Weir Minerals Latin America

Vulco Per S.A.

Installation, Operation and Maintenance Manual

JAW CRUSHER
MODEL CT3042
SAN RAFAEL PROJECT

MINSUR S.A.
PO: 4600017596
OF: 103774
Av. Separadora Industrial 2201
Ate Lima, Per
T: +51 (1) 6187575
E: [email protected]
UNIDAD SAN RAFAEL
W: www.weirminerals.com

Rev.0

Aprobado A
Aprobado con Comentarios AWC

Revisado por:

Luis Prez Abad

Revisado y Comentado - RWC

Rechazado - RS

Fecha:

23-feb-2016

Operation & Maintenance Manual

To the Owner & Operator

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

DANGER
Federal, state and local safety regulations aim to protect both people and property from
accident, injury and harmful exposure. When complied with, such regulations are often
effective. Hazards to personnel and property are further reduced when this equipment is
used in accordance with all operation and maintenance instructions. Generally:
(1) Read and heed all danger, warning, caution, and notice decals. Know what guards and protective
devices are included and see that each is installed and in operational condition. Additional guards and
protective devices may be required and must be installed by the user (owner) before operating.
(2) Never attempt to maintain, lubricate or adjust this equipment while it is running. Lock out and tag
out all energy sources before doing maintenance, cleaning, adjusting or repairing this equipment. Make it
impossible for anyone to start this machine while others are working on it or in it.
(3) Wear personal protective equipment such as hard hats, ear plugs, safety glasses and safety shoes
when operating this equipment. Do not wear loose clothing or long hair.
(4) Think safety and act safely. Stay alert at all times. Eliminate or neutralize potential hazards as soon
as you spot them. Never allow anyone to engage in horseplay when near this equipment.

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

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

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

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

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

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

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Warranty Terms & Conditions

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

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Table of Contents

Copyright 2014 Trio Engineered Products, Inc. All rights reserved. . . . Cover Back Page
To the Owner & Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a
Warranty Terms & Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . c

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

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

Section 3 - General Information

Jaw Crusher Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 1
Serial Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 1
Flywheel Rotation Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 1
Jaw Crusher Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 2
Jaw Crusher Capacities Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 3
Jaw Crusher Gradation Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 4
Jaw Crusher Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 5
Jaw Crusher Weight & Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 5

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Table of Contents

Section 4 - Set-Up & Installation

Crusher Receiving and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 1
Level the Crusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 1
Lifting the Crusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 1
Positioning the Crusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 2
Crusher Auxiliary Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 2
Hydraulic Line Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 2

Section 5 - Inspection, Lubrication & Maintenance Checks

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 1
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 1
Inspection Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 1
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 2
General Lubrication Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 2
Lubricant Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 2
Lubrication Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 3
Bearing Daily Lubrication Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 4
Jaw Crusher Seal Lubrication Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 5
Jaw Crusher Bearing Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 6
Jaw Crusher Seal Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 6
Changing Grease in Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 7
Maintenance Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 9
Exterior Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 9
Interior Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 9
Jaw Crusher Daily Inspection Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 11
Pre-Start-up Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 11
Start-up Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 12
Jaw Crusher Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 13

Section 6 - Start-Up & Operation

Start-Up & Operation Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 1
Crusher Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 2
Oversize Feed Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 2
Unblocking Jammed Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 2

Section 7 - Adjustments & Wear Parts Replacement

Adjustments & Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 1
Jaw Crusher Crushing Chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 1
Closed Side Setting (CSS) Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 1
Shim-Type CSS Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 2
Shim-Type CSS Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 2

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Hydraulic Wedge-Type CSS Adjustment (Manual Hyd. Pump) . . . . . . . . . . . . . . . . . . . . . .7 - 3

Hydraulic Wedge-Type CSS Adjustment (Manual Hyd. Pump) Procedure . . . . . . . . . . . . .7 - 3
Power Hydraulic Pump Unit for CSS Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 4
Power Hydraulic Pump Unit With Electrical Control Box . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 5
Power Hydraulic Pump Unit Hydraulic Schematic Type 1 Connections . . . . . . . . . . . . . . . .7 - 6
Power Hydraulic Pump Unit Hydraulic Schematic Type 2 Connections . . . . . . . . . . . . . . . .7 - 8
Hyd. Wedge-Type CSS Adjustment (Power Hyd. Pump Type 1 Connections) . . . . . . . . . .7 - 10
Hyd. Wedge-Type CSS Adjustment (Power Hyd. Pump Type 1 Connections) Procedure . .7 - 11
Hyd. Wedge-Type CSS Adjustment (Power Hyd. Pump Type 2 Connections) . . . . . . . . . .7 - 12
Hyd. Wedge-Type CSS Adjustment (Power Hyd. Pump Type 2 Connections) Procedure . .7 - 13
Direct Hydraulic Toggle Plate-Type CSS Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 14
Direct Hydraulic Toggle Plate-Type CSS Adjustment Procedure . . . . . . . . . . . . . . . . . . . . .7 - 14
Standard Toggle Seat Tension Rod Spring Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 17
Fully Hydraulic Toggle Plate-Type CSS Adjustment System . . . . . . . . . . . . . . . . . . . . . . .7 - 19
Hydraulic Pump Control Unit Hose Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 20
Hydraulic Control Unit Standby Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 21
CSS Decrease Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 21
CSS Increase Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 21
Tension Rod Spring Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 22
Toggle Cylinders Oil Supplement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 22
Tension Cylinders Oil Supplement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 22
Tramp Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 22
Toggle and Tension Cylinder Fast Reset After Tramp Release . . . . . . . . . . . . . . . . . . . . . . .7 - 23
Hydraulic Unit Valve Pressure Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 23
Toggle Cylinder Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 24
Fully Hydraulic Toggle Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 24
Fully Hydraulic Toggle Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 25
Jaw Die Lifting Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 26
Cheek Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 28
Upper Cheek Plate Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 28
Lower Cheek Plate Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 29
Installation of Lower Cheek Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 29
Installation of Upper Cheek Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 30
Tightening Cheek Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 31
Stationary Jaw Die . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 31
Stationary Jaw Die Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 32
Stationary Jaw Die Rotation or Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 33
Stationary Jaw Die Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 33
Swing Jaw Die . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 34
Swing Jaw Die Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 34
Swing Jaw Die Rotation or Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 36
Swing Jaw Die Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 36
Check & Tighten Jaw Dies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 36
Re-adjust Crusher Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 36

CRSH-OM-0003ENG(OCT-2014)

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Table of Contents

Toggle Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 37
Toggle Plate Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 37
Toggle Plate Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 39
Jaw Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 40
Frame Bearing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 40
Frame Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 42
Pitman Bearing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 44
Pitman Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 46

Appendix A - Torque Specs

Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standard Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Metric Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standard Bolt Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Metric Bolt Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A-1
A-1
A-1
A-2
A-3

Appendix B - V-Belt Drive Information

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

CRSH-OM-0003ENG(OCT-2014)

iv

B-1
B-1
B-2
B-4
B-4
B-6
B-6
B-6
B-6
B-6

Model CT-Series Jaw Crushers

Operation & Maintenance Manual

About This Manual

Section 1 - Introduction

DANGER

About This Manual

This book is an operation and maintenance manual
for the owner or operator of the equipment
described within.

Figure 1 - 2 Safety Alert Hazard Level Symbol

This manual contains information

necessary for proper and safe
operation. Carefully read this
manual before attempting to
operate. Failure to read and heed
instructions preceded by a safetyalert symbol (Figure 1 - 2) can
cause death or severe personal
injury as well as equipment and
environmental damage.

We strongly recommend that anyone working with

this equipment become familiar with the manual,
whether or not you have experience with similar
equipment.
This manual will help you understand how to
install your equipment, prepare it for operation,
and perform normal operation and maintenance
tasks.
Intended Use

Experience has shown it is to your advantage to

keep a copy of this manual where operators can
consult it as needed and to have a copy on file in
your office, so that shift leaders or supervisors can
conveniently refer to it. Additional copies can be
ordered through your distributor.

The Jaw Crusher described within is designed to

crush rock, recycle concrete, and also a wide range
of other products and materials. Use of this
machinery in any other way is prohibited and
contrary to its intended use.

This equipment is precisely engineered, highly

functional, and heavy-duty designed to provide
years of excellent service performing to customer
specifications. We are proud to manufacture this
equipment for your use and profit. We also take
pride in the quality of our service and replacement
parts.

Safety Alert Symbol

The safety alert symbol (Figure 1 - 1) is used to
alert you to potential personal injury hazards.
Obey all safety messages that follow this symbol
to avoid possible injury or death.

Only your Parts Catalog, identified with your

machines serial number, is an authoritative source
of part numbers and part descriptions for your
equipment.
Figure 1 - 1 Safety Alert Symbol

CRSH-OM-0003ENG(OCT-2014)

Ongoing improvement of product design may in

the future result in changes to some parts. Use part
numbers, model numbers and serial numbers from
your Parts Catalog to communicate with your
distributor.

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About This Manual

This Page Intentionally Left Blank

CRSH-OM-0003ENG(OCT-2014)

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Operation & Maintenance Manual

Introduction

Section 2 - Safety

Hazard Classification
A multi-tier hazard classification system is used to
communicate potential personal injury hazards.
The following signal words used with the safety
alert symbol indicate a specific level of severity of
the potential hazard (Figure 2 - 1). Signal words
used without the safety alert symbol relate to
property damage and protection only. All are used
as attention-getting devices throughout this
manual as well as on decals and labels fixed to the
machinery to assist in potential hazard recognition
and prevention.

Introduction
The Jaw Crusher is designed to crush rock, recycle
concrete, and also a wide range of other products
and materials. Use of this machinery in any other
way is prohibited and contrary to its intended use.
When our equipment is used for purposes other
than those for which it was designed, user assumes
sole responsibility for any injuries or damage that
may result from said misuse. We emphatically
recommend that this equipment be operated only
by personnel who are trained in its use.
We make no guarantee, either expressly or by
implication, that this equipment meets all local or
federal safety regulations. It is the responsibility of
those individuals who own and/or operate this
equipment to verify that all safety regulations are
complied with before starting either this unit or
any associated equipment.

DANGER

DANGER indicates an imminently

hazardous situation which, if not
avoided, will result in death or
serious injury.

WARNING

WARNING indicates a potentially

hazardous situation which, if not
avoided, could result in death or
serious injury.

CAUTION

CAUTION indicates a potentially

hazardous situation which, if not
avoided, may result in minor or
moderate injury.

Symbols and Standards

Important symbols and hazard classification
standards relating to safe equipment operation are
used throughout this manual. Make sure you read,
understand and follow all DANGER, WARNING
and CAUTION decals on equipment.

CAUTION

CAUTION used without the safety

alert
symbol
indicates
a
potentially hazardous situation
which, if not avoided, may result
in property damage.

NOTICE

NOTICE indicates information or

a company policy that relates
directly or indirectly to the safety
or protection of property.

Figure 2 - 1 Hazard Classification

CRSH-OM-0003ENG(OCT-2014)

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Operation & Maintenance Manual

Symbols and Standards

Safety Signs and Icons

Beneath all safety regulations lies a set of
common-sense rules. Everyone who works with or
near heavy equipment must be aware of those
rules. To foster and maintain such an awareness in
our customers, safety signs are fixed on our
equipment.

Read manual.

Safety alert symbol.

Icons on our safety signs remind both workers and

supervisors of common hazards and procedures
that, in the course of a busy day, they might
otherwise forget. The language of the icons is
simple and direct (Figure 2 - 2).

Lock out power before servicing

machine.

Wear hearing protection when youre

near this equipment.

Safety Sign Maintenance

Replace any missing or damaged safety signs.
Keep operator safety in mind at all times. Use mild
soap and water to clean safety signs. Do not use
solvent-based cleaners because they may damage
the safety sign material.

Wear eye protection when youre

near this equipment.

Wear respiratory protection when

youre near this equipment.

Wear head protection when youre

near this equipment.

Entanglement hazard. Death or

serious injury can result by getting
caught in belting.

Ensure all guards are in place.

Figure 2 - 2 Safety Pictograms Explained

CRSH-OM-0003ENG(OCT-2014)

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Operation & Maintenance Manual

Personal Safety

Personal Safety
This equipment is designed with the safety of all
personnel in mind. Never attempt to change,
modify, eliminate or bypass any of the safety
devices installed at the factory. Guards, covers and
shields installed around moving parts at the factory
are meant to prevent accidental injury to operators
and other personnel. Do not remove them.

Replace guards, covers and shields when the

task for which you removed them is finished.

Block parts as necessary to prevent their

sudden movement while people are working
on the machine.

Never attempt to clear away jammed feed

material, discharge material or other stoppage
while the machine is running. Stop the
equipment, lock out and tag out before
touching this machine with your tools or your
hands.

Wear proper personal protective equipment,

including eye protection, hard hat and safety
shoes, whenever youre near this machine
while it is running.

Dress appropriately in every way. Never wear

loose clothes, long hair, coat tails, jewelry,
pockets full of tools or any other item that
could get caught in moving parts.

Know where your fellow workers are. Always

look around and inside this machine before
starting it. Make sure nobody is in the way of
moving parts or working on the machine.

Lift with your legs, not with your back. Keep

the weight close to your body. If the load is
more than 40 lbs., get someone to help you.

Never engage in horseplay when near this

machine, or any other.

Report any defective machinery or equipment

and unsafe conditions or activity to your boss
immediately.

Dont limit safety practices to the few rules

listed here. Think safety and act safely at all
times.

Most of all, know your equipment. Understand

the machinery, the conditions under which it
operates and what it is capable of doing.

DANGER
Sometimes, at a customers
request, equipment is shipped
without certain features such as a
drive sheave. In such cases it is the
customers responsibility to guard
the machine properly.
We recommend the following basic safety
practices:
Management Responsibilities

Make sure that everyone working on or near

this equipment is familiar with safety
precautions. Have a supervisor at the job site
responsible for job safety.
Give crew members specific safety
responsibilities and instruct them to report any
unsafe conditions to their supervisor

Operator Responsibilities

Read all danger, warning, caution and notice

signs.

Always lock out and tag out involved energy

sources before performing maintenance or
adjustments on this equipment. Make it
impossible for anyone to start this machine
while others work on it or in it.

Never remove any guard, cover or shield when

this equipment is in motion.

CRSH-OM-0003ENG(OCT-2014)

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Personal Safety

Work Area Safety

Equipment & Tools

Keep the work area as neat and clean as

practical.

Clean tools that are properly labeled and stored

are safer tools. Keep your tools in good order.

Keep all product safety signs clean, clear and

current.

Make sure all electrical equipment is properly

grounded. Wet spots near electrical current are
especially dangerous.

Keep drive belts and sheaves in good

condition. Frayed belts or cracked sheaves are
not only dangerous, they cost you downtime.

Always use mechanical assistance to lift heavy

loads. Never overload a hoist, crane, jack or
other lifting device. Check lifting tackle
regularly; replace it at the first sign of stretch,
fraying or other wear.

Keep your equipment clean, free of dirt and

grease, so that loose, cracked or broken parts
are more easily spotted. Replace defective
parts as soon as they are discovered.

Store hazardous materials in restricted access

areas and mark them clearly. Federal
regulations require special labeling of certain
materials.

Never start an engine in an enclosed space

without properly venting the exhaust.

Do not smoke or allow smoking near fuels and

solvents. Never strike a spark or use an open
flame near fuels and solvents.

Store flammable fuels, solvents and gases in

secure, well ventilated areas. Never allow
fumes to accumulate in the storage area. Use
nonflammable solvents for cleaning parts and
equipment whenever possible.

Know where fire extinguishers and other firesuppression equipment are located. Learn how
to use them effectively.

Training and Knowledge

Proper training and equipment knowledge is
essential to the safe operation of this machine.
Carefully read the entire manual before attempting
to operate. Keep this manual for future reference.

WARNING
Do not operate this equipment until
you have been trained in its
operation or maintenance. This
equipment may only be operated or
maintained by trained personnel,
who have demonstrated their
ability to do so safely.

Be alert and wary around any pressurized

system, hydraulic or pneumatic. High-pressure
oils and gases are very dangerous.

CRSH-OM-0003ENG(OCT-2014)

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Operation & Maintenance Manual

What is Lockout & Tagout?

What is Lockout & Tagout?

When can a lock and tag be removed?

Lockout & Tagout is a procedure thats designed

to prevent the unexpected or accidental startup of
equipment and to alert all workers whenever it is
unsafe to operate any piece of equipment. When
used as intended, Lockout & Tagout also protects
personnel from energy stored in devices such as
springs, accumulators, batteries, hydraulic
systems, etc.

After performing these six steps:

1) All safety guards are back in place.
2) All work is complete and tools are put away.
3) All workers are notified that a lock is being
removed.
4) All workers are positioned safely for startup.
5) Controls are positioned for safe startup.

When is Lockout & Tagout required?

6) The machine is ready for safe operation.

Any time anyone is maintaining, repairing,

lubricating, or, for whatever reason, working
on the equipment.

When the equipment is broken or, for whatever

reason, unfit or unsafe to operate.

While clearing
mechanisms.

Whenever the equipment is left unattended.

blocked

or

Who can remove a lock and tag?

Only the person who applied a lock and tag is

permitted to remove them.

Lockout & Tagout rules laid out here are generic.

To get instructions for your particular workplace,
consult your employers lockout/tagout procedure.

jammed

Who must apply a lock & tag?

Any person working on the equipment.

Foreman or other person responsible for the

work being done.

If several people are working on a machine at

the same time, each person must apply his or
her own lock and tag.

CRSH-OM-0003ENG(OCT-2014)

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What is Lockout & Tagout?

This Page Intentionally Left Blank

CRSH-OM-0003ENG(OCT-2014)

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Jaw Crusher Description

Section 3 - General Information

Serial Numbers

Jaw Crusher Description

Crushers are assigned a serial number which is

stamped on a plate on the machine.

The Jaw Crusher is a high-capacity compressiontype crusher that fractures material along its
natural fault lines.

Other components on the crusher may have

separate serial numbers or identifying numbers.
Always give the model and serial number or
identifying number of your crusher when ordering
parts or requesting information. If parts are
required for the other certain components, you
should supply that serial number or identifying
number as well as the crusher numbers.

Product size is controlled by adjusting the distance

between the fixed jaw die and the moveable
(swing) jaw die fastened to the pitman assembly.
These jaw dies are replaceable and come in several
different profiles depending upon the type of
material to be crushed and customer preference.

Flywheel Rotation Direction

The pitman is protected from damage by the toggle

plate. The toggle plate is intended to bend or
fracture if an uncrushable object enters the
crushing chamber, and thus opens the chamber
allowing the object to pass through.

Crushers are fitted with two flywheels, one of

which acts as the driven sheave. The direction of
rotation and orientation to the crusher is shown in
(Figure 3 - 2).

The Jaw Crusher may be mounted or installed in

static stationary, modular skid, as well as portable
wheel or mobile track plant applications. No
matter which type application the Jaw Crusher is
used in, it must be level to operate properly.

Figure 3 - 2 Flywheel Rotation Direction

Figure 3 - 1 Typical Jaw Crusher

CRSH-OM-0003ENG(OCT-2014)

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Operation & Maintenance Manual

Jaw Crusher Components

Jaw Crusher Components

Each model/size jaw crusher consists of similar

components, however certain models/sizes may
not have all the same components as other models/
sizes.

Be familiar with the crushers components. See

(Figure 3 - 3)

To be certain your machine has the proper

components, check to ensure it was equipped as
ordered.
8

4
3

21

7
9

10
11

20

12

19

13

18

17

16

15

1 2 3 4 5 6 7 8 9 101112131415161718192021-

Crusher Frame
Stationary Jaw Die
Cheek Plate (Key Plate)
Flywheel
Swing Jaw Die
Pitman Liner
Frame Bearing
Pitman
Pitman Bearing
Eccentric Shaft
Spring Guards
Adjustment Hydraulic Ram
Tension Rod Spring
Tension Rod
Shims
Upper Buffer
Toggle Plate
Lower Buffer
Rubber Dust Apron
Wedges for Stationary Jaw
Wedges for Swing Jaw

14

Figure 3 - 3 Typical Jaw Crusher Components

CRSH-OM-0003ENG(OCT-2014)

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Operation & Maintenance Manual

Jaw Crusher Capacities Chart

Jaw Crusher Capacities Chart

.
CT SERIES JAW CRUSHERS OPEN CIRCUIT MAXIMUM CAPABILITIES (STPH)
Jaw
Model
C.S.S. Size
Opening
1"
25 mm
1-1/2"
38mm
2"
50mm
2-1/2"
64mm
3"
76mm
3-1/2"
90mm
4"
100mm
5"
127mm
6"
150mm
7"
175mm
8"
200mm
9"
225mm
10"
250mm
11"
280mm
12"
305mm

CT1030

CT1040

CT1048

CT1252

CT2036

23

30

35

50

28

37

44

63

34

45

55

77

90

42

56

68

90

110

50

66

80

105

60

79

95

130

CT2436

CT2645

CT3042

NCT3042

CT3254

CT3648

CT4254

CT4763

CT6080

96

250

150

126

300

140

170

155

200

220

340

170

190

189

230

240

370

190

210

218

260

280

400

330

230

250

300

300

320

440

310-400

380-500

250-300

391

300-400

320-420

400-500

370-470

450-580

500-650

320-400

522

350-460

380-500

470-570

430-540

520-650

590-750

490-610

575-730

650-840 780-1100

550-700

630-810

740-930 860-1215

675-980

700-900 800-1010 950-1340

880-1100 1030-1455
950-1180 1120-1575

1.

The above information is bas ed on average feed material that weighs approximately 100 lbs/ft crushed of a size which is
readily fed into the crushing chamber without clogging.

2.

Capacities shown may vary depending on the type, size, moisture content, and clay content of material, the bulk density,
method of material feeding. Undersize material should be removed from the crusher feed to eliminate packing and excess
wear.

SETTINGS G REATER THAN INDICATED MAY BE WITHIN DESIGN CAPABILITIES OF THE MACHINES BUT ARE NOT
SHOWN DUE TO ANTICIPATED HIG HER OPERATING CO STS.
The above tables are based on results obtained during actual operation and could vary depending on the type of material, gradation
of feed, method of feeding, moisture and clay content, and other material characteristics. The indicated top size, also influenced by
the above c onditions, is provided to assist in the selection of the c rushing equipment to follow. Contact your dealer for more details.

CRSH-OM-0003ENG(OCT-2014)

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Jaw Crusher Gradation Chart

Jaw Crusher Gradation Chart

.
CT SERIES JAW CRUSHERS PRODUCT GRADATIONS (PERCENT PASSING)
C.S.S. Size Opening
Product
Size
15"
380mm
14"
356mm
13"
330mm
12"
305mm
11"
280mm
10"
250mm
9"
225mm
8"
200mm
7"
175mm
6"
150mm
5"
127mm
4"
100mm
3-1/2"
90mm
3"
76mm
2-1/2"
64mm
2"
50mm
1-3/4"
45mm
1-1/2"
38mm
1-1/4"
32mm
1"
25mm
3/4"
19mm
5/8"
13mm
3/8"
10mm
1/4"
6mm

1"
25 mm

1-1/2"
38mm

2"
50mm

2-1/2"
64mm

3"
76mm

3-1/2"
90mm

4"
100mm

5"
127mm

6"
150mm

7"
175mm

8"
200mm

9"
225mm

10"
250mm

11"
280mm

12"
305mm
100

100

90

100

90

85

100

90

85

75

100

90

85

75

70

100

90

83

75

70

65

100

90

83

75

70

65

60

100

90

83

75

70

65

60

55

100

90

83

75

70

63

60

55

45

100

95

83

75

68

63

58

55

45

40

100

90

85

75

68

60

58

48

45

40

35

100

90

83

75

65

60

55

48

45

40

35

25

95

83

75

70

60

55

50

45

40

35

25

22

100

83

75

70

65

55

50

45

35

30

25

22

20

100

90

75

68

60

55

50

42

35

30

25

22

20

17

90

75

65

58

55

50

40

35

30

25

22

20

17

12

85

70

60

55

50

45

35

30

25

22

20

17

12

10

100

75

65

55

50

45

40

30

25

22

20

17

12

10

95

70

55

50

40

35

30

25

22

20

17

15

10

75

65

45

43

35

30

25

20

17

15

12

10

70

55

40

30

25

22

20

17

15

12

10

60

45

35

25

20

17

15

13

10

45

30

25

20

15

13

10

30

20

15

10

TH E ABOV E TABL ES

AR E BAS ED ON R ES UL TS OBTA INE D D U RIN G AC TUA L OP ER ATION AN D CO UL D V AR Y D EPE ND IN G ON TH E TYPE

OF MA TER IA L, GR AD ATION OF FEED , M ETH OD OF FEE DIN G , MOISTU R E AN D CL AY C ON TEN T , AN D OTH ER MA TER IAL
C HA RA CTE RISTIC S. TH E IN DIC ATED TOP S IZE , AL SO INFL U EN CE D B Y THE ABOV E CO ND ITIO NS , IS PR OVID ED TO A SSIST IN TH E
SE LE CTION OF TH E C R US HIN G EQU IPME NT TO FOL LOW . C ONTA CT YOU R DE AL ER FOR MOR E D ETA IL S.

Jaw crushers reduce large rock to smaller stone using exceptional force. The foundation
therefore must be substantial enough to support the crusher without distortion.

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Jaw Crusher Specifications

Jaw Crusher Specifications

Jaw Crusher Weight & Dimensions

Specifications for the jaw crusher are found in the

serial specific parts manual.

Weights and dimensions for the jaw crusher are

found in the serial specific parts manual.

CRSH-OM-0003ENG(OCT-2014)

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Jaw Crusher Weight & Dimensions

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Crusher Receiving and Inspection

Section 4 - Set-Up & Installation

Level the Crusher

Wherever the crusher is installed, it must be

mounted level. For stationary units, the supporting
structure must be level when completed. For skidmounted, mobile, or portable plant units, the frame
must be leveled. Use leveling jacks or suitable
blocking as needed to bring the unit to a level
position.

Crusher Receiving and Inspection

When the crusher is delivered, thoroughly check
for damage that might have occurred during
transport. Do not set up the unit until the
inspection is complete.
Note any damage on the shippers bill of lading
and have the deliverer sign your description of any
problem(s). Keep a copy of the marked-up bill of
lading for your files. Take photos if possible. File
a claim with the carrier within 30 days of receipt of
the equipment.

Lifting the Crusher

To lift the crusher, use machinery, lifting slings,

and equipment of sufficient size to safely handle
the load. When hooking lifting slings to the
crusher, always attach to the crusher frame. Never
lift complete crusher by attaching to flywheels or
pitman. If only pitman, shaft, and bearing
assembly is to be removed from crusher frame,
fasten lifting slings and equipment to lifting lugs
provided on top of pitman housing.
See (Figure 4 - 1)

Check loose parts, small parts boxes, and tools

against the packing list to ensure all items shipped
are present.

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

Lifting Lugs

Lifting Lugs

Figure 4 - 1 Typical Jaw Crusher Lifting Lugs

CRSH-OM-0003ENG(OCT-2014)

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Operation & Maintenance Manual

Installation

Hydraulic Line Connections

Positioning the Crusher

Allow enough room around the crusher for

conveyors, loaders, and maintenance equipment
and personnel. Allow enough clearance below
crusher for discharge material conveyor and also
clearance above and behind the unit for access.

NOTICE
While making line connections
between the hydraulic power unit
and the crusher, air may become
trapped in the lines. It is necessary
to purge the trapped air. This can
usually be accomplished by
opening and closing the jaw several
times before initial operation.

Crusher Auxiliary Equipment

The crusher utilizes a system to provide hydraulic

power to adjust the jaw die opening. Make sure
this systems hydraulic lines are properly
connected and tightened as well as the electrical
drive motor (if used) is properly connected and
runs in the correct direction.

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General

Section 5 - Inspection, Lubrication &

Maintenance Checks

Inspection Procedures

The following are major steps in a daily inspection

of your crusher:

General
1) Lockout & Tagout all power to crusher before
any lubrication or maintenance is performed.

To insure efficient operation, the crusher should be

inspected, lubricated, and have necessary
maintenance adjustments and repairs made at
regular intervals.

2) Look the complete crusher over carefully.

When sure that everything is in good order
and safe, the crusher should be ready to
operate.

Inspection
Performing a daily inspection is a good way to
keep your crusher performing safely and
efficiently. Utilizing the Daily Inspection Form at
the end of this section as a guide will help you
establish a maintenance routine, provide a
maintenance record, and help monitor the
condition of the equipment.

CRSH-OM-0003ENG(OCT-2014)

3) Remove the lock and tag.

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

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Operation & Maintenance Manual

Lubrication

Lubrication

fittings and openings are cleaned thoroughly

before starting to inject lubricant. In using a grease
gun make sure the nozzle makes proper contact
with the cleaned fittings or openings and that the
nozzle has not been allowed to touch uncleaned
surfaces.

General Lubrication Information

The greatest single factor governing the life and

efficiency of any piece of machinery, where
friction is encountered, is proper lubrication.
While it is generally known that insufficient
lubrication will enable friction to reduce the
efficiency and service life of key parts, it is also
true that the presence of too large a quantity of
grease in a bearing housing usually results in high
operating temperatures and subsequent loss of
efficiency.

Never mix different brands or types of lubricant

within the crusher. Always drain and flush out old
lubricant before changing to a different brand as
chemical breakdown can occur in lubricant
mixtures.

Cleanliness in the handling of lubricants, fittings,

grease guns, and the openings and plugs of
housings is of vital importance.
Foreign
substances contaminate lubricant. Be sure all

Refer to (Table 5 - 1) as a guide for the proper

lubricants used on the crusher. If you do not have
access to the brands shown, see your lubricant
distributor for an equivalent.

Lubricant Specifications

Table 5 - 1 Jaw Crusher Lubricant Specifications

Lubricant Type

Ambient
Temperature
F (C)

Specification

Recommended
Standard Lubricant

Recommended
Synthetic Lubricant

Below 100
(Below 38)

NLGI 2, with EP
Additives

Mobil Delvac Xtreme

Mobilith SHC 220

Above 100
(Above 38)

NLGI 2, with EP
Additives

Mobilith SHC 460

Below 40
(Below 4)

ISO 32, HVI AW

Low Pour Point

Mobil DTE 13M

Mobil SHC 524

Above 40
(Above 4)

ISO 68,
Antiwear

Mobil DTE 26

Mobil SHC 526

Grease

Hydraulic Oil
(Used in Adjusting or
Controls Hydraulic
Systems)

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Lubrication

Lubrication Intervals

The bearings and seals should use the specified

lubricant shown in (Table 5 - 1). See (Table 5 - 2)
for recommended lube intervals.
Table 5 - 2 Jaw Crusher Lubrication Intervals
ITEM

DAILY or
Every 8
Hours

WEEKLY or
Every 40
Hours

MONTHLY
or Every 160
Hours

YEARLY or
Every 2000
Hours

Shaft Labyrinth
Seals

--

--

Add Grease
to Each Seal

Check

Pitman Bearings

Add Grease
to Each
Bearing

Add Grease
to Each
Bearing

--

Change
Grease

Frame Bearings

Add Grease
to Each
Bearing

Add Grease
to Each
Bearing

--

Change
Grease

Hydraulic Oil

Check

Check

--

Change as
Required

CRSH-OM-0003ENG(OCT-2014)

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Operation & Maintenance Manual

Lubrication

Bearing Daily Lubrication Quantity

NOTICE

The following table shows the approximate

amount of grease to be added daily to each bearing
for the particular model jaw crusher.

Note that it takes approximately 20

strokes from a manual type grease
gun to discharge 1 ounce of grease.

Table 5 - 3 Jaw Crusher Bearing Daily Lubrication Quantity

Pitman Bearing
MODEL

Volume

Frame Bearing
Weight

Volume

Weight

Quart

gram

Ounce

Quart

gram

Ounce

CT1030

0.014

0.015

12.5

0.44

0.014

0.015

12.5

0.44

CT1040

0.014

0.015

12.5

0.44

0.014

0.015

12.5

0.44

CT1048

0.017

0.018

14.2

0.50

0.017

0.018

14.2

0.50

CT1252

0.031

0.033

26.6

0.94

0.031

0.033

26.6

0.94

CT2036

0.024

0.025

19.8

0.70

0.020

0.021

17.3

0.61

CT2436

0.029

0.031

25.2

0.89

0.024

0.025

20.4

0.72

CT2645

0.036

0.038

31.7

1.12

0.029

0.031

25.6

0.88

CT3042

0.054

0.057

45.9

1.62

0.052

0.055

43.9

1.55

NCT3042

0.045

0.048

36.9

1.30

0.043

0.045

34.0

1.20

CT3254

0.052

0.055

43.9

1.55

0.044

0.047

38.0

1.34

CT3648

0.054

0.057

45.9

1.62

0.052

0.055

43.9

1.55

CT4254

0.063

0.067

53.9

1.90

0.057

0.060

47.6

1.68

CT4763

0.086

0.091

73.7

2.60

0.085

0.090

70.9

2.50

CT6080

0.158

0.167

139.2

4.88

0.141

0.149

123.7

4.4

CRSH-OM-0003ENG(OCT-2014)

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Lubrication

Jaw Crusher Seal Lubrication Quantity

NOTICE

The following table shows the approximate

amount of grease to be added to each seal for the
particular model jaw crusher.

Note that it takes approximately 20

strokes from a manual type grease
gun to discharge 1 ounce of grease.

Table 5 - 4 Jaw Crusher Seal Lubrication Quantity

Middle Labyrinth Seal
MODEL

Volume

Outer Labyrinth Seal

Weight

Volume

Weight

Quart

gram

Ounce

Quart

gram

Ounce

CT1030

0.016

0.017

14.2

0.5

0.016

0.017

14.2

0.5

CT1040

0.016

0.017

14.2

0.5

0.016

0.017

14.2

0.5

CT1048

0.018

0.019

17.0

0.6

0.018

0.019

17.0

0.6

CT1252

0.032

0.034

25.5

0.9

0.032

0.034

25.5

0.9

CT2036

0.035

0.037

28.3

1.0

0.035

0.037

28.3

1.0

CT2436

0.039

0.041

31.2

1.1

0.039

0.041

31.2

1.1

CT2645

0.039

0.041

31.2

1.1

0.039

0.041

31.2

1.1

CT3042

0.045

0.048

36.9

1.3

0.045

0.048

36.9

1.3

NCT3042

0.043

0.045

34.0

1.2

0.043

0.045

34.0

1.2

CT3254

0.052

0.055

42.5

1.5

0.052

0.055

42.5

1.5

CT3648

0.056

0.059

45.4

1.6

0.056

0.059

45.4

1.6

CT4254

0.060

0.063

51.0

1.8

0.060

0.063

51.0

1.8

CT4763

0.067

0.071

56.7

2.0

0.067

0.071

56.7

2.0

CT6080

0.074

0.078

62.4

2.2

0.074

0.078

62.4

2.2

CRSH-OM-0003ENG(OCT-2014)

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Operation & Maintenance Manual

Lubrication

Jaw Crusher Bearing Lubrication Points

Jaw Crusher Seal Lubrication Points

Do not over-grease bearings. Too much grease in

bearings will cause overheating and premature
bearing failure.

Grease should be added to seals until a fresh bead

of grease appears around the seals to provide a
moisture and dust barrier.

See (Figure 5 - 1) illustration showing the bearing

lubrication points on a jaw crusher.

See (Figure 5 - 2) illustration showing the seal

lubrication points on a jaw crusher.

Hoses to Grease
the Bearings

Grease Fittings

Figure 5 - 1 Typical Jaw Crusher Bearing Lubrication

Points

Grease Fittings
Figure 5 - 2 Typical Jaw Crusher Seal Lubrication
Points

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Changing Grease in Bearings

Changing Grease in Bearings

4) Replace the grease fittings.

Under normal conditions, it is recommended that

grease be changed at least once each year or every
2000 hours of operation, which ever comes first.
See (Figure 5 - 3)

5) Run the crusher empty for at least 10 minutes.

6) Stop unit and remove drain plugs to drain
flushing oil.
7) Replace drain plugs when bearings have been
sufficiently flushed.
8) Install the recommended amount of grease
into each bearing. See (Table 5 - 5)

NOTICE
Frame bearings do not have drains
on the bearing housings. Purging
may require care to avoid a mess.

Drain Plugs
Figure 5 - 3 Typical Jaw Crusher Pitman Bearing
Grease Drain Points

1) Before changing lubricant, run crusher long

enough to heat the existing lubricant to a
consistency that allows it to flow freely.
2) Clean area around drain plugs and grease
fittings then remove plugs and fittings to drain
free flowing lubricant.
3) Replace drain plugs and inject flushing oil in
each bearing to fill pitman barrel and frame
bearing housing to top of fitting holes. An
extreme pressure 150 viscosity, Grade 46
flushing oil can be used.

CRSH-OM-0003ENG(OCT-2014)

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Changing Grease in Bearings

Table 5 - 5 Jaw Crusher Bearing Lubrication Replacement Quantity

Pitman Bearing
MODEL

Volume

Frame Bearing
Weight

Volume

Weight

Gal.

Kg

Lbs.

Gal.

Kg

Lbs.

CT1030

1.06

0.28

0.93

2.06

0.94

0.25

0.83

1.83

CT1040

1.06

0.28

0.93

2.06

0.94

0.25

0.83

1.83

CT1048

1.32

0.35

1.16

2.55

1.06

0.28

0.93

2.06

CT1252

3.19

0.84

2.81

6.18

3.19

0.84

2.81

6.18

CT2036

1.89

0.50

1.66

3.66

1.71

0.45

1.50

3.30

CT2436

2.64

0.70

2.32

5.11

1.89

0.50

1.66

3.66

CT2645

3.70

0.98

3.26

7.17

2.54

0.67

2.24

4.92

CT3042

6.01

1.59

5.29

11.63

4.99

1.32

4.39

9.65

NCT3042

3.44

0.91

3.02

6.65

2.82

0.74

2.48

5.46

CT3254

6.01

1.59

5.29

11.63

4.99

1.32

4.39

9.65

CT3648

7.24

1.91

6.37

14.01

7.06

1.87

6.21

13.67

CT4254

10.27

2.72

9.04

19.89

7.24

1.91

6.37

14.01

CT4763

16.60

4.39

14.61

32.14

14.47

3.83

12.73

28.01

CT6080

35.51

9.40

31.25

68.75

31.02

8.21

27.30

60.06

CRSH-OM-0003ENG(OCT-2014)

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Maintenance Checks

Maintenance Checks

Interior Inspection

The jaw crusher does not have an enclosed,

interior crushing chamber, but does have items
underneath or inside the frame which may require
close inspection. Care must be taken to do this.

Exterior Inspection

1) Lockout & Tagout power to crusher drive,

crusher hydraulic unit, and all other associated
equipment.

1) Verify Lockout & Tagout of crusher drive.

DANGER

DANGER

Failure to Lockout & Tagout all

energy sources will result in death
or severe personal injury. Make it
impossible to start this machine or
associated equipment while people
are working on or in it.

Failure to Lockout & Tagout will

result in death or severe personal
injury.
2) Inspect all crushing chamber components,
including stationary jaw die, swing jaw die,
cheek plates, pitman shaft housing liner to
make sure all are in good condition.

2) Check all exterior components, including

drives, belts, guards, covers and inspection
doors, bearings, seals, hardware and hydraulic
parts to make sure all are in good condition.

3) Repair or replace as necessary any parts that

are damaged, missing, excessively worn, or in
faulty condition. See Section 7 for wear items
adjustment and replacement information.

3) Repair or replace as necessary any parts that

are missing or in faulty condition.

Start-Up

4) Tighten any loose hardware or loose hydraulic

fittings. See Appendix A for hardware torque
specifications.

When all inspection and repairs or necessary

replacements are complete, perform the following
to prepare crusher for start-up.

5) See Appendix B for v-belt drive information.

1) Remove Lockout & Tagout from crusher
drive.
2) Make sure everyone is clear of crusher.
3) Crusher should now be ready for start-up.

CRSH-OM-0003ENG(OCT-2014)

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Maintenance Checks

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CRSH-OM-0003ENG(OCT-2014)

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Jaw Crusher Daily Inspection Form

Jaw Crusher Daily Inspection Form

Date __________
Signature _______________________________

7) Flywheel bolts - tight

OK Not OK See Notes
8) Flywheel counterweights - tight
OK Not OK See Notes

Pre-Start-up Checklist

1) Lockout & Tagout - crusher & assoc. equip.

OK Initials ______________________

9) Jaw dies and cheek plate bolts - tight &

jaw dies in good condition
OK Not OK See Notes

2) Under-crusher discharge area - clear of debris

OK Not OK See Notes

10) Pitman tension rod springs tensioned properly

OK Not OK See Notes

3) Belt guards - present, in good condition

OK Not OK See Notes

11) Crusher setting (C.S.S.) checked & adjusted

properly _________Inches _________mm
OK Not OK See Notes

4) Belts - tensioned, clean, in good condition

OK Not OK See Notes
5) Sheaves - aligned, clean, in good condition
OK Not OK See Notes
6) Pitman Shaft:
a. Seals - good condition
OK Not OK See Notes
b. Seals - greased properly
OK Not OK See Notes
c. Bearings - housing bolts tight
OK Not OK See Notes
d. Bearings - greased properly
OK Not OK See Notes
Last Greased at _______________________
Initials ______________________________

Notes:
_____________________________________
_____________________________________
_____________________________________
_____________________________________
_____________________________________

CRSH-OM-0003ENG(OCT-2014)

12) Hydraulic System:

a. Breather cap, control levers & valves - in
place, secure & tight, no leaks, no damage
OK Not OK See Notes
b. Lines & hoses - in place, secure & tight, no
leaks, no damage
OK Not OK See Notes
c. Cylinder(s) - securely pinned, no leaks, no
damage
OK Not OK See Notes
d. Cylinder hydraulic pressure is adequate and
replenished.
OK Not OK See Notes
e. Reservoir - oil clean and at proper level
OK Not OK See Notes
Oil Added - Qts. ______________________
Initials ______________________________
f. Oil & Filter Changed - Qts._____________
Initials ______________________________
Notes:
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________

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Jaw Crusher Daily Inspection Form

Start-up Checklist

13) Remove Lockout & Tagout - crusher &

associated equipment
OK Initials ______________________
14) Jog crusher drive motor to verify pitman shaft
rotates in proper direction (See Diagram)
OK Not OK See Notes

20) Crusher run 50% load - 2 hours minimum

OK Not OK See Notes
21) 50% load bearing temperatures checked
(140-160F. / 60-70C.)
OK Not OK See Notes
22) 50% load power draw _____________Amps
OK Not OK See Notes
23) 50% load crusher balance is good
OK Not OK See Notes
24) Crusher run 75% load - 4 hours minimum
OK Not OK See Notes
25) 75% load bearing temperatures checked
(140-160F. / 60-70C.)
OK Not OK See Notes
26) 75% load power draw _____________Amps
OK Not OK See Notes

15) Crusher shaft runs at ______________RPM

OK Not OK See Notes
16) Crusher run no load - 2 hours minimum
OK Not OK See Notes
17) No load bearing temperatures checked
(140-160F. / 60-70C.)
OK Not OK See Notes
18) No load power draw _____________Amps
OK Not OK See Notes
19) No load crusher balance is good
OK Not OK See Notes
Notes:
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________

CRSH-OM-0003ENG(OCT-2014)

27) 75% load crusher balance is good

OK Not OK See Notes
28) 100% load power draw _____________Amps
OK Not OK See Notes
29) 100% load bearing temperatures checked
(140-160F. / 60-70C.)
OK Not OK See Notes
30) Crusher at work
Diesel Engine RPM ____________________
Electric Motor Amps ___________________
Total Crushing Hours Today _____________
Downtime Today ______________________
Notes:
________________________________________
________________________________________
________________________________________
________________________________________

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Jaw Crusher Troubleshooting Chart

Jaw Crusher Troubleshooting Chart

The following chart outlines some of the issues,
possible causes, and solutions to those issues you
may encounter with the jaw crusher.
Table 5 - 6 Jaw Crusher Troubleshooting
ISSUE

POSSIBLE CAUSE

SOLUTION

Crusher will not start

Incorrect wiring

Check wiring diagram

No power

Check power source

Defective motor

Check motor. Replace if defective.

Soft start issues

Ensure soft start is functioning properly

Crushing chamber full

Clear crushing chamber

Excessive amp draw

Possible voltage drop. Check power source.

Excessive fines in feed

Remove fines from feed.

Un-crushable object in
crushing chamber

Clear crushing chamber

Damaged or worn bearings

Replace bearings

Discharge opening set too

close

Adjust discharge opening to within specifications

Flywheel/Drive sheave turned

on shaft

Re-mount flywheel/drive sheave in proper position

Excessive fines build up in

flywheels

Clean dust or material build up from flywheels

Crusher running too fast

Ensure crusher is running at proper RPM

Crusher not secured to

mounting structure

Ensure crusher foot mounting bolts are secure to

structure

Loose toggle plate

Check tension springs. Adjust as required.

Gap between upper buffer

and upper buffer guide too
large

Add shims to close gap to between .5 ~ 1.0 mm

Loose die bolts

Tighten die bolts as required

Dirt/material buildup in toggle

plate seats

Remove dirt/material buildup

Loose bolts

Tighten all loose bolts as required

Crusher stops under

load

Crusher shakes/
vibrates

Excessive noise
(knocking,
squeaking,
rattling, etc.)

CRSH-OM-0003ENG(OCT-2014)

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Operation & Maintenance Manual

Jaw Crusher Troubleshooting Chart

Table 5 - 6 Jaw Crusher Troubleshooting

ISSUE

POSSIBLE CAUSE

SOLUTION

Crusher loses RPM

Excessive fines in crushing

chamber

Check material feed and remove fines

Low voltage

Check power source

Loose or worn drive belts

Adjust belt tension and replace belts as required

Worn drive sheave

Replace drive sheave as required

Improper jaw dies for

application

Check with TRIO for jaw die options

Electrical power issues

Check power source, wire size, drive motor

Drive belt issue

Check and adjust belt tension and replace belts as

required

Tension springs not equally

adjusted

Check tension springs. Adjust as required.

Worn buffer(s)

Inspect and replace buffer(s) as required

Worn toggle plate

Inspect both ends of toggle plate to check wear

Crusher not level

Check and make sure crusher is level

Material build up on top of

toggle entering lower buffer

Keep toggle plate area free of material build up and

debris

Tension springs not equally

adjusted

Check tension springs. Adjust as required.

Crushing on one side only

Ensure feed is centered and not segregated

Un-crushable object(s) went

through machine

Remove un-crushable object(s) from feed

Exceeding recommended
reduction ratio

Adjust feed size or adjust C.S.S.

Uneven jaw die wear

Improper feed to crusher

Ensure feed is centered and not segregated

Cracked jaw dies

Jaw dies excessively worn

Replace jaw dies at 80% wear

Crusher frame parent steel

worn

Remove dies, inspect and repair crusher frame as

required

Un-crushable object(s) went

through machine

Remove un-crushable object(s) from feed

Application issues

Evaluate crusher application

Poor crusher
performance

Toggle plate drift

Uneven toggle plate

wear

Cracked/broken
toggle plate

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Operation & Maintenance Manual

Jaw Crusher Troubleshooting Chart

Table 5 - 6 Jaw Crusher Troubleshooting

ISSUE

POSSIBLE CAUSE

SOLUTION

Bearings overheating

Incorrect grease

Use specified type grease

Over greasing or under

greasing

Use proper quantity of lubricating grease

Crusher is overloaded

Eliminate overload condition

Low oil level in system

Ensure oil reservoir is at proper level

Hydraulic pump not operating

Ensure hydraulic pump has power and is activated

Low hydraulic pressure

Ensure hydraulic system pressure is adequate

Hydraulic lines incorrectly

connected

Check and ensure lines are correctly connected

Air in hydraulic system

Bleed air by removing tension spring tension and

attempting to open and close C.S.S. two full cycles

Damaged wedge surface(s)

Ensure wedge surface(s) are smooth and clear of

debris. Replace as required.

Hydraulic leak

Check and repair leaks

Hydraulic lines incorrectly

connected

Check and ensure lines are correctly connected

Adjustment wedges
will not move

Adjustment wedges
open during
operation

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Operation & Maintenance Manual

Jaw Crusher Troubleshooting Chart

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Operation & Maintenance Manual

Start-Up & Operation Information

Section 6 - Start-Up & Operation

3) Start up all other components on the plant in

the proper sequence prescribed for your
particular plant system. If no prescribed
sequence is available, start with the last piece
of equipment to discharge material and work
back toward the initial feed point until all
components are operating empty.

Start-Up & Operation Information

The jaw crusher is generally used as a component
of an overall plant system. Specific equipment
start-up procedures will depend on the particular
plant and the material flow as well as the type of
controls used. Always refer to controls schematics
and information received with your particular
equipment for start-up and operation.

4) Make sure crusher is running at the proper

RPM. See (Table 6 - 1)
Table 6 - 1 Jaw Crusher Operating Speeds

The following steps should be used as a guide to

operation of the jaw crusher:
1) Check the surrounding area to ensure no
personnel are in a dangerous position prior to
start-up.

WARNING
Always sound horn or other warning
device to warn others that you are about to
start up the equipment.
2) If the crusher is part of a plant system, make
sure it is started in proper sequence with other
components.

Jaw Model

RPM

CT1030

300

CT1040

300

CT1048

300

CT1252

300

CT2036

250

CT2436

250

CT2645

300

CT3042

250

NCT3042

250

CT3254

250

CT3648

225

CT4254

220

CT4763

200

CT6080

200

5) Begin material flow to the plant. Keep safety

in mind.
6) Record any observation about plant operating
conditions in the plant log book.

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Operation & Maintenance Manual

Crusher Feed

Crusher Feed

DANGER

The most efficient operation of the crusher results

when the crushing chamber is kept full of material
and when a uniform method of feed is used. The
crusher should ideally be kept full of material but
it should not be allowed to build up above the top
of the jaws.

Failure to Lockout & Tagout will

result in death or severe personal
injury.
3) Use extreme caution when attempting to
dislodge or remove jammed objects. These
objects are under tremendous pressure and can
fracture or dislodge and be thrown out at high
speeds at any time.

During normal operations, the flow of material to

the machine and crushed material out of the
machine forms a steady stream of product from the
crusher.
Oversize Feed Material

DANGER

Avoid feeding material into the crusher that is too

large to pass through the crushing chamber. If a
piece of material is too large, it should be broken
down before it gets to the crushing chamber. A
hydraulic breaker may be installed to assist in this
process.

Never use explosives in a crusher to

clear jammed objects. The crushing
chamber and machine components
are not designed to withstand the
forces generated by explosives.

CAUTION
WARNING
If a hydraulic breaker is installed, it should
never be used to fracture rocks inside the
crushing chamber. Damage to bearings or
other parts may occur. Never use a
hydraulic breaker to break rocks on the
apparatus feeding the crusher.

Never attempt to walk or stand on

jammed or bridged material. The
material could break free at any
time.
4) Remove as much loose material from the top
of the crushing chamber as possible. When the
jammed object becomes accessible, try to
loosen it with a pole, rock hook or breaker bar.
If necessary, use a grappling device to remove
the object out of the feed opening.

Unblocking Jammed Material

If material becomes jammed in the machinery:

1) Stop the machinery immediately!
2) Lockout & Tagout power.

WARNING
Never attempt to dislodge a
jammed object directly by hand.

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Operation & Maintenance Manual

Crusher Feed

CAUTION
If a hydraulic breaker is used when the feed
opening is blocked, extreme care must be
taken to break the jammed rock only.
Never directly hammer on any part of the
crusher or its components. Never pry
against the crusher to free the blockage.
5) After unblocking and clearing is completed,
remove any objects, loose material or debris
from the crusher discharge area.
6) Remove the Lockout & Tagout from the
power source.
Crusher should now be able to be restarted.

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Crusher Feed

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Operation & Maintenance Manual

Adjustments & Replacement

Section 7 - Adjustments & Wear

Parts Replacement

Closed Side Setting (CSS) Adjustment

The jaw crushers crushing chamber discharge
opening governs the size of finished material
produced.

Adjustments & Replacement

As equipment is used, wear parts must be adjusted
and/or replaced to keep the machinery operating
efficiently and properly. The following will give
guidance to adjustment procedures and
replacement for wear items on your jaw crusher.

The CSS is the closest distance the stationary and

swing jaw die faces come measured peak to peak
at the bottom of the chamber. See (Figure 7 - 2)
While the crusher is at rest, the opening at the
bottom of the chamber is somewhat larger and
known as the open measurement. To determine
the CSS, deduct the amount shown in the table
below from the open measurement .

Jaw Crusher Crushing Chamber

The jaw crushers crushing chamber consists of
the stationary jaw die, the swing jaw die
(sometimes called the moveable jaw), and the
cheek plates (sometimes called key plates). The
pitman shaft housing area is also protected by a
replaceable liner. See (Figure 7 - 1)

Table 7 - 1 Deduction To Determine CSS

Jaw Model

Inches

Metric

CT1030

0.394

10mm

CT1040

0.394

10mm

CT1048

0.394

10mm

CT1252

0.591

15mm

CT2036

1.000

25mm

CT2436

1.260

32mm

CT2645

N/A

N/A

CT3042

1.417

36mm

NCT3042

1.181

30mm

CT3254

1.023

26mm

CT3648

1.929

49mm

CT4254

2.087

53mm

CT4763

1.653

42mm

CT6080

N/A

N/A

1 - Swing Jaw Die

2 - Stationary Jaw Die
3 - Cheek Plates (Key Plates)
Figure 7 - 1 Typical Jaw Die & Cheek Plate
Arrangement

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Operation & Maintenance Manual

Closed Side Setting (CSS) Adjustment

Shim-Type CSS Adjustment Procedure

1) Lockout & Tagout crusher drive.

DANGER
Failure to Lockout & Tagout will
result in death or severe personal
injury.
2) Loosen bolts on both sides of machine that
secure the shims.
3) Loosen tension rod spring nuts on both sides
of machine.
Measure peak to peak when
crusher is at rest, then deduct
amount from table to get CSS.

4) Activate hydraulic hand pump to extend

cylinder to push the pitman forward and
relieve the weight off the stack of shims.

Figure 7 - 2 Jaw Crusher Closed Side Setting (CSS)

5) Add or subtract shims as required to achieve

the desired CSS.

Shim-Type CSS Adjustment

On smaller model jaws, the size of the opening is

changed by adding or subtracting shims between
the upper buffer and the frame housing.
See (Figure 7 - 3).

6) With the desired number of shims seated,

retract the hydraulic cylinder to allow the
pitman to rest against the shim stack.
7) Re-tighten the bolts on both sides of machine
securing the shims.
8) Re-set tension rod spring tension on both sides
of machine.
9) Once complete, remove Lockout & Tagout.

Figure 7 - 3 Shim-Type CSS Adjustment

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Operation & Maintenance Manual

Closed Side Setting (CSS) Adjustment

Hydraulic Wedge-Type CSS Adjustment

(Manual Hyd. Pump) Procedure

Hydraulic Wedge-Type CSS Adjustment

(Manual Hyd. Pump)

On some larger model jaws, the size of the opening

is changed by operating a manual hydraulic pump
connected to cylinders moving wedges between
the upper buffer and the frame housing.
See (Figure 7 - 4).

1) Lockout & Tagout crusher drive.

DANGER
Failure to Lockout & Tagout will
result in death or severe personal
injury.

6
5

2) Ensure the hydraulic pump unit is properly

connected to the hydraulic cylinders on the
wedges.

NOTICE
While making line connections
between the hydraulic power unit
and the crusher, air may become
trapped in the lines. It is necessary
to purge the trapped air. This can
usually be accomplished by
opening and closing the jaw several
times before initial operation.

1
2

2
1
2
3
4
5
6

Wedges In
Wedges Out
Manual Hand Pump
Valve Direction - Wedges In
Valve Direction - Wedges Out
Valve Direction - Hold Position

3) Loosen tension rod spring nuts on both sides

of machine.
4) Move the valve to the desired flow direction
(Wedge Out - Increases Opening)
(Wedge In - Decreases Opening)
5) Activate hydraulic hand pump to push or pull
the wedges in or out to the desired CSS.

Figure 7 - 4 Hydraulic Wedge-Type CSS Adjustment

(Manual Hyd. Pump)

6) Move the valve back to the Hold position.

7) Re-set tension rod spring tension on both sides
of machine.
8) Once complete, remove Lockout & Tagout.

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Operation & Maintenance Manual

Closed Side Setting (CSS) Adjustment

Power Hydraulic Pump Unit for CSS

Adjustment

The powered hydraulic pump unit may or may not

have the electrical control box mounted on the
unit. Either unit contains the same hydraulic
components.

Some larger model jaw crushers utilize a powered

hydraulic pump unit to supply power for the CSS
adjustment mechanism.

See (Figure 7 - 5)

Unit Without Electrical Control Box

15 7 17

18 16 13

14

5
16
17
15

12

18

19
9
6 1

11

17

11

10

16

20

1
2
3
4
5
6
7

Unit With Electrical Control Box

Motor
8 - Reservoir Cap / Breather
Coupling
9 - Check Valve
Gear Pump
10- One-way Throttle Valve
Relief Valve
11- Synchronous Valve
Directional Control Valve
12- Pressure Gauge
Oil Level Gauge
13- Gauge Fitting
Return Oil Filter
14- Gauge Hose

151617181920-

P Port / High Pressure Hose

B Port / High Pressure Hose
A Port / High Pressure Hose
T Port / Low Pressure Hose
Electrical Control Buttons
Electrical Control Box

Figure 7 - 5 Power Hydraulic Pump Unit Components

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Operation & Maintenance Manual

Closed Side Setting (CSS) Adjustment

Power Hydraulic Pump Unit With Electrical

Control Box

The electrical schematics below are for reference

when the power hydraulic pump unit used has the
electrical control box mounted.
Circuit Breaker

Pump Motor

Transformer Control and Protection

Pump Motor Control

Stop

Start

Electric Schematic (380V)

Circuit Breaker

Pump Motor

Transformer Control and Protection

Pump Motor Control

Stop

Start

Electric Schematic (460V)

Figure 7 - 6 Power Hydraulic Pump Unit Electrical Schematics

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Operation & Maintenance Manual

Closed Side Setting (CSS) Adjustment

Power Hydraulic Pump Unit Hydraulic

Schematic Type 1 Connections
CT2036, CT2036SA, CT2036T, CT2036TA

The hydraulic schematic below is for reference

when the power hydraulic pump unit is used on the
following model jaw crushers.

CT2436, CT2436J, CT2436JS, CT2436JT,

CT2436TB, CT2436TC, CT2436S
CT2645A
CT3042, CT3042T, CT3042TAC, CT3042S,
CT3042SB, CT3042SC, CT3042SD, CT3042TA,
CT3042TP
CT3254, CT3254PN, CT3254TA, CT3254TB,
CT3254TC, CT3254TD, CT3254TE, CT3254TS
CT3648, CT3648HT, CT3648HTS
CT4254, CT4254S, CT4254SA, CT4254SB,
CT4254T, CT4254U
CT4763, CT4763T, CT4763U, CT4763Y
CT6080

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Operation & Maintenance Manual

Closed Side Setting (CSS) Adjustment

Rated Flow
Rated Pressure
Motor Power
Motor Speed RPM
Filtration
Oil Reservoir Volume

1
2
3
4
5

Motor
Coupling
Gear Pump
Relief Valve
Directional Control Valve

6 7 8 9 10-

Oil Level Gauge

Return Oil Filter
Reservoir Cap / Breather
Check Valve
One-way Throttle Valve

111213141516-

4 ml/r
21 MPa
3KW / 380V or
3.6KW / 460V
1410 / 380V or
1710 / 460V
20 m
65L (17 Gal.)

Synchronous Valve
Pressure Gauge
Gauge Fitting
Gauge Hose
P Port / High Pressure Hose
B Port / High Pressure Hose

Figure 7 - 7 Power Hydraulic Pump Unit Hydraulic Schematic Type 1 Connections & Specifications

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Operation & Maintenance Manual

Closed Side Setting (CSS) Adjustment

Power Hydraulic Pump Unit Hydraulic

Schematic Type 2 Connections
CT3254A, CT3254C, CT3254D

The hydraulic schematic below is for reference

when the power hydraulic pump unit is used on the
following model jaw crushers.

CRSH-OM-0003ENG(OCT-2014)

CT4254B, CT4254HA

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Operation & Maintenance Manual

Closed Side Setting (CSS) Adjustment

Rated Flow
Rated Pressure
Motor Power
Motor Speed RPM
Filtration
Oil Reservoir Volume

1
2
3
4
5
6

Motor
Coupling
Gear Pump
Relief Valve
Directional Control Valve
Oil Level Gauge

7 8 9 101112-

Return Oil Filter

Reservoir Cap / Breather
Check Valve
One-way Throttle Valve
Synchronous Valve
Pressure Gauge

131415161718-

4 ml/r
21 MPa
3KW / 380V or
3.6KW / 460V
1410 / 380V or
1710 / 460V
20 m
65L (17 Gal.)

Gauge Fitting
Gauge Hose
P Port / High Pressure Hose
B Port / High Pressure Hose
A Port / High Pressure Hose
T Port / Low Pressure Hose

Figure 7 - 8 Power Hydraulic Pump Unit Hydraulic Schematic Type 2 Connections & Specifications

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Closed Side Setting (CSS) Adjustment

Hyd. Wedge-Type CSS Adjustment (Power

Hyd. Pump Type 1 Connections)

On some larger model jaws, the size of the opening

is changed by operating a power hydraulic pump
connected to cylinders moving wedges between
the upper buffer and the frame housing.
See (Figure 7 - 9).

1
1
2
3
4
5
6
7

Wedges In
Wedges Out
Power Hydraulic Pump Unit
Valve Direction - Wedges In
Valve Direction - Wedges Out
Valve Direction - Hold Position
Pressure Gauge

Figure 7 - 9 Hydraulic Wedge-Type CSS Adjustment

(Power Hyd. Pump - Type 1 Connections)

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Closed Side Setting (CSS) Adjustment

Hyd. Wedge-Type CSS Adjustment (Power

Hyd. Pump Type 1 Connections) Procedure

1) Lockout & Tagout crusher drive.

DANGER
Failure to Lockout & Tagout will
result in death or severe personal
injury.
2) Ensure the power hydraulic pump unit is
properly connected to the hydraulic cylinders
on the wedges. See (Figure 7 - 9)

4) Engage power to the hydraulic pump unit.

5) Move the control valve lever in the desired
flow direction to move the wedges in or out to
the desired CSS.
(Wedge Out - Increases Opening)
(Wedge In - Decreases Opening)
6) Once the desired CSS has been achieved,
move the control valve lever back to the Hold
position.
7) Disengage power to the hydraulic pump unit.
8) Re-set tension rod spring tension on both sides
of machine.

NOTICE
9) Once complete, remove Lockout & Tagout.
While making line connections
between the hydraulic power unit
and the crusher, air may become
trapped in the lines. It is necessary
to purge the trapped air. This can
usually be accomplished by
opening and closing the jaw several
times before initial operation.
3) Loosen tension rod spring nuts on both sides
of machine.

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Operation & Maintenance Manual

Closed Side Setting (CSS) Adjustment

Hyd. Wedge-Type CSS Adjustment (Power

Hyd. Pump Type 2 Connections)

On some larger model jaws, the size of the opening

is changed by operating a power hydraulic pump
connected to cylinders moving wedges between
the upper buffer and the frame housing.
See (Figure 7 - 10).

1
1
2
3
4
5
6
7

Wedges In
Wedges Out
Power Hydraulic Pump Unit
Valve Direction - Wedges In
Valve Direction - Wedges Out
Valve Direction - Hold Position
Pressure Gauge

Figure 7 - 10 Hydraulic Wedge-Type CSS Adjustment

(Power Hyd. Pump - Type 2 Connections)

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Closed Side Setting (CSS) Adjustment

Hyd. Wedge-Type CSS Adjustment (Power

Hyd. Pump Type 2 Connections) Procedure

1) Lockout & Tagout crusher drive.

DANGER
Failure to Lockout & Tagout will
result in death or severe personal
injury.
2) Ensure the power hydraulic pump unit is
properly connected to the hydraulic cylinders
on the wedges. See (Figure 7 - 10)

4) Engage power to the hydraulic pump unit.

5) Move the control valve lever in the desired
flow direction to move the wedges in or out to
the desired CSS.
(Wedge Out - Increases Opening)
(Wedge In - Decreases Opening)
6) Once the desired CSS has been achieved,
move the control valve lever back to the Hold
position.
7) Disengage power to the hydraulic pump unit.
8) Re-set tension rod spring tension on both sides
of machine.

NOTICE
9) Once complete, remove Lockout & Tagout.
While making line connections
between the hydraulic power unit
and the crusher, air may become
trapped in the lines. It is necessary
to purge the trapped air. This can
usually be accomplished by
opening and closing the jaw several
times before initial operation.
3) Loosen tension rod spring nuts on both sides
of machine.

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Operation & Maintenance Manual

Closed Side Setting (CSS) Adjustment

Direct Hydraulic Toggle Plate-Type CSS

Adjustment

On certain model jaws, the size of the opening is

changed by adding or subtracting shims between
the upper buffer and a hydraulic cylinder
mechanism directly acting against the frame
housing.
See (Figure 7 - 11).

Figure 7 - 11 Direct Hydraulic Toggle Plate-Type CSS

Adjustment

The toggle plate hydraulic cylinder mechanism as

well as the tension rod spring cylinder mechanisms
are powered and held hydraulically by a separate
hydraulic pump control unit. See (Figure 7 - 12)
Make sure the hydraulic pump control unit is
properly connected to the crusher hydraulic
cylinders. See (Figure 7 - 15) schematic.

Figure 7 - 12 Direct Hydraulic Toggle Plate-Type

Hydraulic Pump Control Unit

Direct Hydraulic Toggle Plate-Type CSS

Adjustment Procedure

1) Lockout & Tagout crusher drive.

DANGER

Operating hydraulic pressure on toggle cylinder

mechanism is 16.5 Mpa (2393 psi) and the tension
rod spring cylinders is 12 Mpa (1740.5 psi).
During normal operation, hydraulic unit should be
turned on and running before crusher is started and
the Auto/Manual Switch should be set to Auto.

CRSH-OM-0003ENG(OCT-2014)

Failure to Lockout & Tagout will

result in death or severe personal
injury.
2) Place a Safety Block between the pitman
and the back cross member as shown.
See (Figure 7 - 13)

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Model CT-Series Jaw Crushers

Operation & Maintenance Manual

Closed Side Setting (CSS) Adjustment

Shims

Figure 7 - 14 Direct Hydraulic Toggle Plate-Type CSS

Adjustment Shims

Safety block installed between

pitman and frame cross member.
Safety block should be made
from solid hardwood material.

Shim Bolt

8) Add or remove shims as required to achieve

the desired CSS. Each shim removed will
reduce the CSS by approximately 23mm.

Figure 7 - 13 Direct Hydraulic Toggle Plate-Type CSS

Adjustment Safety Block Installed

9) Re-install bolts on both sides of machine to

secure the shims.

3) Turn Auto/Manual Switch to Manual

10) Turn the Auto/Manual Switch to Auto. This

allows the hydraulic control unit to pressurize
the Toggle Cylinder set and Tension
Cylinders.

4) Push the Tension Cylinder Relief button to

release tension cylinder hydraulic pressure.
5) Push the Toggle Cylinder Relief button to
release toggle cylinder set hydraulic pressure.
6) Remove the adjustment mechanism covers
from both sides of machine.
7) Loosen bolts on both sides of machine that
secure the shims. See (Figure 7 - 14)

CRSH-OM-0003ENG(OCT-2014)

11) Once pressurized, remove the Safety Block.

12) Re-install adjustment mechanism covers on
both sides of machine.
13) Once complete, remove crusher drive Lockout
& Tagout.

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Model CT-Series Jaw Crushers

Operation & Maintenance Manual

Closed Side Setting (CSS) Adjustment
.

Tension

Toggle

Release

Rated Pressure
Max. Pressure
Rated Flow
Operating Voltage
Operating Temp
Filtration
Oil Volume
Motor Power

1 2 3 4 5 6 7 8 9 1011-

Oil Pump
Pump Coupling
Electric Pump Motor
Motor Pump Joint Flange
Reservoir Breather
Oil Level Gauge
Return Line Filter
Hose
Fitting
Accumulator
Pressure Gauge

20MPa
21MPa
18 L/Min.
24V
60 + or - 5 C
10um
200L
7.5Kw/380V/50Hz

12- Pressure Gauge

13- Check Valve
14- Solenoid Valve
15- Valve Block
16- Solenoid Valve
17- Flow Control Valve
18- Check Valve
19- Ball Valve
20- Tension Rod Cylinders
21- Toggle Cylinder Assembly
22- Oil Reservoir

Figure 7 - 15 Direct Hydraulic Toggle Plate-Type Hydraulic Controls Schematic

CRSH-OM-0003ENG(OCT-2014)

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Operation & Maintenance Manual

Standard Toggle Seat Tension Rod Spring Adjustment

Standard Toggle Seat Tension Rod

Spring Adjustment

1) Completely loosen spring tension rod nuts

until springs are at their full, no-load length.
See A above.

After crusher CSS is set, the toggle seat tension rod

springs must be adjusted to apply the proper
amount of spring tension to keep the toggle plate
contained in its seats.
See (Figure 7 - 16)

2) Record this length A.

NOTICE
When measuring spring free length, each
spring length may vary. It is important to
compress each spring the same amount as
shown in (Table 7 - 2) even though this
may make the spring overall lengths differ.
The important issue is that the compression
amount be equal on each side to ensure the
toggle plate remains centered during
operation.

B
A
A - Spring Free Length

3) See (Table 7 - 2) for the amount to compress

springs for your particular model crusher.
See B above.
4) When springs are compressed the amount
specified in (Table 7 - 2), that length will be
dimension B subtracted from dimension A.

B - Spring Compression Deduction Amount

Figure 7 - 16 Typical Toggle Seat Tension Rod Spring
Adjustment

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Operation & Maintenance Manual

Standard Toggle Seat Tension Rod Spring Adjustment

Table 7 - 2 Tension Rod Spring Length Deduction

Jaw Model

Initial mm (inch)

Range mm (inch)

CT1030

21 (0.826)

20~30
(0.787~1.181)

CT1040

31 (1.220)

25~37
(0.984~1.456)

CT1048

57 (2.244)

50~62
(1.968~2.440)

CT1252

64 (2.519)

50~65
(1.968~2.559)

CT2036

39 (1.535)

35~45
(1.377~1.771)

CT2436

35 (1.377)

30~40
(1.181~1.574)

CT2645

N/A

N/A

CT3042

55 (2.165)

50~60
(1.968~2.362)

NCT3042

22 (0.866)

18~27
(0.708~1.062)

CT3254

34 (1.338)

30~40
(1.181~1.574)

CT3648

32 (1.259)

30~38
(1.181~1.496)

CT4254

35 (1.377)

35~50
(1.377~1.968)

CT4763

65 (2.559)

65~100
(2.559~3.936)

CT6080

55 (2.165)

53~60
(2.086~2.362)

CRSH-OM-0003ENG(OCT-2014)

5) When the springs are adjusted on both sides,

start the crusher.
6) Listen for a knocking sound. If a knocking is
heard, the toggle is not held tight enough by
the springs.
7) Further tighten (compress) the tension springs
a slight amount.
8) Run the crusher again and repeat until no
toggle plate knocking sound is detected.

NOTICE
For proper operation and optimum toggle
plate wear performance, the tension rod
springs must be adjusted evenly on both
sides so the toggle plate will run in the
center of the upper and lower buffer seats.
The important issue is that the compression
amount be equal on each side to ensure the
toggle plate remains centered during
operation.

7 - 18

Model CT-Series Jaw Crushers

Operation & Maintenance Manual

Fully Hydraulic Toggle Plate-Type CSS Adjustment System

Fully Hydraulic Toggle Plate-Type CSS

Adjustment System
On certain model jaws, the size of the opening is
changed by a fully hydraulic cylinder mechanism
directly acting against the frame housing and the
swing jaw. The toggle plate tension mechanism is
accomplished by having dual-acting cylinders
between the frame housing and the swing jaw in
addition to tension rods and springs.
See (Figure 7 - 17).

1
2
3

7
9

1
2
3
4

4
7
5
6
Toggle Cylinder 5 - Adapter
Toggle Beam
6 - Tension Rod
Toggle Plate
7 - Tension Spring
Tension Cylinder

Figure 7 - 17 Fully Hydraulic Toggle Plate-Type CSS

Adjustment

The toggle plate hydraulic cylinder mechanism as

well as the tension cylinder mechanisms are
powered and held hydraulically by a separate
hydraulic pump control unit. See (Figure 7 - 18)

CRSH-OM-0003ENG(OCT-2014)

1 - Power
2 - Pump Start
3 - Filter Blocked
Indicator
4 - Pump Stop
5 - CSS Increase

7 - 19

8
6 - CSS Decrease
7 - Adjust/Operate
Mode Switch
8 - E-Stop
9 - Main Power
Switch

Figure 7 - 18 Fully Hydraulic Toggle Plate-Type

Hydraulic Control Unit

Model CT-Series Jaw Crushers

Operation & Maintenance Manual

Fully Hydraulic Toggle Plate-Type CSS Adjustment System

Hydraulic Pump Control Unit Hose

Connections

Make sure the hydraulic pump control unit is

properly connected to the crusher hydraulic
components and cylinders. See (Figure 7 - 19) and
(Figure 7 - 24) schematic.

Figure 7 - 19 Fully Hydraulic Toggle Plate-Type Hydraulic Pump Unit Hose Connections

CRSH-OM-0003ENG(OCT-2014)

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Model CT-Series Jaw Crushers

Operation & Maintenance Manual

Fully Hydraulic Toggle Plate-Type CSS Adjustment System

CSS Increase Adjustment Procedure

Hydraulic Control Unit Standby Mode

When the control unit is first started, no matter if

the panel switch is in Adjustment Mode or
Operation Mode, the unit will be in a Standby
Mode.
CSS Decrease Adjustment Procedure

1) Turn control unit on.

1) Turn control unit on.

2) Turn control panel switch to Adjustment
Mode.
3) Push the CSS Increase button on the control
panel to move the toggle cylinders in until the
desired position is reached.

2) Turn control panel switch to Adjustment

Mode.

NOTICE

3) Push the CSS Decrease button on the control

panel to move the toggle cylinders out until
the desired position is reached.

The displacement of the toggle cylinder is

measured by the sensor ST1 or ST2 on the
toggle cylinders. Output current ranges
from 4 to 20mA. See (Figure 7 - 24)
schematic.
If pressure measured by
pressure sensor (32) is below its upper
limit of 12 MPa (1740 psi), oil will be
supplied to the tension cylinder rod side
chamber until it reaches the upper limit.

NOTICE
The displacement of the toggle cylinder is
measured by the sensor ST1 or ST2 on the
toggle cylinders. Output current ranges
from 4 to 20mA. See (Figure 7 - 24)
schematic.
If pressure measured by
pressure sensor (32) is below its upper
limit of 12 MPa (1740 psi), oil will be
supplied to the tension cylinder rod side
chamber until it reaches the upper limit.
4) The toggle cylinder displacement is now
recorded as the default value for cylinder
reset.

4) The toggle cylinder displacement is now

recorded as the default value for cylinder
reset.
5) CSS adjustment is complete and now control
panel switch can be moved to Operation Mode
and tension rod spring adjustment should now
be made.

5) CSS adjustment is complete and now control

panel switch can be moved to Operation Mode
and tension rod spring adjustment should now
be made.

CRSH-OM-0003ENG(OCT-2014)

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Model CT-Series Jaw Crushers

Operation & Maintenance Manual

Fully Hydraulic Toggle Plate-Type CSS Adjustment System

Tension Rod Spring Adjustment

Toggle Cylinders Oil Supplement

When the crusher CSS has been set or changed as

described above, the tension rod springs must be
adjusted.

While the hydraulic control unit is in operation, the

toggle cylinders must maintain their default value
(CSS setting) described above.
When the
difference between toggle cylinders actual
displacement and the default displacement reaches
the maximum deviation, the valve will be actuated
to move the cylinders to maintain position. This
will continue through the entire crushing process.

1
Tension Cylinders Oil Supplement

2
3

4
1
2
3
4
5
6
7

Toggle Cylinder
Toggle Beam
Toggle Plate
Tension Cylinder
Adapter
Tension Rod
Tension Spring:
Compress springs 28mm (1 - 1/8 in.)
Compressed length 312mm (12 - 3/8 in.)
Both springs should be equally adjusted.

Figure 7 - 20 Fully Hydraulic Toggle Plate-Type CSS

Tension Rod Spring Adjustment

While the hydraulic control unit is in operation, the

tension cylinders must maintain their position and
pressure relative to (CSS setting) described above.
Tension cylinder oil supplement depends on the
pressure measured by the sensor (32). If the
measured pressure is below the lower limit of
5MPa (725 psi), the valve will be actuated to move
the cylinder rod side until the measured pressure
reaches the upper limit of 12MPa (1740 psi). This
will continue through the entire crushing process.
When both toggle cylinders and tension cylinders
need oil supplement, the tension cylinders have
priority.
Tramp Release

If an uncrushable piece of material in the crushing

chamber causing the pressure in safety valve
(29.2) to rise above its setting of 25MPa (3625
psi), it will allow most of the oil to flow across
check valve in (29.1) to toggle cylinder rod side
chamber and the remaining oil to flow back to
tank. See (Figure 7 - 21) and (Figure 7 - 24)

1) Completely loosen spring tension rod nuts

until springs are at their full, no-load length.

Response time is 2 milliseconds and the cylinder

maximum retract speed is 15mm/s.

2) See (Figure 7 - 20) for the amount to compress

springs.

Once the tramp release has occurred, according to

the displacement sensor signal, the hydraulic
control unit will ready itself for cylinder reset.

3) When springs are compressed the amount

specified, tighten tension rod jam nuts.

CRSH-OM-0003ENG(OCT-2014)

7 - 22

Model CT-Series Jaw Crushers

Operation & Maintenance Manual

Fully Hydraulic Toggle Plate-Type CSS Adjustment System

Hydraulic Unit Valve Pressure Adjustments

Toggle and Tension Cylinder Fast Reset After

Tramp Release

The fast reset is the follow-up movement after

tramp release. If the toggle cylinders stop their
retracting and the pistons do not bottom (according
to the signal from the displacement sensor), once
the tramp release is finished, the toggle cylinders
will need to be reset. Reset as outlined above in
CSS Decrease procedure.
If the toggle cylinders pistons bottom, or the
displacement sensor reading does not change and
motor current overloads when toggle cylinders are
resetting, it is a tramp release failure. To protect
the crusher and hydraulic unit, the crusher motor
should be shut down. Manual tramp release
should be performed.
8

The default system pressure setting is

24MPa (3481 psi). See (Figure 7 - 22)
The tension cylinder maximum pressure setting is
13MPa (1885 psi). See (Figure 7 - 22)
The toggle cylinder rod side default pressure
setting is 7 - 8MPa (1015 - 1160 psi) Generally
there is no need to adjust it. See (Figure 7 - 21)
The toggle cylinder piston side pressure should be
adjusted according to the material strength being
crushed. The adjustment range on the valve is
5.5 - 25MPa (798 - 3626 psi). See (Figure 7 - 21)
2

10

6
5
1

4
3

1 - Rod Side Pressure Setting

2 - Piston Side Pressure Setting
3 - Piston Side Connect Between Cylinders
4 - To Piston Side - From Valve
5 - To Rod Side - From Valve
6 - Piston Side Test Point
7 - Displacement Sensor (Inside)
8 - Rod Side Test Point
9 - Rod Side Connect Between Cylinders
10 - To Tank

1 - System Pressure Setting

2 - Tension Cylinder Pressure Setting
3 - Manual Unloading Relief Valve
Figure 7 - 22 Fully Hydraulic Toggle Plate-Type CSS
Adjustment Manifold Valve Pressure Setting

Figure 7 - 21 Fully Hydraulic Toggle Plate-Type CSS

Adjustment Toggle Cylinder and Valve

CRSH-OM-0003ENG(OCT-2014)

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Model CT-Series Jaw Crushers

Operation & Maintenance Manual

Fully Hydraulic Toggle Plate-Type CSS Adjustment System

Toggle Cylinder Maintenance

2) Shut off hydraulic control unit.

Make sure all hoses, valves and fittings are

checked regularly.

DANGER

3) Open manual unloading relief valve to release

hydraulic pressure. See (Figure 7 - 22)
4) If pressure gauge reading is 0, close unloading
relief valve.

Extreme care should be taken due

to the toggle cylinder large oil
capacity and the hydraulic lock
valves.

5) If pressure is not 0, release the pressure by

carefully loosening pressure hose to the piston
side of cylinder.

If it becomes necessary to disconnect hoses, valves

or fittings from the cylinders, make sure to relieve
all hydraulic pressure before service.

6) Once pressure is relieved, make sure hoses,

valves and fittings are re-tightened.
Fully Hydraulic Toggle Electrical Schematic

1) Retract cylinders to the maximum CSS.

Figure 7 - 23 Fully Hydraulic Toggle Plate-Type Electrical Controls Schematic

CRSH-OM-0003ENG(OCT-2014)

7 - 24

Model CT-Series Jaw Crushers

Operation & Maintenance Manual

Fully Hydraulic Toggle Plate-Type CSS Adjustment System

Fully Hydraulic Toggle Hydraulic Schematic

.

A2

DT4 B2

DT3

21.1
A1 DT1

DT2 B1

14

20

23

17

13MPa
33

19

21.2

24MPa

16

13

18

22

DT6 B3

A3 DT5

32
P
I
DPI1 26

15
12

24.1

25.1

27.2

27.1

24.2

8MPa
29.2

29.1

25.2

28

31
30.1

PDS1

3, 4, 5, 6

9
Rod Side Chamber Pressure: 35-210Bar

10

Max. Pressure
25MPa, adjust as need

30.2

ST1

ST2

Piston Side Chamber

Pressure: 55-315Bar

11

1, 2
Specifications:

1 2 3 4 5 6 7 8 9 101112-

1. Rated Pressure: 25MPa

2. Rated Flow: 36L/min
3. Operation Voltage: 24V DC
4. Operation Hydraulic Oil Temp. : 605 C
5. Filtration: 10m
6. Tank Volume: 240L
7. Motor: 18.5 kW, 575V AC, 60HZ
Reservoir
13- Relief Valve
Cabinet
14- Solenoid Valve
Pump Motor Mount
15- Fitting
Pump Coupling
16- Gauge Hose
Gear Pump
17- Pressure Gauge
Pump Drive Motor
18- Manual Relief Valve
Hose
19- Relief Valve
Oil Return Filter
20- Hydraulic Lock
Reservoir Breather Cap
21- Solenoid Valve
Oil Level Gauge
22- Hose
Ball Valve
23- Accumulator
Valve Manifold
24- Hose

252627282930-

Tension Cylinder
Bi-directional Hydraulic Lock
Hose
Valve Manifold
Unidirectional Sequence Valve
Toggle Cylinder
(with Displacement Sensor)
31- Hose
32- Pressure Sensor
33- Check Valve

Figure 7 - 24 Fully Hydraulic Toggle Plate-Type Hydraulic Controls Schematic

CRSH-OM-0003ENG(OCT-2014)

7 - 25

Model CT-Series Jaw Crushers

Operation & Maintenance Manual

Jaw Die Lifting Tools

Jaw Die Lifting Tools

For replacement or rotating jaw dies, it will be
necessary to have a sufficient lifting tool attached
to the dies. Trio manufactures its jaw dies with
wedge slots in each end to facilitate this lifting.
The following drawings give general illustrations
as to these lifting tool attachments.
See (Figure 7 - 25) and (Figure 7 - 26)

1 - Lifting Eye
2 - Steel Plate
3 - Wedge-Shaped
Steel Block
4 - Tack Weld Area

1
2
3

These tools may be fabricated locally. Contact

Trio for details regarding the lifting tools for your
specific size machine.
1 - Lifting Eye
2 - Steel Plate
3 - Wedge-Shaped
Steel Block
4 - Tack Weld Area

1
2
3

Figure 7 - 26 Typical Swing Jaw Die Lifting Tool

Arrangement

Figure 7 - 25 Typical Stationary Jaw Die Lifting Tool

Arrangement

CRSH-OM-0003ENG(OCT-2014)

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Model CT-Series Jaw Crushers

Operation & Maintenance Manual

Jaw Die Lifting Tools

Make sure wedge-shaped steel blocks are made

from at least 1 inch (25 mm) thick steel and lifting
eyes are large enough to hold the weight of the jaw
die.
The wedge-shaped steel blocks must be drilled and
tapped to accept the size threads of the lifting eye
used.

CRSH-OM-0003ENG(OCT-2014)

7 - 27

WARNING
When welding mild steel to
manganese jaw dies or cheek
plates, proper welding procedures
and standards are to be observed
(such as ASTM A128 / A128M).
In particular, use a stainless 310
welding rod (or equivalent), 5/32
inch (3.97 mm) in diameter; make a
number of passes rather than one
large pass; no pre-heating or afterwelding heating (keep welded
surfaces below 500F (260C);
follow all safety precautions when
lifting.

Model CT-Series Jaw Crushers

Operation & Maintenance Manual

Cheek Plates

Cheek Plates

Upper Cheek Plate Removal

The cheek plates, in addition to acting as wear

liners for the crushing chamber, also hold the
stationary jaw die in place on the frame by pressing
on the sides of the die and holding it up tight
against the frame.

1) Lockout & Tagout crusher drive.

If the crusher is left to operate with loose cheek

plates, the stationary jaw will move, causing
excessive wear on the jaw and frame as well as
reducing the capacity of the crusher. To operate
properly, the cheek plates should be driven down
tight and the bolts be kept well tightened to hold
them firmly against the sides of the frame and the
stationary jaw.

DANGER
Failure to Lockout & Tagout will
result in death or severe personal
injury.
2) Install chains or slings to upper cheek plate
using holes on the top of plate or, if no holes
are present, fashion a hook and eye assembly
to fasten to each plate. This may require
welding a lifting hook or eye to the plate.

The crusher may have both upper cheek plates and

one or more lower cheek plates while other
crushers may have a single cheek plate on each
side (depending upon the crusher size). Generally
more wearing action occurs on the lower cheek
plates and they will have to be replaced more often
than the upper plates. Never allow the plates to
become worn completely through or let wear take
place on the crusher frame.

WARNING

Caution should be used during the

following procedures and proper
personal protection equipment and
tools are to be used to ensure
personnel and equipment safety.

When welding mild steel to

manganese jaw dies or cheek
plates, proper welding procedures
and standards are to be observed
(such as ASTM A128 / A128M).
In particular, use a stainless 310
welding rod (or equivalent), 5/32
inch (3.97 mm) in diameter; make a
number of passes rather than one
large pass; no pre-heating or afterwelding heating (keep welded
surfaces below 500F (260C);
follow all safety precautions when
lifting.

NOTICE

3) With a suitable lifting device, put slight

tension on chains or slings to keep cheek plate
in place.

CAUTION

Before replacement of cheek plates, it is

best to adjust the machine to its most open
adjustment setting as this will allow the
most room to work.

CRSH-OM-0003ENG(OCT-2014)

4) Remove bolts from cheek plate.

7 - 28

Model CT-Series Jaw Crushers

Operation & Maintenance Manual

Cheek Plates

5) Remove upper cheek plate from crusher

frame. If it does not come free when bolts are
removed, it may be necessary to strike the
plate to jar it loose.

5) Remove lower cheek plate from crusher

frame. If it does not come free when bolts are
removed, it may be necessary to strike the
plate to jar it loose.

6) Set upper cheek plate aside.

6) Set lower cheek plate aside.

7) Repeat above procedure to remove each upper

plate.

7) Repeat above procedure to remove each lower

plate.

Lower Cheek Plate Removal

Installation of Lower Cheek Plate

1) Once upper cheek plate is removed, fashion a

hook and eye assembly to fasten to each lower
cheek plate. This may require welding a
lifting hook or eye to the plate.

Before installation of lower cheek plates into

crusher, make sure stationary jaw die is aligned
properly in the frame in relationship to swing jaw
die. For installation of stationary jaw, see
procedure in this section.

WARNING
When welding mild steel to
manganese jaw dies or cheek
plates, proper welding procedures
and standards are to be observed
(such as ASTM A128 / A128M).
In particular, use a stainless 310
welding rod (or equivalent), 5/32
inch (3.97 mm) in diameter; make a
number of passes rather than one
large pass; no pre-heating or afterwelding heating (keep welded
surfaces below 500F (260C);
follow all safety precautions when
lifting.

1) Fashion a hook and eye assembly to fasten to

each lower cheek plate. This may require
welding a lifting hook or eye to the plate.

WARNING
When welding mild steel to
manganese jaw dies or cheek
plates, proper welding procedures
and standards are to be observed
(such as ASTM A128 / A128M).
In particular, use a stainless 310
welding rod (or equivalent), 5/32
inch (3.97 mm) in diameter; make a
number of passes rather than one
large pass; no pre-heating or afterwelding heating (keep welded
surfaces below 500F (260C);
follow all safety precautions when
lifting.

2) Install chains or slings to lower cheek plate

using the hook or eye assembly fastened to
plate.
3) With a suitable lifting device, put slight
tension on chains or slings to keep cheek plate
in place.

2) Install chains or slings to lower cheek plate

using the hook or eye assembly fastened to
plate.

4) Remove bolts from cheek plate.

CRSH-OM-0003ENG(OCT-2014)

7 - 29

Model CT-Series Jaw Crushers

Operation & Maintenance Manual

Cheek Plates

3) With a suitable lifting device, lift cheek plate

into place in crusher frame.
4) Using a suitable driver and bar, drive plate
into place tight up against jaw die.
5) Install bolts and snug them up to keep plate in
place.
6) Using the same methods listed above, install
remaining lower cheek plate.
7) When both side lower cheek plates are in
place and tight against the stationary jaw die,
tighten all bolts to the proper torque.
8) With both lower cheek plates in place, proceed
to installation of upper cheek plates.

Installation of Upper Cheek Plate

1) Install chains or slings to upper cheek plate

using holes on the top.
2) With a suitable lifting device, lift cheek plate
into place.
3) Install bolts and snug them up to keep plate in
place.
4) Using a suitable driver, drive plate into place
tight up against jaw die.
5) Repeat above procedure to install each upper
plate.
6) When both side upper cheek plates are in
place and tight against the stationary jaw die,
tighten all bolts to the proper torque.
7) When all cheek plates are in place and tight,
remove crusher drive Lockout & Tagout.

CRSH-OM-0003ENG(OCT-2014)

7 - 30

Model CT-Series Jaw Crushers

Operation & Maintenance Manual

Stationary Jaw Die

Tightening Cheek Plates

Cheek plates may become loose, permitting the

stationary jaw die to move and cause wear to both
the die and crusher frame. Check periodically to
make sure the cheek plates are tight against the
stationary jaw die. If the stationary jaw die moves
during crushing operation, the cheek plates should
be tightened. The following method permits
tightening of the lower plates without removing
the upper plates.
1) Lockout & Tagout crusher drive.

DANGER
Failure to Lockout & Tagout will
result in death or severe personal
injury.
2) Loosen bolts on the upper cheek plates until
they are loose enough to allow the plates to be
lifted up.

8) Using a suitable driver, drive upper plate

down until very tight against the jaw die.
9) Tighten bolts on the upper cheek plate to the
proper torque.
10) Repeat these steps for each side.
11) When all cheek plates are in place and tight,
remove crusher drive Lockout & Tagout.

Stationary Jaw Die

The stationary jaw die is locked in a rigid position
against the back of the crusher frame by the cheek
plates and tapered wedges at the top of the crusher
frame. See (Figure 7 - 27) The stationary jaw die
may be reversed by rotating it top-to-bottom to
gain additional wear life. The worn side of the jaw
die must not be allowed to wear too thin as this will
weaken that side of the die and could potentially
cause damage to the crusher.

3) With a suitable lifting device, lift upper cheek

plate approximately 1/2 inch (12.7 mm) and
place a piece of steel plate or bar as a spacer
between it and the lower cheek plate.

4) Loosen the lower cheek plate bolts slightly

until they are snug, but not tight, and will
allow the plate to be driven down.

5) Using a suitable driver, drive upper plate

down until the lower plate is driven down very
tight against the jaw die.

6) Tighten bolts on the lower cheek plate to the

proper torque.

1 - Stationary Jaw Die

2 - Stationary Jaw Die Wedges
3 - Cheek Plates

7) Remove the steel spacer from between the

plates.

Figure 7 - 27 Typical Stationary Jaw Die & Wedge

Arrangement

CRSH-OM-0003ENG(OCT-2014)

7 - 31

Model CT-Series Jaw Crushers

Operation & Maintenance Manual

Stationary Jaw Die

Stationary Jaw Die Removal

WARNING
Failure to replace jaw dies when
corrugations are worn or running
crusher until die concave sections
are worn will reduce capacity of the
crusher. Jaw dies not replaced at
the proper time can cause
compaction of material in the
crushing chamber and could result
in premature bearing failure,
excessive toggle plate breakage or
other damage to crusher.

2) Cheek plates must be removed prior to

removal of the stationary jaw die. See
procedures in this section for removal.
3) Fashion a hook and eye assembly to fasten to
the top of the stationary jaw die. See jaw die
lifting tool information in this section.

WARNING
When welding mild steel to
manganese jaw dies or cheek
plates, proper welding procedures
and standards are to be observed
(such as ASTM A128 / A128M).
In particular, use a stainless 310
welding rod (or equivalent), 5/32
inch (3.97 mm) in diameter; make a
number of passes rather than one
large pass; no pre-heating or afterwelding heating (keep welded
surfaces below 500F (260C);
follow all safety precautions when
lifting.

CAUTION
Caution should be used during the
following procedures and proper
personal protection equipment and
tools are to be used to ensure
personnel and equipment safety.

NOTICE
Before replacement of the stationary jaw
die, it is best to adjust the machine to its
most open adjustment setting as this will
allow the most room to work.
1) Lockout & Tagout crusher drive.

DANGER
Failure to Lockout & Tagout will
result in death or severe personal
injury.

CRSH-OM-0003ENG(OCT-2014)

4) Install chains or slings to stationary jaw die

using the hook or eye assembly fastened to
die.
5) With a suitable lifting device, put slight
tension on chains or slings to keep jaw die in
place.
6) Loosen stationary jaw die wedge bolts and
hammer wedges toward center of crusher
frame to loosen the die.
7) Lower slightly the jaw die and move it toward
the pitman until it clears the crusher frame.
8) Lift the stationary jaw die out of the crusher
frame and set aside.

7 - 32

Model CT-Series Jaw Crushers

Operation & Maintenance Manual

Stationary Jaw Die

3) Lift the jaw die enough to slide stationary jaw

die top over the wedges and so the bottom of
jaw die is up tight and seated on bottom of
crusher frame.

9) Remove the hook or eye assembly fastened to

the jaw die.
Stationary Jaw Die Rotation or Replacement

If stationary jaw die has enough wear life left to

accommodate rotating it, the hook or eye assembly
removed from it as described above should be
attached to the opposite end at the top. Use the
same steps also described above to fasten the hook
or eye assembly to the jaw die.
If stationary jaw die is to be replaced with a new
one, use the same steps also described above to
fasten the hook or eye assembly to the top of jaw
die.
Both the back of the jaw die and the mating surface
of the crusher frame must be clean and free of
debris before installation into crusher.
Stationary Jaw Die Installation

1) Install chains or slings to stationary jaw die

using the hook or eye assembly fastened to
die.

4) Tighten wedge bolts on each side evenly just

enough to hold jaw die fully seated along the
bottom edge of crusher frame while making
sure the die is centered in the crusher frame.
5) Cheek plates can now be re-installed in the
crusher frame per procedures outlined in this
section.
6) Wedge bolts on each side can now be fully
tightened.
7) Check to make sure the bottom of the
stationary jaw die has remained fully seated
along the bottom edge of the crusher frame.
8) Once jaw die and cheek plates are in place,
remove the Lockout & Tagout.

2) With a suitable lifting device, lift jaw die into

crusher frame and lower it until the bottom of
the die slides over the bottom of the crusher
frame.

CRSH-OM-0003ENG(OCT-2014)

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Model CT-Series Jaw Crushers

Operation & Maintenance Manual

Swing Jaw Die

Swing Jaw Die

Swing Jaw Die Removal

The swing jaw die is held in position against the

face of the pitman by the swing jaw wedges bolted
through at the upper end of the pitman.See (Figure
7 - 28) There may be two types of pitman design,
one which has a replaceable lower wedge bolted to
the pitman or the wedge area machined into the
pitman itself. The swing jaw die may be reversed
by rotating it top-to-bottom to gain additional wear
life. The worn side of the jaw die must not be
allowed to wear too thin as this will weaken that
side of the die and could potentially cause damage
to the crusher.
3

WARNING
Failure to replace jaw dies when
corrugations are worn or running
crusher until die concave sections
are worn will reduce capacity of the
crusher. Jaw dies not replaced at
the proper time can cause
compaction of material in the
crushing chamber and could result
in premature bearing failure,
excessive toggle plate breakage or
other damage to crusher.

CAUTION
Caution should be used during the
following procedures and proper
personal protection equipment and
tools are to be used to ensure
personnel and equipment safety.

2
1
1 - Swing Jaw Die
2 - Swing Jaw Die Wedges
3 - Swing Jaw Bolts

Pitman Design Types

Figure 7 - 28 Typical Swing Jaw Die & Wedge

Arrangement

CRSH-OM-0003ENG(OCT-2014)

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Model CT-Series Jaw Crushers

Operation & Maintenance Manual

Swing Jaw Die

NOTICE
Before replacement of the swing jaw die, it
is best to adjust the machine to its most
open adjustment setting as this will allow
the most room to work.
1) Lockout & Tagout crusher drive.

3) Install chains or slings to swing jaw die using

the hook or eye assembly fastened to die.
4) With a suitable lifting device, put slight
tension on chains or slings to keep jaw die in
place.
5) Remove jaw die wedge bolts from through the
pitman and remove the jaw die wedge
block(s).

DANGER

DANGER

Failure to Lockout & Tagout will

result in death or severe personal
injury.
2) Fashion a hook and eye assembly to fasten to
the top of the swing jaw die. See jaw die
lifting tool information in this section.

WARNING
When welding mild steel to
manganese jaw dies or cheek
plates, proper welding procedures
and standards are to be observed
(such as ASTM A128 / A128M).
In particular, use a stainless 310
welding rod (or equivalent), 5/32
inch (3.97 mm) in diameter; make a
number of passes rather than one
large pass; no pre-heating or afterwelding heating (keep welded
surfaces below 500F (260C);
follow all safety precautions when
lifting.

CRSH-OM-0003ENG(OCT-2014)

Care must be taken to stay clear of

inside of crusher while performing
jaw die replacement as falling jaw
die will result in death or severe
personal injury.
6) Lift the swing jaw die up off the pitman and
out of the crusher frame and set aside.
7) Remove the hook or eye assembly fastened to
the jaw die.

7 - 35

Model CT-Series Jaw Crushers

Operation & Maintenance Manual

Swing Jaw Die

Swing Jaw Die Rotation or Replacement

Check & Tighten Jaw Dies

If swing jaw die has enough wear life left to

accommodate rotating it, the hook or eye assembly
removed from it as described above should be
attached to the opposite end at the top. Use the
same steps also described above to fasten the hook
or eye assembly to the jaw die.

Both the stationary and swing jaw dies should be

checked periodically to make sure they are kept
tight within the crusher.

If swing jaw die is to be replaced with a new one,

use the same steps also described above to fasten
the hook or eye assembly to the top of jaw die.
Both the back of the jaw die and the mating surface
of the pitman must be clean and free of debris
before installation into crusher.

In addition to making sure the stationary jaw die

wedges are kept tight, the cheek plates must be
kept tight as well as described above in this
section. The wedge bolts should be checked daily
after a new die is installed due to the die stretching.
The swing jaw die wedge bolts have spring
washers installed to prevent the bolts from
breaking when the new die stretches. The bolts
should also be checked for tightness.

Swing Jaw Die Installation

1
1) Install chains or slings to swing jaw die using
the hook or eye assembly fastened to die.

2) With a suitable lifting device, lift jaw die into

crusher frame and lower it until the bottom of
the die slides over the bottom seating area of
the pitman.

3
1 - Wedge Block
2 - Retaining Bolt
3 - Spring Washers

3) Center the jaw die on the pitman.

4) Install the jaw die wedge block(s) and the
retaining bolts with spring washers through
the pitman and tighten to proper torque.
See (Figure 7 - 29)
5) Remove the hook or eye assembly fastened to
the jaw die.
6) Once jaw die is in place, remove the Lockout
& Tagout.

CRSH-OM-0003ENG(OCT-2014)

Figure 7 - 29 Typical Swing Jaw Die Retaining Bolt

Arrangement

Re-adjust Crusher Setting

Once all jaw dies and/or cheek plates have been

replaced or rotated and tightened, then crusher
closed side setting should be re-adjusted to the
desired setting.

7 - 36

Model CT-Series Jaw Crushers

Operation & Maintenance Manual

Toggle Plate

Toggle Plate

Toggle Plate Removal

The pitman is protected from damage by the toggle

plate. See (Figure 7 - 30) The toggle plate is
intended to bend or fracture if an uncrushable
object enters the crushing chamber, and thus opens
the chamber allowing the object to pass through. If
the toggle plate becomes damaged or wears out at
the seat areas, it will be necessary to replace it.

CAUTION
Caution should be used during the
following procedures and proper
personal protection equipment and
tools are to be used to ensure
personnel and equipment safety.
1) Lockout & Tagout crusher drive.

DANGER
Failure to Lockout & Tagout will
result in death or severe personal
injury.

DANGER
3

Care must be taken to stay clear of

inside of crusher as well as
underneath the crusher while
performing
toggle
plate
replacement as falling plate will
result in death or severe personal
injury.

1 - Tension Rod Spring

2 - Tension Rod
3 - Toggle Plate
Figure 7 - 30 Typical Jaw Tension Rod &Toggle Plate
Arrangement

2) Install chains or slings through toggle plate

and run up the back side of the pitman to
support toggle plate. See (Figure 7 - 31)
3) Loosen tension rod springs completely and
remove tension rods, springs and nuts from
machine.
4) Install chains or slings to pitman at the tension
rod connection point.
5) Move crusher adjustment wedges to
maximum possible open setting.

CRSH-OM-0003ENG(OCT-2014)

7 - 37

Model CT-Series Jaw Crushers

Operation & Maintenance Manual

Toggle Plate

Hold & Lower Toggle Plate

6) With a suitable lifting device, put slight

tension on chains or slings to hold toggle plate
in place.
7) With a suitable device, pull pitman forward
and hold in place until toggle plate can be
lowered free from seats.
8) Lower toggle out of frame of machine until it
can safely be handled and set aside.

Pull Pitman Forward

Figure 7 - 31 Toggle Plate Removal

CRSH-OM-0003ENG(OCT-2014)

7 - 38

Model CT-Series Jaw Crushers

Operation & Maintenance Manual

Toggle Plate

Toggle Plate Installation

CAUTION
Caution should be used during the
following procedures and proper
personal protection equipment and
tools are to be used to ensure
personnel and equipment safety.
1) Lockout & Tagout crusher drive.

DANGER
Failure to Lockout & Tagout will
result in death or severe personal
injury.

DANGER
Care must be taken to stay clear of
inside of crusher as well as
underneath the crusher while
performing
toggle
plate
replacement as falling plate will
result in death or severe personal
injury.

CRSH-OM-0003ENG(OCT-2014)

2) Maintain the installed chains or slings to

pitman at the tension rod connection point as
in the removal procedure.
3) Place new toggle plate in an area close enough
so it can be lifted up into machine frame.
4) Install chains or slings through toggle plate
and run up the back side of the pitman to
support toggle plate. See (Figure 7 - 31)
5) With a suitable lifting device, lift toggle plate
into place taking care it is completely engaged
into upper seat in the frame.
6) With toggle plate fitted into upper seat, slowly
release pitman and allow it to move backward
to engage toggle plate into the lower seat.
7) Remove chains or slings from tension rod
attachment points.
8) Install tension rods, springs and nuts back
onto machine.
9) Re-adjust crusher to desired closed side
setting and re-set tension rod spring tension.
10) Finally, finish by removing Lockout & Tagout
of crusher drive.

7 - 39

Model CT-Series Jaw Crushers

Operation & Maintenance Manual

Jaw Bearings

Jaw Bearings

Frame Bearing Removal

The jaw crusher is equipped with double row,

spherical roller, self-aligning bearings. Both
frame and pitman bearings are protected against
loss of lubricant and entrance of dirt, sand and grit
by labyrinth-type grease seals.

When bearings are determined to need

replacement, it is recommended to remove as
much of the lubricant from the bearing housings by
draining them while still warm from operation.
The following procedures should then be
followed:

12

11

10
7 8

CAUTION

9
16 17

15

Caution should be used during the

following procedures and proper
personal protection equipment and
tools are to be used to ensure
personnel and equipment safety.
1) Lockout & Tagout crusher drive.

DANGER

3
Failure to Lockout & Tagout will
result in death or severe personal
injury.

13
14

6
5

DANGER

123456789-

Flywheel/Drive Sheave
Outside Seal
Lock Nut
Lock Washer
Frame Bearing Housing
Crusher Frame
Frame Bearing
Withdrawl Sleeve
Frame Bearing Cover

1011121314151617-

Pitman Seal
Pitman Bearing Cover
Pitman Bearing
Grease Keeper
Pitman
Pitman Shaft
Ringfeder
Pitman Cover

Figure 7 - 32 Typical Jaw Bearing Arrangement

CRSH-OM-0003ENG(OCT-2014)

Care must be taken to stay clear of

inside of crusher as well as
underneath the crusher while
performing bearing replacement as
falling parts will result in death or
severe personal injury.
2) Mark the flywheel/drive sheave and pitman
shaft so it can be re-installed in the same
location.
3) Install appropriate lifting slings and use an
adequate lifting device to support flywheel/
drive sheave.

7 - 40

Model CT-Series Jaw Crushers

Operation & Maintenance Manual

Jaw Bearings

4) Remove pitman shaft cover and remove

ringfeder that retains flywheel/drive sheave to
pitman shaft. See (Figure 7 - 32)
5) Remove flywheel/drive sheave from shaft and
set aside.
6) Slide outside seal and key off of pitman shaft
and set aside.
7) Remove the frame bearing cover from the
frame bearing housing and set aside. This will
expose the bearing lock nut and lock washer
that retains the frame bearing to the pitman
shaft.
8) The pitman housing should now be supported
by an adequate method of blocking or lifting
so the pitman shaft will not drop or lower
during the next steps.

12) Using a spanner wrench or suitable special

tool, tighten the withdrawl nut against the
frame bearing to force the withdrawl sleeve
from between the pitman shaft and frame
bearing inner race. Remove the sleeve and nut
and set aside.
13) With adequate lifting device and slings to
support the frame bearing housing, slide the
bearing housing with the bearing out off of the
pitman shaft.
14) The frame bearing will now be able to be
removed from the housing.
15) Place the frame bearing housing on suitable
blocking and push bearing out of housing
using a press, dead blow hammer or other
appropriate driver. See (Figure 7 - 33)

9) Once the pitman is supported, remove the

bolts holding the frame bearing housing to the
crusher frame.
10) Straighten the lock washer tab(s) on the
bearing lock nut then remove the nut and
washer with a spanner wrench or suitable
special tool.
11) Install a withdrawl nut (not shown) onto the
withdrawl sleeve on the frame bearing.
Figure 7 - 33 Frame Bearing Removal From Housing

16) Clean and inspect all parts to replace as

necessary.

CRSH-OM-0003ENG(OCT-2014)

7 - 41

Model CT-Series Jaw Crushers

Operation & Maintenance Manual

Jaw Bearings

Frame Bearing Installation

Replacement with a new bearing requires

determining the bearings unmounted radial
internal clearance before installation.
See (Figure 7 - 34)
This clearance measurement should be taken and
recorded to be referenced later when setting
bearing final clearance after mounting in crusher.

Feeler Gauge Blade

Internal
Clearance

4) Install the withdrawl sleeve onto pitman shaft

and slide it into bearing inner race as far as
possible.
5) At this time, install the lock nut without the
lock washer and screw the nut up snug against
the withdrawl sleeve.
6) Using a spanner wrench or suitable special
tool, tighten the lock nut against the withdrawl
sleeve until the final bearing clearance
measurement is reached. See the following
tables for reduction in unmounted clearance as
well as the final mounted clearance listed by
machine model.
Table 7 - 3 Frame Bearing Reduction in Radial
Internal Clearance
Jaw
Model

Figure 7 - 34 Jaw Bearing Radial Internal Clearance

Measurement

1) After recording unmounted bearing radial

internal clearance described above, install
bearing into frame bearing housing.
2) With adequate lifting device and slings to
support the frame bearing housing, slide the
bearing housing with the bearing onto the
pitman shaft taking care that labyrinth seal
fingers are aligned and slide toghether with no
interference.
3) Bolt frame bearing housing securely to
crusher frame and tighten bolts.

CRSH-OM-0003ENG(OCT-2014)

7 - 42

Min.

Max.

mm

in.

mm

in.

CT1030

0.08

0.0031

0.11

0.0043

CT1040

0.08

0.0031

0.11

0.0043

CT1048

0.09

0.0035

0.13

0.0051

CT1252

0.10

0.0039

0.14

0.0055

CT2036

0.10

0.0039

0.14

0.0055

CT2436

0.11

0.0043

0.15

0.0059

CT2645

0.11

0.0043

0.15

0.0059

CT3042

0.15

0.0059

0.21

0.0083

NCT3042

0.12

0.0047

0.17

0.0067

CT3254

0.15

0.0059

0.21

0.0083

CT3648

0.17

0.0067

0.23

0.0091

CT4254

0.17

0.0067

0.23

0.0091

CT4763

0.21

0.0083

0.28

0.0110

CT6080

0.21

0.0083

0.28

0.0110

Model CT-Series Jaw Crushers

Operation & Maintenance Manual

Jaw Bearings

Table 7 - 4 Frame Bearing Allowable Final Mounted

Clearance
Jaw
Model

Min.

10) Install the frame bearing cover and tighten

bolts to secure it to the frame bearing housing.

Max.

mm

in.

mm

in.

CT1030

0.10

0.0040

0.18

0.0071

CT1040

0.10

0.0040

0.18

0.0071

CT1048

0.10

0.0040

0.20

0.0079

CT1252

0.12

0.0045

0.22

0.0087

CT2036

0.12

0.0045

0.22

0.0087

CT2436

0.13

0.0050

0.24

0.0094

CT2645

0.13

0.0050

0.24

0.0094

CT3042

0.17

0.0065

0.32

0.0126

NCT3042

0.14

0.0055

0.27

0.0106

CT3254

0.17

0.0065

0.32

0.0126

CT3648

0.19

0.0075

0.35

0.0138

CT4254

0.19

0.0075

0.35

0.0138

CT4763

0.23

0.0090

0.42

0.0165

CT6080

0.23

0.0090

0.42

0.0165

Example: Model CT1030

Unmounted clearance = 0.010 in.
Minus max. reduction = 0.0043 in.
Equals - 0.0057 in.
This falls within the min. of 0.0040 in. and
the max. of 0.0071 in.

9) Re-check the bearing mounted clearance again

to make sure the proper clearance was
maintained.

11) Install the outside seal and key onto the

pitman shaft making sure the labyrinth seal
fingers are aligned and slide together with no
interference.
12) Using appropriate lifting slings and an
adequate lifting device, re-install the flywheel/
drive sheave and ringfeder onto the pitman
shaft using the marks made during
disassembly.
13) Re-tighten the ringfeder to lock the flywheel/
drive sheave onto the pitman shaft.
14) Re-install the pitman cover on the end of the
shaft and tighten bolts.
15) Remove blocking or supports from under the
pitman used to hold it in place.
16) Replenish grease into the bearing and seals
using the appropriate quantity as described in
the tables in the Lubrication Section of this
manual.
17) Remove the Lockout & Tagout from the
crusher drive.
Crusher should now be ready to re-start.

6) Once the bearing clearance has been reached,

remove lock nut, install the lock washer and
lock nut back on shaft.
7) Re-tighten lock nut.
8) Bend a tab of the lock washer into one of the
slots in the lock nut.

CRSH-OM-0003ENG(OCT-2014)

7 - 43

Model CT-Series Jaw Crushers

Operation & Maintenance Manual

Jaw Bearings

Pitman Bearing Removal

To remove and replace pitman bearings it will be

necessary to remove the pitman and shaft
assembly from the crusher frame.
When bearings are determined to need
replacement, it is recommended to remove as
much of the lubricant from the bearing housings by
draining them while still warm from operation.
The following procedures should then be
followed:

CAUTION
Caution should be used during the
following procedures and proper
personal protection equipment and
tools are to be used to ensure
personnel and equipment safety.
1) Lockout & Tagout crusher drive.

DANGER
Failure to Lockout & Tagout will
result in death or severe personal
injury.

DANGER
Care must be taken to stay clear of
inside of crusher as well as
underneath the crusher while
performing bearing replacement as
falling parts will result in death or
severe personal injury.

CRSH-OM-0003ENG(OCT-2014)

2) Using the procedure shown earlier in this

section, remove the toggle plate from the
crusher.
3) Mark the flywheel/drive sheave and pitman
shaft so it can be re-installed in the same
location.
4) Install appropriate lifting slings and use an
adequate lifting device to support flywheel/
drive sheave.
5) Remove pitman shaft cover and remove
ringfeder that retains flywheel/drive sheave to
pitman shaft. See (Figure 7 - 32)
6) Remove flywheel/drive sheave from shaft and
set aside.
7) Slide outside seal and key off of pitman shaft
and set aside.
8) Repeat this for the opposite side flywheel/
drive sheave so that both sides have been
removed.
9) Install appropriate lifting slings and use an
adequate lifting device to support the entire
pitman and shaft assembly.
10) Once the pitman and shaft assembly is
supported, remove the bolts holding both side
frame bearing housings to the crusher frame.
11) Once the bolts are removed, lift the pitman
and shaft assembly from the crusher frame.
See (Figure 7 - 35)

7 - 44

Model CT-Series Jaw Crushers

Operation & Maintenance Manual

Jaw Bearings

16) Remove bolts from both pitman bearing

covers, remove covers and set aside. See
(Figure 7 - 37)

Figure 7 - 35 Pitman and Shaft Assembly Removal

From Crusher Frame

12) Lift pitman and shaft assembly and place it

onto cribbing or platform on the ground.
See (Figure 7 - 36)

Figure 7 - 37 Pitman Bearing Covers

17) Next, support pitman shaft at outer ends and

fasten slings from a suitable lifting device.
18) While supported, press shaft with bearings
through and out of the bore of the pitman
housing. See (Figure 7 - 38)

Figure 7 - 36 Pitman and Shaft Assembly Placed on

Ground

13) The frame bearings and housings will now be

able to be removed from the pitman shaft
using the procedure found earlier in this
section.
14) Once the frame bearings and housings are
removed from the shaft, proceed to the next
steps to remove the shaft with bearings from
the pitman housing.
15) Remove pitman seals from the shaft.
Figure 7 - 38 Pitman Shaft and Bearings Being Pressed
from Housing

CRSH-OM-0003ENG(OCT-2014)

7 - 45

Model CT-Series Jaw Crushers

Operation & Maintenance Manual

Jaw Bearings

19) Place shaft with bearings onto suitable

cribbing or platform supported at the outer
ends of the shaft. See (Figure 7 - 39)

Pitman Bearing Installation

Replacement with a new bearing requires

determining the bearings unmounted radial
internal clearance before installation.
See (Figure 7 - 41)
This clearance measurement should be taken and
recorded to be referenced later when checking
bearing final clearance after mounting in the
pitman housing.

Figure 7 - 39 Pitman Shaft and Bearings Removed from

Housing

Thoroughly clean the pitman housing, shaft and all

parts that are to be re-used.

20) Press or pull each bearing and grease keeper

from shaft while maintaining support on the
shaft. See (Figure 7 - 40)

Feeler Gauge Blade

Internal
Clearance

Figure 7 - 40 Pitman Shaft Bearings Being Pressed Off

Shaft

21) To fully remove each bearing and grease

keeper from the shaft, it will be necessary to
lift each end of the shaft from its support so
bearings and grease keepers can be slid off
shaft.

CRSH-OM-0003ENG(OCT-2014)

Figure 7 - 41 Jaw Bearing Radial Internal Clearance

Measurement

7 - 46

Model CT-Series Jaw Crushers

Operation & Maintenance Manual

Jaw Bearings

1) Lift and slide grease keepers onto shaft

making sure they seat fully against the
machined surfaces of the shaft.
See (Figure 7 - 42)

Figure 7 - 43 Pitman Shaft Bearings On Shaft

Figure 7 - 42 Pitman Shaft Grease Keepers On Shaft

2) Bearing installation onto the shaft will be

easier if they are first heated to expand
slightly. The bearings can be heated using
several methods. One method is using an oil
bath. Maximum temperature of the oil bath
should not exceed 120 C (250 F).

4) With adequate lifting device and slings lift the

shaft assembly and start the bearing into the
pitman housing bore, making sure it is square
with the face of the pitman housing.
5) Apply pressure on the shaft assembly and
press it into the pitman housing until each
bearing race is the same distance from the
edge of the pitman housing.
See (Figure 7 - 44)

NOTICE
Bearings should be allowed to heat
long enough to fully expand. Do
not allow bearings to come into
direct contact with the heat source.
3) With adequate lifting device and slings lift
each of the heated bearings into place against
the grease keepers and hold them firmly in
postition until they cool enough to seat on the
shaft. See (Figure 7 - 43)

Figure 7 - 44 Pitman Shaft and Bearings Pressed into

Housing

CRSH-OM-0003ENG(OCT-2014)

7 - 47

Model CT-Series Jaw Crushers

Operation & Maintenance Manual

Jaw Bearings

6) Measure each bearings internal installed

clearance to assure that the bearings have the
proper amount of clearance once installed.
See (Table 7 - 5)
Table 7 - 5 Pitman Bearing Radial Internal Installed
Clearance
Jaw
Model

Min.

7) Using the proper type grease shown in the

tables in the Lubrication Section of this
manual, inject grease into the voids between
the rollers in the bearing, making certain that
it is forced into the center of the bearing. Note
the amount of grease injected into each of the
pitman bearings.
8) Install each side pitman bearing cover and
torque bolts to proper torque.
See (Figure 7 - 45)

Max.

mm

in.

mm

in.

CT1030

0.20

0.0079

0.26

0.0102

CT1040

0.20

0.0079

0.26

0.0102

CT1048

0.20

0.0079

0.26

0.0102

CT1252

0.22

0.0087

0.29

0.0114

CT2036

0.24

0.0094

0.32

0.0126

CT2436

0.26

0.0102

0.35

0.0138

CT2645

0.26

0.0102

0.35

0.0138

CT3042

0.31

0.0122

0.41

0.0161

NCT3042

0.26

0.0102

0.35

0.0138

CT3254

0.31

0.0122

0.41

0.0161

CT3648

0.34

0.0134

0.45

0.0177

CT4254

0.37

0.0146

0.50

0.0197

9) Re-install pitman seals onto shaft.

CT4763

0.41

0.0161

0.55

0.0217

CT6080

0.44

0.0173

0.60

0.0236

10) Re-install frame bearings onto shaft using

procedures shown earlier in this section.

CRSH-OM-0003ENG(OCT-2014)

Figure 7 - 45 Pitman Bearing Covers Installed

7 - 48

Model CT-Series Jaw Crushers

Operation & Maintenance Manual

Jaw Bearings

11) Install appropriate lifting slings and use an

adequate lifting device to support the entire
pitman and shaft assembly.
12) Lift pitman and shaft assembly into crusher
frame, align frame bearing housings with
crusher frame and install bolts.
See (Figure 7 - 46)

13) Torque frame bearing housing bolts to proper

torque.
14) Reinstall each side flywheel/drive sheave
using the procedures shown earlier in this
section.
15) Reinstall toggle plate using the procedures
shown earlier in this section.
16) Once pitman and shaft is re-assembled into the
crusher, complete grease replenishment into
each pitman and frame bearing and seals using
the quantities listed in the tables in the
Lubrication Section of this manual. Take into
consideration also the amount of grease put
into each pitman bearing initially.
17) Remove the Lockout & Tagout from the
crusher drive.
Crusher should now be ready to re-start.

Figure 7 - 46 Pitman and Shaft Assembly Installed Into

Crusher Frame

CRSH-OM-0003ENG(OCT-2014)

7 - 49

Model CT-Series Jaw Crushers

Operation & Maintenance Manual

Jaw Bearings

CRSH-OM-0003ENG(OCT-2014)

7 - 50

Model CT-Series Jaw Crushers

Operation & Maintenance Manual

Torque Charts

Appendix A - Torque Specs

maximum torque values are based on 75% of the

specified minimum proof strength of the bolt steel
in order to provide a safety factor. The term "lube"
applies to cadmium plating and/or application of
thread lubricants. Hardened washers should
always be used, regardless of whether standard
nuts or lock nuts are employed.

Torque Charts
The following pages contain charts for use as
guides when tightening bolts and nuts. These
specifications should be followed unless specific
torques are given elsewhere in this manual.

Metric Bolt Torque

Standard Bolt Torque

Table A - 2 is a list of torque values recommended

for metric bolts. The maximum torque values are
based on 75% of the specified minimum proof
strength. The term "lube" includes the application
of thread lubricants, cadmium plating and the use
of hardened washers regardless of whether
standard or lock nuts are used.

Table A - 1 is a list of recommended torque values

for standard bolts. Use this torque chart to avoid
overstressing standard nuts and bolts used on
equipment. These specifications should be
followed unless specific torques are given. Trio
uses various bolts Grades 2, 5, and 8. The

CRSH-OM-0003ENG(OCT-2014)

A-1

Model CT-Series Jaw Crushers

Operation & Maintenance Manual

Torque Charts

Standard Bolt Torque Chart

S.A.E Grade 2
dia.
(in.)

Dry
pitch
(thd/in.) (ft-lbs) N-M

S.A.E Grade 5

Lube

Dry

S.A.E Grade 8

Lube

Dry

Lube

(ft-lbs)

N-M

(ft-lbs)

N-M

(ft-lbs)

N-M

(ft-lbs)

N-M

(ft-lbs)

N-M

1/4

20

11

12

16

12

1/4

28

10

14

14

19

11

15

5/16

18

11

15

12

17

23

13

18

25

34

19

26

5/16

24

12

16

10

14

19

26

15

20

27

37

21

28

3/8

16

20

27

15

20

31

42

24

33

44

60

34

46

3/8

24

23

31

17

23

35

47

27

37

49

66

38

52

7/16

14

32

43

25

34

49

66

38

52

70

95

54

73

7/16

20

36

49

27

37

55

75

42

57

78

106

60

81

1/2

13

49

66

38

52

75

102

58

79

106

144

82

111

1/2

20

55

75

42

57

85

115

65

88

120

163

92

125

9/16

12

70

95

54

73

109

148

84

114

154

209

118

160

9/16

18

79

107

60

81

121

164

93

126

171

232

132

179

5/8

11

97

132

75

102

150

203

115

156

212

287

163

221

5/8

18

110

149

85

115

170

231

131

178

240

325

185

251

3/4

10

157

213

121

164

266

361

205

278

376

510

289

392

3/4

16

180

244

133

180

297

403

229

311

420

570

323

438

7/8

210

285

160

217

430

583

330

447

606

822

466

632

7/8

14

230

312

177

240

473

641

364

494

668

906

514

697

320

434

240

325

644

873

495

671

909

1233

699

948

14

340

461

255

346

704

955

542

735

995

1349

765

1037

1-1/8

350

475

270

366

794

1077

611

829

1288

1747

990

1342

1-1/8

12

395

536

305

414

891

1208

685

929

1445

1959

1111

1507

1-1/4

495

671

380

515

1120

1519

862

1169

1817

2464

1398

1896

1-1/4

12

550

746

425

576

1241

1683

954

1294

2012

2728

1548

2099

1-3/8

655

888

500

678

1469

1992

1130

1532

2382

3230

1832

2484

1-3/8

12

745

1010

570

773

1673

2269

1287

1745

2712

3677

2086

2829

1-1/2

865

1173

665

902

1949

2643

1500

2034

3161

4286

2432

3298

1-1/2

12

975

1322

750

1017

2194

2975

1687

2288

3557

4823

2736

3710

1-3/4

1370

1857

1055

1430

2286

3100

1758

2384

4988

6764

3837

5203

4.5

2060

2793

1585

2149

3438

4662

2644

3585

7500

10170

5769

7823

2-1/4

4.5

3015

4088

2320

3146

5027

6817

3867

5244

10969 14874

8438

11442

2-1/2

4125

5593

3170

4298

6875

9323

5288

7171

15000 20340 11538 15646

2-3/4

5590

7579

4300

5830

9321

12639

7170

9723

17794 24129 13688 18561

7385

10013

5680

7701

12313 16696

9472

12844 23507 31875 18082 24519

Table A - 1: Torque Values for Standard Hardware

CRSH-OM-0003ENG(OCT-2014)

A-2

Model CT-Series Jaw Crushers

Operation & Maintenance Manual

Torque Charts

Metric Bolt Torque Chart

Property Class = 8.8
Dry
dia pitch
(mm) (mm) (ft-lbs) N-M

Property Class = 10.9

Lube

Dry

Property Class = 12.9

Lube

Dry

Lube

(ft-lbs)

N-M

(ft-lbs)

N-M

(ft-lbs)

N-M

(ft-lbs)

N-M

(ft-lbs)

N-M

6.9

9.3

5.2

9.7

13.2

7.3

9.9

11.6

15.7

8.7

11.8

17.7

23.9

13.3

18

24.9

33.8

18.7

25.4

29.8

40.4

22.4

30.4

10

1.5

30

41

24

32

44

60

34

46

52

71

40

54

10

1.25

32

43

24

33

46

63

36

49

55

74

42

57

12

1.75

53

72

41

55

77

105

60

81

91

123

70

95

12

1.25

58

78

44

60

85

115

65

88

99

134

76

103

14

85

115

65

88

124

168

95

129

145

196

111

151

14

1.5

91

124

70

95

134

181

103

139

156

212

120

163

16

131

178

101

137

192

260

148

200

225

305

173

234

16

1.5

140

190

108

146

204

277

157

213

240

325

184

250

18

2.50

181

246

139

189

265

359

204

276

311

421

239

324

18

1.5

204

276

156

212

297

403

229

310

349

473

268

364

20

2.5

256

347

197

267

374

507

288

390

439

595

338

458

20

1.5

284

385

218

296

415

563

319

433

487

660

375

508

22

2.5

349

473

268

364

510

692

392

532

599

812

460

624

22

1.5

383

519

294

399

560

759

431

584

657

891

505

685

24

443

600

340

461

647

877

497

674

759

1029

583

791

24

482

654

371

503

705

956

543

736

828

1122

637

863

27

648

879

499

676

949

1286

729

989

1112

1508

856

1160

27

700

949

538

730

1023

1387

787

1067

1200

1627

923

1252

30

985

1335

741

1004

1389

1883

1044

1416

1665

2257

1252

1697

36

1716

2326

1290

1749

2419

3280

1819

2466

2900

3931

2180

2956

42

2753

3732

2070

2806

3882

5263

2919

3957

4652

6307

3498

4742

48

4156

5634

3124

4236

5860

7944

4406

5973

7023

9521

5280

7159

56

6662

9032

5009

6791

9393

12735

7063

9575

11259 15264

8465

11477

64

9954

13496

7484

10147 14035 19028 10553 14307 16822 22807 12648 17148

72

14410 19536 10835 14689 20319 27547 15277 20712 24353 33016 18310 24824
Table A - 2: Torque Values for Metric Hardware

CRSH-OM-0003ENG(OCT-2014)

A-3

Model CT-Series Jaw Crushers

Operation & Maintenance Manual

Torque Charts

This Page Intentionally Left Blank

CRSH-OM-0003ENG(OCT-2014)

A-4

Model CT-Series Jaw Crushers

Operation & Maintenance Manual

General Belt Care

Appendix B - V-Belt Drive

Information

5) Do not overtighten belts. Overtightening

shortens the useful life of belts and sheaves.
This can also cause premature bearing
failures. Ideal belt tension is the lowest at
which belts wont slip under peak loads.

General Belt Care

V-belts achieve more service life if kept clean and
dry. Rock dust and rust from metals are abrasive.
Oils and acids deteriorate belt material. Dust and
moisture on belts can cause slippage. Dust buildup
in sheaves can cause harmful vibration.

6) Periodically inspect v-belt drives for wear on

belts or sheaves. See (Figure B - 1) and
(Figure B - 2) Replace worn sheaves.
Worn
Sheave

Belt dressing compounds are available and are

sometimes used for various reasons. While they
may be used, belt dressing may actually shorten
belt life. Clean, well cared for belts are the best
way to care for belt problems. Daily cleaning of
belts and sheaves by blowing them off with
compressed air can increase their useful life.

Worn Belt
or Sheave

Normal

Store un-used belts in a cool and dry environment

with no direct sunlight. Store on shelves or in
original containers. Do not allow belts to be bent
to diameters smaller that what is recommended for
the belt cross section.
Figure B - 1 Typical Belt & Sheave Wear

General Belt Recommendations

1) Keep belts and sheaves clean.
2) Avoid belt or sheave rubbing. Dont let belts
or sheaves rub against a guard (or anything
else) while they are running.
3) Drive belts with motors mounted on
adjustable bases. This allows convenient and
proper installation of belts without prying on
belts.
4) Keep belts properly tightened. Most belt
stretch occurs in the first 30-40 hours of
operation. Check belt tension frequently
during this period.

CRSH-OM-0003ENG(OCT-2014)

Figure B - 2 Sheave Gauge Shows Wear

B-1

Model CT-Series Jaw Crushers

Operation & Maintenance Manual

Belt Drive Troubleshooting

8) If a drive uses multiple belts, use only

matched belts. A matched set of belts last
longer and loading is evenly divided among
all the belts. Belts from different
manufacturers should not be mixed in a set
because material differences could reduce belt
life. Always replace belts in full sets.

7) Keep belts straight. Dont allow v-belts to run

out of alignment. To run properly, sheaves
must be parallel and grooves must be in line.
See (Figure B - 3)

9) Dont overload belts. If the drive has 10

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

Belt Drive Troubleshooting

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

CRSH-OM-0003ENG(OCT-2014)

B-2

Model CT-Series Jaw Crushers

Operation & Maintenance Manual

Belt Drive Troubleshooting

Table B - 1 Belt Drive Troubleshooting

Trouble

Cause

Correction

Belt Slip (sidewalls glazed)

Insufficient tension

Replace belts; increase tension

Drive squeals

Overloaded drive
Arc of contact too short
Heavy starting load

Find cause and correct

Increase distance between hubs
Increase tension

Broken cord caused by prying

Overloaded drive
Impulse loads

Replace belt correctly

Redesign drive
Apply proper tension

Misalignment
Worn sheave grooves
Flat idler sheave

Realign drive
Replace sheave
Align and reposition

Excessive vibration

Check drive design, mounting

Consider banded belts

New belts installed with old

Replace belts with matched set

Sheave grooves worn unevenly

Improper groove angle

Replace sheaves

Shafts not parallel

Align drive

Shock loads

Apply proper tension

Heavy starting load

Apply proper tension

Use compensator starting

Belt pried over sheaves

Foreign object in drive

Replace belt correctly

Determine source of object,
design guard to correct problem

Sheave grooves worn

Sheave diameter too small
Mismatched belts
Drive overloaded
Belt slips
Sheaves misaligned
Oil present
Excessive heat present

Replace sheaves
Redesign drive
Replace with matched set
Redesign drive
Increase tension
Align sheaves
Eliminate oil
Ventilate drive

Belts roll over

Mismatched belts

Belt breaks

Belt wears prematurely

CRSH-OM-0003ENG(OCT-2014)

B-3

Model CT-Series Jaw Crushers

Operation & Maintenance Manual

Maintaining V-Belt Tension

Maintaining V-Belt Tension

1/64 inch per each inch of span length.

Example:
For a 100 inch span, the deflection would be
100/64, or approximately 1-1/2 inches.

V-belt tension must be maintained to provide

proper drive effectiveness. The following method
of tensioning v-belts has been established as an
acceptable and preferred method.

4) Compare the force measurement to the

recommended ranges shown in (Table B - 2)
below for the appropriate belt cross section
type shown in.

Tension-Deflection Method

1) Place a straightedge across the top of both

sheaves. See (Figure B - 4)

5) Tighten or loosen belt to bring it into the

recommended range.

2) Measure the span length.

6) When installing new belts, tighten them to

Initial Installation tension. This tension will
drop during the run-in period.

3) Using a spring scale at right angle to belt at

1/2 of span length, apply a force to the scale
on one of the belts enough to deflect the belt

1
2
3

7
9

8
6

1 - Straightedge

5 - Motor Drive Sheave

2 - Span Length

6 - V-belt

3 - 1/2 Span

7 - Spring Scale

4 - Deflection Measurement - 1/64 Inch for each

Inch of Span Length

8 - Force Measurement
9 - Driven Sheave

Figure B - 4 Tension-Deflection Diagram

CRSH-OM-0003ENG(OCT-2014)

B-4

Model CT-Series Jaw Crushers

Operation & Maintenance Manual

Maintaining V-Belt Tension

Table B - 2 Belt Deflection Forces

Recommended Belt Deflection Force (Pounds)
V-Belt
Cross
Section

Smallest Sheave
Diameter Range
(Inches)

Initial
Installation

- 3.0
3.1 - 4.0
4.1 - 5.0
5.1 -

Retensioning
Maximum

Minimum

3.6
4.2
5.2
6.1

3.1
3.6
4.6
5.3

2.4
2.8
3.5
4.1

- 4.6
4.7 - 5.6
5.7 - 7.0
7.1 -

7.3
8.7
9.3
10.0

6.4
7.5
8.1
8.8

4.9
5.8
6.2
6.8

- 7.0
7.1 - 9.0
9.1 - 12.0
12.1 -

12.5
15.0
18.0
19.5

10.7
13.0
16.3
16.9

8.2
10.0
12.5
13.0

12.0 - 13.0
13.1 - 15.5
15.6 - 22.0

25.5*
30.0*
32.0*

22.1
26.0*
28.0*

17.0
20.0
21.5

18.0 - 22.0
22.1 -

45.0*
52.5*

39.0*
45.5*

30.0*
35.0*

AX

- 3.0
3.1 - 4.0
4.1 - 5.0
5.1 -

5.1
5.5
6.0
6.7

4.4
4.8
5.2
5.9

3.4
3.7
4.0
4.5

BX

- 4.6
4.7 - 5.6
5.7 - 7.0
7.1 - 12.0

10.0
11.0
11.5
10.1

8.7
9.5
9.9
7.8

6.7
7.3
7.6

CX

- 7.0
7.1 - 9.0
9.1 - 12.0
12.1 -

18.0
19.5
20.0
21.0

15.6
16.9
17.6
18.2

12.0
13.0
13.5
14.0

3V

2.65 - 3.35
3.65 - 4.50
4.75 - 6.0
6.5 - 10.6

4.6
5.5
6.4
7.3

4.0
4.8
5.6
6.4

3.1
3.7
4.3
4.9

5V

7.1 - 10.3
10.9 - 11.8
12.5 - 16.0

16.5
19.5
21.0

14.3
16.9
18.2

11.0
13.0
14.0

8V

12.5 - 16.0
17.0 - 20.0
21.2 - 24.4

39.0*
45.0*
51.0*

33.8*
39.0*
44.2*

26.0*
30.0*
34.0*

3VX

2.2 - 2.5
2.65 - 4.75
5.0 - 6.5
6.9 -

4.8
5.7
7.2
8.7

4.2
4.9
6.2
7.5

3.2
3.8
4.8
5.8

5VX

- 5.5
5.9 - 8.0
8.5 - 10.9
11.8 -

15.0
19.0
21.0
22.0

13.0
16.9
18.2
19.5

10.0
13.0
14.0
15.0

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

the number of belts in the band.
CRSH-OM-0003ENG(OCT-2014)

B-5

Model CT-Series Jaw Crushers

Operation & Maintenance Manual

Belt Type Cross-Sections

Belt Type Cross-Sections

Backside Idler

A backside idler increases the arc of contact on

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

Figure B - 5 Belt Type Cross-Sections

Figure B - 7 Backside Idler

Belt Idlers

Kiss Idler

A properly designed v-belt drive does not require

and idler to deliver full horsepower if proper belt
tension can be maintained. Idlers should be
avoided if possible because it puts additional
bending stress points on the belt. Due to drive
design parameters, idlers are sometimes used. The
following are general descriptions of the types of
idlers that may be used.

A kiss idler differs from the backside idler because

the kiss idler does not penetrate the belt span and
create a backward bend on the belt. A kiss idler
does not contribute to premature belt failure. Use
of a kiss idler can help control belt vibration and
whip on drives subject to shock and pulsating
loads. If a kiss idler is used, the diameter should
be at least 1 - 1/2 times the diameter of the small
sheave.

Inside Idler

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

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

Figure B - 8 Kiss Idler

Figure B - 6 Inside Idler

CRSH-OM-0003ENG(OCT-2014)

B-6

Model CT-Series Jaw Crushers

Trio Engineered Products, Inc. 12823 Schabarum Ave. Irwindale, CA 91706 Telephone 626-851-3966 Fax 626-851-9526

CT Series 30 x42A
Jaw Crusher

Parts Manual

30 x 42

Size:
Serial Number:

CT3042-346-AU1078

2015.12.08
CT3042A Jaw Crusher Manual

Parts: Jaw Crusher(With Drive)

CT3042AJaw Crusher Manual

Parts List
Item

Part #

Description

QTY. STOCK CODE

CT3042A-AU1078

30"42" Jaw Crusher(With Drive)

C3042A.00

CT3042 Jaw Crusher Assembly

101711000

T7510-1

Fixed Jaw Die

301701053

T7510-6

Swing Jaw Die

301701058

C3042FHZ.3

Guard For Sheave

301711008

C3042FHZ.4

Guard For Flywheel

301711009

GB13575.2

V-Belt 25N 6980mm

424001185

NEP447T-6

Motor 150HP/460V/60HZ +5000m

421300032

GB5782-zn/M2090/GD8.8

Bolt M2090

401022055

GB93/20

Lock Washer 20

403015010

10

GB97.1/20

Washer 20

403020008

11

GB6170-zn/M20/GD8

Nut M20

402011006

12

CMS132A.2

Motor Mount

101750074

13

CT.APP.WEG.6

Hydraulic Unit

102000251

14

T7510P-2

Drive Sheave

101750013

15

T7510P-3

Bushing

101750014

16

GB5782-zn /M16220/GD8.8

Bolt M16220

401022090

17

GB93/16

Lock Washer 16

403015008

CT3042AJaw Crusher Manual

Parts: Tension Rod and Toggle Plate Assembly

Illustration
The following illustration identifies the essential parts comprising the tension rod and toggle
seat assembly.

CT3042A Jaw Crusher Manual

CT3042AJaw Crusher Manual

Parts List
Item

Part #

Description

QTY. STOCK CODE

41

T7510-15

Guard

101701070

42

GB5782-zn/M2465/GD8.8

Bolt For Guard

401022098

43

GB7244/24

Lock Washer For Guard

403005005

44

T7510-29

Tension Rod

101701084

45

GB6170-zn/M48/GD8

Nut For Tension Rod

402011016

46

GB56-zn/M48/GD8

Nut For Tension Rod

402009010

47

T7510-30A

Spring Keeper (Upper)

101701086

48

T7510-31

Spring

301701087

49

T7510-32A

Spring Keeper (Lower)

101701089

52

C3042A-1

Buffer (Upper)

101711002

53

T7510-34A

Buffer Retainer For Buffer (Upper)

101701093

54

GB70.1-zn/M2465/GD8.8

Bolt For Buffer (Upper)

405009056

55

T7510-35

Limit Plate

101701094

56

GB5782-zn/M1645/GD8.8

Bolt M1645

401022025

57

GB93/16

Lock Washer 16

403015008

58

T7510A-12

Rubber Dust Cover

101710004

59

T7510-14

Rubber Clamping For Rubber Dust Cover

101701069

60

GB5782-zn/M1030/GD8.8

Bolt For Rubber Dust Cover

401022143

61

GB93/10

Lock Washer For Rubber Dust Cover

403015005

62

T7510-38

Pin Shaft For Tension Rod

301701097

63

1380-49

Washer

301301146

64

GB91-zn/870

Split Cotter For Tension Rod

410011026

65

T7510-11B

Toggle Plate

101701066

102

T7510-36

Rubber Dust Apron

101701095

103

T7510-37

Clamping Plate For Rubber Dust Apron

101701096

104

GB93/10

Lock Washer For Rubber Dust Apron

403015005

105

GB5782-zn/M1030/GD8.8

Bolt For Rubber Dust Apron

401022143

106

C3042A.DE-1

Buffer (Lower)

101711003

107

T7510.6-2

Buffer Retainer For Buffer (Lower)

101701048

108

GB70.1-zn/M1025/GD8.8

Bolt M1025

405011006

CT3042AJaw Crusher Manual

Parts: Bearings and Eccentric Shaft Assembly

Illustration
The following illustrations identify the essential parts of the bearing and eccentric shaft assembly.

CT3042A Jaw Crusher Manual

Parts List
Item
12
13
14
15
16
17
18
19
20
21
22
23
24
25
69
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
(86)
99
100
101

Part #
T7510A.3
T7510.4A
T7510-16
GB1972/A80-2
GB6170-zn/M36/GD8
T7510A.5
GB5867/Z2-280355
T7510-20
GB32.1-zn/M3090/GD8.8
GB7244/30
GB343-zn
GB32.1-zn/M42165/GD10.9
JB/ZQ4335-86
GB343-zn
T7510-39B
T7510-9A
1380-27-R
1380-27-L
GB825-zn/M20
GB1152/M101
1380-33
GB1096/1635
GB288/23168CA/W33C3
T7510-17
T7510-49
T7510-18
GB288/23164 CAK/W33C3
GB6584/AH3164
1380-28A
1380-50
GB32.1-zn/M2065/GD10.9
GB7244/20
GB343-zn
1380-31
GB1096/1635
1380-30
C3254A.2-2RH
C3254A.2-2LH
1380-51

CT3042A Jaw Crusher Manual

Description
Flywheel Assembly
Wedge For Fixed Jaw Die
Washer For Fixed Jaw Wedge
Belleville Washer For Fixed Jaw Wedge
Nut For Fixed Jaw Wedge
Sheave Assembly
Locking Assembly Z2-280355
Shaft Cover
Bolt For Shaft Cover
Lock Washer For Shaft Cover
Steel Wire 3 L=800
Bolt For Bearing Housing
Washer 42
Steel Wire 5 L=1450
Pitman
Eccentric Shaft
Bearing Housing(RH)
Bearing Housing(LH)
Eyebolt M20
Grease Fitting M101
Grease Retainer
Key 1635
Pitman Bearing
Pitman Seal (Bearing Cover)
Shim 5867180.2
Middle Labyrinth Seal
Frame Bearing
Withdraw Sleeve
Bearing Housing Seal (RH)
Shim 5506800.2
Bolt M2065
Lock Washer 20
Steel Wire 3 L=1200
Outer Labyrinth Seal
Key 1635
Lock Washer For Round Nut
Round Lock Nut For Round Nut (RH)
Round Lock Nut For Round Nut (LH )
Bearing Housing Seal (LH)

Qty.

Stock Code

1
2
2
4
4
1
2
2
6
6
2
16
16
2
1
1
1
1
2
6
2
2
2
2
2
2
2
2
1
2
48
48
4
2
2
2
1
1
1

101710012
101701043
301701071
425004007
402011011
101710016
411002009
101701075
401012019
403005007
401014029
403023004
101701100
101701061
101301204
101301118
405031003
428001000
101301124
409001008
407003040
101701072
101701120
101701073
407003039
412001005
101301182
101301148
401014017
403005003
101301122
409001008
301301121
101314035
101314018
101301183

Parts: Jaw Dies and Cheek Plates

Illustration
The following illustrations identify the essential components comprising the jaw dies and cheek
plates.

CT3042AJaw Crusher Manual

Parts List
Item

Part #

Description

Qty.

Stock Code

T7510A.1

Frame

101710001

T7510-1

Fixed Jaw Die

301701053

T7510-2-L

Upper Cheek Plate(LH)

301701054

T7510-2-R

Upper Cheek Plate(RH)

301701123

1380-5

Bolt For Cheek Plate

301301084

T6090-53

Washer For Cheek Plate

301250123

GB1972/A63-2

Belleville Washer For Cheek Plate

16

425004005

GB6170-zn/M30/GD8

Nut For Cheek Plate

402011010

GB6172.1-zn/M30

Nut M30

402020003

T7510-3-L

Lower Cheek Plate(LH)

301701055

T7510-3-R

Lower Cheek Plate(RH)

301701124

10

C3042A.DE

Pitman Assembly

101711001

13

T7510.4A

Wedge For Fixed Jaw Die

101701043

14

T7510-16

Washer For Fixed Jaw Wedge

301701071

15

GB1972/A80-2

Belleville Washer For Swing Jaw Wedge

425004007

16

GB6170-zn/M36/GD8

Nut For Swing Jaw Wedge

402011011

70

T7510-6

Swing Jaw Die

301701058

T7510-5A-L

Wedge For Swing Jaw Die(LH)

301701057

T7510-5A-R

Wedge For Swing Jaw Die(RH)

301701125

72

T7510-7

Bolt For Swing Jaw Wedge

301701059

73

C1048-29

Washer For Swing Jaw Wedge

301101076

74

GB1972/A80-2

Belleville Washer For Fixed Jaw Wedge

16

425004007

75

GB6170-zn/M36/GD8

Nut For Fixed Jaw Wedge

402011011

76

T7510-4

Pitman Guard

101701056

77

GB5782-zn/M2480/GD8.8

Bolt For Pitman Guard

401022087

78

GB7244/24

Lock Washer For Pitman Guard

403005005

71

CT3042AJaw Crusher Manual

10

Parts: Lubrication
Illustration
The following illustration identifies the location of each grease fittings on the jaw crushers.

Parts List
Item

Part #

Description

Qty.

Stock Code

69

T7510-39B

Pitman

101701100

79

JB/ZQ4450/M201.5

Drain Plug M201.5

432250001

80

JB982/20

Washer

499001205

84

GB1152/M101

Grease Fitting M101

428001000

11

T7510A.7

Lubrication System

101710003

CT3042A Jaw Crusher Manual

11

Lubrication System

T7510A.7

Parts List
Item

Part #

Description

Qty.

Stock Code

T7510A.7

Lubrication System

101710003

1380.7.1

Connector

101301071

GB9065.3/DN8/M161.5, L=1400mm

Hose DN8/M161.5, L=1400mm

426001017

GB9065.3/DN8/M161.5, L=1050mm

Hose DN8/M161.5, L=1050mm

426001009

JB984/M141.5/161.5

Connector M141.5/161.5

427420000

GB3452.1/ 8x1.8

O Ring

413003072

1380.7-3A

Distributor

101301179

GB1152/M101

Grease Fitting M101

428001000

GB5783-zn/M1280/GD8.8

Bolt M1280

401034092

GB93/12

Lock Washer 12

403015006

CT3042AJaw Crusher Manual

12

Appendix A: Discharge Setting Adjusting Procedure

CT3042A Jaw Crusher Manual

13

Parts List
Item

Part #

Description

Qty.

Stock Code

16

GB6170-zn/M36/GD8

Nut M36

402011011

26

T7510-27

Rear Wedge For Discharge Adjustment

101701082

27

T7510-28

Front Wedge For Discharge Adjustment

101701083

28

GB5782-zn/M2495/GD8.8

Bolt M2495

401022088

29

GB7244/24

Lock Washer 24

403005005

30

T7510-25

Guider (II)

101701080

31

GB5782-zn/M1645/GD8.8

Bolt M1645

12

401022025

32

GB7244/16

Lock Washer 16

12

403005002

33

T7510-13

Pin (I)

101701068

34

GB5867/Z2-90130

Locking Assembly Z2-90130

411002013

35

T7510-24

Washer

301701079

36

T7510-YYG-X

Hydraulic Cylinder 431+183

301710009

37

T7510-YYG-Z

Hydraulic Cylinder 416+167.5

301710010

38

T7510-23

Pin (II)

101701078

39

T7510-22

Guider (I)

101701077

50

T7510-21

Support Plate (I)

101701076

51

T7510-26

Support Plate (II)

101701081

CT3042A Jaw Crusher Manual

14

CT.APP-WEG.6

CT3042A Jaw Crusher Manual

Hydraulic Unit Parts

15

Parts List
ITEM

PART #

DESCRIPTION

QTY.

STOCK CODE

CT.APP.WEG.6

Hydraulic Unit

102000251

CT.APP 100

Valve Subassembly

102000027

CT.LM 010

Valve Base

102000107

6C-18LN/RN

Connector

427120139

CT.APP 200

Box

102000028

A-1416SC

Control Box

433050012

GB70.1-zn/M820/GD8.8

Bolt M820

405009003

GB93/8

Lock Washer 8

403015004

GB97.1/8

Washer 8

403020002

PT-7

Fitting

437001392

10

GB70.1-zn/M865/GD8.8

Bolt M865

405009082

11

SD5/1-P(KG-3)/28LAET

Valve

434001143

12

RSO-31TN/36M4-1000

Hose

437001389

13

Y-60ZT

Pressure Gauge

434005024

14

1CB-18-06WD/RN

Connector

427120177

15

1CM-18WD/RN

Connector

427070011

16

CT.APP 500

Hose

102000163

17

CT.APP 600

Hose

102000164

18

CT.APP 700

Hose

102000165

19

5B-06-04WD

Connector

480001506

20

CT.APP 300A

Tank Cover Assembly

102000188

21

GB70.1-zn/M825/GD8.8

Bolt M825

405009070

22

GB93-zn/8

Lock Washer 8

403014002

23

GB97.1/8

Washer 8

403020002

24

CT.APP 001

Seal For Tank Cover

102000031

25

CT.APP 400

Tank

102000032

26

GB70.1-zn/M1225/GD8.8

Bolt M1225

405009080

27

GB97.1/12

Washer 12

403020004

28

W21-100L-4

Motor 3kW/WV/BT5/IE2

421150060

QTY.

STOCK CODE

ITEM

PART #

DESCRIPTION

29

CT.APP.PP.1

Hose

102000045

30

CT.APP.PP.2

Hose

102000046

CT3042A Jaw Crusher Manual

16

CT3042A Jaw Crusher Manual

17

Parts List
ITEM

PART #

DESCRIPTION

QTY.

STOCK CODE

CT.APP 300A

Tank Cover Assembly

102000188

CT. APP 310

Cover Assembly

102000036

RFA-4020LY

Filter

480002469

GB70.1-zn/M825/GD8.8

Bolt M825

405009070

VST-M272WD

Plug

427150013

GB5782-zn/M1260/GD8.8

Bolt 1260

401022012

GB93-zn/12

Lock Washer 12

403014004

GB97.1/12

Washer 12

403020004

CT.APP 301

Gasket

102000037

2MC-14-16WD

Connector

480001483

10

1C-16-22

Connector

427070101

11

2C9-22RN

Connecter

427070032

12

152CF

Steel Pipe

0.2m

480002593

13

CBWmb-F4.0-ALP

Pump

416005024

14

GB70.1-zn/M1030/GD8.8

Bolt M1030

405009007

15

GB97.1/10

Washer 10

403020003

16

1CM-18-14WD/RN

Connector

427070100

17

121.5CF

Steel Pipe

0.3m

480003075

18

1CM-18WD/RN

Connector

427070011

19

PAF2-0.02-0.75-20-F

Air Filter

480002470

20

BR250

Guard

422300263

21

CR24 2850/1230

Coupling

480002471

CT3042A Jaw Crusher Manual

18