as a piece of tramp iron could be substantially reduce the time and effort which
wedged between the bowl liner and mantle but ordinarily would be required to clear a Crusher AND is
HIDDEN by the loose material in the cavity. recommended as the SAFEST way to clear a jammed
crushing cavity.
3 With the aid of such tools as a sledge hammer,
and a long chisel or steel bar which has an end A portable electric power unit, when connected to
bent into the form of a hook, the wedged or hydraulic jacks either around the outside of the main
tightly compacted material must be punched or frame or on top of the adjustment ring, lifts the entire
picked out. adjustment ring vertically off its seating surface on the
main frame a predetermined distance. See the
4 In those machines which are crushing relatively illustration HYDRAULIC CLEARING SYSTEM.
fine material, a plugged Crusher can sometimes This additional clearance relieves the pressure from the
be cleared by inserting a high pressure water material wedged between the crushing members. The
hose into the crushing cavity and washing away material is now free to pass through the Crusher
the material. SAFELY or can now be EASILY CLEARED by
manual means. Installation, operation and maintenance
5 In Crushers which are crushing a coarser of the HYDRAULIC CLEARING SYSTEM are
completely described in Section 13.

BOWL ADJUSTMENT ADJUSTMENT RING

LINER RING IN RAISED POSITION

BOWL LINER AND

MANTLE ON CLOSED SIDE

C-1483 11-19
 ADJUSTMENT
RING

CLEARING JACK
CYLINDER CAP

HOSE
GUARD

M/2 HP, 3 PHASE

ELECTRIC
MALE MOTOR
FITTING
PRESSURE
GAUGE

RESERVOIR

HOSE

CONTROL
RELIEF VALVE VALVE
ADJUSTING
SCREW

HYDRAULIC CLEARING SYS

11- 20 C-1492
 TRAMP IRON REMOVAL type cutting torch is a self-contained tool which
consists of a combination of special metal alloy wires
inserted inside a long steel pipe which heats to a
As a piece of tramp iron enters the crushing cavity, the temperature in excess of 4,500° Fahrenheit when
springs around the outside of the Crusher allow the combined with pressurized oxygen forced through the
bowl and the adjustment ring to rise, thus preventing pipe. The intense concentrated heat, generated by such
damage to the Crusher. Immediately upon passage of a thermal cutting torch, melts the tramp iron with such
the tramp iron, the springs automatically return the speed that there is usually no structural damage to the
bowl and adjustment ring to the normal operating surrounding materials. A rotary motion to the burning
position. Refer to the illustration SPRING ACTION. torch is recommended in order to produce a washing
On occasion an oversize piece of tramp iron can action which permits the melted slag from the tramp
become caught, imbedded, or wedged between the iron to be blown out as the washing progresses. Its
crushing members and cause the Crusher to stall. compact size, mobility and low cost should make the
thermal torch a most desirable addition to a crushing
plant’s list of tools.

When the tramp iron becomes wedged between the To remove tramp iron wedged between the bowl liner
bowl liner and mantle, the tramp material causes the and mantle using a thermal cutting torch proceed as
adjustment ring to rise in the area where the tramp iron follows:
is caught by overcoming the spring force holding the
adjustment ring to the main frame. The spring force 1 Shut the power OFF to the crusher motor and
pulling down on the adjustment ring and bowl is what LOCK OUT the motor.
makes tramp iron removal extremely dangerous,
because in the process of removing the tramp iron, the 2 Clean out all loose material in the crushing cavity
highly compressed spring clusters pull the adjustment as described in the paragraphs CLEARING THE
ring back down to its original position on the main CRUSHER located in this Section. If the Crusher
frame almost instantaneously. stalled due to a piece of tramp iron proceed to Step
3.

One of the MOST DANGEROUS OPERATIONS WARNING

around a Crusher is the REMOVAL OF TRAMP IRON Extreme precautionary safety measures
which has jammed in the crushing chamber. Extremely must be taken when removing tramp iron.
severe injuries can occur by trying to remove tramp The reason such caution must be exercised is
iron in an incorrect manner. ABSOLUTELY NO that it is impossible to know how securely
WORK SHOULD BE DONE IN TRYING TO the tramp iron is wedged between the bowl
REMOVE TRAMP IRON LODGED IN THE liner and mantle. It is possible to have a
CRUSHING CAVITY WITHOUT FIRST READING piece of tramp iron caught between the
THOROUGHLY THESE PARAGRAPHS and the crushing members very tightly; it is also
paragraphs in CLEARING THE CRUSHER. possible to have the tramp material wedged
between the liners with only a small
The hydraulic clearing system, as previously described wedging force so that the slightest jarring of
in the paragraphs CLEARING THE CRUSHER, will the tramp iron could cause it to be squirted,
substantially reduce the time and effort which propelled or ejected rapidly upwards
ordinarily would be required to clear the Crusher AND towards the feed opening. Therefore the
is recommended, as it will permit the removal of tramp operator should use great caution whenever
iron SAFELY. See the illustration HYDRAULIC attempting to remove a piece of tramp iron
CLEARING SYSTEM. Installation, operation and from within the crushing cavity. UNDER
maintenance of the HYDRAULIC CLEARING NO CIRCUMSTANCES S H O U L D
SYSTEM are completely described in Section 13. A N Y O N E E N T E R T H E CRUSHING
CAVITY WHEN A PIECE OF T R A M P
I R O N I S W E D G E D BETWEEN THE
BOWL LINER AND MANTLE.
Should your Crusher not be equipped with a hydraulic
clearing system, the use of THERMAL CUTTING
TORCHES is recommended.
THERMAL CUTTING TORCHES. There are various
types of thermal cutting torches on the market that
operate with much higher temperatures than a
conventional oxy-acetylene cutting torch. The thermal

C-1483 11-21
 6 After the tramp iron has been located, lower the
3 For safety reasons and to permit a clear view into the cutting torch into the crushing cavity and proceed to
crushing cavity, the feed platform should be “wash” the tramp iron away. Start at the top of the
removed. tramp iron and wash the molten metal downward. It
is very important that the molten metal can run out
freely and it does not form a puddle on the tramp
IF THE CRUSHER IS EQUIPPED WITH A MAIN iron. Use a slight rotary motion to the cutting portion
SHAFT NUT AND FEED PLATE, SEE THE of the torch to speed up the “washing” operation and
ILLUSTRATION TRAMP IRON RE- MOVAL to keep the tramp iron from rewelding itself.
(STANDARD CRUSHER), THE MAIN SHAFT
NUT AND FEED PLATE CAN USUALLY BE
LEFT IN PLACE AS THE FEED OPENING IS DO NOT TOUCH THE TRAMP IRON OR PUT
WIDE ENOUGH TO PERMIT A CLEAR VIEW ANY PRESSURE ON IT WITH THE TORCH.
INTO THE LOWER PORTION OF THE ALWAYS MAINTAIN A SHORT GAP WHEN
CRUSHING CAVITY. CUTTING METALS. ALWAYS KEEP THE
TORCH MOVING TO PREVENT IT FROM
BEING FUSED TO THE METAL BEING
BURNED.
IF THE CRUSHER IS EQUIPPED WITH A During the cutting operation protect the
FEED DISTRIBUTOR AND FEED PLATE, discharge conveyor and nearby walls or flooring
SEE THE ILLUSTRATION TRAMP IRON from sparks or hot metal as it is possible for
REMOVAL (SHORT HEAD CRUSHER), IT IS molten slag to drop out of the Crusher onto the
ADVISABLE TO REMOVE THE FEED conveyor belt.
DISTRIBUTOR AND FEED PLATE IN
ORDER TO OBTAIN A CLEAR VIEW OF
THE TRAMP IRON.

WARNING
4 Since a thermal cutting torch is usually a steel pipe WHEN DOING ANY TORCH CUTTING
approximately 10 ft. long, the operator should stand AROUND A CRUSHER, PERSONNEL
on an operator’s platform surrounding the Crusher on SHOULD BE REQUIRED TO WEAR
the opposite side from where the tramp iron is RESPIRATORS, AS THE NOXIOUS
wedged, for a clear view of the crushing cavity AND FUMES PRODUCED DURING THE
FOR MAXIMUM SAFETY. The “pipe” can easily CUTTING PROCESS CAN BE HARMFUL
be bent to permit working in the crushing cavity. IF BREATHED CONTINUOUSLY IN
CONCENTRATED FORM. AVOID
INHALING FUMES! PROVIDE
ADEQUATE VENTILATION!
5 Connect the cutting torch to an oxygen supply, set 7 Work quickly as the burning time of the 10 ft.
the oxygen pressure and permit a small amount of long thermal cutting torch is 3 to 5 minutes.
oxygen to flow through the cutting torch. Ignite
the cutting end of the torch following the
manufacturer’s operating instructions very The pipe portion of a thermal cutting torch is
carefully; then open the oxygen regulating valve similar to a conventional welding electrode in
completely. The thermal cutting torch should now that the entire 10 ft. long pipe is self-consuming
burn vigorously. or “disappears” during use. THEREFORE FOR
MAXIMUM SAFETY DO NOT USE A
THERMAL CUTTING TORCH PIPE WHEN
WARNING THE PIPE LENGTH IS SHORTER THAN 5 FT.,
EITHER THREAD OR PUSH ON AN
WHEN WORKING WITH TORCH ADDITIONAL 10 FT. LENGTH AS THESE
CUTTING EQUIPMENT, USE HEAT CUTTING TORCHES ARE DESIGNED FOR
RESISTANT PROTECTIVE CLOTHING QUICK ATTACHMENT OF PIPE LENGTHS.
AND GLOVES, SHADED WELDING
GOGGLES, HARD HAT AND FACE
SHIELD FOR SAFETY REASONS.

11- 22 C-1492
CRUSHING CAVITY HAS Usually such equipment requires plant personnel to be
BEEN CLEANED OUT TO near the place where the tramp material is caught and
EXPOSE THE TRAMP IRON
does not offer any protection should the tramp iron
“slip” during the cutting process.
THEREFORE AN OXY-ACETYLENE CUTTING
TORCH IS NOT A SUITABLE METHOD FOR
WARNING REMOVAL OF TRAMP IRON AND SHOULD NOT
DO NOT ATTEMPT TO DISLODGE OR BE USED.
“LOOSEN” THE TRAMP MATERIAL
WITH A SLEDGE HAMMER, PRY BAR LANCING. Lancing is an operation in which
OR LONG PIPE. SERIOUS PERSONAL pressurized oxygen is fed through a long steel pipe by
INJURY COULD RESULT. DO NOT means of a hose and an oxy-acetylene cutting or
ATTEMPT TO DISLODGE OR uLOOS- welding torch is used to pre-heat the surface of the
EN” THE TRAMP MATERIAL USING material to be removed. The oxygen lance directed
ANY TYPE OF EXPLOSIVE DEVICE. against the pre-heated tramp iron causes the tramp
SERIOUS PERSONAL INJURY AND material to burn at a much higher temperature than a
SEVERE DAMAGE TO THE CRUSHER conventional cutting torch. However, if the tramp iron
COULD RESULT. is caught in the lower portion of the crushing members
pre-heating of the tramp iron would be extremely
DO NOT PLACE ANY BLOCKING OR difficult, if not impossible.
WEDGES BETWEEN THE
ADJUSTM E N T R I N G , M A I N F R A M E THEREFORE AN OXYGEN LANCE IS NOT A
O R SPRING CLUSTERS TO HOLD THE SUITABLE METHOD FOR R E M O V A L O F
ADJUSTMENT RING IN ITS RAISED TRAMP IRON AND SHOULD NOT BE USED.
POSITION WHILE REMOVING TRAMP
IRON IN THE CRUSHING CAVITY. FACTORY OVERHAUL
ONCE THE TRAMP IRON HAS BEEN Special facilities are available for rebuilding complete
REMOVED, THE SPRING FORCE Crushers or reconditioning parts which may have seen
PULLING DOWN ON THE unusual hard service or have become worn after long
ADJUSTMENT RING AND BOWL MAY periods of operation. It may prove advisable and
CAUSE THE BLOCKING OR WEDGES advantageous to return the Crusher to the factory for
TO SLIP OR SQUIRT OUT, OR THEY this work. A complete overhaul at times is more
MAY BE PINCHED SO TIGHTLY THAT economical than mere replacement of some badly
THEY MUST BE REMOVED IN THE worn parts. Crushers are completely dismantled, all
SAME MANNER AS A PIECE OF parts are inspected to determine serviceability and
TRAMP IRON. SERIOUS PERSONAL worn parts are replaced with factory made parts to
INJURY COULD RESULT. assure proper operation.
CHECK WITH THE FACTORY REGARDING
THIS SERVICE BEFORE SCRAPPING WORN
8 Once the tramp iron has been washed away and PARTS SUCH AS HEAD, BOWL, ADJUSTMENT
the adjustment ring lowers to its original RING, OR MAIN FRAME. Considerable savings
postition on the main frame, the cutting torch may be possible through reconditioning of such parts.
should be QUICKLY withdrawn. It is possible to
occasionally damage a cutting torch with the INSPECTION PERIODS
procedure just described as the torch can become
pinched between the bowl liner and mantle if the The best method of keeping a Crusher in good operating
adjustment ring returns to its seating surface on condition after it has been erected and operating
the main frame before the cutting torch can be satisfactorily, is regular periodic inspections. It is
withdrawn. recommended that the Crusher be inspected regularly
and adjustments made and worn parts replaced before a
major breakdown develops. The inspections that are
OXY-ACETYLENE CUTTING TORCHES. Oxy- required and the intervals of time for each inspection are
acetylene cutting is an operation in which a mixture of clearly given on the chart INSPECTION AND
pressurized oxygen and acetylene is fed through a MAINTENANCE PERIODS. These inspections are
conventional welding torch equipped with a cutting meant only as a guide and some individual judgement
attachment. The cutting torch directed towards the will have to be used to determine whether the
tramp iron causes the tramp iron to be cut only in the inspections are to be performed at closer or further
area directly beneath the cutting tip. intervals. The type of material handled, climate and
operating conditions will dictate the frequency of
inspections.

C-1483 11-23
Keep the Crusher clean and well painted. A clean
machine, as a rule, receives better care, is better
maintained and will not depreciate as quickly as one
which is neglected or abused.

11- 24 C-1492
 INSPECTION AND MAINTENANCE PERIODS

8 HOURS 40 HOURS 200 HOURS 2 000 HOURS

1. Check the level of oil in 1. Check V-Belts for 1. Release bowl assembly 1. Check step bearing
the oil tank. tension wear or breaks. from its crushing plates for wear.
position and rotate back
and forth.

2. Check the lubricating oil

2. Check oil 2. Check for oil leaks in both for dirt and sludge. 2. Check inner and outer
temperature pipeline and Crusher. Change if necessary. eccentric bushing
wear.
3. Inspect the oil strainer
within the oil tank for
3. Check for oil flow in the 3. Check mantle and bowl metal chips. Occasional 3. Inspect gear and
sight feed gauge or oil liner for tightness. small metal flakes are pinion teeth for
pressure if so equipped. normal. A large quantity wear and check
of chips may indicate backlash and root
excessive pressure on
bearing surfaces or clearances.
possible bearing failure.

4. Check mantle and bowl

liner for wear.

5. Check feed plate and

feed cone for wear.

4. Check power draw on 4. Check crusher 4. Check socket

motor. setting. liner wear.

5. Check adjustment cap 5. Check end float. 5. Check socket sealing

screws or tapered ring and spring
keys for tightness. housing for wear.
Also check sealing
ring springs
effective pressure
(Standard seal only).

6. Inspect main shaft

and head for wear.
6. Check for loose 6. Clean countershaft box and
fasteners or oil tank air breathers.
connections.
7. With bowl in crushing
position, grease
7. Check for unusual noise, adjustment ring and bowl 7. Inspect bowl and
indications of wear, or threads using grease adjustment ring
undue strain on fittings on the adjustment threads for wear.
crusher parts. ring.

C-1493 11-25
 INSPECTION AND MAINTENANCE PERIODS

8 HOURS 40 HOURS 200 HOURS 2000 HOURS

8.When crushing 8. Check adjust- 8. Check counter-

members ment cap seal shaft bushing
approach wear for tightness wear.
limit check against bowl
daily. hopper. 9. Look for leakage at
gaskets,
9.Check the oil flow 9. Check for packings, ’’O’’
back into the oil spring action or rings, and seals.
tank, both from the movement of
Crusher and from adjustment ring. 10. Inspect oil collar
the relief valve gear and oil pump gear
tooth wear
Check that alarm Check sheaves for (Integral pump only).
10. system is 10. dust accumu-
functioning lation, cracked
spokes and 11. Check if rubber
tightness on skirt around water
shaft. chamber has clear-
11.Check when stop- 11. Check feed ance between the
ping Crusher that plate bolts for baffle ring on head
Crusher ’’floats’’ tightness and the skirt. (Water
to easy stop. seal only).

12. Check that feed 12. Check main frame

to Crusher is properly liner wear.
distri-
buted. 13. Check arm guard and
countershaft
13.Check that box guard wear.
Crusher has a
free discharge. 14. Check for any cracked
welds.

15. Change oil in oil tank.

16. Check the springs around

the outside
of the Crusher for the proper
installed length.

11-26 C-1495
TYPICAL CRUSHER PROBLEMS
CRUSHER REFER TO
PROBLEMS POSSIBLE CAUSES COMMENTS/CORRECTIONS SECTION-PAGE
Crusher 1. Pump worn—not delivering enough oil. 1 • Check for proper oil flow (GPM) in 10-3
Overheating drain line.

2. Insufficient running clearances 6-26

between main shaft and inner 2. Check socket liner and ball of head
eccentric bushing. for wear. Use templates to check
the socket.liner and ball of head for
wear.
CONSULT THE FACTORY. The
socket liner undercut can be used
as a guide, the head should be
smooth without any noticeable
step.
3. Oil not draining properly. 2-11
3. Check pitch in drain line from
crusher to oil tank. (Minimum
1” per 12”).

Clean air breather on side of

10-39
countershaft box.

Drain line clogged with dirt or other

debris.
4. Improper crusher liners for application. 1-3
4. Too much crushing in lower portion
of crushing cavity causing
excessive power draw.

5. Hot or unusually hard feed causes 5. Requires installation of oil cooler 10-25
crusher to generate more heat. due to application. 10-31
6. Insufficient clearance for oil to flow 6-33
between top of eccentric and 6. Establish proper socket and
underside of socket. eccentric clearance, oil trapped
between inner eccentric bushing
and main shaft causing local “hot”
spot (1/4” to 1/8” clearance
required).
7. Insufficient oil supply. 10-32
7. Check relief valve for
malfunctioning due to wear, chips
or stuck spring, oil bypassing
crusher.

Check for the proper oil level in

10-5
tank.

8. V-belts tensioned too tight. 8. Retension V-belts. 2-5

9. Improper oil installed in crusher. 10-1
9. Change to proper oil. Extreme
Pressure oil recommended.

10. No end float 10. Reset end float (1/32” to 1/16”). 4-4, 4-6

11- 27
C-1547
 INSPECTION AND MAINTENANCE PERIODS

CRUSHER REFER TO
PROBLEMS POSSIBLE CAUSES COMMENTS/CORRECTIONS SECTION-PAGE
11. Crusher pulling too much power. 11. Improper feed conditions often 1-3
involved Excessive amount of
fines in feed, or crusher set too
tight for application.

Large amount of tramp material

in the feed causing overloads.
12. Crusher set too tight. 12. Do not set crusher setting below 11-11
recommended minimum
discharge setting.

13. Oil trapped between outer 3-5

13. Insufficient clearance between top
eccentric bushing and eccentric
of outer eccentric bushing and
—top of bushing must be flush
underside of gear.
with top of main frame.
14. Do not use shims thinner than 5-4
14. Too thin of step bearing plate shim 1/32”.
between lower step bearing plate
and main frame cap can “shift” and
close off center oil hole causing
reduced lubrication to the inner
eccentric bushing.
15. Lubrication hole in the main shaft 10-1
or head plugged with dirt or other 15. Vertical hole in main shaft,
debris. inter-connecting horizontal hole
in shaft and angular hole in
head must be cleaned using
high pressure air.
16. Outer eccentric bushing pulled in or 3-4
collapsed near where the gear well 16. Main frame bore must be
of the main frame joins the restored to its original diameter
either by machining or by hand
eccentric hub of the frame.
grinding. Hand grinding can
take as many as six to eight
hours to complete and is in a
confined area. While the “hand
ground” bore is somewhat
rough and irregular, it is an
effective way to remove the
pulled-in or collapsed area of
the frame.

17. Inner eccentric bushing pulled in 17. Hand grind the pulled in or 5-7
or collapsed at the TOP of the collapsed area of the eccentric 5-8
bushing on the THIN side of the until the bushing fits in the 5-9
eccentric. That area directly eccentric so that it is tight at the
opposite the main gear key. bottom. Do not force the
bushing into position.
CRUSHER
PROBLEMS POSSIBLE CAUSES COMMENTS/CORRECTIONS REFER TO
SECTION-P
AGE
Crusher
Throwing 1. Bearing surface of socket liner 1. Usually shows up as 6-26
Oil
worn away. (0-10 RPM normal excessive head spin. Regrind
head spin). socket liner or replace socket
liner, make sure contact area is
2. Socket sealing ring jammed in 2. Usually due to one of the 6-20
upward position holding head up locking keys in cocked position
away from socket liner. dust build-up around sealing
ring springs and housings, or
3. High oil pressure. 3. Excessive pressure lifts head 10-6
out of socket liner. Cold weather
start-ups often major factor.

Oil too cold or incorrect relief 10-32

valve.

4. Closed-in inner eccentric 4. Usually shows up as 6-26

bushing, creating more friction on excessive head spin. Head will
main shaft due to improper running spin at eccentric speed, usually
clearances. due to worn socket liner or
5. Excessive wear on feed plate or 5. Replace feed plate or add 7-1
on feed distributor assemblies. weight (welded plates) to top of 7-11
feed distributor to provide
proper balance.
6. Slabby feed being trapped 6. Cut down on feed size. 7-1
under feed plate and cocking
head.

7. Oil too cold. 7. Install oil tank immersion 10-6

heater and heat oil to 80° F.

8. Crusher lightly loaded. 8. Increase feed to crusher. 6-26

Under load contact area on
socket liner is at outer edge,
wnen crusher is lightly loaded

CRUSHER REFER TO
PROBLEMS POSSIBLE CAUSES COMMENTS/CORRECTIONS SECTION-PAGE
9. Excessive countershaft speed 9. Check for correct countershaft 11-2
(RPM). speed (RPM).
10. Change to proper oil. 10-1
10. Improper oil installed in crusher.
Oil too heavy.
 INSPECTION AND MAINTENANCE PERIODS

11. Crusher not vented properly. 10-39

11. Clean breather on side of
countershaft box. Use high 10-40
pressure air to clean out long
cored hole in countershaft box
to which the breather is
connected.
6-23
12. Oil passages or air vents in 12. Dismantle and clean all socket
socket plugged to prevent proper and liner oil drain holes and air
oil drainage. passages.
13. Drain hose from flinger housing 4-18
kinked or plugged. 13. Replace drain hose and/or
eliminate kink or sharp bend in
drain piping.

14. Oil not draining fast enough, from 14. Run separate drain line back to 4-19
flinger housing, especially when oil tank
oil is cold.

15. Drain line clogged with dirt or 15. Inspect drain line, clean if
None
other debris. necessary.
None
16. No orifice or too large of a hole in 16. Consult the factory for correct
the orifice in the bottom of the orifice hole size.
main shaft.

CRUSHER REFER TO
PROBLEMS POSSIBLE CAUSES COMMENTS/CORRECTIONS SECTION-PAGE
Capacity 1. Feed opening in bowl liner has 1. Replace liners or torch-cut 1-3
Falling Off closed-in due to wear restricting larger feed opening.
feed entry.
2. Low operating speed (RPM). 11-2
2. Check for correct countershaft
speed (RPM).

3. Too much moisture in the feed, 3. Moisture must be less than 5%. None
slowing the movement of the feed
in the crushing cavity.
4. Reduce feed size. 7-1
4. Extremely slabby feed causing
bridging before the feed opening at
the top of the liners.
5. Feed to crusher should be free 2-2
5. Large pieces of debris in the feed
(wood, tree roots, re-bar, etc.) of this type of material.
slowing feed movement.

6. Too large of a feed top size. 6. Reduce feed size. 2-2

7. Remove clay or sticky material

7. Large amount of clay in the feed. from the feed. None
 8. Correct feed arrangement. 2-2
8. Incorrect feed distribution,
segregated feed causes fines to be
fed in one side of the crushing
cavity.
9. Broken or cracked main shaft. None
9. Remove main shaft assembly
and carefully inspect the area
where the main shaft is pressed
into the head for possible
movement of the shaft within
the head bore. If in doubt have
the main shaft sonic tested.

CRUSHER REFER TO
PROBLEMS POSSIBLE CAUSES COMMENTS/CORRECTIONS SECTION-PAGE
Crusher 1. V-belts too loose. 1 • Retension V-belts. 2-5
Stalling
2. Electrical problems with drive 2. Check power draw of crusher None
motor. running empty and compare to
power draw of motor running
free (without belts). If both
readings are close, have
electrician check motor.
3. Wet, sticky feed to crusher.
3. Install water jets to flush
11-16
material through crusher, thus
11-17
preventing build-up in cavity.
4. Build-up under crusher. 2-3
4. Check foundation for ample
discharge of crushed material.
Install bin indicator and/or zero
speed switch on discharge
conveyor tail pulley.
5. Countershaft speed too low. 11-2
5. Check for correct countershaft
speed (RPM)
6. Oil pressure (PSI) too low. 6. Check for correct operating 10-3
pressure (PSI)

7. Feed level too high in crushing 7. Reduce amount of feed to 2-2

cavity causing excessive power crusher. 2-3
draw.
8. Electric motor or engine 2-11
8. Improper electric drive motor or
horsepower service factor too
diesel engine. low.
9. Incorrect feed opening (too small) 9. Check for correct selection 1-3
in crushing cavity. Most crushing of liners thru
being done at top of feed opening 1-9
which increases power draw.

10. Closed-in outer and/or inner 10. Crusher must be disassembled 3-4
 INSPECTION AND MAINTENANCE PERIODS

eccentric bushing thereby reducing to inspect condition of the 5-7

running clearances. bearings.

CRUSHER REFER TO
PROBLEMS POSSIBLE CAUSES COMMENTS/CORRECTIONS SECTION-PAGE
Water Getting 1. Vent passages not installed in 1. Dismantle socket and install 6-24
Into Oil socket. vents.
(Water Seal)
2. Oil passages and air vents 2. Dismantle and clean all socket 6-23
plugged to prevent proper venting and liner oil drain holes and
of water chamber. air passages.

3. Excessive water flow to chamber. 3. Check for proper water GPM 6-15
and constant water pressure.
Fluctuating pressure causes
splashing of water.
6-25
Check that water jets are all
pointing in a clockwise direction
to permit smooth water flow.

4. Inside diameter of baffle ring worn 4. Consult the factory for the 6-22
so that it no longer remains in the correct dimension.
water circulating in the water
chamber as the head gyrates.

5. Dirty water plugging drain lines 5. Water should be clean and free 6-15
from the water chamber. from foreign matter and
excessive sediment.

CRUSHER REFER TO
PROBLEMS POSSIBLE CAUSES COMMENTS/CORRECTIONS SECTION-PAGE
Frozen or 1. V-Belts tensioned too tight. 1. Retension V-belts and check 2-5
Broken sheave alignment.
Countershaft
2. No lubrication or not enough 2. Check for some type of None
lubrication to countershaft restriction between main oil
bushings. supply line and entry hole in
countershaft box. Remove any
type of valve or some other
means of restriction in the
supply line.
4-16
3. Oil groove in outer countershaft 3. V-belt drive should never pull
bushing in wrong position. countershaft into oil groove.

4. No end float. 4. Reset end float (1/32” to 1/16"). 4-4, 4-6

5. Bent countershaft. Usually shows 5. Replace countershaft. 4-15

up as excessive vibration to end of
countershaft or “wobble” to
crusher sheave.
 6. Oil groove in outer countershaft 6. Clean oil groove. 4-15
bushing plugged with dirt or other
debris.

7. Broken gear or pinion tooth. 7. Replace gear or pinion. 5-5, 4-11

5-2
8. Incorrect backlash and/or root 8. Check for correct backlash and
clearance between gear and root clearance.
pinion.

CRUSHER REFER TO
PROBLEMS POSSIBLE CAUSES COMMENTS/CORRECTIONS SECTION-PAGE
Stuck Bowl Accumulation of dirt or rust Try the following steps in order 11-12
between threads of adjustment ring
and bowl because of:

Hot incoming feed (slag). Pour anti-freeze into threads.

Poor thread lubrication. Loosen adjustment cap screws 11-4

or Duckworth keys or release the 11-6
pressure in the hydraulic lock 11-8
posts and run material through 12-17
crusher.

Worn adjustment cap seal or dust Run pieces of lumber through 11-12
collar seal. crusher.

Throw small pieces of “soff ’ steel

No weather protection.
through crusher.

Operating too long at one setting. Heat adjustment ring.

Galled bowl and/or adjustment Heat adjustment ring and cool

ring threads. bowl.
DO NOT REMOVE
Broken Threads. ADJUSTMENT RING FROM
MAIN FRAME.

CRUSHER REFER TO
PROBLEMS POSSIBLE CAUSES COMMENTS/CORRECTIONS SECTION-PAGE
Loose Bowl 1. Mantle - Main shaft nut or locking 1. Check for zinc or NORDBAK 7-8
Liner or nut does not self-tighten. poured too high and left in 7-18
Mantle contact with underside of main
shaft nut or locking nut.

2. Mantle - Crusher countershaft 2. Self-tightening feature of 7-4

rotating in wrong direction. mantle
will not work if countershaft is 7-14
rotating in wrong direction.

3. Locking nut on short head crusher 3. Insufficient clearance between 7-14

 INSPECTION AND MAINTENANCE PERIODS

bottoming on head. bottom of locking nut and top of

head. Minimum clearance
should be approximately 3/8”.

4. Mantle or head seating surfaces 4. Restore seating surfaces to None

worn or not machined correctly. factory dimensions.

5. Insufficient backing clearance 5. Backing clearance should be at 7-6, 7-8

between mantle and head. least 1/4" to 3/8". 7-17, 7-19

6. Mantle out-of-round. 6. Maximum out-of-round None

condition should be 1/4”.

7. Mantle not centered on head. 7. Check with feeler gauge at 7-6

bottom of mantle. Clearance 7-8
should be no more than 7-17
0.004 inch. 7-19

8. Mantle not tight on head during 8. See comment No. 7. 7-6, 7-8
initial installation. 7-17, 7-19

9. Mantle — Operating Crusher 9. Maximum idle time should be None

without feed for too long of a time. 30 minutes.

10. Mantle too thin. 10. Wear not to exceed 2/3 of None
mantle thickness.

11. Old backing not completely 11. Remove all old backing to 7-6
removed before installing new permit the new mantle to seat 7-16
mantle. correctly on the head.
12. Bowl liner - broken hooks 12. Badly worn bowl linen thin 8-1
section flexing.

13. Bowl liner - loose or broken 13. Rubber belting washers not 8-9
U-bolts. installed when bowl liner was
replaced.

14. Wear not to exceed 2/3 of bowl

14. Bowl liner too thin. liner thickness. None

15. Too much tramp iron or sticky 15. Too much tramp iron or sticky 2-2
material going through the crusher. material will cause adjustment
ring to jump.

16. Bowl liner or bowl seating surfaces 16. Restore seating surfaces to None
worn or not machined correctly. factory dimensions.

CRUSHER REFER TO
PROBLEMS POSSIBLE CAUSES COMMENTS/CORRECTIONS SECTION-PAGE
17. Old backing not completely 17. Remove all old backing to permit 8-7
removed before installing new the new bowl liner to seat
bowl liner. correctly in the bowl.
 8-8
18. U-shaped fiber glass inserts used 18. Remove bowl liner, trim the
around bowl liner hooks caught inserts to provide a 1/2”
between bowl liner seat and bowl minimum clearance between
causing improper seating. bottom of insert and edge of
bowl liner seat.

CRUSHER REFER TO
PROBLEMS POSSIBLE CAUSES COMMENTS/CORRECTIONS SECTION-PAGE
Oil Leak at 1. Crusher not vented properly. 1. Clean breather on side of 10-39
Sheave End of countershaft box. Use high 4-1
Countershaft pressure air to clean out long
Box cored hole in countershaft box
to which the breather is
connected.
2. Drain hose from flinger housing 4-18
2. Replace drain hose and/or
kinked or plugged.
eliminate kink or sharp bend in
drain piping.
4-19
3. Oil not draining fast enough, from
3. Run spearate drain line back to
flinger housing, especially when oil
is cold. oil tank

4. Worn piston ring between oil 4. Replace piston ring and rework 4-11
flinger and flinger housing. housing bore, if necessary.

CRUSHER REFER TO
PROBLEMS POSSIBLE CAUSES COMMENTS/CORRECTIONS SECTION-PAGE
Excessive 1. Weight change due to worn 1. Excessively worn feed plate or 7-1
Vibration crusher parts. feed distributor parts. Add 7-11
weight onto feed distributor or
replace worn parts.

2. Excessive head spin. 5-8

2. Head and main shaft moving
with eccentric due to seized
inner eccentric bushing.
3. Gear and pinion tooth root 3. Improper gear mesh, gear 5-2
interference. bottoming on pinion. Raise
eccentric assembly by
shimming.
4. Bent countershaft. 4. Replace countershaft. 4-15

5. Crusher sheave badly out of 5. Remove dirt build-up from

4-4
balance. spokes and rim of sheave.
6. Check cribbing or soil 0-8
6. If crusher is mounted on a
conditions.
portable plant, cribbing or soil
conditions maybe inadequate.
 INSPECTION AND MAINTENANCE PERIODS

7. Check foundation or soil 2-1

7. Inadequate foundation and/or soil
bearing capacity. conditions.

7-4, 7-14,
8. Loose mantle. 8. Remove mantle and re-install.
7-20

9. Countershaft speed (RPM) too 9. Check for correct countershaft 11-2

high. speed (RPM).

CRUSHER REFER TO
PROBLEMS POSSIBLE CAUSES COMMENTS/CORRECTIONS SECTION-PAGE
Wear on Head 1. Crusher operating with loose 1. Make sure crushing members 8-8
or Bowl mantle or bowl liner. are seated properly when 8-9
Seating assembling with related parts 7-7
Surface and that locking nut or main 7-9
shaft nut is tightened securely 7-17
BEFORE operation. 7-19

2. Crusher operating with excessively 2. Thin section of crushing None

worn mantle or bowl liner. member flexes, accelerating
wear on head or bowl seating
surfaces.

3. Wearing completely through 3. See comment No. 2. None

mantle or bowl liner and crushing
on head or bowl.

4. Cracked mantle or bowl liner. 4. See comment No. 2. None

 INSPECTION AND MAINTENANCE PERIODS

CRUSHER REFER TO
PROBLEMS POSSIBLE CAUSES COMMENTS/CORRECTIONS SECTION-PAGE
Dust and 1. Insufficient grease in socket 1. Fill socket sealing ring with 6-21
Dirt Getting sealing ring. proper quantity of grease.
Into Lube
System 2. Insufficient water in water 2. Check for proper water GPM 6-15
chamber. and constant water pressure.

3. Baffle ring welded to head with 3. Weld baffle ring to head with a 6-24
intermittant weld. 1/4” continuous fillet weld.

4. No air breather on side of 4. Install breather on side of 10-39

countershaft box. countershaft box.

5. Breather on side of countershaft 5. Clean both breathers; with 10-5

box or oil tank not functioning crusher operating, a piece of 10-39
properly. paper placed over the breather
piping should move in and out.

6. Crusher sheave swirling dust into 6. Using hose, relocate counter- 10-39
the countershaft box breather. shaft box breather away from
crusher sheave.

7. Dust and dirt falling into Crusher 7. Cover socket and eccentric None
when Crusher has been dis- area with canvas tarpaulin or
mantled for servicing or polyethylene (plastic) sheeting
maintenance. when servicing crusher.

8. Vent passages in water seal 8. Check that drain holes or 6-23

socket plugged. chipped grooves are open.

9. Water seal socket not vented. 9. Check that vent pipes or water 6-23
chamber baffle ring are 6-24
installed.
10. Worn socket sealing ring or head 10. Replace socket sealing ring or 6-18
wiper allowing dust to infiltrate build-up with weld and rema- thru
into the crusher. chine head wiper to original 6-21
factory dimensions.

11. Socket sealing ring jammed in the 11. Dismantle and thoroughly
downward position or cocked on clean socket sealing ring area
the socket. and replace socket sealing ring
springs and housings.

12. Too great of a vertical drop in the 12. Dust and dirt will be sucked None
crusher drain line between into socket area. Add an
crusher and oil tank. additional breather in crusher
drain line in vertical pipe just
below countershaft box elbow,
Y-branch or tee coming from the
horizontal pipe.
Consult factory.

13. No seals or gaskets between oil 13. Replace seals or gaskets. None
tank and oil tank cover.

14. Insufficient quantity of air for 14. Check for correct CFM and PSI. 6-6
air sealing arrangement. 6-7
 CRUSHER REFER TO
PROBLEMS POSSIBLE CAUSES COMMENTS/CORRECTIONS SECTION-PAGE
Gear and 1 • Excessively dirty oil. 1. Replace oil and clean oil tank. 10-1
Pinion Tooth
Wear 2. Tooth wear profile too low. 2. Worn step bearing plates. 5-2
Raise eccentric assembly by
shimming.
3. Tooth wear profile too high. 5-2
3. Lower eccentric assembly by
removing shims beneath the
lower step bearing plate.
4. Crusher overloaded. 4. Usually shows up as jumping
1-3
adjustment ring. Reduce feed to
3-14
crusher.

5. Tooth wear profile on the ends of 5. Excessive wear on inner or

the teeth. None
outer eccentric bushings.
6. Incorrect oil or oil too cold 6. Two distinct wear patterns on 10-1
causing eccentric assembly to lift or the gear and pinion. Change to 10-6
run in raised position most of the proper oil or install oil tank
time. immersion heater and heat oil to
80°F.

7. Excessive end float. 7. Reset end float (1 /32” to 1 /16”). 4-4, 4-6

8. Running with “tipped” eccentric 8. Foreign material caught 5-1

assembly. between lower step bearing 5-3
plate (or shims) and the top of
main frame cap.

CRUSHER REFER TO
PROBLEMS POSSIBLE CAUSES COMMENTS/CORRECTIONS SECTION-PAGE
Nosiy 1. Incorrect backlash and/or root 1. Recheck backlash and/or root 5-2
Gear and clearance. clearance.
Pinion
2. Operating crusher with new gear 2. None. None
and worn pinion or worn gear
and new pinion.

3. Mis-matched gear and pinion 3. Consult factory. None

profile (14-1/2° vs 20。involute).

CRUSHER REFER TO
PROBLEMS POSSIBLE CAUSES COMMENTS/CORRECTIONS SECTION-PAGE
Tilted 1 • Uneven wear on top of main 1. Improper feed distribution in 3-16
Adjustment frame and/or adjustment ring crushing cavity. Rotate adjust-
Ring seating surfaces. ment ring 180°.

2. Uneven wear on main frame 2. Improper feed distribution in 3-16

 INSPECTION AND MAINTENANCE PERIODS

seat liners. crushing cavity. Replace seat

liners.

3. Continuous overload or improper 3. Refer "selection of proper 1-3

liners causing adjustment ring to liners” paragraphs and tables. thru
“pound” on the main frame 1-9
seating surface. Reduce feed to crusher. 2-2, 2-3
4. Recheck spring installed
4. Incorrect spring lengths holding 3-13
lengths.
adjustment ring to main frame *
causing adjustment ring to jump.

★Spring installed lengths shown in the table refer ONLY to the springs presently being furnished on current machines. For the correct spring installed lengths
on older Crushers consult the factory.
CRUSHER REFER TO
PROBLEMS POSSIBLE CAUSES COMMENTS/CORRECTIONS SECTION-PAGE
Loose Bowl 1. Worn adjustment ring and bowl 1. Remachine 45° surface of None
threads. threads to provide uniform pitch
if threads are not worn too badly.

2. Operating without tightening 2. Tighten cap screws or Duck- 11-4

adjustment cap screws or worth keys properly or pres- 11-6
Duckworth keys or hydraulic surize the hydraulic lock posts 11-8
lock posts sufficiently. to the proper PSI. 12-17

3. Open crusher setting until bowl 3-14

3. Too close of a crusher setting.
stops jumping. 11-11
4. Using too thick of a mantle and/ or None
bowl liner. 4. Adjustment cap does not
contact the top of the adjustment
ring. Thinner liners or special
adjustment cap spacer required.

5. Operating with broken adjustment 5. Replace adjustment cap 11-4

cap screws, Duckworth posts or screws,
Duckworth posts or hydraulic 11-6
hydraulic lock posts. lock post bolt assembly. 11-8
6. Too large of a crusher setting. 6. Close crusher setting until 11-11
adjustment cap makes contact
with the top of the adjustment
ring.
7. When power unit is operating None
hose between power unit and
7. If Crusher has been furnished with lock posts should feel somewhat
hydraulic clamping and adjustment “stiff’.
mechanism check that the hose
between power unit and lock posts
is properly connected.

CRUSHER REFER TO
PROBLEMS POSSIBLE CAUSES COMMENTS/CORRECTIONS SECTION-PAGE
Broken 1. Frequent tramp iron passing 1. Install metal protection device. 11-20
Main Shaft through crusher. SHAFT BREAKS
IN HEAD FIT PORTION OF MAIN
SHAFT.

Shaft may break in either head fit

area or lower portion (tapered
portion) depending on actual
fatigue conditions. When breakage
occurs in head fit portion it is
usually a short distance above
head ball area.

2. Crusher continually overloaded. 2. Usually shows up as jumping 11-16

SHAFT BREAKS IN HEAD FIT adjustment ring. Reduce feed to 11-17
PORTION OF MAIN SHAFT. crusher.
3. Excessive wear on socket liner 3. Replace socket liner, weld and 6-26
and/or ball of head allowing main remachine ball of head or shim 5-8
shaft to penetrate too far into socket to compensate for 7-1
inner eccentric bushing, thereby socket liner AND head ball 7-11
reducing running clearance and wear thereby restoring proper 5-2
causing lubrication failure. SHAFT geometry within the crusher.
BREAKS IN LOWER PORTION
OF MAIN SHAFT. (TAPERED Use templates to check the
PORTION) socket liner and ball of head for
wear.

CONSULT THE FACTORY.

The socket liner undercut can be

used as a guide, the head
should be smooth without any
noticeable step.

4. Main shaft bears at top of inner 4. Incorrect geometry between 6-26

eccentric bushing instead of at main shaft, socket liner and 5-8
bottom of inner bushing. SHAFT inner eccentric bushing. 7-1
BREAKS IN LOWER PORTION socket
Replace liner, weld and 7-11
OF MAIN SHAFT. (TAPERED ball of head or shim socket to
remachine 5-2
PORTION) compensate for socket liner
AND head ball wear.
INSPECTION AND MAINTENANCE PERIODS
INSPECTION AND MAINTENANCE PERIODS
 (1) Location Crusher Circulating Oil
Lubricant--------- Oil; 350 SSU @ 100°F, 54 SSU @ 210°F, 90 VI minimum
Interval ----------- Change every 2000 hours
Method----------- Circulation
(2) Location---------- Hydraulic Power Unit, Lock Posts &Bowl Adj Rams (Hydraulic Crusher Only) Oil;
Lubricant--------- 150 SSU @ 100°F, 45 SSU @ 210°F, 90 VI minimum Change every 2000 hours
Interval ----------- Circulation
Method------------
Countershaft
(3) Location---------- Oil; 150 SSU @ 100°F, 45 SSU @ 210°F, 90 VI minimum During Assembly Manual,
Lubricant--------- brush
Interval-----------
Method----------- Spring Bolt Threads
Oil; 150 SSU @ 100°F, 45 SSU @ 210°F, 90 VI minimum 2000 hours Manual, brush
(4) Location----------
Lubricant--------- U-Bolt Threads
Interval ----------- Oil; 150 SSU @ 100°F, 45 SSU @ 210°F, 90 VI minimum Every liner change Manual,
Method----------- brush

(5) Location-—-- Feed Adjustment Post Threads

Lubricant--------- Oil; 150 SSU @ 100°F, 45 SSU @ 210°F, 90 VI minimum 1000 hours Manual, brush
Interval-----------
Method----------- Bowl & Head Surfaces that contact NORDBAK or Zinc backing Oil; 150 SSU @
100°F, 45 SSU @ 210°F, 90 VI minimum Every liner change Manual, brush
(6) Location----------
Lubricant--------- Fill Socket Sealing Ring Chamber(s) (Standard Seal Crusher Only)
Interval----------- Grease; Lithium base NLGI No. 1 Every liner change Manual, hand packing
Method-----------
Bowl Adjustment Ram & Bowl Lock Torsion Springs (Hydraulic Crusher Only)
(7) Location---------- Grease; Lithium base NLGI No. 1 200 hours Manual, brush
Lubricant---------
Interval----------- Bowl & Adjustment Ring Threads
Method------------ Grease; Lithium base NLGI No. 1 with 5-10% molybdenum disulfide powder 40
hours； Every liner change (by volume)
(8) Location---------- Grease fittings; Manual, brush
Lubricant---------
Interval ----------- Main Shaft & Nut Threads
Method------------ Grease; Lithium base NLGI No. 1 with 5-10% molybdenum disulfide powder Every
liner change (by volume)
(9) Location---------- Manual, brush
Lubricant---------
Interval ----------- Main Frame & Adjustment Ring Seating Surfaces
Method----------- Grease; Lithium base NLGI No. 1 with 5-10% molybdenum disulfide powder During
Assembly (by volume)
(10) Location----------
Lubricant---------
Manual, brush
Interval -----------
Method------------

(11) Location----------
Lubricant---------
Interval------------
Method------------

(12) Location----------
Lubricant---------
Interval------------
Method------------
 (13) Location--------Adjustment Cap Screw Threads (Cap Screw Adjustment Only) OR
Adjustment Lock Post Threads (Duckworth Adjustment Only)
Lubricant------- Grease; Lithium base NLGI No. 1 with 5-10%.molybdenum disulfide powder
Interval----------Every liner change (by volume)
Method----------Manual, brush
(14) Location--------Socket Liner, Socket & Countershaft Box Interference Fits
Lubricant------- White lead & Oil; 60% white lead, 40% boiled linseed oil
Interval----------During Assembly
Method----------Manual, brush
(15) Location--------Pinion & Countershaft Interference Fits
Lubricant------- White lead & Oil; 60% white lead, 40% boiled linseed oil
Interval----------During Assembly
Method----------Manual, brush
(16) Location--------Gear or Counterweight & Eccentric Interference Fits
Lubricant------- White lead & Oil; 60% white lead, 40% boiled linseed oil
Interval----------During Assembly
Method----------Manual, brush
(17) Location--------Main Frame Pin Interference Fits
Lubricant------- White lead & Oil; 60% white lead, 40% boiled linseed oil
Interval----------During Assembly
Method----------Manual, brush
(18) Location----------- Head & Main Shaft Interference Fits
Lubricant--------- White lead & Oil; 60% white lead, 40% boiled linseed oil
Interval During Assembly
Method , Manual, brush
GENERAL LUBRICATION INFORMATION

1 All machined surfaces, especially bearing surfaces, are to be lightly coated with oil (150
SSU @ 100°F, 45 SSU @ 210°F, 90 VI minimum) PRIOR to assembly unless otherwise
specified.
2 All fastener threaded surfaces (capscrews, bolts, nuts, etc.) are to be coated with oil (150
SSU @ 100°F, 45 SSU @ 210°F, 90 VI minimum) PRIOR to assembly unless otherwise
specified.
3 DO NOT use any lubricant containing molybdenum disulfide or graphite for any assembly
procedure unless otherwise specified.

C-1455
 INSPECTION AND MAINTENANCE PERIODS
Symons cone crusher
FOR OIL
LUBRICANT WHEN MANUFACTURER'S
WHERE USED APPLICATION
SPECIFICATIONS PERFORMED SEE SECTION BRAND NAME
Oil Circulating System 350 SSUatl00°F 54 Change every 10*
SSUat210°F 2000 hours
Q0 VT fnirviTYvnm
)°F lubricant
Heating required below tempe !0°F lubricant rature
6( Cooling required above lc temp erature
Hydraulic Clamping and 150 SSUatl00°F 45 Change every
Adjustment SSUat210°F 90 2000 hours 12
System VI minimum
Gear Reducer on Independent Change every 10
Oil Pump (Helical Gear 0°-40°F ambient 2000 hours
Reducer) 280 to 360
SSUatl00°F
40°-110°Famb. 700
to 1000 SSUatl00°F

Gear Reducer on Motorized Change every None*

0°-40°F ambient
Rotating 1000 hours
90 to 125
Feed Distributor (Worm Gear
SSUat 210°F
Reducer)
40°-110°F amb
125 to 190
SSUat 210°F

* Extreme Pressure Lubri 2ant Preferred

C-1456
 Symons cone crusher
FOR OIL
LUBRICANT WHEN
WHERE USED APPLICATION MANUFACTURER’S
SPECIFICATION PERFORMED SEE SECTION BRAND NAME
Bowl and Adjustment Lithium Base Replace every liner 8, 11
Ring Threads NLGI No. 1* change and add
every 40 hours

Main Shaft Nut Threads Lithium Base Replace every liner

7
(Standard Crusher only) NLGI No. 1* change
Lithium Base Replace every liner 7
Locking Collar, Locking Nut
NLGI No. 1* change
and Locking Nut
Cover Threads (Short Head
Crusher only)
Lithium Base Add every
Ram and Bowl Lock Torsion NLGI No, 1*
Springs (Hydraulic Crushers 200 hours
12
only)

Lithium Base Replace every liner 6

Socket Sealing Ring change
NLGI No. 1
Chamber(s) (Standard
Multi-Purpose
Seal Crusher only)
*Can be used.
Add every None
Lithium Base
Motorized Rotating 40 hours
NLGI No. 1
Feed Distributor
Multi-Purpose *
Bearings and Seals (If used)
Can be used.

*With molybdenum disulfic e additive or ext. reme pressure c haracteristics

C-1457
 INSPECTION AND MAINTENANCE PERIODS
Section 4

LUBRICATING SYSTEM

We can supply water cooling,air cooling,electric cooling lubricating system

according to user request.About the detail,user may reference lubricating
system manual.

Section 5

HYDRAULIC CLAMPING AND ADJUSTMENT MECHANISMS

DESCRIPTION ......................................................................................................................................... 12-1

GENERAL INFORMATION ................................................................................................................... 12-1

INFORMATION FURNISHED ............................................................................................................... 12-1

INSTALLATION ....................................................................................................................................... 12-1

LOCATION OF POWER UNIT ................................................................................................................ 12-3

HYDRAULIC OIL SPECIFICATIONS ................................................................................................... 12-3

ASSEMBLY OF HYDRAULIC LOCK POSTS ...................................................................................... 12-3

ASSEMBLY OF ADJUSTMENT CAP TO BOWL ............................................................................. 12-4

ASSEMBLY OF BOWL ADJUSTMENT RAMS ................................................................................... 12-4

ASSEMBLY OF BOWL INTO ADJUSTMENT RING .......................................................................... 12-7

ASSEMBLY OF BOWL LOCK ............................................................................................................. 12-11

HYDRAULIC CIRCUIT ARRANGEMENT ......................................................................................... 12-15

HYDRAULIC POWER UNIT ................................................................................................................. 12-15

STARTING THE CRUSHER ................................................................................................................. 12-16

TYPICAL ADJUSTING CYCLE ............................................................................................................ 12-17

REMOVAL OF BOWL FOR LINER CHANGE ................................................................................... 12-18

GENERAL INFORMATION ON OPERATION ................................................................................... 12-18

C-1458
 PERIODIC MAINTENANCE ................................................................................................................ 12-18

TROUBLE SHOOTING ......................................................................................................................... 12-20

ACTUATOR FAILURE IN BOOSTER (AIR POWER UNIT) ............................................................. 12-20

TROUBLE SHOOTING DATA ............................................................................................................. 12-21

REUSABLE HOSE COUPLINGS ......................................................................................................... 12-21

CLEANING HYDRAUUC AND CIRCULATION SYSTEMS ............................................................ 12-22

C-1459
 INSPECTION AND MAINTENANCE PERIODS

POWER
UNIT

QUICK
DISCONNECT
^ HYDRAULIC LOCK POST .COUPLING

DJUSTMENT CAP

OWL LOCK

TO POWER UNIT
ADJUSTMENT RING

C-1460
C-1461
 INSPECTION AND MAINTENANCE PERIODS

SECTION5
HYDRAULIC CLAMPING AND ADJUSTMENT MECHANISMS

DESCRIPTION written to cover only those conditions which may arise

during normal operation of the Crusher and hydraulic
Another arrangement, for rotating and clamping the mechanism.
bowl, which provides all the conveniences of effortless
remote control, is the hydraulic clamping and The installation, operation and maintenance procedures
adjustment arrangement. This system, although optional, described herein should be followed as closely as
is available on the 4 Ft., 5100, 4-1/4 Ft., 5-1/2 Ft. and 7 possible to insure optimum performance and life of the
Ft. Crushers and can be installed on new machines as hydraulic components. Study these instructions
well as existing machines now in operation. All the thoroughly and make them available to the persons
adjustments are made from a power unit, either entrusted with the care of the Crusher.
electrically or air operated. Positive clamping of the
bowl assembly is automatically maintained by
hydraulic lock posts which replace the standard lock INFORMATION FURNISHED
posts or adjustment cap screws.
The following drawings and data for your particular
A lever on the power unit releases clamping pressure on Crusher will be found in a separate book entitled
the hydraulic lock posts while adjustments are being
made, and when the lever is returned to the clamp INSTALLATION DRAWINGS.
position, pressure is automatically re-applied. Hydraulic
adjustment rams rotate the bowl to the desired setting by 1 Hydraulic Circuit Assembly Drawing
engaging notches on the adjustment cap driver ring. A
ratchet type bowl lock automatically engages these 2 Power Unit Parts List and General Arrangement
notches after each retraction of the bowl adjustment Drawing
rams and positively holds the setting until another
change in setting is necessary. 3 Schematic and Pictorial of Hydraulic Circuit

Installation, operation and maintenance of the hydraulic 4 Wiring Diagram for Electric Power Unit.
components are completely described in this section.
See the illustration HYDRAULIC ADJUSTMENT All other drawings or informational data that might be
ARRANGEMENT. required for your specific installation are also furnished.
SINCE CLAMPING PRESSURE IS UNIFORM AND
AUTOMATICALLY SUSTAINED, NO PERIODIC INSTALLATION
INSPECTIONS FOR BOWL LOOSENESS ARE MODIFY EXISTING ADJUSTMENT CAP: (Field
NECESSARY AND THE POSSIBILITY OF Conversion Only)
DAMAGE CAUSED BY BOWL MOVEMENT
DURING OPERATION HAS BEEN ELIMINATED. It is strongly recommended that a new adjustment cap
be purchased with each hydraulic field conversion due
to the extensive amount of welding required on an
existing cap. Should it be decided to modify the existing
GENERAL INFORMATION adjustment cap, both the necessary conversion drawing
and parts will be furnished.
These instructions cover only the electric and air
hydraulic clamping and adjustment mechanism as
installed on these Crushers.
For the convenience of the crusher operators, the
maintenance section of this instruction manual has been

12-10 C-1462
C-1463 12-11
 AND MAINTENANCE have anti-wear additives.
MODIFY ADJUSTMENT RINGINSPECTION AND BOWL: (Field PERIODS
Conversion Only) responding to a viscosity index of 90 or higher. For
such all year operating conditions, lubricants with
The adjustment ring and bowl of the Crusher must be viscosities higher than 300 SSU at 100。Fahrenheit, or
modified to a certain extent by the addition of certain lower than 100 SSU at 100° Fahrenheit are not
parts; since these parts vary with each crusher recommended.
installation, modification drawings for each of the
various types of installation will be furnished. However, OIL SPECIFICATIONS
in most installations the modification should not consist
of more than the welding on of these various Viscosity at 100°F ..................... 140-160 SSU
component parts and the drilling of locating and grease
lubricating holes. Viscosity at 210°F ........................ 40-50 SSU
Viscosity Index (V.I.) ................ 90 or higher
LOCATION OF POWER UNIT Correct lubricants meeting the above specifications are
essential for the protection of the working parts of our
ELECTRIC Crushers. They are available from all major oil
companies. Improper lubricants can ruin the Crusher
The power unit of the hydraulic mechanism which and their use will void any warranties pertaining to such
consists of an electric motor, hydraulic pump, Crushers.
accumulator and other electric and hydraulic
components, should be placed in a location where the DO NOT USE FIRE RESISTANT HYDRAULIC
FLUIDS AS THESE HYDRAULIC SYSTEMS ARE
crusher operator has good visibility to both the NOT DESIGNED FOR THE USE OF SUCH FLUIDS.
hydraulic lock posts on top of the adjustment cap and
also the bowl adjustment rams. It is recommended that Fire resistant hydraulic fluids MAY NOT be
the power unit be placed no farther than 30 feet from compatible with packings, seals, accumulator bladders,
the Crusher. hoses and other components within the hydraulic
system. Pump life MAY decrease and any paint inside
AIR the oil tank MAY soften and lift off. Contact the factory
The power unit of the hydraulic mechanism which before using any fire resistant hydraulic fluids.
consists of an air-hydraulic booster, filter-lubricator
and other hydraulic components, should be placed in a Approximately 55 U.S. gallons will be required to fill
location where the crusher operator has good visibility the power unit reservoir, hydraulic lock posts, bowl
to both the hydraulic lock posts on top of the adjustment rams and interconnecting hoses.
adjustment cap and also the bowl adjustment rams. It is
recommended that the power unit be placed no farther
than 30 feet from the Crusher-
ASSEMBLY OF HYDRAULIC LOCK POSTS

HYDRAULIC OIL SPECIFICATIONS 1 FT., 5100 ， 4-1/4 FT., AND 5-1/2 FT.
CRUSHERS.
For the hydraulic clamping and adjustment mechanism
use a high grade paraffin (not naphthene) base To assemble the lock post to the bowl and adjustment
industrial oil of viscosity specified, having high film cap proceed as follows：
strength, having high affinity for and adhesiveness to
metal surfaces, having stable chemical and physical 1 Remove one hair pin cotter, and slide out the key.
properties. Such lubricants should have a high viscosity See the illustration HYDRAULIC LOCK POST
index, rapid water separation, resist foaming, offer ASSEMBLY; 4 FT., 5100, 4-1/4 FT. AND 5-1/2
some rust and corrosion protection, resist oxidation and FT. CRUSHERS.
For normal, all year operating conditions, the lubricant post by using the ring located on the cover and
should have a viscosity of 140 to 160 SSU (Seconds place the post in position on top of the adjustment
Saybolt Universal) at 100。Fahrenheit and a viscosity of cap-
40 to 50 SSU at 210。Fahrenheit, cor
2 The upper and lower spherical washers can then be THE LOCK POSTS SHOULD BE LIFTED
removed from the bolt assembly and should be WITH A CRANE, SLOWLY AND
placed into each boss on the bowl. CAREFULLY AS DURING THE LIFTING
3 Remove the dust cap and carefully lift the lock STAGE THE BOLT ASSEMBLY MAY

12-10 C-1464
 SLOWLY SLIDE DOWN OUT OF THE as shown on the circuit drawing. At this point
CYLINDER. there should be no fittings screwed onto the
cross fittings.
4 The lock posts should be placed on top of the
adjustment cap so that the tapped hole on the side ASSEMBLY OF
of the cylinder faces the outside of the adjustment ADJUSTMENT CAP TO BOWL
cap.
1 Lift the adjustment cap approximately 4 or 5 feet
5 Fasten the lock posts to the adjustment cap with off the ground and pull down the bolt assembly
capscrews as shown. as far as possible. Follow this procedure for all
the lock posts.
6 Alternately thread the cross and tee fittings as
shown on the HYDRAULIC CIRCUIT 2 Then lift the cap over the bowl and slowly lower
ASSEMBLY DRAWING into the sides of the the cap until the bolt assembly drops into the
cylinders. bowl boss far enough so that the key can be
inserted with the nut (or spherical washers),
7 Then interconnect the posts with the hoses also as against the underside of the bowl boss.
shown on the circuit drawing. At this point there
should be no fittings screwed onto the cross WARNING
fittings. As a safety precaution the adjustment cap
should be blocked up in some manner
ASSEMBLY OF HYDRAULIC LOCK POSTS during this operation so that in case of a
crane failure the cap would not drop and
7 FT. CRUSHERS. cause injury to the operator’s hands.
To assemble the lock post to the bowl and
adjustment cap proceed as follows: 3 After the keys have all been put in place, re-insert
the hair pin cotter.
1 Remove one hair pin cotter, and slide out the key.
See the illustration HYDRAULIC LOCK POST 4 Slowly lower the adjustment cap until it bottoms
ASSEMBLY; 7 FT. CRUSHERS. on the bowl bosses. For the initial installation
only, it is suggested that the cap be lifted with a
2 The special nut can then be removed from the bolt crane as soon as the lock posts are connected to
assembly and placed into each boss on the bowl. the bowl, until the entire assembly is just lifted off
the ground.
THE LOCK POSTS SHOULD BE LIFTED
WITH A CRANE, SLOWLY AND 5 Attach the quick-disconnect sockets at this point,
CAREFULLY AS DURING THE LIFTING this will prevent an air pocket from forming in the
STAGE THE BOLT ASSEMBLY MAY cylinders.
SLOWLY SLIDE DOWN OUT OF THE
CYLINDER.
ASSEMBLY OF BOWL ADJUSTMENT RAMS
3 Lift the lock post and place the post in position on WITH TORSION、、SPRING〃
top of the adjustment cap. The lock posts should be
placed on top of the adjustment cap so that the The bowl adjustment ram assemblies should be
tapped hole on the side of the cylinder faces the placed into position on the adjustment ring
outside of the adjustment cap.
4 Fasten the lock posts to the adjustment
cap with capscrews as shown.

5 Alternately thread the cross and tee fittings as

shown on the HYDRAULIC CIRCUIT
ASSEMBLY DRAWING, into the sides of the
cylinders.

6 Then interconnect the posts with the hoses, also

C-1465 12-11
 INSPECTION AND MAINTENANCE PERIODS
LIFTING RING

BREATHER
RETAINING RING

)-RING

COVER

O-RING AND BACK-UP

DISC SPRINGS WASHER

SPRING WASHER
BOLT ASSEMBLY

CYLINDER

O-RING AND
BACK-UP
WASHER

GLAND

O-RING AND
BACK-UP
ROD WIPER WASHER

CAPSCREW

KEY

HAIR PIN
UPPER AND LOWER COTTER
SPHERICAL WASHERS

LOCK POST ASSEMBLY

4 FT., 5100, 4-1/4 FT. AND 5-1/2 FT. CRUSHERS

12-10 C-1466
 LIFTING
INSPECTION AND RING PERIODS
MAINTENANCE

LOCK POST ASSEMBLY

7 FT. CRUSHERS

12-10 C-1467
 before assembling the bowl into the adjustment
INSPECTION ring. PERIODS
AND MAINTENANCE 4 Slide the ram stop plate with the two dowels
To assemble the bowl adjustment rams equipped with pointing down and facing away from the Crusher
a torsion “spring” into the adjustment ring proceed as onto each torsion bar from the bottom of the
follows: adjustment ring until the end of the bar is even
with the bottom surfaces of the plate.
Insert one end of the torsion spring into the
drilled hole on top of the adjustment ring boss as 5 Screw the 1/2" x 4〃 setscrew into and through the
shown in the illustrations BOWL side of the adjustment ring boss far enough for the
ADJUSTMENT RAM ASSEMBLY WITH screw to go between the dowels in the ram stop
TORSION “SPRING”. plate and beneath the torsion rod.
2 Place the two bowl adjustment rams into position 6 Screw the 3/8" x 1-1/2 〃 setscrew into the ram
on the adjustment ring bosses 180° apart. Lower the retainer until it bottoms in the ram post groove
ram so that the other end of the torsion spring enters then turn the setscrew out, one turn.
the cavity on the underside of the ram retainer. This
torsion spring will keep constant pressure on the 7 Position the rams so that when they extend they
ram to keep it in contact with the notched driver ring will turn the bowl clockwise when looking down
on the adjustment cap. into the Crusher. Then turn the entire ram
assembly until contact is made against the ram
3 Position the rams so that when they extend they stop blocks welded to the adjustment ring. Insert a
will turn the bowl clockwise vAien looking down 1/2" diameter steel rod into the hole in the
into the Crusher. adjustment ring just to the side of the ram stop
located on the ram retainer. This will lock the ram
4 Center the ram fork so that equal clearance exists away from the adjustment cap when the bowl
on top and bottom between the driver ring and the assembly is being assembled or disassembled
fork. If the fork and driver ring on the adjustment from the Crusher.
cap are not centered properly, remove the brass plug
from the adjustment screw which supports the ram 8 After the adjustment cap and bowl is assembled
and either raise or lower the adjustment screw to into the Crusher remove the 1/2 〃 diameter rods
center the fork on the driver ring. On the 7 Ft. and allow the rams to come to rest against the
Crushers the adjusting screw is called the saddle. driver ring on the adjustment cap.
9 Center the ram fork so that equal clearance exists
ASSEMBLY OF BOWL ADJUSTMENT RAMS on top and bottom between the driver ring and the
WITH TORSION ''BAR" fork. If the fork and driver ring on the adjustment
cap are not centered properly, either raise or lower
The bowl adjustment ram assemblies should be the adjustment screw to center the fork on the
placed into position on the adjustment ring before driver ring.
assembling the bowl into the adjustment ring. To
assemble the bowl adjustment rams equipped with a
torsion “bar” into the adjustment ring proceed as
follows: ASSEMBLY OF
BOWL INTO ADJUSTMENT RING
1 Remove the torsion bar and ram stop plate from 1 Coat the threads of the bowl and adjustment ring
the two ram assemblies, then place each with grease as per normal operating procedure.
assembly in the adjustment ring bosses located
180° apart. See the illustration BOWL 2 Lift the bowl assembly by the hooks on the
ADJUSTMENT RAM ASSEMBLY WITH adjustment cap and position it over the adjustment
TORSION “BAR”. ring on the Crusher. The initial lift on the cap will
cause the adjustment cap alone to raise first, after
2 Swivel the bowl adjustment ram so the fork a short rise the entire bowl assembly will be lifted.
points toward the center of the Crusher.
3 From the bottom side of the adjustment ring
insert the torsion bar up through the ram post
and into the square hole in the ram retainer so
the top of the bar is even with the top of the ram
retainer surface.

BOWL ADJUSTMENT RAM ASSEMBLY WITH TORSION ''SPRING"

4 FT., 5100, 4-1/4 FT. AND 5-1/2 FT. CRUSHERS
12-8 C-1468
 GUIDE ROD

C-1469 12-11
O-RING AND BACK-UP

INSPECTION AND MAINTENANCE PERIODS

12-12 C-1625
01626 12-13
BOWL LOCK ASSEMBLY WITH TORSION ''SPRING
5-1/2 FT. CRUSHERS
 INSPECTION AND MAINTENANCE PERIODS

BOWL LOCK POST

LOCATING
PIN

ARM IS POINTED IN THE RIGHT DIRECTION; WITH A CRUSHER WHOSE COUNTERSHAFT IS ROTATING
CLOCKWISE, THE BOWL LOCK ARM MUST POINT IN A COUNTERCLOCKWISE DIRECTION WHEN
IT IS IMPORTANT THAT THE BOWL LOCK ARM IS POINTED IN THE RIGHT DIRECTION; WITH
A CRUSHER WHOSE COUNTERSHAFT IS ROTATING CLOCKWISE, THE BOWL LOCK ARM MUST POINT
IN A COUNTERCLOCKWISE DIRECTION WHEN LOOKING DOWN INTO THE CRUSHER;
WHEREAS A CRUSHER THAT HAS THE COUNTERSHAFT ROTATING COUNTERCLOCKWISE, THE BOWL
LOCK ARM MUST POINT IN A CLOCKWISE DIRECTION. THE BOWL LOCK ASSEMBLY IS
DESIGNED TO OPERATE IN EITHER DIRECTION SIMPLY BY “FLIPPING” THE LOCK ARM OVER
AND REENGAGING THE TORSION BAR.BOWL LOCK ASSEMBLY WITH TORSION ''SPRING
4 FT., 5100 AND 4-1/4 FT. CRUSHERS
LOOKING DOWN INTO THE CRUSHER; WHEREAS A CRUSHER THAT HAS THE COUNTERSHAFT ROTATING
COUNTERCLOCKWISE, THE BOWL LOCK ARM MUST POINT IN A CLOCKWISE DIREC-

RING

01626 12-13
BOWL LOCK ASSEMBLY WITH TORSION ''SPRING
5-1/2 FT. CRUSHERS
TORSION SPRING SPRING PIN

BOWL LOCK ARM TO POINT IN THIS DIRECTION FOR CLOCKWISE ROTATION OF CRUSHER
COUNTERSHAFT

IT IS IMPORTANT THAT THE BOWL LOCK ARM IS POINTED IN

THE RIGHT DIRECTION; WITH A CRUSHER WHOSE
COUNTERSHAFT IS ROTATING CLOCKWISE, THE BOWL LOCK
ARM MUST POINT IN A COUNTERCLOCKWISE DIRECTION WHEN
LOOKING DOWN INTO THE CRUSHER; WHEREAS A CRUSHER
THAT HAS THE COUNTERSHAFT ROTATING
COUNTERCLOCKWISE, THE BOWL LOCK ARM MUST POINT IN A
CLOCKWISE DIRECTION, THE BOWL LOCK ASSEMBLY IS
DESIGNED TO OPERATE IN EITHER DIRECTION SIMPLY BY
“FLIPPING” THE LOCK ARM OVER AND RE-ENGAGING THE
TORSION SPRING.

01626 12-13
BOWL LOCK ASSEMBLY WITH TORSION ''SPRING
5-1/2 FT. CRUSHERS
To assemble the bowl lock assembly equipped
INSPECTION with a
AND MAINTENANCE Place the lock arm cap onto the lock arm and
6PERIODS
torsion “bar” on the adjustment ring proceed as engage with the torsion bar.
follows:
1 Locate the bowl lock assembly on the flat area on 7 Push the lock arm against the adjustment cap
the adjustment ring which has been provided for making sure the arm is against the inside of the
this purpose. Insert the two 1/2 〃 diameter adjustment cap driver ring and not on top of one of
locating pins in the bottom of the bowl lock post the driver ring notches.
in the drilled holes in the adjustment ring. 8 Turn the lock arm cap in the opposite direction the
2 The bowl lock arm should be parallel and aligned lock arm is pointing until the holes in the cap line
to obtain the proper relationship to the driver ring up with the tapped holes in the lock arm and bolt
on the adjustment cap and the fork on the bowl the cap to the lock arm.
adjustment rams. See the illustration BOWL
LOCK ASSEMBLY WITH TORSION “BAR”. 9 Screw the 3/8" x 1-1/2" setscrew into the lock arm
Bowl lock post should be shimmed, if necessary. until it bottoms in the lock post groove then turn it
out, one turn.
3 Weld the lock post to the adjustment ring.
TO KEEP THE LOCK ARM FROM
4 Insert the torsion bar down into the center hole in CONTACTING THE DRIVER RING WHEN
the lock post and engage it into the square hole INSTALLING OR REMOVING THE
located in the bottom of the lock post. After the ADJUSTMENT CAP AND BOWL FROM THE
bar is in the square hole it is to be pushed down CRUSHER, PULL THE LOCK ARM AWAY
until it bottoms. FROM THE CAP UNTIL THE HOLE IN THE
STOP, WELDED TO THE REAR OF THE LOCK
ARM, IS LINED UP WITH THE HOLE IN THE
LOCK POST. THEN INSERT A 1/2"

12-16 C-1472
 HYDRAULIC POWER UNIT
DIAMETER STEEL ROD THROUGH THE
LOCK ARM STOP AND INTO THE LOCK ELECTRIC POWER UNIT
POST.
The hydraulic power unit is composed of a cabinet
with the electric motor, hydraulic pump, accumulator,
HYDRAULIC CIRCUIT ARRANGEMENT gauges, and other electrical and hydraulic components.
The Gauge and Control Valve Sub-Assembly is a
All piping between the power unit and the Crusher has complete unit by itself and, if necessary, is readily
been provided with quick-disconnect couplings for removable for service of individual units.
quick assembly and disassembly.
The electric motor is a 5 HP motor with electrical
characteristics tailored to the individual user. All fuse
IT IS MOST IMPORTANT THAT DURING THE protection equipment is to be furnished by the
ENTIRE PIPING PROCEDURE ALL DIRT AND customer to conform to local electrical codes. The
FOREIGN MATTER BE KEPT OUT OF THE starter for the power unit motor is also to be furnished
HOSES AND FROM ALL FITTINGS. by the customer to meet the customer’s specific needs,
location and electrical interconnecting requirements.
It is suggested that all three hoses be first connected to Attach a No. 8 or larger ground wire to the power unit.
the power unit and just prior to connection to the Direction of rotation of the motor and pump can be
hydraulic lock posts and rams, all hoses be bled by either clockwise or counterclockwise.
depressing the needle valve on the quick-disconnect The hydraulic pump is a piston-type pump with a total
socket and running oil through these lines so as to fill of six cylinders. The flow from the pump is split into a
the entire hose. five cylinder-one cylinder arrangement and regulated
by an unloading valve so that all six cylinders are
1 Color code the hose between the hydraulic lock pumping until a pressure of 1,500 PSI is reached. At
posts and the power unit GREEN. See the this point, only one cylinder is actually pumping and
illustration HYDRAULIC CIRCUIT the other five cylinders are bypassing oil.
ARRANGEMENT.
A pressure switch will automatically shut the pump off
2 Connect the GREEN quick-disconnect coupling when a pressure of 2,500 PSI is reached and turn the
to the hydraulic lock post which is located pump on when the pressure drops to 2,100 PSI.
approximately 90° to the right of the power unit.
The green pilot light on the control panel of the power
3 Color code the hoses from the power unit to the unit indicates that power is available to the power unit
extend side of each ram ORANGE. The extend motor even though the motor is not running. THIS
side of the ram is the right hand fitting on the ram LIGHT MUST BE ON WHENEVER THE
when facing the ram fork. CRUSHER IS RUNNING.
4 Connect the ORANGE coded hose from the AIR POWER UNIT
power unit to a tee and then from the tee to the
extend fitting of each ram. The hydraulic power unit is composed of a cabinet
with the booster, gauge and control valve and air
5 Color code the hoses from the power unit to the filter-lubricator sub-assemblies. Each sub-assembly is
retract side of each ram BLUE. The retract side of a complete unit by itself and, if necessary, is readily
the ram is the left hand fitting on the ram when removable for service of individual parts.
facing the ram fork.
This power unit is operatedby using compressed air.
6 Connect the BLUE coded hose from the power Use an air system which is reasonably DRY. Connect a
unit to a tee and then from the tee to the retract compressed air line (80 to 100 PSI - 80 PSI minimum)
fitting of each ram. to the valve located on the left side of the power unit
cabinet. No electrical connections are required.
CHECK THE POSITION OF THE
HYDRAULIC LINES TO THE BOWL The amount of air required for the proper operation of
ADJUSTMENT RAMS SO THEY WILL NOT the power unit is 5 standard cubic
INTERFERE WITH ANY MOVING PARTS.
feet per minute (SCFM) at 15 PSI, 60° Fahrenheit.
It is possible to keep the Crusher running and still

C-1648 12-17
remove one or more of the sub-assemblies for MAINTENANCE
INSPECTION AND service PRESENT.
PERIODS

for a relatively short period of time, such as changing mounted inside the power unit on the left side. The
one of the components. The Pictorial Circuit of the PRESSURE DIFFERENTIAL SETTING inside the
Air-Hydraulic Power Unit shows the procedures to be pressure switch should be maintained at 400 PSI.
followed. Following these procedures will permit
removal of the various sub-assemblies without any
loss of pressure in the lock posts. The Crusher can now be started. The right handle on
the control valve should always remain in the back
However, if some trouble should arise which requires (handle towards operator) or clamp postion during
considerable time to repair, it is desireable to shut actual crushing operation of the machine. Check that
down the Crusher completely. the bowl lock arm is engaging the notched driver ring
REMOVAL OF ONE OR MORE on the adjustment cap and that it is pointing in the right
SUB-ASSEMBLIES WILL MAINTAIN PRESSURE
IN THE SYSTEM IF THERE ARE NO LEAKS direction.

STARTING THE CRUSHER (Electric Power Unit) POWER UNIT CONTROL VALVE HANDLES. Turn
Before the Crusher is actually started, all hydraulic lines, the air valve on, this will allow the air to pass into the
both at the power unit and at all connections on the power unit and activate the air- hydraulic booster. At
Crusher, should be carefully checked for leaks. Pay
particular attention to the quick-disconnect coupling to this point the booster should begin its reciprocating
make sure that the plug is properly engaged with the motion and start to pump the oil through the control
socket so that the hydraulic fluid can pass through. valve; however, the oil, with both valves in the neutral
Check the control valve handles to see that they are in position, will be bypassing through the valve and will
the neutral or middle position. See the illustration, not be doing any actual work. Pull the right handle of
POWER UNIT CONTROL VALVE HANDLES. Push the valve back. This procedure will start the automatic
the ”ONn button on the power unit. At this point the clamping cycle on the hydraulic lock posts. When the
electric motor will start to pump the oil through the
valve；however, the oil, with both handles in the neutral air has been initially turned on it will take a few
position will be by-passing through the valve and will moments before the booster can fill the hydraulic lock
not be doing any actual work at this point. Pull the right posts with oil. The lock posts have been designed to
handle of the valve back. This procedure will start the operate at a hydraulic pressure of 2,000 PSI. As the
automatic clamping cycle on the hydraulic lock posts. power unit is operating it will continue pumping oil into
When the motor has been initially turned on it will take the cylinders until this pressure has been reached and
a few moments before the pump can fill the hydraulic
lock posts with oil. The lock posts have been designed then stop automatically. If the booster should stop at any
to operate at a hydraulic pressure of 2,500 PSI. As the pressure other than 2,000 PSI, the pressure can be
power unit is operating it will continue pumping oil into regulated by changing the air pressure going into the
the cylinders until this pressure has been reached and power unit.
then stop automatically. If the hydraulic pump should EXTEND UNCLAMP
stop at any pressure other than 2,500 PSI, the pressure i i
can be regulated by adjusting the setscrew found on top t 1
of the pressure switch. The pressure switch is RAM L0CKP0ST
STARTING THE CRUSHER (Air Power Unit) VALVE VALVE
i 1
T T
Before the Crusher is actually started, all hydraulic lines, RETRACT CLAMP
both at the power unit and at all connections on the
Crusher, should be carefully checked for leaks. Pay
particular attention to the quick-disconnect coupling to
make sure that the plug is properly engaged with the
socket so that the hydraulic fluid can pass through.

Check the control valve handles to see that they are in

the neutral or middle position. See the illustration,

C-1648 12-18
 then depressurized by pushing the right handle forward
(away from the operator) and leaving it in this position.
After the lock posts pressure gauge reads zero pull the
right hand handle to the neutral or middle position. The
next step is to extend the rams by pushing the left handle
forward until the rams come to a complete stop. It is
advisable to occasionally check the pressure range on
the rams during the extending stroke. Normally this
pressure during the actual extending should be between
300 to 700 PSI and as the ram comes to a complete stop
the pressure should jump up to 2,800 PSI (Electric) or
2,000 PSI (Air).
Ram pressures over 800 PSI while in the extending
stroke indicates something abnormal and the Crusher
should be inspected to find the cause of the high
pressure required to move the bowl. After the ram has
been fully extended it can be retracted by pulling the left
handle back until the ram again comes to a dead stop in
the fully retracted position. It should be noted that there
is no gauge which indicates the pressure while the ram
is retracting. The rams are then extended and retracted
as many times as required to reach the proper setting.
A pressure regulator will be found on the air Always extend and retract the rams to the limit of their
filter-lubricator inside the power unit. Turning the stroke so that the ram comes to a dead stop. After the
adjusting screw on this regulator IN will result in an proper setting has been reached, return the handle to the
INCREASE in air pressure and turning the screw OUT neutral or middle position. The hydraulic lock posts are
will DECREASE the air pressure. now repressurized by pulling the right handle back and
LEAVING it in this clamped position. Check the
The booster is designed to give approximately 25 PSI cylinder pressure gauge to make sure that the cylinders
have a pressure of 2,500 PSI (Electric) or 2,000 PSI
hydraulic pressure for every one (1) pound of air (Air).
pressure.
It will be found that as the adjustment cap rotates the
Check the air and hydraulic pressures only after the GREEN hose which is connected to the hydraulic lock
booster has stopped working and has settled at a posts will turn along with the adjustment cap and
constant pressure. gradually move out of position. When this occurs the
hose line should be disconnected from its particular
NORMAL OPERATING AIR PRESSURE SHOULD
BE APPROXIMATELY 85 PSI AND NORMAL quick-disconnect socket and then moved to the next
HYDRAULIC PRESSURE OF THE CYLINDERS convenient quick-disconnect socket. See the illustration,
SHOULD BE APPROXIMATELY 2,000 PSI. HYDRAULIC CIRCUIT ARRANGEMENT. This,
however, must be done when the pressure to the
The Crusher can now be started. The right handle on the cylinders is off. It is important that the hose be
control valve should always remain in the back (handle reconnected immediately.
towards operator) or clamped position during actual
crushing operation of the machine. Check that the bowl THE NORMAL OPERATING POSITION OF THE
lock arm is engaging the notched driver ring on the
adjustment cap and that it is pointing in the right
direction.

TYPICAL ADJUSTING CYCLE

After the bowl liner and mantle have worn to a
condition where the setting must be adjusted, the feed to
the Crusher should be stopped (it is preferable to stop
the motor on the Crusher). The hydraulic lock posts are
C-1648 12-19
VALVE HANDLES DURING THE CRUSHING
INSPECTION AND MAINTENANCE of the ram will change the crusher setting 3/64". It has
PERIODS

CYCLE HAS THE RIGHT HANDLE (HYDRAULIC been found, through experience, that optimum crushing
LOCK POST VALVE) IN THE CLAMP POSITION operations result from frequent small changes in liner
(PULLED BACK TOWARDS THE OPERATOR) setting rather than a few large changes.
AND THE LEFT HANDLE (RAM VALVE) IN THE
NEUTRAL (MIDDLE) POSITION. SEE THE A total of 32 strokes of the bowl adjustment rams are
ILLUSTRATION, POWER UNIT CONTROL required for one complete revolution of the bowl on the
VALVE HANDLES. 7 Ft. Extra Heavy Duty Crusher and 48 strokes on the 7
A relief valve set at 2,800 PSI is built into the operating Ft. Heavy Duty，5-1/2 Ft. Heavy Duty, 4-1/4 Ft., 5100
valve. This is a safety feature of the power unit and and 4 Ft. Crushers.
should never be tampered with or changed.
In the event of tramp iron passing through the Crusher,
there may be a nominal increase in hydraulic pressure.
REMOVAL OF BOWL FOR LINER CHANGE This has been carefully considered in the design and
After the liners have been worn out, stop the Crusher should result in no damage whatsoever to the hydraulic
and depressurize the hydraulic lock posts. Disconnect system.
the green hydraulic hose from the lock posts completely.
The bowl lock arm and adjustment rams are to be In the event of the bowl threads becoming stuck, it is
moved out of the notched driver ring on the adjustment possible that the bowl adjustment rams can be turned in
cap and held away from it until the bowl is turned out of the opposite direction and used to turn out the bowl;
the adjustment ring in the conventional manner. however, IT SHOULD BE STATED THAT THE
DO NOT WRAP THE CABLE AROUND THE RAMS HAVE NOT BEEN DESIGNED TO CLEAR A
LOCK POSTS WHEN TURNING THE BOWL. PLUGGED MACHINE DUE TO EITHER TRAMP
Till-；CABLES SHOULD BE WRAPPED AROUND IRON OR AN OVERLOAD.
THE SHELL OF THE ADJUSTMENT CAP.
Lift the entire bowl assembly with the hooks on the
adjustment cap. Again it will be found that the cap PERIODIC MAINTENANCE
will rise alone first, then the entire assembly will be
lifted. Place the bowl assembly on the ground and WARNING
block up the adjustment cap. Then remove the hair pin Depressing the ’’Stop’’ button on top of the
cotter from the keys in the bolts. Remove the keys and power unit cabinet will only turn off the
the nuts or spherical washers. The entire adjustment electric motor. When servicing the electric
cap is now free and can be lifted with the lock posts power unit the，，MAIN" power supply to the
and hose in place and is ready for re-assembly when power unit must be shut off. Always lock out
the new bowl liner has been installed in the bowl. ALL electrical controls BEFORE
setting 1/16"，on the 7 Ft. Heavy Duty, 5-1/2 Ft. Heavy performing any maintenance work on the
Duty, 4-1/4 Ft., 5100 and 4 Ft. Crushers one full stroke Crusher.

12-20 C-1472
GENERAL INFORMATION ON OPERATION
It is suggested that a mark be painted on the bowl hopper, as described in the paragraph DETERMINING LINER
WEAR in Section 11 to indicate to the operator the point at which the liner wear has reached its maximum. As the
adjustment cap seal reaches this mark, the operator would then know that the liners are fully worn and ready to be
changed.
On the 7 Ft. Extra Heavy Duty Crusher, one full stroke of the ram will change the crusher
WARNING

When servicing the air power unit the air control valve located on the left side of the power unit
cabinet must be in the f?OFFn position.

CHECK OIL LEVEL

The oil level should be checked periodically to insure smooth operation; however, it is suggested that the tank be
filled with oil as indicated on the power unit only when installing new liners and that the cylinders are completely
filled in order to prevent an overflow. One inch of oil in the tank is equivalent to 1.7 gallons.
STRAINER (Electric Power Unit)
The strainer located between the hydraulic pump and oil tank should be cleaned at regular intervals. The
frequency of these intervals must be determined by the individual operator and the dust conditions in the plant.
AIR FILTER-LUBRICATOR (Air Power Unit)
FILTER. The filter has a quick release bowl, making the filter element readily available for cleaning. Remove the
bowl and clean the filter element periodically by washing with kerosene or other similar cleaner and dry with
compressed air.
Using the petcock drain at least once per shift or as frequently as possible.

When cleaning or replacing filter element blow off cover assembly louvers with air.

LUBRICATOR. To fill the lubricator, turn off the air pressure and remove one of the fill plugs, (the first turn of
the fill plug vents the air pressure from the bowl) or remove the bowl and pour the oil into it.
Pour in only clean oil, use the same light oil as is in the oil tank. DO NOT fill the bowl above the indicated mark.
This lubricator is unique, in that only particle sizes 2 microns or smaller are permitted to flow from the lubricator;
because of this characteristic, only one drop in 20, visible in the sight dome, passes into the system. A count of 40
to 50 drops per minute will result in something over 2 drops per minute output.
Control the rate of oil entering the air stream by turning the adjustment screw in to give less oil and out to give
more oil.
Since lubrication in this micro-mist form is very penetrating, only a minimum amount is required. This setting will
satisfy the minimum flow requirements of the equipment. If the booster is cycled rapidly, the lubricator will

C-1475 12-21
 INSPECTION AND MAINTENANCE PERIODS

BO W L LU G AN D GU I DE BA R CL E A R AN C E S

automatically increase its oil output.

Periodically clean the adjusting screw needle valve and fTOn ring and the screen located on the siphon tube inlet
by swishing in -a solvent and blowing off with air.
Drain off any contaminants or water if they settle in the bottom of the bowl.

CHANGING HYDRAULIC OIL

The hydraulic oil in the complete system should be changed AT LEAST once a year. During this change, the
inside of the oil tank should also be thoroughly cleaned of any sludge accumulation.

BOWL
The lugs or nearsn on the bowl bosses should be checked at every second or third liner change for wear. A
MAXIMUM clearance of l/8n between the ears and guide bars of the
adjustment cap should be held. If the clearance becomes larger, the ears should be built up with weld and then
ground smooth until the clearance is plus 1/16” or minus l/8n. See the illustration, BOWL LUG AND GUIDE
BAR CLEARANCES.

BOWL ADJUSTMENT RAM AND LOCK

At least once a month, grease the ram retainer shaft or ram post by using the grease fitting on the side of the
12-22 C-1472
adjustment ring boss or ram retainer, also force grease through the fitting on the side of the bowl lock arm.

TROUBLE SHOOTING

Because of the nature of a hydraulic system, most trouble will present itself in the form of an oil leak. The oil leak
will create a pressure drop which, in turn, will cause the pump or booster to work more often to return the pressure
in the system to its proper setting.
Any abnormal running of the pump or booster means that there is a continuous oil leak at some location in the
system. If the leak happens to be past one of the “O” rings in the lock post, it will be very difficult to find the leak
because the oil will run down the inside of the cylinder and into the bowl boss. Any other leak will reveal itself in
a pool of oil visible to the operator.
In the event of leakage in a hydraulic lock post, it is recommended that the defective lock post be bypassed by
using the extra long hose furnished for that purpose. Normal crushing can then be resumed and the defective
cylinder repaired during a liner change. Under EXTREME conditions the entire system can operate for a short
period on only four lock posts, if it ever becomes necessary.

Any repair work done on a hydraulic component should always be done in relatively
clean and dirt-free surroundings.
Possible malfunctions with causes and corrections are shown in TROUBLE SHOOTING
DATA found in this Section.

ACTUATOR FAILURE IN BOOSTER (AIR POWER UNIT)

If the oil pressure as shown on the ’’cylinder" pressure gauge does not go up to the
required setting, there could be an actuator failure in the booster. If so, proceed as
follows:
1 There are two actuator assemblies in the booster, one located at each end of the
ram heads. Only the indicating rod of the actuator protrudes out of the booster.
2 If there is a pressure failure in the system or if the booster fails to start after the air
pressure has been turned off for TROUBLE SHOOTING DATA

C-1475 12-23
 INSPECTION AND MAINTENANCE PERIODS

SYMPTOM POSSIBLE CAUSE CORRECTION

Oil pressure does not go up to the

required setting. (Electric. Power Incorrect adjustment of pressure switch. Readjust setscrew on pressure switch.
Unit)

Check plant air pressure- 80 psi

Oil pressure does not go up to the Insufficient air pressure.
minimum.
required setting. (Air Power Unit) Actuator failure in booster.
See Page 10.

Reset adjustment screw or saddle

located on ram retainer casting directly
Misalignment of ram in relation to driver under ram cyli nder.
Ram fork slipping out of position. ring on adjustment cap.

Torsion spring or bar beneath retainer Clean torsion spring or bar thoroughly
plugged with dirt or broken. Torsion spring and re-engage with both adjustment
jumped out of engagement with either ring boss and ram retainer. Clean all
adjustment ring or ram retainer. rust and pitting from ram retainer shaft
Ram no longer pushes against the Ram retainer shaft rusty. and grease thoroughly.
driver ring on the adjustment cap.

Bowl adjustment ram no longer Clean torsion spring or bar thoroughly.

pushes against the driver ring on Remove all rust and pitting from bowl
the adjustment cap. Torsion spring or bar clogged with dirt. lock post and grease thoroughly.
Rust on bowl lock post.
Depress needle valves at end of plug
or socket (with a brass rod and a soft
hammer blow, if necessary), until back
Difficulty in engaging Locked-inpressure either plug or socket pressure is relieved.
quick-disconnect caused by disconnecting in pressurized
couplings. condition.
some time, pull on the indicating rod of Ft. hose proceed as follows: the actuator
with a pair of pliers. If this
does not start the unit, shut off the air 1 Cut the hose with a hacksaw to the required pressure and replace the
actuator assembly. length.

12-24 C-1472
 3 Remove the actuator assembly by removing the retaining ring in the
bore of the ram head and pulling
INSPECTION on thePERIODS
AND MAINTENANCE indicating rod. This will pull
out the actuator spacer and the actuator.
4 Replace the actuator assembly with a new one. The spacer and
retaining ring can be used again as they normally do not require
replacement.
REUSABLE HOSE COUPLINGS

The three 30 Ft. hoses between the power unit and the Crusher can be shortened to suit the
location of the power unit since each of these hoses is equipped with one reusable hose
coupling. To shorten the 30
2 Strip the hose of its rubber cover before installing the reusable
coupling.
3 To strip the hose, cut around the entire outside of the hose, down to
the wire braid.
4 Slit the covering lengthwise, lift the flap and pull off with a pliers.
BE CAREFUL NOT TO FRAY OR DAMAGE THE WIRE BRAID.
5 The length of hose to be stripped can be determined by placing the
coupling shell next to the hose and measuring from the hose end of
the shell to the large notch on the shell.
6 Place the coupling shell in a vise and screw the hose counter-clockwise into the shell until
it is inserted to its full depth.
7 Apply oil to the threads on the coupling insert and to the inside of the hose.
8 With the coupling shell held firmly in a vise, screw the threaded insert clockwise into the
shell until it is tight.
CLEANING HYDRAULIC AND CIRCULATION SYSTEMS
Fluid contamination is the most common cause of hydraulic and circulation oiling systemsT
poor performance. As contamination in a system builds up, the performance becomes
progressively worse. Initially it may be an almost un- no tic eable slowing down of actions.
Later, as contaminants increase, the system may fail completely.
Interference with a system fs operation may be the result of oil oxidation and varnish
formation, viscosity change, or additive depletion. It may even be from particles preventing
the free flow of oil or the movement of close fitting parts.
In new systems, harmful dirt, sludge, and abrasives may be introduced during manufacture
and erection. Slivers or chips of metal from pipe threads and tube cutting, pipe joint sealant,
and weld spatters are the most common built-in con- taminants that resist initial flushing and
cleaning procedures.
In operating systems, abrasive particles are produced as a result of wear of moving parts or
erosion within the system. Foreign particles or dust may enter through seals, fluid filler pipes,
and breather caps on reservoirs during normal operation. Condensation may occur when a
system cools after shutdown and result in a critical amount of water contamination. Oil
degradation from additive depletion and oxidation from aeration and high temperatures may
cause the formation of varnish and sludge deposits.
CLEANLINESS REQUIREMENTS
Some or all of the previously mentioned contaminants can be found in every hydraulic or
circulation system. Even the careful addition of initial fill or make-up oil to the system
through 5-micron filters will add some small amount of contamination.
The complete removal of all contaminants is economically not practical. A system !s
tolerance for contamination must be found and the system then maintained below this
contamination level.
As a guide to determine a system’s tolerance level, the following general classifications of
types of systems may be useful.

LOW PRESSURE CIRCULATION OIL SYSTEMS

Crushing equipment, paper machines, and steel mill circulation oiling systems may operate
at pressures up to about 500 PSL They are usually equipped with suction strainers of 10 to
100 mesh and a main pressure line filter of 75 microns nominal rating. The clearances in
pumps, motors, valves, and cylinders in these systems are large enough so that operating
efficiency is not impaired by spherical particles up to about 100 microns in
diameter--providing the concentration of these particles is low. Even at low concentrations
some abrasive wear may take place as a result of particles carried by the fluid scratching
against metal surfaces.
LOW TO MODERATE PRESSURE HYDRAULIC SYSTEMS

These are systems operating at pressures up to about 2500 PSI. They are usually equipped
with 80 to 100 mesh filters to remove all spherical particles over about 50 microns diameter.
Clearances in pumps, motors, valves, and cylinders are so small that large particles of
contaminants can cause jamming, or sticking. Abrasive wear of close fitting parts by minute
contaminants can be serious in these systems.
MEASURING CLEANLINESS
The surest method of rating a circulation oiling system Ts cleanliness is the scheduled
inspection of key parts of the system (valve removed or piping section disassembled for
visual inspection). These regular inspections allow the determination of the rate of
contaminant buildup and thus provide a check on filtering efficiency.
Another method is to regularly test samples of the fluid to determine rate of oil deterioration
and contaminant buildup. However, this method may not indicate possible deposition of
material. If the contaminants are insoluble in oil, they may be deposited in low flow rate
areas of the system and not show up in the oil samples. For this reason, periodic checks of the
system itself should be made. However, when dealing with critical
hydraulic systems, opening them up often introduces an intolerable
amount of dirt. Therefore, these systems should not be opened
periodically for visual inspection.
Analysis of periodic samples will indicate any deterioration of the oil that
is taking place through oxidation or other chemical reactions (such as
additive depletion etc.). Also if particle sizes of the insoluble
contaminants are small enough, and oil flow is high, the rate of
INSPECTION AND MAINTENANCE PERIODS

formation of these materials may be measured by checking the amounts

present in the oil. The gravimetric method gives an accurate quantitative
reading on the total amount of insoluble contamination in an oil.
CLEANING NEW SYSTEMS
Machine manufacturers exercise great care in cleaning their equipment
and preparing it for shipment. Despite the precautions taken, impurities
get into hydraulic or circulation systems during shipment and erection.
The latter, in particular, offers opportunities for the entrance of foreign
materials which interfere with operation, such as dirt, rags, wood blocks,
paint flakes, and rust particles. All these materials should be removed
from the machines after erection but before placing machines in service.
The following cleaning procedures should be performed before
operating machines under load:
1 Examine the interior of the reservoir and other accessible interior
spaces for contamination or foreign matter. Carefully remove all
such materials by manual methods --hand, brushing, wiping with
lint-free rags, etc.
If, in a large machine, piping has been assembled or welded on the
job, or holes have been drilled and tapped in lines or machines,
carefully remove pipe scale, weld spatter, surplus thread compound,
gasket cement, metal chips, and debris.
2 Where the machine builder recommends flushing with lubricating oil
alone but specific instructions are not available, generally follow the
procedure outlined in the preceding paragraph, using oil of suitable
viscosity without addition of solvent: (1) If the flushing oil is to be
circulated by means of the regular pump, use oil substantially the same
viscosity as that to be used in regular operation. During flushing, provide a fine screen
of adequate capacity on the pump suction to prevent entrance of abrasive particles. (2)
If an independent pump can be used for circulation, the use of a low viscosity flushing
oil may be considered. After flushing, drain the system immediately, taking all
necessary steps to remove all of the flushing charge.

3 Examine filter cartridges and suction screens for cleanliness, and clean or replace
them if necessary. Also, clean filter housings.
4 After carefully examining and cleaning the system, install the
proper grade and quantity of lubricating oil or hydraulic fluid.
CLEANING MACHINES IN SERVICE

Inspection may indicate several reasons for cleaning systems that have been in service for
some time;
1 Deposits in the reservoir or on parts within the system.

2 Erratic operation of hydraulic systems or high oil temperatures.

3 Poor oil condition as evidenced by dark color, cloudy appearance, a ’’burned oil” or
rancid odor, or the wrong viscosity of oil.
4 Presence of emulsions or process fluid contamination.
If the machine is functioning satisfactorily, the last two conditions (poor oil condition or
contamination) may be remedied by the procedure outlined under CLEANING DURING
SHUTDOWN.
If deposits are found, or if the machine is operating erratically, it may be desireable to clean
the machine thoroughly.
CLEANING DURING SHUTDOWN.
FIRST STEP - Drain the entire system immediately after shutdown while the oil is still hot.
Otherwise, solid contaminants will settle out, and as the oil cools, some soluble oxidation
products will become insoluble and also settle out. A sample of the drained oil may be sent to
a laboratory for a check on its condition. If the oil is still suitable for continued service, it can
be filtered and used as make up. Otherwise, it may possibly be used for general-purpose
lubrication of non-critical machine parts.
In many reservoirs the drain plug is incorrectly located above the bottom, leaving some oil in
the machine when it is drained. In hydraulic systems, oil may be left in cylinders,
accumulators, and lines when the reservoir is drained. Use special care to drain all of the old
oil from such systems as completely as possible. Oil left in the bottom of a reservoir can
usually be removed effectively with a hose connected to a suction pump or by mopping with
lintless rags.

SECOND STEP- After removing all the oil wipe the reservoir clean with lint-free rags. The
nature of any dirt found in the reservoir should be determined. Visual inspection should
make it possible to identify paint flakes, rust, wear particles, lint, or other similar material.
Remove loose paint or rust found on the reservoir surfaces. If metallic wear particles are
found, the installation of a magnetic drain plug should be considered. Also, the reasons for
the wear should be determined.
THIRD STEP - Remove and replace renewable filter cartridges, and clean the elements of
other types of filters and suction strainers in the system. Also clean the filter housings.
FOURTH STEP • Recharge the system with the proper grade and quantity of lubricating oil
or hydraulic fluid.

BENEFITS
The benefits from following a comprehensive program of checking on a system’s cleanliness,
and acting to maintain the system below its contamination limit, include the following:
 1 Less machine unscheduled downtime, with loss of production, will result in increased
productivity. INSPECTION AND MAINTENANCE PERIODS

2 Machines are more responsive, or faster acting, when contamination is maintained at a

low level and results in increased productivity.
3 Wear of machine is reduced thereby lengthening its service life, which will result in
increased productivity.
Section 6
HYDRAULIC CLEARING SYSTEM

DESCRIPTION ....................................................................................................................... 13- 1

OPERATION ....................................................................................................................................... 13-2

CONNECTING THE POWER UNIT ......................................................................................... 13-2

HYDRAULIC OIL SPECIFICATIONS ..................................................................................... 13-2

DISCONNECTING THE POWER UNIT .................................................................................. 13-7

PREPARATIONS BEFORE STARTING .................................................................................. 13-7

CLEARING THE CRUSHER ................................................................................................. 13- 8

ADJUSTING THE POWER UNIT ........................................................................................... 13-11

MAINTENANCE .............................................................................................................................. 13-12

CLEARING JACK REMOVAL,

4 FT. CRUSHERS .......................................................................................................... 13-12

CLEARING JACK ASSEMBLY,

4 FT. CRUSHERS ............................................................................................................. 13-14

CLEARING JACK REMOVAL,

5100 AND 4-1/4 FT. CRUSHERS .......................................................................................... 13-14

CLEARING JACK ASSEMBLY,

5100 AND 4-1/4 FT. CRUSHERS .................................................................................... 13-15

CLEARING JACK AND PUSH ROD INSTALLATION,

5100 AND 4-1/4 FT. CRUSHERS .................................................................................... 13-15

CLEARING JACK REMOVEL,

5-1/2 FT. AND 7 FT. CRUSHERS .................................................................................. 13-15

CLEARING JACK REBUILDING,

5-1/2 FT. AND 7 FT. CRUSHERS .................................................................................. 13-18

CLEARING JACK INSTALLATION,

5-1/2 FT. AND 7 FT. CRUSHERS .................................................................................. 13-21

JAMMED CLEARING JACK REMOVAL,

5-1/2 FT. AND 7 FT. CRUSHERS ................................................................................... 13-22

 INSPECTION AND MAINTENANCE PERIODS

SECTION 6

HYDRAULIC CLEARING SYSTEM

DESCRIPTION
For efficient continuous operation of a Crusher, there with pressures of 8,000 PSI on the 7 Ft. Extra Heavy Duty
must be a consistent, uniform flow of material through and 9,000 PSI on the 4 Ft” 5100, 4-1/4 Ft., 5-1/2 Ft. and 7
the crushing cavity. Ft. Heavy Duty Crushers. See the table SYSTEM
PRESSURE AND ADJUSTMENT RING
Should the Crusher stop under load, no attempt should
VERTICAL LIFT USING HYDRAULIC
be made to start the Crusher again until the entire
CLEARING. A three-way, three position control valve
crushing cavity has been cleared. Attempting to start
directs hydraulic oil to each of three hydraulic jacks,
the Crusher with the cavity full of material may result
one located at each arm on the main frame flange or
in serious damage to the Crusher and crusher motor.
four hydraulic jacks equally spaced around the
Some of the reasons a Crusher stops under load are as
underside of the main frame upper ring or fourteen or
follows; for example, crusher drive motor or engine
sixteen hydraulic jacks equally spaced around the top
stopped because of power failure or lack of fuel, too
of the adjustment ring. The piston, within each jack
much feed entering the crushing cavity causing the
cylinder extends and lifts the adjustment ring upwards
Crusher to stall, discharge conveyor stopped allowing
off of its seating surface on the main frame a distance
discharging material to back up and plug the Crusher
of 1〃 on the 4 Ft., 1-1/2〃 on the 5100, 4-1/4 Ft., 5-1/2
or a piece of tramp iron becoming caught in the
Ft. and 7 Ft. Heavy Duty and 2" on the 7 Ft. Extra
crushing cavity.
Heavy Duty Crushers. This additional clearance
The hydraulic clearing system, described in this
relieves the pressure off the material between the
Section, will substantially reduce the time and effort
crushing members and the material is free to pass
which ordinarily would be required to clear the
through the Crusher or can now be easily cleared by
Crusher and permit the removal of tramp iron
manual means as described in the paragraphs
SAFELY.
CLEARING THE CRUSHER in Section 11.
A motor driven two-stage pump provides an oil flow

C-1511 13-13
 INSPECTION AND MAINTENANCE PERIODS

5100 AND 7 FT. 7 FT.

CRUSHER SIZE 4 FT. 5-1/2 FT.
4-1/4 FT. HEAVY DUTY EXTRA HEAVY
DUTY
NUMBER OF
CLEARING JACKS
4 3 14 16 16

SYSTEM AND POWER 9,000 9,000 9,000 9,000 8,000

UNIT PRESSURE (POUNDS
PER SQUARE INCH- PSI)

ADJUSTMENT RING
1" 1-1/2" 1-1/2" 1-1/2〃 2"
VERTICAL LIFT (INCHES)

hose and the tee at the pump (power unit).

SYSTEM PRESSURE AND ADJUSTMENT RING
VERTICAL LIFT USING HYDRAULIC
CLEARINGOPERATION IT IS MOST IMPORTANT THAT DURING THE
ENTIRE PIPING PROCEDURE ALL DIRT
CONNECTING THE POWER UNIT AND FOREIGN MATTER BE KEPT OUT OF
THE HOSES AND FROM ALL FITTINGS.
When clearing of the Crusher is required, the portable
4 Check the power unit to be certain the control
hydraulic power unit is to be placed in a suitable valve handle is in the PRESSURE OFF position.
location near the Crusher and close to an electrical
power source as shown in the illustrations 5 Connect the power unit electric motor to a 1-1/2
HYDRAULIC CLEARING SYSTEM. The power unit HP, 3 phase power source. Direction of rotation of
is connected to the Crusher as follows: the motor is counterclockwise when viewing from
the shaft end of the motor. Jog the motor to check
1 The power unit, which has a built-in reservoir, is to for the correct rotation.
be filled with oil by removing the filler plug on the
top of the power unit. Use a hydraulic oil as Check the motor nameplate for the correct voltage,
described in HYDRAULIC OIL frequency and phase; electrical connections are
SPECIFICATIONS. Measure from the top of the also shown on the nameplate. For the proper
reservoir to the surface of the hydraulic oil. This operation and lubrication of the motor, refer to the
distance should be 1" to 1-1/4” ， when properly
filled. manufacturer’s service bulletin.
All fuse protection equipment is to be furnished
2 On the 4 Ft., 5100 and 4-1/4 Ft. Crushers, remove by the customer to conform to local electrical
the specially vented dust cap from the male fitting codes. The starter for the power unit motor is also
mounted on the side of the manifold block or one to be furnished by the customer to meet the
of the clearing jacks as shown in the illustrations
HYDRAULIC CLEARING SYSTEM, 4 FT., customers specific needs, location and electrical
5100 AND 4-1/4 FT. CRUSHERS. On the 5-1/2 Ft. interconnecting requirements. Attach a No. 8 or
and 7 Ft. Crushers, remove the dust cap from the larger ground wire to the power unit.
male fitting mounted on the front of one of the
clearing jacks as shown in the illustrations 6 Turn the electrical power to the power unit motor
HYDRAULIC CLEARING SYSTEM, 5-1/2 FT. OFF.
AND 7 FT. CRUSHERS.
3 Then connect the 12 Ft. long hose to the power
unit and to the manifold block or clearing jack on
the Crusher. HYDRAULIC OIL SPECIFICATIONS

Carefully clean the hydraulic fitting on the For the hydraulic clearing system use a high grade
manifold block or clearing jack; both ends of the

13-12 C-1512
paraffin (not naphthene) base industrial oil of viscosity
specified, having high film strength, having high
affinity for an adhesiveness to metal surfaces, having
stable chemical and physical properties. Such
lubricants should have a high viscosity index, rapid
water separation, resist foaming, offer some rust and
corrosion protection, resist oxidation and have antiwear
additives.
For normal, all year operating conditions, the lubricant
should have a viscosity of 300 to 350 SSU (Seconds
Saybolt Universal) at 100° Fahrenheit and a viscosity of
50 to 60 SSU at 210° Fahrenheit, corresponding to a
viscosity index of 90 or higher. For such all year
operating conditions, lubricants with viscosities higher
than 400 SSU at 100° Fahrenheit, or lower than 300
SSU at 100° Fahrenheit are not recommended.

OIL SPECIFICATIONS
Viscosity at 100°F ................. 300-350 SSU
Viscosity at 210°F ................... 50-60 SSU
Viscosity Index (V.I.) ........... 90 or higher
Correct lubricants meeting the above specifications are
essential for the protection of the working parts of our
Crushers. They are available from all major oil
companies. Improper lubricants can ruin the Crusher
and their use will void any warranties pertaining to such
Crushers.
DO NOT USE FIRE RESISTANT
HYDRAULIC FLUIDS AS THESE
HYDRAULIC SYSTEMS ARE NOT
DESIGNED FOR THE USE OF SUCH
FLUIDS.
Fire resistant hydraulic fluids MAY NOT be
compatible with packings, seals, hoses and other
components within the hydraulic system. Pump life
MAY decrease and any paint inside of the oil tank
MAY soften and lift off. Contact the factory before
using any fire resistant hydraulic fluids.

HYDRAULIC CLEARING SYSTEM

4 FT. CRUSHERS
C-1513 13-3
INSPECTION AND MAINTENANCE PERIODS

13-12 C-1514
INSPECTION AND MAINTENANCE PERIODS
ADJUSTMENT RING

5100 AND 4-1/4 FT. CRUSHERS

134 C-1515
 INSPECTION AND MAINTENANCE PERIODS

ADJUSTMENT
RING

CLEARING JACK
CYLINDER CAP 、PRESSURE ON

HOSE
GUARD
NEUTRAL

PRESSURE OFF

-1/2 HP, 3 PHASE

ELECTRIC MOTOR
MALE
FITTING

RESERVOIR

POWER
UNIT

CONTROL
RELIEF VALVE VALVE
ADJUSTING
SCREW

HYDRAULIC CLEARING SYSTEM

7 FT. EXTRA HEAVY DUTY CRUSHERS
13-6 C-1516
HYDRAULIC CLEARING SYSTEM
5-1/2 FT. AND 7 FT. HEAVY DUTY CRUSHERS
C-1517 13-5
 INSPECTION AND MAINTENANCE PERIODS
PRESSURE ON

CONTROL VALVE HANDLE POSITIONS

CLEARING
JACK ADJUSTMENT RING
CYLINDER
CAP

1/2 HP, ,•
ELECTRIC
MOTOR

PRESSURE
GAUGE

OIL
RESERVOIR
FILLER
PLUG

MALE
FITTING

FEMALE HOSE
CONNECTION

POWER
UNIT
CONTROL
RELIEF VALVE VALVE
ADJUSTING
SCREW

HYDRAULIC CLEARING SYSTEM

7 FT. EXTRA HEAVY DUTY CRUSHERS
13-6 C-1518
Approximately 25 U.S. gallons will be required
INSPECTION to fill
AND MAINTENANCE IT IS IMPORTANT THAT THE HYDRAULIC
PERIODS

the power unit reservoir, hydraulic clearing jacks and CIRCUIT BE KEPT FREE OF* DIRT, DUST
interconnecting hoses. OR ANY OTHER ABRASIVE MATERIAL.
THE OIL CLINGING TO THE INTERNAL
WALL OF THE HOSE WILL QUICKLY
ACCUMULATE ANY DUST OR DIRT
SUSPENDED IN THE AIR AROUND THE
DISCONNECTING THE POWER UNIT
WORK SITE. WHEN THE POWER UNIT IS
During normal crusher operation the power unit is to NEXT PUT IN USE, THE MATERIAL
be disconnected from the Crusher and stored in a WOULD BE FLUSHED FROM THE HOSE
readily accessible and clean location as follows: AND CIRCULATED THROUGH THE
1 Turn the electrical power to the power unit motor SYSTEM, CAUSING DAMAGE TO THE
OFF and disconnect the motor from the power CLOSELY MACHINED SURFACES IN THE
source. CLEARING JACKS, CONTROL VALVE AND
PUMP.
2 Place the control valve handle in the PRESSURE 7 Store the power unit in as clean a location as
OFF position. possible. If nothing else is available, the power
unit should, at least, be covered by a suitable
3 Observe the pressure gauge at the power unit and protective covering.
wait until the gauge indicates 0 PSI.
PREPARATIONS BEFORE STARTING
4 Slowly loosen the female hose connection at the
manifold block or clearing jack and relieve any
pressure remaining in the system through the Air entrapped in the empty hose will almost certainly
loosened connection before removing the hose be introduced into the hydraulic circuit when the hose
completely. is connected to the Crusher and the hydraulic system is
pressurized. To insure satisfactory and safe operation
the hydraulic circuit must be bled and the system
WARNING checked as follows:
Under no circumstances should the hose be 1 Connect the power unit to the Crusher as
disconnected from the manifold block or instructed under CONNECTING THE POWER
clearing jack while there is a pressure UNIT.
reading on the pressure gauge. Recheck to 2 Place the control valve handle in the PRESSURE
be certain the control valve handle is in the OFF position.
PRESSURE OFF position. Disconnecting
the hose while under pressure is dangerous 3 Turn the electrical power to the power unit motor
due to the high velocity of the escaping oil ON and let the power unit run depressurized for 2
and to the possibility of being struck by the or 3 minutes.
free end of a whipping hose. 4 Locate the clearing jack that is the farthest from
the power unit connection and “crack” open the
hose connection or pipe plug 1 to 1-1/2 turns.
5 Move the control valve handle to the PRESSURE
5 Disconnect the female hose connection. On the 4 ON position. Leave the handle in this position
Ft” 5100 and 4-1/4 Ft. Crushers install the special until a steady, clear stream of oil flows from the
vented dust cap, making certain it is tightened loosened connection.
securely on the male fitting at the manifold block
or on the end of the elbow on the clearing jack. 6 Return the control valve handle to the
On the 5-1/2 Ft. and 7 Ft. Crushers install the dust NEUTRAL position, then securely tighten the
cap, making certain it is tightened securely on the previously loosened hose connection or pipe
end of the male fitting on the clearing jack plug.
cylinder cap.
6 Plug the female hose connection to keep the hose 7 Place the control valve handle in the PRESSURE
and power unit clean during storage. ON position and allow the system to build up to

C-1519 13-13
 2,000 PSI then return the control valve
INSPECTION handle
AND to
MAINTENANCE
1 Shut the power OFF to the crusher motor as
PERIODS

the NEUTRAL position. The system should quickly as possible.

remain pressurized while in the neutral position. 2 Connect the hydraulic power unit to the Crusher as
8 Check the hose connections at the clearing jacks instructed under CONNECTING THE POWER
and at the power unit to be certain there are no UNIT and PREPARATIONS BEFORE
leaks. Tighten the hose connections if necessary. STARTING. The control valve handle should be in
the PRESSURE OFF position.
9 Move the control valve handle to the
PRESSURE ON position and watch the pressure 3 Turn the electrical power to the power unit motor
gauge to see if system pressure reaches and ON. Place the control valve handle in the
holds 8,000 PSI or 9,000 PSI depending on the PRESSURE ON position. When the full system
crusher size. See the paragraph DESCRIPTION pressure of 8,000 PSI or 9,000 PSI is reached, the
for crusher sizes. If there is a 500 PSI (±500 PSI) adjustment ring is in the raised position. Jog the
pressure variation from the 8,000 PSI or 9,000 Crusher by applying short spurts of power to the
PSI, the relief valve on the power unit will need crusher drive motor to clear the crushing cavity.
an adjustment as instructed under ADJUSTING
THE POWER UNIT. 4 If the crushing head is free and the cavity is clear of
material, place the control valve handle in the
10 After the system pressure reaches and holds the PRESSURE OFF position and allow the
correct pressure, place the control valve handle adjustment ring to return to its seating surface on
in the PRESSURE OFF position. the main frame. JACK PRESSURE MUST BE
RELEASED BEFORE STARTING THE
11 Observe the pressure gauge at the power unit and CRUSHER. Then resume normal crushing
wait until the gauge indicates 0 PSI. operations. If jogging the Crusher a few times does
not free the head, proceed to Step 5.
12 Turn the electrical power to the power unit motor
OFF. 5 Release the jack pressure by moving the control
valve handle to the PRESSURE OFF position.
This will allow the crusher spring pressure to lower
the adjustment ring and compress or crush any
CLEARING THE CRUSHER material that shifted during the time the adjustment
ring was lifted.
Should the Crusher stop under load, no attempt should
6 Raise the adjustment ring again, to relieve the
be made to start the Crusher again until the entire spring pressure on the jammed material by moving
crushing cavity has been cleared. Attempting to start the control valve handle to the PRESSURE ON
the Crusher with the cavity full of material may result position. This will allow any material to fall free
in serious damage to the Crusher and crusher motor. that was crushed while spring pressure to the
Some of the reasons a Crusher stops under load are as adjustment ring was re-applied.
follows; for example, Crusher drive motor or engine 7 Jog the Crusher a few times as instructed in Step 3
stopped because of power failure or lack of fuel, too and again check for free head movement.
much feed entering the crushing cavity causing the
('rusher to stall, discharge conveyor stopped allowing 8 If the crushing cavity is cleared, resume normal
discharging material to back up and plug the Crusher crushing. If the head is still not free, repeat Steps 3
or a piece of tramp iron becoming caught in the through 7 several times or as long as material
continues to discharge from the crushing cavity.
crushing cavity.
The gyrating crushing action of the head could 9 If the crushing cavity still is not cleared after
possibly cause the material caught between the repeated cycling of the clearing system, raise the
crushing members on the closed side to tip and raise adjustment ring by moving the control valve
the adjustment ring a small amount. This caught handle to the PRESSURE ON position. After the
full system pressure is reached, swing or slide the
material wedges very tightly between the bowl liner safety block assemblies located around the top of
and mantle because of the compression of the spring the main frame or loosen the hex nut and raise the
clusters in that area. handle arms on the safety block assemblies located
T(> clear the Crusher or to remove tramp iron wedged around the outside of the adjustment ring, to the
l)ctween the bowl liner and mantle using the hydraulic horizontal position as shown in the illustrations
SAFETY BLOCKS. Move each safety block
clearing system, proceed as follows: toward the Crusher as far as possible under the

13-12 C-1520
 adjustment ring as shown in the illus-

SAFETY BLOCK AND SAFETY BLOCK POSITIONS

4 FT., 5100 AND 4-1/4 FT. CRUSHERS
C-1521 13-9
trations SAFETY BLOCK INSPECTION
POSITIONS. These
AND MAINTENANCE 10 With the safety blocks inserted, proceed with the
PERIODS

blocks, when slid into position, fit between the main manual clearing procedure as described in the
paragraphs TRAMP IRON REMOVAL in
frame and adjustment ring and will keep the Section 11.
adjustment ring and bowl in the raised position in
case of a sudden loss of pressure due to a hydraulic THE PROBABILITY OF AN
line, pump, or jack failure. UNCRUSHABLE OBJECT LODGING
ITSELF WITH ITS MAXIMUM DIAMETER
WARNING
OR SIZE ALIGNED BETWEEN THE
THE SAFETY BLOCKS MUST BE CRUSHING MEMBERS IS RARE. IF THIS
SECURELY PLACED BETWEEN THE SHOULD HAPPEN AND THE OBJECT IS
MAIN FRAME AND THE ADJUSTMENT LARGE ENOUGH, IT IS POSSIBLE THAT
RING BEFORE ANY MANUAL CLEARING LIFTING THE ADJUSTMENT RING AND
OF THE CRUSHER BEGINS. THIS IS A JOGGING THE CRUSHER WILL NOT
SAFETY FEATURE TO PROTECT HANDS ALLOW THE OBJECT TO DROP OUT OF
OR ARMS OR EQUIPMENT FROM BEING THE CRUSHER. IF THIS SHOULD OCCUR,
CAUGHT BETWEEN THE CRUSHING IT MAY BE NECESSARY TO “WASH” THE
MEMBERS IN THE EVENT OF A TRAMP IRON PIECE AWAY BY USING A
HYDRAULIC FAILURE. THERMAL CUTTING TORCH AS
DO NOT PLACE FEET OR HANDS ON THE INSTRUCTED IN TRAMP IRON REMOVAL
SPRING CLUSTERS; IN THE SPACE IN SECTION 11.
BETWEEN THE ADJUSTMENT RING AND
MAIN FRAME; OR ANY PART OF THE WARNING
BODY BETWEEN THE LOWER SPRING
SEGMENTS AND THE MAIN FRAME UNDER NO CIRCUMSTANCES
FLANGE. ALWAYS POSITION THE ENTER THE CRUSHING CAVITY
SAFETY BLOCKS BETWEEN THE MAIN 11 When the cavity is cleared, swing or pull the safety
FRAME AND ADJUSTMENT RING WHEN blocks outward as shown in the illustra-
THE ADJUSTMENT RING IS IN THE WHEN A PIECE OF TRAMP IRON IS
RAISED POSITION AND TRAMP IRON IS WEDGED BETWEEN THE BOWL
BEING REMOVED. LINER AND MANTLE.
ADJUSTMENT RING

BLOCK
IN

-HANDLE IN
“FOLDED-
POSITION”

ADJUSTMENT RING IN NORMAL CRUSHING

13-12 C-1522
 POSITION WITH SAFETY ADJUSTMENT RING IN
BLOCK PULLED OUT FOR RAISED POSITION AND
NORMAL CRUSHING SAFETY BLOCK PUSHED IN
FOR MANUAL CLEARING OF
CRUSHING CAVITY

SAFETY BLOCK AND SAFETY BLOCK POSITIONS

4 FT., 5100 AND 4-1/4 FT. CRUSHERS
C-1523 13-9
SAFETY BLOCK
PULLED OUT INSPECTION AND MAINTENANCE PERIODS

SAFETY BLOCK SAFETY BLOCK

SAFETY BLOCK PUSHED IN FOR

PULLED OUT FOR MANUAL CLEARING
NORMAL OF CRUSHING
CRUSHING CAVITY

SAFETY BLOCK POSITIONS

5-1/2 FT. AND 7 FT. HEAVY DUTY CRUSHERS

SAFETY BLOCKS
5-1/2 FT CRUSHERS

13-10 c
 INSPECTION AND MAINTENANCE PERIODS

CRUSHING CAVITY
SAFETY BLOCK POSITIONS SAFETY BLOCKS

7 FT. EXTRA HEAVY DUTY CRUSHERS 7 FT. EXTRA HEAVY DUTY CRUSHERS

tions SAFETY BLOCK POSITIONS. Release 4-1/4 Ft” 5-1/2 Ft. and 7 Ft. Heavy Duty
the jack pressure by placing the control valve Crushers. THE POWER UNIT MUST BE
TESTED WITH THE CONTROL VALVE
handle in the PRESSURE OFF position. JACK HANDLE IN THE “PRESSURE ON”
PRESSURE MUST BE RELEASED BEFORE POSITION AND WITH THE HYDRAULIC
STARTING THE CRUSHER. OIL ACTING AGAINST AN IMMOVABLE
RESISTANCE. THIS CAN BE
12 Resume normal crushing. ACCOMPLISHED BY EITHER
CONNECTING THE POWER UNIT TO THE
13 Disconnect the power unit as instructed under CRUSHER AS INSTRUCTED UNDER
DISCONNECTING THE POWER UNIT. CONNECTING THE POWER UNIT AND/OR
BY REMOVING THE POWER UNIT HOSE
WARNING AT THE PRESSURE GAUGE AND
INSTALLING A THREADED PIPE PLUG IN
Under no circumstances should the Crusher be THE GAUGE ADAPTER FITTING.
2 If the hydraulic pressure is more than 500 PSI
started and crushing resumed with the clearing above 8,000 PSI or 9,000 PSI, proceed as follows:
jacks in the RAISED position or in any position
A. Place the control valve handle in the
other than fully RETRACTED. SERIOUS
PRESSURE OFF position and turn the electrical
PERSONAL INJURY AND SEVERE power to the power unit motor OFF.
DAMAGE TO THE CRUSHER COULD
B. Turn the relief valve adjusting screw OUT
RESULT. Hydraulic jacks could be torn loose (counterclockwise) two turns as shown on the
from their mountings and the jacks ejected illustrations HYDRAULIC CLEARING
rapidly outwards or hydraulic hoses could SYSTEM.
rupture. C. Turn the electrical power to the power unit
motor ON and place the control valve handle in
ADJUSTING THE POWER UNIT the PRESSURE ON position.
D. Carefully, and slowly, turn the relief valve
If the system pressure varies more than 500 PSI from adjusting screw IN (clockwise) until the pressure
the specified pressure (±500 PSI), the relief valve on gauge reads and holds 8,000 PSI or 9,000 PSI.
the power unit must be adjusted as follows: NO ATTEMPT SHOULD BE MADE TO
1 Place the control valve handle in the TURN THE RELIEF VALVE ADJUSTING
PRESSURE ON position and wait until the SCREW OUT (COUNTERCLOCKWISE)
pressure gauge indicates the maximum, pressure, WHILE THERE IS HYDRAULIC PRESSURE
which should be 8,000 PSI on the 7 Ft. Extra IN THE SYSTEM. IF THE PRESSURE SET
Heavy Duty and 9,000 PSI on the 4 Ft” 5100, POINT OF 8,000 PSI OR 9,000 PSI
('-1624 13-11
 IS EXCEEDED WHILE TURNING THE RELIEF VALVE ADJUSTING SCREW IN (CLOCKWISE),
THE SYSTEM MUST BE DEPRESSURIZED AND THE PROCESS OF ADJUSTING THE
PRESSURE MUST BE STARTED OVER. FOR COMPLETE ACCURACY THE FINAL
ADJUSTMENT MUST BE MADE WHILE IN THE PROCESS OF INCREASING PRESSURE BY
TURNING THE RELIEF VALVE ADJUSTING SCREW IN (CLOCKWISE).
3 If the hydraulic pressure is more than 500 PSI below 8,000 PSI or 9,000 PSI, proceed as follows:

A. Turn the electrical power to the power unit motor ON and place the control valve handle in the
PRESSURE ON position.
B. Carefully, and slowly, turn the relief valve adjusting screw IN (clockwise) until the pressure gauge reads
and holds 8,000 PSI or 9,000 PSI.

Since the pressure is already below either 8,000 PSI or 9,000 PSI, there is no need to depressurize the
system and turn the relief valve adjusting screw OUT (counterclockwise).

MAINTENANCE

It is important to maintain the clearing jacks in good operating condition. By carrying out simple preventive
maintenance procedures, expensive repair costs can be avoided. If hydraulic system pressure cannot be
maintained with the control valve in the NEUTRAL position, it is a good indication of oil leakage in the hydraulic
circuit. Oil leakage coming from between the piston and the cylinder of the jack is an indication that the clearing
jacks will require rebuilding. If after prolonged usage there is oil leakage at one or more of the clearing jacks, it is
advisable to rebuild all the jacks rather than just the immediate problem. In addition, from time to time, check the
hoses and all connections to insure that they are not leaking. If they are leaking, tighten the fittings and/or replace
the fittings and hoses.

CLEARING JACK REMOVAL, 4 FT. CRUSHERS

To remove one of the clearing jacks for inspection or all the clearing jacks for rebuilding, proceed as follows:
1 Disconnect the power unit from the Crusher as instructed under DISCONNECTING THE POWER UNIT.
2 Relieve any remaining pressure in the hydraulic circuit by “cracking” open one of the hose connections at any
of the clearing jacks, 1 to 1-1/2 turns.
3 Remove the hoses from the bottom of the clearing jack, being careful not to damage any of the hydraulic
fittings.

DURING THE REBUILDING PROCESS IT IS EXTREMELY IMPORTANT THAT THE HOSES BE

PROTECTED AGAINST DIRT AND DUST ENTERING THE HOSE PASSAGES. IMMEDIATELY
AFTER REMOVAL, STORE THE HOSES IN A CLEAN, DUST FREE AREA.
4 Using a plumber’s wrench with a canvas strap, unscrew the clearing jack cylinder from the cylinder head
which is located on the underside of the main frame upper ring, see the illustration CLEARING JACK
ASSEMBLY, 4 FT. CRUSHERS.

DO NOT USE A PIPE WRENCH TO REMOVE THE CLEARING JACK. INDENTATIONS CREATED
FROM THE JAWS OF THE PIPE WRENCH CAN CAUSE THE CLEARING JACK CYLINDER TO FAIL
WHEN PRESSURIZED.
Care should be taken when lowering the clearing jack cylinder as the push rod and piston should slide
downward with the cylinder. If these parts stick in the cylinder head, care should be taken so that they do not
drop accidently and become damaged.
C-23 13-13
 INSPECTION AND MAINTENANCE PERIODS

5 Remove the push rod from within the cylinder head by pulling downward on the rod. If the push rod cannot be
removed, this is usually a result of the head of the rod being peened over. The cylinder head and push rod will
have to be removed from the crusher main frame before the push rod can be removed.
MAIN FRAME
IF THE PUSH ROD IS PEENED OVER AT THE TOP, MACHINE THE PUSH ROD 1/32〃 SMALLER IN
DIAMETER FOR A l/; LENGTH.
6 Loosen the cylinder head from the underside of the main frame by using a brass rod and hammer in the holes on
the bottom of the cylinder head. Then finish removing by unscrewing the cylinder head completely.
7 Inspect the cylinder bore and piston for nicks, scratches or excessively worn spots. If there is excessive wear on
any of these parts, they should

PUSH ROD

CYLINDER
HEAD

CYLINDER

O-RING AND BACK-UP

WASHERS

13-12 C-24
 CLEARING JACK ASSEMBLY
4 FT. CRUSHER

C-25 13-13
be replaced. Excessive wear on theINSPECTION
cylinder AND
boreMAINTENANCE
and/or 7 Recheck the hose connections to be certain they
PERIODS

piston will cause the piston to cock. are tight.

Check the push rod for rust, galling, bending or 8 Test the hydraulic circuit for leaks and bleed the
peening. system as instructed under PREPARATIONS
BEFORE STARTING.
Check the piston O-ring and back-up washers for
breaks or flat spots. Check the outside diameter of CLEARING JACK REMOVAL,
the piston for galling or peeling of the bronze
plating. 5100 AND 4-1/4 FT. CRUSHERS

CLEARING JACK ASSEMBLY, 4 FT. CRUSHERS To remove one of the clearing jacks for inspection or
all the clearing jacks for rebuilding, proceed as follows:
To assemble and install the clearing jacks, proceed as
follows: 1 Disconnect the power unit from the Crusher as
instructed under DISCONNECTING THE
1 All surfaces of the cylinder bore, piston, push rod POWER UNIT.
and cylinder head are to be clean and dust free.
Any rust on these surfaces should be removed by 2 Relieve any remaining pressure in the hydraulic
buffing with a fine abrasive rubbing compound. circuit by “cracking” open one of the hose
DO NOT FILE OR USE EMERY PAPER. IF connections at any of the clearing jacks, 1 to 1-1/2
RUST IS EXTENSIVE AND CANNOT BE turns.
REMOVED WITH RUBBING COMPOUND,
THE JACK MUST BE REPLACED. Closely 3 Remove the hoses from each clearing jack, being
examine the inside bore for scratches. Any deep careful not to damage any of the hydraulic fittings.
scratches or scoring will cause leakage and the
jack must be replaced. DURING THE REBUILDING PROCESS IT IS
EXTREMELY IMPORTANT THAT THE
USE LINT-FREE RAGS WHEN CLEANING HOSES BE PROTECTED AGAINST DIRT
HYDRAULIC COMPONENTS. AND DUST ENTERING THE HOSE
2 Liberally coat the threads on the cylinder head PASSAGES. IMMEDIATELY AFTER
with a mixture of grease and 5-10% (by volume) REMOVAL, STORE THE HOSES IN A CLEAN,
of molybdenum disulfide powder. Install the DUST FREE AREA.
cylinder head into the main frame upper ring and 4 Lift the push rods slightly and slide the jack off
tighten, using a brass rod and hammer in the holes the pedestal on the main frame. See the illustration
on the bottom of the cylinder head. The cylinder PUSH ROD INSTALLATION, 5100 AND 4-1/4
head should bear tightly against the underside of FT. CRUSHERS.
the main frame upper ring.
5 To remove the piston from within the jack
3 Install the O-ring and back-up washers in the cylinder, connect the jack directly to the pumping
piston as shown in the illustration CLEARING unit used to operate the clearing system. Slowly
JACK ASSEMBLY, 4 FT. CRUSHERS. Coat the pressurize the jack until the piston is free from the
bore of the cylinder with a light oil and install the jack cylinder bore.
piston in the cylinder with the chamfered portion
of the piston against the bottom of the cylinder. TAKING THE JACK APART SHOULD BE
4 Apply a coat of oil to the push rod and insert it into DONE IN A DUST FREE AREA SO AS NOT
the cylinder head. Hold the push rod up in the TO C O N T A M I N A T E T H E C L O S E L Y
cylinder head until the cylinder with the piston MACHINED INTERNAL PARTS. DIRT
installed has been threaded onto the cylinder head. WOULD CAUSE EXCESSIVE WEAR AND
5 To tighten the cylinder on the cylinder head use a
PREMATURE SEAL FAILURE WHEN THE
plumber’s wrench with a canvas strap. The JACK IS REASSEMBLED.
cylinder will have approximately 1/8 〃 clearance
with the underside of the main frame upper ring 6 Pour the oil out of the jack cylinder and inspect the
when properly installed. cylinder bore and piston for nicks, scratches,
6 Reconnect the hoses to the bottom of the clearing rust or excessively worn spots. If there is
jack. excessive wear on any of these parts, they should

C-1525 13-15
 be replaced. Excessive wearINSPECTION
on the cylinder bore CLEARING JACK
AND MAINTENANCE PERIODS
AND PUSH ROD
and/or piston will cause the piston to cock. INSTALLATION,
Check the rod wiper and rod seal for breaks or
flat spots.
5100 AND 4-1/4 FT. CRUSHERS
CLEARING JACK ASSEMBLY,
To assemble the clearing jacks and push rods, proceed
as follows:
14. There are three sets of push rods; each set
5100 AND 4-1/4 FT. CRUSHERS consists of one upper push rod and one lower push
rod, installed at each jack location. Refer to the
illustration, PUSH ROD ASSEMBLY, 5100
To assemble the clearing jacks, proceed as follows: AND 4-1/4 FT. CRUSHERS. The upper push rod
can be identified by the rounded nose on one end
17. All surfaces of the cylinder bore and piston are of the rod. This rod is to be inserted, rounded end
to be clean and dust free. Any rust on these up, up through the lower and upper push rod
surfaces should be removed by buffing with a bosses, located on the side of the main frame.
fine abrasive rubbing compound. DO NOT FILE
OR USE EMERY PAPER. IF RUST IS 15. Then insert the lower push rod up under the
EXTENSIVE AND CANNOT BE REMOVED upper push rod through the same lower push rod
WITH RUBBING COMPOUND, THE JACK boss. The turned end of the lower push rod is to be
MUST BE REPLACED. Closely examine the pointing up when being installed.
inside bore for scratches. Any deep scratches or
scoring will cause leakage and the jack must be 16. Slide both push rods up far enough to slide the
replaced. clearing jacks into position under the rods with
the jack hydraulic connection pointing out, then
USE LINT-FREE RAGS WHEN CLEANING allow the push rods to rest on the jack pistons.
HYDRAULIC COMPONENTS.
17. Center each jack under the push rods.
18. Install the rod seal in its groove in the cylinder
bore. The seal is to be installed with the solid end 18. Connect all the fittings, hoses and pump to the
of the seal toward the top of the jack cylinder as jack as shown in the illustration, HYDRAULIC
shown in the illustration CLEARING JACK CLEARING SYSTEM, 5100 AND 4-1/4 FT.
ASSEMBLY, 5100 AND 4-1/4 FT. CRUSHERS.
CRUSHERS.
19. Recheck the hose connections to be certain
19. Install a new rod wiper in its counterbore they are tight.
located at the top of the cylinder bore.
20. Test the hydraulic circuit for leaks and bleed
20. Coat the jack cylinder bore and piston liberally the system as instructed under PREPARATIONS
with a light oil. BEFORE STARTING.
21. Carefully insert the piston into the cylinder
and push it into the cylinder until it bottoms.
CLEARING JACK REMOVAL,
22. Install the jack on the Crusher as described
under PUSH ROD INSTALLATION, 5100
AND 4-1/4 FT. CRUSHERS.

5-1/2 FT. AND 7 FT. CRUSHERS

To remove one of the clearing jacks for inspection or
all the clearing jacks for rebuilding, proceed as follows:
14 Disconnect the power unit from the Crusher as

13-16 C-1526
 instructed under DISCONNECTING THE
POWER UNIT.
15 Relieve any remaining pressure in the hydraulic
circuit by “cracking” open one of the pipe plugs
at any of the cylinder caps, so equipped, 1 to 1-1/2
turns.
16 Remove the hose guards by removing the hose
guard capscrews which attach the guards to the
cylinder caps. See the illustrations HYDRAULIC
CLEARING SYSTEM, 5-1/2 FT. AND 7 FT.
CRUSHERS.
17 Remove the hoses from each of the cylinder caps,
being careful not to damage any of the hydraulic
fittings.

13-16 C-1527
 INSPECTION AND MAINTENANCE PERIODS

5100 AND 4-1/4 CRUSHERS

13-16 C-1528
 INSPECTION AND MAINTENANCE PERIODS

CYLINDER

CLEARING JACK
ASSEMBLY
5100 AND 4-1/4 FT. CRUSHERS

C-1529 13-15
 DURING THE REBUILDING PROCESS
INSPECTION IT IS
AND MAINTENANCE BLOCKING.
PERIODS
EXTREMELY IMPORTANT THAT THE
9 Remove the two socket head capscrews which
HOSES BE PROTECTED AGAINST DIRT attach the cylinder cap to the cylinder and lift the
AND DUST ENTERING THE HOSE cap free of the cylinder.
PASSAGES. IMMEDIATELY AFTER
REMOVAL, STORE THE HOSES IN A 10 Thread an eyebolt into the tapped hole in the top
CLEAN, DUST FREE AREA. of the piston and lift the piston free from the
cylinder as shown in the illustrations
18 Remove the clearing jack mounting bolts from CLEARING JACK ASSEMBLY.
each corner of the cylinder cap as shown in the 11 Remove the O-ring from the top of the cylinder; on
illustrations CLEARING JACK CYLINDER the 7 Ft” also remove the plastic wear ring from
the bottom of the cylinder. Thoroughly clean the
CAP, 5-1/2 FT. AND 7 FT. CRUSHERS. inside bore of the cylinder. Any rust on the inside
surfaces of the cylinder should be removed by
19 Thread two eyebolts into the tapped holes at the buffing with a fine abrasive rubbing compound.
top of the cylinder cap. Connect a steel cable to
the eyebolts and to a suitable overhead lifting
device. Take a slight strain on the cable to DO NOT FILE OR USE EMERY PAPER. IF
determine whether the cylinder is free within the RUST IS EXTENSIVE AND CANNOT BE
adjustment ring. If the clearing jack assembly is REMOVED WITH RUBBING COMPOUND,
loose, remove the unit from the adjustment ring THE CYLINDER MUST BE REPLACED.
and proceed with clearing jack rebuilding as Closely examine the inside bore for scratches. Any
instructed under CLEARING JACK
REBUILDING, 5-1/2 FT. AND 7 FT. deep scratches or scoring will cause cylinder
CRUSHERS. leakage and the cylinder must be replaced.
ON THE 7 FT. CLEARING JACKS MAKE
20 If the clearing jack is not readily removable, CERTAIN THE 1/8" VENT HOLE IS FULLY
unscrew the two eyebolts and install the two OPEN AND FREE OF ANY DIRT OR GREASE.
jacking screws in the two tapped holes, in place 12 Place a new wear ring in position inside the
of the eyebolts. Alternately tighten each jacking cylinder groove. This can be accomplished by
screw a small amount until the cylinder assembly overlapping the two ends of the wear ring by
is loose. Reinstall the eyebolts and lift the unit exerting finger pressure and inserting it from the
free of the adjustment ring. bottom of the cylinder until the wear ring snaps
into the groove, see the illustration PLASTIC
WEAR RING, 7 FT. CRUSHERS.
CLEARING JACK REBUILDING,
THE PROCEDURE DESCRIBED IN STEP 5
DOES NOT APPLY TO THE 5-1/2 FT.
13 Stand the cylinder upright on suitable blocking
such as was used during disassembly.
5-1/2 FT. AND 7 FT. CRUSHERS
14 Remove the Poly-Pak seal and the modular bearing
on the 5-1/2 Ft. or the T-seal on the 7 Ft. from the
piston and thoroughly clean the piston and the seal
groove. Examine the piston for any galling or
Be sure that a sufficient quantity of O-rings, wear corrosion. Light scratches or scoring on the large
diameter piston surface are not critical since
rings, and T-seals or O-rings, Poly-Pak seals and sealing between the piston and cylinder is
modular bearings, depending on the style of clearing provided by the Poly-Pak seal or the T-seal. Any
jacks, are on hand before the rebuilding work begins. roughness on the piston surfaces must be polished
During the entire rebuilding process it is important out with a rubbing compound.
that the work is done on a clean surface and in a dust
free atmosphere. To disassemble, inspect, rebuild, and DO NOT FILE OR USE EMERY PAPER ON
reassemble the clearing jacks, proceed as follows: THE PISTON.
15 Lightly coat the piston surface with light oil.
8 Set the clearing jack upright on suitable blocking Position the new Poly-Pak seal and modular
so that the piston is raised off the work area as bearing at the same time or a new three-piece
shown in the illustration CLEARING JACK T-seal in the groove in the side of the piston. See
the illustrations CLEARING JACK ASSEMBLY,

13-16 C-1530
 5-1/2 FT. AND 7 FT. CRUSHERS. Use just
enough force over the top of the piston to clear the
outside diameter of the piston. Avoid any undue
stretching which will permanently distort the seal.

C-1531 13-19
 INSPECTION AND MAINTENANCE PERIODS
PLASTIC WEAR
RING
7 FT. CRUSHERS

5-1/2 FT. AND 7 FT. HEAVY DUTY CRUSHERS

CLEARING JACK CYLINDER

CAP
7 FT. EXTRA HEAVY DUTY CRUSHERS

13-16 C-1532
 INSPECTION AND MAINTENANCE PERIODS

CLEARING JACK ASSEMBLY

13-20 C-1533
 INSPECTION AND MAINTENANCE PERIODS bly and to prevent jack seizure when the clearing
IF THE SEAL IS STRETCHED OUT OF
SHAPE, IT MUST BE DISCARDED AND A jacks are again removed.
NEW SEAL MUST BE USED. 9 Lower the jacks into the adjustment ring bores
16 Slowly insert the piston into the clean cylinder. making certain the jack cylinder is fully seated
When the modular bearing or T-seal is flush with on the bottom of the adjustment ring bore and the
the top of the cylinder bore the piston snould be holes in the cap are in alignment with the tapped
rotated back and forth in a circular motion while holes in the adjustment ring.
exerting slight downward pressure. Once the seal
is fully seated in the cylinder bore, the piston can
be tapped into place with a wooden hammer THE TWO JACKS THAT ARE EQUIPPED
handle. FOR CONNECTING TO THE POWER UNIT
MUST BE POSITIONED 180° APART WITH
ON THE 5-1/2 FT. CLEARING JACK, MAKE THE STRAIGHT MALE FITTING AND DUST
SURE THE SLOT IN THE SIDE OF THE CAP FACING OUTWARD.
PISTON IS IN LINE WITH THE PISTON 10 Coat the threads of the four clearing jack
RETAINING SCREW. SEE THE mounting bolts with Never-Seez lubricating
ILLUSTRATION CLEARING JACK compound and install the four bolts at the corners
of the cylinder cap. Alternately tighten the bolts
DISASSEMBLY. on the 5-1/2 Ft. to 250 Ft-Lbs in 50 Ft-Lb
increments and the 7 Ft. to 200 Ft-Lbs in 50
17 Place a new O-ring in the ring groove at the top of Ft-Lb increments following the torquing
the cylinder bore. sequence shown in the illustration CLEARING
18 Thoroughly clean the cavity in the cylinder cap,
then flush and use high pressure air to blow out
the internal oil passages. Then plug the straight◎| 3
❹
male fitting with easily removable clean waste
material. Coat the entire inside diameter of the
cylinder cap with Never-Seez lubricating TOP VIEW OF CLEARING JACK
compound. Carefully place the cap in position on CLEARING JACK MOUNTING
BOLTS
the cylinder being certain to align the two holes
in the cylinder cap with the two tapped holes at
the top of the cylinder wall. Also be careful not to ◎ 4 2(g)
let the O-ring get pinched when installing the JACK TORQUE REQUIREMENTS.
cylinder cap.
19 Thoroughly clean the two socket head capscrews ALTERNATELY TIGHTEN THE
and insert them through the two inside diameter BOLTS ON THE 5-1/2 FT. TO 250
FT-LBS IN 50 FT-LB INCREMENTS
holes in the cylinder cap and tighten the AND THE 7 FT. TO 200 FT-LBS IN 50
capscrews fingertight only. The two cylinder cap FT-LB INCREMENTS FOLLOWING
socket head capscrews should be tightened to the THE TORQUING SEQUENCE
specified torque value at the time the clearing SHOWN.
jacks are reinstalled on the adjustment ring.
CLEARING JACK TORQUE
REQUIREMENTS

13-22 C-1534
CLEARING JACK INSTALLATION, IF ALL THE CLEARING JACKS HAVE BEEN
REMOVED FOR REBUILDING, ONLY EVERY
OTHER JACK SHOULD BE TIGHTENED TO THE
FULL TORQUE VALUE AT THIS TIME. THE
MOUNTING BOLTS ON THE REMAINING
5-1/2 FT. AND 7 FT. CRUSHERS JACKS SHOULD BE LEFT LOOSE ENOUGH TO
To install the clearing jacks on the crusher adjustment ALLOW SOME MOVEMENT TO ALIGN THE
ring proceed as follows: HOSE ASSEMBLIES. IF ONLY ONE CLEARING
JACK WAS REMOVED FOR INSPECTION, THE
16 Wipe off the outside diameter of the jack MOUNTING BOLTS SHOULD NOT BE
cylinders and thoroughly clean the bores in the TIGHTENED UNTIL AFTER THE HOSES ARE
adjustment ring. Coat the adjustment ring bores INSTALLED.
with Never-Seez lubricating compound to aid
assem-

C-1535 13-21
 clearing jack, thus preventing the adjustment ring from
INSPECTION AND MAINTENANCE PERIODS

11 Torque the cylinder cap socket head capscrews to a returning to the main frame seat, proceed as follows:
torque value of 6 Ft-Lbs on those clearing jacks at
which the mounting bolts have been tightened. H. Release the jack pressure by placing the control
valve handle in the PRESSURE OFF position.
12 Carefully clean the threads of the straight male Disconnect the power unit as instructed under
fitting and remove the waste material that had DISCONNECTING THE POWER UNIT.
been inserted as a plug. Install the clean hoses Locate the clearing jack cylinder(s) with the
between the jack assemblies. Position the loose jammed rod. Normally, the adjustment ring
jack assemblies so that the straight male fitting section where the jammed cylinder(s) is mounted
extending out from the cylinder cap will align will remain in a partially raised position after all
with the hose fittings. Securely tighten the hose pressure has been relieved from the system.
fittings.
I. In order to insure that all hydraulic pressure is
13 Tighten the clearing j ack mounting bolts and the relieved from the jammed clearing jack cylin-
cylinder cap socket head capscrews at those der(s), carefully “crack” open the pipe plug 1 to
clearing jacks which were not tightened in Steps 3 1-1/2 turns.
and 4. Follow the tightening procedure given in
Steps 3 and 4.
J. Lower all of the spring clusters as instructed in
14 Recheck the hose connections to be certain they are Section 3, MAIN FRAME, ADJUSTMENT
tightened securely. RING AND SPRING RING ASSEMBLIES.

15 Apply a bead of silicone sealant around the entire

outside diameter of the cylinder where the K. Remove the clearing jack cylinder(s) as instructed
cylinder contacts the adjustment ring bore as under CLEARING JACK REMOVAL, 5-1/2 FT.
shown in the illustration CLEARING JACK AND 7 FT. CRUSHERS.
SEALING ARRANGEMENT.
IT IS RECOMMENDED THAT AT LEAST
16 Test the hydraulic circuit for leaks and bleed the FOUR MORE CLEARING JACK CYLINDERS
system as instructed under PREPARATIONS BE REMOVED FOR INSPECTION, TWO ON
BEFORE STARTING. EACH SIDE OF THE JAMMED
CYLINDER(S).
17 Install the hose guards and tighten the hose guard
capscrews.
CLEARING L. Reassemble the spring clusters as instructed in
Section 3, MAIN FRAME, ADJUSTMENT
RING AND SPRING RING ASSEMBLIES.

M. Recondition the removed clearing jack cylinders)

as instructed under CLEARING JACK
REBUILDING, 5-1/2 FT. AND 7 FT.
CRUSHERS.

Reinstall the clearing jack cylinder(s) onto the

adjustment ring as instructed under CLEARING
JACK INSTALLATION, 5-1/2 FT. AND 7 FT.
CRUSHERS.

ARRANGEMENT

JAMMED CLEARING JACK

REMOVAL, 5-1/2 FT. AND 7 FT.
CRUSHERS
If a cylinder rod becomes jammed in the cylinder of a

13-22 C-1536