C_Jaw_Instruction_EN_Rev_N (140588) (Updated).pdf

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NORDBERG C SERIES JAW CRUSHERS

INSTRUCTION MANUAL

140588-EN

REV. N





EN 140588-0_N NORDBERG C SERIES JAW CRUSHERS 0-1

NORDBERG C SERIES JAW CRUSHERS CHAPTER 0

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

Because of the continuous development of the product, the manufacturer reserves a right to alter thetechnical specifications written in this manual, without any advance information. In case of conflicts

between different language versions, the English version of this manual is the original and prevails.

Copyright © 2010 Metso. Printed in Tampere, Finland.

Manufacturer:

Metso Minerals , Inc., Tampere Works

Lokomonkatu 3, P.O. Box 306

33101 Tampere

Finland

Phone: +358 204 84 142

Fax: +358-204-84 143

email: [email protected]

www.metso.com



0-2 NORDBERG C SERIES JAW CRUSHERS 140588-0_N EN

CHAPTER 0 - NORDBERG C SERIES JAW CRUSHERS

This Page Left Intentionally Blank.



Nordberg C Series Jaw Crushers

Table of Contents

NORDBERG C SERIES JAW CRUSHERS

PREFACE

1.1 FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.2 SAFETY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

SAFETY

2.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

2.1.1 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2.1.2 Operation safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2.1.3 Maintenance safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

2.2 WARNING SIGNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

2.2.1 Warning sign codes and texts (ANSI). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-82.2.2 Warning sign codes and texts (ISO). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

GENERAL CRUSHER INFORMATION

3.1 CRUSHER TERMINOLOGY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.2 CRUSHER COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3.3 SPARE PARTS BOOK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

3.4 ORDERING PARTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

3.5 ESTIMATING CRUSHER CAPACITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

3.6 ESTIMATING CRUSHER PRODUCT GRADATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

3.7 CRUSHER SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

3.8 CRUSHER SETTING LIMITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

3.9 OPTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

3.9.1 Intermediate Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

3.9.2 Protection Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

3.9.3 Conveyor Belt Protector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

3.9.4 Hydraulic Setting Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

3.9.5 Automatic Lubrication Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14




Table of Contents

OPERATING INSTRUCTIONS

4.1 PREPARATIONS BEFORE STARTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.2 STARTING THE CRUSHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.3 STOPPING THE CRUSHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.4 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4.4.1 Oversized Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4.4.2 Tramp Iron/Uncrushables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4.4.3 Packing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4.5 RE-STARTING A CRUSHER STALLED UNDER LOAD . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

4.6 CRUSHER SETTING ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

4.6.1 Mechanical wedge setting adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

4.6.2 Hydraulic wedge setting adjustment (optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

4.6.3 Active setting control adjustment (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

4.7 TOGGLE PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

4.8 SPACER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

4.9 TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

MAINTENANCE

5.1 SPACER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3

5.1.1 Spacer Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5.1.2 Spacer Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

5.2 TOGGLE PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-75.2.1 Replacing the Toggle Plate And Toggle Seats (with wedge setting adjustment) . . . . . . 5-7

5.2.2 Replacing the Toggle Plate And Toggle Seats with Active Setting Control . . . . . . . . . . 5-9

5.3 LUBRICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

5.3.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

5.3.2 Grease Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

5.3.3 Eccentric Shaft Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

5.3.4 Eccentric Shaft Bearing Temperatures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

5.3.5 Jack-shaft Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

5.3.6 Jack-shaft Bearing Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

5.3.7 Thrust Bearing And Cap Nut Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

5.3.8 Tension Cylinder Slide Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

5.3.9 Electric Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

5.3.10Toggle Seats And Toggle Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19

5.3.11Setting Adjustment Wedges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20




Table of Contents

5.4 INSTRUCTIONS FOR LIFTING A JAW CRUSHER WHEN REPLACING

CRUSHER SUPPORT BRACKET DAMPERS . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

5.5 HYDRAULIC POWER UNIT (OPTIONAL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22

5.5.1 Checking oil level and temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22

5.5.2 Changing oil and filter (Figure 5.11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-225.5.3 Oil recommendation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24

5.5.4 Bleeding the hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25

5.6 PERIODICAL MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28

5.6.1 Daily maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28

5.6.2 Weekly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29

5.6.3 Monthly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30

5.6.4 Twice a Year. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30

5.6.5 Regularly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30

5.7 MAINTENANCE INTERVALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31

5.8 BOLT TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33

REPLACEMENT OF WEAR PARTS

6.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2

6.2 JAW DIE SELECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6.3 JAW DIE WORK HARDENING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6.4 CHEEK PLATE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6.4.1 Cheek Plate Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

6.4.2 Cheek Plate Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

6.5 CHANGING OR ROTATING THE JAW DIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

6.5.1 One piece jaw dies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

6.5.2 Two-piece jaw die removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17

6.5.3 Welding lifting lugs to the jaw die . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28

6.6 PITMAN EYE PROTECTION PLATE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31

6.7 FEED HOPPER LINER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31

6.8 TOGGLE PLATE SEAT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31




Table of Contents

APPENDIX A

SAFETY, OPERATING AND MAINTENANCE INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . .A-1

1. Purpose of the jaw die lifting tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1

2. Storage of the jaw die lifting tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-13. Safe use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1

4. Commissioning and operating conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2

5. Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2

6. The jaw die lifting tool verification before first use and in service. . . . . . . . . . . . . . . . . .A-2

7. Handling the load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2

8. Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

9. Operating instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5

APPENDIX B

SAFETY, OPERATING AND MAINTENANCE INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . .B-1

1. Purpose of the cheek plate lifting tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1

2. Storage of the cheek plate lifting tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1

3. Safe use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1

4. Commissioning and operating conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2

5. Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2

6. The cheek plate lifting tool verification before first use and in service . . . . . . . . . . . . . .B-2

7. Handling the load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3

8. Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3

9. Operating instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7



EN 140588-1_N NORDBERG C SERIES INSTRUCTION MANUAL 1-1

PREFACE CHAPTER 1

1.1 FOREWORD

This instruction manual provides guidance for firsttime operators of the crusher as well as technical

procedures as a reference for the experiencedcrusher operator. Read, study, and keep it for futurereference.

The instructions given are for the operation and basic maintenance procedures only, as thisinstruction book is not a repair manual. Shouldmaintenance procedures not covered in this manual

be required, contact Metso.

Illustrations and instructions guide the operatorthrough correct procedures for checking, operatingand maintaining the crusher and its accessories.

Operating techniques outlined in this manual are basic. Operating skills and additional techniqueswill develop through experience as the operatorgains knowledge of the crusher and its capabilities.

Continuing improvement and advancement of product design may result in changes to your newmachine that may not be included in this

publication. As required, each publication isreviewed and revised to update and includeappropriate changes in the later editions.

The descriptions and specifications in this manualwere in effect at the time this manual was approvedfor printing. Metso reserves the right to discontinuemodels at any time and to change specifications anddesigns, without notice and without incurringobligation.

Whenever a question arises concerning yourcrusher, or this publication, please consult yourMetso representative for the latest availableinformation.

1.2 SAFETY

BASIC RULES REGARDING SAFETY IN ANDAROUND A CRUSHING PLANT AREOUTLINED IN THE SECTION ENTITLED"SAFETY."

OPERATOR SAFETY AND THE SAFETY OFOTHERS DEPEND UPON REASONABLECARE AND JUDGEMENT IN THE OPERATIONOF THIS CRUSHER. A CAREFUL OPERATORIS GOOD INSURANCE AGAINST ANACCIDENT.

MOST ACCIDENTS, NO MATTER WHERETHEY OCCUR, ARE CAUSED BY FAILURE TOOBSERVE AND FOLLOW SIMPLE

FUNDAMENTAL RULES OR PRECAUTIONS.FOR THIS REASON RECOGNIZING HAZARDSAND TAKING STEPS TO AVOID THEM CANPREVENT MOST ACCIDENTS.

REGARDLESS OF THE CARE USED IN THEDESIGN AND CONSTRUCTION OF THISTYPE OF EQUIPMENT, THERE ARECONDITIONS THAT CANNOT BECOMPLETELY SAFEGUARDED AGAINSTWITHOUT INTERFERING WITHREASONABLE ACCESSIBILITY ANDEFFICIENT OPERATION. WARNINGS ARE

INCLUDED IN THIS INSTRUCTION MANUALTO HIGHLIGHT THESE CONDITIONS.



1-2 NORDBERG C-SERIES INSTRUCTION MANUAL 140588-1_N EN

CHAPTER 1 - PREFACE





SAFETY CHAPTER 2

2.1 GENERAL

The instructions of the safety guide, these safetyinstructions and other manuals and safety labels forthe equipment must be read, understood and used

by each person who works with this equipment.

The following symbol is used in this manual and onthe machine to call attention to instructions, which

will help prevent machine related injuries.

When you see this symbol on your machine or inthis manual, be alert to the potential for personalinjury.

Figure 2.1 Alert Symbol

This manual uses the alert symbol, with words suchas DANGER, WARNING or CAUTION, to alertyou and other Crushing Plant personnel of actionsor conditions that pose a potential safety hazard,with an attending risk of personal injury (includingdeath) or property damage. The machine also

displays safety signs, labels and tags at appropriate points to show safety risks that may exist.

Figure 2.2 Danger, warning, caution signs andtheir meaning

WARNING!

In addition to these unit-specific safetyinstructions, the operators of thisequipment must also read the safetyguide with instructions for generaloperational safety.

Sign Description

DANGERImmediate hazards or unsafe practicesthat will result in severe personal injuryor death.

WARNINGHazards or unsafe practices that couldresult in severe personal injury or death

CAUTION

Hazards or unsafe practices that couldresult in minor personal injury orequipment damage

DANGER

CAUTION

WARNING



2-2 NORDBERG C SERIES INSTRUCTION MANUAL 140588-2_N EN

CHAPTER 2 - SAFETY

Personal protective equipment and clothing such asfoot protection, helmet, hearing protection, dust

protective devices, safety glasses or other personal protective clothing and equipment should be wornat all times.

Figure 2.3 Personal safety equipment

2.1.1 General safety instructions

1. Ignoring the safety instructions or thewarning signs increases the risk of thesevere injury or death.

2. Nordberg C series jaw crushers has beendesigned for safe operation when used by

professional staff in the operating situationsincluded in this instruction manual. All

other service and repair procedures must be performed by specially trained personnel orauthorized Metso service staff.

3. The crushing plant and auxiliary equipmentsuch as chutes, transfer stations, screens,

DANGER!

When working outside service platforms, safety harnesses must beworn!

WARNING!

Before performing any maintenance orrepair work, make sure that the crusheris stopped and locked out.

LOCKOUT PROCEDURE of theLokotrack installed crushers

1. Switch off engine

2. Remove the ignition key and keep iton person during lockout

3. Place appropriate maintenancewarning signs (TAG OUT)

LOCKOUT PROCEDURE of theelectrical motor driven crushers

1. Switch off motor

2. Lock the main switch of the motorwith a padlock or make sure in someother way that the engine cannot bestarted

3. Lock the main switch of the hydraulicadjustment power unit (if delivered)with padlock

4. Keep the keys on person duringlockout

5. Place appropriate maintenancewarning signs (TAG OUT).




CHAPTER 2 - SAFETY

etc. can create dust and, if not contained, thedust can escape into the air. Metso highlyrecommends that dust protective devicessuch as an appropriate respirator be worn byanyone exposed to airborne dust to preventits inhalation. It is the responsibility of theOwner and Operator to determine thenecessity and adequacy of protectivedevices and warnings, to provide them, andto ensure that they are used and followed!

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

5. Keep the warning signs clean. Replaceillegible and damaged signs before startingthe crusher. Make sure that the warning

signs are not hidden from sight wheninstalling the crusher. If a part with awarning sign is replaced, make sure that thenew part also has the required warningsigns.

2.1.2 Operation safety instructions

1. Never operate the crusher without propercovers and safety devices. If the covers orsafety devices have not been purchased fromMetso, a customer has to ensure that the

covers and safety devices are according tolaw and regulations.

2. Before starting the crusher make sure that noone is near the crusher.

3. It is prohibited to stay in the danger areaduring the crushing process. The crushingmaterial may be thrown into a few metersdistance from the crusher. Always usehelmet and safety glasses.

4. Do not look into the jaw cavity duringcrushing. Material may be thrown from thecrusher during crushing and cause injuries.

Always use a helmet and safety glasses.5. Because the crusher is installed on rubber

dampers, it moves during crushing. Thismovement causes a crushing danger. Never

put your hands or feet between the moving parts and the structure of the crusher duringcrushing. The movement may be as much as± 10mm.

6. Clearing a jammed cavity is extremelydangerous. Do not attempt to clear the cavityuntil the crusher has stopped completely.




CHAPTER 2 - SAFETY

2.1.3 Maintenance safety instructions

1. The crusher does not stop immediately afterthe motor has been turned off. Make surethat the crusher has stopped completely

before opening any covers, performing any

maintenance, or adjusting the crusher.2. Before performing any maintenance or

repair work, make sure that the crusher isstopped and locked out.

3. The surfaces of the crusher may become hotduring crushing. Hot surfaces can causesevere burn injuries. Make sure that thesurfaces have cooled before performing anymaintenance work.

4. Before changing any wear parts of thecrusher, read chapter 6: Replacement ofwear parts and appendixes A and B

carefully.5. Before lifting any wear parts, check the

weight of the component and ensure thatlifting equipment being used is adequate tolift the weight. In addition, familiarizeyourself with all the special tools providedwith the crusher specifically for replacingthe wear parts.

6. Read the instructions regarding the liftingtools and replacing wear parts carefully

before replacing any wear parts. Make surethat the parts are adequately supported

before lifting. Never go under the suspended

load. The lifting tools delivered with thecrusher are designed to be used only withoriginal Metso wear parts.

7. The spring of the mechanical settingadjustment may accumulate significantamount of energy. Follow the instructionsstrictly and be extremely accurate whenadjusting the spring. Never release the

protective plate.

8. The pressure accumulator of the hydraulicalsetting adjustment may be charged only by a

professional. If the pressure accumulator is

charged incorrectly, it may explode. Do notcharge the accumulator yourself. Release the pressure from the hydraulic systemaccording to instructions before anymaintenance to the system.




CHAPTER 2 - SAFETY

NOTE: If the gib key is not pointing down, startthe crusher for a second.

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

WARNING!

Ensure that the crusher has stopped tothe “rest position”. In other words there

is no potential energy remaining in theflywheels. This can be determined fromthe position of the gib key. It should

point down. (Figure 2.4)




CHAPTER 2 - SAFETY

2.2 WARNING SIGNS

The warning signs attached to the equipment mustalways be kept readable and clean. Damaged orloose signs must be replaced at once before startingthe crusher. Make sure that the warning signs are

not covered during installation. If a part of thecrusher attached a warning sign are replaced,always make sure that the warning signs needed areincluded in a new part.

Figure 2.5 The locations of the warning signs

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

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

The warning signs 3 are delivered only if thecrusher delivery includes the drive guards.

The warning sign 5 is delivered only with crushersthat have a mechanical setting adjustment.

The warning signs 6, 7, and 9 are delivered onlywith crushers that have a hydraulical settingadjustment.

IMPORTANT!

There are two different sets of warningsigns depending on the delivery country.You can check which set of warning

signs is used on your machine from theside of the machine or the spare partmanual.

IMPORTANT!

Warning signs 1, 2, 3 and 4 are notattached on crushers installed inLokotracks or Nordwheelers.




CHAPTER 2 - SAFETY

Figure 2.6 Warning s igns (ANSI)

1

2

3 4 5 6

78

9




CHAPTER 2 - SAFETY

2.2.1 Warning sign codes and texts (ANSI)

1. MM0229994WARNINGRead and understand instruction manual

before using or maintaining this machine.Failure to follow operating instructions mayresult in death or serious injury.

DANGERLung disease hazard.Dust protection required.

WARNING

Risk of eye injury.Use of eye protection required.

CAUTIONRisk of head injury.Use of a helmet required.

CAUTION

Hazardous noise level.Use of ear protection required.

2. MM0229995DANGER

Moving parts can crush and cut.Do not insert tools in the crusher cavitywhen the motor is running.

WARNINGMaterial can fall out.do not stand in the vicinity of the crusherwhen the motor is running.

3. MM0229997WARNING

Exposed moving parts can cause severeinjury.Do not open drive guard before machine iscompletely stopped.

4. MM0229996

WARNINGExposed moving parts can cause severeinjury.Do NOT operate this machine without

proper guards.

5. MM0229998DANGERSpring in compression.Read and understand instruction manual

before adjusting or servicing.Do NOT remove this protection plate.

6. MM0230002WARNINGServicing while pressurized can causesevere injury.Lock out source and relieve pressure beforeservicing.

7. MM0230006CAUTION

Hot surface.Contact with skin may cause burns.

Do not touch.

8. MM0230004CAUTION

Hot surface.Contact with skin may cause burns.Do not touch.

9. MM0230447WARNING

Pressurized device.Only authorized personnel should servicethis dev ice.

See instruction manual for safetyinformation.




CHAPTER 2 - SAFETY

Figure 2.7 Warning signs (ISO)

1

2

3

5

9

6 7

8

4




CHAPTER 2 - SAFETY

2.2.2 Warning sign codes and texts (ISO)

1. MM0250258WARNINGRead and understand instruction manual

before using or maintaining this machine.Failure to follow operating instructions mayresult in death or serious injury.

DANGERLung disease hazard.Dust protection required.

WARNING

Risk of eye injury.Use of eye protection required.

CAUTIONRisk of head injury.Use of a helmet required.

CAUTION

Hazardous noise level.Use of ear protection required.

2. MM0250251DANGER

Moving parts can crush and cut.Do not insert tools in the crusher cavitywhen the motor is running.

WARNINGMaterial can fall out.do not stand in the vicinity of the crusherwhen the motor is running.

3. MM0250244WARNING

Exposed moving parts can cause severeinjury.Do not open drive guard before machine iscompletely stopped.

4. MM0250244

WARNINGExposed moving parts can cause severeinjury.Do NOT operate this machine without

proper guards.

5. MM0250242DANGERSpring in compression.Read and understand instruction manual

before adjusting or servicing.Do NOT remove this protection plate.

6. MM0250241WARNINGServicing while pressurized can causesevere injury.Lock out source and relieve pressure beforeservicing.

7. MM0250239CAUTION

Hot surface.Contact with skin may cause burns.

Do not touch.

8. MM0251117CAUTION

Hot surface.Contact with skin may cause burns.Do not touch.

9. MM0250104WARNING

Pressurized device.Only authorized personnel should servicethis device.

See instruction manual for safetyinformation.




GENERAL CRUSHER INFORMATION CHAPTER 3

3.1 CRUSHER TERMINOLOGY

Throughout this instruction manual, technical termsare used to describe the crusher, its components andits operation. These terms are defined herein withthe intent of avoiding any confusion ormisunderstanding.

Figure 3.1 Jaw crusher terminology

Feed: The raw material to be crushed, such as therock type (limestone, basalt, granite, etc.) orman-made materials such as concrete and asphalt.The feed size is typically denoted in terms of a sizedistribution or based on an average top (maximum)

size.

Product size: The size of the material after it has been crushed. Similarly to the feed size, the productsize is typically denoted in terms of a size

distribution or based on an average top (maximum)size.

Capacity: The output of the crusher in tons perhour.

Feed Opening: The opening where the feedmaterial is fed into the crusher. The feed openinghas two dimensions: a width and a depth. The feedopening depth is a critical dimension because itdictates the maximum feed size a given jaw crushermodel can accept.

Callout Description Callout Description

1 Feed opening depth 5 Stroke2 Moving jaw 6 Nip angle

3 Stationary jaw 7 Feed opening width

4 Closed side setting (c.s.s)




CHAPTER 3 - GENERAL CRUSHER INFORMATION

Maximum Recommended Feed Size: As ageneral guideline, the maximum averagerecommended feed size should be about 80% of thefeed opening depth. Such measures will ensure thatany bridging events resulting from oversized feedare kept to a minimum. A rock hammer isrecommended for applications where the maximumfeed size is regularly close to the feed openingdepth.

Table 3-1 Maximum recommended feed sizes

Nip Angle: The angle between the fixed andmoving jaws. The nip angle is often referred to asthe "bite" angle as well.

Jaws: The members that perform the crushing arecommonly referred to as jaws. The jaws consist of astationary and moving jaw, and depending on themodel each one of these may consist of either 1 or 2

pieces. Different jaw die profiles are available fordifferent applications.

Discharge Setting: The shortest distance betweenthe bottom of the fixed and moving jaws as

measured at the point where the jaws are at theirclosest relationship during their work cycle (i.e. theclosed side setting, or c.s.s.). The method in whichthe setting is measured varies depending on the jawdie profile. These differences are explained in detailin the CRUSHER SETTING section.

Stroke: The difference between the maximum andminimum distances at the bottom of the fixed andmoving jaws during one revolution of the eccentricshaft.

Feed Opening

MaximumRec. Feed

Size

mm inch mm inch

C80 800 X 510 20 X 32 408 16

C96 930 X 600 24 X 37 480 19

C100 1000 X 760 30 X 40 608 24

C106 1060 X 700 28 X 42 560 22

C110 1100 X 850 34 X 44 680 27

C116 1150 X 800 32 X 45 610 24

C3054 1380 X 760 30 X 54 608 24

C125 1250 X 950 37 X 49 760 30

C140 1400 X 1070 42 X 55 856 34

C145 1400 X 1100 43 X 55 880 35

C160 1600 X 1200 47 X 63 960 38

C200 2000 X 1500 59 X 79 1200 47





3.2 CRUSHER COMPONENTS

Figure 3.2 Jaw crusher main components


1 Front frame 12 Moving jaw, lower

2 Upper wedge 13 Frame bolt

3 Filling wedge 14 Fixed wedge

4 jaw die bolt 15 Pitman eye protection plate

5 Disc spring package 16 Flywheel

6 Cheek plate, upper 17 Eccentric shaft

7 Fixed jaw, upper 18 Pitman bearing

8 Moving jaw, upper 19 Pitman9 Center wedges 20 Frame connecting rods

10 Cheek plate, lower 21 Side plate

11 Fixed jaw, lower 22 Toggle seat





Figure 3.3 Jaw crusher rear frame components


1 Rear frame 8 Tension rod

2 Adjustment wedges 9 Toggle plate

3 Spacer 10 Piston rod

4 Toggle seat holder 11 Piston

5 Toggle seat 12 Pressure relief valve6 Locking nuts with thrust bearing 13 Pressure accumulator

7 Tension spring 14 Tension cylinder

15 Cylinder cover

Mechanical wedge setting adjustment

Hydraulic wedge setting adjustment

Acti ve sett ing

control adjustment





3.3 SPARE PARTS BOOK

A Spare Parts Book containing various assemblydrawings pertaining to your crusher will be sentimmediately after the crusher has been shipped.This book illustrates each and every part used in theassembly of the machine and is to be used whenordering spare or replacement parts.

3.4 ORDERING PARTS

Metso endeavors to carry an ample supply of partsin stock to provide prompt and efficient service onall orders for repairs and replacements.

To avoid delay and the possibility of incorrect parts

being furnished, the following information should be given:

1. Crusher size.

2. The serial number of the crusher which isstamped on the crusher nameplate. Theserial number is also on the cover of thespare parts books.

3. Complete name and part code number asshown in the Spare Parts Book.

4. Exact quantity of each part ordered.

5. Complete shipping instructions.

If your crusher Spare Parts Books have been lost,destroyed or misplaced, an additional set can beordered.

For proper operation, only genuine factory partsshould be installed. These are guaranteed as toaccuracy, workmanship and material. Using pirate

parts may put your safety and that of your crusherat risk. Make sure you completely understand yourcrusher's Warranty conditions at all times.

3.5 ESTIMATING CRUSHER CAPACITY

The capacity of the crusher depends on factors suchas the type of feed (material type, size distribution,fracture characteristics, moisture content, etc.), typeof operation (feed availability, feed arrangement)

and discharge setting. To obtain an estimate of thecapacity, refer to the following capacity table.These capacities are based on results obtained inactual practice with hard granite that has a bulkdensity of 1.6 t/m3 (100 lb/ft3), and are where thefeed has been properly graded so that bridging doesnot take place.

To obtain more accurate capacity estimates specificto your actual crushing application, contact yourlocal Metso sales representative to request acomputer simulation of your circuit's operatingcondition





Table 3-2 Nominal jaw crusher capacities

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

Mtph Mtph Mtph Mtph Mtph Mtph Mtph Mtph Mtph Mtph Mtph Mtph

mm in Stph Stph Stph Stph Stph Stph Stph Stph Stph Stph Stph Stph

40 631-5/8” 72

50 80

2” 90

60 97 120

2-3/8” 107 132

70 114 140 150 168 185 190 240

2-3/4” 125 154 165 185 204 209 264

80 131 160 171 190 207 212 268

3-1/8” 143 175 187 208 227 232 293

90 148 180 192 213 230 235 295

3-1/2” 161 196 209 232 250 256 322

100 165 200 213 235 252 257 290 323

4” 185 224 238 263 282 287 324 361

125 207 250 265 291 308 313 350 386 400 392

5” 232 280 296 325 344 350 391 432 447 439

150 250 300 317 346 363 368 410 454 470 462 520

6” 280 336 355 388 407 412 458 508 526 516 581

175 292 350 369 402 419 424 470 522 541 531 596 760

7” 327 392 413 450 469 475 525 584 605 594 666 849

200 421 458 475 480 530 590 611 600 672 853

8” 471 513 531 537 593 659 683 671 751 953

225 590 657 681 748 946

9” 660 735 762 836 1058

250 650 725 752 824 1039

10” 727 811 841 921 1162

275 822 900 1132

11” 920 1006 1266

300 976 1225

12” 1091 1370





3.6 ESTIMATING CRUSHER PRODUCTGRADATION

The crusher's product gradation depends on thesame factors that affect capacity. The followingfigure gives an indication of the product gradationas a function of the closed side setting (c.s.s.).

These product gradations are based on resultsobtained in actual practice with hard granite.

To obtain more accurate product gradationestimates, contact your local Metso salesrepresentative to request a computer simulation of

your circuit's operating conditions.

Figure 3.4 Crusher product gradation

0

10

20

30

40

50

60

70

80

90

100

1 10 100 1000

Product size

P e r c e n t a g e p a s s i n g , w e i g h t %

40 50 70 100 130 160 200 250 300

4" 16"2" 8"1"

css





3.7 CRUSHER SETTING

The Crusher setting is the most important Crusher parameter since it determines the Crusher's capacityas well as the top size of the Crusher product. It istherefore indispensable for everyone to understandhow the Crusher setting is measured.

The discharge setting is the shortest distance between the bottoms of the fixed and moving jawsduring their work cycle. This distance is referred toas the closed side setting (c.s.s.), and it is acalculated distance as the Crusher setting istypically measured when the Crusher is at rest. Thelargest distance between the bottoms of the fixedand moving jaws is referred to as the open sidesetting (o.s.s.), and it is typically a distance that is

directly measured when the Crusher is at rest.

The Crusher setting is measured in three differentways, first referring to the tooth groove (bottom) orcrown (top) of the stationary jaw and then to thetooth groove (bottom) or crown (top) of themovable jaw. Thus, the setting is always measuredfrom the Stationary (bottom or top) to the Movable

jaw (bottom or top). The three alternatives areshown in Table 3-3.

The measurement type depends on the profile aswell as on the Crusher model. This information isalso found in the Crusher Spare Parts Book.

Table 3-3 Measurement types

Figure 3.5 Crusher setting measurement

MeasurementType

Reading Sequence (Jaws)

Stationary to Movable

1 Bottom to Top

2 Top to Top

3 Top to Bottom





For example, the setting of the C125, equipped withQuarry jaw dies, is measured from Top to Top(Type 2). However, with Standard jaw dies, thesetting is measured from Bottom to Top (Type 1).

It is easiest to measure the setting when the Crusheris at rest with a device such as a block of wood ofknown dimensions (several blocks should beavailable if more than one setting is typically used).The distance measured this way is larger than theclosed side setting (c.s.s.) because the pitmanalways stops at its lowest point. This value is close(±2mm/±0.08") to the open side setting (o.s.s.). As

previously mentioned, the closed side setting iscalculated by deducting the stroke from the openside setting (Table 3-4).

Table 3-4 Dimension (stroke) to be deductedfrom the open side setting (o.s.s.) to calculate

the closed side setting (c.s.s.).

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

IMPORTANT!

The Crusher setting must always bemeasured in a straight line at the bottom ofthe crushing cavity. Measure the settingalways from the least worn area.

Model Stroke

mm Inch

C80 24 1

C96 32 1¼

C100 32 1¼

C106 34 13/8

C110 36 17/16

C116 37 1½

C3054 32 1¼

C125 41 15/8

C140 41 15/8

C145 41 15/8

C160 41 15/8

C200 50 2

Example

Crusher: C140

Stroke: 42 mm (15/8” ) (Table 3-4)

jaw die Profile: Quarry (top to top)O.S.S.: 230 mm (9")

C.S.S.: 230 – 42 = 188 mm (9" – 1 5/8" = 7 3/8")





Figure 3.6 Measuring the setting

NOTE: The C.S.S does not have to be calculated ifthe user knows the Crusher setting limits in termsof the O.S.S. The C.S.S. is typically calculated

because Crusher capacity is always denoted in

terms of the C.S.S. only.

3.8 CRUSHER SETTING LIMITS

All C-Series Crusher models have a maximum possible setting as well as a minimum allowedsetting, and it is very important that the userunderstands why these are important to keep thesein mind at all times.

The maximum possible setting is simply themaximum setting that the Crusher is physically ableto accommodate. Typically, such setting isindicated with new jaw dies, and the settingactually depends on the jaw die profile as well as onwhether a spacer is being used or not. This

information is always found in the Crusher SpareParts Book.

The minimum allowed setting (c.s.s. or o.s.s.) is the

minimum setting at which the Crusher can be usedwhen the Crusher is operated according to Metso 'recommendations. The minimum allowed setting isvery important as it takes into account the designand operation limits of the Crusher. Not respectingthese recommendations can lead to a poorutilization of the jaw dies (high scrap rate) as wellas a shortened Crusher life.

The minimum allowed setting varies depending onwhether the application is a normal rock application(Normal), or a recycling application (Special),when materials such as concrete, asphalt and bricksare being crushed. Note that the minimum allowed

setting does not depend on the jaw die profile (it isalways the same for a specific Crusher model). SeeTable 3-5.





Table 3-5 Minimum allowed settings fo r hard rock, soft rock and recycling applications.

Crusher model

CSS OSS

Hard rock(>150 Mpa)

(> 22 000 psi)

Soft Rock(<150 MPa)

(<22 000 psi )Recycling

Strokemm

Hard rock(>150 Mpa)

(> 22 000 psi)

Soft Rock(<150 MPa)

(<22 000 psi)Recycling

mm mm mm mm mm mm

C80 40 30 20 24 64 54 44

C96 60 45 25 32 92 77 57

C100 70 60 45 32 102 92 77

C106 70 50 25 34 104 84 59

C110 70 60 45 36 106 96 81

C116 70 60 45 37 107 97 82

C3054 70 60 45 32 102 92 77

C125 100 N.A N.A 39 139 N.A N.A

C140 130 N.A N.A 42 172 N.A N.A

C145 125 N.A N.A 36 161 N.A N.A

C160 150 N.A N.A 39 189 N.A N.AC200 175 N.A N.A 50 225 N.A N.A

Crusher model

CSS

Strokein

OSS

Hard rock(>150 Mpa)

(> 22 000 psi)

Soft Rock(<150 MPa)

(<22 000 psi )Recycling

Hard rock(>150 Mpa)

(> 22 000 psi)

Soft Rock(<150 MPa)

(<22 000 psi)Recycling

in in in in in in

C80 1 5/8 1 2/8 7/8 1 2 5/8 2 2/8 1 6/8

C96 2 4/8 1 7/8 1 1 2/8 3 6/8 3 1/8 2 3/8

C100 2 7/8 2 4/8 1 7/8 1 2/8 4 1/8 3 6/8 3 1/8C106 2 7/8 2 1 1 3/8 4 3/32 3 5/16 2 21/64

C110 2 7/8 2 4/8 1 7/8 1 4/8 4 3/8 3 7/8 3 2/8

C116 2 6/8 2 3/8 1 6/8 1 4/8 4 2/8 3 7/8 3 2/8

C3054 2 7/8 2 4/8 1 7/8 1 2/8 4 1/8 3 6/8 3 1/8

C125 4 1/8 N.A N.A 1 5/8 5 5/8 N.A N.A

C140 5 2/8 N.A N.A 1 6/8 7 N.A N.A

C145 5 1/8 N.A N.A 1 4/8 6 5/8 N.A N.A

C160 6 1/8 N.A N.A 1 5/8 7 6/8 N.A N.A

C200 7 1/8 N.A N.A 2 9 1/8 N.A N.A





3.9 OPTIONS

Following options can be installed on Crusher afterstart-up.

3.9.1 Intermediate Plate

Fitting an intermediate (backing) plate behind thefixed jaw reduces the nip angle of the crusher. Theintermediate plate reduces the feed opening and thesetting range by approximately the same amount asits thickness. However the intermediate platedoes not, under normal circumstances, allow theuser to use a smaller setting than the minimumrecommended setting.

If available with the specific C-Series jaw crushermodel, an intermediate plate may be used for the

following reasons:• To improve the nip angle (by decreasing the

nip angle) when crushing slippery material(material that is difficult to bite).

• To change the profile of the cavity so that thecrusher starts the crushing higher in the cavity(prolonging the service life of wear parts)when the feed material is continuouslysignificantly smaller than the maximum feedmaterial size of the crusher.

The intermediate plate is not available for allmodels. Moreover, multiple plate thicknesses areavailable with certain models. Before orderingintermediate plate consult Metso if it fits to yourapplication.

3.9.2 Protection Plates

Protection plates are designed for additional

protection of the crusher's front frame and pitman.They are recommended when using small settings(always greater than or equal than the minimumrecommended setting) and/or when the rock to becrushed is very hard (very low crushability). Ofcourse, these can be used at any time for added

protection.

NOTE: The front frame protection plate is notused when an intermediate plate is used.

Protection plates are not available options with allC-Series crusher models.

NOTE: Excessive replacement of the protection plates indicated a feed problem. Contact Metso ifsuch is the case with your Crusher.

WARNING!

The minimum allowed setting of aCrusher must be respected at all times

unless otherwise indicated by Metso. Not respecting these recommendationscan lead to a poor utilization of the jawdies (high scrap rate) as well as to ashortened Crusher life. Moreover,operating the Crusher at settings smallerthan allowed will void the Crusher'swarranty.

WARNING!

The maximum size of tramp iron(rebars, excavator teeth, etc.) must besmaller than the Crusher closed sidesetting (c.s.s.).

IMPORTANT!

When using protection plates, different bottom retaining wedges must be used.





Figure 3.7 Protection plates

3.9.3 Conveyor Belt Protector

Conveyor belt protector prolongs lifetime ofconveyor belt under Crusher. Angle of the protectorcan be adjusted.

Especially in recycling applications, rebars can

damage the belt.


1 Front frame protection plate 2 Pitman protection plate





Figure 3.8 Conveyor belt protector

3.9.4 Hydraulic Setting Adjustment

A Crusher equipped with mechanical settingadjustment can be retrofitted with the hydraulicsetting adjustment.

Refer to Chapter 4.6.2.

3.9.5 Automatic Lubrication Unit

The lubrication system automatically lubricates thefour (4) eccentric shaft bearings in accordance withthe recommendations provided by the factory.

Refer to Chapter 5.3 and Installation ManualChapter 6.5.

Callout Description

1 Protector plate

2 Support holder

3 Eye screw

4 Split pin

5 Washer

6 Washer

7 Hex screw

8 Hex nut

9 Joint pin




OPERATING INSTRUCTIONS CHAPTER 4

4.1 PREPARATIONS BEFORE STARTING

Good inspection habits will do much to insure yearsof successful operation of the Crusher. Do not relyon memory alone to regulate required periodicmaintenance, keep an accurate written record.Regularly performing pre-start and maintenanceinspections will pay off in the way of eliminatingcostly down time and prolonging the life of theCrusher.

4.2 STARTING THE CRUSHER

An electric motor or diesel engine drives theCrusher. Starting the Crusher merely amounts tostarting the motor or engine according to the

manufacturers' instructions. Do not introduce anyfeed to the Crusher during starting. To start theCrusher, proceed as follows:

1. Start the discharge conveyor.

2. Start the electric motor or diesel engine. If aslip ring motor is used, wait until its startingresistor reaches the operating stage. If a

pounding or thumping sound is heard, referto the TROUBLESHOOTING section ofthis chapter ( page 14).

3. Start the feeder.

This is a brief outline of the control logic sequencethat is required to start the Crusher. Other measuresmay be taken in accordance with local conditions.

Figure 4.1 Starting and stopping sequence

4.3 STOPPING THE CRUSHER

To stop the Crusher, proceed as follows:

1. Stop the feeder.

2. Wait until the Crusher cavity is empty.

3. Stop the electric motor or diesel engine.

4. Stop the discharge conveyor.

WARNING!

Before starting the Crusher, perform thefollowing operations:

1. Make a final inspection of theCrusher to be certain that no toolsor mechanical obstructions are on

the Crusher, that all joints andfasteners are properly tightened,that no leaks are apparent andthat there is no other reason whythe Crusher should not be started.

2. Ensure that the Crusher cavity isempty.

3. Ensure that there is a protectivecover in the feed hopper and thatit is closed during operation.

4. Ensure also that there are no persons in the area whose safety

may be endangered. Walk aroundthe Crusher and ensure that thereis nobody on, by or below theCrusher. Warn everybody in thevicinity before starting.

WARNING!After stopping the Crusher motor or dieselengine, the Crusher may coast down up toseven minutes.




CHAPTER 4 - OPERATING INSTRUCTIONS

4.4 OPERATION

Feed the material to the Crusher evenly inaccordance with the feed arrangementrecommendations. Note that the Crusher operatesmost efficiently when the crushing cavity istwo-thirds (2/3) full. An ultrasonic level sensormay be integrated into the Crusher control in orderto optimize the feed level of the Crusher.

NOTE: Metso recommends that the level detectoris used to prevent the overflow of the feed material.

Figure 4.2 Recommended filling ratio

Refer to the WEAR PARTS section for operatinginstructions pertaining to wear parts.

4.4.1 Oversized Feed

Avoid trying to crush oversized feed (feed too largefor the cavity). Having to reposition rock wastestime, reduces capacity and imposes unnecessaryloads on the Crusher. Therefore attention must be

paid to the size of feed. A stationary grizzly is asuitable alternative for limiting oversized feed. Ahydraulic hammer can be used for breakingoversized material and is recommended if such

problems are foreseen.

The oversized rock can be lifted out of the cavity

with a "clamp" and crane or it can be turned to a better position.

When the Crusher is running a hydraulic hammercan be used for breaking the oversized or blockedfeed.

4.4.2 Tramp Iron/Uncrushables

Uncrushable ("tramp iron") material larger than theCrusher's c.s.s., such as excavator teeth, should be

prevented from entering the Crusher by installing a

magnetic separator. Uncrushable material largerthan the c.s.s will cause the toggle plate to buckle,and will impose unnecessary stresses on theCrusher.

If tramp iron enters and stays in the Crusher, stopthe feeder and Crusher immediately. Be extremely

WARNING!

Single stones may be thrown from the

crusher cavity. Ensure the even materialflow to the crusher.

WARNING!

Lift or turn the rocks in the cavity onlywhen the Crusher is stopped. Do not tryto clear the blocked crushing cavitywhen the Crusher is running. Be alwaysvery careful when clearing the cavity.

Never use an iron bar to turn oversizedfeed.

DANGER!

Never use explosives to clear a blockedcrushing cavity. Make sure noexplosives enter the Crusher





cautious when emptying the cavity and removingthe tramp iron. If possible increase the Crushersetting to remove the tramp iron.

4.4.3 Packing

The Crusher should never be operated when thefeed is packing in the crushing cavity (i.e. when thefeed packs in such a way that it cannot be reducedin size), as this results in a drastic reduction of the

Crusher lifetime.

When packing occurs, the:

1. Crusher speed slows down.

2. Engine speed slows down.

3. Load of the Crusher rises.

4. The Crusher is overloaded.

Packing can occur due to the following reasons:

1. There is too much fines in the feed material.

2. The maximum feed size relative to the feedopening is very small (less than 50 % of the

feed opening width).

3. The material is very brittle and readily breaks into fines (material characteristics).

4. Wet feed material.

5. Incorrect jaw dies.

To prevent packing, all possible causes must beaddressed. If, however, the causes cannot beeliminated, the material level in the Crusher cavitymust be lowered and/or the Crusher setting must beincreased.

IMPORTANT!Always inspect the toggle plate, tensionrod and spring (or hydraulic cylinder)for possible damage.

IMPORTANT!

Never operate the Crusher when thefeed is packing in the cavity. This willresult in a drastic reduction of theCrusher lifetime.





4.5 RE-STARTING A CRUSHER STALLEDUNDER LOAD

A stalled Crusher MUST be treated as possibly being jammed and therefore a potential hazard.Clear the plant area of all personnel. Notify themanager or his deputy of a stalled Crusher situationimmediately.

Find out why the Crusher stalled. If, after carefulexamination, there appears to be no electrical ormechanical reason why the Crusher has stalled, itwould indicate that the Crusher is jammed by theingress of foreign matter and is in a hazardous state.

If a Crusher stalls under load any stored energywithin a mechanism due to tramp material can bereduced to insignificant level by ensuring that the

jaws are moved to the open position. After that startthe Crusher. If the Crusher won't start, repeat this

procedure. When the jaws are fully open, don't startthe Crusher anymore. In this case stones and trampmetal must be removed from the Crusher manually.

WARNING!

Be extremely cautious when checkingthe crusher cavity. Tramp iron could beejected from the crushing cavity.Serious personal injury can result.






Figure 4-3 At the “ rest position” the gib key is pointing down

WARNING!



point down. (Figure 4-3)





4.6 CRUSHER SETTING ADJUSTMENT

The setting adjustment of C Series Jaw Crushers isdone either by means of moving two wedgesagainst or away from each other or optionally witha active setting control.

4.6.1 Mechanical wedge setting adjustment

The movement of the wedges changes the effectivethickness "s" of the wedge pair, which in turnincreases or decreases the Crusher setting,respectively.

The setting adjustment may be done mechanically by turning cap nut(s) manually, or alternativelyhydraulically (option) through the use of anelectrical control panel. For instructions concerningthe hydraulic setting adjustment (option), refer tochapter 4.6.2.

The main components of the device are theadjusting wedges, cap nut(s) (2) and locking pipe(s)(3). Changing the setting requires the use of theratchet delivered with the Crusher (special tool) toturn the cap nuts.

Figure 4.4 Mechanical setting adjustment

To change the setting, the locking nuts of thetension rod must be loosened, and then the cap nuts

must be turned clockwise or counterclockwise toincrease or decrease the Crusher setting,respectively. A single complete rotation of one capnut has a net effect on the Crusher setting asindicated in Table 4-1. Turning both cup nuts onecomplete rotation in the same relative direction willthus change the Crusher setting by twice as what isindicated in Table 4-1.

Table 4-1 Average change in setting per cap nutrotation

Callout Description

1 Adjusting wedges

2 Cap nut

3 Locking pipe

4 Rubber bellow

4

WARNING!

Turning the cap nuts should be madewith the ratchet provided with the

Crusher. NO HYDRAULIC ORPNEUMATIC WRENCH MAY BEUSED

IMPORTANT!

The wedges are self-restraining andtheir surfaces must not be lubricated. Itmay overload the adjusting mechanism.

ModelChange in Setting

mm (in)

C80 2.3 (0.09)

C96 2.2 (0.09)C100 2.3 (0.09)

C106 2.2 (0.09)

C110 2.0 (0.08)

C116 2.3 (0.09)

C3054 2.3 (0.09)

C125 1.7 (0.07)

C140 2.3 (0.09)

C145 2.5 (0.10)

C160 2.2 (0.09)

C200 3.2 (0.12)





To calculate how many rotations the cap nuts must be turned to change the Crusher setting, simplydivide the desired setting change amount by theappropriate value in Table 4-1 and the quantity ofcap nuts.

Required Rotations = (Desired SettingChange)/(Crusher Change in Setting)

Round the result to the nearest higher number.

4.6.1.1 Decreasing the Crusher Setting

The Crusher setting can only be adjusted while thecrusher is at rest.

1. Stop crushing, then stop the Crusher.

2. Determine how much the setting must bedecreased and calculate how many rotationsthe cap nuts must be turned.

3. Loosen the locking nuts of the tensionspring (Figure 4.5). Be careful not to dropthe toggle plate as the spring gets loose.

4. Remove the locking pin from the locking pipe and push the pipe towards the Crusher.

5. Turn the cap nuts COUNTERCLOCKWISE.Make sure that both wedges are adjustedequally so that their position in relation tothe Crusher remains the same. If you have tochange the setting remarkably, turn the capnuts for a while and loosen the spring

locking nuts again if necessary. There arewashers fastened to the rear end of theadjusting wedges. When decreasing thesetting, push the wedges only until thesewashers are against the guide plates.

6. Lock the pipes with the pin.

7. Adjust the spring length according toTable 4-2 (see Figure 4.5).

8. Start the Crusher and listen if the toggle plate knocks. If it knocks, contact Metso.

9. Start crushing.

Example:

To change the setting of a C125 by 10 mm(3/8"), turn the cap nuts as follows:

10 mm / 1.7 mm / rotation = 5.88 => 6 totalrotations => 3 rotations per cap nut

3/8" / 0.07" / rotation = 5.35 => 6 total rotations=> 3 rotations per cap nut

WARNING!

With mechanical setting adjustment the

crusher setting can be adjusted onlywhile the crusher is at the rest.Adjusting the tension spring duringcrusher running can cause return rod

breakage, which may lead up to aserious injury or death.

WARNING!

Always tighten and loosen the springfrom the side. Never remove the

protection plate





Figure 4.5 Mechanical wedge setting adjus tment

Table 4-2 Tension Spring Operating Length

4.6.1.2 Increasing the Crusher Setting

The Crusher setting can only be adjusted while thecrusher is at rest.

1. Stop crushing, then stop the Crusher.

2. Determine how much the setting must beincreased and calculate how many rotationsthe cap nuts must be turned.

3. Loosen the locking nuts of the tensionspring (Figure 4.5).

4. Remove the locking pin from the locking pipe and push the pipe towards the Crusher.

5. Turn the cap nuts CLOCKWISE. Make surethat both wedges are adjusted equally so that

their position in relation to the Crusherremains the same. Be careful not to drop thetoggle plate as the spring gets loose.

6. Lock the pipes with the pin.

7. Adjust the spring length according toTable 4-2 (Figure 4.5).

8. Start the Crusher and listen if the toggle plate knocks. If it knocks, contact Metso.

9. Start crushing.

ModelTension Spring Length

L mm (in.)

C80 310 (12 ¼")C96 385 (15 ¼”)

C100 370 (14 ½")

C106 365 (14 ¼")

C110 365 (14 ¼")

C116 365 (14 ¼")

C3054 440 (17 1/3")

C125 425 (16 ¾")

C140 540 (21 ¼")

C145 540 (21 ¼")

C160 540 (21 ¼")

C200 540 (21 ¼")

WARNING!


protection plate





4.6.2 Hydraulic wedge setting adjustment(optional)

Hydraulic wedge setting adjustment enables remotesetting adjustments that are much quicker andsimpler as setting adjustments are made remotely

by operating a control panel.

Figure 4.6 Hydraulic wedge setting adjustment

The system is powered with an independenthydraulic unit, or it can be connected to a largehydraulic system, as in the Lokotrack. Thehydraulic oil pressure forces the wedges eithertowards or apart from each other, thereforedecreasing or increasing the setting, respectively.

Setting can be adjusted while the Crusher is at restor idling. If adjustment of setting is done duringcrushing lifetime of crusher components is shorter.For detailed information, refer to the Installation

Manual, Chp. 4.7 Installing the Hydraulic Unit.

4.6.2.1 Oil heater (optional)

The hydraulic setting adjustment power unit isequipped with a hydraulic oil heater. The heater’sthermostat is set to switch the heater on when theoil temperature is below 35°C (95°F). The heatercan be switched on/off from the control panel (7,Figure 4.7).

Use the heater for about 30 minutes before settingadjustment when the oil temperature is below 0°C(32°F).

4.6.2.2 Decreasing the setting

Turn the setting adjustment switch 6 (located in thecontrol panel) to the "decrease" position. Observethe wedge movement. Time relay in control panelwill stop the adjusting after 6 sec. To adjust thesetting more you have to turn the switch back to"neutral" position and again to "decrease" position.

Adjust the setting in several stages. Check the

setting between adjustments, see the minimumsetting in chapter General Crusher Information.

After adjustment, check the pressure value in thetension cylinder.

IMPORTANT!

The hydraulic setting adjustment systemin the Lokotrack is different from thesystem shown here. See details in theLokotrack manual.

IMPORTANT!

Do not let the jaw dies hit each other.





Figure 4.7 Setting adjustment control panel

4.6.2.3 Increasing the setting

Turn the setting adjustment switch 6 (located in thecontrol panel) to the "increase" position. Observethe wedge movement. Setting adjustment may stopif the pressure in the tension cylinder decreases. Toadjust the setting more you have to turn the switch

back to "neutral" position and again to "increase" position.

When the setting is increased, the pressure in theadjusting cylinder will rise automatically and thewedges will stop for a moment.


4.6.3 Active setting control adjustment(optional)

Active setting control adjustment is used in basically the same way as the hydraulic wedgesetting adjustment.

The system is powered with an independenthydraulic unit, or it can be connected to a largehydraulic system, as in the Lokotrack. Thehydraulic oil pressure moves the cylinder, whichincreases or decreases the setting.

Setting can be adjusted while the Crusher is at rest,idling or running.

Figure 4.8 Active setting con trol

The active setting control also functions as a safetydevice. If there are any uncrushable objects in the

jaw cavity, the pressure in the cylinders rises. Whenthe pressure rises over a pre-set value, the pressurerelief valves open and let the piston move

backwards. The crusher setting opens and theuncrushable material can exit the jaw cavity.

In a Lokotrack, after the uncrushable material hasleft the cavity, the setting returns to where it was.

Callout Description

1 Main switch

2 Hydraulic pump

3 Hydraulic pump, ON

4 Setting (Increase <=> Decrease)

5 Hydraulic pump running

6 Oil heating (optional)

7 Oil heating, ON

1

3 5

7

2

4

6





4.6.3.1 Oil heater (optional)

The hydraulic setting adjustment power unit isequipped with a hydraulic oil heater. The heater’sthermostat is set to switch the heater on when theoil temperature is below 20°C (68°F). The heatercan be switched on/off from the control panel (7,Figure 4.7). Use the heater for about 30 minutes

before setting adjustment when the oil temperatureis below 0°C (32°F).

4.6.3.2 Decreasing the setting

Turn the setting adjustment switch 6 (located in thecontrol panel) to the "decrease" position. Timerelay in control panel will stop the adjusting after 6sec. To adjust the setting more you have to turn theswitch back to "neutral" position and again to"decrease" position.

Adjust the setting in several stages. Check thesetting between adjustments, see the minimumsetting in chapter General Crusher Information.


4.6.3.3 Increasing the setting

Turn the setting adjustment switch 6 (located in thecontrol panel) to the "increase" position. Observethe pitman movement.


4.7 TOGGLE PLATE

For spontaneous overloading or uncrushableobjects that are larger than the Crusher setting, suchas excavator bucket teeth, the Crusher is equippedwith a toggle plate that serves as a safety device. Inthe event of overloading, the toggle plate collapsesthrough elastic buckling, frequently preventingdamage to more costly parts.

The function of the toggle seats is based upon a

rolling concept against the roll-shaped surfaceswith different radii against each other. Thereforethe toggle seats should be kept dry and must not belubricated.

IMPORTANT!

The active setting control works as asafety device only in the adjustment range

of the cylinders. If the uncrashable objectis larger than the maximum setting, thetoggle plate collapses through elastic

buckling. (See chapter 4.7)

IMPORTANT!

Do not let the jaw dies hit each other.

IMPORTANT!

Note that the toggle plate is designed to buckle when overload events occur in thelower half of the crushing cavity. Thetoggle plate will not buckle if the crusheris overloaded due to oversized feed or aninadequate feed arrangement. Thus, inthese cases, certain crusher componentssuch as the eccentric shaft, flywheels,

bearings and bearing housings will beunnecessarily loaded.

IMPORTANT!

Although the toggle plate is designed to protect the more expensive Crushercomponents, certain overload events areoften so violent in nature that it is possiblefor other components such as the tension

spring, tension rod and tension spring bracket to fail when the toggle plate buckles

IMPORTANT!

Toggle plate is not protecting crushercomponents of fatigue damages whencrusher is continuously overloaded withsmaller setting than allowed by Metso.





Check the condition of the seats and protection

rubber regularly during weekly maintenance. Theymust be kept clear of dust and dirt. If dust hasentered the seat surfaces, flush with running water.If there is no water available, compressed air may

be used. It is important that dust doesn't enter theseareas and contaminate seat surfaces.

Toggle plate and seat installation and removaldescribed in Maintenance chapter.

IMPORTANT!

Do not lubricate the toggle seats, toggle plate or toggle plate ends. This area of

the crusher is designed to operatewithout lubrication.

IMPORTANT!

Always use original Metso toggle plates. Using a toggle plate that is notmanufactured by Metso will put theCrusher at risk and will void theCrusher's warranty.





4.8 SPACER

A spacer may be placed between the loweradjusting wedge and the toggle seat holder (notapplicable to models with the active settingcontrol).

The use of the spacer reduces both the Crusher'sminimum and maximum setting. Refer to theCrusher parts book for details concerning the effectof the spacer on the Crusher setting range for aspecific jaw die profile.

Spacer installation and removal instructions can befound in Maintenance chapter.

Figure 4-9 Spacer

IMPORTANT!

The use of the spacer makes it possibleto use two different Crusher settingranges, but its use does not permit thatthe Crusher is used with settings smallerthan the minimum allowed settings (seethe Crusher Setting section).

Callout Description

1 Spacer





4.9 TROUBLESHOOTING

PROBLEM CAUSE REMEDY

Toggle plate falls out of

seat.

Feed material is too large. Feed the Crusher with proper size material. Make sure

the feed hopper's rear wall is properly designed.Tension spring too loose. Tighten the tension spring.

Material fed directly ontothe upper pitman cover.

Material must be fed into the crushing chamberwithout hitting the upper pitman cover. Make sure thefeed hopper's rear wall is properly designed.

Tension cylinder hydraulicpressure too low.

Check the pressure.

Toggle plate seatingsurfaces wearprematurely.

Tension spring too loose. Tighten the tension spring.

Toggle plate breaks(buckles).

Feed material is too small. Feed the Crusher with proper size material.

Tramp iron or other

uncrushable materialcaught near the bottom ofthe crushing chamber.

Empty the crushing chamber to remove tramp iron or

other uncrushable material.

Toggle plate not installedcorrectly.

When installing the toggle plate, inspect the toggleseats for good condition and smooth, even surfaces.

Feed hopper hasloosening or breakingbolts.

Feed material is beingcrushed too high in thechamber.

RESTRICT FEED! Feed to keep the chamber 2/3 fullwith proper size material for greatest efficiency.

Bolt fastener not applied tothe feed hopper bolts.

Apply bolt fastener.

jaw die bolts looseningor breaking.

Incorrect jaw dies installed. Use Metso jaw dies.

Jaw dies installedincorrectly.

Re-install the jaw dies.

Insufficient capacity. Feed too large. Check for proper feed size.

Wrong direction of flywheelrotation.

Make sure the flywheels turn in the correct direction.

Incorrect speed. Check for proper speed.

Discharge setting toosmall.

Increase the discharge setting.

jaw dies worn excessively. Replace the jaw dies.

Loose jaw dies. Tighten the jaw die bolts.

Wrong jaw die profile. Consult your Metso representative.

Stalled Crusher. Large rock or tramp iron jammed in the crushingchamber.

Remove stuck material. DO NOT USE EXPLOSIVESTO CLEAR A STALLED CRUSHER!

Discharge setting is toosmall.

Each Crusher has a minimum recommended setting.DO NOT use a smaller setting unless authorized byMetso.

Power failure. Check all fuses in the motor electrical control panel.

Motor failure. Check the motor.





Damaged and/or looseV-belts.

Check the condition of the V-belts.

Excessive vibration. Wrong speed. Operate the Crusher at the recommended speed.

Flywheels loose. Tighten the flywheels properly. Weld the bolts together

with plates to prevent them from coming loose.Flywheel aligned with thewrong keyway (gibkey)during assembly.

Remount the flywheel with the appropriate keyway(gibkey).

Counterweights incorrectlyinstalled.

Consult your Metso representative.

Bearings too hot. Bearings damaged. Consult your Metso representative.

Too much or insufficientgrease.

Use correct quantity of grease for each bearing. Seata schedule for greasing of the bearings.

Incorrect crusher speed. Check the Crusher's speed.

Crusher operating at asmaller setting thanrecommended.

Each Crusher has a minimum recommended setting.DO NOT use a smaller setting unless authorized byMetso.

Crusher not level. Check or re-level the Crusher.

Feeding the Crusher withvery fine material.

Feed the Crusher with proper size material.

Crusher speed varies. Damaged and/or looseV-belts.

Check the condition of the V-belts.

Inadequate plant voltagelevel.

Check the plant's voltage level.

A "knocking" is heardwhile operating.

Tension spring too loose. Tighten the tension spring.

Toggle plate improperlyseated.

Check the toggle plate and seats for wear.


Jaw dies hitting each other. Check the Crusher's discharge setting.Tension cylinder hydraulicpressure too low.

Check the pressure.

Movement of the jawdies.


Inadequate clearance. Check that the clearance between the upper andlower jaw dies is between 5-8 mm (3/16-5/16").

Centralizing lug worn out. Repair the lug.

Adjusting wedges don´tmove

Wedge surfaces worn. Drop a couple of small stones to cavity to decreasefriction between wedges.

Active setting control:The setting opens byitself. There is nouncrushable material inthe cavity.

The seals are leaking. Check the possible oil leaks.

Pressure relief valves arefaulty.

Contact Metso.

Feed material is too small. Feed the crusher with proper size material.

PROBLEM CAUSE REMEDY









MAINTENANCE CHAPTER 5

WARNING!

Before performing any maintenance orrepair work, make sure that the crusheris stopped and locked out.






1. Switch off motor




5. Place appropriate maintenance

warning signs (TAG OUT).




CHAPTER 5 - MAINTENANCE



WARNING!








5.1 SPACER

A spacer is only used in crushers with wedgesetting adjustment.

A spacer may be placed between the loweradjusting wedge and toggle seat holder(Figure 5.2). Use of the spacer makes it possible touse two different crusher setting ranges. Never usea setting smaller than the minimum allowed settingeven using the spacer.

After installing or removing the spacer the crushersetting must be adjusted (also when using hydraulicsetting adjustment).

Before you operate the machine make sure thatthere is no clearance between the upper and lowerwedge. When using the spacer make sure there isno clearance between the spacer and adjustingwedges.

Figure 5.2 Spacer makes it possible to use twodifferent crusher setting ranges

5.1.1 Spacer Installation

1. Open the crusher’s setting to maximum

2. a. Hydraulic setting:

In the valve unit, release the hydraulic pressurefrom the return cylinder by turning the knob ofthe shut-off valve (1) counter-clockwise. Youcan check the pressure level from the pressuregauge (2).

IMPORTANT!

After installing or removing the spacer theCrusher setting and the spring tensionmust be adjusted.





2b. Mechanical setting:Loosen the tension spring in order to be able tomove the pitman.

3. Use a come-along in order to retract the

pitman. Attach a shackle (1) and the wirerope/chain (2) to the back of the pitman.Attach the come-along properly to the framestructures to use it safely.

4. Inch the come-along until the loweradjustment wedge touches the washers (orthe jaw dies contact each other).

5. Insert the spacer between the front wedgeand toggle seat holder by inserting thespacer through the side plate hole.

DANGER!

Do not stay directly under the crusherwhen using the come-along.

Falling toggle plate may crush and cut.

1

2

IMPORTANT!

Be careful not to drop the toggle plate.

WARNING!


protection plate





6. Release the pitman and remove thecome-along and shackles.

7. a. Hydraulic setting:Pressurize the return cylinder by turning theknob of the shut-off valve clockwise in the

valve unit (check the pressure level from the pressure gauge).

7 b. Mechanical setting:Fasten the locking nuts of the tension spring.Adjust the tension spring length.

IMPORTANT!

After installing or removing the spacer theCrusher setting and the spring tensionmust be adjusted





5.1.2 Spacer Removal

1. When removing the spacer pull the settingadjustment wedges as far out as possible.Secure the wedges so that they do not slidedown when spacer is being removed.

2. Make sure that the toggle plate does not falldown.

3. Loosen the tension rod spring to make it possible to move the pitman.

4. Pull the pitman forward with a come-along.Remove the flange from the end of thespacer. Then pull the spacer out.





5.2 TOGGLE PLATE

5.2.1 Replacing the Toggle Plate AndToggle Seats (with wedge settingadjustment)

If the toggle plate has to be replaced, it isrecommended that the following steps be followed:

1. Open the crusher's setting to maximum.

2. Remove all necessary covers.

3. Attach and tighten lifting hooks (3, fig below) to the toggle plate on both sides.

4. Attach the chain of a come-along to thetoggle plate lifting tool (3, fig below) andupper end for example to the eyebolt of the

pitman (4, fig below).

5. Tension the come-along so that the toggle plate does not drop.

6. Support the lower setting adjustment wedgeto its position by using a proper sling. Makesure that the sling is properly tensioned.


In the valve unit, release the hydraulic pressurefrom the return cylinder by turning the knob ofthe shut-off valve (1, fig below)counterclockwise. You can check the pressurelevel from the pressure gauge (2, fig below).

5_9_1_1

5_9_1_2

5_9_1_3





7 b. Mechanical setting:

Remove the locking nuts of the tension spring(fig below).


Unfasten the return cylinder from the pitman.


Unfasten the tension rod from the pitman.

9. Use a come-along in order to retract the pitman. Attach a shackle (1) and the wirerope/chain (2) to the back of the pitman.Attach the come-along properly to the framestructures to use it safely.

10. Inch the come-along until the toggle plate isloose.

11. Lower the toggle plate on to the dischargeconveyor belt and take it out.

12. Check the condition of the toggle seats andother related components.

13. Replace the toggle seats if they aredamaged.

14. Install the new toggle plate and release the pitman.

15. Remove lower adjusting wedge support.


Attach the return cylinder to the pitman and pressurize the hydraulic return cylinder


Attach the tension rod to the pitman and fastenthe locking nuts of the tension spring.

Adjust the tension spring length according toTable 5.1

17. Remove the toggle plate lifting tool.

WARNING!


protection plate

5_9_1_5

1

2

DANGER!







Figure 5.3

Table 5.1 Tension spring operating length

5.2.2 Replacing the Toggle Plate AndToggle Seats with Acti ve Setting Control

If the toggle plate has to be replaced, it isrecommended that the following steps be followed:

1. Open the crusher's setting to maximum.

2. Remove all necessary covers.

3. Attach and tighten lifting hooks (3, fig below) to the toggle plate on both sides.

4. Attach the chain of a come-along to thetoggle plate lifting tool (3, fig below) andupper end for example to the eyebolt of the

pitman (4, fig below).

5. Tension the come-along so that the toggle plate does not drop.

6. Ensure that the pistons cannot move.

7. In the valve unit, release the hydraulic pressure from the return cylinder by turningthe knob of the shut-off valve (1, fig below)

counterclockwise. You can check the pressure level from the pressure gauge (2,fig below).

Callout Description

1 Lifting tool

2 Chain block

3 Protection rubber 4 Chain block

ModelTension Spring Length L

mm inch

C80 310 12 ¼

C96 385 15 ¼

C100 370 14 ½

C106 365 14 ¼

C110 365 14 ¼C116 365 14 ¼

C3054 440 17 1/3

C125 425 16 ¾

C140 540 21 ¼

C145 540 21 ¼

C160 540 21 ¼

C200 540 21 ¼

5_9_1_1

5_9_1_2

5_9_1_4





8. Unfasten the tension cylinder from the pitman.

9. Use a come-along in order to retract the pitman. Attach a shackle (1) and the wire

rope/chain (2) to the back of the pitman.Attach the come-along properly to the framestructures to use it safely.

10. Inch the come-along until the toggle plate isloose.

11. Lower the toggle plate on to the dischargeconveyor belt and take it out.

12. Check the condition of the toggle seats andother related components.

13. Replace the toggle seats if they aredamaged.

14. Install the new toggle plate and release the pitman.

15. Release the pistons.

16. Attach the return cylinder to the pitman and pressurize the hydraulic return cylinder

17. Remove the toggle plate lifting tool.

DANGER!



1

2





5.3 LUBRICATION

5.3.1 GENERAL

The appropriate lubrication of your crusher is of

outmost important. To ensure that your crusher isappropriately lubricated at all times, follow theinstructions provided in this chapter diligently.

5.3.2 Grease Specifications

For lubrication points, lithium-based multi-purposegrease with the following characteristics isrequired:

• NLGI-class of 2• Minimum viscosity of the base oil must be 160

mm2/s (cSt) in +40ºC/104ºF with a minimumviscosity-index 80.

• Appropriate for cold temperatures(-30ºC/-22ºF) and hot temperatures(continuous operating temperatures of+100ºC/212ºF).

• Good resistance to water

• The grease must not oxidize easily and it mustcontain EP-additives.

Some of the recommended lithium based grease brands are as follows. Other grease brands withsimilar characteristics may be used as well.

Table 5.2 Recommended grease brands

Metso does not recommend that different brands ofgrease are mixed. When in doubt, please contactMetso.

Brand Type

CASTROL APS 2

BP Energrease LS-EP 2

ESSO Mobilux EP 2GULF Gulfcrown Grease EP 2

KLUBER Centoplex 2 EP

MOBIL Mobilux EP 2

SHELL Alvania Grease EP 2

SKF LG EP 2

CALTEX Starplex EP 2

TOTAL Complex EP 2

WARNING!Do not use grease types containingmolybdenum or calcium as their solidcomponents cause additional wear in the

bearings and thus decrease bearinglifetime.

IMPORTANT!

C Series crushers are not designed tooperate at temperatures lower than-30ºC/-22ºF. Should operatingtemperatures be lower than -30ºC/-22ºF,contact Metso.





5.3.3 Eccentric Shaft Bearings

Lubrication of the jaw crusher spherical roller bearings is accomplished by using a manual typegrease gun or an automatic lubricating systemthrough four grease fittings. Refer to Figure 5.4 andFigure 5.5.

Some crushers are equipped with the distributorunit with grease nipple (Figure 5.6). Through thatnipple, grease is distributed to all four bearings.

NOTE: When adding grease, make sure that theamount of grease is adequate for four bearings.Refer to Table 5.4.

Figure 5.4 Lubrication of jaw crusher spherical roller bearings with grease gun

IMPORTANT!

In cold operating temperature:

Crushers equipped with the distributor

with grease nipple or the automaticlubrication system ensure the functionof the greasing system. Stiffened greasemight not reach the lubrication point. Ifnecessary, disconnect the grease hosesand lubricate manually through thegrease nipple on each point.

IMPORTANT!

Use only grease brands recommended by Metso even in the very coldtemperatures.





Figure 5.5 Lubrication of jaw crusher spherical roller bearings using automatic lubr icating system


1 Pump unit 2 Distributor unit





Figure 5.6 Distributor unit with grease nipple

During operation there is always a very slightworking of the grease out through the pitman andframe bearings and adjacent labyrinth seals.Movement of the grease out of the bearing and theadhering of grease outside the seal, protects the

bearing and seal from foreign particles. Byobservation of this grease working action, theoperator will soon be able to estimate the amountand frequency of bearing grease requirements. Theamount of grease required and the length of time

between greasings will vary in accordance withoperating conditions.

Before greasing the bearings, thoroughly clean thearea around each grease fitting before removing thecover from the fitting. If the grease gun method oflubrication is used, add the grease immediatelyafter shut down while the bearings are still warm.Refer to the Lubrication Schedule in Table 5.3.


1 Grease nipple 2 Distributor unit





Table 5.3 Lubrication schedule of eccentric shaft bearings

Table 5.4 Lubrication schedule of eccentric shaft bearings (distributor with grease nipple (Figure 5.6))

Model

Manual Lubrication Automatic Lubrication

Normal Conditions(every 80 hours)

Very Dusty Conditions(every 40 hours )

Al l Condit ions(continous)

Grease Amount/Nipplegrams (oz.)

Grease Amount/ Nipplegrams (oz.)

Grease Amount/ Nippleg/h (oz./h)

C80 60 (2.1) 30 (1.1) 1.1 - 1.8 (.04 - .06)

C96 125 (4.4) 63 (2.2) 2.0 - 3.4 (.07 - .11)

C100 175 (6.1) 88 (3.1) 2.9 - 4.8 (.1 - .17)

C106 125 (4.4) 63 (2.2) 2.0 - 3.4 (.07 - .11)

C110 175 (6.1) 88 (3.1) 2.9 - 4.8 (.1 - .17)

C116 175 (6.1) 88 (3.1) 2.9 - 4.8 (.1 - .17)

C3054 175 6.1) 88 (3.1) 2.9 - 4.8 (.1-.17)

C125 250 (8.8) 125 (4.4) 3.9 - 6.5 (.14 - .23)

C140 300 (10.5) 150 (5.3) 4.7 - 7.8 (.16 - .27)

C145 300 (10.5) 150 (5.3) 4.7 - 7.8 (.16 - .27)

C160 400 (14) 200 (7) 5.9 - 9.8 (.2 - .34)C200 500 (17.5) 250 (8.8) 7.7 - 12.9 (.27 - .45)

Model

Manual Lubrication (distributor with grease nipple)

Normal Conditions(every 80 hours)

Very Dusty Conditions(every 40 hours )

Grease Amountgrams (oz.)

Grease Amountgrams (oz.)

C80 240 (8.4) 120 (4.4)

C96 500 (17.6) 252 (8.8)

C100 700 (24.4) 352 (12.4)

C106 500 (17.6) 252 (8.8)C110 700 (24.4) 352 (12.4)

C116 700 (24.4) 352 (12.4)

C3054 700 (24.4) 352 (12.4)

C125 1000 (35.2) 500 (17.6)

C140 1200 (42) 600 (21.2)

C145 1200 (42) 600 (21.2)

C160 1600 (56) 800 (28)

C200 2000 (70) 1000 (35.2)

IMPORTANT!

Avoid using too much grease asexcessive grease will cause overheatingand shorten the bearing life.





5.3.4 Eccentric Shaft BearingTemperatures

Bearing temperature should be checked frequentlyand greasing accomplished immediately if anunusual temperature rise is noted. During

operation, bearings will feel warm to the touch butit should always be possible to touch them for a fewseconds without discomfort to the hand. Normal

bearing operating temperature is 40-70°C(104-158°F). Should operating temperature reach75°C (167°F) or in very warm conditions 90°C(194°F) a check should be made to determine thecause. A check should also be made, if one bearingis over 10-15°C (18-27°F) warmer than the other

bearings.

IMPORTANT!

C Series crushers are not designed tooperate at temperatures lower than-30ºC/-22ºF. Should operatingtemperatures be lower than -30ºC/-22ºF,contact Metso.

IMPORTANT!

If temperature sensors are not installedon the crusher, temperature readingmust be done when the crusher is at rest.





5.3.5 Jack-shaft Bearings

When applicable, the jack-shaft bearings must belubricated manually with a grease gun. Beforegreasing the bearings, thoroughly clean the areaaround each grease fitting before removing the

cover from the fitting. If the grease gun method of

lubrication is used, add the grease immediatelyafter shut down while the bearings are still warm.Refer to the Lubrication Schedule in Table 5.5.

Figure 5.7 Jack-shaft bearings lubrication (electric drive)

Figure 5.8 Jack-shaft bearings lubrication (hydraulic drive)





Table 5.5 Lubrication schedule of jack-shaftbearings

5.3.6 Jack-shaft Bearing Temperatures

Bearing temperature should be checked frequentlyand greasing accomplished immediately if anunusual temperature rise is noted. Duringoperation, bearings will feel warm to the touch butit should always be possible to touch them for a fewseconds without discomfort to the hand. Normal

bearing operating temperature is 40-70°C(104-158°F). Should operating temperature reach75°C (167°F) or in very warm conditions 90°C(194°F) a check should be made to determine thecause.

5.3.7 Thrust Bearing And Cap Nut Bearings

This only applies to crushers equipped withmechanical setting adjustment. The turning capnut(s) and the thrust bearing must be manuallylubricated in accordance with the following

Lubrication Schedule (Table 5.6).

Table 5.6 Lubrication schedule of thrustbearings

5.3.8 Tension Cylinder Slide Bearings

This only applies to crushers equipped with tensioncylinder. Add 20 g (0.7 oz.) grease per greasenipple every 80 h (40 h in very dusty conditions).

Stop the crusher and release the pressure before performing the lubrication. For more detailedinstructions refer to the section 5.1.1.

5.3.9 Electric Drive Motor

For instructions, refer to the motor documentationthat has been provided with the crusher.

Model

NormalConditions

(every 80 hours )

Very DustyConditions

(every 40 hours)

Grease Amount/

Nipplegrams (oz.)

Grease Amount/

Nipplegrams (oz.)

C80 40 (1.4) 20 (0.7)

C96 40 (1.4) 20 (0.7)

C106 40 (1.4) 20 (0.7)

C110 70 (2.5) 35 (1.2)

C116 55 (2) 28 (1)

C3054 55 (2) 28 (1)

C125 70 (2.5) 35 (1.2)

C140 70 (2.5) 35 (1.2)

C145 70 (2.5) 35 (1.2)

C160 80 (2.8) 40 (1.4)

C200 80 (2.8) 40 (1.4)

IMPORTANT!

Avoid using too much grease asexcessive grease will cause overheatingand shorten the bearing life.

IMPORTANT!

If temperature sensors are not installedon the crusher, temperature readingmust be done when the crusher is at rest.

Model

Thrust Bear ings Cap Nut(s )

Grease Amount/Nipple

grams (oz.)

Grease Amount/Nipple

grams (oz.)

C80 n/a 20 (0.7)

C96 20 (0.7) 20 (0.7)

C106 20 (0.7) 20 (0.7)

C110 20 (0.7) 20 (0.7)

C116 20 (0,7) 20 (0,7)

C3054 20 (0.7) 20 (0.7)C125 20 (0.7) 20 (0.7)

C140 20 (0.7) 20 (0.7)

C145 20 (0.7) 20 (0.7)

C160 20 (0.7) 20 (0.7)

C200 20 (0.7) 20 (0.7)





5.3.10 Toggle Seats And Toggle Plate

Figure 5.9 Do not lubricate the toggle seats, toggle plate or toggle plate ends

IMPORTANT!

Do not lubricate the toggle seats, toggle plate or toggle plate ends. This area ofthe crusher is designed to operatewithout lubrication





5.3.11 Setting Adjustment Wedges 5.4 INSTRUCTIONS FOR LIFTING A JAWCRUSHER WHEN REPLACING CRUSHERSUPPORT BRACKET DAMPERS

Two crusher lifting brackets (if applicable) are usedto lift a jaw crusher when replacing crusher support

bracket dampers.

The crusher is lifted one side at a time. For locationof the crusher lifting bracket in relationship to thecrusher, refer to Figure 5.10.

1. Loosen and remove stop block bolts andrubber dampers.

2. Fasten the lifting brackets with bolts tocrusher support bracket.

3. Once the lifting brackets are secured to thecrusher brackets, place a hydraulic jack(cylinder) under each lifting bracket.

4. Once desired height is achieved to removeworn dampers, block the crusher with timberor steel blocks.

5. Remove worn dampers and replace withnew. Refer to Table 5.11.

6. Remove the blocks.

7. Simultaneously lower the crusher on the

dampers.

8. Remove the jacks and crusher lifting brackets.

9. Repeat the procedure on the opposite side.

CAUTION!

Do not lubricate the setting adjustment

wedges. This area of the crusher isdesigned to operate without lubrication.Water or dust suppression spray mistsmust be kept away from this area of theCrusher.

WARNING!

Make sure that the lifting bracket boltsare properly tightened before attemptingto lift the crusher.

WARNING!

Make sure that the jacks that wereselected are capable of lifting thecrusher weight. Weight of the crushershould be checked from the machine

plate of the crusher.

WARNING!

Do not attempt to remove the worndampers before the crusher is properly

blocked.





Figure 5.10


1 Lifting bracket 3 Washer

2 Bolt 4Hydraulic cylinder (not a part of thedelivery)

4

1

2

3





5.5 HYDRAULIC POWER UNIT (OPTIONAL)

The hydraulic setting adjustment is powered withan independent hydraulic power unit, or it can beintegrated to an extensive hydraulic system, as inthe Lokotrack.

Hydraulic power unit produces oil flow to theadjusting cylinders and keeps the correct pressurelevel in the tension cylinder.

Hydraulic setting adjustment system has a dumpvalve, which automatically releases the tensioncylinder pressure when the crusher is stopped. Thishelps adjustment wedges to move smoother.

This function is tightly limited to take place onlywhen the crusher is completely stopped. After the

power of the crusher motor is switched off, timerelay prevents valve to open until preset time

(Table 5.7). This prevents pressure release whilethe crusher is coasting down. The pressure releasewhile crusher is rotating will cause the drop of thetoggle plate.

Table 5.7

Hydraulic setting adjustment system relief valve pressure settings and pressure accumulator filling pressures are shown in Table 5.9.

5.5.1 Checking oil level and temperature

Hydraulic oil level can be checked from sight glass(3) on the tank's front panel. Oil level is correctwhen the oil level is visible in the sight glass.

The glass also houses a thermometer showing thetemperature of the oil in the tank.

5.5.2 Changing oil and filter (Figure 5.11)

Change oil and the filter in the hydraulic unit forthe first time after 100 operating hours. After thatthe oil and the filter must be changed at 1000 hourintervals or at least twice a year.

• Stop the crusher and wait until it is completelystopped.

• Turn off and lock out power from main switch(located in the control panel).

• Remove cover of the hydraulic power unit.

• Blow off the dust on the unit using pressurizedair.

• In the valve unit, release the hydraulic pressurefrom the tension cylinder by turning the knobof the shutoff valve (1) counterclockwise. Youcan check the pressure level from the pressuregauge (2). Remember to shut the pressuregauge valve after checking.

• Drain oil by removing the drain plug (5).

• Loosen the filter cover (4) screws.

• Pull the cover out carefully. Observe the filterassembly when it is dismantled for the firsttime.

• Pull the filter cartridge out. If possible, cleanthe filter base groove. Protect the filter housingfrom contamination when changing filtercartridges.

• Install a new cartridge.

Model Time relay setting (min)

C80 2

C96 2

C100 2

C106 2

C110 2

C116 2C3054 2

C125 3

C140 3

C145 3

C160 4

C200 7

WARNING!

Only authorized personnel can adjustrelief valves and refill the accumulator.





• Check the seal surfaces and renew seal ifnecessary.

• Replace the cover carefully, so that thecartridge settles into the correct position.

• Fill the oil tank with new oil. Oil amount is: – 40 litres (10½ gal) in all crushers other

than C200

– 125 litres (33 gal) in C200 and machineswith Active Setting Control.

• Tighten the pressure relief knob (1).

• Turn the main switch on and check the pressure level of the tension cylinder from pressure gauge (2). Correct pressure values areshown in Table 5.9. Remember to shut the

pressure gauge valve after checking.

• Check the oil level.

Figure 5.11 Hydraulic power unit





5.5.3 Oil recommendation

Oil amount in the hydraulic unit is:

– 40 litres (10½ gal) in all crushers other

than C200 – 125 litres (33 gal) in C200 and machines

with Active Setting Control.

Use only high quality hydraulic oil with goodresistance to corrosion, water, air and foam. The oilmust not oxidize easily. The minimum viscosityindex is 100.

Suitable brands are listed in Table 5.8.

Table 5.8 Suitable o il brands

Ambienttemperature-40...+35°C(-22...+77°F)

Ambienttemperature-10...+60°C

(+14...+140°F)

BP Bartran HV 32 Bartran HV 46

ESSO Nuto H 32 Nuto H 46

SHELL Tellus Oil T 32 Tellus Oil TX 46

TEBOILTebo Hydraulic Lift

32Tebo Hydraulic Lift

46

MOBIL DTE 13M DTE 15M

CASTROL Rando HD 32 Rando HD 46





Table 5.9 Tension cylinder and accumulator pressures

Table 5.10 Tension cylinder and accumulator pressures fo r crushers with active setting cont rol

5.5.4 Bleeding the hydraulic system

Air in the hydraulic system can be bled with thefollowing procedures. When installing the adjustingcylinders, tension cylinder and pipes/hoses must be

properly filled with hydraulic oil. Observe oil levelduring bleeding and add oil if necessary.

Recover all hydraulic oil coming out from thesystem during bleeding. Waste it properly.

ModelTension cylinderlower limit bar

(PSI)

Tension cylinderupper limit bar

(PSI)

Pressureaccumulator fillingpressure bar (PSI)

Pressure reliefvalve bar (PSI)

C80 80 (1160) 100 (1450) 70 (1015) 120 (1740)

C96 100 (1450) 115 (1670) 80 (1160) 125 (1815)

C100 135 (1960) 155 (2250) 100 (1450) 170 (2465)

C106 135 (1960) 155 (2250) 100 (1450) 170 (2465)

C110 135 (1960) 155 (2250) 100 (1450) 170 (2465)

C116 160 (2321) 175 (2538) 130 (1885) 190 (2756)

C3054 135 (1960) 155 (2250) 100 (1450) 170 (2465)

C125 80 (1160) 100 (1450) 70 (1015) 120 (1740)

C140 135 (1960) 155 (2250) 100 (1450) 170 (2465)

C145 135 (1960) 155 (2250) 100 (1450) 170 (2465)

C160 90 (1305) 105 (1520) 75 (1090) 125 (1815)

C200 100 (1450) 120 (1740) 85 (1230) 145 (2100)

ModelTension cylinderlower limit bar

(PSI)

Tension cylinderupper limit bar

(PSI)

Pressureaccumulator fillingpressure bar (PSI)

Pressure reliefvalve bar (PSI)

C96 100 (1450) 150 (2175) 80 (1160) 170 (2465)

WARNING!

Pressurized oil in the system.

Oil can splash causing severe injury ordeath.

Use eye protection and safety gloves.

WARNING!

Air in the tension cylinder may cause

the toggle plate fall down.

CAUTION!

Read the oil supplier’s safetyinstructions before handling hydraulicoil. Beware of hot oil!





Bleeding the tension cylinder when the cylinderis removed for maintenance or is new:

1. Place the tension cylinder and the pressureaccumulator beside the crusher. Turn hosecouplings upwards and the piston rod end of

the cylinder higher than the other end.2. Push the piston rod fully in.

3. Fill the cylinder, accumulator and hoseswith new hydraulic oil. Preventcontamination.

4. Connect the hoses and disconnect the C-linefrom the hydraulic power unit (refer to theInstallation Manual, fig. 4-11 and 4-12).Plug the C-line hose by the power unit.Prevent contamination.

5. Install the accumulator and the tensioncylinder’s cap end to the rear frame.

6. Ask an assistant to unplug the C-line hoseand pull the piston rod of the tensioncylinder out enough to install it to pitman.Use a come-along if needed. The oil comingout from the C-line hose must be recoveredand wasted properly. The hose must beconnected to the power unit immediatelyafter the rod is out enough.

7. Install the rod end of the tension cylinder.

Bleeding the tension cylinder when the cylinderhas not been removed.

1. Stop the crusher and wait until it iscompletely stopped.

2. Turn off the hydraulic unit power from themain switch (located in the control panel).

3. Make sure that the toggle plate does notdrop (See chapter 5.2.1).

4. In the valve unit, release the hydraulic pressure from the return cylinder by turningthe knob of the shutoff valve (Figure 5.11:1) counterclockwise. You can check the

pressure level from the pressure gauge

(Figure 5.11: 2). Remember to shut the pressure gauge valve after checking.

5. Loosen the vent screw (Figure 5.12: 1) ofthe pressure accumulator carefully using a10mm wrench. Do not turn the screw formore than 8 revolutions.

6. Ask an assistant to turn the hydraulic powerunit on and observe the oil coming out fromthe system. Recover the oil to a containerand waste it properly.

7. Wait until the oil has no air bubbles in it and

tighten the screw immediately.

Figure 5.12 Pressure accumulator vent screw

Bleeding the adjusting cylinders:


2. Adjust the setting to maximum.

3. Slightly loosen the hoses at the inner ends ofthe adjusting cylinders. Recover the oil to acontainer and waste it properly.

4. Turn the setting adjustment switch to the"decrease" position. Observe the oil comingfrom the hose. Tighten the hoses when theoil has no air bubbles in it.

5. Slightly loosen the hoses at the outer ends ofthe adjusting cylinders. Recover the oil to acontainer and waste it properly.

6. Turn the setting adjustment switch to the"decrease" position. Observe the oil comingfrom the hose. Tighten the hoses when theoil has no air bubbles in it. Do not let the jawdies hit each other!





Bleeding the active setting control cylinders:


2. Decrease the setting, if it is increased, to fillthe cylinders with oil.

3. Loosen the bleeding screws (Figure 5.13: 1).

4. Turn the setting adjustment switch to the"increase" position. Observe the oil comingfrom the hose. Tighten the screw when theoil has no air bubbles in it . Recover the oil toa container and waste it properly.

Figure 5.13 Active setting con trol vent screws





5.6 PERIODICAL MAINTENANCE

5.6.1 Daily maintenance

• BEFORE STARTING

See Figure 5.14 for reference.

1. Check the tension of the V-belts. See chapter3.8.2 Installation Manual.

2. Check the tightness of the jaw die bolt nuts(A). The washers must be in the levelwith the disc spring housing 0-0,5mm(0-0.02")

3. Check the tightness of the cheek plate bolts(B), see the tightening torque in chapter 5.8.

4. Check that the protection rubber of thetoggle plate (C) is in good condition and in

place.

5. Clean all safety signs and ensure that theyare legible.

6. Active setting control: Drive the setting tothe minimum and to the maximum to ensurethe functioning of the lubrication.

7. Active setting control: Check for possibleoil leaks.

8. Check the tension and operation of the returnrod, see chapter 4.4 - 4.7 Installation Manual.

Figure 5.14 C80, C96, C100, C106, C110, C116, C125, C140, C145, C160, C200





• DURING OPERATION

Listen to the sound of the bearings and check theirtemperature (max. 75°C/167°F). Check for the

proper outflow of grease.

5.6.2 Weekly Maintenance

If an automatic lubrication device is not used,lubricate the eccentric shaft bearings (Figure 5.15).Before lubrication, the grease nipples must becleaned. Under normal operating conditions addgrease every 80 operating hours. Under dustycondition the frequency must be doubled (to every40 hours). See the required grease quantity inTable 5.3.

Lubricate the cap nut bearings of the settingadjustment device and check their rubber bellows(mechanical setting adjustment), seeChapter 5.3.7 .

Check the wear on the cheek plates. Change if

necessary.Check the toggle plate for alignment, straightnessand cracks.

Check the toggle seats and their stopper plates.Clean or replace if necessary.

Check the tightness of the frame tie bolts.

Check the mounting and condition of the flywheeland the tightness of the gib keys.

Check the mounting of the crusher.

Figure 5.15 Lubricate eccentric shaft bearings weekly





5.6.3 Monthly Maintenance

Check the tightness of the frame mounting bolts onthe side plates.

Check the rubber dampers under the crusher'smounting brackets. If any damper is damaged, itshould be changed. Refer to Table 5.11.

Table 5.11 Height of the rubber damper

NOTE: The rubber dampers must be installed tothe crusher when they are measured.

5.6.4 Twice a Year

Check the condition of the eccentric shaft bearings,using e.g. a hearing device.

Check for any wear on the seating surfaces of the pitman as well as the front frame.

Check for any wear on the seating surfaces betweenthe side plates and cheek plates.

Check the active setting control seals for leaks.Replace the seals, if necessary.

Check the pressure of the pressure accumulator.This is allowed only for authorized personnel.

5.6.5 Regularly

Change oil and the filter in the hydraulic unit firsttime after 100 operating hours. After that the oil

and the filter must be changed at 1000 hoursintervals or at least twice a year.

Model

Height of the rubber damper(mm)

new, uninstalledworn, installed(to be replaced)

C80 15 11

C96 20 14

C100 16 12

C106 15 11

C110 32 25

C116 32 25C3054 32 25

C125 32 25

C140 32 25

C145 32 25

C160 32 25

C200 35 26





5.7 MAINTENANCE INTERVALS

ITEM Daily Weekly MonthlyEvery 6months

Check V-belt tension. X

Check the tightness of jaw die bolts. X

Check the tightness of cheek plate bolts. X

Check wear on the jaw dies X

Check the sound, temperature (max. 75°C/167°F) and grease flowin the eccentric bearings.

X

Lubricate eccentric shaft bearings. X

Check wear on the cheek plates. X

Check toggle plate for alignment, straightness and cracks X

Check the toggle seats and their stopper plates. Clean or replaceas necessary.

X

Check the tightness of the mounting bolts of the labyrinth covers. X

Check the tightness of the frame tie rods X

Check the mounting and condition of the flywheel and thetightness of the gib keys. X

Lubricate crusher drive jackshaft (optional). X

Check the tightness of the frame mounting bolts on the sideplates.

X

Check the rubber dampers under the crusher's mounting brackets,and the mounting of the crusher.

X

Check the bearings on the eccentric shaft. X

Check for any wear on the contact surfaces of the pitman and frontframe.

X

Check for any wear on the contact surfaces between the sideplates and cheek plates.

X

Mechanical wedge setting adjustment

Check tension and operation of tension rod spring. XLubricate the cap nuts of the setting adjustment device X

Check the rubber covers X

Lubricate thrust bearing. X

Hydraulic wedge setting adjustment

Check the pressure of the tension cylinder. X

Check operation and oil amount (add oil if necessary). X

Change oil and filter. X

Check the pressure accumulator pressure (only authorizedperson).

X

Active set ting cont rol

Drive the setting to the minimum and to the maximum to ensure

the functioning of the lubrication. X

Check for possible oil leaks. X

Check the seals for leaks. Replace the seals, if necessary. X

Check the pressure accumulator pressure (only authorizedperson).

X





Automatic lubr icating device

Check operation and grease amount (add grease if necessary). X

ITEM Daily Weekly MonthlyEvery 6months





5.8 BOLT TORQUE VALUES

NOTE: Tightening torques of the bearing housing bolts, frame tie rods and flywheel bolts must bechecked from the Installation Manual.

All other bolts must be tightened according to thetable below. Correct pretightening is possible onlywith clean , unlubricated screw threads that are notsurface treated. The table applies to bolts with

property class 8.8.

Table 5.12

BoltTorque

Nm kpm ft lbs

M10 47 4.8 35

M12 81 8.3 60M16 196 20 145

M20 382 39 285

M24 662 67 490

M30 1320 135 975

M36 2310 236 1705

M42 3700 378 2730

M48 5590 570 4125

M52 7180 733 5295

M56 8960 914 6610

M64 13460 1370 9930

M72 19350 1970 14275

M80 26850 2740 19805

M100 53340 5440 39280









REPLACEMENT OF WEAR PARTS CHAPTER 6

DANGER!

When lifting the crusher or itscomponents, be extremely cautious!

Never go under the suspended load!

Make sure that there are no people in thelifting area during lifting!

All lifting operations must be performed by the experienced professional!

Before lifting ensure that all lifting toolsand lifting points are in good condition!

WARNING!

Before performing any maintenance orrepair work, make sure that the crusher

is stopped and locked out.






1. Switch off motor




5. Place appropriate maintenancewarning signs (TAG OUT).



CHAPTER 6 - REPLACEMENT OF WEAR PARTS




6.1 GENERAL

Before performing any maintenance or repair work,make sure that the crusher is stopped and lockedout.

Nordberg C-Series crusher jaw dies are made from

Manganese steel which work hardens. For differentmaterials and applications there are different jawdie profiles to obtain the best possible capacity to

jaw die cost ratio.

Before lifting any wear parts, check the weight ofthe component and ensure that lifting equipment

being used is adequate to lift the weight. Inaddition, familiarize yourself with all the specialtools provided with the crusher specifically forreplacing the wear parts.

WARNING!








For more detailed information on liftingaccessories, see appendices A and B.

6.2 JAW DIE SELECTION

There are several different jaw dies available forthe Nordberg C-Series jaw crusher. For profiledetails and application guidelines contact a Metsorepresentative.

The type of jaw die must be selected according to

the feed material and desired end product. Becauseof many different applications and variables, one jaw die profile is capable of performing in manyapplications.

If you are experiencing problems with your existingapplication or would like to improve the

application, contact your Metso representative.When inquiring about the correct jaw die profile,the following information must be provided:

1. Feed size and gradation

2. Feed type and characteristics

3. End product gradation

4. Capacity required

5. Options; intermediate plate, spacer

6. Crusher setting

6.3 JAW DIE WORK HARDENING

Because the wear and work hardening does notoccur evenly in the crushing cavity, it isrecommended that the following measures aretaken to maximize the useful life of the jaw dies:

– When using 2-piece jaw dies, and tooptimize the wear profile, flip the upperand lower jaw dies after first 50 to 200hours. Hardness of the feed material willdictate when to rotate the jaw dies.

– Flip the upper and lower jaw dies afterevery 400 to 500 operating hours (200hours if the material is very hard) to

properly work harden the jaw dies.

6.4 CHEEK PLATE REPLACEMENT

The lower cheek plates will normally wear beforethe upper cheek plates. When the lower cheek

plates are replaced, a small shelf may form betweenthe upper and lower cheek plate. This shelf mayslow down the material movement through thecrusher.

DANGER!

Before entering into the crushing cavity,remove any loose rocks from the feed

hopper and the feeder.

WARNING!

The lifting tools are designed by Metsoto lift Metso manufactured wear parts.Metso cannot be responsible for any

personal injury or property damage, bodily harm, or equipment damageresulting from attempting to lift othermanufacturer’s wear parts.

These lifting tools are sized based on the

wear part being lifted. If a customerdecides to purchase a one-piece jaw dieinstead of a two-piece jaw die, then adifferent lifting tool must be purchasedto make that lift. Never attempt to lift a

jaw die with a lifting tool that isintended for a lighter jaw die.

CAUTION!

Damage to the crusher side plates, pitman and front casting will result ifthe cheek plates and jaw dies are

allowed to wear through.

DANGER!

Before lifting the cheek plate, check thecondition of the lifting hole in the plate.Lifting hole is acceptable when thelifting tool locks into the cheek plateand does not come loose in any position.

If the lifting tool comes loose from thecheek plate, do not try to lift the plate.Contact Metso for more information.





6.4.1 Cheek Plate Removal

To remove the cheek plate, refer to Figure 6.3 and proceed as follows:

1. Loosen the lock nuts approximately 12 mm(1/2”) and pull the cheek plate away fromthe side plate,so that the cam of the liftingtool can be rotated into the locked position.(Figure 6.2).

Figure 6.2

2. Lock the lifting tool.

3. When the lifting tool is engaged and lockedto the cheek plate, remove the lock nuts (5),washers (4), and bolts (3).

4. Lift the upper cheek plate (1) out from thecrusher.

5. Follow the above procedure for removal ofthe lower cheek plates (2).

WARNING!

Make sure that the hoist being used iscapable of lifting the cheek plate weight.

WARNING!

The cheek plate lifting tools aredesigned by Metso to lift Metso

manufactured cheek plates. Metsocannot be responsible for any personalinjury or property damage, bodily harm,or equipment damage resulting fromattempting to lift other manufacturer’scheek plates.





Figure 6.3 Cheek plate removal


1 Cheek plate, upper 4 Washer 2 Cheek plate, lower 5 Locking nut

3 Bolt





6.4.2 Cheek Plate Assembly

Figure 6.4 Cheek plate assembly


1 Cheek plate, upper 2 Cheek plate, lower





To assemble the cheek plates, refer to Figure 6.4 and proceed as follows:

1. Insert and lock the cheek plate lifting toolinto the cheek plate. Refer to appendix B.

2. Align the lower cheek plate with the boltholes.

3. Insert bolts and washers and tighten the nutsso that a 12 mm (1/2”) gap exists betweenthe cheek plate and the side plate.

4. Unlock and remove the lifting tool byturning the lever.

5. Tighten the cheek plate bolts to torquespecified in Table 6.1.

Follow the above procedure to install the uppercheek plate (1).

Table 6.1 Cheek plate bol t torques.

6.5 CHANGING OR ROTATING THE JAWDIES

NOTE: Metso’s customers have different preferences regarding material choice andconfiguration of their work platforms. As a resultMetso does not sell working platforms for use withthe C-Series jaw crushers.

Regardless of the material or configuration of theworking platform, it must rest securely in the jawcavity, must protect the personnel against fallhazards, and must restrain the jaw dies to preventunintended movement.

DANGER!

Make sure e.g. with a wooden block,that the cheek plate does not fall ontoyou.

BoltSize

Torque

Nm kpm ftlbs

C80 M24 216 22 160

C96 M24 216 22 160C100 M30 437 44.5 325

C106 M24 216 22 160

C110 M36 760 77.5 560

C116 M24 216 22 160

C3054 M24 216 22 160

C125 M36 760 77.5 560

C140 M42 1216 124 900

C145 M42 1216 124 900

C160 M48 1834 187 1355

C200 M42 1216 124 900

DANGER!

Never place yourself or other personnelin a position beneath or adjacent to a

jaw die that is not properly securedagainst unintended movement.

DANGER!

A working platform should be installedinto the crushing cavity before entering.

WARNING!

It is the customer’s responsibility to provide a safe working environment forhis employees, including safe working

platforms.

DANGER!

The lifting holes in a worn jaw die mayhave worn bigger from the original size.

After locking the lifting tool in thelifting hole, carefully ensure that thelocked lifting tool cannot come loose

from the jaw die in any position. If thelifting tool comes loose from the jawdie, stop working and move to section6.5.3





6.5.1 One piece jaw dies

6.5.1.1 Removal

To remove the jaw die, refer to Figure 6.5,Figure 6.6, and Figure 6.7 and proceed as follows:

1. Stationary jaw die removal

– Insert a working platform into thecrushing cavity.

– Remove material build up from the jawdie lifting holes.

– Remove material build up between thestationary jaw die and cheek plates.

– Insert the jaw die lifting tool into thelifting holes of the jaw die, and lock it in

place. Refer to Appendix A for additionalinformation.

.

– Make sure the lifting hoist is capable oflifting the weight of the one piece jaw die.

– Remove the hex nuts (10) and the jaw diedisc spring assembly (8).

– Remove the jaw die bolts (6), tighteningwedge (4) and filling wedge (3).

– Exit the crushing cavity and remove theworking platform.

– Remove the jaw die. (Figure 6.5, b)

– Place the jaw die on wooden blocks.(Figure 6.6)

NOTE: If the jaw die is being rotated, beforeinstallation make sure that all the jaw die seatingsurfaces are clean.

DANGER!


DANGER!

After locking the lifting tool in thelifting hole, carefully ensure that thelocked lifting tool cannot come loosefrom the jaw die in any position. If thelifting tool comes loose from the jaw

die, stop working and move to section6.5.3

DANGER!

Properly retain the jaw die fromunintended movement before releasingthe locking mechanism of the liftingtool.

WARNING!

The lifting tool’s locking mechanismmust be engaged (cammed over into the

locking position and secured with the butterfly screw) prior to attempting toremove any jaw die lockingcomponents. Never attempt to lift a jawdie without the lifting tool’s lockingmechanism fully engaged and in thelocked position.





Figure 6.5

a b





Figure 6.6

2.1 Movable jaw die removal (all jaw crushermodels except C106 and C116) Figure 6.7


– Remove material build up from the jaw

die lifting holes.

– Remove any loose material from betweenthe movable jaw die and cheek plates.



.

– Make sure that the lifting hoist is capableof lifting the weight of the one piece jawdie.

– Remove the hex nuts (10) and jaw die discspring assembly (8) (Figure 6.7).

– Remove the jaw die bolts (7), tighteningwedge (5), and filling wedge (3).

– Exit the crusher cavity and remove theworking platform.

– Remove the jaw die (2).


NOTE: If the jaw die is being rotated, beforereinstallation make sure that all the jaw die seatingsurfaces are clean.

DANGER!


DANGER!

After locking the lifting tool in thelifting hole, carefully ensure that the

locked lifting tool cannot come loosefrom the jaw die in any position. If thelifting tool comes loose from the jawdie, stop working and move to section6.5.3

DANGER!

Properly retain the jaw die fromunintended movement before releasing

the locking mechanism of the liftingtool.

WARNING!

The lifting tool’s locking mechanismmust be engaged (cammed over into thelocking position and secured with the

butterfly screw) prior to attempting toremove any jaw die locking

components. Never attempt to lift a jawdie without the lifting tool’s lockingmechanism fully engaged and in thelocked position.





Figure 6.7

2.2 Movable jaw die removal C106 and C116(Figure 6.8)


– Remove material build up from the jawdie lifting holes.

– Remove any loose material from betweenthe movable jaw die and cheek plates.


place. Refer to Appendix A for additionalinformation..

d c

DANGER!

A working platform should be installedinto the crushing cavity before entering. DANGER!

After locking the lifting tool in the

lifting hole, carefully ensure that thelocked lifting tool cannot come loosefrom the jaw die in any position. If thelifting tool comes loose from the jawdie, stop working and move to section6.5.3





– Make sure that the lifting hoist is capableof lifting the weight of the one piece jawdie.

– Remove the hex nuts (10) and jaw die discspring assembly (8).


– Exit the crusher cavity and remove theworking platform.



DANGER!



WARNING!




WARNING!

Make sure that the pitman protection plate (11) is securely attached to the pitman so that it cannot fall.





NOTE: If the pitman protection plate or thetightening wedge are worn, replace them whenreplacing the jaw die.

Figure 6.8





6.5.1.2 Assembly

Before installing new or partially worn jaw dies,make sure that the jaw die and crusher cavity (frontframe and pitman) seating surfaces are cleaned. The

jaw dies must have metal to metal contact on allseating surfaces. (Figure 6.9).

Check the condition of the protection plate (ifequipped). Replace if necessary.

Figure 6.9 Checking the straightness of a jaw die

NOTE: If the ends of the jaw dies are bent in, ordistorted, excess material must be removed tooriginal shape by torching before the jaw dies can

be installed.

IMPORTANT!

When rotating the jaw dies, it is a good practice to check the seating surfaces ofthe jaw die for straightness. This is easilyaccomplished with the use of a straightedge.

The jaw die can warp or deform if the jawdie is not properly tightened, or is allowedto wear thin while crushing.

CAUTION!

DO NOT install jaw dies into thecrusher if the jaw die seating surfaces

are not straight. Warped or distorted jawdies can cause severe damage to thecrusher seating surfaces. Contact yourMetso representative for assistance.





Figure 6.10 jaw die seating surfaces

1. Stationary jaw die installation (Figure 6.5)

– Clean all jaw die seating surfaces(Figure 6.10).

– Insert and lock the the jaw die lifting toolto the jaw die according to appendix A.

– Install the jaw die into the crushing cavity,making sure that the jaw die seatingsurface makes full contact with the lowerwedge.

– Insert the working platform into thecrushing cavity.

DANGER!






– Install the filling wedge (3), tighteningwedge (4) and jaw die bolts (6).

– Install the disc spring assembly (8). Makesure that the disc spring stack up isaccording to Figure 6.16.

– Tighten the spring assembly perChapter 5.6 , and lock with double hexnuts (10).

– Remove the jaw die lifting tool.

– Remove the working platform.

2. Movable jaw die installation (Figure 6.7)


– Insert and lock the jaw die lifting tool tothe jaw die according to appendix A.

– Install the jaw die into the crushing cavity.Make sure that the jaw die seating surfacehas full contact with the lower wedge.



– Install the disc spring assembly (8). Makesure that the disc spring stack up isaccording to Figure 6.16.

– Tighten the spring assembly perChapter 5.6 , and lock with double hexnuts (10).



WARNING!



IMPORTANT!

Check the compression of the disc springsshortly after the re-start of the jaw crusher.Retighten the disc springs if necessary.

IMPORTANT!

This installation and removal procedure ofthe jaw dies is also used on a C3054 jawcrusher with one exception. The C3054does not use the filling wedges.

DANGER!


WARNING!


IMPORTANT!Check the compression of the disc springsshortly after the re-start of the jaw crusher.Retighten the disc springs if necessary.

IMPORTANT!

Prior to starting the crusher, the crusherdischarge setting must be adjusted.





6.5.2 Two-piece jaw die removal

To remove a two piece jaw die, refer to Figure 6.11 and proceed as follows:

1. Stationary jaw dies


– Remove material build up from the upper jaw die lifting holes.

– Remove material build up between thestationary upper jaw die and cheek plates.

– Insert the jaw die lifting tool into thelifting holes of the upper jaw die and lockit in place. Refer to Appendix A for moreinformation..

– Make sure the lifting hoist is capable oflifting the weight of the two piece jaw die.


– Remove the jaw die bolts (8), tightening

wedge (6), and filling wedge (4). – Exit the crushing cavity and remove the

working platform.

– Remove the upper jaw die.



NOTE: A smaller working platform might berequired, as it is fitted further into the crushingcavity when the lower two piece jaw die isremoved.

– Remove material build up from the lowerstationary jaw die lifting holes.

– Remove material build up between thestationary lower jaw die and cheek plates.

DANGER!


DANGER!

After locking the lifting tool in thelifting hole, carefully ensure that thelocked lifting tool cannot come loose

from the jaw die in any position. If thelifting tool comes loose from the jawdie, stop working and move to section6.5.3

DANGER!


WARNING!

The lifting tool’s locking mechanism

must be engaged (cammed over into thelocking position and secured with the butterfly screw) prior to attempting toremove any jaw die lockingcomponents. Never attempt to lift a jawdie without the lifting tool’s lockingmechanism fully engaged and in thelocked position.

DANGER!


DANGER!






– Insert the jaw die lifting tool into thelifting holes of the lower jaw die and lockit in place. Refer to Appendix A for moreinformation

– Remove the disc spring assembly (11)from center jaw die bolts (7)

– Remove the jaw die bolts and centerwedge.


– Remove the lower jaw die.

– Place the jaw die on wooden blockins.(Figure 6.6)

DANGER!



WARNING!








Figure 6.11 Removal of a fixed jaw die


1 Fixed jaw die 7 Jaw die bolt

3 Center wedge 8 Jaw die bolt

4 Filling wedge 11 Spring package

6 Filling wedge 13 Hex nut





2. Movable jaw die removal (ref. Figure 6.12)


– Remove material build up from the uppermovable jaw die lifting holes.

– Remove any loose material from betweenthe upper movable jaw die and cheek

plates.










NOTE: Smaller working platform might be

required, as it is fitted further into the crushingcavity when the lower two piece jaw die isremoved.

– Remove material build up from the lowermovable jaw die lifting holes.

– Remove any loose material from betweenthe lower movable jaw die and cheek

plates.



– Remove the disc spring assembly from thecenter movable jaw die bolts (9).

– Remove the jaw die bolts and centerwedge.

– Exit the crushing cavity and remove thework platform..

– Remove the lower jaw die.


DANGER!

A working platform should be installed

into the crushing cavity before entering.

DANGER!

After locking the lifting tool in thelifting hole, carefully ensure that thelocked lifting tool cannot come loosefrom the jaw die in any position. If thelifting tool comes loose from the jawdie, stop working and move to section6.5.3

DANGER!


WARNING!


butterfly screw) prior to attempting to

remove any jaw die lockingcomponents. Never attempt to lift a jawdie without the lifting tool’s lockingmechanism fully engaged and in thelocked position.

DANGER!








Figure 6.12


2 Moving jaw die 9 Jaw die bolt

3 Center wedge 10 Jaw die bolt

4 Filling wedge 11 Spring package

5 Tightening wedge 13 Hex nut





6.5.2.1 Two Piece jaw die assembly

Before installing new or partially worn jaw dies,make sure that the jaw die and crusher cavity (frontframe and pitman) seating surfaces are clean. The

jaw dies must have metal to metal contact on allseating surfaces.

Check the condition of the protection plate (ifequipped). Replace if necessary.

NOTE: If the ends of the jaw dies are bent in, ordistorted, before the jaw dies can be installed,excess material must be removed to original shape

by torching.

To install a two piece jaw die refer to Figure 6.13,Figure 6.14, Figure 6.15, and Figure 6.16 and

proceed as follows:

IMPORTANT!

When rotating the jaw dies, it is a good practice to check the seating surfaces ofthe jaw die for straightness (Ref.Figure 6.9). This is easily accomplishedwith the use of a straight edge. The jaw die

can warp or deform if the jaw die is not properly tightened, or allowed to wear thinwhile crushing.

CAUTION!

DO NOT install jaw dies into theCrusher if the jaw die seating surfacesare not straight. Warped or distorted jawdies can cause severe damage to thecrusher seating surfaces. Contact yourMetso representative for assistance.





Figure 6.13 Jaw die seating surfaces

1. Two Piece Stationary jaw die installation(Figure 6.11)



– Install the jaw die into the crushing cavity,making sure that the jaw die seatingsurface makes full contact with the lowerwedge.


DANGER!






– Install the center wedge (3) and jaw die bolts (7).

– Install the spring assembly (11) makingsure that the disc spring stack up isaccording to Figure 6.16.

– Tighten the center jaw die bolt nuts untilmost of the clearance between all thewedge retention components is removed.The center wedge should be positionedfarthest away from the front casting on top

of the lower jaw die. – Clean all jaw die seating surfaces of the

stationary upper jaw die (Figure 6.13).


– Install the jaw die into the crushing cavity,making sure that the jaw die seatingsurface makes full contact with the centerwedge.



– With center jaw die bolt hex nuts, adjustthe gap between the lower and upper jawdie. A gap of 5 - 8 mm (.20” - .30”) must

exist between the two jaw dies. Refer toFigure 6.14.

– Tighten the disc spring assembly perChapter 5.6 , and lock with a double hexnut (13).



2. Movable Two Piece jaw die installation(Figure 6.12)



– Install the lower movable jaw die into thecrushing cavity, making sure that the jawdie seating surface makes full contact withthe lower wedge.


– Install the center wedge (3) and jaw die bolts (9).

– Install the spring assembly (11) makingsure that the disc spring stack up isaccording to Figure 6.16.

– Tighten the center jaw die bolt nuts until

most of the clearance between all thewedge retention components is removed.The center wedge should be positionedfarthest away from the pitman on top ofthe lower jaw die.

WARNING!



DANGER!


IMPORTANT!

Check the compression of the disc springsshortly after the re-start of the jaw diecrusher. Retighten the disc springs ifnecessary.

DANGER!

A working platform should be installed

into the crushing cavity before entering.





– Clean all jaw die seating surfaces of themovable upper jaw die (Figure 6.13).


– Install the jaw die into the crushing cavity,making sure that the jaw die seatingsurface makes full contact with the centerwedge.

– Insert the working platform into the

crushing cavity. – Install the filling wedge (4), tightening

wedge (5) and jaw die bolts (10).

– With center jaw die bolt hex nuts, adjustthe gap between the lower and upper jawdie. A gap of 5 - 8 mm (.20” - .31”) mustexist between the two jaw dies. Refer toFigure 6.14.

– Clean all jaw die seating surfaces of thestationary upper jaw die (ref. Figure 6.13).


– Install the lower movable jaw die into thecrushing cavity, making sure that the jawdie seating surface makes full contact withthe lower wedge.


– Install the filling wedge, tightening wedgeand jaw die bolts.

– With center jaw die bolt hex nuts, adjustthe gap between the lower and upper jawdie. A gap of 5 - 8 mm (.20” - .31”) mustexist between the two jaw dies. Refer toFigure 6.14.

– Install the disc spring assembly makingsure that the disc spring stack up isaccording to Figure 6.16

– Tighten the filling wedge spring assemblyChapter 5.6 , and lock with double hexnut.



DANGER!


DANGER!


WARNING!Properly retain the jaw die fromunintended movement before releasingthe locking mechanism of the liftingtool.

IMPORTANT!

Check the compression of the disc springsshortly after the re-start of the jaw crusher.Retighten the disc springs if necessary.

IMPORTANT!

Prior to starting the crusher, the crusherdischarge setting must be adjusted.





Figure 6.14

Figure 6.15





Figure 6.16 Assembly o rder

Callout Description

1 Washer

2 Cup spring

3 Spring casing

4 Rubber plate





6.5.3 Welding lifting lugs to the jaw die

The jaw die lifting holes may get worn and becomelarger. When using the lifting tool intended forlifting the jaw dies, carefully ensure that the lockedtool cannot come loose from the jaw die in any

position. If the locked tool comes loose, it mustabsolutely not be used for lifting the jaw die.Instead, separate lifting lugs must be welded to the

jaw die according to the following instructions.

The jaw dies are made of special manganese steel,due to which the welding process differs from thewelding of standard steel. Thus, the person

performing the welding must be appropriatelyskilled. If you have doubts concerning the successof the welding, please contact your local Metsorepresentative.

Figure 6.17 Measures of the lifting lug

Make two lifting lugs according to Figure 6.17. Use10mm (3/8") thick steel plate made fromISO-EN10025-S355 (ASTM A 572/572M-04 Gr.50) or similar. Weld the lugs to the jaw dieaccording to Figure 6.18. Use the followingwelding procedure:

Model Measure

1 2 3 4 5

mm inch mm inch mm inch mm inch mm inch

C80 100 4” 50 2” 50 2” 90 3 5/8” 40 1 5/8”

C96 100 4” 50 2” 50 2” 90 3 5/8” 40 1 5/8”

C100 100 4” 50 2” 50 2” 90 3 5/8” 40 1 5/8”

C106 100 4” 50 2” 50 2” 90 3 5/8” 40 1 5/8”

C110 100 4” 50 2” 50 2” 90 3 5/8” 40 1 5/8”

C116 100 4” 50 2” 50 2” 90 3 5/8” 40 1 5/8”

C3054 100 4” 50 2” 50 2” 90 3 5/8” 40 1 5/8”

C125 150 6” 75 3” 60 2 3/8” 125 5” 50 2”

C140 150 6” 75 3” 60 2 3/8” 125 5” 50 2”

C145 150 6” 75 3” 60 2 3/8” 125 5” 50 2”

C160 150 6” 75 3” 60 2 3/8” 125 5” 50 2”

C200 150 6” 75 3” 60 2 3/8” 125 5” 50 2”

DANGER!

Welding or flame cutting manganesesteel generates gas that is extremelyhazardous to health and causes

manganese poisoning. This kind ofwork must be done outdoors or inwell-ventilated premises equipped withlocal exhaust ventilation.





1. Insert the working platform into thecrushing cavity.

2. Use austenitic stainless steel electrodes:AWS A5.4: E 307-16EN 1600: E 18 8 Mn R26

(e.g. ESAB OK 67.45)3. Do not preheat the jaw die. Interpass

temperature must remain under 200°C

(392°F). Observe the temperature closelyand let the jaw die cool down if necessary.

4. Carefully grind the surfaces to be welded.

5. Weld the lugs to the jaw die by a fillet weld(a=5 mm (1/5")) around the lug.

6. Fill any craters.

Figure 6.18 Lifting lugs welded on the jaw die

– After welding the lugs, attach a suitablelifting tool (e.g., chain sling) to the lugs.(Figure 6.19)

– Exit the crushing cavity and remove theservice platform.

– Ensure that there are no persons near themachine.

– Lift the jaw die out of the cavity withextreme caution.

– Lower the jaw die onto the ground as soonas possible.

– Install the new jaw die using the jaw dielifting tool. Do not use welded lugs forlifting the new jaw die.

DANGER!

Lifting the jaw die using the weldedlugs is highly dangerous. Ensure that all

persons in the area have been warnedand that there is no-one near thesuspended jaw die at any stage.





Figure 6.19 Lifting the jaw die using welded lugs





6.6 PITMAN EYE PROTECTION PLATEREPLACEMENT

Pitman eye protection plate is designed to protectthe pitman from wear. The wear to the protection

plate is contributed by feed material impact if thefeed material enters the crushing cavity too fast. Inaddition, the protection plate will show prematurewear, if it is allowed for the feed material to becrushed to high in the cavity. To prevent the

protection plate from wearing through, periodicreplacement is necessary.

6.7 FEED HOPPER LINER REPLACEMENT

The jaw crusher feed hopper is lined with anabrasion resistant plate. This liner should bereplaced, and not allowed to be worn through.Abrasion of the material being crushed will dictatethe frequency of replacement.

6.8 TOGGLE PLATE SEAT REPLACEMENT

The toggle plate seats are hardened in the toggle plate contact area. The hardness depth isapproximately 3 mm (.12”). If the seats are wornmore than 3 mm (.12”), they should be replaced.








EN N11450704_N JAW DIE LIFTING TOOL A-1

APPENDIX A A

NORDBERG C-SERIES JAW CRUSHER'S JAW

DIE LIFTING TOOL

SAFETY, OPERATING AND MAINTENANCEINSTRUCTIONS

1. Purpose of the jaw die lifting too l

The jaw die lifting tool that is provided with Nordberg C Series jaw crushers is intended forlifting of genuine Metso Nordberg C Series wear

parts (jaw dies) only. The jaw die lifting tool is notdesigned nor tested for lifting of other types of jawdies (including copies of the Nordberg C Series jawdies).

2. Storage of the jaw die lifting tool

When not in use the jaw die lifting tool should bekept out from the weather elements. After use, and

to protect the tool from damage, it should be properly stored. In applications where the liftingtool is used infrequently, to protect the tool fromcorrosion, after each use, the tool should be cleanedand moving parts lightly lubricated.

3. Safe use

Read carefully all instructions concerning the jawdie lifting tool and make sure that the tool isinspected regularly.

The lifting tool's locking mechanism must beengaged (cammed over into the locking position)

prior to attempting to remove any jaw die lockingcomponents.

This tool was designed by Metso to lift Metsomanufactured jaw dies, and Metso can not beresponsible for any personal injury or property

damage, bodily harm, or equipment damageresulting from an attempt to use this tool if a toolfails, attempting to lift other manufacturers jawdies.

While crushing, mud and rock will fill the liftingholes, and voids between the side plates, cheek

plates and jaw dies.

When removing used jaw dies from the crusher thelifting holes in the jaw dies must be cleaned. Inaddition material build up between the dies and side

plates must be removed. When operating in coldclimates, chipping of ice and frozen mud betweenthe die and the side plate might be required.

This procedure will insure that the jaw die liftingtool is lifting the weight of the jaw die only, and nottrying to break the jaw die loose from a jammedand stuck condition.

DANGER!

The lifting holes in a worn jaw die mayhave worn bigger from the original size.

After locking the lifting tool in thelifting hole, carefully ensure that thelocked lifting tool cannot come loosefrom the jaw die in any position. If thelifting tool comes loose from the jawdie, stop working and move to section6.5.3

WARNING!Before lifting any wear parts, check theweight of the component and ensure thatthe lifting equipment being used isadequate to lift the weight.

DANGER!

Never attempt to lift a jaw die withoutthe lifting tool's locking mechanismfully engaged and in the locked position.

Falling jaw die can crush and cut.

DANGER!


jaw die that is not properly securedagainst unintended movement. Aworker must never be in the crushing

cavity while a jaw die is being lifted outor lowered in.



A-2 JAW DIE LIFTING TOOL N11450704_N EN

APPENDIX A

4. Commissioning and operatingconditions

The jaw die lifting tool is supplied fully assembledand it is ready for immediate use.

The jaw die lifting tool can be used in the sameoperating conditions as the jaw crusher.

5. Technical data

The maximum lifting load is mentioned on theattached tag of the jaw die lifting tool. Table 1shows available lifting tools.

Table 1

6. The jaw die lifting tool verif ication beforefirst use and in service

Before first use

Before the tool is used for the first time, thefollowing should be verified:

a. the jaw die lifting tool is as ordered

b. the working load l imit marking on the jaw die lifting tool is bigger than theweight of the jaw die to be lifted

Before each use

Before each use the jaw die lifting tool should beinspected for any damage or deterioration (seesection 8.Maintenance / Inspection). If damage isfound during this inspection, follow procedureoutlined in section 8.

Prior to every lift, visual jaw die lifting toolinspection should be made. To ensure the tool is ingood working order, a detailed inspection should bemade at least once a year. See detailed instructions

below. Inspection records should be maintained.

A damaged jaw die lifting tool must be replaced orrepaired immediately. Special attention should be

paid to the condition of the threads, welds andfasteners.

Prior to inspection, the tool should be cleaned.

Inspection should be carried out in a well lit shopatmosphere. All components of the jaw die liftingtool should be inspected for wear, distortion andexternal damage.

7. Handling the load

Preparation

Attention should be given to any specificinstructions provided for the handling of the load.Before starting the lift, it should be ensured that theload is free to move and is not bolted down orotherwise obstructed.

Mass of the load

It is essential that the mass of the load to be lifted isknown. If the mass is not marked the informationshould be obtained from the instruction manual,

packing documents, or contacting Metsorepresentative.

Centre of gravity

The position of the centre of gravity of the loadshould be established in relation to the possible

points of attachment of the chain sling. To lift theload without it tilting or toppling the following

conditions should be met:a. For two leg chain slings the attachment

points should be either side of and abovethe centre of gravity.

b. The hook to which the jaw die liftingtool is attached should be directly abovethe centre of gravity.

Method of connection

The jaw die lifting tool is attached to the load andthe crane by means of terminal fittings such ashooks and links. Chains should be without twists orknots. Hooks that are permanently attached to the

ends of wire rope or chain slings must not be pointloaded or wedged on a load. For the same reason,the master link should be free to incline in anydirection on the hook to which it is fitted.

Liftingtool

Maximum li fting load(Working load limit, WLL)

582133 1500 kg (3307 lbs)

582151 2800 kg (6173 lbs)585042 5000 kg (11023 lbs)




APPENDIX A

Straight leg

In this case lower terminals are connected directlyto the attachment points. Selection of hooks andattachment points should be such that the load iscarried in the seat of the hook and point loading of

the hook is avoided.In order to prevent dangerous swaying of the loadand to position it for loading, a tag line isrecommended.

When loads are accelerated or deceleratedsuddenly, high dynamic forces occur whichincrease the stresses in the chain. Such situations,should be avoided. Check the hitch at all pointswhen the slack has been taken out to see that it issafe, secure and in balance.

Safety of lift

Hands and other parts of the body should be keptaway from the chain to prevent injury as the slack is

being removed. Once the slack is removed, the loadshould be raised slightly and checked to make surethat it is secure and assumes the position intended.This is especially important with basket or otherloose hitches where friction retains the load.

Landing the load

A clear area with adequate blocking should be prepared when selecting a place for the load. Avoid

placing the load on weak structures, aisles,roadways or heavy occupied areas.

8. Maintenance

Inspection

During service, the jaw die lifting tool is exposed toconditions which affect their safety.It is necessarytherefore to ensure, that the chain sling is safe forcontinuous use.

If the tag or label identifying the chain sling and its

working load limit becomes detached and thenecessary information is not marked on the masterlink itself, or by some other means, the jaw dielifting tool should be removed from service.

The chain sling should be withdrawn from serviceand sent to a authorized inspection facility. The jawdie lifting tool should be inspected for thefollowing:

a. The chain sling markings are illegible,

i.e. information on the chain slingidentification and/or the working loadlimit.

b. Distortion of the upper or lowerterminals.

c. Chain stretch can exist if the links areelongated or if there is any lack of freemovement between the links ornoticeable difference in the leg length ofmulti-leg chain slings.

d. Wear by contact with other objectsusually occurs on the outside of the

straight portions of the links where it iseasily seen and measured. Wear betweenadjoining links is hidden. The chainshould be slack and adjoining linksrotated to expose the inner end of eachlink. Inter-link wear, as measured bytaking the diameter indicated ( d1) andone at right angles, (d2) may be tolerateduntil the mean of these diameters has

been reduced to 90 % of the nominaldiameter (dn) (see Figure 1) provided

Figure 1

e. Cuts, nicks, gouges, cracks, excessivecorrosion, heat discoloration, bent ordistorted links or any other defects.

d d d n9.02

21 >+




APPENDIX A

f. Check the condition of the pin in position 1 (see Figure 2) below. If the pinis worn by 10% (or more) of its originaldimension, it must be replacedimmediately.

Figure 2

Dimension L (4), measured between positions 2and 3, must not exceed 10% of the value given inTable 2 below. If dimension L (4) exceeds 10% ofthe original value, the jaw die lifting tool must bereplaced immediately.

Table 2

g. Check the condition of the lockingmechanism (5).

h. Lubricate the mechanism (6) with sprayvaseline oil and turning the lever.

i. Check the surfaces of the centre pin (7)and shoulder (8) visually.

j. The locking bolt (9) must be able to lockthe lever during lifting. If worn ordamaged replace the jaw die lifting toolimmediately.

Thorough examination

A thorough examination should be carried out by aauthorized person at intervals not exceeding twelvemonths. Records of such examinations should bemaintained.

Chains slings should be thoroughly cleaned so as to be free from oil, dirt and rust prior to examination.Any cleaning method which does not damage the

parent metal is acceptable. Methods to avoid are

those using acids, overheating, removal of metal ormovement of metal which may cover cracks orsurface defects.

Inspection should be carried out in a well lit shopatmosphere. The chain sling should be examinedthroughout its length to detect any evidence ofwear, distortion or external damage.

Repair

Any replacement component or part of the chainsling should be in accordance with the appropriate

local standard for that component or part.If any chain link within the leg of a chain sling isrequired to be replaced then the entire chain withinthat leg should be replaced.

Components that are cracked, visibly distorted ortwisted, severely corroded or have deposits whichcannot be removed should be discarded andreplaced. Minor damage such as nicks and gougesmay be removed by careful grinding or filing. Thesurface should blend smoothly into the adjacentmaterial without abrupt change of cross section.The complete removal of the damage should notreduce the thickness of the section at that point toless than the manufacturers specified minimumdimensions or by more than 10 % of nominalthickness of the section.

Liftingtool

Check dimension L

582133 382 +38 mm (15.04" +1.50")

582151 367 +37 mm (14.45" +1.47")

585042 395 +40 mm (15.55” +1.57”)




APPENDIX A

In the case of the jaw die lifting tool on whichrepair work has involved welding, each repairedchain sling should be proof tested following heattreatment using a force equivalent to twice theworking load limit and thoroughly examined beforeit is returned to use. However, where repair iscarried out by inserting a mechanically assembledcomponent, proof-testing is not required providingthat the component has already been tested by themanufacturer in accordance with the relevantEuropean standard.

The accuracy of the tensile test equipment should be of class 2 as given in EN 10002-2.

9. Operating instructions

a. Clean lifting holes of the jaw diesensuring that the cam of the jaw dielifting tool can be placed in a locked

position.

b. jaw die lifting holes can be kept clean byfilling them with polyurethane. The

polyurethane must withstand ambient

temperatures and must be melted awaywith a torch prior to inserting the jaw dielifting tool.

c. Rotate the locking handle of the jaw dielifting tool in a down vertical position.This aligns the lifting pins with the camof the tool. (Ref. Figure 3 B).

d. Insert both lifting pins of the jaw dielifting tool into the lifting holes, androtate the locking handles 180 degrees inthe up vertical position. This off-sets thecam from the locking pin, and preventsthe pin from sliding out from the lifting

hole.(Ref. Figure 3 A). To prevent thetool from premature disengagement fromthe jaw die, a locking wing nut isscrewed in finger tight.

e. Remove all slack from the chains of the jaw die lifting tool.

f. Remove all wedge bolts and wedges.Make sure fines are cleaned from

between the jaw dies and crusher cheek

plates.

WARNING!Before lifting any wear parts, check theweight of the component and ensure thatthe lifting equipment being used isadequate to lift the weight.

WARNING!


jaw die that is not properly securedagainst unintended movement. Aworker must never be in the crushingcavity while a jaw die is being lifted outor lowered in.




APPENDIX A

Figure 3 Lifting tool usage: A) LockedB) Unlocked



EN N11456138_N CHEEK PLATE LIFTING TOOL B-1

APPENDIX B B

NORDBERG C-SERIES JAW CRUSHER'S

CHEEK PLATE LIFTING TOOL

SAFETY, OPERATING AND MAINTENANCEINSTRUCTIONS

1. Purpose of the cheek plate lifting tool

The cheek plate lifting tool that is provided with Nordberg C Series jaw crushers is intended for thelifting of genuine Metso Nordberg C Series wear

parts (cheek plates) only. The cheek plate liftingtool is not designed nor tested for the lifting ofother types of objects.

2. Storage of the cheek plate lifting tool

When not in use the cheek plate lifting tool should be kept out from the weather elements. After use,and to protect the tool from damage, it should be

properly stored. In applications where the liftingtool is used infrequently, to protect the tool fromcorrosion, after each use, the tool should be cleanedand moving parts lightly lubricated.

3. Safe use

The lifting tool's locking mechanism must beengaged (cammed over into the locking position)

prior to attempting to remove any cheek platelocking components.

This tool was designed by Metso to lift Metsomanufactured cheek plates, and Metso can not be

responsible for any personal injury or propertydamage, bodily harm, or equipment damageresulting from an attempt to use this tool if a toolfails, attempting to lift other manufacturers cheek

plates.

While crushing, mud and rock will fill the liftingholes, and voids between the side plates, cheek

plates and jaw dies.

When removing used cheek plates from the crusherthe lifting holes in the cheek platess must becleaned. In addition material build up between thedies and side plates must be removed. Whenoperating in cold climates, chipping of ice and

frozen mud between the die and the side platemight be required.

This procedure will insure that the cheek platelifting tool is lifting the weight of the cheek plateonly, and not trying to break the cheek plate loosefrom a jammed and stuck condition.

WARNING!

Before lifting any wear parts, check theweight of the component and ensure thatthe lifting equipment being used is

adequate to lift the weight.

DANGER!

Before lifting the cheek plate, check thecondition of the lifting hole in the plate.Lifting hole is acceptable when thelifting tool locks into the cheek plateand does not come loose in any position.

If the lifting tool comes loose from thecheek plate, do not try to lift the plate.Contact Metso for more information.

DANGER!

Never attempt to lift a cheek platewithout the lifting tool's lockingmechanism fully engaged and in thelocked position.

Falling cheek plate can crush and cut.

DANGER!

Never place yourself or other personnelin a position beneath or adjacent to acheek plate that is not properly secured

against unintended movement. Aworker must never be in the crushingcavity while a cheek plate is being liftedout or lowered in.



B-2 CHEEK PLATE LIFTING TOOL N11456138_N EN

APPENDIX B

4. Commissioning and operatingconditions

The cheek plate lifting tool is supplied fullyassembled and it is ready for immediate use.

The cheek plate lifting tool can be used in the sameoperating conditions as the jaw crusher.

5. Technical data

The maximum lifting load is mentioned on theattached tag of the cheek plate lifting tool. Table 1shows available lifting tools and the correspondinglifting hole sizes.

Table 1

6. The cheek plate lifting tool verificationbefore first use and in service

Before first use

Before the tool is used for the first time, thefollowing should be verified:

a. the cheek plate lifting tool is precisely asordered

b. the working load limit marking on thecheek plate lifting tool is bigger than theweight of the cheek plate to be lifted

Before each use

Before each use the cheek plate lifting tool should be inspected for any damage or deterioration (seesection 8.Maintenance / Inspection). If damage isfound during this inspection, follow procedureoutlined in section 8.

Prior to every lift, visual cheek plate lifting toolinspection should be made. To ensure the tool is in

good working order, a detailed inspection should bemade at least once a year. See detailed instructions below. Inspection records should be maintained.

A damaged cheek plate lifting tool must bereplaced or repaired immediately. Special attention

should be paid to the condition of the threads,welds, and fasteners.

Prior to inspection, the tool should be cleaned.Inspection should be carried out in a well lit shopatmosphere. All components of the cheek platelifting tool should be inspected for wear, distortionand external damage.

Lifting toolMaximum lifti ng load

(Working load limit, WLL)Diameter of l ifting hole

MM0209800 1000 kg (2204 lbs) 80 mm (3.1”)

MM0209814 500 kg (1102 lbs) 40 mm (1.6”)




APPENDIX B

7. Handling the load

Preparation

Attention should be given to any specificinstructions provided for the handling of the load.Before starting the lift, it should be ensured that theload is free to move and is not bolted down orotherwise obstructed.

Mass of the load

It is essential that the mass of the load to be lifted isknown. If the mass is not marked the informationshould be obtained from the instruction manual,

packing documents, or contacting Metsorepresentative.

Centre of gravity

The position of the centre of gravity of the loadshould be established in relation to the possible points of attachment of the chain sling. To lift theload without tilting or toppling it, the followingconditions should be met:

a. For two leg chain slings the attachment points should be on either side of andabove the centre of gravity.

b. The hook to which the cheek plate liftingtool is attached should be directly abovethe centre of gravity.

Method of connection

The cheek plate lifting tool is attached to the loadand the crane by means of terminal fittings such ashooks and links. Chains should not have any twistsor knots. Hooks that are permanently attached tothe ends of wire rope or chain slings must not be

point loaded or wedged on a load. For the samereason, the master link should be free to incline inany direction on the hook to which it is fitted.

Straight leg

In this case the lower terminals are connected

directly to the attachment points. The hooks andattachment points should be selected so that theload is carried in the seat of the hook and pointloading of the hook is avoided.

In order to prevent dangerous swaying of the loadand to position it for loading, a tag line isrecommended.

When loads are accelerated or deceleratedsuddenly, high dynamic forces occur that increase

the stresses in the chain. Such situations, should beavoided. Check the hitch at all points when theslack has been taken out to see that it is safe, secureand in balance.

Safety of lift

Hands and other parts of the body should be keptaway from the chain to prevent injury as the slack is

being removed. Once the slack is removed, the loadshould be raised slightly and checked to make surethat it is secure and assumes the position intended.This is especially important with basket or other

loose hitches where friction retains the load.

Landing the load

A clear area with adequate blocking should be prepared when selecting a place for the load. Avoid placing the load on weak structures, aisles,roadways or heavy occupied areas.

8. Maintenance

Inspection

During service, the cheek plate lifting tool isexposed to conditions which affect their safety. It isnecessary therefore to ensure, that the chain sling issafe for continuous use.

If the tag or label identifying the chain sling and itsworking load limit becomes detached and thenecessary information is not marked on the masterlink itself, or by some other means, the cheek platelifting tool should be removed from service.

The chain sling should be withdrawn from serviceand sent to a authorized inspection facility. The

cheek plate lifting tool should be inspected for thefollowing:




APPENDIX B

a. The chain sling markings (informationon the chain sling identification and/orthe working load limit) are illegible.

b. Distortion of the upper or lowerterminals.

c. Chain stretch can exist if the links areelongated or if there is any lack of freemovement between the links ornoticeable difference in the leg length ofmulti-leg chain slings.

d. Wear by contact with other objectsusually occurs on the outside of thestraight portions of the links where it iseasily seen and measured. Wear betweenadjoining links is hidden. The chainshould be slack and adjoining linksrotated to expose the inner end of eachlink. Inter-link wear, as measured bytaking the diameter indicated (d1) andone at right angles, (d2) may be tolerateduntil the mean of these diameters has

been reduced to 90 % of the nominaldiameter (dn) provided. (see Figure 1)

Figure 1

e. Cuts, nicks, gouges, cracks, excessivecorrosion, heat discoloration, bent ordistorted links or any other defects.

f. Check the condition of the pin in position 1 (see Figure 2). If the pin isworn by 10% (or more) of its original

dimension (MM0209800 = 10 mm, 0.39";MM0209814 = 8 mm, 0.31”), it must bereplaced immediately.

d d d

n9.02

21>

+




APPENDIX B

Figure 2

Dimension L (4), measured between positions 2and 3, must be within the values given in Table 2. Ifdimension L (4) is outside of the values given in thetable, the cheek plate lifting tool must be replacedimmediately.

Table 2

g. Check the condition of the lockingmechanism (8).

h. Lubricate the mechanism (7) with sprayvaseline oil and turning the lever.

i. Check the surfaces of the centre pin (5)and shoulder (6) visually.

j. The locking bolt must be able to lock thelever during lifting. If worn or damagedreplace the cheek plate lifting toolimmediately.

Lifting tool Min. length L Max. length L

MM0209800 210 mm (8.3”) 250 mm (9.8”)

MM0209814 182 mm (7.2”) 222 mm (8.7”)




APPENDIX B

Thorough examination

A thorough examination should be carried out by aauthorized person at intervals not exceeding twelvemonths. Records of such examinations should bemaintained.

Chains slings should be thoroughly cleaned so as to be free from oil, dirt and rust prior to examination.Any cleaning method which does not damage the

parent metal is acceptable. Methods to avoid arethose using acids, overheating, removal of metal, ormovement of metal which may cover cracks orsurface defects. Inspection should be carried out ina well lit shop atmosphere.

Adequate lighting should be provided and the chainsling should be examined throughout its length todetect any evidence of wear, distortion or externaldamage.

RepairAny replacement component or part of the chainsling should be in accordance with the appropriatelocal standard for that component or part.

If any chain link within the leg of a chain sling hasto be replaced then the entire of the chain withinthat leg should be replaced.

Components that are cracked, visibly distorted ortwisted, severely corroded, or have deposits whichcannot be removed should be discarded andreplaced. Minor damage such as nicks and gougesmay be removed by careful grinding or filing. The

surface should blend smoothly into the adjacentmaterial without abrupt change of cross section.The complete removal of the damage should notreduce the thickness of the section at that point toless than the manufacturer’s specified minimumdimensions or by more than 10 % of nominalthickness of the section.

If the repair work of the cheek plate lifting tool hasinvolved welding, each repaired chain sling should

be proof-tested following heat treatment using aforce equivalent to twice the working load limit,and thoroughly examined before it is returned touse. However, where repair is carried out by

inserting a mechanically assembled component, proof-testing is not required providing that thecomponent has already been tested by themanufacturer in accordance with the relevantEuropean standard.

The accuracy of the tensile test equipment should be of class 2 as given in EN 10002-2.




APPENDIX B

9. Operating instructions

a. Clean lifting holes of the cheek platesensuring that the cam of the cheek platelifting tool can be placed in a locked

position.

b. Cheek plate l ifting holes can be keptclean by filling them with polyurethane.The polyurethane must withstandambient temperatures and must bemelted away with a torch prior toinserting the cheek plate lifting tool.

c. Rotate the locking handle of the cheek plate lifting tool in a down vertical position. This aligns the lifting pins withthe cam of the tool.

d. Insert both lifting pins of the cheek platelifting tool into the lifting holes, androtate the locking handles 180 degrees inthe up vertical position.This off-sets thecam from the locking pin,and preventsthe pin from sliding out from the liftinghole. To prevent the tool from prematuredisengagement from the cheek plate, a

locking wing nut is screwed in fingertight

e. Remove all slack from the chains of thecheek plate lifting tool.

f. Remove all wedge bolts and wedges.Make sure fines are cleaned from

between the jaw dies and crusher cheek plates.

WARNING!

Before lifting any wear parts, check the

weight of the component and ensure thatthe lifting equipment being used isadequate to lift the weight.

DANGER!

Never place yourself or other personnel

in a position beneath or adjacent to acheek plate that is not properly securedagainst unintended movement. Aworker must never be in the crushingcavity while a cheek plate is being liftedout or lowered in.



APPENDIX B


Documents

C_Jaw_Instruction_EN_Rev_N (140588) (Updated).pdf