Operation & Maintenance Manual

JAW CRUSHERS Bolted Bearing Blocks Pull-Type Bearing Sleeves

A Terex Company 22783 (8/02)

A Terex Company

To the Owner & Operator: We have tried to provide information that gives our customers a clear understanding of equipment construction, function, capabilities and requirements. This information is based on the knowledge and experience of qualified people at our company and in our field organization. Proper use of this information rewards s 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. s will as a matter of course encounter problems and circumstances that raise questions not anticipated here. Such questions should be directed to their distributor or the factory. Anyone who uses this equipment for any purpose other than that for which it was intended assumes sole responsibility for dangers encountered and injuries sustained as a result of such misuse.

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

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

22783 (8/02)

Bolted Bearing Block/Pull-Type Sleeve Jaw Crushers

A Terex Company

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

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

22783 (8/02)


A Terex Company

22783 (8/02)


Table of Contents

Section 1 - Introduction About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 1

Section 2 - Safety General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 1 Decal Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 3 Personal Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 4 Lockout & Tagout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 5

Section 3 - General Jaw Crusher Information Crusher Description & Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 1 General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 2 Operating Principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 2 Crusher Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 2 Left/Right Side Designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 2 Crusher Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 3 Lifting Crusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 4 Direction of Flywheel Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 4 Crusher Drive Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 4 Maximum & Minimum Crusher Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 5 Capacity of Crusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 5 Crusher Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 6

Section 4 - Set-up & Operation Mounting & Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 1 Mounting Crusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 1 Mounting Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 1 Flywheel Counterweight Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 1 Guarding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 3 Prior To Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 3 Starting Crusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 3 Cold Weather Startup Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 3 During Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 4 Oil Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 4 Stopping Crusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 4 Feeding The Crusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 5 Material Feed Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 5 Clay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 5 Adjusting Closed Side Setting (CSS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 6

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Table of Contents

Section 5 - Lubrication & Maintenance General Lubrication Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 1 Capped Grease Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 2 Grease Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 2 Lubricating Stored Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 3 Bearing Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 3 Grease Lube Labyrinth Seal Crushers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 3 Labyrinth Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 3 Daily Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 3 Changing Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 5 Grease Lube Annular/Labyrinth Seal Crushers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 6 Annular/Labyrinth Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 6 Daily Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 6 Changing Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 7 Oil Lube Annular/Labyrinth Seal Crusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 9 System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 9 Low Oil Flow Alarm System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 11 Annular/Labyrinth Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 12 Daily Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 12 Periodic Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 14 Oil Heater (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 16 Cycle Timer (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 16 Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 18 Maintenance Benchmark Check Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 19 Periodic Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 20

Section 6 - Electrical Standard Drive Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 1

Section 7 - Troubleshooting Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 1 Crusher Not Operating At Rated Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 1 Bearings Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 1 Excessive Jaw Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 2 Difficult to Adjust Closed Side Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 2

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Table of Contents

Appendix A - Torque Specs Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A - 1 Standard Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A - 1 Metric Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A - 1 Standard Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A - 2 Metric Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A - 3

Appendix B - General Belt Drive Care General Belt Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintaining V-Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Check Belt Tension with Mechanical Tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Belt Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Idlers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inside Idler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Back-Side Idler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kiss Idler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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B-1 B-2 B-4 B-6 B-7 B-7 B-7 B-7


Table of Contents

22783 (8/02)

iv


Introduction

About This Manual

Section 1 - Introduction

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

About This Manual This book is an operation and maintenance manual for the owner or operator of the equipment described within. We strongly recommend that anyone working with this equipment become familiar with the manual, whether or not you have experience with similar equipment. This manual will help you understand how to install your equipment, prepare it for operation, and perform normal operation and maintenance tasks.

DANGER This manual contains information necessary for proper and safe operation. Carefully read this manual before attempting to operate. Failure to read and heed instructions preceded by a safetyalert symbol can cause death or severe personal injury as well as equipment and environmental damage.

22783 (8/02)

This equipment is precisely engineered, highly functional, and heavy-duty designed to provide years of excellent service performing to customer specifications. We are proud to manufacture this equipment for your use and profit. We also take pride in the quality of our service and replacement parts. This manual, however, is not a parts catalog and should not be used to order parts. Only your Parts Book, identified with your machine’s serial number, is an authoritative source of part numbers and part descriptions for your equipment. Ongoing improvement of product design may in the future result in changes to some parts. Use part numbers, model numbers and serial numbers from your Parts Book to communicate with your distributor.

1-1


Introduction

About This Manual

22783 (8/02)

1-2


Safety

General Safety

Section 2 - Safety

Hazard Classification

General Safety This equipment is designed expressly for processing rock and recycling concrete and asphalt. When our equipment is used for purposes other than those for which it was designed, assumes sole responsibility for any injuries or damage that may result from said misuse. There are many hazards involved in rock processing and in the use of rock-processing equipment. That is why we emphatically recommend that this equipment be operated only by personnel who are trained in its use.

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

We make no guarantee, either expressly or by implication, that this equipment meets all local or federal safety regulations. It is the responsibility of those individuals who own and/or operate this machine to that all safety regulations are complied with before starting either this unit or any associated equipment.

DANGER

DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

WARNING

WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION

CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

Safety Alert Symbol The safety alert symbol (Figure 2 - 1) is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage.

NOTICE

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

Figure 2 - 2 Hazard Classification

Figure 2 - 1 Safety Alert Symbol

22783 (8/02)

CAUTION

2-1


Safety

General Safety

Decals and Icons Beneath all safety regulations lies a set of commonsense rules. Everyone who works with or near heavy equipment must be aware of those rules. To foster and maintain such an awareness in our customers, safety decals are fixed on our equipment. Icons on our safety decals remind both workers and supervisors of common hazards and procedures that, in the course of a busy day, they might otherwise forget. The language of the icons is simple and direct (Figure 2 - 3).

Place guards around all moving parts on this machine. Never start the machine if those guards are broken or missing. Keep hands, feet, clothes and hair away from moving belts and sheaves.

Wear hearing protection when you’re near this equipment.

Wear respiratory protection when near this equipment. Rock dust is hard on your lungs. Rock chips sometimes come flying out of equipment. Wear goggles or safety glasses near this equipment.

Falling rock is a hazard around any rock-processing operation. Wear your hard hat.

Lockout & Tagout. Equipment may be energized. Lockout and tagout all energy sources prior to performing maintenance or adjustments.

Read all the manuals that shipped with your equipment. Maintenance is done more easily and safely when you know what you’re doing.

Figure 2 - 3 Safety Pictograms Explained

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2-2


Safety

Decal Location

Decal Location

1-16

1-15

04494-104-01

04418-542

1-16

04494-104-01

1-15

04418-542

STAMP SERIAL NO. IN PARENT METAL (SEE P/L 01376EAS)

DANGER

DANGER

ENTANGLEMENT HAZARD

ENTANGLEMENT HAZARD

04490-031

T PELIGRO

EQUIPMEN LOCKED OUT

Keep all guards in place. DANGER

EQUIPMEN LOCKED OUT

Death or serious injury will result.

DANGER

DANGER

LOCKED OUT

DANGER

PELIGRO

T

Keep all guards in place. SWITCH OFF and LOCKOUT & TAGOUT equipment before opening or removing guards. 04490-031

1-8

Do not reach into unguarded machine, you can be pulled in.

NOTE: WIRE TIE DECAL AROUND GROOVED FLYWHEEL. (SEE P/L 05077SBK, DECAL P/N 04490-026).

Death or serious injury will result.

LOCKED OUT

Do not reach into unguarded machine, you can be pulled in.

1-8

SWITCH OFF and LOCKOUT & TAGOUT equipment before opening or removing guards. 04490-031

04490-031

CAUTION EQUIPMENT DAMAGE HAZARD

CAUTION

May cause damage to motor or crusher. Keep crusher pulley free of dust and dirt buildup to avoid shaking of machine.

EQUIPMENT DAMAGE HAZARD

04492-005b

May cause damage to motor or crusher. Keep crusher pulley free of dust and dirt buildup to avoid shaking of machine.

04492-005

1-11

04492-005b

04492-005

1-11 Roller Bearing Crusher Grease Lubrication Jaw, Impact Breaker, Hammermill

Lubricant:

Lithium base, extreme pressure type, grade 1 grease.

Caution:

Over lubrication will result in elevated operating temperatures.

STAMP SERIAL NO. IN PARENT METAL (SEE P/L 01376EAS)

Brand Names: Chevron Dura-Lith EP1 Exxon Lidok EP1 Mobil Mobilux EP1

Shell Alvania EP1 Texaco Multifak EP1

Bearings & Seals: Grease must extrude from the seals at all times to produce an effective dust & moisture seal. Greasing intervals must be established to maintain this visible grease slick. Safety

Refer to Operation & Maintenance Manual for detailed lubrication instructions.

DANGER

04494-100-01a

04494-100-01

04418-955d

Made In United States of America

1-14

OR Roller Bearing Crusher Circulating Oil System

Built under one or more of the following patents:

Great Britain:

Do not reach into unguarded machine, you can be pulled in. Death or serious injury will result. Keep all guards in place.

Safety

Refer to Operation & Maintenance Manual for detailed lubrication instructions.

4493-023

New Zealand: 04494-100-04a

Wear proper eye personal protective equipment.

*

04494-100-04

222,991 - 228,746 - 212,988

Wear proper hearing personal protection equipment.

May cause difficulty in breathing. Wear proper respiratory personal protective equipment.

Read all manuals prior to operation. DO NOT OPERATE equipment if you do not understand the information in the manuals. Consult your supervisor, the owner, or the manufacturer. 04490-103-01

534,673 - 534,674 - 534,675 - 548,832 - 552,227 - 557,149 - 557,477 - 569,405 579,784 - 615,281

1-3 1-4

Other Patents Pending.

04493-023 07073-015

1-10

04490-103-01

DANGER

NOTICE

WARNING

ENTANGLEMENT HAZARD

FALLING MATERIAL May cause death, or severe personal injury. Wear proper head personal protective equipment.

Do not reach into unguarded machine, you can be pulled in. Death or serious injury will result.

FLYING MATERIAL May cause loss or degradation of eye sight.

Keep all guards in place.

Wear proper eye personal protective equipment.

HEARING HAZARD May cause loss or degradation of hearing over a period of time. Wear proper hearing personal protection equipment.

RESPIRATORY HAZARD May cause difficulty in breathing. Wear proper respiratory personal protective equipment.

MENT D EQUIP LOCKE OUT

NOTES: 1. ASSEMBLY IS FOR ALL JAW CRUSHERS. DECAL LOCATIONS AS SHOWN, OR AS CLOSE AS POSSIBLE. 2. ITEMS MARKED * ARE ON PARTS LIST 03042ED (JAW OIL LUBE EMBLEMS).

PELIGRO

Equipment may be energized. Lockout and Tagout all energy sources prior to performing maintenance or adjustments.

DANGER

LOCKOUT & TAGOUT

READ MANUALS DANGER

D

May cause loss or degradation of hearing over a period of time.

RESPIRATORY HAZARD

DANGER

HEARING HAZARD

OUT

Wear proper head personal protective equipment.

MENT D EQUIP LOCKE OUT

May cause death, or severe personal injury.

May cause loss or degradation of eye sight.

Australia:

1-19

NOTICE

WARNING FALLING MATERIAL

FLYING MATERIAL

PELIGRO

ENTANGLEMENT HAZARD

DATE OF MANUFACTURE

2213398 - 2127500

DANGER

CEDAR RAPIDS, IOWA U.S.A.

MODEL NUMBER

9010205

D

DANGER

A Terex Company SERIAL NUMBER

:

Lubricant: Lithium base, extreme pressure type, grade 2 grease. Grease must extrude from the seals at all times to produce an effective dust & moisture seal. Greasing intervals must be established to maintain this visible grease slick.

DANGER

Seals:

Canada:

OUT

United States: 4,454,994 - 4,477,031 - 4,571,112 - 4,699,326 - 4,717,084 - 4,773,604 - 4,896,838 4,919,348 - 4,919,349 - 4,925,114 - 5,083,714 - 5,111,569 - 5,005,772 - 5,004,169 5,996,916 - 5,312,053 - 5,350,125 - 5,718,390 - 5,875,981 - 5,927,623 - 5,718,391 5,799,886 - 5,803,382 - 5,944,265 - 5,971,306 - 5,810,268 - 6,070,819 - 6,070,820 6,089,481 - 6,126,101 - 6,149,086 - 6,155,507 - 6,161,650 - 6,189,820

1,282,391 - 1,313,170 - 2,015,298 - 2,015,299 - 2,112,946.

LOCKE

Lubricant: Extreme pressure lubricating oil. Fill supply tank with recommended lubricant.

DANGER

04418-955

Crushing & Screening Patents

Pitman & Side Bearings:

Brand Names: Ambient Temperature Guide - (Above 32˚f) [Below 32˚f] Chevron Gear Compound EP (220) [150] Exxon Spartan EP (220) [150] Shell Omala EP (220) [150] Texaco Meropa (220) [150] Mobil Mobilgear (630) [629] Every 1000 hours or seasonally, drain the supply tank and fill with flushing oil. Proceed with flushing operation. See specific instructions in Operations Manual.

LOCKE

1-19

LOCKOUT & TAGOUT Equipment may be energized. Lockout and Tagout all energy sources prior to performing maintenance or adjustments.

READ MANUALS DANGER

Read all manuals prior to operation. DO NOT OPERATE equipment if you do not understand the information in the manuals. Consult your supervisor, the owner, or the manufacturer. 04490-103-01

1-10

04490-103-01

A Terex Company 04418-031y

1-17

22783 (8/02)

04418-031

2-3


Safety

Personal Safety

Personal Safety

•

Never attempt to clear away jammed feed material, discharge material or other stoppage while the machine is running. Stop the equipment, lock out and tag out before touching this machine with your tools or your hands.

•

Wear proper personal protective equipment, including eye protection, hard hat and safety shoes, whenever you’re near this machine while it is running.

•

Dress appropriately in every way. Never wear loose clothes, long hair, coat tails, jewelry, pockets full of tools or any other item that could get caught in moving parts.

•

Know where your fellow workers are. Always look around and inside this machine before starting it. Make sure nobody is in the way of moving parts or working on the machine.

•

Make sure that everyone working on or near this equipment is familiar with safety precautions. We recommend the following basic safety practices:

Lift with your legs, not with your back. Keep the weight close to your body. If the load is more than 40 lbs., get someone to help you.

•

Never engage in horseplay when near this machine, or any other.

•

Read all danger, warning, caution and notice signs.

•

•

Always lock out and tag out involved energy sources before performing maintenance or adjustments on this equipment. Make it impossible for anyone to start this machine while others work on it or in it.

Report any defective machinery or equipment and unsafe conditions or activity to your boss immediately.

•

Don’t limit safety practices to the few rules listed here. Think safety and act safely at all times.

•

Most of all, know your equipment. Understand the machinery, the conditions under which it operates and what it is capable of doing.

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

DANGER Sometimes, at a customer’s request, equipment is shipped without certain features such as a drive sheave. When this occurs, we attach a warning decal to alert installers that the related guard or other safety feature is missing. In such cases it is the customer’s responsibility to guard the machine properly.

•

Never remove any guard, cover or shield when this equipment is in motion.

•

Replace guards, covers and shields when the task for which you removed them is finished.

•

Block parts as necessary to prevent their sudden movement while people are working on the machine.

22783 (8/02)

2-4


Safety

Lockout & Tagout

Work Area Safety •

Keep the work area as neat and clean as practical.

•

Keep all product safety signs clean, clear and current.

•

Make sure all electrical equipment is properly grounded. Wet spots near electrical current are especially dangerous.

•

Store hazardous materials in restricted access areas and mark them clearly. Federal regulations require special labeling of certain materials.

Always use mechanical assistance to lift heavy loads. Never overload a hoist, crane, jack or other lifting device. Check lifting tackle regularly; replace it at the first sign of stretch, fraying or other wear.

•

Keep your equipment clean, free of dirt and grease, so that loose, cracked or broken parts are more easily spotted. Replace defective parts as soon as they are discovered.

Lockout & Tagout Code of Federal Regulations number 1910.147 requires that employers establish and follow a Lockout & Tagout procedure and train their employees in that procedure before any employee can operate, service or maintain any piece of power equipment.

Never start an engine in an enclosed space without properly venting the exhaust.

•

Do not smoke or allow smoking near fuels and solvents. Never strike a spark or use an open flame near fuels and solvents.

•

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

•

Know where fire extinguishers and other firesuppression equipment are located. Learn how to use them effectively. Be alert and wary around any pressurized system, hydraulic or pneumatic. High-pressure oils and gases are very dangerous.

To promote safety in its use, we ship a Lockout & Tagout Kit with the equipment. The kit and its contents are illustrated in (Figure 2 - 4).

u t

o

c k

L o

FED ER AL

-

t

g o u

a

T

Keep drive belts and sheaves in good condition. Frayed belts or cracked sheaves are not only dangerous, they cost you downtime.

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K o u t g T a t o u L

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Clean tools that are properly labeled and stored are safer tools. Keep your tools in good order.

it

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•

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No

Employers are required to make periodic inspections to see that their Lockout & Tagout procedures are being followed, and they must monitor and update their program on an ongoing basis. Employees are responsible for seeing that equipment is locked out and tagged out in accordance with the employer’s policy.

Equipment & Tools •

!

ate

Do

•

•

•

Figure 2 - 4 Lockout & Tagout Kit 22783 (8/02)

2-5


Safety

Lockout & Tagout

What is Lockout & Tagout?

Who must apply a lock & tag?

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

•

Any person working on the equipment.

•

Foreman or other person responsible for the work being done.

•

If several people are working on a machine at the same time, each person must apply his or her own lock and tag.

When can a lock and tag be removed? How to Lockout & Tagout

After performing these six steps:

•

Install one or more locks to hold the master switch lever in the OFF position.

1) All safety guards are back in place.

If the switch is keyed, turn the key to the OFF position and remove the key.

3) All workers are notified that a lock is being removed.

•

Disconnect the batteries.

5) Controls are positioned for safe startup.

•

Regardless of which lockout method is used, place one or more tags on machine control s, access doors and electrical s.

6) The machine is ready for safe operation.

•

2) All work is complete and tools are put away.

4) All workers are positioned safely for startup.

•

When is Lockout & Tagout required? •

Any time anyone is maintaining, repairing, lubricating, or, for whatever reason, working on the equipment.

•

When the equipment is broken or, for whatever reason, unfit or unsafe to operate.

•

Whenever the equipment is left unattended.

22783 (8/02)

Who can remove a lock and tag? Only the person who applied a lock and tag is permitted to remove them.

Lockout & Tagout rules laid out here are generic. To get instructions for your particular workplace, consult your employer’s lockout/tagout procedure.

2-6


General Jaw Crusher Information

Crusher Description & Information

Section 3 - General Jaw Crusher Information 1


2

3

4

5

6

7

18

17

16

15

14 1 - Pitman 2 - Pitman bearing 3 - Side bearing 4 - Eccentric shaft 5 - Key plate 6 - Base

13

12

11

10

7 - Stationary jaw 8 - Movable jaw 9 - Toggle seat 10 - Toggle plate 11 - Toggle seat base 12 - Hydraulic ram

9

8 13 - Tension spring 14 - Tension spring collar 15 - Hand pump 16 - Tension rods 17 - Shims 18 - Shim cover

Figure 3 - 1 Jaw Crusher Parts

22783 (8/02)

3-1




General Description Cedarapids roller bearing jaw crushers are used both as primary and secondary crushers depending on the size of the material to be crushed. They will break rock down to the size specified in one operation or to a size that can be further reduced by a secondary crusher such as a rollercone or a smaller jaw crusher. These crushers are made of welded type construction and can be used in either a stationary or portable plant. The jaw crusher consists of two readily separable subassemblies; the base assembly and the shaft and pitman assembly. Refer to Figure 3 - 1. The base assembly consists of the crusher base, stationary jaw, key plates and adjusting mechanism. The shaft and pitman assembly is composed of the moving parts of the crusher; the eccentric shaft, pitman, movable jaw, side and pitman bearings, side bearing housings, all bearing seals and spacers and the two flywheels.

diminishes between the top and the bottom of the movable jaw, producing a long primary crushing stroke at the top of the jaw and a short stroke for crushing to a more uniform size at the bottom. Crusher Sizes Jaw crusher size refers to the opening at the top of the crusher. This opening is rectangular and is measured from the top of the movable jaw (A) to the top of the stationary jaw (B), and from side key plates (C) to opposite side key plate (D) (Figure 3 2). For example: a Model 3042 jaw crusher has an intake opening of 30 inches (762 mm) between jaws (A) to (B) and 42 inches (1067 mm) between key plates (C) to (D). The dimensions will vary slightly due to the casting tolerances of jaws and key plates. B

Operating Principle

D

The stationary jaw is wedged in place in the base by the key plates and the movable jaw, which is attached to the pitman. The pitman is mounted on roller bearings on the eccentric portion of the crusher shaft, the concentric ends of which are mounted in housed roller bearings rigidly attached to the crusher base. The lower end of the pitman is hinged on one end of the toggle plate; the other end of the toggle plate oscillates in a groove in the toggle bearing wedge, which is attached to the crusher base. The replaceable cast iron toggle plate serves as a fuse or safety device in the crusher, as it will break when uncrushable material such as a shovel tooth es between the jaws. Due to the eccentric shaft and the toggle plate, a combination crushing and downward motion is imparted to the pitman and movable jaw as the shaft is revolved. The horizontal length of the crushing motion gradually 22783 (8/02)

C

A

LEFT SIDE

RIGHT SIDE

Figure 3 - 2 Jaw Crusher Opening

Left/Right Side Designation Right and left side of crusher are determined when standing facing the tension springs (Figure 3 - 2).

3-2




Crusher Weights The approximate weights listed in Table 3 - 1 are based on clean new standard components. Weights may vary and listed weights should be considered only an approximation.

Model

Complete Crusher (Base, Pitman Assy, & Flywheels)

Pitman Assembly (Pitman Assy & Flywheels)

Flywheel Only (Each)

lbs

kg

lbs

kg

lbs

kg

1016

5,306

2,406

2,844

1,293

690

314

1024

8,255

3,752

4,817

2,190

1,275

580

1036

12,551

5,705

7,449

3,386

1,223

556

1236

13,978

6,354

8,007

3,640

1,250

568

1242

19,521

8,873

12,120

5,509

2,098

954

1248

24,300

11,045

14,374

6,534

2,175

989

1524

12,305

5,593

6,771

3,078

1,215

552

1636

21,003

9,547

11,895

54,07

2,075

943

1642

33,998

15,454

19,642

8,928

2,741

1,246

1648

32,406

14,730

16,988

7,722

2,684

1,220

1824

12,426

5,648

6,771

3,078

1,215

552

1836

21,280

9,673

12,105

5,502

2,126

966

2236

24,903

11,320

14,266

6,485

2,785

1,266

2248

43,094

19,588

25,746

11,703

3,700

1,682

2436

46,737

21,244

22,861

10,391

3,462

1,574

2438

26,017

11,826

14,501

6,591

2,873

1,306

2540

45,000

20,455

18,950

8,614

4,200

1,909

2542

42,095

19,134

21,832

9,924

3,584

1,629

2742

48,520

22,055

25,842

11,746

4,194

1,906

3042

48,520

22,055

25,842

11,746

4,194

1,906

3054

52,740

23,973

27,525

12,511

4,194

1,906

3242

57,137

25,971

28,755

13,070

4,028

1,831

3648

79,653

36,206

39,524

17,965

5,560

2,527

3660

107,664

48,938

58,478

26,581

5,595

2,543

4242

58,838

26,745

28,755

13,070

4,028

1,831

4248

104,567

47,530

52,827

24,012

5,595

2,543

5460

196,258

89,208

102,715

46,689

10,570

4,805

5748

117,000

53,182

52,827

24,012

5,595

2,543

Table 3 - 1 Approximate Crusher and Component Weights

22783 (8/02)

3-3




Lifting Crusher

Crusher Drive Speed

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

The correct speed of the crusher will be stamped into the crusher base (Figure 3 - 3). Correct speed is one of the basic requirements to obtain maximum capacities with minimum wear.

Direction of Flywheel Rotation The overhead eccentric force feed jaw crusher are designed to have the shaft assembly with flywheel rotate downward and toward the crushing chamber. Standing on the left side of the crusher, the flywheels will be rotating in a counterclockwise direction (Figure 3 - 3). Right and left hand are determined when facing the tension spring.

Always maintain speed of the crusher according to the factory recommendations. Crushers are designed to run at a certain speed with a specific flywheel and counterweight configuration. Changing speed will change the flywheel and counterweight requirements. Consult factory if operating speed will vary more than +/- 25 rpm from the speed marked on the crusher.

CAUTION Operating with incorrect speeds and flywheels can increase compaction in the crusher and lead to premature shaft and bearing failure.

SPEED

Figure 3 - 3 Direction of Flywheel Rotation

22783 (8/02)

3-4




Maximum & Minimum Crusher Settings

Capacity of Crusher

Cedarapids has established limits for the discharge opening of each crusher. For safe and efficient operation, the following maximum and minimum openings should govern crushing extremes. Refer to Table 3 - 2.

Crusher capacity is measure both by the size of material that can be fed into the crusher and throughput of the crusher. In general, the maximum feed size for jaw crushers is 80% of the jaw opening in sand and gravel applications and 90% of the jaw opening in quarry applications. For example, a 3042 crusher with a jaw opening of 30” by 42” will have a maximum feed size of 24” by 33.6” in sand and gravel applications and 27” by 37.8” in quarry applications. These are general guidelines and may vary in certain applications.

Minimum

Maximum

Size inches

mm

inches

mm

1016

3/4

19

3 1/2

89

1020

3/4

19

3 1/2

89

1024

3/4

19

3 1/2

89

1036

1 1/2

38

3 1/2

89

1236

1 1/2

38

5

127

1242

1 1/2

38

5

127

1248

1 1/2

38

5

127

1524

1 1/2

38

5

127

1636

1 1/2

38

5

127

1642

1 1/2

38

5

127

1648

1 1/2

38

5

127

1824

1 1/2

38

5

127

1836

1 1/2

38

5

127

2236

2 1/2

64

6

152

2248

2 1/2

64

6

152

2436

2 1/2

64

6

152

2438

4 1/2

114

8

203

2542

3 1/2

89

10

254

2742

3 1/2

89

10

254

3042

4

102

13

330

3054

3 1/2

89

13

330

3242

4

102

13

330

3648

4

102

13

330

3660

4

102

13

330

4242

14

356

23

584

4248

4

102

13

330

5460

6

152

20

508

5748

19

483

28

711

Crusher throughput capacities are based on average conditions and will vary widely with different types of rock and stone, uniformity of feed and moisture content of material being crushed. Crusher throughput and gradation information is available by ing your Cedarapids distributor.

Table 3 - 2 Closed Stroke Setting Limits

22783 (8/02)

3-5




Crusher Dimensions

F

C E

D

A B

H

G

Tension Spring Location on 1016 & 1020

Model

1016

1020

1024

1036

1236

1242

1248

1524

1636

1642

1648

1824

1836

2236

A

40 1015

48 1220

45 1145

48 1220

48 1220

56 1420

59 1500

55 1395

61 1550

71 1800

66 1675

56 1420

64 1625

65 1650

B

– –

– –

– –

– –

– –

– –

– –

– –

– –

73 1855

– –

– –

– –

– –

C

41 1040

46 1170

46 1170

46 1170

51 1295

55 1395

56 1420

57 1445

63 1600

76 1930

70 1780

57 1445

63 1600

77 1955

D

24 610

28 710

28 710

28 710

32 810

33 840

35 890

36 915

41 1040

46 1170

41 1040

36 915

41 1040

48 1220

E

26 660

28 710

28 710

28 710

33 840

34 865

35 890

39 990

42 1065

48 1220

42 1065

39 990

42 1065

49 1245

F

58 1470

72 1830

72 1830

81 2055

81 2055

98 2490

104 2640

67 1700

92 2335

99 2515

94 2385

77 1955

92 2335

92 2335

G

22 560

26 660

27 685

41 1040

41 1040

47 1195

53 1345

27 685

41 1040

47 1195

53 1345

27 685

41 1040

43 1090

H

14 355

14 355

21 535

18 455

19 480

20 510

19 480

18 455

16 405

20 510

16 405

19 480

16 405

17 430

Model

2248

2436

2438

2542

2742

3042

3054

3242

3648

3660

4242

4248

5748

5460

A

79 2005

88 2235

67 1700

82 2080

88 2235

88 2235

88 2235

93 2360

107 2715

118 2995

103 2615

123 3125

138 3505

149 3785

B

81 2055

91 2310

– –

85 2160

88 2235

91 2311

91 2311

99 2515

113 2870

– –

109 2770

126 3200

141 3580

152 3860

C

83 2110

89 2260

77 1955

93 2360

92 2337

92 2337

92 2337

105 2665

120 3050

125 3175

105 2665

137 3480

137 3480

172 4370

D

52 1320

61 1550

50 1270

63 1600

62 1575

62 1575

63 1600

75 1905

82 2080

86 2185

75 1905

96 2440

96 2440

127 3225

E

54 1370

61 1550

49 1245

65 1650

64 1626

64 1626

64 1626

77 1955

84 2135

88 2235

77 1955

101 2565

101 2565

130 3300

F

99 2515

94 2385

92 2335

95 2415

99 2515

99 2515

110 2795

99 2515

101 2565

119 3025

99 2515

120 3050

120 3050

140 3555

G

53 1345

43 1090

43 1090

45 1145

47 1195

47 1195

69 1755

47 1195

52 1320

78 1980

47 1195

55 1395

55 1395

67 1700

H

16 405

17 430

18 455

19 480

17 430

17 430

20 510

22 560

20 510

28 711

22 56 0

20 510

20 510

18 455

Figure 3 - 4 Crusher Dimensions to nearest inch and mm 22783 (8/02)

3-6


Set-up & Operation

Mounting & Set-up

Section 4 - Set-up & Operation

The crusher must be perfectly level across the length of the shaft (side-to-side) to maintain even load on all the bearings and ensure proper lubrication of the bearings.

Mounting & Set-up The jaw crusher may be installed on a portable plant or as a component for installation in a stationary plant or customer supplied portable plant. Mounting a jaw crusher requires careful planning to ensure: •

mounting structure is capable of ing the weight and forces generated by an operating jaw crusher.

•

adequate clearance has been left around the crusher to allow safe operation without interference.

Mounting Clearance Adequate clearances must be maintained above the crusher for feeding material into it as well as facilitate maintenance of the crusher. Likewise, adequate clearance must be below the crusher to allow for material to exit the crusher without buildup. Flywheel Counterweight Installation

•

crusher flywheel and drive are appropriately guarded to prevent access during operation.

•

provisions are made allowing the power source to be locked out and tagged out.

•

guard rails and walkways are installed where necessary.

•

a means of feeding material to the crusher and removing crushed material from under the crusher are provided.

Normal flywheel counterweight location when the crusher is at rest, is indexed approximately 30° toward the crushing chamber from top dead center (12 o’clock) position. It is very important that counterweights on one flywheel be directly across from the counterweights on the other flywheel. (Figure 4 - 1) Incorrect flywheel counterweight positioning will cause the crusher to vibrate excessively. Flywheel with Counterweights

Mounting Crusher All foundations and crusher s must be designed by a qualified engineer to meet local code requirements. Information needed to design the crusher foundation or may be obtained from Cedarapids. When installing crusher in a stationary plant, place on an adequately designed foundation. There must be ample clearance maintained between crusher discharge and receiving conveyor for the material to discharge without rubbing end of pitman. Consideration for overhead clearance must also be made should removal of the pitman become necessary. 22783 (8/02)

4-1

Figure 4 - 1 Flywheel Counterweight Installation


Set-up & Operation

Mounting Crusher

Guarding It is the responsibility of the equipment owner and operators to ensure that adequate guarding is designed and built. The following are situations that should be considered when installing a jaw crusher. Each installation is unique with special hazards that must be considered and guarded. The entire installation should be reviewed by a qualified safety engineer before operation begins. •

The drive system from the drive shaft on the power unit to the flywheels on the crusher should be guarded to prevent access during operation. This includes the v-belts and both flywheels.

•

The power unit must provide a means to disengage the power source and install a lock and hasp to prevent accidental starting of the crusher. This could include accidental starting of the engine if a wrench falls onto the starter or start switch.

•

The area between the crusher and feeder should be guarded to prevent access during operation.

•

Any conveyor, feeder or other equipment that is overhead or accessible by workers while the crusher is operating must be guarded to prevent any worker from ing moving parts. This equipment must also be guarded to prevent material from dropping off the equipment and hitting a worker.

•

Guarding, handrails and walkways must be designed and operated in compliance with all current applicable OSHA, MSHA, National Electric Code (NEC), federal, state, and local regulations.

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4-2


Set-up & Operation

Operation

Operation

B) Control valves regulate the oil flow to the bearings. Flow to each bearing is controlled independently.

Prior To Starting Perform all daily and periodic lubrication and maintenance tasks listed in Section 5.

C) Fully open all valves. Brass indicators in the flow indicator tubes will rise to their highest points in the tubes.

WARNING

D) Allow the crusher to run until the oil is warmed up.

Shut down, lock out and tag out all drives, power sources, and electric power s prior to performing any maintenance.

E) Partially close the valves until all the indicators are at the same level.

Starting Crusher

4) Start or engage crusher drive.

Grease Lube Systems

5) Allow the crusher to run empty for a few minutes.

1) Start or engage crusher drive. 6) Start under-crusher conveyor. 2) Allow the crusher to run empty for a few minutes until the lubricant is warmed up.

7) Start feeder.

3) Start under-crusher conveyor.

Cold Weather Startup Notes

4) Start feeder. Oil Lube Systems

•

Allow the crusher extra time to run empty to ensure the lubricant is warmed.

•

If the crusher is hard to start, change to lighter lubricant. Refer to lubrication instructions for more information.

1) If the crusher is equipped with the optional oil lubrication system with oil reservoir heaters, turn on heaters and allow oil to warm to operating temperature. 2) If the crusher is equipped with the optional oil lubrication system with optional cycle timer, switch the Day-Night switch to Day. 3) If the crusher is equipped with the optional oil lubrication system operate as follows. A) Start oil lubrication pump.

22783 (8/02)

4-3


Set-up & Operation

Operation

During Operation

Stopping Crusher

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

•

•

Check crusher bearings for the appearance of overheating. Do not operate crusher if bearings overheat until the cause is determined and corrected. Ensure tension springs are tight enough to keep the toggle plate from clattering when the crusher is running empty. After changing the crusher discharge opening or replacing the toggle plate listen for a clattering or pounding noise, indicating the tension springs are too loose. Adjust tension springs before resuming operation.

1) Stop the feed to the crusher. 2) Allow the material in crusher to be fully crushed and empty out the crushing chamber. 3) Shut off the power to the crusher drive. 4) Shut off the power to the under-crusher conveyor.

Observe the stationary jaw for slight up and down movement. If such movement is visible, tighten the key plates. If crusher is operated with loose key plates, the resulting movement of the stationary jaw will cause unnecessary wear on the jaw and base as well as reduce the capacity of the crusher.

CAUTION Avoid stopping the crusher when the jaws are full of material. Restarting the loaded crusher produces an excessive load on the power unit and an extreme pull on the belts. A plugged crusher should be at least partially emptied by hand before restarting.

Oil Lubrication System •

Periodically check the level of the flow indicators. If the level falls in any of the tubes, it could be a sign of bearing problems or clogged filters.

•

The filter gauge shows the pressure in the feed line to the filter. Readings will vary with ambient temperature, type of lubricant, operating temperature, etc.

•

The suction gauge will normally show little or no reading.

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4-4


Set-up & Operation

Feeding The Crusher

Feeding The Crusher The most efficient operation of the crusher results when the crushing chamber is kept full of material and when a uniform method of feeding is used. The crusher should be kept full of material however, material should not be allowed to build up above the tops of the jaws.

In general, the maximum feed size for jaw crushers is 80% of the jaw opening in sand and gravel applications and 90% of the jaw opening in quarry applications. For example, a 3042 crusher with a jaw opening of 30” by 42” will have a maximum feed size of 24” by 33.6” in sand and gravel applications and 27” by 37.8” in quarry applications. These are general guidelines and may vary in certain applications.

CAUTION DANGER

Allowing material to build up to the pitman during crushing could damage the pitman. Do not allow material to build up higher than the tops of the jaw dies.

Do not use explosives in crusher chamber. The crushing chamber is not designed to withstand the forces generated by explosives. Explosives can cause premature failure of bearings and breakage of the pitman, eccentric shaft and base.

Material Feed Size Material typically found in sand and gravel operations has rounded corners. Shot material typically found in quarry operations tends to be more cubical with square corners. Rounded material requires a smaller nip angle so the jaws can grab and crush the material. Material that is not grabbed by the jaws will slide up and down as the jaws open and close. This wears the jaws without producing product. This material should be removed from the crusher and broken up before attempting to crush again. A rock breaker can be installed that will allow material to be broken up in the crusher or feeder.

CAUTION Always turn off the crusher and feeder before using a rock breaker.

WARNING Running the crusher with oversized or uncrushable material sliding on the top of the pitman can damage the pitman. Shut down and remove oversized material. Clay Clay tends to build up in the corrugations of the jaw. This reduces jaw capacity and could damage the crusher. When crushing material containing clay, the crusher should be stopped periodically and clay should be cleaned from the jaw corrugations. Material containing heavy clay should be scalped to remove clay before feeding into the jaw crusher.

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4-5


Set-up & Operation

Adjusting Closed Side Setting (CSS)

Adjusting Closed Side Setting (CSS) The crusher discharge opening governs the size of finished material produced by the crusher.The size of the crusher discharge opening is changed by adding or removing shims from behind the toggle seat base. The opening is reduced by moving the base toggle seat forward with the hydraulic mechanism and shimming behind the seat. Refer to Figure 4 - 3. Adjust as follows:

2) Some crushers are equipped with toggle plate base wedges which lock the toggle plate base during operation. This prevents any rocking movement of the base during operation, reducing wear on the toggle seat insert and on the end of the toggle plate. If your crusher is equipped with toggle plate base wedges, perform the following steps. Refer to Figure 4 - 2.

Slot (for loosening wedge)

5) Attach hydraulic pump to ram(s).

Toggle Plate Base

6) Make a wooden spacer similar to that shown in Figure 4 - 3, to the exact thickness of the correct discharge opening. When lumber of proper width or thickness is not available, make up a lamination, including plywood, hard fibre board, or metal to obtain the correct thickness. Spacer must be wide enough to bridge between several jaw plate tips as shown in Figure 4 - 3. This is especially important when the desired setting is close to the minimum closed side setting of the crusher. Adding a handle to spacer block will make it easier to properly position at the bottom of the jaws.

Figure 4 - 2 Toggle Plate Base Wedge

A) When the crusher opening is to be adjusted, loosen the four wedge tightening locknuts (2 per side) at the sides of the crusher base. Loosen 1/2 inch. 22783 (8/02)

3) Loosen tension spring nuts so that shim pack can be adjusted. 4) Install hydraulic rams to push toggle seat forward. Some crushers have two mounts near the bottom of the crusher used to adjust the crusher and a single mount around the midpoint of the pitman used to push the pitman forward when installing a toggle plate. Always install the rams in the lower holes when adjusting the closed side setting. Refer to Figure 4 - 3.

1) When the crushing chamber is completely empty, stop the jaw crusher drive and lock out the power source.

Wedge

B) Insert a bar through the hole in each side of the crusher base side plate and through a slot in each of the angles, to the wedges. Hit the bar with a sledge until wedge is loose and the toggle plate base is free to move.

7) Rotate and hold the flywheel so that the eccentric shaft closes the jaws as much as possible. Using a ratcheting cable puller (come-along) will make it easier to rotate and hold the flywheel in the desired position.

4-6


Set-up & Operation


8) Hold the wood spacer as shown in Figure 4 - 3 so that it is centered in the crushing chamber and extends below the jaws.

DANGER Never run the crusher while holding anything in the crushing chamber. Doing so could result in serious injury or death.

11) Tighten all wedge bolt locknuts. This draws the angles up tight against the ends of the toggle seat to prevent any movement. After the next day of crusher operation, retighten all wedge bolt locknuts. 12) Remove hydraulic pump and rams from crusher.

WARNING Failure to remove hydraulic rams before operating crusher could result in serious personal injury and/or damage to the equipment.

9) To change jaw opening, A) Close valve on hydraulic pump. B) Pump up rams to push toggle plate base forward relieving pressure on shims. C) If decreasing closed side setting, pump hydraulic pump until jaw is tight against wood spacer.

WARNING A failure of the hydraulic system while adding or removing shims from the shim pack could result in serious personal injury. Keep hands and fingers clear of shims when adjusting crusher. Use a tool to pull shims out of shim pack. D) Add shims as needed to achieve desired jaw spacing. E) To increase closed side setting, force jaw forward, remove several shims and proceed with step C. 10) Tighten tension spring nuts to restore holding force on toggle plate.

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4-7


Set-up & Operation


Racheting Cable Puller

Pitman Eccentric Rotated To Minimum Jaw Opening

Hydraulic Ram Toggle Plate Change Position

Shims Hydraulic Ram Adjusting CSS Position Toggle Plate Base

Handle

Toggle Plate Base Wedge

Tension Spring Nuts

Laminated Spacer Same Thickness As Desired CSS

Spacer Must Span Several Corrugations Figure 4 - 3 Setting closed side setting

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4-8


Lubrication & Maintenance

General Lubrication Information

Section 5 - Lubrication & Maintenance

Side Bearing


Seal

Cedarapids has built crushers using three possible lubrication/seal configurations. It is important to know which type of seal and lubrication your crusher uses. The three configurations are: 1) Grease lubrication with a labyrinth seal (Figure 5 - 1). 2) Grease lubrication with an annular/labyrinth seal (Figure 5 - 2). 3) Oil lubrication with an annular/labyrinth seal (Figure 5 - 2). The differences between these configurations will be explained in depth later in this section. Most current production jaw crushers use the annular/ labyrinth seal configuration with grease or oil lubrication.

Figure 5 - 2 Annular/labyrinth seal grease or oil design

WARNING Side Bearing

Never attempt to lubricate or maintain the crusher until flywheels are stopped and drive is locked out.

Seal

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

Figure 5 - 1 Labyrinth seal grease lube design

22783 (8/02)

5-1




Cleanliness in the handling of lubricants, fittings, grease guns and the openings and plugs of housings is of vital importance. Foreign substances contaminate lubricant. Be sure that all fittings and openings are thoroughly cleaned of all foreign substances before starting to inject lubricant. In using the grease gun always see that the gun makes proper with the cleaned fittings and that the nozzle has not been allowed to touch unclean surfaces.

Grease Capacities Table 5 - 1 lists amount of grease required to completely drain and refill each bearing housing with grease. Add 20% to the quantity listed when refilling after overhauling the crusher.

NOTICE Never mix different types of lubricant within the crusher. Always drain and flush out old lubricant before changing to a different brand, as chemical breakdown can occur in lubricant mixtures. Capped Grease Fittings A special type grease fitting with screw-on metal cap is used on all crushers. This type of fitting not only makes complete protection of the grease entrance point possible, the tight fitting cap also prevents grease from being squeezed back out of the crusher by internal pressure. Always keep the metal cap screwed down tight after each greasing (Figure 5 - 3). Install Cap After Greasing

Side Bearing (each)

Pitman Bearings

lbs

kg

lbs

kg

1016

2

0.9

4

1.8

1020

2

0.9

5

2.3

1024

2

0.9

8

3.6

1036

2

0.9

14

6.4

1236

2

0.9

18

8.2

1242

4

1.8

27

12.3

1248

4

1.8

32

14.5

1524

3

1.4

8

3.6

1536

6

2.7

25

11.4

1636

6

2.7

25

11.4

1642

10

4.5

48

21.8

1648

9

4.1

38

17.3

1824

3

1.4

8

3.6

1836

6

2.7

25

11.4

2236

4

1.8

23

10.5

2248

8

3.6

55

25.0

2436

12

5.5

29

13.2

2442

7

3.2

33

15.0

2540

7

3.2

33

15.0

2640

10

4.5

48

21.8

2742

10

4.5

47

21.4

3040

10

4.5

48

21.8

3042

10

4.5

48

21.8

3054

10

4.5

48

21.8

3242

10

4.5

48

21.8

3648

12

5.5

64

29.1

4242

10

4.5

48

21.8

4248

9

4.1

51

23.2

5460

31

14.1

158

71.8

5748

9

4.1

51

23.2

Table 5 - 1 Crusher grease capacities

Figure 5 - 3 Typical capped grease fitting 22783 (8/02)

Crusher Size

5-2



Grease Lube Labyrinth Seal Crushers

Grease Lube Labyrinth Seal Crushers

Lubricating Stored Equipment Idle equipment whether new or used; must be turned over at least every 30 days either by power or hand to redistribute the lubricant. Rotating the bearing assemblies periodically redistributes lubricant on all surfaces of the bearing. Failure to rotate bearings when crusher is idle will permit lubricant to drain to the bottom of the bearing assembly. Moisture from condensation could collect and set up a chemical reaction in the bearing assemblies know as corrosive staining. These stained areas are a positive point for premature bearing failures, as flaking will start at these points when the equipment is put back into operation.

Labyrinth Seals Labyrinth seals are designed with a series of interlocking ages that block dirt from getting into the bearings (Figure 5 - 4). As the crusher runs, grease works its way through the labyrinth ages pushing dirt out of the seal. This causes a film of grease to constantly build up around the outside of the seal. This film helps keep dirt and moisture out of the seal and should be allowed to build up. Grease film forms outside of seal.

Bearing Temperature Normal operating bearing temperature should be 100° to 150°F (38° to 66°C) but in warm climates may reach 180° to 200°F (82° to 93°C). Excessive heat in the bearings may indicate the presence of foreign material between the fixed and rotating seals, and it is recommended that grease be injected into the bearings through the lubrication fittings to force the foreign material out and reduce heat generation. The reduction of temperature in the bearing will be slow because heat will continue to exist until the internal pressure inside the housing forces out the excess lubricant. If the crusher stops, back up the shaft assembly one-half a revolution to see if foreign material has been expelled. Repeat process until shaft assembly turns over easily; if the grease seals do not break loose,” then a complete overhaul is the only solution.

22783 (8/02)

Figure 5 - 4 Labyrinth seal

Daily Lubrication Grease should be added to one grease fitting on each side bearing and one on the center of the pitman (Figure 5 - 5). If the bearing is properly lubricated, a fresh film of grease will be present around the edge of the inner and outer seals of each bearing. As the bearings and grease seals become worn, more lubricant will be extruded from the seals. More frequent greasing may be required to maintain a film of grease around the outside of the seals.

5-3



Grease Lube Labyrinth Seal Crushers Lubricate with a lithium base, extreme pressure, Grade 1 grease.

Typical brand names are: Chevron Dura-Lith EP1, Exxon Lidok EP1, Mobil Mobilux EP1, Shell Alvania EP1, Texaco Multifak EP1.

1

2 4

Side Bearing 1 Pitman Bearing

3

4 2 1 - Pitman grease fitting 2 - Pitman magnetic drain plug

3 - Side bearing grease fitting 4 - Side bearing magnetic drain plug

Figure 5 - 5 Grease lubrication points

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5-4



Grease Lube Labyrinth Seal Crushers Changing Lubricant

CAUTION

Under normal conditions, it is recommended that grease be changed every 1000 hours of actual crushing or once each year, whichever occurs first.

Failure to thoroughly clean drain plugs and fittings before installation could cause grease contamination. Grease must be kept clean to prevent damage to bearings.

1) Before changing lubricant, run crusher long enough to heat the existing lubricant to a consistency that allows it to flow freely. 2) Clean area around drain plugs and grease fittings then remove plugs and fittings to drain free flowing lubricant. Refer to Figure 5 - 5. 3) Replace drain plugs and inject flushing oil in each bearing to fill pitman barrel and base housing to top of fill hole. An extreme pressure 150 viscosity, Grade 46 flushing oil should be used. 4) Replace the grease fittings. 5) Run the crusher empty for at least 10 minutes. 6) Stop unit and remove drain plugs to drain flushing oil.

NOTICE Running crusher slowly while draining flushing oil will expedite the draining. 7) Thoroughly clean and replace the magnetic drain plugs and inject a recommended grease in each bearing. 8) Replace and tighten the grease fittings and fitting caps.

22783 (8/02)

9) Refill bearing housing with grease. In determining the amount of grease to be used be governed by the fact that a pint of grease weighs slightly less than one pound. It is recommended in a complete overhaul, that 20% more lubricant be added in both of the side bearings and in the pitman. When starting a new crusher for the first time, or after an overhaul, apply a liberal amount of gear lube to the area between the pitman and side bearing seals. Apply oil until grease inside bearing begins to extrude from the grease seals. This precautionary measure insures lubrication until the actual lubricating system begins to function. A crusher which has been idle for a period of time and exposed to the weather should receive the same consideration. At the end of a season’s operation it is recommended that the lubricant be drained, flushed and new lubricant be injected into the housing. The crusher should be operated without load for approximately one hour to permit new lubricant to be evenly distributed in the bearing assembly and housing. New lubricant in the housing would tend to eliminate the possibility of corrosive reactions which might be evident if worked” and oxidized” lubricant is allowed to remain in the housing when the crusher is not in use for long periods of time.

5-5



Grease Lube Annular/Labyrinth Seal Crushers

Grease Lube Annular/Labyrinth Seal Crushers Annular/Labyrinth Seals Annular/labyrinth seals are designed with a series of annular rings and a labyrinth age (Figure 5 6). Clean grease is pumped into the seal fitting on the outer side bearing seal. All other seals are lubricated with grease that works into the seal from the bearing. As the crusher runs, grease works its way through the labyrinth age pushing dirt out of the seal. This causes a film of grease to constantly build up around the outside of the seal. This film helps keep dirt and moisture out of the seal and should be allowed to build up. Grease also works its way into the annular rings where it creates a barrier to dirt and moisture entering the bearing.

lubricated, a fresh film of grease will be present around the edge of the inner and outer seals of each bearing. As the bearings and grease seals become worn, more lubricant will be extruded from the seals. More frequent greasing may be required to maintain a film of grease around the outside of the seals. Lubricate with a lithium base, extreme pressure, Grade 1 grease. Typical brand names are: Chevron Dura-Lith EP1, Exxon Lidok EP1, Mobil Mobilux EP1, Shell Alvania EP1, Texaco Multifak EP1.

Grease film forms outside of seal. Labyrinth

Annular Rings Figure 5 - 6 Annular/labyrinth seal

Daily Lubrication Grease should be added to one grease fitting on each of the four bearings and one on each outer side bearing seal (Figure 5 - 7). If the bearing is properly 22783 (8/02)

5-6



Grease Lube Annular/Labyrinth Seal Crushers

2 4

1

3

Pitman Bearing

5

Side Bearing

4 2 1 - Pitman bearing grease fitting 2 - Pitman magnetic drain plug 3 - Side bearing grease fitting

4 - Side bearing magnetic drain plug 5 - Side bearing outer seal grease fitting

Figure 5 - 7 Grease lubrication points

Changing Lubricant Under normal conditions, it is recommended that grease be changed every 1000 hours of actual crushing or once each year, whichever occurs first.

22783 (8/02)

1) Before changing lubricant, run crusher long enough to heat the existing lubricant to a consistency that allows it to flow freely. 2) Clean area around drain plugs and grease fittings then remove plugs and fittings to drain free flowing lubricant. Refer to Figure 5 - 7.

5-7



Grease Lube Annular/Labyrinth Seal Crushers 3) Replace drain plugs and inject flushing oil in each bearing to fill pitman barrel and base housing to top of fill hole. An extreme pressure 150 viscosity, Grade 46 flushing oil should be used. 4) Replace the grease fittings. 5) Run the crusher empty for at least 10 minutes. 6) Stop unit and remove drain plugs to drain flushing oil.

NOTICE Running crusher slowly while draining flushing oil will expedite the draining. 7) Thoroughly clean and replace the magnetic drain plugs and inject a recommended grease in each bearing.

When starting a new crusher for the first time, or after an overhaul, apply a liberal amount of gear lube to the area between the pitman and side bearing seals. Apply oil until grease inside bearing begins to extrude from the grease seals. This precautionary measure insures lubrication until the actual lubricating system begins to function. A crusher which has been idle for a period of time and exposed to the weather should receive the same consideration. At the end of a season’s operation it is recommended that the lubricant be drained, flushed and new lubricant be injected into the housing. The crusher should be operated without load for approximately one hour to permit new lubricant to be evenly distributed in the bearing assembly and housing. New lubricant in the housing would tend to eliminate the possibility of corrosive reactions which might be evident if worked” and oxidized” lubricant is allowed to remain in the housing when the crusher is not in use for long periods of time.

8) Replace and tighten the grease fittings and fitting caps.

CAUTION Failure to thoroughly clean drain plugs and fittings before installation could cause grease contamination. Grease must be kept clean to prevent damage to bearings. 9) Refill bearing housing with grease. In determining the amount of grease to be used be governed by the fact that a pint of grease weighs slightly less than one pound. It is recommended in a complete overhaul, that 20% more lubricant be added in both of the side bearings and in the pitman.

22783 (8/02)

5-8



Oil Lube Crusher

Annular/Labyrinth

Seal

Oil Lube Annular/Labyrinth Seal Crusher

reservoir. The flow indicators must be checked periodically during operation to ensure that flow to any of the bearings has not stopped.

System Overview

A low oil flow alarm system will sound if low oil flow is detected on one or more of the bearing supply lines. If the feeder control is connected to the oil flow system as recommended, the feeder will shut down.

The oil lubrication system is standard on the 5460 and optional on most other crusher models. Refer to Figure 5 - 8. It is recommended for use on larger crushers or when the crusher will be operated in cold environments. Oil is drawn from the reservoir by the oil pump. The oil pump is normally driven by an electric motor. An optional flywheel driven oil pump is available although, electric drive is usually preferred. The electric driven lube system can be started before engaging the crusher. This ensures lubrication of the bearings the moment the crusher is started. The reservoir size is dependent upon the crusher size. Capacities will vary by crusher size. The reservoir is set lower that the bearings so that oil flows by gravity from the bearings to the reservoir.

Some crushers were built with a stand pipe on the oil outlet at the bottom of each bearing cavity. This Stand pipe retained a small amount of oil in each cavity to ensure the bearings remained lubricated in case of lube pump failure. Use of the Stand pipes is no longer recommended on crushers equipped with electric motor driven pumps. If your crusher is equipped with electric pump drive and STAND pipes, the STAND pipes should be removed when the crusher is disassembled.

For operation in cold environments, an optional reservoir heater and cycle timer are available. The heaters are thermostatically controlled to maintain the oil at a working temperature. A cycle timer can be used to periodically start and stop the electrically driven oil pump when the crusher is not running. This ensures that oil in the lines and bearing cavities is circulated back to be warmed in the reservoir. Oil is strained between the reservoir and pump and filtered between the pump and bearings. A vacuum gage is mounted on the strainer. A pressure gauge is mounted on the filter. Oil from the filter runs through the flow control valves and indicator. Oil flow to each bearing is individually controlled and monitored. From the flow indicator, the oil flows into the top of each bearing and flows by gravity through the bearing. Oil collects at the bottom of each of the bearing cavities and returns by gravity to the 22783 (8/02)

5-9



Oil Lube Crusher

8

7

Annular/Labyrinth

Seal

7

6

9 10

5

17 16 4 15 3 3

4

2 11 1 12 14

1 - Breather/filler cap 2 - Suction vacuum gauge 3 - Side bearing drain lines 4 - Pitman bearing drain lines 5 - Electric motor/pump 6 - System pressure gauge

13

7 - Bearing supply lines 8 - Flow indicators/controls 9 - Low flow alarm horn 10 - Lube system junction box 11 - Reservoir 12 - Reservoir sight gauge

13 - Reservoir drain 14 - Oil heaters (optional) 15 - Suction strainer 16 - By line 17 - Filter

Figure 5 - 8 Electric drive oil Lube system

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5 - 10



Oil Lube Crusher

Annular/Labyrinth

Seal

Low Oil Flow Alarm System The low oil flow alarm system will sound when the flow of oil to the bearings drops below minimum setting. If the electrical system is wired according to the schematic in Figure 5 - 9, the feeder will shut down when the low oil flow alarm is activated.

Figure 5 - 9 Low oil flow alarm system schematic

22783 (8/02)

5 - 11



Oil Lube Crusher Annular/Labyrinth Seals Annular/labyrinth seals are designed with a series of annular rings and a labyrinth age (Figure 5 10). Clean grease is pumped into the seal fitting. As the crusher runs, grease works its way through the labyrinth age pushing dirt out of the seal. This causes a film of grease to constantly build up around the outside of the seal. This film helps keep dirt and moisture out of the seal and should be allowed to build up. Grease also works its way into the annular rings where it creates a barrier to dirt and moisture entering the bearing. Grease stored in the annular rings also prevents oil in the bearings from leaking out of the seal.

Annular/Labyrinth

Seal

Oil leaking from the seals indicates that more frequent greasing of the seals is required. Lubricate seals with a lithium base, extreme pressure, Grade 2 grease. The oil level in the reservoir should be checked daily before operation begins. Oil level is checked at the sight gauge on the side of the oil reservoir. Refer to Table 5 - 2 when selecting the proper lubrication oil.

Grease film forms outside of seal. Labyrinth

Annular Rings Figure 5 - 10 Annular/Labyrinth seal

Daily Lubrication Grease should be added to each of the six seal fittings (Figure 5 - 11). If the seal is properly lubricated, a fresh film of grease will be present around the edge of the inner and outer seals of each bearing. As the seals become worn, more lubricant will be extruded from the seals. More frequent greasing may be required to maintain a film of grease around the outside of the seals. 22783 (8/02)

5 - 12



Oil Lube Crusher

Annular/Labyrinth

Seal

2 4

5

1 Pitman Bearing

3 5

Side Bearing

4 2 1 - Pitman bearing inlet line 2 - Pitman drain line 3 - Side bearing inlet line

4 - Side bearing drain line 5 - Seal grease fittings Figure 5 - 11 Grease lubrication points

22783 (8/02)

5 - 13



Oil Lube Crusher Periodic Lubrication Lubricating oil should be changed every 1000 hours of crusher operation or once each year, whichever occurs first. 1) The oil should be changed after the crusher has been run and the oil is at operating temperature.

Annular/Labyrinth

Seal

13) Refill the reservoir with the appropriate oil listed in Table 5 - 2. Selecting the proper oil viscosity is critical to maintaining lubrication of the bearings. Thinner oils have less lubricating ability. Thicker oils may not flow freely at lower temperatures which could cause insufficient oil to be delivered to the bearings. Regardless of which oil is used, the temperature of the oil returning from the bearings (operating temperature) must not exceed the Maximum Operating Temperature listed in Table 5 - 2.

2) Stop the crusher and clean area around drain plugs, fill plugs, and reservoir. 3) Drain the reservoir by removing the drain plug in the bottom of the reservoir. Since the oil in the bearing cavities drains by gravity back to the reservoir, draining the reservoir removes most of the oil from the crusher.

CAUTION Failure to use oil of proper viscosity could result in insufficient bearing lubrication. This could lead to premature bearing failure.

4) Remove the screen from suction strainer and clean it. 5) Reinstall the screen and drain plugs.

CAUTION

6) Add at least 10 gallons of flushing oil to the supply reservoir.

Do not allow the crusher to operate when the temperature of the oil returning from the bearings exceeds the temperature listed in Table 5 - 2. Failure to follow this warning could cause premature bearing failure.

7) Run the crusher empty for at least 10 minutes. 8) Stop the crusher. 9) Drain the flushing oil from the reservoir. If it appears extremely dirty, repeat the flushing with fresh flushing oil to remove more of the contaminants until the drained flushing oil appears sufficiently clean. 10) Remove the screen from suction strainer once again and clean it. 11) Reinstall the screen. 12) Remove and replace the filter element.

22783 (8/02)

5 - 14



Oil Lube Crusher

Annular/Labyrinth

Seal

Brand

Ambient Temp 32°F (0°C) or above

Ambient Temp 32°F (0°C) to 0°F (-18°C)

Ambient Temp below 0°F (--18°C)

Chevron Gear Compound EP

220

150

Exxon Spartan EP

220

150

68

Shell Omala EP

220

150

68

Mobil Mobilgear

630

629

68

Texaco Meropa

220

150

68

Maximum Operating Temperature (Returning from bearings)

190°F (88°C)

170°F (77°C)

130°F (54°C)

Table 5 - 2 Recommended oil viscosities/brands

22783 (8/02)

5 - 15



Oil Lube Crusher Oil Heater (optional) For operation in cold weather, an optional oil heater system is available. Immersion heaters mounted in the tank maintain oil at a thermostatically controlled temperature. Set the temperature of the thermostat no higher than the Maximum Operating Temperature listed in Table 5 - 2. When using the oil heaters, the temperature of the oil returning from the bearings to the reservoir should be monitored to ensure that the operating temperature does not exceed maximum operating temperature for the viscosity of oil being used. This

Annular/Labyrinth

Seal

is especially important when using the lower viscosity oils since their maximum operating temperature is low.

CAUTION Do not heat oil by applying a torch flame directly to the reservoir. Extreme heating could burn the oil and reduce the oils ability to lubricate. The optional oil heaters should be installed according to the schematic in Figure 5 - 12.

120 VAC by customer 30 Amp Service

30 Amp 104

100

102

Heater Power OFF 104

Heater #1

105

1000 W

ON OFF 104

Heater #2

106

1000 W

ON

Figure 5 - 12 Oil heater electrical schematic

Cycle Timer (optional) When operating in cold weather with the optional oil heater system, an optional cycle timer can be used to warm the crusher and oil when not operating. The cycle timer can be set to run the lubrication pump for short periods of time when the crusher is not in operation. With the heaters 22783 (8/02)

running, the warm oil in the reservoir will be ed through the bearings and hoses to prevent oil in these areas from gelling. The cycle timer should be installed and wired as shown in the typical wiring schematic shown in Figure 5 - 13.

5 - 16



Oil Lube Crusher The timer can be set to cycle time from 0.6 seconds to 24 hours. By changing dip switch settings, the time range of the timer dials is changed. The Off timer controls the amount of time that the lube pump will shut off. The On timer controls the length of time that the lube pump will be running. Setting the dip switches to the setting shown in Figure 5 - 13 will give the Off timer a range of 1145 minutes. The On time will have a range of 1.5 -

Annular/Labyrinth

Seal

5.5 minutes. Other time ranges can be selected by changing the dip switch settings according to the chart on the side of the timer. For normal operation the Day-Night switch should be in the Day position which will allow the lube pump to run continuously when started. When the Day-Night switch is in the Night position the lube pump will run on the timed cycle set by the timer dials.

Timer Dials

Timer Dip Switches

Figure 5 - 13 Lube pump cycle timer

22783 (8/02)

5 - 17



Periodic Maintenance

Periodic Maintenance Maintenance Benchmark Checklist The maintenance benchmark checklist can be a useful tool to determine if bearings or components are operating outside of normal operating ranges. Refer to Table 5 - 3. When the crusher is first put into service and at operating temperature, record the following in the “Benchmark” column. •

Bearing Temperature

•

Electrical Component Temperature

•

Full Load Amps and Voltages

•

Belt Tension

Each month the readings should be taken again and recorded in the appropriate column. Always to use the same measuring procedure. If a reading varies significantly from previous or benchmark readings, investigate the cause.

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5 - 18



Maintenance Sheet

Benchmark

Check

December

November

October

September

August

July

June

May

April

March

February

January

Benchmark

Maintenance Benchmark Check Sheet

I) Temperatures A. Bearings 1. Drive Side 2. Non Drive Side 3. Drive Side Pitman 4. Non Drive Side Pitman 5. Jack Shaft/Outboard Bearing B. Electrical Components 1. Starters 2. Breakers 3. Motor 4. Plug II) Electrical Checks A. Full Load Amps 1. At Motor 2. Below Starter 3. Top of Starter 4. Below Breaker 5. Above Breaker B. Voltage (each leg) 1. L1 2. L2 3. L3 III) Belt Tension A. Drive Belts B. Oil Pump Drive

Table 5 - 3 Maintenance Benchmark Check Sheet

22783 (8/02)

5 - 19



Maintenance Sheet Periodic Inspections 1) Check and tighten all fastening and mounting bolts, cap screws and set screws. 2) Inspect the stationary and movable jaws for wear. To maintain efficient operation the jaws should be turned when the corrugations at the lower end are worn almost smooth, or replaced after both ends are worn. The stationary jaw will generally require turning or replacing more often than the movable jaw.

Benchmark

Check

5) The toggle plate needs no care other than lubrication and replacement when natural wear reduces the balls on both ends. When the balls have worn 1 inch (25.4 mm) on each end or half the original ball, replace toggle plate. Do this before excessive wear occurs to toggle seat insert in pitman and the base toggle seat. Be sure the toggle plate is located as centrally in position as possible in relation to the toggle seat insert in the pitman.

WARNING Failure to replace jaws when corrugations are worn smooth, or running crusher until concave sections are worn in jaws will reduce capacity of crusher. Also, jaws not changed when recommended will cause compaction of material in crushing chamber and could result in premature bearing failure, excessive breakage of toggle plates or shaft or base breakage. 3) Inspect the key plates, especially the lower sections, for wear. Replace when worn through. Tighten both of the key plates. 4) Check and tighten the movable jaw wedge to prevent the movable jaw from becoming loose and causing wear or damage to the pitman.

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5 - 20


Electrical

Standard Drive Electrical

Section 6 - Electrical Standard Drive Electrical No drive electrical controls are provided as standard with the crusher. It is usually controlled from the main power . Check with the supplier of the electrical system for specific information.

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6-1


Electrical

Standard Drive Electrical

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6-2


Troubleshooting

Troubleshooting

Section 7 - Troubleshooting

The following are some of the most common causes of bearing overheating:

Troubleshooting

1) Improper lubricant level. Too much lubricant will not allow for proper circulation and air space inside housing. Fill only to correct levels.

Crusher Not Operating At Rated Capacity 1) Pitman shaft direction of rotation incorrect.

2) Insufficient, dirty or improper lubricant.

2) Stationary jaw loose.

3) Operating at a speed faster than recommended.

3) Speed incorrect.

4) Crusher out of level. This will cause lubricant to flow away from the high bearing. Make sure crusher is level.

4) Jaws excessively worn. 5) Attempting to feed raw material larger than crushing chamber.

5) Side bearing outer seal and flinger not turning with shaft.

6) Incorrect toggle plate for size of crusher discharge opening.

6) Insufficient radial clearance between side bearing outer seal and end cap.

7) Lack of raw material or erratic feeding of crusher.

7) Toggle plate improperly seated.

8) Insufficient power or v-belt slippage.

8) Bearing(s) damaged and/or failing.

Bearings Overheating

9) Movable jaw rubbing on base or key plates.

The bearings normally operate at 100° to 150°F (38° to 66°C) but in warm climates may reach 180° to 200°F (82° to 93°C). Under these conditions and within these limits the bearings are not overheating. However, if a bearing maintains 212°F (100°C) or higher, it is considered to be overheating. The cause should be found and corrected.

10) Bent pitman shaft. 11) Seals Rubbing.

Temperature should be checked on housing closest to the bearing or on the end plate nearest the bearing.

22783 (8/02)

7-1


Troubleshooting

Troubleshooting

Excessive Jaw Wear 1) Stationary jaw loose. 2) Closing crusher below minimum recommended discharge opening. 3) Operating faster than recommended. 4) Not using genuine Cedarapids jaws. 5) Very abrasive material. Difficult to Adjust Closed Side Setting 1) Tension spring not released. 2) angles on base not loose. 3) Toggle seat loose and “peened” into base.

22783 (8/02)

7-2


Torque Specs

Torque Charts

Appendix A - Torque Specs Torque Charts The following pages contain charts for use as guides when tightening bolts and nuts. These specifications should be followed unless specific torques are given elsewhere in this manual. Standard Torque Chart Table A - 1 is a list of recommended torque values for standard bolts. Use this torque chart to avoid overstressing standard nuts and bolts used on the equipment. These specifications should be followed unless specific torques are given. The equipment uses Grades 2, 5, and 8. The maximum torque values are based on 75% of the specified minimum proof strength of the bolt steel in order to provide a safety factor. The term “lube” applies to cium plating and/or application of thread lubricants. Hardened washers should always be used, regardless of whether standard nuts or lock nuts are employed. Metric Torque Chart Table A - 2 is a list of torque values recommended for metric bolts. The maximum torque values are based on 75% of the specified minimum proof strength. The term “lube” includes the application of thread lubricants, cium plating and the use of hardened washers regardless of whether standard or lock nuts are used.

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A- 1


Torque Specs

Torque Charts

Standard Torque Chart S.A.E Grade 2 dia. pitch (inches) (thread/in.) 1/4

20

Torque (ft-lbs) Dry

Lube

Clamp Load (lbs)

5

4

S.A.E Grade 5 Torque (ft-lbs)

S.A.E Grade 8

Dry

Lube

Clamp Load (lbs)

2020

12

9

2860

Dry

Lube

Clamp Load (lbs)

1310

8

6

Torque (ft-lbs)

1/4

28

6

5

1500

10

7

2320

14

11

3270

5/16

18

11

9

2160

17

13

3340

25

19

4710

5/16

24

12

10

2390

19

15

3690

27

21

5220

3/8

16

20

15

3190

31

24

4940

44

34

6970

3/8

24

23

17

3620

35

27

5590

49

38

7900

7/16

14

32

25

4380

49

38

6770

70

54

9560

7/16

20

36

27

4890

55

42

7560

78

60

10680

1/2

13

49

38

5850

75

58

9040

106

82

12770

1/2

20

55

42

6590

85

65

10190

120

92

14390

9/16

12

70

54

7500

109

84

11600

150

115

16380

9/16

18

79

60

8370

121

93

12940

170

130

18270

5/8

11

97

75

9320

150

115

14400

210

160

20340

5/8

18

110

85

10560

170

130

16320

240

180

23040

3/4

10

170

130

13770

265

200

21290

375

285

30060

3/4

16

190

145

15380

295

225

23770

415

320

33570

7/8

9

165

125

11430

425

330

29450

605

465

41580

7/8

14

180

140

12590

470

360

32440

665

510

45810

1

8

245

190

14990

640

495

38630

905

695

54540

1

14

270

210

16400

700

540

42260

990

765

59670

1-1/8

7

350

270

18880

790

610

42340

1285

990

68670

1-1/8

12

395

305

21180

890

685

47500

1440

1110

77040

1-1/4

7

495

380

23980

1120

860

53770

1815

1395

87210

1-1/4

12

550

425

26550

1240

950

59550

2010

1545

96570

1-3/8

6

655

500

28580

1465

1130

64100

2380

1830

103950

1-3/8

12

745

570

32540

1670

1285

72980

2710

2085

118350

1-1/2

6

865

665

34770

1945

1495

77970

3160

2430

126450

1-1/2

12

975

750

39120

2190

1685

87740

3555

2735

142290

1-3/4

5

1370

1055

47020

2285

1755

78370

4985

3835

170990

2

4.5

2060

1585

61870

3435

2640

103120

7500

5765

225000

2-1/4

4.5

3015

2320

80430

5025

3865

134060

10960

8435

292500

2-1/2

4

4125

3170

99000

6875

5285

165000

15000

11530

360000

2-3/4

4

5590

4300

122010

9320

7165

203360

17790

13680

388230

3

4

7385

5680

147750

12310

9470

246260

23500

18080

470130

Table A - 1: Torque Values for Standard Hardware

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A- 2


Torque Specs

Torque Charts

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

Property Class = 10.9

Lube

Dry

Property Class = 12.9

Lube

Dry

Lube

(ft-lbs)

N-M

(ft-lbs)

N-M

(ft-lbs)

N-M

(ft-lbs)

N-M

(ft-lbs)

N-M

10

1.5

37

50

29

39

53

72

41

56

62

84

48

65

10

1.25

39

53

30

41

56

76

43

58

66

89

51

69

12

1.75

65

88

50

68

93

126

71

96

109

148

83

113

12

1.25

71

96

55

75

101

137

78

106

119

161

91

123

14

2

104

141

80

108

148

201

114

155

173

235

133

180

14

1.5

112

152

86

117

160

217

123

167

187

254

144

195

16

2

161

218

124

168

230

312

177

240

269

365

207

280

16

1.5

172

233

132

179

246

334

189

256

287

389

221

300

18

2.50

230

312

177

240

318

431

245

332

372

504

286

388

18

1.5

258

350

199

270

357

484

275

348

418

567

321

435

20

2.5

325

441

250

339

450

610

346

469

525

712

404

548

20

1.5

360

488

277

376

499

677

384

521

583

791

448

607

22

2.5

443

601

341

462

613

831

471

639

716

971

551

747

22

1.5

486

659

374

507

673

913

518

702

786

1066

605

820

24

3

562

762

432

586

777

1054

598

811

908

1231

698

946

24

2

612

830

471

639

847

1149

652

884

990

1342

762

1033

27

3

823

1116

633

858

1139

1544

876

1188

1331

1805

1024

1389

27

2

889

1205

683

926

1229

1667

945

1281

1436

1947

1105

1498

Table A - 2: Torque Values for Metric Hardware

22783 (8/02)

A- 3


Torque Specs

Torque Charts

22783 (8/02)

A- 4


General Belt Drive Care

General Belt Information

Appendix B - General Belt Drive Care General Belt Information You get more service from V-belts if you keep them clean and dry. Rock dust and rust from metals are abrasive. Oils and acids deteriorate belt material. Dust buildup in sheaves causes harmful vibration. On belts, dust or water causes slippage. For maintenance purposes, so-called belt dressing compounds are worse than worthless. Most belt dressings actually shorten belt life. Clean, well cared for belts are the best answer to problems that belt dressings are meant for but do not solve. Daily cleaning of belts and sheaves by blowing them off with compressed air increases their useful life and saves you money.

5) Periodically inspect the V-belt drive for wear (Figure B - 2) and for proper sheave alignment (Figure B - 1). 6) Do not overtighten belts. Overtightening shortens useful life of belts and sheaves and also places undue strain on shafts which, in turn, causes premature bearing failure. Ideal belt tension is lowest at which belts won't slip under peak load.

OK

1) Keep belts and sheaves clean. 2) Avoid belt or sheave rubbing. Don't let belts or sheaves rub against the guard (or anything else) while they’re running. 3) Drive your belts with motors mounted on adjustable bases. Mount drive motors on a slotted base, so you can shorten the distance from motor to driven sheave when you need to do so. This allows convenient and proper installation of belts. Prying on belts with tools cracks and prematurely breaks them. With belts already lightly seated in their grooves, you can tighten the belts correctly by moving the motor and rolling the sheaves at the same time. 4) Keep belts tight. Most belt stretch occurs in the first 30-40 hours of operation after new belts are installed. Check belt tension frequently during this period. Slack belts cause slipping and excessive wear. They cost you money by delivering less power and causing more frequent replacement.

22783 (8/02)

OK

Figure B - 1: Align Sheaves

7) Keep belts straight (Figure B - 1). Don't allow V-belts to run out of alignment. To run properly, sheaves must be parallel and grooves must be in line. 8) Use only matched belts. A matched set of belts lasts longer because loading is evenly divided among all the belts.

B- 1



Maintaining V-Belt Tension

Belts often wear at the sides, so their crosssectional area decreases. They stretch with use and age. New belts ride higher in sheave grooves. They travel faster and take higher tension than worn belts. If its center cord breaks, a belt stretches and won't carry its load. Putting one or two new belts on a partially used set very soon wears and stretches the new ones until they are in poor condition. Their cost is wasted.

5) If belts are not tight enough, loosen drive motor mount bolts and adjust take-up bolts to tighten belts. Retighten motor mount bolts to hold tension. Worn Sheave

Worn Belt or Sheave

Just Right

Belts from different manufacturers should not be mixed in a set because of slight material and quality differences that could reduce the life of all the belts. Always replace belts in full sets. 9) Don't overload. If the sheave has 10 grooves, use 10 belts. Using less than the designed number of drive belts puts too much strain on remaining ones. They will break down quickly and cause you downtime.

Figure B - 2: Belt & Sheave Wear

10) Replace worn sheaves. Worn sheaves reduce belt life. If the sheave is worn enough that belts touch bottom in the grooves, belts soon start to slip and burn. If your maintenance program takes all of those things into , your troubles with belts and sheaves will be minimal. Still, you’re bound to experience some problem, sooner or later. When you do, use Table B - 1 as a diagnostic tool.

Maintaining V-Belt Tension Figure B - 3: Sheave Gauge Shows Wear

1) Check drive belt tension daily. Check condition of belts and sheaves (Figure B - 2). 2) If belts are worn, replace with a matched set. 3) Use a sheave gauge (Figure B - 3) to look for steps worn in sheave grooves. Steps are a measure of sheave wear. Belts must not bottom out in grooves. 4) If sheaves are worn excessively, replace them.

22783 (8/02)

B- 2



Maintaining V-Belt Tension

Trouble

Cause

Correction

Belts slip (sidewalls glazed)

Insufficient tension

Replace belts; increase tension

Drive squeals.

Overloaded drive. Arc of too short. Heavy starting load.

Find cause and correct. Increase distance between hubs. Increase tension.

Rock gets into drive. Broken cord caused by prying. Overloaded drive. Impulse Loads.

Replace belt correctly. Redesign drive. Apply proper tension.

Belt rolls over.

Mismatched belts

Excessive vibration.

Check drive design, mounting. Consider banded belts.

New belts installed with old.

Replace belts with matched set.

Sheave grooves worn unevenly. Improper groove angle.

Replace sheaves.

Shafts not parallel.

Align drive.

Shock loads.

Apply proper tension.

Heavy starting load.

Apply proper tension. Use compensator starting.

Belt pried over sheaves. Foreign object in drive.

Replace belt correctly. Determine source of object, design guard to correct problem.

Sheave grooves worn. Sheave diameter too small. Mismatched belts. Drive overloaded. Belt slips. Sheaves misaligned. Oil present. Excess heat present.

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

Belt breaks

Belt wears prematurely.

Realign drive. Replace sheave. Align and reposition.

Misalignment. Worn sheave grooves. Flat idler sheave.

Table B - 1: Belt-Drive Diagnostics

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B- 3



Check Belt Tension with Mechanical Tester

Each 1/64" mark equals 1" of belt span (Centimeters on Opposite Side)

Each Mark Equals 1 Pound Pressure (Kilograms on Opposite Side)

Large O-ring

Small O-ring

Figure B - 4: Belt Tension Tester (Cedarapids P/N 45500-036-08)

Small O-ring

Bottom of Straightedge or Top of Adjacent Belt

Span "t"

Deflection to be 1/64" Per Inch Span

Large O-ring

Figure B - 5: Using the Belt Tension Tester

Check Belt Tension with Mechanical Tester 1) Measure span length "T" (Figure B - 5). 2) Position large O-ring on tester at 1/64 inch (0.397 mm) for each inch of belt span. Set small O-ring at zero (Figure B - 5). Example: For belt span of 48 inches (1.219 m), setting would be 48/64 inch (3/4 inch, or 19.05 mm). 3) At center of belt span, push yellow tipped plunger until bottom of large O-ring is level with top of adjacent belt (Figure B - 5). If there is no adjacent belt, lay straight edge between sheaves for reference.

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4) Remove tester and read belt deflection force, in pounds, at small O-ring. Compare this figure with values given in tables that follow. If required force is within limits shown in table for that particular belt, drive tension should be satisfactory. If required force is outside these limits, drive should be retensioned. 5) When installing new belts, tension may relieve during run-in. After drive is operated for several days, tension should be checked and adjusted to recommended tension values.

B- 4


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B- 5 D

CX

B, BX

A, AX

Cross Section

5.4 4.7

1000 - 2500 2501 - 4000

5.0 - 7.0

11.5 9.4 14.1 12.5 24.9 21.2 30.4 25.6

500 - 1740 1741 - 3000 500 - 1740 1741 - 3000 200 - 850 851 - 1500 200 - 850 851 - 1500

7.0 - 9.0 9.5 - 16.0 12.0 - 16.0 18.0 - 20.0

45.2 38.0

37.0 31.3

21.0 18.5

17.0 13.8

9.4 8.9

15.9 14.6

14.7 11.9

8.5 7.3

Table B - 3: Belt Deflection Force

6.3 6.0

860 - 2500 2501 - 4000

7.1 7.1

7.9 6.7

860 - 2500 2501 - 4000

5.7 5.1

5.0 4.3

4.1 3.4

4.9 4.2

5.8 - 8.6

4.4 - 5.6

8.0 7.0

6.8 5.7

5.5 4.2

860 - 2500 2501 - 4000 5.3 4.5

4.5 3.8

1000 - 2500 2501 - 4000

3.8 - 4.8

3.4 - 4.2

3.7 2.8

1000 - 2500 2501 - 4000

3.0 - 3.6

23.52 1.6

21.8 21.6

12.6 10.9

10.5 9.1

7.2 6.2

9.4 7.6

7.4 6.4

6.1 5.0

New Belt

Used Belt

New Belt

Used Belt

RPM Range

Smallest Sheave Diameter Range

Cogged Torque-Flex & Machined Edge Torque Team Belts

Uncogged Hy-T Belts & Uncogged Hy-T Torque Team Belts

Belt Deflection Force (Pounds)

8V

5V, 5VX

3V, 3VX

Cross Section

39.6 35.3

59.2 52.7

49.3 39.9

23.4 21.8

18.9 16.7

7.3 6.6

5.1 4.4

New Belt

17.1 16.8

14.8 13.7

10.2 8.8 5.6

5.3 4.9

4.2 3.8

3.3 2.9

Used Belt

25.5 25.0

22.1 20.1

15.2 13.2 8.5

7.9 7.3

6.2 5.6

4.9 4.3

New Belt

Cogged Hy-T Wedge Belts & Hy-T Wedge Machine Edge Torque Team

Table B - 2: Belt Deflection Force

200 - 850 851 - 1500

33.0 26.8

200 - 850 851 - 1500 12.5 - 17.0 18.0 - 22.4

15.5 14.6

12.7 11.2

4.9 4.4

3.6 3.0

Used Belt

500 - 1740 1741 - 3000

500 - 1740 1741 - 3000

500 - 1749 1750 - 3000 3001 - 4000

1000 - 2500 2501 - 4000

1000 - 2500 2501 - 4000

1000 - 2500 2501 - 4000

RPM Range

11.8 - 16.0

7.1 - 10.9

4.4 - 6.7

4.12 - 6.90

2.65 - 3.65

2.2 - 2.4

Smallest Sheave Diameter Range

Uncogged HyT Wedge Belts & Uncogged Hy-T Wedge Torque Team

Belt Deflection Force (Pounds)


Check Belt Tension with Mechanical Tester



Belt Guards

Belt Guards

3V

1.0”

.62”

.38” .31”

5V

V-belt drive guards promote both cleanliness and safety. Screened, meshed or grilled guards are best because they allow air to circulate and heat to escape.

.54”

8V

.88”

.50”

A

.31”

.66”

B

.41”

.88”

C

.53”

1.25”

D

.75”

1.5”

E

.91”

Figure B - 6: Belt Types in Cross-Section

22783 (8/02)

B- 6



Idlers

Idlers A properly designed V-belt drive does not require an idler to deliver full rated horsepower if proper belt tension can be maintained. Idlers should be avoided if possible because an idler puts an additional bending stress point on the belt. This reduces the belt’s horsepower rating and its life expectancy. The smaller the idler, the greater the stress and the more belt life is reduced.

Driver Driven

Inside Idler A V-grooved idler located on the inside of the belts on the slack side of the drive is recommended over a back-side idler. The idler should be located near the large sheave to minimize reduction of the arc of across the small sheave. The diameter of the V-idler pulley should be equal to or larger than that of the small sheave.

Kiss Idler A kiss idler differs from the back-side idler because the kiss idler does not penetrate the belt span and create a back-bend on the belt. Consequently, the kiss idler does not contribute to premature belt failure. Use of a kiss idler can help control belt vibration and whip on drives subject to shock and pulsating loads. Kiss idlers can be used in single-belt drives where ed belts are not applicable. If a kiss idler is used, diameter of the flat pulley should be at least 1-1/2 times (1.5x) greater than the diameter of the small sheave.

Driver Driven

Back-Side Idler A back-side idler increases the arc of on both sheaves. However, it forces a backward bend in the V-belt that contributes to premature belt failure. The idler puts additional stress on the bottom portion of the belt which will result in bottom cracking. If a back-side idler must be used, the diameter of the flat idler pulley should be at least 1-1/2 times (1.5x) the diameter of the small sheave. A back-side idler should be located as close as possible to the small sheave.

22783 (8/02)

B- 7

Driver Driven



Idlers

NOTES:

22783 (8/02)

B- 8


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