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K-03 JAW CRUSHER OPERATION AND MAINTENANCE

MANUAL

EDITION: 2002/A

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1.0. IMPORTANT !

These Operating and Maintenance Instructions and Safety Regulations shall be

read and observed carefully prior to transport, installation, commissioning, maintenance
and servicing of the machine!

Authorised personnel only, who is familiar with the operating and maintenance
instructions and the appropriate instructions with regard to safety at work and accident
prevention, is allowed to use, maintain and repair the machine.

The manufacturer NA-CE MACHINERY Co. herewith declares, that the new
machine as described in the following is in compliance with the regulations of the
Machinery Safety 05/06/2002-official gazette : 24776 and thus complies also with the
Machinery Directive 98/37/EEC in its applicable version.

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1.1. Preamble
NA-CE Machinery Industry Co. thanks you for the confidence that you have
placed in NA-CE with the purchase of this equipment.

The information given to you with these operating and maintenance instructions
shall direct the user’s attention to design, construction and functioning of the JAW CRUSHER
K-03 and impart all knowledge necessary for a successful application, use, trouble-free
operation, expert maintenance and correct purchase of spare parts.

The present “Operating and Maintenance Instructions” shall not cancel the current
national laws and accident prevention regulations.

Jaw crusher shall be used by expert and authorised personnel only and exclusively
for the purpose it had been designed and made for.

Additionally, start-up, operating and maintenance conditions (in accordance with

the operating and maintenance instructions) as specified by the manufacturer of the crusher
shall be strictly observed.

Furthermore, foreseeable wrong behaviour of personnel and the directions of the

relevant local safety regulations and laws shall be well considered too.

The crusher shall be operated and maintained by authorised persons only, who
have been registered in the equipment check list and are therefore familiar with the crusher
and know the risks and hazards very well.

Any other use of the crusher shall not be covered by the above-mentioned
instructions. The manufacturer of the crusher shall neither be made liable for defects nor
consequential defects and damage resulting from such use, nor shall he take over any
liability with regard to the Product Liability Act.

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10 Commandments of Safety

1. Support all efforts to keep the place of work safe and healthy.

2. Act and do everything with responsibility and utmost care if your safety and the
safety of others is at stake.

3. Regularly check all protection devices and tools for completeness and safe
functioning.

4. Inform yourself and others about the risks involved with the job so that such
risks can be prevented in the most effective way.

5. To avoid injuries and mechanical defects inform yourself about hazards and
safety measures if you feel not having enough knowledge on this subject.

6. Always bear dangers of injuries and accidents in mind before you begin with a
new work. Prepare well thought out safety precautions to protect yourself and
others. Revise such measures regularly and introduce necessary improvements.

7. Warn others of possible risks and defects if you see that they are working in a
very dangerous way or are about to cause dangerous situations.

8. Pay attention to changes in working conditions and working processes and act
accordingly.

9. Hazardous and risky behaviour, dangerous conditions and processes, which

could have caused accidents, must be reported to the management without
delay. Do not assume that somebody else will do this. Do not take drugs, pills
etc. and never drink alcohol when operating or maintaining the machine, or
prohibit consumption of drugs and alcohol during working hours.

10. Keep your place of work/area of work tidy. Tools and auxiliary means must be
collected after use and kept in a place especially provided for this purpose.

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Additional Safety Regulations

Inform operating personnel of the emergency numbers. The emergency numbers
must be made clearly visible close to the telephone.

Let the operating personnel attend a First Aid Course if they do not have such
knowledge.

In case of injuries to a person call for a doctor or other ambulance personnel at

once and take care of the injured person without delay.

All accident must be reported at once to the management.

Take off rings, bracelets, wristwatches, necklaces etc. before you start working at
the crusher.

For lifting heavy loads (above 25 kg) always use appropriate lifting devices.

Lift loads only out of the legs with stretched back.

Never stand under lifted loads and check all load raising devices for damage and
sufficient load-bearing capacities before each use.

Protect hair with a hairnet and avoid loose clothing when working at the machine
to avoid getting caught by rotating parts.

Always wear helmets for your own safety.

Depending on the crushing material noise level may reach an extent that will force
you to use ear-plugs.

Crushing material and operating conditions may create dusty environments, which
necessitate the use of protection masks.

Protect your eyes with safety glasses to avoid injuries

caused by dust and flying particles.

Always USE safety work-shoes and gloves to avoid injuries.

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Avoid deposition of material on or under the machine.

Unauthorised stay of persons within dangerous areas of the machine is strictly

forbidden.

Do not change or remove installations that ensure safety and avoid accidents.
Always keep them in a safe-to-operate condition.

Prior to each start-up the crusher personnel must make sure that no unauthorised
persons are within the dangerous areas of the machine.

Visually verify that all personnel and objects are clear of

equipment prior to operation.

Service and maintenance work are only allowed - and that without any exception -
when the machine is switched off and protected against unintended start-up (lock main
switch).

In case of defects which reduce the crusher’s safety, stop the machine at once
resp. switch it off and inform the management.

Careful and detailed instruction and training of the operating,

maintenance and repair personnel only as well as observation
and keeping of the safety regulations and working prescriptions
of the operating instructions ensure high availability of the
equipment with regard to trouble-free operation and economical
application.
Supplement the safety regulations of this operating instruction with
internal operating instructions based on national prescriptions, local
and national environmental laws, national accident prevention
regulations etc.

In this connection reference is made to the EC-Directive (89/655/EEC).

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1.2. Machine-specific Safety Instructions

Feeding and Crushing
Expert and skilled persons only with adequate training, who are familiar with the
operating instructions and dispose of sufficient experiences to operate the crusher are
authorised to do so. Such persons must be registered with their names in the list of
operators of the crusher and confirmed by signature.

Prior to start the crushing operation the following must be considered:

Starting the crusher despite of visible defects or other damage is strictly forbidden.

All safety installations must be correctly mounted and be in a ready-to-operate

condition.

The crusher itself must be free from crushing material to ease starting the crusher
drive.

Check both of jaws, liners and state of wear and tight seat.

For switching on the crusher wait until the material throughput shows no
obstructions and all operating personnel is well away from the plant.

Never start the crusher drive before all above-mentioned

conditions have been fulfilled.

Do not feed the material before the crusher’s driving motor has reached its
operating speed after start-up.

Within the working area of the feeding equipment (excavator,

loader) there is always an acute hazard due to falling material.

Any stay within this area of hazard during material loading by the feeding
equipment is strictly forbidden.

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Always wear suitable protection clothing (safety gloves, safety shoes etc.) to avoid
injuries. Make sure that iron pieces or other unbreakable material are not loaded into the
crusher.

Material only which is specified shall be fed into the crusher to enable the crusher
to achieve the indicated throughput capacity.

Should it be the cases that oversize material pieces get stuck in the inlet itself use
a suitable lifting device to remove them, with stopped crusher drive.

Never try to:

• Push material pieces got stuck in the inlet into the crushing chamber by using
rods or similar.

• Blast material pieces got stuck in the inlet.

The crushing process must be permanently watched to avoid critical situations

even before they probably occur.

Do not pass beneath the machine.

Prior to stop the crusher, run it until all the material is broken and discharged from
the machine.

Permanent observation leads to a continuous flow of material, which favourably

influences the throughput capacity.

Dangers in case of material clogging and material flow irregularities

Elimination of irregularities in the material flow and in particular, removal of

clogged material will often lead to risky situations.

Having eliminated the malfunction re-mount all safety installations and check them
again for proper functioning and operation reliability.

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Electrical Equipment

NA-CE-authorised personnel only are allowed to perform repair work at

the electrical equipment.

Expert personnel of a licensed company only are allowed to work on the

electrical equipment of the machine.

Carefully check whether the crusher has been earthed in accordance

with the local provisions.

Welding repairs at the crusher without adequate safety precautions will damage
the electrical equipment.

Emergency-Off
The machine may only be operated with an emergency off device.

Determine the cause of the malfunction at once and initiate corrective actions.

In case of art EMERGENCY-OFF unbroken material may remain in the crusher,

which could block the crusher’s drive at a new start.

Make sure that such material is reliably removed from the crusher.

Never use the EMERGENCY-OFFS for a normal stop of the crusher. Check these
EMERGENCY-OFFS regularly for proper functioning.

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Maintenance and Servicing

lndicated lubrication and oil changing intervals must be kept.

Maintenance and servicing jobs at the crusher must only be carried out during
standstill of all drives.

Make sure to prevent unintended starting of the crusher (e.g. blocking the main
switch).

Never use any other lubricants than those recommended by NA-CE.

Never mix up lubricants based on different substances (e.g. lithium-soaped grease

with calcium-soaped grease) because otherwise this could considerably damage bearings and
scaling under certain circumstances.

After completion of maintenance and repair work re-mount all available safety
installation and check them again for proper functioning and operation reliability.

Hazardous Material Disposal

Waste oil, waste grease, cleansing liquids, remnants of paints etc. must be
disposed of in an expert way and in accordance with the relevant national environmental
laws that are generally applicable.

Welding repairs
Welding repairs on NA-CE - CRUSHER must only be done after consultation of NA-
CE MACHINERY Co.!!

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Hydraulic Equipment
Do not dismount any connection when hydraulic equipment is under pressure.

Do not handle or repair hydraulic equipment with wasted hands.

Always take care of clean conditions when repairing the hydraulic equipment.
Close all openings immediately with plugs.

Refill new hydraulic oil through undamaged filter only.

Damaged pipes, filters, hoses and so on must be replaced at once.

The crusher’s own hydraulic control unit supplies all hydraulic cylinders with the
necessary pressure. Actuation is done with hand valve.

1.3. Warning Paint, Lettering and Warning Signs

Nameplates and warning signs must never be removed or painted over.

Illegible and defective nameplates and warning signs must be replaced at once by
identical new ones. Nameplates may be obtained from NA-CE Machinery Industry/TURKIYE.

1.4. Faulty Delivery

For damage in transit and missing goods the responsibility will rest with the
forwarding agent. All dispatched items shall be examined exactly at arrival and be compared
with the enclosed packing list. Any deviation from the should-be condition (such as damage,
missing parts etc.) must be made known to the forwarding agent at once.

In case of complaints please always inform NA-CE Machinery Industry to allow

them to carry out subsequent checks, (if necessary).

Bearings and labyrinths are completely filled with grease.

2.0. GENERAL INFORMATION

2.1. General Description of Crusher
2.1.1. Components

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The jaw crusher consists of two parts. The Base Assembly, and the Shaft and
Pitman Assembly. The Base Assembly consists of the crusher base, stationary jaw, liners, and
adjusting mechanism. The Shaft and Pitman Assembly is composed of the moving parts of
the crusher; that is, the eccentric shaft, pitman, movable jaw, side and pitman bearings, side
bearing housings, all bearing seals and spacers, and the two flywheels.

2.1.2. Operating Principle

Rock is crushed between the stationary jaw, which is wedged in placed in the base
by the liners, and the movable jaw, which is attached to the pitman. The pitman is mounted
on roller bearings on the eccentric portion of the crusher shaft. The concentric ends of which
are mounted in housed roller bearings rigidly attached to the crusher base. The lower end of
the pitman is hinged on one end of the toggle plate; the other end of the toggle plate
oscillates in a groove in the toggle bearing wedge, which is attached to the crusher base.

The replaceable cast iron toggle plate also serves as a fuse of safety device in the
crusher, as it will break when uncrushable material such as a shovel tooth passes between
the jaws. Due to the eccentric shaft and toggle plate, a combination crushing and downward
motion is imparted to the pitman and movable jaw as the shaft is revolved. The horizontal
length of the crushing motion gradually diminishes between the top and the bottom of the
movable jaw, producing a long primary crushing stroke at the top of the jaw and a short
stroke for crushing to a more uniform size at the bottom.

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2.2. Jaw Crusher Size

Jaw crusher size refers to the

opening at the top of the crusher. This
opening is rectangular and is measured from
the top of the movable jaw (A) to top of
stationary jaw (B), and from side liners (C) to
opposite side liners. Size is given in four digits
with the first two digits given in millimetres of
the distance between (A) and (B). The last
two digits is distance between (C) and (D).

2.2. Jaw Crusher Size

Right and left side of crusher are determined when standing facing the tension
springs. See figure above.

2.3. Lifting Crusher

To lift crusher, always fasten chain or cable to crusher base. Never lift complete
crusher with cables attached to flywheel or pitman. If only pitman, shaft and bearing
assembly is to be removed from crusher base, fasten chain or cable to lifting lugs provided
on top of pitman housing.

F During lifting of loads take care that there are no persons

staying under suspended loads!

2.4. Direction of Rotation

The overhead eccentric force feed jaw crushers are designed to have the shaft
assembly with flywheel rotate downward and toward the crushing chamber. In other words,

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standing on the left side of the crusher the flywheels will be rotating in a counter clockwise
direction.
Right and left hand are determined when facing the tension springs.

2.5. Speed of Crusher

The correct speed of the crusher will be stencilled on the crusher.
Correct speed is one of the basic requirements to obtain maximum capacities with
minimum of wear.
Always maintain speed of the crusher according to the factory recommendations.
Consult factory if speed is varied over 25 RPM. For example, reducing speed will change the
flywheel and counter-weight requirements. Such a change can create compaction in the
crusher and possible shaft and bearing failure.

2.6. Capacity of Crusher

The capacity is based on average condition and will vary widely with different
formations of rock and stone, uniformity of feed, and moisture content of material being
crushed. When using small discharge opening, scalp out fines as much as possible, to
prevent any compaction.

2.7. Size of Crushed Product

In general, the crusher discharge opening should be the same as the desired size
of the crushed product.

3.0. OPERATING INSTRUCTIONS

3.1. Care of The Crusher
To insure efficient operation of the crusher, it is recommended that the operator
inspect, lubricate, and make necessary adjustments and repairs at regular intervals. The
following outline for the operator tells what is to be done after a given period of operation.
Actual instructions for the care and servicing are referred to as follows.

3.1.1. During Operation

Throughout the daily operating period the operator should check for unusual
sounds or other signs of abnormal operation that warn of future trouble if not promptly
corrected.

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- Side and Pitman Bearings: Check crusher bearings for overheating. Do not
operate crusher if bearings overheat until the cause is determined and
corrected.
- Tension Spring: See that the tension spring is tight enough to keep the toggle
plate from clattering when the crusher is running empty. After changing the
crusher discharge opening or replacing the toggle plate listen for a clattering or
pounding noise, indicating the tension spring is too loose. Adjust tension
springs before resuming operation.
- Stationary Jaw: Observe the stationary jaw for slight up and down movement.
If such movement is visible, tighten the liners. If crusher is operated with loose
liners, the resulting movement of the stationary jaw will cause unnecessary
wear on the jaw and base as well as reduce the capacity of the crusher.

3.1.2. Every Week or 60 Hours of Operation

- Lubrication: Lubricate the toggle plate, tension rod threads and tension rod
pin.
- Bolts: Check and tighten all fastening and mounting bolts, cap screws and set
screws.
- Jaws: Inspect the stationary and movable jaw for wear. To maintain efficient
operation the jaws should be turned when the corrugations at the lower end
are worn almost smooth, or replaced after both ends are worn. The stationary
jaw will generally require turning or replacing more often than the movable
jaw.

CAUTION: Failure to turn or replace jaws when corrugations are worn smooth, or
until concave sections are worn in jaws will reduce the capacity of crusher. Also, jaw not
changed when recommended will cause compaction of material in crusher chamber which
will result in premature bearing failure, excessive breakage of toggle plates, and shaft and
base breakage.
- Liners: Inspect the key plates, especially the lower sections for wear. Replace
when worn through. Tighten both of the liners.
- Movable Jaw Wedge: Check and tighten the movable jaw wedge to prevent
the movable jaw from becoming loose and causing wear or damage to the
pitman.
- Toggle Plate: The toggle plate needs no care other than lubrication and
replacement when natural wear reduces the balls on both ends. When the balls
have worn 1-inch on each end or half the original ball, replace toggle plate

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before excessive wear occurs to toggle seat insert in pitman and the base
toggle seat. Be sure the toggle plate is located as centrally in position as
possible in relation to the toggle seat insert in the pitman.

3.1.3. Every Four Months or 1,000 Hours of Operation

- Lubrication: Change lubricant in the side and pitman bearings.

3.2. Crusher Support

When installing crusher in a stationary plant, place on concrete foundation. It is
permissible to use the wood skids as a cushion between the foundation and the crusher. Be
sure to build foundation with sufficient height so pitman does not hit any stationary
obstruction when at its lowest point. There must be ample clearance maintained between
crusher discharge and receiving conveyor for the material to discharge without rubbing end
of pitman.
The crusher must be perfectly level the length of the shaft to maintain even load
on all the bearings and proper distribution of grease in the bearings.

3.3. Starting and Stopping Crusher

3.3.1. Starting Crusher
At the beginning of a day’s run, especially in cold weather, start the crusher and
allow it to run slowly and empty a few minutes before crushing. If the crusher is very hard to
start in cold weather, change to lighter lubricant or dilute the grease in the crusher
NOTE: To aid in cold weather starting, direct the flame from a torch evenly over
the side bearing housings and pitman head to warm the lubricant before starting the
crusher. Then change to lighter lubricant.

3.3.2. Stopping Crusher

Stop the feed to the crusher and allow it to “run out”, that is, allow the material in
the crusher to be crushed before shutting off the power.
CAUTION: Avoid stopping the crusher when the jaws are full of material, because
restarting the loaded crusher produces an excessive load on the power unit and an extreme
pull on the belts. A plugged crusher or one full of material containing damp clay when
stopped should be at least partially emptied by hand before restarting.

3.4. Feeding Crusher

3.4.1. General
The most efficient operation of the crusher results when the crushing chamber is
kept full of material; that is, up to the level of the top of the jaws. Although feeding directly

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from a power shovel into the crusher hopper is not objectionable, providing a grizzly is used,
greater capacities are obtained when a more uniform method of feeding is used, such as a
mechanical feeder. When crushing material containing damp clay, the feed to the crusher
should be stopped occasionally and compacted clay scraped out of the jaw corrugations.

3.4.2. Size of Feed

The top of the crushing chamber measurements is the size of rock crusher is
capable of crushing. K03 crusher is capable of crushing rock 900 x 650 mm. However, the
problem of guiding a rock of that size into the chamber and preventing it from “bridging”
across the top of the jaws, thus delaying production and entailing considerable hand labour,
makes feeding of that size material impractical. Limit the size of feed to rocks measuring at
least 2 or3 inches smaller each way than the top opening of the crushing chamber. Oversize
material will bridge between the hopper and the pitman and cause crushing action to be
subjected to the back of the hopper and will shear the bolts holding the hopper to the
crusher base.
CAUTION: Do not dynamite in crusher chamber because it can cause premature
failure of bearings, and breakage of the pitman, eccentric shaft and base.

3.5. Crusher Discharge Opening

3.5.1. General
The crusher discharge opening governs the size of finished material produced by
the crusher.

3.5.2. Range of Crusher Discharge Opening

The size of the crusher discharge opening is changed by a hydraulic adjusting
mechanism and shims. The opening is reduced by moving the base toggle seat forward with
the hydraulic mechanism and shimming behind the seat.
The toggle plate, one end of which is seated at the bottom of the pitman and the
other in the base toggle seat, is pushed forward reducing the distance between the bottom
of the stationary jaw and movable jaw. Removing shims and allowing pressure from the
pitman to push the toggle seat back increases the size of discharge opening.

3.5.3. Adjusting Crusher Discharge Opening

It is advised to prepare a gauge or template for each jaw setting as shown in
figure below.

Jaw Opening Setting Template

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a) Settle the jaw opening to closed position by turning the flywheel.

b) Remove nuts and washers on the spring to loosen the spring.

c) Loosen the adjustment block key bolts and knock forward with a hammer to
loosen the adjustment block.

d) Loosen the adjustment bolt.

e) Push the adjustment block forward until the adjustment plates can be removed.

f) To obtain the required setting, move adjustment block backward or forward.

g) One must use the template defined above to obtain the desired jaw opening.
Position the template with the sharp edge in the groove of two teeth on the
fixed jaw, and the wide edge on top of the corresponding tooth on the swing
jaw.

h) Measure the distance between back of adjustment block and it’s seating. This
measurement is equal to the total thickness of adjustment plates required.

i) Select the adjustment plates totalling measurement taken, remove template

and move adjustment block forward to allow adjustment plate(s) to be fitted
then settle the plates.

j) Tighten adjustment bolts to move the adjustment block back on to shims.

k) Retighten the nut of drawback spring.

l) Retighten adjustment block key bolts.

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Parts of Jaw Settings

4.0. LUBRICATION
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4.1. Grease Lubrication-General

CAUTION: Never attempt to lubricate the crusher until flywheels are stopped and
drive is locked out.
General Lubricating Data: The greatest single factor governing the life and
efficiency of any piece of machinery, where friction is encountered, is proper and intelligent
lubrication. While it is generally known that insufficient lubrication will enable friction to
reduce the efficiency and service life of key parts, it is also true that the presence of too
large a quantity of grease in a bearing housing usually results in high operating temperatures
and subsequent loss of efficiency.
Cleanliness in the handling of lubricants, fittings, grease guns and the openings
and plugs of housings is of vital importance. Foreign substances contaminate lubricant.
Be sure that all fittings and openings are thoroughly cleaned of all foreign
substances before starting to inject lubricant.
Never mix different brands of lubricant within the crusher. Always drain and flush
out old lubricant before changing to different brand, as chemical break-down can occur in
lubricant mixtures.
Proper lubrication is an important factor in extending service life of the machine.
Lubricant equipment and grease fitting must be kept clean of grit to assure the longest
possible bearing life. Always wipe fittings grease gun nozzle before adding lubricant.
There is an electric motor under the grease tank. And lubricating is made
automatically.
Greasing nipples have been placed on the machine. Lubricating periods of some
lubricating points are described below.
a) Housings and Labyrinths:
Lubricate everyday from greasing nipples on both pitman and housings.
b) Drawback Complete:
Lubricating points of drawback complete will be lubricated as shown below.

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Recommended Lubricants:

a) Mild Climate (0°C - 32°C)

Shell : Alvania grease R3
Mobil Oil : Mobilplex 47
Castrol : Spheerol AP 3
b) Cold Climate (below 0°C)
Shell : Alvania grease R2
Mobil Oil : Mobilplex 47
Castrol : Spheerol AP 2
c) Hot Climate (above 32°C)
Shell : Alvania grease R3
Mobil Oil : Mobilplex 47
Castrol : Spheerol AP 3

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The grease of lithium base is strongly advised to use for bearings. Crusher has
been filled with Shell Alvania R3 after manufacturing. We strongly advise to use the same
grease if it’s possible.
It’s recommended to use spray/spread Molyb. Disulphide as a thin film lubrication
onto outer surface of bearings, inner surface of pitman and housings. We advise to use
‘ROCOL’ Anti-scuffing for this job that will be done before mounting. This condition is a
precaution in order to prevent wearing of housing. After that, 1/2 or 2/3 parts of housings
must be filled with one of the recommended greases. To be sure it’s clean, lubricate from all
greasing nipples. Clean excess grease.

CAUTION!
Do not over-lubricate. Too much lubricant will cause abnormally high
operating temperatures.

4.2. Detailed Bearing Lubrication

In each one of the side bearings use one of the recommended lubricants listed
below. Pitman bearings will use the same lubricant as side bearings.
Under normal conditions, it is recommended that grease be changed every 1000
hours of actual crushing or for every seasonal change, whichever occurs first. However,
lubricating inlets are provided to replace the lubricant that is expelled during normal
operation. Also, as the bearings and grease seals become worn, more lubricant will be
extruded from assembly. If the bearing is properly lubricated, a fresh film of grease will be
present around the edge of the inner and outer seals.
The reduction of temperature in the bearing will be slow because heat will
continue to exist until the internal pressure inside the housing forces out the excess
lubricant. If the crusher stops, back up the shaft assembly one-half a revolution too see if
foreign material has been expelled. Repeat process until shaft assembly turns over easily; if
the grease seals do not “break loose”, then a complete overhaul is the only solution.
When changing lubricant, drain only after the crusher has been run long enough
to heat the existing lubricant to a consistency that allows it to flow freely. Clean drain and
grease fittings and the area around the opening before removing the fittings. After draining
lubricant, replace cleaned drain plugs and inject a quantity of flushing oil in each bearing and
replace the grease fittings. Run the crusher empty for at least 10 minutes, stop unit and
remove drain plug on one side and inspect oil by allowing some to drain out into a small
receptacle. When the bearings have been sufficiently flushed, drain oil in both the bearings,
running crusher to expedite the draining. Thoroughly clean and replace the drain plugs and
inject a recommended grease (of proper grade for prevailing temperature) in each bearing.
Replace and tighten the grease fittings.

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NOTE: Too much caution cannot be exercised in cleaning dirt, stone dust, etc.,
from the area around the grease openings before removing drains and grease fitting caps.
Be absolutely certain that receptacle containing grease is kept clean. Do not allow it to be
used as a general purpose grease. Keep the cover on at all times when not actually in use.
When starting a new crusher for the first time, or after an overhaul, oil freely the
area between the pitman and side bearings where the grease seals revolve in the side
bearing housings. Apply oil until grease inside bearing begins to extrude from the grease
seals. This precautionary measure insures lubrication until the actual lubricating system
begins to function. A crusher which has been idle for a period of time and exposed to the
weather should receive the same consideration.
At the end of a season’s operation it is recommended that the lubricant be
drained, flushed and new lubricant be injected into the housing. The crusher should be
operated without load for approximately one hour to permit new lubricant to be evenly
distributed in the bearing assembly and housing. New lubricant in the housing would tend to
eliminate the possibility of corrosive reactions which might be evident if “worked” and
“oxidized” lubricant is allowed to remain in the housing when the crusher is not in use for
long periods of time.

5.0. MAINTENANCE INSTRUCTIONS

5.1. Side Liners
5.1.1. General
The side liners, hold the stationary jaw in place and, with the jaws, form the
crushing chamber of the crusher. These plates should be checked for tightness after every
period of approximately 100 hours of operation.
If crusher is left to operate with loose liners, stationary jaw will move, causing
excessive wear on the jaw and base as well as reducing the capacity of the crusher. The
liners must be driven down tight and the bolts be kept well tightened to hold the plates
firmly against the sides of the crusher and against the stationary jaw.

5.1.2. Disassembly of Liners From Crusher

Remove liner bolts and hook chain to upper bolt holes and other end of chain to
bucket of power shovel or similar equipment. Have operator of shovel put a steady pull on
the chain or cable, and then have someone strike the side of the key plate with a heavy
sledge to jar it loose. Set upper liner aside and use same procedure on lower liner. No
handles exist on these liners and it will be necessary to improvise a hook and eye assembly
to hook into the bolt hole.

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Liners are interchangeable and they can be used until they are nearly worn
through. They are only reversible. More wearing action takes place on the lower liners and
they will have to be changed oftener than the upper liners. Never allow wear to take place
on the side of the crusher; liners worn completely through, impede the flow of material
through the crusher discharge opening.
Caution should be taken during this disassembly operation so the liner will not
suddenly become loosened and spring into the air after being struck with a sledge.
If power equipment is not available to apply pressure on liner, a bar and fulcrum
assembly can be improvised to achieve the same results.

5.1.3. Reassembly of Liners To Crusher

Reverse disassembly procedure. Align stationary jaw in base so the root of the
corrugations match the crown of the corrugations in the movable jaw if a corrugated jaw is
used. Check for proper seating of jaw on the back of the base.
Install the bottom liners first, using a sledge and heavy bar to drive liner firmly
into place. Replace bolts and snug them up to keep liner from springing up when force is
applied in the tightening process. Drive on bar, holding opposite end of bar on top of liners,
changing the point of contact so the liners are tightened evenly along face of the jaw and in
the liner guide. Tighten both liners, drive on one liner and then on the other, so the tension
on the jaw is evenly distributed. When the plates are driven in very tightly, draw up the nuts
on the bolts and set the lock nut. Install upper liners, following same procedure as outlined
above.

5.1.4. Tightening Side Liners

Side liners may become loose, permitting the stationary jaw to move and cause
excessive wear to both jaw and base. Check liners every week by driving on side of plate
with sledge and unless they “ring solid” they should be tightened. If the stationary jaw
moves during the crushing operation, the key plates should be tightened. The following
method permits tightening of the lower liners without removing the upper plate.
Loosen the bolts on the upper liners until they are loose enough to allow the
plates to be lifted up. Raise upper liner about ½-inch and place a piece of steel plate or bar
between it and the lower liner. Loosen the lower liner bolts slightly until they are snug, but
not tight, and will allow the liner to be driven down. With a sledge and a bar drive on top of
upper liner until the lower liner is driven down very tight. Tighten the bolts on lower liner,
remove spacer between liners, drive upper liner down tightly, and tighten upper liner bolts.
The liner bolts should be tightened regularly as instructed.

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5.2. Stationary Jaw

5.2.1. General
The stationary jaw is locked in a rigid position against the back of the base by the
side liners. These jaws may be turned end for end to maximize wear.

5.2.2. Disassembly of Stationary Jaw From Crusher

Loosen and remove the side liners. Weld a U-bolt to the jaw face and run a hoist
chain through the bolt. Apply tension to the chain and swing the stationary jaw toward the
movable jaw. Lift the jaw out of the crushing chamber and set it on the ground with the
corrugations down.
NOTE: In order to remove the stationary jaw it will sometimes be necessary to
drive out the shims which are located between the top of the base and the jaw.
When replacing, turn the jaw over to equalize wear and weld the U-bolt to the
other end of the jaw.

5.2.3. Reassembly of Stationary Jaw To Crusher

Carefully clean the finished surface of the jaw before replacing it in the crushing
chamber.
Position the jaw with the worn end at the top of the crushing chamber. If a new
jaw is installed, it does not matter which end is at the top as the jaw is interchangeable end
for end.
After the jaw is positioned in the base, hoist the jaw slightly.

5.3. Movable Jaw

5.3.1. General
The movable jaw is held in a fixed position against the face of the pitman by the
movable jaw wedge. Most of the wear on the jaw plates is at the bottom where the setting is
the smallest, so the jaws are designed so they can be turned end to obtain the maximum
wear.

5.3.2. Disassembly of Movable Jaw From Crusher

Remove the movable jaw wedge
Insert a pointed bar in the tapped hole in the jaw and wedge the jaw forward.
Block securely. Hook a chain to an eye bolt screwed into the tapped hole in the end of the
jaw or run a standard bolt with a flat washer through a link in a chain. Lift the jaw out of the
crushing chamber and set it on the ground with the corrugations down.

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5.3.3. Reassembly of Movable Jaw To Crusher
Carefully clean the finished surface of the jaw before replacing it in the crushing
chamber. Clean the angular seat at the bottom of the pitman.
If rotating the jaw end for end, change the bolt to the other end of the jaw.
Replace the jaw in the crushing chamber.
Replace the movable jaw wedge and tighten the bolts as described.

5.4. Movable Jaw Wedge

5.4.1. General
The movable jaw wedge is a tapered wedge which holds the movable jaw firmly
against the face of the pitman by means of large bolts running through the holes cast in the
pitman.

5.4.2. Disassembly of Movable Jaw Wedge From Pitman

Remove the long machine bolts. Drive the wedge out of the pitman by inserting a
long 1-inch bar (2.54 cm) into the holes in the pitman from underneath and striking the bar.
Hold the wedge from falling into the crushing chamber by inserting two of the
long bolts into the wedge from the jaw side of the pitman. When the wedge is loose, remove
it from the pitman.

5.4.3. Replacing Movable Jaw Wedge

Clean the faces on the movable jaw and the movable jaw wedge. Line up the
holes in the wedge with the holes in the pitman. Insert the long machine bolts and draw
them up tightly.
With a heavy sledge, drive on the solid face of the movable jaw wedge, and at the
same time tighten up the nuts on the bolts. Drive along the wedge at points directly above
the bolts being tightened until all the bolts are tight and the wedge is firmly seated between
the pitman and the end of the movable jaw. Put on the lock nuts and draw them up tight.
After wedge is tight check between back of wedge and pitman face to make sure
there is no contact which would give a false tightness on movable jaw. If this condition
should exist install a shim between top of wedge and pitman.
After the crusher has operated under a load, loosen lock nuts and draw up bolts
as mentioned in paragraph above. KEEP THESE BOLTS TIGHT.

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5.5. Tension Springs And Rod

5.5.1. General
The tension springs together with tension rods and nuts hold the pitman firmly
against the toggle plate, maintaining proper seating of the toggle plate. There are two
tension rod assemblies on the crusher.

5.5.2. Disassembly of Tension Spring

Remove tension rod nuts by turning them in a counter clockwise direction.
Remove tension spring collar and slide off tension spring.

5.5.3. Disassembly of Tension Rods From Crusher

Remove tension rod nuts by turning in a clockwise direction, slide off tension
spring collars and tension springs.
Straighten cotter pin in tension rod yoke pins holding the tension rod yokes to the
pitman. Remove cotter pins and slide pins out of tension rod. Remove tension rod from
crusher.

5.5.4. Reassembly of Tension Springs And Rods

Reverse disassembly procedure. Tighten spring equally and until all clattering or
pounding noise is eliminated.

5.6. Hydraulic Adjusting System

5.6.1. General
The hydraulic mechanism is portable, and is used to change the position of the
pitman and base toggle seat.

5.6.2. Care of The Hydraulic Mechanism

The hydraulic system requires very little maintenance. Periodically inspect the
hoses for cracks or abrasions and replace if necessary. Regularly inspect hydraulic system for
leakage and tighten connections if necessary.
Fill the hydraulic pump with the recommended lubricant and bleed the lines of the
system to make the hydraulic mechanism work satisfactory.
CAUTION: Make sure the hydraulic pump pressure is released on the two base
toggle seat rams and pump after adjustment and before operating crusher. It is
recommended that hydraulic system be stored in a dry and clean area when not in use.

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5.7. Toggle Plate

5.7.1. General
The toggle plate is the oscillating link between the bottom of the pitman and the
base toggle seat. It serves as a fuse or safety device in the crusher and will break when
uncrushable material is encountered. With the eccentric shaft, toggle plate imparts a
combination crushing and downward motion to the pitman and movable jaw as the shaft is
revolved.

5.7.2. Disassembly of Toggle Plate From Crusher

Attach a cable or chain through the toggle plate holes and fasten the other end of
chain to crusher frame.
Loosen nuts on the tension rod to release all compression on tension springs.
Pitman must be free to push forward toward stationary jaw.
Also attach a cable or chain through the holes of drawback assemblies at the
bottom of pitman
Use a suitable equipment to pull pitman forward.
Bring down the toggle plate until it will be free.
It is taken out from top of the crusher.
Inspect toggle plate to see if it is deformed or worn, and replace with a new plate
if necessary.

5.7.3. Reassembly of Toggle Plate In Crusher

Before replacing toggle plate, inspect each end of toggle plate for wear. If balls on
ends of toggle plate are worn half the original diameter, replace toggle plate before excessive
wear occurs to toggle seat in pitman and the base toggle seat. Inspect the base toggle seat
and pitman seat for cracks and wear and replace, if necessary.
With the pitman pushed forward, coat toggle seats with grease.
Bring down toggle plate into crusher by a lifting device.
Guide rounded edge of toggle plate into seat in pitman toggle seat.
Slowly release pitman using chain or cable, until insert in pitman mates with lower
rounded edge of toggle plate.
Reassemble and tighten tension spring assembly.
Adjust crusher opening.
Make sure tension springs are tensioned to eliminate any clattering or pounding
noise when crusher is operating.

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5.8. Base Toggle Seat

5.8.1. General
The base toggle seat seats firmly against the adjusting shims. The base toggle
seat holds the toggle plate in position and is prevented from moving vertically.

5.8.2. Disassembly of Base Toggle Seat From Crusher

Dismount the toggle plate as described above.
Unscrew the bolts on the base toggle seat. Then screw the ring bolts.
Attach a lifting device to rings and support weight of base toggle seat.
Dismount the base toggle seat by lifting device.

5.8.3. Reassembly of Base Toggle Seat To Crusher

Use same chain method as in disassembly. Lift the toggle seat until it meets the
pads on the base. Replace bolts and remove chain assembly used to lift toggle seat.
Reassemble toggle plate to crusher.
Reassemble tension spring.
Adjust crusher discharge opening and tighten tensions springs.

5.9. Toggle Seat

5.9.1. General
The toggle seat located at the base of the pitman, is replaceable. Replace toggle
seat before the toggle plate starts wearing into the pitman. Also replace if cracked, or when
the wear is more pronounced on one end than the other. When replacing a toggle plate a
new toggle seat may be required to give full bearing across the toggle plate.

5.9.2. Disassembly of Toggle Seat From Pitman

Remove toggle plate.
Unscrew the bolts of connection between toggle seat and pitman.
Remove the toggle seat by lifting device.

5.9.3. Reassembly of Toggle Seat In Pitman

Remove any high spots on the new toggle seat by grinding or chipping so that
toggle seat lies solidly in the groove in the pitman.
Grease the toggle seat and the base toggle seat groove thoroughly before
installing new toggle plate.
Renew the toggle seat with opposite way of dismounting.

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5.10. Side and Pitman Bearings

5.10.1. General
The crusher is equipped with double row spherical roller, self-aligning bearings.
Both side and pitman bearings are protected against the loss of lubricant and the entrance of
sand and grit by labyrinth type grease seals. Sufficient grease is permitted to work through
the seals to prevent dust and grit from entering the bearing housings.

5.10.2. Checking Side and Pitman Bearings

The bearings normally operate at a temperature of 100°F to 150°F, but in warm
climates may operate at 180°F periodically running as high as 200°F. Under these conditions
and within these limits there is no cause for alarm. However, if a bearing maintains a
temperature of 212°F, or higher, it is considered as overheating and the cause should be
found and corrected to prevent damage.
A Fahrenheit thermometer provides the best method of checking bearing
temperatures. Remove fill plug and insert pencil type thermometer in lubricant in housing
and get actual reading. Readings for the side bearings can be taken on the bearing caps, and
the readings for the pitman bearings can be taken by removing the fill plug on the pitman
and inserting thermometer.
The bearing temperatures can be checked by placing the hand on the bearing
housing or pitman; if the hand can be held there for a few seconds, the bearing is not too
warm.
In the event the housing is too warm to be touched, pour several drops of water
on the bearing cap or pitman, selecting a spot from which the water will not run. If the water
does not rapidly boil and pass off as steam, the bearing is not too warm. If the water
steams, the temperature is greater than 212°F, and the bearing is overheating.
CAUTION: Never reduce bearing temperatures by artificial means, such as pouring
water on them as the sudden change in temperature is apt to warp, crack or crystallize some
part of the bearing assemblies.

5.10.3. Side and Pitman Bearing Heating Causes

The most common cause of overheating is too much lubricant and most generally
occurs when the crusher is new or immediately after lubricant has been changed. The
bearing will heat up and force out excessive lubricant until the proper amount is left and then
gradually cool down to the normal operating temperature.
The bearing will overheat if the crusher is operating faster than recommended
under full load. Check the speed with a speed indicator or by counting the movements of the
pitman and timing them with a watch.

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One of the pitman bearings may overheat if the unit is operated decidedly out of
level. An extremely unlevel position may result in one of the bearings not receiving its share
of lubricant and the bearing will begin to get hot.
The toggle plate may not be seating true in the toggle seats, throwing an
excessive load on one of the bearings and causing it to overheat. Inspect toggle plate and
toggle seat for uneven wear.
Overheating is also a sign that bearing failure is developing. Check the
overheating bearings for condition and wear by jacking up the flywheel end of the shaft at
the affected side bearing; or for a pitman bearing, by placing a pry between the back of the
base and the pitman head, at the overheated side, and raising the pitman, Observe the shaft
assembly during these operations. THE BEARING SHOULD NOT PERMIT PERCEPTIBLE UP
AND DOWN MOVEMENT. If movement is visible, bearing is excessively worn and should be
replaced.
Heat will result if there is insufficient radial clearance between the side bearing
end cap and the side bearing outer labyrinth seal. If these seals are touching at any point,
there apparently is a bearing failure or the housing has changed from its original position and
eliminated the radial clearances.
In case the housing has changed its position, with a heavy bar and sledge, strike
the base of the housing and jar it back into position to get the required radial clearances. To
force the housing out, place a wedge between the pitman and the housing and force it over
to get the proper radial clearances. When the radial clearances are the same or nearly so
completely around the seals, tighten the cap screws which hold the housings to the base.
Slowly turn the flywheels so a check of radial clearance can be made at all points.
Heat will continue to exist in the grease seals until these radial clearances are sufficient to
allow for the clearances in the bearing itself when the crushing force is applied to the pitman
assembly.

5.10.4. Disassembly of Side Bearings From Crusher

Drain lubricant from the housings preferably when it is hot and check for foreign
particles. If a quantity of steel or brass particles are in evidence the bearing undoubtedly has
failed and must be replaced.
Remove cotter pin on the locking nut.
Loosen locking nut, and remove washer.
If parts are to be used again, matchmark the parts as they are removed to be
sure of getting them in the same relationship and on the same side of crusher when
reassembled.
Remove flywheel from shaft with power shovel, jib crane or similar equipment.
Loosen bolts, and remove side bearing housing outer labyrinth.

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Loosen side bearing housing outer&inner covers bolts. Then, remove side bearing
housing outer cover.
Remove side bearing housing cap bolts, nipples and cap.
Place a wood wedge between the two jaws on the side from which the bearing is
to be removed in order to keep the pitman from moving forward. Place a jack under the end
of the shaft from which the bearing is being removed, and raise the eccentric shaft to free
bearing from the shaft.
CAUTION: Do not lift too high or damage to the opposite seal assembly may
result. A hydraulic jack placed beneath the pitman on the same side as the defective bearing
will also support the shaft assembly. Block pitman securely and remove lifting assembly.
Remove locking nut and locking washer. Then remove the side bearing.
After the side bearing has been removed from the shaft, remove the side bearing
housing inner cover.
Remove the side bearing housing inner labyrinth.
Clean labyrinths and bearing with cleaning solvent or white gasoline. Inspect for
imperfections, galled areas in the labyrinths, and scored areas in rollers and races of the
bearings. Replace all damaged parts.

5.10.5. Reassembly of Side Bearings To Crusher

NOTE: The following procedure is used to replace either right or left hand side
bearings, or both bearings.
Clean all parts, remove any imperfections in labyrinths and the housing.
Mount the parts with opposite way of dismounting.
Remove jack from under shaft and the wood wedges from between the jaws of
the crusher.
Tighten all the cap screws.
Clean the exposed end of eccentric shaft and flywheel base, coat with light
grease, raise the flywheel with a suitable hoist and slide into place on the crusher shaft.
Replace conical squeeze. Replace the shaft endcap and cap screws.
When starting a new crusher for the first time or after on overhaul, OIL FREELY
the areas between the pitman and the side bearings where the labyrinths revolve in the side
bearing housing. Apply oil until the grease inside the bearing begins to extrude from the
labyrinths. This precautionary measure insures lubrication until the actual lubricating system
begins to function.

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5.11. Dismounting of Shaft

Bearing renewal must be considered as a major maintenance operation. We
strongly advise that the services of a skilled engineer and an engineering workshop are
employed.
NOTE: Mark all parts when dismantling to ensure correct positions when re-fitting.

a) Remove to toggle plate is mentioned above.

b) Remove cotter pins, nuts and washers from shaft and slide the crusher
flywheels off the shaft with a suitable hoist.

c) Remove side bearing housing outer labyrinth.

d) Loosen side bearing housing outer&inner covers bolts. Then, remove side
bearing housing outer cover.

e) Remove side bearing housing cap bolts, nipples and cap.

f) Using suitable lifting equipment, the pitman assembly may now be lifted out of
the machine. Chains can be attached to the lifting parts over the machine.

g) Remove locking nut and locking washer. Then remove the side bearing.

h) After the side bearing has been removed from the shaft, remove the side
bearing housing inner cover.

i) Remove the side bearing housing inner labyrinth.

j) Remove pitman labyrinth.

k) Loosen pitman cover bolts.

l) Remove pitman cover.

Repeat these procedures for both sides of shaft. Then remove the shaft from
pitman bearings and pitman.
NOTE: If necessary renew the bearings otherwise do not attempt to remove them is
any way.

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5.12. Mounting New Bearings With Heating Method

After selection of suitable new bearing, it is necessary to heat through two hours
in the oil bath that almost 93°C. Use a clean thin oil for heating, which has inflammation
temperature is 20-30°C over the oil bath temperature. It’s recommended that keep the
bearing away from sides in the oil bath, by hanging with a clamp. This will prevent directly of
heating of bearing parts that touching to container. For heating and holding jobs, it’s
recommended that make a circle formed clamp. And attach the clamp over the bearing. Then
hang it up to crane hook by a spring.
This method provides necessary movement for placement. After heating enough
the bearings, take them out quickly. Then clean the oil on it, and mount it until it leans to
grease holder. Let the bearings get cold.
ATTENTION!
Bearing must be slided smoothly over the shaft. If not, it’s necessary to heat again
in oil bath. Trying to mount the unsuitable heated bearing onto shaft causes unsuitable
placement. This makes big difficulties to dismount.

5.13. Mounting of Shaft Complete

Place vertical the pitman into a suitable hollow. Then lift the shaft complete by a
winch. And place it towards down. This is the general method in order to mount the shaft
complete into pitman.
In order to clean the waste of paint and grease, wash all parts will be mounted by
a suitable solvent or gas. To wipe the shaft, use an oakum. Do not use waste of cotton cloth.

5.14. V-belt drive

5.14.1. Installation of V-belt drive

[Link] all oil, grease or rust from the pulley grooves.

[Link] certain that the pulleys are correctly aligned and that the shafts are
parallel.

[Link] force belts onto pulleys. Always shorten the centre distance until belts can
be slipped on easily.

To determine the minimum allowances for shortening or lengthening the centre

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distance between pulleys. See Table [Link]. “V-belt take-up allowances”.

Minimum allowances mm (inches) below centre distance for installation of belts

Min. allowance
above centre
Belt Length* V-belt section
dist. For stretch
and wear
8V 8V banded belts SPC
mm inch mm-----inch mm---------inch mm----------inch mm---------inch
2000-2749 79-108 40 1½ 85 3 3/8 35 1 3/8 40 1½
2750-3499 108-138 40 1½ 85 3 3/8 35 1 3/8 45 1¾
3500-4499 138-177 40 1½ 85 3 3/8 35 1 3/8 55 2 1/8
4500-5499 177-216 45 1¾ 90 3½ 35 1 3/8 65 2½
5500-6499 216-256 45 1¾ 90 3½ 40 1½ 85 3 3/8
6500-7999 256-315 45 1¾ 90 3½ 40 1½ 95 3½
8000-9999 315-394 50 - 100 - 45 1¾ 110 4 3/8
10000-over 394-over 50 - 100 - 45 1¾ 140 5½
*In each group the range is to, but not including the second length.
Table [Link]. “V-belt take-up allowances”

After calculating a centre distance from a standard pitch length make provision
that the centres can be moved closer together by the amount shown in the following table to
facilitate installing the belts without deterioration. Also, the centres should be adjustable over
the calculated distance by an amount as shown in last column the table because of
manufacturing tolerance and possible stretch and wear of belt.

4. Always use a matched set of belts and use new belts of the same manufacturer.
Never mix worn- belts.

5. Place belts on pulleys and run the drive for a few minutes. Then tension the
drive until only a sag appears on the slack side of the belts when the drive is running. An
example of tight side is shown in Figure [Link] below. The slack side depends on motor

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position and rotation direction.

Figure [Link]. Determining slack side

5.14.2. Tensioning the V-belt drive

Tensioning the drive is a term used when force is applied to the V-belt by some
method to provide the
Wedging action between the V-belt and the pulley. This wedging action provides
the ability for a V-belt to transmit power from motor pulley to the crusher pulley.

Various methods of tensioning V-belts have been established. Two simplified

method will be described in the following paragraphs. Tension-deflection and percent (%) of
elongation. Either of these two methods will provide satisfactory belt tension. Each has
certain advantages for a given type of belt.
For tensioning the drive using the TENSION-DEFLECTION method, proceed as
follows:

1. Place a straight edge across the top of both pulleys. See Figure [Link]
2. Measure the span length.
3. Using a spring scale at right angles to the centre of the span length, apply a
force to the scale great enough to deflect one of the belts the equivalent of 0.016 times
millimetres of span length (0.016 times inches of span length).
4. The force should approximate the forces shown in Table [Link]. “Flexion

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forces” for a properly tensioned drive.

Figure [Link]. Tension deflection method

EXAMPLE
V-belt section = Standard 8V belt

Span length (centre distance) 1575 mm (62”)

Deflection force (from table) = 15-22 Kg. (34-50 Lbs.)

Deflection = 1575 mm (62”) x 0.016 = 25 mm (1”)

Therefore, on a NEW installation with a standard 8V section belt and a span length
of 1575mm (62”), the belt should deflect 25 mm (1”) with a spring force of 15-22 Kg. (34-50
Lbs.) for a properly tensioned drive.
5. At the end of 2-4 hours of operation, the drive should be retensioned to
approximately the maximum force.
6. After 24-48 hours, it is well to check the drive to see if the force on the belts is
between the minimum and maximum force shown in table. Retension if necessary. Either
excessively low or high tension will affect the life and operation of a V-belt.

FWHEN PROPERLY TENSIONED A NARROW V-BELT MAY NOT FEEL

AS TIGHT AS ONE MIGHT FROM THE TENSION THEY CARRY. THEREFORE, IT IS
AD VISABLE TO USE A SPRING SCALE TO CHECK BELT TENSION ON THESE BELTS.

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STANDARD BELT BANDED BELT*

Minimum Tension Maximum Tension Minimum Tension Maximum Tension
Belt section
Kg Kg Kg Kg
(in Lbs.) (in Lbs.) (in Lbs.) (in Lbs.)

8V 15.4 (34) 22.7 (50) 18.1 (40) 272 (60)

SPC 10.4 (23) 15.4 (34) 11.8(26) 18.1 (40)

*Multiply these values by number of belts in band.

Table [Link]. “Flexion forces”

For tensioning the drive using the PERCENT (%) OF ELONGATION method,
proceed as follows. This particular method of tensioning V-belt drives was developed
primarily for tensioning banded belts.
1. Remove the slack from the belts.
2. Next, wrap a 15 meters (50 foot) steel tape around the outside circumference
of the belt and measure to nearest millimetre (1/16”). Record this length. See Figure [Link]
“Percent of elongation method”.

Figure [Link]. Percent of elongation method

3. Multiply this recorded length by a percent of elongation factor which is shown in

table [Link]. “ Elongation factors” and add this amount to the initial measurement.

4. Elongate the belt to this new reading.

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EXAMPLE
V-belt section = Standard 8V belt

Initial tape reading = 3 meters, 48 mm (120”)

Elongation factor (from table) = 0.009 (multiplier) which is 0.9% (percent)

New length reading = 3 meters, 48 mm (120”) initial reading x 0.009

elongation factor =

3 meters, 48mm (120”) + 27mm (1-1/16”) or 3 meters, 75mm (121-1/16”).

Belt Multiplier Percent (%)

Section*

8V 0.009 0.9
*Standard or banded belts
Table [Link]. Elongation factors

Therefore, on an installation with an 8V belt and an outside circumference

measurement of 3 meters, 48 mm (120”), the motor pulley should be moved away from the
crusher pulley until the steel tape reads 3 meters, 75 mm(121-1/ 16”) for a properly
tensioned drive.

5. Periodic belt tension checks must be made and if retensioning becomes

necessary, the tensioning process just described should be repeated.

It must be pointed out that the TENSION-DEFLECTION METHOD is the preferred

method of tensioning V-belts.

Usually the first sign that indicates retensioning is necessary is belt slippage. This
slippage will show up in loss of power and speed at the crusher pulley and in a high rate of
belt and pulley groove wear. These conditions are usually accompanied by belt “squeal” and
also a heating up of belts and pulleys. These conditions are readily apparent and can be
detected by simply looking, listening and feeling.

5.14.3. V-belt precaution

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

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DO DON’T
-Check belt tension
frequently during the first few days of -Over tighten belts as too
run-in operation. When the belts have much tension shortens both belt and
had time to become seated in the bearing life. Maintain uniform tension.
pulley groove, retension the belts. New Idle belts should appear tight; in
belts have a certain amount of initial motion, they have slight sag on the
stretch and will require additional slack side.
tensioning.

Keep drives well ventilated

as heat build-up over 600C (1400F)
causes belt life to become short. The Allow any oil or grease to
sides of the belt guard must be come in contact with the belts as
designed to allow for adequate excessive oil causes them to swell and
circulation of air. Either perforated the belts to fail prematurely.
plate or expanded metal is ideal for
this type of application.

Make V-belt drive general

inspections on a periodic basis. The
following points must be checked at
each inspection.
A. Loss of crusher
speed – check tension.
B. Unequal stretch –
check each belt.
C. Excessive
elongation - check for overload.
D. Belt softening or
swelling-check for oil or grease.
E. Belt hardening and
cracking – check for excessive heat.

DRIVE SAFETY GUARD

The drive guard protects the operator and the drive from accidental rock falls.
As the motor position is specific to each crusher installation: the guard is often
designed and produced specifically for each crushing station.

FOR THE SAFETY OF THE PERSONNEL THE DRIVE GUARD MUST BE

BUILDED IN COMPLIANCE WITH CURRENT SAFETY REGULATIONS FOR THE
SITE ON WHICH THE CRUSHER IS USED.
THE GUARD MUST BE IN POSITION WHEN THE CRUSHER IS OPERATING.

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LIST OF OPERATORS

Each operator of the crusher confirms by his signature that he has received, read
and understood these operating and maintenance instructions.
In case of non-observance the rights to claim under guarantee shall be lost and NA-
CE does not take over any liability with regard to the Product Liability Act.

NAME TAKEN OVER ON SIGNATURE

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MAIN DIMENSIONS
TYPE A B C D E F G H I J K L
K03 1970 2074 900 650 2210 1200 375 1180 1270 1685 1610 580

M N O P Q R S T U V W X Y
1884 300 1245 100 1122 1600 100 2870 3070 3780 3980 4030 400

TECHNICAL SPECIFICATIONS

INLET FLYWHEEL
MOTOR WEIGHT
TYPE OPENING SPEED
(kW) (rpm) (kg)
(mmxmm) (rpm)

K03 900x650 75 – 1000 293 11400

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Important Checks:
Check that jaws are not breathing. Jaw wedges must be kept tight during
operation. At the first sign of looseness, allow the jaws to clear, before stopping the crusher
and tightening the jaw wedge bolts.

Check that the drawback spring is correctly tensioned. i.e. to prevent chatter.

Check that the flywheel keys are secure.

Ensure that bearings are not overheating.

We do not need to explain importance of using and keeping all parts clean and
without dust and sand. After mounting, lubricate the housings until overflow.
Check all barriers and tightness of V-belt. Also check tightness of drawback spring
and tightly pressing onto adjustment plates of adjustment block. After 30 minutes light
running of the crusher, as described, retighten the bolts and load the crusher.

F Material-feeding mechanism must first be stopped, before

stopping the crusher.

6.0. FAULT FINDING

Fault Cause Remedy

Crusher does not start or Electrical system or crusher Have electrical system or crusher
stops. motor defective motor checked by a licensed
electrician

Crusher blocked by material Remove material from crushing

chamber

Ferrous pieces have entered the Remove ferrous parts from

crusher crushing chamber

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Fault Cause Remedy

Abnormal noise at crusher Defective bearings Have bearing replaced by expert

personnel

Loose jaws Fasten jaws

Loose wearing lining(s) Fasten wearing lining(s)

Vibrations at crusher Crusher clogged with material Clean crusher

Vee belt pulley clogged with Clean vee belt pulleys

material

Crusher bearings too hot Insufficient grease quantity Refill grease

Wrong grease quantity Fill in correct grease quality

Bearings defective Have bearings replaced by

expert personnel

Too much grease Reduce grease quantity

Labyrinth rings have become Tighten labyrinth rings

loose

Vee belt rupture after short Mounting by force Belt installation without using
time of operation (belt torn) force acc. to operating instr.

Foreign body effects Check protection device

Crusher drive is blocking Check reason and correct

Ruptures and cracks in belt Increased belt slip Re-tension drive

substructure
Chemical influences Check reason and correct

Strong vibration of vee belts Too less pre-tensioning Correct pre-tensioning

Belts cannot be re-tensioned Incorrect belt length Use shorter belts

anymore

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K03-000-00 JAW CRUSHER COMPLETE

K03-000-00

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NO DRAWING NO PART NAME QUA.

1 BASE
2 K03-200-00 ERECTION COMPLETE
3 K03-300-00 CHASSIS
4 K03-000-04 MOTOR PULLEY 1
5 K03-000-05 PITMAN 1
6 K03-000-06 MOVABLE JAW 1
7 K03-000-07 STATIONARY JAW 1
8 NUT 10
9 K03-000-09 STATIONARY JAW BOLT 5
10 WASHER 5
11 K03-000-11 SIDE LINERS
12 COUNTERSUNK HEAD BOLT 12
13 WASHER 12
14 BOLT, NUT 4
15 WASHER 4
16 K03-000-15 FLYWHEEL WEIGHT 2
17 V-BELT 12
18 K03-000-17 MOVABLE JAW BOLT 5
19 NUT, WASHER
20 K03-000-22 TOGGLE SEAT 2
21 K03-000-23 TOGGLE PLATE 1
22 K03-000-27 ADJUSTMENT BLOCK 1
23 NUT 2
24 WASHER 1
25 K03-000-46 SPRING PRESSING PART 1
26 K03-000-47 SPRING 1
27 K03-000-48 BALL SOCKET 1
28 K03-000-36 TIGHTENING BOLT 1
29 K03-000-39 PIN 1
30 COTTER PIN 1
31 WASHER 1
32 BOLT, NUT 8
33 WASHER 8
34 MOTOR 1
35 BOLT, NUT 4
36 WASHER 4
37 K03-000-54 BELT GUARD 1
38 K03-000-55 MOTOR GUARD 1

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K03-200-00

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K03-200-00 ERECTION COMPLETE

NO DRAWING NO PART NAME QUA.

1 BOLT 16
2 WASHER 2
3 COTTER PIN 2
4 K03-200-04 NUT 2
5 KEY 2
6 BOLT 8
7 K03-200-07 SIDE BEARING HOUSING COVER 2
8 NIPPLE 4
9 K03-200-09 SIDE BEARING HOUSING INNER LABYRINTH 2
10 PITMAN BEARING 2
11 K03-200-11 PITMAN COVER 2
12 K03-200-12 PITMAN LABYRINTH 2
13 K03-200-13 FLYWHEEL 2
14 LOCKING WASHER 2
15 K03-200-15 LOCKING NUT 2
16 K03-200-16 SIDE BEARING HOUSING OUTER LABYRINTH 2
17 SIDE BEARING 2
18 K03-200-18 SIDE BEARING HOUSING INNER COVER 2
19 K03-200-19 GREASE HOLDER 2
20 K03-200-20 SHAFT 1
21 BOLT 24

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NO DRAWING NO PART NAME QUA.

1 PISTON HEAD
2 ADJUSTMENT SHIMS
3 PISTON
4 BOLT
5 NUT
6 WASHER
7 PISTON CONNECTION PART
8 PIN
9 WASHER
10 COTTER PIN
11 ADJUSTMENT BOLT
12 NUT

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K03-000-11 SIDE LINERS

NO DRAWING NO PART NAME QUA.

1 LINER 2
2 LINER 2
3 LINER 2

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SPARE PART ORDER FORM

Please use the form when giving orders for your machine.

SPARE PART ORDER FORM ORDER NO :

NAME OF FIRM : ORDER DATE :

ADDRESS : DELIVERY DATE :
CONTACT PERSON:
DRAWING NO PART NAME QUANTITY PRICE TOTAL PRICE

CUSTOMER APPROVAL NA-CE SPARE PART MANAGER DISTRIBUTE

FORM NO: FYD.01 12/02/1999-03 DISTRIBUTION : [Link] Purchasıng [Link] Inventory [Link] Back to spare parts manager
, [Link] Spare Parts Manager

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