TP401 PDF

TELSMI
TH
Models 38, 44, 52, 57 and 68 H/SBS
Cone Crushers
Wear Liner Replacement
ISSUE DATE: 07/09 (Rev 1) TP401
SAFETY
Be sure to read and fully understand the precautions shown on the inside front cover of this manual before
operating or servicing your Telsmith product. Also refer to Chapter 1 for important safety information.
! WARNING
Failure to follow the safety precautions shown below may result
in serious personal injury or death!
Never attempt to work on quarry equipment while it is in operation. Always stop the machinery, lockout power
and tag controls:
1. Before performing any lubrication, maintenance, adjustment, or repairs.
2. Before removing spilled materials.
3. Before clearing jams or working inside the machinery.
4. If any unusual noises or sudden changes in operation are noticed.
Stay clear of feed and discharge areas and other places where falling rock is present. Keep away from loading
vehicles. Wear and use personal protective equipment in accordance with all applicable health and safety
regulations. Safety goggles, hard hat, ear plugs and steel-toed shoes are mandatory when working near
machinery. Wear and use additional personal protective equipment as required.
Stay clear of springs and other pinch points. Never reach in-between vibrating equipment and its support
structure. Keep a safe distance from all moving components.
Never attempt to enter the crushing chamber when tramp iron or other uncrushable objects are wedged inside.
These materials are under tremendous pressure and may be propelled upward through the feed opening at any
time. On crushers not equipped with hydraulic clearing, use a pole, hook, grappling device, or breaker bar to
safely dislodge uncrushable objects.
Do not make equipment modifications that will result in a safety hazard or create a dangerous situation. Never
remove or disable safety devices. Maintain all machinery in accordance with manufacturers instructions and
maintenance schedules.
Read the operators manual for the equipment that you operate. Be sure that you fully understand all phases of
operation for each machine. A careful and well-trained operator is the best insurance against an accident.
Refer to Chapter 1, Safety, for important quarry safety information. If your copy is missing, replacement
copies may be obtained from your local Telsmith Dealer or the Telsmith Parts Department.
All rotating power products are potentially dangerous and must be properly guarded. Placement of guards and
other safety equipment is the users responsibility. Such equipment must be installed wherever appropriate and
maintained as required.
It is the purchasers responsibility to ensure that quarry equipment is installed and used in a safe and lawful
manner. All machinery must be operated in compliance with applicable health and safety laws and general
standards of reasonable care.
Foreword
INTRODUCTION ORDERING REPLACEMENT PARTS
This manual will help you achieve optimum performance For replacement parts information, please refer to the SBS-
from your Telsmith SBS Cone Crusher. It contains complete Series Cone Crusher Drawings. These drawings contains
repair and overhaul instructions for all SBS-Series models. exploded diagrams and parts lists to help you quickly identify
the major components used on your crusher.
The data and instructions contained in this manual are based
on the latest information at the time of publication. Telsmith's If your prints have been lost or damaged, new copies are
policy of continuous improvem ents, features and available from your local approved Telsmith Distributor or
specifications are subject to change without notice. the Telsmith Parts Department.
Actual dimensions, weights, and clearances may be different To ensure that you receive the correct parts for your machine,
than shown, due to fabrication variables, custom engineering always include the model number and serial number when
or optional equipment. ordering.
Please note that some features shown in this manual may not
be present on your machine. Some equipment described may MODEL and SERIAL NUMBER PLATE
be optional at extra cost, or available only on selected LOCATION
models.
HOW TO CONTACT TELSMITH INC.

Use the following information when you wish to contact
Telsmith:
General: Phone (262) 242-6600 (24/7)
FAX (262) 242-5812
Parts: Phone (800) 688-6601 (24/7)
FAX (262) 242-7861
Written: Telsmith, Inc.
10910 N. Industrial Drive
P.O. Box 539
Mequon, WI 53092-0539
U.S.A.
Send all e-mail to:
[email protected]
REQUESTING SERVICE ASSISTANCE

If service assistance is required or you have questions about
maintenance or repair procedures in this manual, please
contact your local approved Telsmith Distributor. If
additional assistance is necessary, contact the Telsmith
Service Department.
Service technicians are available by telephone 24 hours a day,
seven days a week. To ensure faster response, always have
your machines model and serial numbers ready when
calling.
Model and serial numbers are located on a data plate attached
to the machine main frame. Always lockout power and tag
controls before reading data plate!
07/09 (Rev 1) 3
Foreword Wear Liner Replacement
Telsmith SBS Cone Crusher
OPERATION AND MAINTENANCE CONTACTS

INSTRUCTIONS TELSMITH PARTS DEPARTMENT CONTACTS
This manual includes procedures for cone crusher repair and
overhaul only. For detailed operation and maintenance
Name:
instructions, please refer to the SBS-Series O peration and
M aintenance M anual. Phone (Office):
Phone (Cell):
The Operation and Maintenance Manual is provided with all
new SBS-Series cone crushers. Replacement copies, if FAX:
needed, may be ordered from your local Telsmith dealer or
the Telmith Parts Department. Name:
Phone (Office):
SERVICE BULLETINS
Phone (Cell):
Telsmith periodically issues service bulletins to inform FAX:
customers of the latest repair and maintenance procedures.
Service bulletins may have been included separately with this
manual. Always read and understand all service bulletins TELSMITH SERVICE DEPARTMENT CONTACTS
before starting any maintenance or service work.
Name:
SAFETY
Phone (Office):
All quarry personnel operating or servicing the machine must Phone (Cell):
read and fully understand the information included in
FAX:
Chapter 1, Safety of this manual.
ILLUSTRATIONS TELSMITH APPROVED DISTRIBUTOR CONTACTS

This manual contains some illustrations in which guards,
access panels and other safety equipment have been removed Name:
for instructional purposes or to provide greater clarity.
Phone (Office):
However, to prevent serious personal injury or death, always
be sure all such equipment is installed before operating the Phone (Cell):
product. FAX:
INSTALLATION & ASSEMBLY DRAWINGS OTHER CONTACTS

Installation and assembly drawings (blueprints) are provided
with all new Telsmith products. These drawings are normally
Name:
included with the technical manuals but may be shipped
separately for some orders. Phone (Office):
Phone (Cell):
The drawings include specifications, dimensions and other
information for use during installation and assembly FAX:
procedures. Contact your local Telsmith dealer or the
Telsmith Service Department if you have any questions about Name:
information contained on the drawings. Phone (Office):
If the drawings are lost, replacement copies may be ordered Phone (Cell):
from your local Telsmith dealer or the Telsmith Parts FAX:
Department.
4 07/09 (Rev 1)
Table of Contents
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
GENERAL INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SUPPORT BOWL AND CONCAVE RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
MANTLE AND HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Appendix A - Torque Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Appendix B - Conversion Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Appendix C - Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Appendix D - Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
Appendix E - Sealants and Compounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1
Appendix F - Removal Clearances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-1
Appendix G - Wear Liner Wear Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-1
(Continued on next page)

07/09 (Rev 1) 1
Table of Contents Wear Liner Replacement
Telsmith
12 07/09 (Rev 1)
Wear Liner Replacement Chapter 1
Telsmith Silver Bullet Series Gyrasphere
Chapter 1
Safety
Page
SAFETY OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
HAZARD AND ADVISORY STATEMENTS . . . . . . . . . . . . . . . . . . . . . . 1-2
LOCKOUT/TAGOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1
GYRASPHERE SAFETY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
QUARRY SAFETY SUMMARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
MACHINERY INSTALLATION SAFETY . . . . . . . . . . . . . . . . . . . . . . . . 1-8
MAINTENANCE AND REPAIR SAFETY. . . . . . . . . . . . . . . . . . . . . . . . 1-9
HOISTING AND HANDLING SAFETY . . . . . . . . . . . . . . . . . . . . . . . . 1-11
TRANSPORTING MACHINERY . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
7F
07/09 (Rev 1) 11
Safety Wear Liner Replacement
SAFETY OVERVIEW A Note is a basic informational statement or helpful

suggestion. An Important is used to draw attention to a
It is the responsibility of the quarry management team to procedure that must be observed to prevent machine damage
develop a comprehensive safety awareness program, and to or malfunction.
ensure that all quarry workers and support personnel receive
appropriate safety training as required by federal, state and
local regulations.
Safety is basically common sense. There are standard safety
rules, but each situation has its own peculiarities which can
not always be covered by rules. Therefore, quarry personnel
must continually watch for possible safety hazards and be
prepared to take prompt corrective action when necessary. ! DANGER
Failure to observe the precautions contained in this chapter
can result in serious personal injury and even loss of life. As
with most industrial work environments, a careful operator is Hazard
the best insurance against an accident. ! WARNING!!!
DANGER Statements
1 The complete observance of one simple rule would prevent

many unnecessary injuries and deaths each year. This rule is:
Never attempt to clean, lubricate, repair or adjust any ! CAUTION
DANGER !!!
machinery unless it is stopped and properly locked out.
Please note that this chapter is only intended as a brief review
of basic quarry safety precautions and procedures. The
general guidelines included in the following paragraphs
should not be considered in lieu of a quarrys official safety Important Advisory
procedures, insurance company requirements, or applicable Statements
federal, state and local regulations. Note
HAZARD AND ADVISORY STATEMENTS

Throughout this manual, the use of hazard and advisory Figure 11. Hazard and Advisory Statements
statements have been emphasized. Examples of these are
shown in Figure 1-1.
LOCKOUT/TAGOUT
Hazard Statements
7F The Caution, Warning and Danger statements are hazard
Who Must Use Lockout/Tagout?
Quarry owners, managers, and safety officers must be aware
statements used to alert workers of unsafe practises and
of OSHAs lockout/tagout standard: CRF Section 29
potentially harmful or life-threatening situations. Each of
1910.147, The Control of Hazardous Energy. This standard is
these statements is preceded by the Safety Alert Symbol.
also recognized by MSHA.
Failure to follow the instructions contained in a Caution
All mechanics, maintenance personnel, operators, and
statement may result in MINOR PERSONAL INJURY.
electricians must fully understand and comply with this
Failure to follow the instructions contained in a Warning standard to ensure the safety of all employees.
statement could result in SERIOUS PERSONAL
INJURY or DEATH. What is Lockout/Tagout?
Failure to follow the instructions contained in a Danger Lockout/tagout is a means to ensure that personnel who
statement will result in SEVERE PERSONAL INJURY install, operate, repair, maintain, service or otherwise disable
or DEATH. machines, equipment, or electrical energy systems are
protected from harm due to unexpected energizing, or the
Advisory Statements release of stored energy by...
The Note and Important statements are advisory statements 1. Lockout Placing a disconnect switch, circuit breaker,
which relate to equipment operation, maintenance and valve, or other energy-isolating mechanism in the off or
service procedures. They are used to draw attention to proper safe position and securing it with a lock so the energy-
procedures and practises. isolating mechanism cannot be activated.
12 07/09 (Rev 1)
Wear Liner Replacement Safety
2. Tagout A prominent written warning (tag or label) 1. Prepare for shutdown Before shutting down a piece
placed on the energy-isolating mechanism indicating the of equipment, know the type and magnitude of the energy
name of the individual placing the mechanism out-of- that powers it, the hazards of that energy, and how to control
service, and stating that the energy isolating mechanism it. Warn all employees that the machinery is about to be shut
cannot be activated until the tagout device is removed. down.
When Must Lockout/Tagout Occur? 2. Shutdown the equipment After warning all
employees, shut down the machine, equipment, or electrical
Lockout/tagout must occur whenever service or maintenance system by the normal stopping procedure.
is performed, and injury could occur due to the unexpected
start-up of equipment, or the release of stored energy. See 3. Control stored energy any potentially hazardous
Figure 1-2. stored energy (electrical, mechanical, hydraulic, pneumatic,
etc.) that remains must be released, dissipated, restrained, or
In general, lockout/tagout procedures must be performed otherwise rendered safe. If stored energy reaccumulates,
under the following circumstances: monitor it until the possibility of accumulation no longer
Before cleaning, lubricating, adjusting or repairing exists.
machinery or equipment. 4. Isolate the equipment Disengage all isolating
devices, both primary and secondary, so that the equipment
Before working on electrical, hydraulic or pneumatic
circuits or devices. is isolated from all of its energy sources (electrical, 1
mechanical, hydraulic, pneumatic, etc.).
Before clearing jammed mechanisms, machinery or
equipment. 5. Apply lockout/tagout devices Attach lockout tagout
devices (according to your companys safety program) in
Before removing guards or other protective devices. such a manner that the isolating device (circuit breaker,
Whenever a machine or its controls will be left control, etc.) will be held in a safe or off position. Attach tags
unattended. to alert others that the machinery is being serviced.
How is Lockout/Tagout Performed? 6. Verify that equipment is isolated After warning all
employees to stay clear, engage the start button to confirm
OSHA has identified the following step-by-step lockout/ the machine is inoperable. Return the control to the off
tagout procedure: position before proceeding with servicing.
LOCKOUT / TAGOUT POWER...

Before making inspections or adjustments.
Before performing any lubrication, maintenance or repairs.
7F
Crusher lockout/tagout summary:
1. Always lockout/tagout power to crusher drive motor.
2. Always lockout/tagout controls for diesel engine (If equipped).
Disconnect batteries and shut-off fuel supply.
3. Always lockout/tagout power to crusher lubrication and hydraulic
systems.
4. Always lockout/tagout power to all crusher feed and discharge
equipment, such as feeders, conveyors and screens.
! WARNING!!!
DANGER
Failure to perform lockout/tagout procedures can result
in serious personal injury or death!
Figure 12. Lockout/Tagout
07/09 (Rev 1) 13
When Can Lockout/Tagout Devices be Your companys lockout/tagout program may be

Removed? somewhat different than described in this manual. If so, be
sure to completely follow your companys official
Lockout/tagout devices can only be removed after the policies and procedures when lockout/tagout is necessary.
following conditions are met: Consult your companys safety officer if you have any
All guards and protective devices are properly re- questions.
installed. A lock must have only one user and one key. Anyone who
All tools and repair equipment are removed from the installs a lock must keep the key in their possession at all
equipment and the immediate area. times. Except in an emergency situation, only the person
that installs a lock is authorized to remove it.
All mechanics and other personnel are clear of the
equipment and its immediate area. To prevent accidental start-up, never give your lock or its
key to another employee.
All personnel have been warned that the equipment is
about to be restarted (sound warning horn and activate Your key must open your lock only. Your key should not
warning lights). be capable of opening any other locks. Keys for other
locks should not be capable of opening your lock.
After removing lockout/tagout devices, always use the
1 normal start-up procedure as described in the operators Except in an emergency situation, never attempt to
manual for the machinery. remove anyone elses lock. Do not allow others to remove
your lock.
Lockout/Tagout Devices
When disconnecting power, be sure that the circuit
Lockout/tagout devices include: breaker handle (or other isolating device) is in the OFF
position. Accidentally locking a control in the ON
1) locks
position could result in serious personal injury or death.
2) tags and labels
3) multiple lockout devices If two or more people are working on a machine, a
multiple lockout device must be used to prevent
A lock must be sufficiently durable, so it can withstand the
accidental start-up in the event that one person finishes
environmental conditions (heat, cold, moisture, etc.) around
working before another.
it. A lock must also be strong enough so that it cannot be
easily removed or forced open. Each lock must have a tag. If two or more people are
working on a machine, each person must attach a separate
A tag or label must be affixed to each lock to alert others that
tag to their lock. Never attach a lock without a tag.
service work is in progress. Each tag or label must have the
following characteristics: Never use tags alone. A tag should always be
accompanied by a lock which prevents the isolating
Be sufficiently durable to withstand wear and abuse, even
7F if used in dirty or damp environments.
device from becoming energized.
Additional Lockout/Tagout Requirements

Be securely attached with a cable that is difficult to
remove, cut or tear. Be sure that the power is COMPLETELY turned off. A
Contain the name of the person that applied it. motor may be stopped and locked out. However,
interlocks, starters, and other supplemental electrical
Contain a warning or other precautionary statement that components may still be energized. Use a voltmeter and/
briefly indicates why the machine is locked out and what or ammeter to verify that all electrical circuits are
hazards could result if the equipment is started while completely dead.
service work is in progress.
Always be sure that all peripheral equipment, such as feed
When two or more people are working on a piece of conveyors, grizzly feeders and discharge conveyors, is
equipment, a multiple lockout device must be used. This also tagged and locked out. Serious personal injury or
allows each person to install their own lock, preventing death can result if any of these items starts unexpectedly
accidental start-up. while the crusher is being serviced.
Lockout/Tagout Rules Although lockout/tagout procedures are most commonly
associated with electrical systems, be aware that
Always lockout/tagout any machinery before performing
hydraulic, pneumatic and mechanical systems must also
any adjustment, inspection, lubrication, maintenance or
be tagged and locked out before servicing. This may
repair procedures. Failure to observe this precaution may
involve the lockout/tagout of valves, levers and other non-
result in serious personal injury or death.
electrical devices.
14 07/09 (Rev 1)
For machinery powered by internal combustion engines Never attempt to manually clear jammed material from
(diesel, gas, etc.), always disconnect batteries and shut-off the crushing chamber while the upper frame is in the
fuel supply before servicing the machinery. Lockout/ lowered (clamping) position. Any material lodged in the
tagout engine controls to ensure that engine is not chamber could release without warning, and may be
accidentally started while the machinery is being propelled upward through the feed opening. Serious
serviced. injury or death could result. Refer to the Operation and
Maintenance Manual for jam removal procedures.
Always be sure that all hydraulic or air pressure is
completely relieved before working on hydraulic or Do not tamper with crusher alarm components. Never
pneumatic systems. Dangerous pressures can be present, attempt to defeat electrical interlocks or to disable crusher
even when equipment is turned off and locked out. protective devices.
After maintenance or repairs are completed, always warn Never place hands on cylinder rods. Stay clear of pinch-
all employees that the machinery is about to be restarted. point area between the upper and main frames.
Be sure no one is on or near the equipment before a lock
Never stand on hydraulic hoses or use them as steps. If
and tag is removed.
hoses rupture, serious injury or death could result. As
As a precaution, always activate a warning horn or light required, use a safety harness during servicing.
before restarting the machinery. This will provide
additional warning for personnel to stay clear of
Always lockout/tagout power to the crusher drive motor, 1
crusher oil lubrication system and crusher hydraulic
machinery that is about to be started.
system before performing any inspection, adjustment
lubrication, maintenance or repair procedures. Also
GYRASPHERE SAFETY lockout power to all crusher feed and discharge
Perform a complete walk around inspection before equipment. Be sure pressure is fully relieved before
starting the crusher. Be sure that no persons are on, inside servicing the hydraulic system.
or under the crusher. Refer to the Operation and If the crusher is powered by a diesel engine, always
Maintenance Manual for crusher daily start-up disconnect batteries and shut-off fuel supply before
procedures. performing any inspection, adjustment, lubrication,
Be sure that all guards and other safety devices are maintenance or repair procedures. Lockout/tagout
correctly installed and tightly secured before starting the engine controls to prevent the engine from being
crusher. Stay clear of rotating or moving parts during accidentally started while the crusher is being serviced.
crusher operation. Support the crusher upper frame with hardwood blocking
Do not allow personnel to be on or near the crusher during or steel safety spacers before entering the crushing
operation. Stay clear of feed and discharge areas to chamber for service work. Never rely on hydraulic
prevent being injured or killed by flying or falling rock. pressure to keep the upper frame raised. You could be
crushed and killed if the upper frame lowers
Rock projected upwards through the feed opening can
injure or kill. Do not look directly into the feed opening
unexpectedly. 7F
while the crusher is operating. Use mirrors or closed- Always stop the crusher immediately if any gauges show
circuit cameras if close observation of the feed abnormal readings, or if there is a sudden obvious change
arrangement is necessary for troubleshooting or in operation. Be alert for noises that might indicate
evaluation purposes. trouble.
Never attempt to clear jammed material from the crushing Inspect, lubricate, maintain and repair the crusher in
chamber while the crusher is operating. Serious injury or accordance with the instructions contained in this manual
death could result if you are pulled into, or fall inside, the and any additional manuals or documentation provided
crushing chamber. with the crusher.
07/09 (Rev 1) 15
QUARRY SAFETY SUMMARY Wear steel-toe safety boots, heavy-duty gloves and a hard
hat. This equipment is mandatory in most areas of the
Know Your Machinery quarry.
Read the manufacturers operation and maintenance Use respirators in dusty locations and when working with
manuals for all machinery and equipment that you hazardous substances. Prolonged exposure to rock dust or
operate. Be sure that all hazard statements contained chemical fumes can cause permanent respiratory illness.
within the manuals are completely understood.
Other personal protective equipment may be necessary for
Become familiar with the controls, functions and settings your specific job assignment, such as a full face shield and
of each machine. Fully understand all phases of each safety harness. Wear or use these items when necessary
machines operation. and as required by applicable federal state and local
Be sure that you completely understand and follow all regulations.
start-up and shut-down procedures as described in the Observe Personal Safety Precautions
manufacturers manuals.
Never wear loose or ragged clothing when working on or
Be familiar with the safety signs on your equipment, and around rotating power equipment. Avoid wearing
the hazards against which they warn. necklaces, rings or other jewelry. These items can become
1 Check the legibility of all safety signs every day. Order caught or tangled in the machinery, resulting in severe
new signs from the machinery manufacturer if they personal injury or death.
become illegible or worn. Keep hair short, if possible. Keep long hair securely tied-
Be Prepared for Emergencies up to prevent it from becoming caught in the machinery.
Know the proper emergency shut-down procedures for Be especially careful whenever using wet walkways,
the equipment you operate. platforms, or ramps. The combination of rock dust and
wet metal can create an extremely slippery surface. Keep
Know where fire extinguishers are kept and how to use all walkways and other access structures clean, dry and
them. Be sure that fire extinguishers are properly rated, free of grease or oil.
and that they remain fully charged and ready for use at all
times. Use walkways and ladders when working near machinery,
or observing its operation. Use a safety harness when
Know the procedure for contacting emergency medical necessary. Keep handrails and machine contact surfaces
personnel. Keep a list of emergency phone numbers clean.
handy at all times.
To avoid back injuries, always use proper lifting
Know where first-aid kit, stretcher and other emergency techniques to safely lift heavy objects. Lift with your legs
supplies are kept. Be sure that first aid supplies are and keep your back straight. Keep the materials or object
7F properly maintained and ready for use.

Make sure that a clear path to emergency equipment and
close to your body. Have a co-worker assist you if the load
cannot be lifted safely by one person.
exits is always maintained. Do not allow equipment, Never attempt to catch falling materials or objects.
spilled materials or other obstructions to get in the way.
Be aware of flammable liquids and other potential fire
Know how to report accidents. Always report all hazards. Do not smoke when refilling engines or using
accidents immediately to the appropriate supervisor. cleaning solvents.
Wear Personal Protective Equipment Do not stand under equipment or components that are
(PPE) being hoisted or suspended. Never allow other quarry
personnel to do so.
Wear safety glasses or goggles whenever outside of an
approved operator s enclosure. Failure to wear Before you assemble, operate, clean, lubricate, or adjust
appropriate eye protection can result in permanent eye machinery, be sure to read and understand all procedures
injuries and loss of sight. contained in the machinery manufacturers manual.
Wear appropriate ear protection when working within 50 Be sure to operate quarry machinery in compliance with
feet of any operating quarry machinery, and in other areas current OSHA and MSHA regulations, and all applicable
where noise levels are high. Prolonged exposure to high state and local regulations.
noise levels can cause permanent hearing loss.
16 07/09 (Rev 1)
Help Prevent Accidents Practice Good Housekeeping

Do not allow unauthorized personnel in or near the work Do not store tools or equipment on walkways.
area. Never allow unauthorized personnel to operate,
Be sure that all walkways, platforms, stairs and ramps are
adjust, maintain or repair machinery.
kept free of spilled material and trash. A build-up of
Allow only properly trained and experienced personnel to material in these areas can cause slips and falls. Make
operate machinery. Be sure inexperienced operators are repairs as required in areas where spillage is present.
carefully supervised at all times.
Do not allow machinery to become buried under piles of
Before start-up, visually check that no personnel are spilled material. This will make the machinery more
inside, on, under or beside the machinery. Alert all difficult to inspect and may hide broken welds, loose
workers that start-up is about to occur. Always sound fasteners and other serious problems that could cause a
warning horn before starting the machinery. safety hazard.
Do not allow personnel to be near loading areas, or Keep the areas around control panels and machinery free
anywhere else that falling or ejected material could hit of spilled material. Free access must be maintained at all
them. times. In the event of an emergency, quick access to
controls could prevent injury or death.
Use extreme caution if the machinery must be operated
for inspection or observation purposes. Stay a safe Clean up spilled fuel or oil immediately to eliminate 1
distance from the machinery and wear appropriate slipping hazards. If necessary, use an oil absorbent.
personal protective devices.
Always be sure that power is tagged and locked out before
Before making repairs to the machinery, always clear all cleaning spilled material or oils. Never clean-up these
quarry material from the feed and discharge devices items while the machinery is operating.
(feeders, conveyors, chutes, etc.).
Inspect And Maintain Machinery
In areas which present a danger of falling, use an
appropriate fall protection device, such as a safety harness Always perform a safety inspection at the beginning of
and lifeline. each shift. Refer to the machinery manufacturers
operation and maintenance manuals for detailed pre-start-
Always report any unsafe conditions or defective up inspection and maintenance procedures.
equipment to the appropriate supervisor.
Test all warning devices before starting the machinery to
Avoid Alcohol and Other Drugs ensure that they are working properly. Never disable or
bypass any alarm systems or interlocks.
Do not operate or work near quarry machinery when
under the influence of alcohol or other drugs. These items Be sure that any defective components or systems are
can result in reduced alertness and impaired judgement. properly repaired by a qualified technician before the
Serious personal injury or death could result.
Some prescription and non-prescription medications can
machinery is started. Immediately report any serious
problems to the appropriate supervisor. 7F
cause drowsiness or other adverse side effects. Do not Before performing inspections or maintenance, always
operate or work near quarry machinery when under the lock out power and tag controls to the machine drive, and
influence of such medications. to all feed and discharge equipment. Warn all personnel
that the equipment is being serviced. Refer to the Lockout/
Be Aware of Your Surroundings Tagout section of this chapter for additional information.
The quarry environment contains many situations that are Maintenance inspection procedures are included
potentially hazardous. Use extreme caution to avoid being throughout this manual. Although maintenance is not
struck by haul trucks, loaders and other quarry mobile typically a safety concern, machinery that is regularly
equipment. maintained and in proper working condition will
Be aware of idle machinery that could start-up without minimize the occurrence of safety hazards and emergency
warning. Stay clear of such machinery and the immediate situations.
area.
Be aware of overhead obstructions, such as conveyors,
support structures or power lines.
07/09 (Rev 1) 17
MACHINERY INSTALLATION SAFETY Electrical Hook-up

Foundations
Proper foundations and support structures are essential to
! WARNING!!!
DANGER
ensure the safe and efficient operation of quarry equipment. When installing any electrical equipment, be sure
Crushing machinery needs a firm foundation on which to t o c o m p l e t e l y f o l l o w t h e m a n u f a c t u r e r s
operate. This does not need to be a poured pad, but it must instructions. Failure to observe this precaution
not be unstable ground. When selecting the location, be could result in a dangerous electrical shock hazard.
sure that the entire area is as level as possible. Be sure that all electrical equipment is properly grounded.
Follow all manufacturers installation drawings and Lay out the power lines, especially those for portable
specifications when constructing the base pads for plants, so that contact with standing water is minimized.
permanent plants.
Do not place power lines in an area where they will be
If any questions arise regarding foundation requirements driven over by transport vehicles or other quarry
or modifications necessary for Telsmith machinery, please equipment. If it is absolutely necessary to extend a power
contact the Telsmith Service Department. line across a traffic area, protect the cable with properly
1 Customer-designed support structures for Telsmith rated bridging.
equipment must meet Telsmiths engineering standards. Be sure that all auxiliary control panels or power supply
All plans must be submitted in advance to the Telsmith panels can be securely locked out. This type of panel is
Engineering Department for approval. mandatary.
Guarding Maintain adequate overhead clearance from power lines
or other obstructions, particularly when planning to use
Quarry management is responsible for the proper
stacking conveyors for stockpiles.
installation and placement of guards to prevent personnel
from coming in contact with rotating or moving parts. Be sure that electrical power supplies are located in an
area that will be safe from accidental contact during
In addition to the guards supplied with the machinery,
crushing operations.
additional guards and related safety equipment may be
required to comply with OSHA, MSHA and any All Telsmith machinery is designed with electrical
applicable local regulations. The proper fabrication, components of the proper size and voltage. Any
installation and placement of these items is the users modifications to these components or to the power supply
responsibility. must be approved in writing by the Telsmith Engineering
Department.
When fabricating guards, refer to MSHAs Guide to
Equipment Guarding at Metal and Nonmetal Mines. Be sure that all connections are in accordance with the
7F Additional information can also be provided by the safety
officer at your worksite.
National Electric Code and any applicable state or local
codes.
Never remove guards until the machinery is stopped,
power is locked out, and controls are tagged. Be sure that
guards are properly re-installed before reconnecting
power.
Customer Modifications
Do not modify quarry machinery in any way without prior
approval from the manufacturer. Such modifications may
include (but are not limited to) changing machine speed or
direction of rotation, drilling additional holes and welding
or bolting additional equipment to the machinery.
All customer modifications to Telsmith machinery must
be approved in writing in writing by the Telsmith
Engineering Department.
18 07/09 (Rev 1)
MAINTENANCE AND REPAIR SAFETY Pressurized Systems (hydraulic and air)

Adjust, maintain and repair all pressurized systems only
! WARNING!!! in accordance with the instructions contained in the
DANGER manufacturers manuals provided with the machinery.
Always lockout/tagout power to machinery and
Never attempt to work on a pressurized system while it is
conveying equipment before performing any
pressurized or in operation.
maintenance or repairs. Warn all personnel that the
machinery is being serviced. Before performing maintenance or repairs on any
pressurized system:
General Precautions
- Cycle the controls through all operating positions to
To help ensure safe machine operation, use only genuine relieve any trapped pressure.
OEM replacement parts that are sold or approved by the
machines manufacturer. Use of non-OEM parts may - Check that ALL pressure is relieved from the system.
adversely affect machine operation and could result in an Pressure gauges must read zero (0) PSI.
a hazardous situation. - Lockout and tag all controls. Be sure electrical power is
Always tighten all fasteners to the proper torque as properly locked out and tagged.
described in the repair procedures. When torque Allow time for hot hydraulic oil to cool before performing 1
specifications are not listed, use the values in the torque any maintenance or repairs. Hot oil can cause burns.
chart at the back of this manual. Refer to Appendix A of
this manual. Before loosening fittings or removing components,
always recheck that ALL pressure is relieved from the
Be sure all replacement fasteners are of the proper grade system. Pressure gauges must read zero (0) PSI.
and specifications. Replace any worn or damaged
fasteners. Never attempt to crack a hydraulic fitting while a
hydraulic system is pressurized. You could be injured or
Electrical Systems killed by a stream of high pressure oil.
Always read, understand and follow appropriate electrical Never have your face near, or stand directly in front of a
system troubleshooting, maintenance and repair hydraulic line when cracking a fitting, even after system
instructions in the machinery manufacturers manuals. pressure has been relieved. Always assume that the line
has pressure.
Allow only trained and licensed electricians to install,
troubleshoot and repair electrical equipment. All Use a piece of cardboard to check for hydraulic oil leaks,
procedures must be in compliance with the National not your hand. Escaping fluid under pressure can
Electric Code and any applicable state or local penetrate the skin, resulting in serious personal injury.
regulations.
7F
Clean-up any spilled hydraulic fluid. Hydraulic fluid is
When servicing an electrical system, work with the power extremely slippery, and can be especially dangerous if
locked out and tagged. Always assume that an electrical spilled on an elevated walkway or platform.
system is live until it has been locked out.
Repair any leaks immediately. Always relieve system
Always tag and lockout power before removing cables pressure and lockout/tagout power before tightening
with quick-disconnect plugs. fittings or making repairs.
Repair any obviously worn or damaged wires and Never attempt to adjust pressure relief valves to above the
connectors. machinery manufacturer s recommended settings.
Serious personal injury and/or equipment damage could
Inspect power cables and connections daily for signs of
result.
wear, cracked insulation and worn or damaged
connectors. Repair or replace as required. Do not operate any hydraulic or air system with obviously
worn or damaged, or leaking components. Always replace
Do not store tools inside electrical cabinets.
any defective components immediately.
Verify that all tools are grounded with a three wire plug or
double insulated. Be sure that all extension cords are Never place hands on hydraulic cylinder rods while
grounded with a three wire plug. equipment is in operation. Do not step on the hydraulic
relief cylinder hoses when climbing on the crusher.
07/09 (Rev 1) 19
Refer to manufacturers instructions when recharging Always remove all jammed material before restarting the
hydraulic accumulators or checking accumulator machinery. To prevent damage, never attempt to restart a
pressure. Allow only trained and certified hydraulic stalled machine without first removing the jammed
system technicians to depressurize, recharge or repair material.
hydraulic accumulators.
Never use dynamite or other explosives to clear jams.
Welding On Machinery Explosives are dangerous and can injure or kill personnel.
Damage to machinery could also occur.
Be sure to provide adequate ventilation when welding
inside enclosed areas to prevent the buildup of hazardous Hazardous Materials
fumes. Special concern should be exercised when welding
Be aware potentially hazardous chemicals or materials.
chromium, manganese, cadmium, copper, cobalt, lead and
Such items can be harmful if they are improperly used,
nickel, as these materials are considered to be potentially
stored, mixed or transported, or if they are inhaled,
carcinogenic.
swallowed or allowed to contact the skin.
Be sure to wear the proper welding shield, welding gloves
Consult your employers hazard communications plan for
and clothing. Do not wear synthetic fabric clothing or
instructions regarding the proper handling and use of
clothing which could be easily ignited by sparks.
hazardous materials. Read and understand the labels
1 Always follow all standard safety procedures when attached to the product containers. Always follow the
welding. Be sure that all systems are shut down, power is instructions carefully.
locked out, and controls are tagged. Provide welding
Consult the manufacturers material data sheet (MMD)
screens to protect other employees working in the area.
for potential hazards and appropriate medical procedures
Relieve all hydraulic pressure before welding near should an accident occur.
hydraulic components and lines. Cover hydraulic
Store hazardous materials only in approved containers. Be
components to protect them from weld spatter and sparks.
sure containers are clearly labeled.
Do not weld near flammable liquids or hydraulic oils.
To avoid potential health hazards, persons in regular
Welding lifting eyes or hooks to manganese steel castings contact with hydraulic oils must be aware of the
is strongly discouraged, and should be done only if importance of thorough hygiene, and the proper methods
absolutely necessary. Always use a stainless steel or for handling mineral oils.
manganese weld rod. Never allow personnel to walk or
Mineral-based hydraulic oils act as solvents on the natural
work underneath castings being lifted or supported.
oils of the skin. Frequent and prolonged skin contact can
Never ground the welder so that the electrical power will cause dermatitis or severe irritation.
flow through bearings, hydraulic components or electrical
Always wear suitable protective clothing when handling
equipment. Serious damage could result.
hydraulic oil.
7F Be sure all compressed gas cylinders are stored upright,
chained and capped. Turn-off all cylinders when not in
Be sure protective clothing and proper wash-up facilities
are available to all personnel that may come in contact
use.
with mineral-based hydraulic oils.
Clearing Jammed Material Always dispose of used rags or paper towels in the correct
If material becomes jammed in the machinery: and safe fashion.
- Immediately stop the machinery.

- Lockout/tagout power. Warn others that the machinery is
being serviced.
- Follow the instructions in the operation and maintenance
manual of the affected equipment. (The jam removal
procedure for Silver Bullet Series crushers is located in
the Operation and Maintenance Manual).
To prevent serious personal injury or death, never attempt
to remove jammed material while the machinery is in
operation.
110 07/09 (Rev 1)

Disposal Of Excess Fuels, Lubricants And Wire Rope

Liquids Wire rope requires careful use, handling and maintenance to
Quarry personnel are responsible for the proper disposal of ensure long life and safe operation. Always observe the
unused fuels, used lubricating oils, used hydraulic oils, and following precautions.
other toxic materials. DO NOT dispose of these materials in Be sure to use the correct wire rope for the application.
an unapproved manner. Follow all applicable federal, state
and local regulations. Be sure that the wire rope is inspected regularly following
the manufacturers guidelines.
Flammable and Combustible Liquids
Avoid sudden loading in cold weather. Never use frozen
Store flammable liquids in a safe place, away from quarry wire rope.
machinery and personnel. Use approved safety containers
and be sure that they are clearly marked. Containers must Use suitable padding to protect wire rope from sharp
be covered when not in use. corners or edges.
Keep flammable liquids away from sparks, open flame, Avoid dragging wire rope underneath loads or over
and other ignition sources. Do not smoke around obstacles.
flammable liquids. Always obey posted no smoking Never use wire rope that is cut, badly kinked, frayed or
signs. crushed. 1
Be familiar with the locations of fire extinguishers Avoid reverse bends.
throughout the quarry. Be sure they remain accessible at
all times, and are not blocked by obstructions. Be sure that rope ends are properly sized.
Do not use gasoline or other flammable liquids to clean Use thimbles in eye fittings at all times.
tools or parts. Use only approved non-flammable Watch for local wear. Reposition or shorten wire rope to
solvents. remove the worn section from the area of lifting tension.
Always shut-off engines before refueling. Ground fuel Follow the manufacturers instructions for lubrication if
spout against the filler neck to prevent static electricity. using wire rope for lifting purposes.
Never smoke while refueling.
Connecting Or Clamping Wire Ropes
Use only approved safety containers for storing and
transporting small quantities of flammable liquids. Keep When connecting or clamping wire ropes, use one of the
containers covered when not in use. following:
Clamp and thimble connections combine both the
HOISTING AND HANDLING SAFETY clamp and thimble in one unit. Clamp and thimble
connections are capable of supporting 80% of the rated
General Precautions
Do not allow personnel to work or walk under loads
wire rope load. 7F
Cable clips are the most common way to secure a rope to
supported by a crane or hoist. a piece of equipment or to make an eye. The cable clip or
Use appropriate lifting devices to secure the load to the Crosby Clip is made of a U-bolt and saddle. If this type
crane. See the following paragraphs of this section for of clip is used to make an eye, the use of a properly sized
additional information. thimble is mandatory. If not, the cable may kink, forming
a permanent weak spot.
Use the correct lifting hooks to support the load. Refer to
the Operation and Maintenance Manual for crusher Chains
lifting points and procedures.
Chains require careful use, handling and maintenance to
Use extreme caution when operating a crane near power ensure long life and safe operation.
lines or electrical equipment.
Be sure that the correct size chain is being used for the
Do not exceed the cranes rated load capacity. Always application.
subtract the weight of the hook block, slings, chains,
Be sure that the chain is inspected regularly following the
spreader bars and any additional equipment to determine
manufacturers guidelines.
the maximum load that can be safely lifted.
Avoid sudden or shock loading (DO NOT jerk load
upright).
07/09 (Rev 1) 111

Use suitable padding to protect the chain from sharp Be sure that all tractor-trailer components are working and
corners or edges. in good condition. Test all systems (brakes, steering,
lights, etc.) for proper operation and/or adjustment before
Avoid dragging the chain under loads or over obstacles.
beginning the move. Check air pressure in all tires and
Use the proper fittings at all times. replace any tires that are worn or damaged.
Watch for local wear. Reposition or shorten chain (as After the machinery has been transported, block the tires
required) to remove the worn section from the area of if the trailer will remain stationary for an extended period
tension. of time.
Inspect links to determine the amount of wear. Refer to
manufacturers specifications for wear tolerance ranges.
Be sure that all connections between chain sections are
completed with properly sized hardware and lifting
hooks.
! CAUTION
DANGER !!!
1
Always follow proper rigging procedures as provid-
ed by the chain manufacturer. The angle of rigging
may decrease the rated lifting capacity.
Fiber Or Synthetic Slings

Slings require careful use, handling and maintenance to
ensure long life and safe operation.
Be sure that slings are rated or coded for the hitch or
application.
Be sure that slings are inspected regularly following the
manufacturers guidelines.
Slings may be safely used in a temperature range of 20 to
180 F (-6 to 82C) without decreasing load limits. For
temperatures beyond this range or for wet/frozen slings,
follow manufacturers instructions for load reductions.
7F Do not use synthetic slings in temperatures exceeding

180F (82C).
Avoid sudden or shock loading (DO NOT jerk load
upright).
TRANSPORTING MACHINERY
Be sure that the machinery is properly secured so that it
cannot vibrate or move during transport. Remove any dirt,
stones or other loose material from the machinery.
Install shipping brackets, wood blocking or other shipping
materials as directed in the machinery manufacturers
manuals. Perform any shipment preparation procedures as
indicated in the manuals.
Plan your route carefully. Know the clearance height of
the machinery. Be aware of bridges, power lines and steep
or uneven grades. Be aware of any other conditions which
may present hazards or obstructions.
112 07/09 (Rev 1)

Wear Liner Replacement Chapter 2
Chapter 2
General Instructions
Page
WORK SAFELY AND USE COMMON SENSE . . . . . . . . . . . . . . . . . . . . 2-2
TOOLS AND SUPPLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
LUBRICANTS & SEALANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
PART IDENTIFICATION & INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 2-2 2

HANDLING SEALS & MACHINED PARTS . . . . . . . . . . . . . . . . . . . . . . 2-2
HANDLING BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
USING HEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
HYDRAULIC SYSTEM SAFETY SUMMARY . . . . . . . . . . . . . . . . . . . . . 2-3
DISCONNECTING HYDRAULIC LINES . . . . . . . . . . . . . . . . . . . . . . . . 2-3
DEPRESSURIZING THE POWER ROTATOR CIRCUIT . . . . . . . . . . . . . . . 2-4
7F
07/09 21
General Instructions Wear Liner Replacement
WORK SAFELY AND PART IDENTIFICATION & INSPECTION

USE COMMON SENSE Tag and mark all parts during removal and disassembly
Refer to Chapter 1 of this manual for important quarry procedures.
safety information. Also refer to the Telsmith Quarry Clean all parts as removed. Verify that they are free of
Equipment Safety Guide for additional safety precautions. cracks, nicks, burrs and other imperfections.
Observe all precautionary statements (DANGER, Check clearances and dimensions as instructed in the
WARNING, CAUTION, IMPORTANT, and NOTE) that procedures.
are included within the repair and overhaul procedures.
Replace any excessively worn or damaged parts.
Be sure all lifting devices, slings and supports are in good
condition and of adequate rated capacity. Refer to If possible, take reference photographs of the machinery
Appendix C for component weights. as it is disassembled. During reassembly, use the
photographs to verify that all parts are correctly
Keep cleaning solvents and other combustibles away from reinstalled.
heat and open flame. Do not smoke around flammable
liquids.
HANDLING SEALS & MACHINED PARTS
2 Wear appropriate personal protective equipment (PPE).
Keep the work area clean and well organized. Be careful not to cut or damage seals during installation.
If service assistance is needed, contact your local Telsmith Handle shafts carefully to prevent damage. Do not nick or
dealer or the Telsmith Service Department. mar finished surfaces.
If shafts, bearings or other machined items are to be
TOOLS AND SUPPLIES removed from the machinery for more than a few days,
cover them with a protective coating of rust-preventative
The following common tools, shop equipment and supplies lubricant.
are required to complete the repair and overhaul procedures
in the following chapters of this manual:
HANDLING BEARINGS
Impact wrench with a 3/4 inch drive minimum, 1 inch
preferred. Remove any loose dirt from the machinery before
exposing bearings. Handle bearings with clean, dry hands.
Set of sockets and breaker bars, minimum 3/4 inch drive
with sockets up to 3-1/2 inches. Use only clean lint-free rags. Use clean tools in clean
surroundings. Use clean solvents and flushing oils.
Cold chisel, 3/4 inch.
Install new bearings as removed from packaging without
Hammers (various sizes). washing. Do not remove bearings from packaging until
7F Cables, slings, and chains. ready to use.
Soak used bearings in solvent. Then wash the bearings
Crane or hoist of adequate capacity.
(Refer to Appendix C for component weights) and blow them dry with filtered, moisture-free
compressed air. Dip the bearings in oil immediately after
Feeler gauge and inside/outside micrometers. drying to prevent rust.
Cleaning solvent.
Flushing oil. ! WARNING!!!
DANGER
Refer to the Tools and Supplies Required heading at the Always wear eye protection and face shield when
beginning of each chapter for additional items needed to using compressed air.
perform specific repair and overhaul procedures.
To prevent bearing damage, do not spin the bearings by
hand or with compressed air after the bearing surfaces
LUBRICANTS & SEALANTS have dried.
Required lubricants and sealants are listed at the beginning of
each chapter under the Tools and Supplies Required heading.
Detailed specifications for these items are located in
Appendixes D and E.
22 07/09 (Rev 1)
Wear Liner Replacement General Instructions
USING HEAT Clean-up any spilled hydraulic oil. Hydraulic oil is

extremely slippery, and can be especially dangerous if
When using an oil bath, avoid contact with hot oil. spilled on an elevated walkway or platform.
Use an acetylene torch if heat is required to remove an Refer to Chapter 1 for additional safety precautions and
interference-fit part and it is not practical to use hot oil. warnings which apply to pressurized systems and related
Keep flame moving continuously. Do not let flame touch machinery.
the part being removed.
Refer to the crusher operation and maintenance manual
If a part is to be destroyed by heat, be careful not to for complete hydraulic system operation, maintenance
damage other reusable parts nearby. and troubleshooting procedures.
Be careful when using heat and handling hot parts. To
prevent burns, always wear appropriate hand, face and DISCONNECTING HYDRAULIC LINES
eye protection.
HYDRAULIC SYSTEM SAFETY SUMMARY ! WARNING!!!

DANGER
Up to 3000 PSI (206 bar) may remain trapped in the
! WARNING!!!
DANGER power rotator circuit even when the hydraulic
pump is off and the pressure gauge indicates zero
2
Lockout/tagout power to the hydraulic control (0) PSI. Before disconnecting the power rotator
console before performing any hydraulic system hoses, be certain that pressure is completely
maintenance or repairs. relieved. Refer to the following section of this
chapter for procedure.
! WARNING!!!
DANGER
! WARNING!!!
DANGER
Before disconnecting the power rotator hoses, be
certain that any trapped pressure is completely Failure to relieve pressure before disconnecting
relieved. the power rotator hoses may result in the sudden
release of pressurized hydraulic oil. Serious
Refer to the following sections of this chapter for additional personal injury or death can occur if pressurized
information. hydraulic oil penetrates the skin.
Observe the following precautions when performing Observe the following precautions when disconnecting
hydraulic system maintenance or repairs: hydraulic lines during maintenance and repair procedures:
Allow only qualified hydraulic service technicians to Lockout/tagout power to the hydraulic control console
perform hydraulic system troubleshooting and repairs.
All persons working on the hydraulic system must have
appropriate training and certification.
before disconnecting hydraulic lines. Be certain that
trapped pressure is completely relieved before loosening 7F
any hydraulic fittings (see next section of this chapter).
Allow only licensed electricians to troubleshoot and Wear appropriate eye, face and hand protection, when
repair hydraulic system electrical components and wiring. disconnecting hydraulic hoses or loosening hydraulic
Use common sense when observing hydraulic system fittings. Wear or use additional personal protective
operation. Be aware of potential hazards at all times. Stay equipment (PPE) as required.
clear of all moving or rotating parts. Always assume that the system is pressurized, even if
Wear appropriate eye, face and hand protection, when pressure appears to have been relieved. Some residual
troubleshooting or repairing the hydraulic system. Wear pressure may remain trapped within the system even
or use additional personal protective equipment (PPE) as when the pressure gauge indicates zero (0) PSI.
required. Before disconnecting a hydraulic hose, verify that it is
Use a piece of cardboard to check for hydraulic oil leaks, relaxed and not stiff. A stiff hose indicates that pressure
not your hand. Escaping fluid under pressure can has not been relieved.
penetrate the skin. Never have your face directly in front of a hydraulic line
Avoid unnecessary contact with hydraulic oil. when loosening a fitting, even after system pressure has
been relieved. Always assume that the line has pressure.
07/09 (Rev 1) 23
As hydraulic lines are disconnected, catch any oil leakage 11. To verify that pressure has been relieved, check that both
in an appropriate container. power rotator hoses are relaxed and not stiff. A stiff hose
indicates that high pressure remains trapped in the circuit.
To prevent contamination, cap all ports and hose fittings
immediately after hydraulic lines are disconnected.
ON
OFF
DEPRESSURIZING THE POWER ROTATOR CRUSH
CLEAR EXTRACT
HIGH
SPEED
START CLOSE
STOP OPEN
CIRCUIT
MANUAL AUTO
Crush/Clear
High Speed
Switch
! WARNING!!!
DANGER 38/44 Models
Up to 3000 PSI (206 bar) may remain trapped in the
power rotator circuit even when the hydraulic
pump is off and the pressure gauge indicates zero
(0) PSI. Be sure that the power rotator circuit is
completely depressurized before disconnecting
the power rotator hoses or servicing any hydraulic Old Style Models
2 components in the power rotator circuit. 52/57/68
The power rotator hoses must be disconnected before
performing some repair and overhaul procedures in this
manual. Before disconnecting hoses, depressurize the power
rotator circuit as described in the following steps:
1. Stop the crusher. Lockout/tagout power to the crusher
drive and to all feed and discharge equipment (Refer to
Chapter 1 for complete lockout/tagout procedures).
2. Stop the hydraulic pump. Lockout/tagout power to the
hydraulic control console.
3. Jog the Crush/Clear/High Speed switch on the
Hydraulic Control Panel (Fig. 2-1) between CLEAR and
CRUSH several times. Then allow the switch to return to the
CRUSH position. New Style Models
52/57/68
4. Check the hydraulic pressure gauge or sensor readout. (Pressure Sensor)
7F Verify that the gauge indicates zero (0) PSI. See Figure 2-1.
5. Locate counterbalance valve A. Refer to Figures 2-3
and 2-5 for valve locations.
6. Loosen the pressure adjustment screw locknut. Refer to
Figure 2-2.
7. Turn the pressure adjustment screw CLOCKWISE Figure 21. Hydraulic Pressure Gauge Locations
about three turns. Listen for a hissing sound. This indicates
that pressure is being relieved.
Pressure Adjustment
8. After relieving pressure, reset the pressure adjustment Screw
screw to its original setting (turn the pressure adjustment
screw COUNTERCLOCKWISE the same number of turns
as in step 6).
9. Re-tighten the pressure adjustment screw locknut.
10. Repeat steps 5 through 8 for counterbalance valve B.
Refer to Figures 2-4 and 2-6 for valve locations.
Locknut
IMPORTANT: Pressure must be relieved at both
counterbalance valves to ensure that all pressure in the Figure 22. Counterbalance Valve Details
power rotator circuit is completely relieved.
24 07/09 (Rev 1)
Wear Liner Replacement General Instructions
Counterbalance
Valve A Counterbalance
Valve A
Figure 23. Counterbalance Valve A Figure 25. Counterbalance Valve A 2

(Models 38 and 44) (Models 52, 57 and 68)
7F
Counterbalance
Valve B
Counterbalance
Valve B
Figure 26. Counterbalance Valve B

(Models 52, 57 and 68)
Figure 24. Counterbalance Valve B

(Models 38 and 44)
07/09 (Rev 1) 25
NOTES
7F
26 07/09 (Rev 1)
Chapter 3
Support Bowl and Concave Ring
3
CONTENTS
Page
GENERAL SHUTDOWN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
TOOLS AND SUPPLIES REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
EXPLODED VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Type A Support Bowl and Concave Ring Assembly . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Type B Support Bowl and Concave Ring Assembly . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Type C Support Bowl and Concave Ring Assembly . . . . . . . . . . . . . . . . . . . . . . . . 3-6
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
SUPPORT BOWL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Type A and B Bowl Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Type C Bowl Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
CONCAVE RING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Old Style TypeA and B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
New Style Type C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
CONCAVE RING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Old Style Type A and B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
New Style Type C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
SUPPORT BOWL PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
SUPPORT BOWL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

Old Style A and B Support Bowl. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
New Style C Support Bowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
RECEIVING HOPPER INSTALLATION (Old Style A and B) . . . . . . . . . . . . . . . . 3-36
DRIVE RING COVER INSTALLATION (New Style C). . . . . . . . . . . . . . . . . . . . . . . 3-38
MIXING AND POURING SMITHBOND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
07/09 (Rev 1) 31
Support Bowl and Concave Ring Wear Liner Replacement
Support Bowl
Concave Ring
32 07/09 (Rev 1)
Wear Liner Replacement Support Bowl and Concave Ring
GENERAL SHUTDOWN PROCEDURE TOOLS AND SUPPLIES REQUIRED

Suitable rigging and hoisting equipment
Prior to Working On Crusher
5 pound hammer
1. Stop the material feed. Operate the SBS Crusher until the
crushing chamber is completely empty. If necessary, use the Sledge hammer
hydraulic clearing function to clear the crushing chamber.
Extension brackets (special tools - provided with crusher)
3
2. Lockout/tagout power to the crusher drive motor. Refer
Eyebolts 3/4-10 UNC 2B (quantity = 3)
to Chapter 1 for detailed lockout/tagout information and
procedures. Crowbar
3. Lockout/tagout power to all crusher feed and discharge Hand grinder
equipment.
Feeler gauge
4. Lockout/tagout power to the crusher oil lubrication
Tape measure
system.
Cold steel chisel
5. Jog the CLEAR/CRUSH/HIGH SPEED switch on the
Hydraulic Control Panel (Fig. 3-1) between CLEAR and Cleaning solvent
CRUSH several times. Then allow the switch to return to the
Putty
CRUSH position.
Moly-based EP-2 grease (refer to Appendix D)
6. Lockout/tagout power to the crusher hydraulic control
console. Smithbond backing compound (refer to Table 3-1)
7. Check that the hydraulic system pressure gauge on your
unit is registering zero (0) psi.
Crush
Clear Extract Start Close
High Spd
Manual Auto Stop Open
Figure 31. SBS Hydraulic Controls
07/09 33
3 B
D
E
F
G
H
Type A
Crushers with slotted concave

ring lugs only
W
K
X X
J
N L
M
O Model 38 only
P
O S
T
Q
X
O
U
R V
Figure 32. Support Bowl and Concave Ring Assembly, Type A

A. Capscrew B. Flatwasher C. Outer Receiving Hopper D. Felt Seal E.Socket Head Capscrew
F. Flatwasher G. Support Bowl Driver H. Inner Receiving Hopper I. Support Bowl J. Smithbond Compound
K. Concave Ring L. Filler Ring M. Felt Seal N. Capscrew O. Flatwasher
P. Extension Bracket Q. Nut R. Nut S. Drive Ring T. Upper Frame
U. Locknut Ring V. Ring Gear W. Tapered Key X. Wedge
34 07/09 (Rev 1)
A C
B 3
Type B
D
Crushers with slotted concave

ring lugs only
F
G
V
H
W
I
Model 38 only
K
J W
A
M
B
L O
B W
S
P
Q
T
U
Figure 33. Support Bowl and Concave Ring Assembly, Type B

A. Capscrew B. Flatwasher C. Outer Receiving Hopper D. Inner Receiving Hopper E. Felt Seal
F. Socket Hd Capscrew G. Flatwasher H. Support Bowl Drive Key I. Support Bowl J. Smithbond Compound
K. Concave Ring L. Extension Bracket M. Filler Ring N. Nut O. Felt Seal
P. Flatwasher Q. Nut R. Drive Ring S. Upper Frame T. Locknut Ring
U. Ring Gear V. Tapered Key
07/09 35
A
Type
TYPE B
C
3
38 SBS 44/52/57/68 SBS
C Non-Rimmed Wedge Rimmed Wedge
E
F
L
M
Figure 34. Support Bowl and Concave Ring Assembly, Type C

A. Drive Ring Cover B. Cover Fastener (12) C. Drive Ring D. Keeper E. Felt Seal
F. Extension (3) G. Support Bowl H. Felt Seal I. Locknut J. Felt Strip
K. Pin Retainer L. Thrust Pin Bushing M.Upper Frame N. Felt Strip
36 07/09
DESCRIPTION
The concave ring is a replaceable casting that forms the upper
surface of the crushing chamber. It is made from manganese A
steel, a wear-resistant alloy that work hardens during
crushing.
The concave ring is mounted inside the crusher support bowl. 3
Rotation of the support bowl raises or lowers the concave
ring, allowing the crusher discharge setting to be adjusted as
needed.
During crushing, the support bowl is held stationary by a B
series of hydraulic locking cylinders and a threaded locknut C
ring. The locknut ring is located just above the upper frame.
When energized, the locking cylinders exert an upward force
D
on the locknut ring that is transmitted to the support bowl.
This force lodges the slanted buttress threads of the support
bowl tight against the slanted buttress threads of the upper
frame, preventing any support bowl movement. See Fig. 3-5.
Depressing the open or close pushbutton on the hydraulic
control console partially de-energizes the hydraulic locking
cylinders. This unlocks the support bowl, allowing it to be
turned in the desired direction. See Figure 3-6.
The open pushbutton rotates the support bowl counter-
clockwise, increasing the discharge setting. The close Figure 35. Support Bowl, Locked Position
pushbutton rotates the support bowl clockwise, decreasing A. Support Bowl B. Locknut Ring
the discharge setting. Adjustments can be made at any time, C. Locking Cylinder D. Upper Frame
even while crushing. Full locking force resumes immediately
when either pushbutton is released.
Support bowl rotation is achieved by one or two power
A
rotators (depending on crusher model) mounted on the upper
frame. A large ring gear transmits force from the power
rotator(s) to a drive ring weldment which engages and turns
the support bowl.
On models 44, 52 and 57, one full rotation of the support bowl
changes the discharge setting approximately 1-1/2 inches. On
Model 68 only, a full rotation changes the discharge setting
approximately 2 inches. B
C
To facilitate concave ring replacement, a special high-speed
extract function allows the support bowl to be quickly
unthreaded from the upper frame. D
The concave ring is tightly secured to the support bowl by a

series of tapered steel wedges. Smithbond, a special epoxy-
based backing compound, fills the void area between the
concave ring and the support bowl. Smithbond must be re-
poured whenever the concave ring is replaced.
Concave ring replacement intervals will vary, depending on
the amount and type of material being crushed. However,
replacement should always be performed before the concave
ring becomes cracked or excessively worn. Refer to
Figure 36. Support Bowl, Unlocked Position
Appendix G for additional information.
A. Support Bowl B. Locknut Ring
C. Locking Cylinder D. Upper Frame
07/09 37
SUPPORT BOWL REMOVAL

A
Remove the support bowl from the crusher upper frame as
described in the following steps. Refer to Figures 3-2, 3-3 and
3-4 for exploded views and parts designations. Refer to other
B
figures as indicated.
3 1. Lockout/tagout power. Perform the General Shutdown C
Procedure as described earlier in this chapter. Refer to
Chapter 1 for complete lockout/tagout instructions.
2. Remove chutes, conveyors or other feeding devices above
the crusher.
3. Verify that there is adequate clearance above the crusher
for support bowl removal. Refer to Appendix F for removal
clearances.
Type A and B Bowl Removal

1. Remove capscrews (A) flatwashers (B), and nuts securing B
the outer receiving hopper (C) to the drive ring (Figs. 3-2 &
3-3).
D
! WARNING
Always use suitable rigging and hoisting equipment Figure 37. Extension Bracket
to stabilize and lift heavy objects. Lifting heavy (Type A Support Bowl Assemblies Only)
components with inadequate hoisting apparatus A. Capscrew B. Flat Washer
can damage machinery and may result in serious C. Extension Bracket (3) D. Nut
personal injury or death. Refer to Appendix C for .
weights.
A
2. Using an appropriate lifting device and cables, carefully
lift the outer receiving hopper (C, Fig. 3-2 & 3-3) straight up
and remove it from the support bowl (I, Fig. 3-2 & 3-3). The B
hopper is sealed with a felt seal and rope caulk, so some effort C
may be required to loosen it.
3. Remove any loose dust and dirt from the area between the
support bowl and the inner receiving hopper (H, Fig. 3-2 &
D, Fig. 3-3).
lift the inner receiving hopper straight up and remove it from
the support bowl (I, Fig. 3-2 & 3-3).
5. Install the extension brackets (C, Fig. 3-7 & C, Fig. 3-8) B
on the drive ring. Secure with capscrews, flatwashers and
nuts. D
Figure 38. Extension Bracket

(Type B and C Support Bowl Assemblies Only)
A. Capscrew B. Flat Washer
C. Extension Bracket (3) D. Nut
38 07/09
Cutaway
View
Moly-Based
EP-2
Figure 39. Buttress Thread Lubrication

6. Apply a generous amount of moly-based EP-2 grease at 10. Visually check that no personnel are on, under, inside or
each of the four grease fittings around the upper frame. See beside the crusher.
Figure 3-9. Refer to Appendix D for grease specifications.
11. Connect power to the hydraulic control console. Move the
7. Be sure that power to the hydraulic power unit is locked- function selector switch to EXTRACT-HIGH SPEED. See
out, and that the hydraulic pressure gauge indicates zero (0) Figure 3-11 for typical control console diagram.
PSI.
12. Depress the START button. The hydraulic pump will
8. Disconnect the hydraulic locking cylinder hose at the start.
hydraulic power unit. Leave all other hoses connected. See
Figure 3-10.
Hydraulic Locking
Cylinder Hose
Function
Selector
Switch
Figure 310. Hydraulic Locking Cylinder Hose Figure 311. Hydraulic Control Console
9. Check the oil level in the hydraulic reservoir. Be sure that
the oil level is up to the black line of sight gauge. Add oil if
oil level is low. Refer to Appendix D for oil specifications.
07/09 39
3
B
Figure 312. Unthreading Support Bowl

A. Support Bowl B. Drive Ring C. Ring Gear D. Upper Frame
13. Depress and hold the OPEN button. Visually check that .
the ring gear (C, Fig. 3-12) begins turning slowly

counterclockwise. On some crushers, there may be a brief
delay before the gear starts turning.
14. Depress and hold the OPEN button. Allow the support
bowl (A, Fig. 3-12) to become completely unthreaded from
th e u pp e r fr a m e ( D , F i g . 3 - 12 ) a nd lo c k n ut r i n g.
Approximately 7 to 10 revolutions will be required,
depending on the initial position of the support bowl.
15. Depress the STOP button after the support bowl becomes
completely unthreaded. Lockout/tagout power to the
hydraulic control console.
16. Type A support bowl assemblies only: Install 3/4 inch
eyebolts in the three lifting holes on the support bowl driver.
Secure the eyebolts with jamnuts.
17. Type B support bowl assemblies only: Install 3/4 inch
eyebolts in the three lifting holes on the top edge of the
support bowl (Fig. 3-13). Secure the eyebolts with jamnuts.
lift the support bowl straight up and remove it from the upper
frame. See Figure 3-13.
19. Suspend the support bowl over a clean, flat work area.
Figure 313. Support Bowl Lifing Arrangement
310 07/09
Figure 314. Support Bowl on Blocking (cutaway view)

20. Arrange four evenly spaced hardwood blocks directly
beneath the outer edge of the support bowl. Each timber
should be exactly the same height (approximately 3 inches
(7.6 cm). See Figure 3-14.
IMPORTANT:
Do Not place timbers beneath the lower lip of the
concave ring. This area must remain unobstructed to
allow room for the concave ring removal.
21. Slowly lower the support bowl onto the timbers.
07/09 311
Type C Bowl Removal

1. Remove the nine hex head capscrews and washers bolting B A
the drive ring cover (A, Fig. 3-15) to the drive ring (B, Fig. 3-
A
15). D
3
C A
D
A
Figure 316. Drive Key Extension Mounting Points

A. Drive Key Extension (3) B. Support Bowl
C. Drive Ring D. Drive Keys (3)
! CAUTION
If you are using the EXTRACT HIGH SPEED mode to
remove the support bowl, make certain all hydraulic
pressure is released from the locking cylinder
circuit. Failure to disconnect the hydraulic pressure
line to the cylinders could result in damage to the
support bowl or locking nut threads if the control
B
switch was inadvertently returned to the CRUSH
position with hydraulic pressure still connected to
Figure 315. Drive Ring Cover Removal
the locking cylinders.
A. Drive Ring Cover B. Drive Ring
C. Drive Ring Lift Points 4. Move the control switch to the EXTRACT HIGH SPEED
position (Fig. 3-11) and press the OPEN button. Hold both
2. Install lift eyes or lift hooks and a lifting harness of switches in this position while the support bowl unthreads
sufficient capacity to the three lift eyes cast in the cover (Fig. from the threaded portions of the main frame and locknut. DO
3-15). (Drive ring covers weigh in a range from 675 lbs (306 NOT allow the control switch to return to the CRUSH
Kg) on 38SBS to 1330 Lbs (603 Kg) on 68 SBS). Lift the position while the bowl is unthreading, as this could damage
cover straight up off the drive ring to remove. the threads. As the support bowl rises, watch for thread
3. Transfer the drive ring cover capscrews and washers from disengagement and release the switch from the EXTRACT
the points on the cover with three adjacent fasteners to the HIGH SPEED position when the end of the thread on the
three drive key extensions (Fig. 3-16) supplied loose with support bowl becomes visible.
your crusher. (Drive key extensions are pn BE-272-2174W). 5. Press the STOP button on the hydraulic control panel and
Bolt the drive key extensions to the top of the drive ring with disconnect power to the hydraulic unit pump.
three fasteners per extension as shown in Fig. 3-16.
6. Before removing the support bowl from the crusher, mark
the point on the upper rim with paint where the external
threads end at the bottom of the bowl. Mark the
corresponding position on the locking ring where the internal
threads start. This will help correctly position components
and start thread engagement when replacing the support
bowl.
312 07/09
7. Thread three 3/4 lift eyes fully into the upper rim of the
support bowl (A, Fig. 3-17) and attach a lift harness and hoist
of sufficient capacity to lift the bowl (bowls range in weight
D
from 2700 lbs (1225 Kg) on the 38SBS to 13,000 lbs (5,900
Kg on the 68 SBS). Make certain the external threads on
the support bowl are fully disengaged from the threads on
the lock ring. Lift the support bowl straight up out of the
B
3
drive ring until the drive keys (D, Fig. 3-16) clear the drive
key extensions (A, Fig. 3-16). C
A A C
A
A
Figure 318. Felt Seal Installation.

A. Felt Seal B. Support Bowl Upper Lip
C. Rough Side Facing Out D. Smooth Side Facing Up
Figure 317. Support Bowl Lift Eyes

A. Lift Eyes (3) B. Support Bowl External Thread
C. Upper Frame Internal Thread
8. Lower the support bowl onto blocking, making certain the

blocking is placed under the support bowl casting, not the
maganese concave liner.
9. Examine the condition of the drive keys (D, Fig. 3-16). If
keys are deformed, cracked or excessively worn replace them
at this time.
10. Inspect the felt seal on the inside upper lip of the support
bowl. If it is worn, torn, damaged or heavily contaminated
with metal filings or debris, remove it and replace with new
felt. All SBS crushers with the exception of the Model 68,
require 5/8 in. square felt approximately 15 feet long. Model
68 crushers will require 3/4 in square felt approximately 20
feet long. Install new felt into groove with the smooth side
facing up, and the rough side facing out (Fig. 3-18). Use a
rubber faced mallet to seat felt in groove. Trim felt to size so
that ends meet square and no material is bulging from the
groove. Just prior to installation of the support bowl, coat the
rough face with moly based EP#2 grease.
07/09 313
CONCAVE RING REMOVAL

Remove the concave ring from the support bowl as described
in the following steps. Refer to Figures 3-1, 3-2 and 3-3 for
exploded views and component designations. Refer to other
figures as indicated.
3
Old Style Series A and B Removal
1. Place the support bowl on timbers as described in the
previous section of this chapter. Be sure that the timbers are
located only under the concave ring outer edge. The timbers
must not extend beneath the concave ring lower lip. See
Figure 3-14.
2. Clean the area around the concave ring mounting lugs.
Remove all accumulated dust and dirt.
! CAUTION
The concave ring can release and drop at any
time after the mounting lugs are cut. To prevent
serious personal injury, be sure that all
personnel are clear of the area between the
concave ring lower lip and the ground.
3. Using a torch or air-arc, cut the concave ring mounting
lugs. The number of lugs will vary depending on crusher
model. Refer to Figure 3-19.
4. Using a sledge hammer, strike the top edge of the
concave ring until it breaks loose and drops from the support
bowl.
5. Units with standard concave ring lugs (Fig. 3-19): Using
a torch, remove the cut-off lug ends from the taper wedge
CUT LUG HERE
segments. Save the taper segments for later use.
6. Units with slotted concave ring lugs (Fig. 3-2 & 3-3):
Using a torch, remove the cut-off lug ends from the tapered
keys (W, Fig. 3-2). Save the keys and taper wedge segments
(X, Fig. 3-2) for later use.
Note: Quantity of
! WARNING lugs varies by
crusher model
Always use suitable rigging and hoisting equipment
to stabilize and lift heavy objects. Lifting heavy Figure 319. Cutting Concave Ring Lugs
components with inadequate hoisting apparatus
can damage machinery and may result in serious
New Style Series C Removal
personal injury or death. Refer to Appendix C for
weights. 1. When the support bowl is removed from the upper frame,
suspend it over a clean, flat work area.
7. Using an appropriate lifting device, move the support
bowl to a suitable work area where it can be thoroughly 2. Arrange four evenly spaced hardwood blocks directly
cleaned and inspected. below the support bowl on the work area. Each timber must
be the same height. Timbers at least 3 inches (7.6 cm) tall are
8. If present, remove the filler rings (M, Fig. 3-3) from the required.
old concave ring. Save the filler rings for later use.
314 07/09
3. Slowly lower the support bowl onto the timbers (Fig. 3-

20) Make certain the support timbers are placed beneath the
lower ring of the support bowl only. If timbers protrude in and
reach under the concave ring, they will prevent the concave
ring from dropping during removal.
Figure 320. Blocking Up Support Bowl

A. Support Bowl B. Concave Ring Lip C. Hardwood Mounting Blocks (4)
C
! CAUTION
Removing the tapered wedges that support the con-
cave ring may require standing inside the support
bowl. Make certain your feet are not below the con-
cave ring lower lip when driving out wedges. The
concave liner could drop suddenly as the tapered
wedges are driven out. Serious personal injury B B
could result if all personnel are not clear of the area A
beneath the concave ring lower lip and the ground
as the liner is prepared for removal.
4. Torch or grind off the welds holding the tapered wedges Figure 321. Wedge Removal
in place at the concave ring ears (B, Fig. 3-21). If possible, Do A. Tapered Wedge B. Weld C. Concave Ear
Not cut through the wedges, as they will be reused when
6. If the concave liner does not drop down after the wedges
mounting the new concave ring.
are removed, it will be necessary to strike the top edge of the
5. Use a sledge and driver bar to drive the tapered wedges liner and the ears with a sledge hammer to free the liner.
out from beneath the mounting ears. The concave ring should
7. When the liner has dropped, use a torch to remove the
drop down of its own weight as the final tapered wedge is
wedges (and keys if used) from the torched off mounting ear
driven out.
segments. If wedges and keys are not damaged they can be
reused in the new liner installation.
07/09 315
! WARNING
A B
Always use suitable rigging and hoisting
equipment to stabilize and lift heavy objects.
Lifting the support bowl or concave ring with
3 inadequate hoisting apparatus can damage
machinery and may result in serious personal
injury or death.
8. Using a hoist and crane of suitable rating, lift the support
bowl a slight distance off the concave ring and check for the
location of the filler rings (if your crusher is equipped with
filler rings). If filler rings (L, Fig. 3-2) are stuck to the support D C
bowl by Smithbond, remove them before they drop and cause
damage. If all filler rings have remained seated on the old
concave ring, continue to lift the support bowl free of the Figure 322. Filler Ring Inspection
concave ring. A. Filler Ring B. Lift Hole
C. Locator Mounting Hole D. Mounting Feet (4)
! WARNING
CONCAVE RING INSTALLATION
When grinding, cutting or breaking up pieces of
old Smithbond filler it is mandatory to wear a
Old Style Series A and B
respirator that prevents inhalation of toxic
fumes. Failure to provide adequate ventilation 1. Place a new concave ring on hardwood blocking so it is
and filter toxic fumes could cause injury to raised about 3 or 4 inches (7.6 - 10.1 cm) off the ground. The
personnel working on the crusher. ring must be evenly supported and completely level (Fig. 3-
23).
9. Move the support bowl to a suitable stand or work area
where it can be cleaned and examined. Clean any remaining
Smithbond backing material from the bowl with a handheld
grinder. Use a grinder to remove any weld in the area where
the wedges were removed. Be careful not to nick or scratch
the machined seat of the support bowl while cleaning or
grinding on the bowl. Check that the mounting surfaces for
the concave support ears are clean and flat. Check that the
exterior threads on the bowl are undamaged. If support bowl
is reusable, remove the old grease from threads, as
contamination in the grease could cause problems during
reassembly.
10. Remove the filler rings from the old concave ring and
clean any Smithbond filler from the rings. Check the filler
rings (Fig. 3-22) for signs of damage, particularly at the lower
seating surface and at the mounting holes. If a filler ring is Figure 323. Concave Ring on Blocking
bent, shows signs of chatter marks on the surface or has
2. Inspect the machined seat area on both the support bowl
damaged mounting holes or broken or bent mounting feet,
and the new concave ring (Fig. 3-24). Remove any burrs or
replace it.
rough spots with a grinder. The seating surfaces must be
clean, dry and with a uniform surface free of rust, paint etc. to
promote a proper seal.
316 07/09
Coat With 3
Heavy
Gear Oil
(ISO 150)
No Lube
No
Lu
be
A
No
Lu
be
Figure 325. Lubricant Application Area

6. Install 3/4 inch eyebolts into the three lifting holes on the
top edge of the support bowl. Secure the eyebolts with
jamnuts.
Figure 324. Seat Inspection
A. Concave Ring B. Support Bowl ! WARNING
3. Apply a coat of heavy gear oil (ISO 150) to the curved Always use suitable rigging and hoisting
upper surface of the support bowl (Fig. 3-25). DO NOT apply equipment to stabilize and lift heavy objects.
any lubricant to the machined seat at the bottom. Lifting heavy components with inadequate
hoisting apparatus can damage machinery and
may result in serious personal injury or death.
IMPORTANT: Support bowls range in weight from 2,600 lbs
DO NOT apply any lube to the concave ring. (1179 Kg) on the Model 38 to 12,000 lbs (5443 Kg)
4. Apply a thin coat of heavy gear oil to the complete surface on the Model 68.
of each filler ring. (Lubricant is applied to help prevent 7. Slowly lower the support bowl onto the concave ring (Fig.
adhesion of filler compound.). 3-26. Align the support bowl so that the support bowl slots
5. Lift each filler ring up into position on the concave ring align with the concave ring lugs. Lower the support bowl so
with a suitable lifting device. Position the filler ring locator the slots pass down over the lugs.
mounting hole (C, Fig. 3-22) over the mounting stub on the
concave ring and lower into position.
07/09 317
Figure 327. Positioning The Concave Ring

A. Take Measurement at 4 places 90o apart
B. Space lugs evenly between support bowl cutouts
11. If necessary, shift the concave ring with a crowbar so that

it is centered within the support bowl (Fig. 3-28).
Figure 326. Lowering the Support Bowl onto the

Concave Ring
8. When the support bowl slots are approximately 1/2 (1.2
cm) below the lugs, stop lowering the support bowl. Rotate
the support bowl so that the lugs on the concave ring are
centered between the slots (Fig. 3-27). Finish lowering the
support bowl down onto the concave ring when the lugs are
correctly aligned.
9. Remove the lifting cables from the support bowl.
10. When the concave ring lugs are correctly positioned in
relation to the cutouts, check that the concave ring is centered
in the support bowl. Measure the distance from the inner edge
of the support bowl to the top edge of the concave ring at four
l o c a t i on s 9 0 o d e gr e e s a p a r t ( F i g . 3 - 2 7 ) . A l l f o ur
Figure 328. Center Concave Ring
measurements must be equal.
12. Install the wedges under the concave ring lugs. On models
with slotted lugs, install the keys (W, Fig. 3-2).
318 07/09
13. Using a hammer, alternately tap all wedge segments into

place until they are snug against the machined surface of the
support bowl.
14. Switch to a sledge hammer and drive bar and alternately
drive the wedge segments tight until they will not move (Fig.
3-29). Follow the sequence in Figure 3-30 when tightening 3
the wedges on your model crusher.
38, 44 & 52
Figure 329. Tightening Wedge Segments

57 Only
IMPORTANT:
Be certain that all wedge segments are driven as tight
as possible. Failure to fully tighten wedge segments
could allow the concave ring to loosen during crushing.
15. Re-check the concave ring position in the support bowl
when all wedges are tight. Check that the ring is still centered
in the bowl and has not shifted. If measurements are unequal
(Fig. 3-27), it will be necessary to drive the wedge segments
back out and re-center the ring in the bowl.
68 Only
Figure 330. Wedge Tightening Sequence per Model
16. Using a feeler gauge check that the machined seat of the
concave ring is TIGHT against the machined seat of the
support bowl. Move completely (360o) around the lower edge
of the support bowl checking the clearance (Fig. 3-31). There
should be no clearance at any point.
07/09 319
Figure 331. Checking Ring to Bowl Clearance
IMPORTANT:
Make certain the concave ring is properly installed as
described in the previous steps. Serious damage to the
support bowl will occur if the concave ring is loose or Figure 332. Welding Wedge Segments
cocked when the crusher is put into production. 19. For crusher models equipped with a tapered key and a
17. If any clearance is detected in Step 16, check again that tapered wedge (Fig. 3-33), tack weld the wedge to the tapered
the concave ring is centered in the support bowl, and that all key.
wedges are fully seated. If the concave ring is correctly
seated, any clearance may indicate that the support bowl has
wear on the machined seat. Any worn areas will need to be
sealed with putty before pouring the Smithbond sealant. This
will prevent any of the backing sealant from leaking out
through the worn areas.
! CAUTION
DO NOT weld the tapered wedges to the support
bowl. Concave ring lugs may break if tapered
wedges are welded to the support bowl.
18. For crusher models using a tapered wedge only (Fig. 3-
32), tack weld the taper wedges to the concave ring lugs.
Figure 333. Welding Taper Key Models
320 07/09
20. Before mixing and pouring Smithbond epoxy backing

compound, determine the amount of Smithbond required for
your crusher model using Table 3-1. Make certain you have
an adequate amount of compound to complete the job.
Table 31. Smithbond Required Quantities (22 Pound Containers)
3
Fine Medium Medium Medium Coarse Extra
Crusher
Concave Fine Concave Coarse Concave Coarse
Model
Concave Concave Concave
38S N/A N/A 2 2 2 N/A
38FC 6 N/A 6 N/A 6 N/A
44S N/A N/A 5 N/A 5 5
44FC 4 N/A 5 N/A 5 N/A
52S N/A N/A 8 N/A 6 6
52FC 7 N/A 6 N/A 6 N/A
57S N/A N/A 15 N/A 10 8
57FC 18 16 15 12 14 N/A
68S N/A N/A 16 N/A 16 16
68FC 24 N/A 22 N/A 22 N/A
NOTE: Quantities shown are approximate. Actual quantities required may vary. Consult Telsmith if your
liner configuration is not shown above.
21. Mix each pail of Smithbond one-at-a-time as described in 22. Continue mixing and pouring Smithbond until the
the Mixing and Pouring Smithbond section of this chapter. Smithbond is level with the bottom of the support bowl
After mixing, pour the Smithbond mixture through the vertical face (Fig. 3-35). Do Not overfill the slots with
support bowl slots as shown in Figure 3-34. Smithbond and allow the level to rise up and overflow onto
the wedge seating surfaces. Correct Smithbond level can be
determined by measuring Dimension A between the
bottom of the support bowl vertical face and the machined
wedge seating surface. The pour dimension is model specific
as outlined in the dimension chart of Figure 3-35. Pouring
time can be reduced if more than one individual pours
Smithbond, allowing the pour to occur at multiple locations
around the top of the support bowl at one time.
Figure 334. Pouring Concave Ring Smithbond
07/09 321
New Style C
1. Place a new concave ring on hardwood blocking so it is
raised about 3 or 4 inches (7.6 - 10.1 cm) off the ground. The
ring must be evenly supported and completely level (Fig. 3-
B 36).
3
A
B
Dimension A (Backing Fill Level):

38 SBS: 0.88 (2.2 cm)
44 H/SBS: 1.00 (2.5 cm)
52 H/SBS: 1.38 (3.5 cm)
Figure 336. Blocking Up New Concave Ring
57 H: 1.61 (4.0 cm)
57 SBS: 1.00 (2.5 cm) 2. Inspect the machined seat area on both the support bowl
68 H: 2.38 (6.0 cm) and the new concave ring. (Fig. 3-37). Remove any burrs or
68 SBS: 1.38 (3.5 cm) rough spots with a grinder. The seating surfaces must be
Figure 335. Support Bowl Backing Fill Level clean, dry and with a uniform surface free of rust, paint etc. to
promote a proper seal.
A. Fill Dimension (Concave Ring) B. Smithbond Backing Levels
C. Support Bowl D. Concave Ring
E. Mantle F. Head
23. Allow adequate time for Smithbond to harden. In most

climates, at least four hours will be required. In colder
climates, allow at least eight hours or let Smithbond harden
overnight.
24. Prepare and install the support bowl in the upper frame
following the instructions in this chapter when the Smithbond
has fully hardened.
322 07/09
IMPORTANT:
DO NOT apply any grease or gear oil to the concave
ring.
NO GREA
SE
NO GREA
S E
NO
GR
EA
SE
Figure 337. Seat Inspection

3. Apply a thin coat of NLGI#2 grease, or a generous coating
of heavy gear oil to the curved upper surface of the support
bowl including the lug pockets (Fig. 3-38). DO NOT apply Figure 338. Greasing the Support Bowl
any grease or gear oil to the machined seat at the bottom.
4. Apply a thin coat of grease to the complete surface of each
filler ring. (Grease is applied to help prevent adhesion of filler
compound.)
5. Lift each filler ring (if used) up into position on the
concave ring with a suitable lifting device (Fig. 3-39).
Position the filler ring locator mounting hole over the
concave mounting stub (B, Fig. 3-39) and lower into position.
07/09 323
A
B
Figure 339. Concave Ring Installation

A. Filler Ring B.Concave Mounting Stub
C. Concave Ring D. Lift Hole
6. Install 3/4 inch eyebolts into the three lifting holes on the
top edge of the support bowl. Secure the eyebolts with
jamnuts.
! WARNING
Lifting heavy components with inadequate
hoisting apparatus can damage machinery and
Support bowls range in weight from 2,600 lbs
(1179 Kg) on the Model 38 to 12,000 lbs (5443 Kg)
on the Model 68.
7. Slowly lower the support bowl onto the concave ring (Fig.
3-40). Align the support bowl so that the support bowl slots
align with the concave ring lugs. Lower the support bowl so
the slots pass down over the lugs. Lower the support bowl
until it is resting on the machined lip of the concave ring. DO Figure 340. Lowering the Support Bowl onto the
NOT rotate the support bowl, the support bowl cutout slots Concave Ring
must remain aligned with the ears on the concave ring.
8. Remove the lifting cables from the support bowl.
9. Measure the distance from the inner edge of the support
bowl to the top edge of the concave ring at four locations 90o
apart (Fig. 3-41). All four measurements must be equal.
324 07/09
IMPORTANT:
The taper wedges used on Model 38 liners differ from
2 the wedges used on 44/52/57/68 liners. Model 38
1 wedges do not have a rim. Wedges are not
interchangeable (see Fig. 3-44 & 3-45). 3
12. Switch to a sledge hammer and drive bar and alternately
drive the wedge segments tight until they will not move (Fig.
3-43). Follow the sequence in Figures 3-44 & 3-45 when
tightening the wedges on your model crusher.
4 3
Figure 341. Concave Ring Centering Measurements

10. If necessary, shift the concave ring with a crowbar so that
it is centered within the support bowl (Fig. 3-42). When the
concave ring is correctly centered, check to make sure that the
ears are still located directly above the support bowl slots. If
not, rotate the concave ring until ears are above the slots.
Figure 343. Tightening Wedge Segments
3
Non-Rim
Wedge
MODELS 38
Figure 344. Wedge Tightening Sequence Model 38
Figure 342. Centering The Concave Ring.

11. Using a hammer, alternately tap all taper wedge segments
into place until they are tight beneath the concave ring ears
and have bridged the slots in the support bowl.
07/09 325
IMPORTANT:
Make certain that all wedge segments are driven as
1 tight as possible. Failure to fully tighten wedge
segments could allow the concave ring to loosen during
3 crushing.
4 13. Re-check the concave ring position in the support bowl
when all wedges are tight. Check that the ring is still centered
in the bowl and has not shifted. If measurements are unequal
3
(Fig. 3-41), it will be necessary to drive the wedge segments
back out and re-center the ring in the bowl. When re-
Rimmed
tightening the wedges, make certain to alternate wedges
Wedge every few blows to prevent the bowl from shifting to one side.
2
14. Using a feeler gauge, check that the machined seat of the
MODELS 44 & 52 concave ring is TIGHT against the machined seat of the
support bowl. Move completely (360o) around the lower edge
of the support bowl checking the clearance (Fig. 3-46). There
4
should be no clearance at any point.
5
2
1
Rimmed
Wedge
MODEL 57
1
6
Figure 346. Measuring Seat Clearance
4
3
IMPORTANT:
Make certain the concave ring is properly installed as
described in the previous steps. Serious damage to the
Rimmed
Wedge support bowl will occur if the concave ring is loose or
5
cocked when the crusher is put into production.
2
15. If any clearance is detected in Step 14, check again that
MODEL 68 the concave ring is centered in the support bowl and that all
wedges are fully seated. If the concave ring is correctly
seated, any clearance may indicate that the support bowl has
Figure 345. Wedge Tightening Sequence per Model
wear on the machined seat. Any worn areas will need to be
sealed with putty before pouring the Smithbond sealant. This
will prevent any of the backing sealant from leaking out
through the worn areas.
326 07/09
16. Tack weld the taper wedges to the concave ring lugs (Fig.
3-47). ! CAUTION
DO NOT weld the tapered wedges to the support
bowl. Concave ring lugs may break, if tapered
wedges are welded to the support bowl.
17. Before mixing and pouring Smithbond epoxy backing 3
compound, determine the amount of Smithbond required for
your crusher model using Table 3-2. Make certain you have
an adequate amount of compound to complete the job.
Figure 347. Welding Tapered Wedge Segments

Table 32. Smithbond Required Quantities (22 Pound Containers)
Crusher
Model #1 #2 #3 #4 #5 #6 #7 #8 #9
38SBS N/A* N/A* N/A* NA* NA* NA* N/A* N/A* N/A*
44SBS 7 7 7 7 3 3 3 N/A N/A
52SBS N/A 6 6 6 6 8 8 8 8
57SBS N/A 16 11 11 11 8 8 6 6
68SBS N/A 18 18 6 18 16 16 16 16
NOTE: Quantities shown are approximate. Actual quantities required may vary. Consult Telsmith if your liner
configuration is not shown above.
*Model 38 SBS crushers use non-numbered liners. Use the 38S quantities in Table 3-1 when determining
quantities for the SBS.
18. Mix each pail of Smithbond one-at-a-time as described in

the Mixing and Pouring Smithbond section of this chapter.
After mixing, pour the Smithbond mixture through the
support bowl slots as shown in Figure 3-48.
07/09 327
B
3
A
B
Figure 348. Pouring Smithbond Backing F

19. Continue mixing and pouring Smithbond until the
Dimension A (Backing Fill Level):
Smithbond is level with the bottom of the support bowl 38 SBS: 0.88 (2.2 cm)
vertical face (Fig. 3-49). Do Not overfill the slots with 44 H/SBS: 1.00 (2.5 cm)
Smithbond and allow the level to rise up and overflow onto 52 H/SBS: 1.38 (3.5 cm)
the wedge seating surfaces. Correct Smithbond level can be 57 H: 1.61 (4.0 cm)
determined by measuring Dimension A between the 57 SBS: 1.00 (2.5 cm)
bottom of the support bowl vertical face and the machined 68 H: 2.38 (6.0 cm)
wedge seating surface. The pour dimension is model specific 68 SBS: 1.38 (3.5 cm)
as outlined in the dimension chart of Figure 3-49. Pouring
Figure 349. Support Bowl Backing Fill Levell
time can be reduced if more than one individual pours
Smithbond, allowing the pour to occur at multiple locations A. Fill Dimension (Concave Ring) B. Smithbond Backing Levels
around the top of the support bowl at one time. C. Support Bowl D. Concave Ring
E. Mantle F. Head
20. Allow adequate time for Smithbond to harden. In most

climates, at least four hours will be required. In colder
climates allow at least eight hours or let Smithbond harden
overnight.
21. Prepare and install the support bowl in the upper frame
following the instructions in this chapter when the Smithbond
has fully hardened.
328 07/09
SUPPORT BOWL PREPARATION

Prepare the support bowl for installation as described in the
following steps.
1. Be sure that power remains locked-out. Refer to
Chapter 1 for complete lockout/tagout instructions.
3
2. Replace the concave ring if it is cracked, damaged or
worn beyond its useful life. Refer to the procedures earlier in
this chapter for concave ring removal and installation
procedures.
3. Remove all dirt, rust and old grease from the buttress
threads of the support bowl (Fig. 3-50), the locknut ring and
the upper frame..
Figure 350. Cleaning the Buttress Threads

4. Use a wire brush on the buttress threads. File any rough
areas. Remove any nicks, burrs or scratches.
5. After cleaning, carefully inspect all buttress threads for
signs of damage or excessive wear. Make repairs as required.
6. Inspect the support bowl felt seal. On Type A
assemblies, the seal is located inside the support bowl driver.
On Type B & C assemblies, the seal is located near the top
of the support bowl. Replace the seal if it is worn or damaged.
Refer to Figure 3-51 for seal lengths. See Figure 3-52 for seal
orientation.
7. Inspect the felt seal at the bottom of the upper frame.
Replace the seal if it is worn or damaged. Refer to Figure 3-
51 for seal lengths. See Figure 3-52 for seal orientation.
07/09 329
A
B
Crusher Model 38 44 52 57 68
Seal Length in 11.0 12.5 14.4 16.3 18.4
feet/(cm) (335.3) (381.0) (438.9) (496.8) (560.8)
Seal Thickness in 5/8 5/8 5/8 5/8 5/8
inches/(mm) (16) (16) (16) (16) (16)
Note: All dimensions shown above are approximate
Figure 351. Felt Seal Installation (Support Bowl)

A.Type A Support Bowl Felt Seal B. Type B & C Support Bowl Felt Seal
8. Type A support bowl assemblies only: If removed, .

reinstall the support bowl driver. Secure with socket head
capscrews and flatwashers. Apply thread locking compound
to capscrews as installed. Refer to Appendix E for thread
locking compound specifications. See Appendix A for torque
specifications.
9. Type B & C support bowl assemblies only: If removed,
reinstall the support bowl driver keys. Secure with socket
head capscrews and flatwashers. Apply thread locking
compound to capscrews as installed. Refer to Appendix E for
thread locking compound specifications. See Appendix A for
torque specifications B
A
Figure 352. Seal Orientation (all felt seals)

A. Rough Side Faces OUT B. Smooth side faces UP
330 07/09
. IMPORTANT: Use only moly-based EP-2 grease in the

following steps. Refer to Appendix D for grease
specifications. Before applying grease, be certain that
the buttress threads are clean, in good condition and
completely free of any rust, nicks or burrs.
10. Coat the buttress threads of the locknut ring and the upper 3
frame with moly-based EP-2 grease (Fig. 3-54).
11. Coat the buttress threads of the support bowl with moly-
based EP-2 grease (Fig. 3.54).
12. Coat the smooth lower surface of the support bowl with
moly-based EP-2 grease.
13. Coat both felt seals with moly-based EP-2 grease.
IMPORTANT: Failure to apply grease as described in
the previous steps may result in thread damage and/or
excessive thread wear.
Crusher Seal Length Seal Thickness

Model feet/(cm) inches/(mm)
12.3 5/8
38
(374.9) (16)
13.3 5/8
44
(405.3) (16)
16.4 5/8
52
(499.8) (16)
18.0 5/8
57
(548.6) (16)
20.0 3/4
68
(609.6) (16)
Note: All dimensions shown are approximate
Figure 353. Felt Seal Installation (Upper Frame)
07/09 331
3 A C
Figure 354. Greasing Threads and Seals

A. Grease Buttress Threads B. Grease Machined Surface C. Grease All Felt Seals
332 07/09
SUPPORT BOWL INSTALLATION 6. If removed, reinstall the extension brackets onto the drive
ring (Fig. 3-55). Secure the extension brackets with
Old Style A and B capscrews, flatwashers and nuts. Refer to Figures 3-7 and 3-
Install the support bowl as described in the following steps: 8 for installation details.
1. Be sure that power remains locked-out. Refer to Chapter

1 for complete lockout/tagout procedures. ! WARNING 3
2. Prepare the support bowl for installation as described in Always use suitable rigging and hoisting equipment
the Support Bowl Preparation section of this chapter. to stabilize and lift heavy objects. Lifting heavy
components with inadequate hoisting apparatus
3. Type A support bowl assemblies only: Install 3/4 inch can damage machinery and may result in serious
eyebolts into the three lifting holes on the support bowl driver personal injury or death. Refer to Appendix C for
. Secure the eyebolts with jamnuts. weights.
4. Type B support bowl assemblies only: Install 3/4 inch 7. Using an appropriate lifting device and cables, suspend
eyebolts into the three lifting holes on the top edge of the the support bowl several inches over the threaded bore of the
support bowl (Fig. 3-55). Secure the eyebolts with jamnuts. locknut ring (Fig. 3-55).
5. If not done previously, disconnect the locking cylinder .
hose at the hydraulic power unit. Leave all other hoses
connected. Refer to Figure 3-10.
Figure 355. Positioning The Support Bowl

A. Support Bowl Buttress Threads B. Locknut Ring Threads C. Allow 6 inches clearance between thread starts D. Extension Bracket
07/09 333
8. Slowly rotate the support bowl until the leading end of the 20. Depress and hold the CLOSE button. Verify that the
support bowl buttress thread is positioned about 6 inches support bowl begins turning slowly clockwise.
(15.2 cm) behind the start of the locknut ring buttress thread.
21. Allow the support bowl to become threaded within the
See Figure 3-55.
bore of the locknut ring and the upper frame (Fig. 3-56). The
9. Visually check that no personnel are on, under, inside or support bowl will move slowly downward as it rotates.
3 beside the crusher.
22. Type A support bowl assemblies only: Continue to
10. Connect power to the hydraulic control console. Move the depress the CLOSE button until the keys on the drive ring
function selector switch to EXTRACT-HIGH SPEED. Refer become fully engaged in the keyways of the support bowl
to Figure 3-11 for control console diagram. driver.
11. Depress the START button. The hydraulic pump will 23. Type B support bowl assemblies only: Continue to
start. depress the CLOSE button until the support bowl drive keys
become fully engaged in the keyways of the drive ring.
12. Type A support bowl assemblies only: Depress and
hold the OPEN or CLOSE pushbutton until the keys on the 24. Depress the STOP button. Lockout/tagout power to
extension brackets become aligned with the keyways on the the hydraulic control console. Refer to Chapter 1 for
support bowl driver. complete lockout/tagout procedures.
13. Type B support bowl assemblies only: Depress and hold 25. Remove capscrews, flatwashers, nuts and extension
the OPEN or CLOSE pushbutton until the keyways on the brackets.
extension brackets become aligned with the support bowl
26. Install the inner and outer receiving hoppers. Refer to the
drive keys.
Receiving Hopper Installation section of this chapter for
IMPORTANT: Be sure that the support bowl remains procedure.
level as it is lowered in step 14 or 15. On some crushers,
.
it may be necessary to loosen the extension brackets
slightly to allow key engagement. B
14. Type A support bowl assemblies only: Slowly lower the

support bowl. Allow the keys on the extension brackets to
enter the keyways in the support bowl driver. Continue
lowering the support bowl until its bottom buttress thread is
resting on the top buttress thread of the locknut ring .
15. Type B support bowl assemblies only: Slowly lower the
support bowl. Allow the drive keys to enter the keyways of A
the extension brackets. Continue lowering the support bowl
until its bottom buttress thread is resting on the top buttress
thread of the locknut ring .
16. Measure the support bowl height at all three extension
brackets. Measurements must be approximately equal in all
three locations. C
IMPORTANT: Be sure that the support bowl is not Figure 356. Threading Support Bowl
cocked. To ensure proper thread engagement, the
A. Extension B. Support Bowl
support bowl must be completely level as it is threaded C. Drive Ring
into the locknut ring.
17. Disconnect the lifting cables and remove the eyebolt.
18. Visually check that no personnel are on, under, inside or
beside the crusher.
19. With the function selector switch in the EXTRACT-
HIGH SPEED position, depress the START button. The
hydraulic pump will start.
334 07/09
New Style C
1. Apply Moly-based EP#2 grease to the support bowl felt
seal as shown in Figure 3-57.
3
D
Figure 357. Felt Seal Installation.

A. Felt Seal B. Support Bowl Upper Lip Figure 358. Assembly Grease Points
C. Rough Side Facing Out D. Smooth Side Facing Up
IMPORTANT: Failure to properly grease adjuster
2. Apply a liberal amount of Moly-based EP#2 grease to the component threads prior to assembly can result in
internal threads of the locknut and upper frame. Also apply thread damage and/or rapid thread wear.
grease to the external threads of the support bowl and the 4. Install the three 3/4 inch threaded lift eyes fully in the
machined area beneath the threads (Fig. 3-58). support bowl as shown in Figure 3-59. Attach a lift device and
3. If your upper frame requires new inner or outer felt seals, cables or chain of sufficient capacity to the lift eyes.
install them at this time (Fig. 3-57), and coat outer face NOTE: It is recommended that a lift device with a hook
liberally with Moly-based EP#2 grease. or lift eye that can rotate 3600 be used to ease the re-
threading of the support bowl. The lifting device will
need to rotate without binding or putting excess strain
on the lift chains or cables while engaging the threads.
5. Carefully lift the support bowl and suspend a few inches
above the drive key extensions. Make certain the support
bowl is completely level. Rotate the support bowl until the
match marks you made previously on the support bowl and
the locking ring are aligned .
07/09 335
9. Hold the control switch in the Extract High Speed

position and activate the Close button. The support bowl
E
should rotate slowly down into the upper frame. If any
grinding, jerking or slowing of the rotation is noted, STOP the
A rotation immediately by releasing the Close button. If the
3 bowl does not rotate smoothly, this could be a sign of cross
threading, damaged threads or resistance created by the lift
apparatus.
NOTE: If the lift apparatus remains attached while the
bowl is descending into the upper frame, continue to
D
provide additional slack in the lift harness. Failure to
provide sufficient slack could result in the support bowl
threads being pulled up against the upper frame
threads, creating resistance to rotation.
10. When the support bowl has rotated completely to the
bottom of the upper frame, stop the rotation and remove the
lift eyes and lift apparatus from the bowl if not removed
B
previously. Unbolt the drive key extensions (B, Fig. 3-59)
from the drive ring.
C RECEIVING HOPPER INSTALLATION

Old Style A and B
Figure 359. Orienting Support Bowl
A. Drive Key (3) B. Drive Key Extension (3)
Reinstall the inner and outer receiving hoppers as described
C. Locking Ring Match Mark D. Support Bowl Match Mark in the following steps. Refer to Figures 3-2 and 3-3 for
E. Lift Eye (3) exploded views.
6. Rotate the support bowl back (counterclockwise) from the 1. Be sure that power remains locked-out. Refer to Chapter
locking ring mark until the drive keys on the support bowl are 1 for complete lockout/tagout procedures.
aligned with the drive key extensions. (Rotating the bowl
2. Reinstall the support bowl as described in the Support
back will help ensure that the threads engage properly in step
Bowl Installation sections earlier in this chapter.
7). Lower the support bowl down, engaging the drive keys in
the drive key extensions.
! WARNING
7. Manually rotate the support bowl clockwise a small
amount to ensure the support bowl threads engage correctly Always use suitable rigging and hoisting equipment
with locking ring threads. (Using a long bar as a lever on top to stabilize and lift heavy objects. Lifting heavy
of the bowl may be necessary to rotate the bowl). If any components with inadequate hoisting apparatus
resistance is felt or the bowl refuses to turn, back up and start can damage machinery and may result in serious
over. Any resistance is an indication the threads are cross personal injury or death. Refer to Appendix C for
threaded or jammed. weights.
8. Restore hydraulic and electrical power to the crusher. 3. Using an appropriate lifting device and cables, slowly
Provide some slack in the lift apparatus to allow the bowl to lower the inner receiving hopper straight down into the
rotate down. support bowl.
NOTE: When the support bowl has rotated several 4. Clean the top surface of the drive ring and the mating
rotations and the threads have moved through the surface of the outer receiving hopper. Apply a bead of caulk
locking ring and down into the upper frame, it is completely around the drive ring. See Figure 3-60.
permissible to stop the rotation and remove the lift
apparatus and lift eyes from the bowl.
336 07/09
Figure 360. Caulk Application

A. Caulk B. Drive Ring Upper Flange
5. If not done previously, coat the felt seal with moly-based

EP-2 grease. Refer to Appendix D for grease specifications.
6. Using an appropriate lifting device and cables, slowly Figure 361. Outer Receiving Hopper Installation
lower the outer receiving hopper into the concave ring (Fig.
7. Remove the lifting cables from the outer receiving
3-61). Be sure that bolt holes are aligned.
hopper.
8. Using a mallet, evenly tap completely around the edge of
the outer receiving hopper until it is firmly seated against the
top of the drive ring. Secure the hopper with capscrews
flatwashers and nuts. Torque fasteners to 150 ft. lb. (203 nm).
9. Reconnect the locking cylinder hose at the hydraulic
power unit.
10. Restore power to the crusher, and rotate the support bowl
open and closed to check adjusting assembly operation. If the
unit is working correctly, set your crusher final discharge
setting by following the instructions in your Operation and
Maintenance Manual.
11. Install any conveyors, chutes, hoppers or any other feed
equipment that was removed to gain access to the support
bowl.
07/09 337
DRIVE RING COVER INSTALLATION 6. Install any conveyors, chutes, hoppers or any other feed
equipment that was removed to gain access to the support
New Style C bowl.
1. Install the support bowl following the instructions in
Adjuster Assembly Support Bowl Installation in this chapter.
3 2. Remove drive key extensions and store for future use.
3. Install lift eyes and lift apparatus of sufficient capacity to
the drive ring cover and lift cover into position above drive
ring (Fig. 3-62). Align mounting holes with the threaded
holes in the drive ring where the drive key extensions were
removed. Install nine (9) hex head cap screws and washers
and torque to 150 Ft. lb. (203 Nm).
Figure 362. Install Drive Ring Cover

4. Install the clamping cylinder hydraulic hoses at the
hydraulic power unit manifold.
NOTE: If the hydraulic clamping cylinder hydraulic
circuit was opened (cylinder replaced, cylinder hoses
disconnected etc.) during adjusting assembly service, it
will be necessary to bleed the hydraulic clamping
cylinder circuit. Follow the instructions in Upper Frame
Hydraulic System Service in this chapter.
5. Restore power to the crusher, and rotate the support bowl
open and closed to check adjusting assembly operation. If the
unit is working correctly, set your crusher final discharge
setting by following the instructions in your Operation and
Maintenance Manual.
338 07/09
MIXING AND POURING SMITHBOND

The epoxy based material required to fill the voids between
the concave ring and support bowl of the crusher is
Smithbond. This compound provides a solid backing surface
that helps prevent the concave ring from becoming deformed A
during crushing. New Smithbond is required whenever the 3
concave ring is replaced.
B
Smithbond Safety Precautions
! WARNING
Failure to observe the following safety
precautions may result in serious personal
injury or death. C
Mix and pour Smithbond only in a well ventilated area.
Avoid inhaling fumes. D
Wear rubber or plastic gloves when working with

Smithbond. Always wear eye protection.
Avoid contact with Smithbond. Use soap and water to
remove any Smithbond that comes in contact with the
E
skin. Immediately flush eyes with running water if eye
contact occurs.
Clothes soiled with Smithbond must be laundered before
being re-worn.
Provide adequate ventilation when removing parts backed
F
with Smithbond. Wear an airline grade respirator to
prevent inhalation of fumes when torch cutting, grinding
or chopping Smithbond. Figure 363. Smithbond Kit Components
Read the labels on the Smithbond pail and the Smithbond A. Hardener Can B. Plastic Partition
hardener can (Fig. 3-63) for additional warnings, C. Cover D. Resin
E. Stirring Rod F. Pail
directions and safety precautions.
For best results, crusher parts should be between 65oF
Tips for Handling Smithbond (18oC) and 90oF (32oC) during pouring.
The Smithbond kit is shipped in a plastic pail. Each kit Subsequent batches required to completely fill the cavity
contains a pre-measured amount of liquid resin. Included may be mixed and added at any time. Newly poured
separately inside the pail is a small can of liquid hardener Smithbond will adhere to any Smithbond that has already
and a stirring rod (Fig. 3-63) hardened.
The required quantities of Smithbond are listed in the Do not mix Smithbond in batches larger than 22 pounds.
Tables under Concave Ring Installation in this chapter. It For best results, mix and pour each pail one at a time. Do
is recommended that one extra pail of Smithbond be Not re-use stirring rods.
ordered as a precaution when preparing to pour concave
Store Smithbond at temperatures below 100oF (38oC).
ring backing.
Smithbond is stable for at least 12 months after the date of
Ensure that Smithbond is at room temperature (about manufacture. Smithbond can be used up to 24 months
70oF (21oC)) before mixing. If Smithbond is too cold, it after manufacture, but hardening times will increase as
can become viscous and have difficulty flowing into small the kit grows older.
spaces. If the Smithbond is too warm, it may harden
before it is completely poured.
07/09 339
Mixing Smithbond
1. Read and understand all safety precautions on the
Smithbond pail and hardener before proceeding with mixing.
2. Mix the resin using the stirring rod and a low speed
3 electric drill. Continue stirring the resin for about 5 minutes.
If any crust has formed on the top of the resin use a sharp tool
to break it up.
3. As stirring continues, add the entire contents of the
hardener can into the pail at a slow, continuous rate. Mix until
a uniform color is obtained. Be sure all settled material is
thoroughly mixed (Fig. 3-64).
4. Pour Smithbond IMMEDIATELY after mixing in
hardener. DO NOT allow Smithbond to stand. Hardening
begins quickly and the mixture will remain pourable for only
about 15 minutes.
! CAUTION
Smithbond may become hot when mixed,
especially if pouring occurs during high ambient
temperatures. To avoid burns, use gloves when
handling the Smithbond pail. Avoid contact with
the concave ring while pouring Smithbond.
5. Mix and pour additional batches of Smithbond as required
to completely fill the cavity.
Figure 364. Mixing Smithbond
340 07/09
Chapter 4
Mantle and Head
CONTENTS
Page
EXPLODED VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
SHUTDOWN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
TOOLS AND SUPPLIES REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
MANTLE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
MANTLE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
HEAD and SHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

Mantle Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
HEAD and SHAFT INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
HEAD and SHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

Mantle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
4
Installation - Crushers Without Anti-Spin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Installation - Crushers With Anti-Spin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
FINAL INSTALLATION and ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
07/09 (Rev 1) 41
Mantle and Head Wear Liner Replacement
Shaft Nut Cap

Mantle
Head
42 07/09 (Rev 1)
Wear Liner Replacement Mantle and Head
H G B
F E
D I
Figure 41. Exploded View, Head and Shaft Components (Type A)

A. Main Shaft C. Mantle E. Shaft Nut (FC Only) G. Feed Plate (FC Only) I. Inner Piston Ring
B. Taper Head D. Burn Ring F. Shaft Nut (S Only) H. Shaft Nut Cap (S Only)
07/09 (Rev 1) 43
G H
F E
J
B
Figure 42. Exploded View, Head and Shaft Assembly (Type B)

A. Main Shaft C. Mantle E. Shaft Nut G. Feed Plate (FC Only) I. Inner Piston Ring
B. Taper Head D. Burn Ring F. Spacer (FC Only) H. Shaft Nut Cap (S Only) J. Smithbond
K. Shaft Nut Wrench
44 07/09 (Rev 1)
Model 38 Models 44-68
H
B
G
4
Figure 43. Exploded View, Head and Shaft Components (Type C)
A. Main Shaft C. Mantle E. Shaft Nut G. Washer I. Bolt Locking Plate
B. Taper Head D. Burn Ring F. Shaft Nut Cap H. Hex Head Capscrew Gr5
07/09 45
DESCRIPTION
The mantle (C, Fig. 4-1, 4-2 & 4-3) is a replaceable cone-
shaped maganese steel casting that forms the lower surface of
the crushing chamber.
The mantle is secured by a shaft nut (E, Fig. 4-1, 4-2 & 4-3)
located on the upper threaded portion of the main shaft.
Before the nut is loosened for removal, a burning ring (D)
located between the mantle and the nut must be cut away with
a torch. A special wrench supplied with the special tools kit
is required to remove the nut. Nuts come in several styles. A
matching wrench is required for loosening and tightening
each style nut.
B
Smithbond, a special epoxy based backing compound, fills
the void area between the top surface of the taper head (B)
and the underside of the mantle (C).
Mantle replacement intervals will vary, depending on the
amount and type of material being crushed. Replacement
should always be performed before the mantle becomes
excessively worn or cracked.
A
Mantle replacement can be performed in two ways. One
method involves leaving the shaft and taper head in the
crusher and removing only the mantle. The second method
involves removing the mantle, taper head and shaft assembly
as a unit before removing the mantle. Both methods are
covered in this chapter. It is recommended that the complete
assembly be removed at every other mantle change to allow
the shaft, taper head skirt, the inner piston ring and the upper
thrust bearing to be completely inspected.
Figure 44. Type C Mantle Nuts and Wrenches

A. New Style Nut & Wrench (44-68) B. Old Style Nut & Wrench
C. Model 38 Nut & Wrench
46 07/09
SHUTDOWN PROCEDURE TOOLS AND SUPPLIES REQUIRED

Suitable rigging and hoisting equipment
! WARNING Standard open-end and socket wrenches
Always lockout/tagout power before performing
any maintenance, adjustments, lubrication or Standard hex wrenches
repairs. Failure to lockout/tagout power may Sledge hammer
result in serious personal injury or death!
Shaft nut wrench*
1. Stop the material feed, operate the crusher until the
crushing chamber is completely empty. If necessary, use the Shaft nut cap lift lug*
hydraulic clearing function to clear the crushing chamber. Eyebolt, 1-1/4 inch or 1-1/2 inch
2. Lockout/ tagout power to the crusher drive motor. Shut Crowbar
off fuel supply and disconnect batteries if the crusher is
powered by a diesel engine. Refer to Chapter 1 for detailed Hand grinder
safety procedures and lockout/tagout information. Tape measure and feeler gauge
3. Lockout /tagout power to all crusher feed and discharge Cold steel chisel
equipment.
Cleaning solvent, clay and putty
4. Lockout/tagout power to the crusher oil-lubrication
system. Shaft nut burning ring (new)
NLGI #2 grease
IMPORTANT: Lubricating oil
Be sure that power remains connected to the hydraulic Smithbond backing compound
control console during the next step.
* Supplied with crusher special tools
5. Depress the STOP button on the hydraulic control
console. Then jog the function selector switch between
CLEAR, CRUSH, EXTRACT HI-SPEED positions several
times.
6. Check that all hydraulic pressure gauges and indicators
indicate zero PSI (0 bar). Repeat step 5 if any pressure is
indicated.
7. Lockout/tagout power to the crusher hydraulic control
console. 4
8. If you will be disconnecting the power rotator hoses or
servicing the hydraulic components in the power rotator
circuit, depressurize the power rotator circuit following the
instructions in Chapter 10 of your SBS Operation and
Maintenance manual.
! WARNING
Pressures of up to 4000 PSI (276 bar) may remain
trapped in the power rotator circuit even when
the hydraulic pump is off and the pressure
gauge indicates zero PSI (0 bar). Relieve
pressure as described in Chapter 10 of your
Operator Manual before disconnecting the
power rotator hoses or servicing any hydraulic
components in the power rotator circuit.
07/09 47
MANTLE REMOVAL 7. On Model 38 crushers the shaft nut cap can be lifted off
and removed by hand as it weighs approximately 20 lb. (9
1. Lockout/tagout power. Perform the Shutdown Procedure kg). It is suggested that model 44-68 shaft nut caps be lifted
described earlier in this chapter. Refer to Chapter 1 for off using appropriately sized lift apparatus. The new C style
complete lockout/tagout instructions. shaft nut cap on models 44-68 can be lifted off using the lift
2. Remove chutes, conveyors or other feeding devices from lug supplied in the special tools kit. Insert the lifting lug (Fig
above the crusher. 4-6) through the slot in the shaft nut cap and turn 90o to
engage the lifting lug tangs in the pockets of the cap. Use a
3. Remove the complete upper frame assembly from the properly rated lift device to lift the lug and cap off the shaft
crusher following the instructions in Chapter 3 of this nut.
manual.
4. Remove any built-up dirt or debris from inside the
crusher.
5. Using a torch, cut through the perimeter of the burn ring
(Fig. 4-5). Move completely around (360o) the burn ring
while cutting. Use the groove in the center of the ring as a B
guide while cutting the ring in half. The ring will collapse
when cut, relieving pressure on the shaft nut.
! CAUTION
To avoid heat damage when cutting the burn
ring, direct the cutting torch away from the taper A
head and the shaft nut (Fig. 4-3).
Figure 46. C Style Shaft Nut Cap Removal

A. New Style Shaft Nut Cap B. Shaft Nut Cap Lift Lug
8. Type A head and shaft assemblies only: Secure the shaft

nut wrench to the shaft nut with capscrews, flatwashers and
nuts (Fig. 4-1).
9. Type B head and shaft assemblies only: Secure the shaft
nut wrench to the shaft nut with capscrews (Fig. 4-2).
10. Note that the Type C 38 model shaft nut removal
4 wrench, requires four 3/4 x 11/4 shoulder screws to bolt the
wrench to the shaft nut. The new style shaft wrench used on
Type C 44-68 models must be clamped around the shaft nut
and tightened down into the pockets on the nut as shown in
Figure 4-4.
11. Use a sledge hammer to loosen the shaft nut (Fig. 4-7 &
4-8). Drive the wrench COUNTERCLOCKWISE to loosen
the nut.
Figure 45. Burn Ring Removal
6. Use a torch to cut the welds holding the bolt locking plate
(I, Fig. 4-1) to the shaft nut cap (F, Fig. 4-1). Remove the
locking plate, the hex head cap screw (H) and the flat washer
(G) from the shaft nut cap.
48 07/09
Figure 47. Shaft Nut Removal (Style A)
Figure 49. Breaking Mantle Loose

13. Lifting of the worn mantle from the taper head is most
commonly done by welding lifting eyes to the mantle in three
places. Weld three pieces of mild steel stock that can be bent
to conform to the mantle surface into place using stainless
steel welding rod AWSE3091L-17 (Fig. 4-10). Cut lift holes
in the steel stock to mount lift eyes.
Figure 48. Shaft Nut Removal (New Style C)
12. When the shaft nut is successfully removed, use the
sledge hammer to strike the mantle in several places to break
it loose from the taper head (Fig.4-9). If the mantle will not
break loose using the sledge hammer, it may be necessary to
use the cutting torch to cut the mantle in half so it can be
removed in two pieces.
4
! WARNING
You must provide adequate ventilation when
removing parts backed with Smithbond with a
torch. Wear a properly rated respirator to
prevent inhalation of fumes when torch cutting,
grinding or chopping maganese and Smithbond.
Figure 410. Mantle Lift Eye Installation
07/09 49
16. Using a hammer, chisel and hand grinder, remove all old
! CAUTION Smithbond and any accumulated debris from the surface of
Welding lift eyes to the mantle maganese must the taper head. Do not nick or scratch the machined seat at the
be done carefully with the correct equipment. bottom of the taper head.
Welds have a tendency to pull out of the surface
of worn maganese if the lift eyes are not ! WARNING
correctly welded into place with maganese
Provide adequate ventilation when removing
compatible welding rod. Stainless steel rod
Smithbond debris. Wear a certified respirator to
AWSE309L-17 is recommended.
prevent inhalation of fumes when torch cutting,
14. Using a suitable lifting device of correct capacity, lift the grinding or breaking up Smithbond or
mantle a short distance off the taper head. Place blocking components backed with Smithbond.
around the circumference of the mantle to hold it in the lifted
position. Remove the lift device and cables from the lift eyes. MANTLE INSTALLATION
15. Install mantle U hooks at three points around the lower lip 1. Inspect the machined seat on the taper head and the new
of the mantle (Fig. 4-11). Transfer the lift device and cables mantle (Fig. 4-12). No paint, dirt, grease or rust should be
to the U hooks (Fig. 4-11). present on either machined surface. Remove any rough spots
or burrs with a grinder.
4
B
Figure 411. Mantle Lifting Arrangement

A. U Hook (3) C. Cable or Lift Harness
B. Mantle D. Lift Device B
NOTE: Figure 412. Seat Inspection

If U hooks are not available, it is possible to sling
through the mantle (running the slings through the shaft A. Mantle Machined Seat B. Taper Machined Seat
mounting hole at the top) at several places. When
installing slings that run up the inside of the mantle, be
aware of pieces of Smithbond backing that could break
off and fall to the ground.
410 07/09
2. When both the taper head and the new mantle are clean
and dry, apply a coat of heavy gear oil (ISO 150) to the
unmachined upper surface of the taper head (Fig. 4-13). Do
Not apply any oil to the machined seat of the taper or any C
portion of the new mantle.
B
Apply ISO 150 NO LUBE ON SEAT

Gear Oil
Figure 414. Burning Ring Installation

Figure 413. Taper Head Lubrication Area A. Mantle B. Burn Ring
C. Shaft
! WARNING
Always use suitable rigging and hoisting when
lifting the mantle into place. Lifting heavy
components with inadequate or incorrectly
stabilized hoisting apparatus could damage
components or result in serious injury or death
to personnel.
3. Install U hooks at three points around the mantle (Fig.4-
11). Install an appropriate lift device and cables and lower the
new mantle down into the crusher onto the taper head.
! CAUTION 4
Do Not weld lifting eyes to a new mantle. Welding
on the new maganese could damage the new
mantle if the lift eyes were to fail. Use only lift U
hooks or lift harnesses to install the new mantle
on the taper head.
4. Remove the lifting apparatus and the U-hooks from the Figure 415. Centering Mantle
mantle. 6. Measure from the shaft to the inside edge of the mantle at
5. Place a new burning ring around the threaded portion of four positions 90o apart as shown in Figure 4-16. All four
the main shaft (Fig. 4-14). Center it on the upper lip of the measurements must be equal; if they are not, continue using
mantle. If the new burn ring will not drop down into position, the pry bar to position the mantle.
it may be necessary to use a pry bar to center the top of the
mantle in relation to the main shaft (Fig. 4-15).
07/09 411
A B
C
D
Figure 416. Mantle Measurements
IMPORTANT:
Telsmith introduced a new style tapered shaft nut for all
sizes of H/SBS cone crushers in 2008. When replacing
your burn ring, it will be necessary to use the new style
nut, a new style cap and a new style shaft nut wrench I
for the installation (Fig. 4-17).
Figure 417. Required New Parts and Tool

4 A. Cap Bolt Locking Plate B. Shaft Nut Cap Bolt
C. Washer D. Cap Lifting Lug
E. Shaft Nut Cap F. Shaft Nut Wrench
G. Tapered Shaft Nut H. Burn Ring
I. Mantle/Head and Shaft Assembly
7. Secure the shaft nut wrench (F, Fig. 4-17) to the shaft nut
(G), and hand thread the shaft nut onto the shaft until it is snug
against the burn ring (H).
8. Final tighten the shaft nut using a sledge hammer to strike
the shaft nut wrench (Fig. 4-18). Tighten the nut
CLOCKWISE until it stops turning. To prevent the mantle
from loosening during crushing, the shaft nut must be as tight
as possible against the burning ring.
412 07/09
Figure 418. Tightening Shaft Nut

9. Remove the shaft nut wrench and all mounting hardware
and store for future use.
10. Using a feeler gauge, check that the machined seat of the
mantle is tight against the machined seat of the taper head.
Check clearance at multiple points moving 360o around the
taper head (Fig 4-19). There should be no clearance at any Figure 419. Checking Mantle to Taper Clearance
point.
11. Install the shaft nut cap using the lift lug (D, Fig. 4-17) to
lower the cap into position. Install the washer and Grade 5
IMPORTANT: hex head capscrew torquing to specification.
Carefully inspect the joint between the mantle and the
taper head. Seal any worn areas that create a gap with
Table 41. Shaft Nut Torque Values
putty to prevent Smithbond leakage during backing
installation. If any major clearance is detected, check
Cone Model Torque Specification
that the mantle is not cocked, or the shaft nut not fully
tightened. 38 840 Ft-lb. (1138 N-m)
44 840 Ft-lb. (1138 N-m)
52 1500 Ft-lb. (2033 N-m) 4

57 1500 Ft-lb. (2033 N-m)
68 1500 Ft-lb. (2033 N-m)
NOTE:
It is possible to use a new style shaft nut cap on an old
style shaft nut on models 44, 52 and 57 cone crushers.
To use the new style cap, grind off the locating lug (Fig.
4-20) until it is smooth with the surrounding surface.
07/09 413
A
A A
Figure 420. Modifying a New Style Cap

A. Grind Lug Flush With Surface
12. The void between the mantle and the taper head will now Figure 421. Mantle Pouring Holes
need to be filled with Smithbond epoxy-based backing A. Pour equal amounts of Smithbond through each access hole.
compound. Refer to Table 4-2 for the approximate amount of
Smithbond needed for your particular model crusher. Be sure 14. Mix a pail of Smithbond as described in the Mixing and
that an adequate supply of Smithbond is available before Pouring Smithbond section in Chapter 3.
beginning the pour. 15. Slowly pour the Smithbond mixture into the clay pouring
funnel at one of the pouring holes (Fig. 4-22). Allow the
Smithbond to flow into the cavity between the mantle and
Table 42. Smithbond Quantities - Mantle* taper head. Continue pouring until the pail is completely
empty.
Quantity
Crusher Model
(22 Pound Container)
38S/FC 2
44S 2
44FC 3
52S/FC 4
57S 8
4 57FC 6
68S/FC 7
*Quantities are approximate, actual quantities may vary
13. Form a clay funnel around each of the two pouring holes
near the top of the mantle (Fig. 4-21).
Figure 422. Pouring Smithbond

16. Mix another pail of Smithbond and pour into the opposite
funnel from the first pour. Continue pouring until the pail is
completely empty. Pouring should be alternated between the
two pouring holes.
414 07/09
17. Mix and pour additional pails of Smithbond until the level 23. Weld the shaft nut cap to the burning ring using stainless
just reaches the lower edge of the pour hole on the mantle steel weld rod E (R) 309L. Apply 2 welds in four places as
(Fig. 4-23). DO NOT fill the holes so that backing compound shown in Figure 4-24.
backs up into the clay funnels. If this occurs, quickly remove
the clay funnels and allow backing compound to drain down
to the correct level.
WEL
WELD D
A
C
A
Figure 423. Smithbond Fill Level

WELD
A. Mantle Fill Level B. Mantle
C. Taper Head D. Shaft
Figure 424. Installing Shaft Nut Cap and Locking
18. Check for Smithbond leakage at the joint between the Devices
mantle and the taper head (Fig. 4-19). Seal any leaks with A. Shaft Nut Cap Bolt B. Washer
putty. C. Shaft Nut Cap Bolt Locking Plate
19. Allow Smithbond to fully harden. In most climates, at

least four hours will be required. In cold climates allow 8
hours.
20. After the Smithbond has fully hardened, remove the clay
4
pouring funnels and any clay putty that was used at the mantle
joint. Grind off any excess Smithbond residue.
21. Tack weld the shaft nut locking plate to the shaft nut cap
(Fig. 4-24) using stainless steel weld rod E (R) 309L.
IMPORTANT:
If the shaft nut cap bolt locking plate is not welded to the
shaft nut cap, the bolt could loosen and cause damage
to the shaft nut cap or crusher. If you have further
questions on how or where to weld the shaft nut, shaft
nut cap or burning ring, contact Telsmith Service.
22. Weld the burning ring to the mantle using stainless steel
weld rod E (R) 309L. Apply 2 welds in four places as shown
in Figure 4-24.
07/09 415
HEAD and SHAFT REMOVAL

If removal of the mantle also requires removal of the shaft
and head assembly, remove the complete assembly as
follows:
1. Lockout/tagout power. Perform the Shutdown Procedure
described earlier in this chapter. Refer to Chapter 1 for
complete lockout/tagout instructions.
2. Remove chutes, conveyors or other feed devices from
above the crusher.
3. To provide access, remove the complete upper frame
assembly as detailed in Chapter 4 of this manual.
4. Verify that there is adequate space above the crusher to
allow head and shaft removal.
NOTE:
Perform steps 5 and 6 ONLY if your crusher is equipped
with the anti-spin option (4-25). If your crusher is not
equipped with anti-spin, skip steps 5 and 6.
Figure 426. Bottom of Head Skirt to Frame Arm

Measurement
6. At a point near the Step 5 match marks, place additional
match marks on the taper head skirt, the rotary seal ring, the
main frame hub and the main frame liner (Fig. 4-27). These
marks will be used during reassembly.
With Anti-Spin
Without Anti-Spin
Figure 425. Anti-Spin Option Check

5. At one of the crusher arms, measure the distance between
the top of the frame arm and the bottom of the taper head
skirt. (Fig. 4-26). Record this measurement for further use. It
will be checked again during reassembly procedures.
416 07/09
Figure 428. Shaft Nut Cap Removal (New Style)

A A. New Style Shaft Nut Cap B. Shaft Nut Cap Lift Lug
10. Thread an eyebolt of suitable capacity to support the head

and shaft assembly into the tapped hole at the top of the shaft
(Fig. 4-29). Make certain the eyebolt is threaded completely
B
into the hole until it is tight. Install a suitable lift device
through the eyebolt.
! WARNING
Figure 427. Match Marks
A. Main Frame B. Rotary Seal Ring equipment to stabilize and lift heavy objects.
C. Head Skirt
Lifting heavy components with inadequate
7. Remove the shaft nut cap bolt, washer and shaft nut hoisting apparatus can damage machinery and
locking plate from the shaft nut (Fig. 4-24). It will be may result in serious personal injury or death.
necessary to use a cutting torch to remove the weld holding
shaft nut locking plate to the shaft nut cap.
8. Use a torch to cut the weld holding the shaft nut locking
plate (Fig. 4-24) to the shaft nut cap. Remove the locking
plate, the hex head cap screw and the flat washer from the 4
shaft nut cap.
9. On Model 38 crushers, the shaft nut cap can be lifted off
and removed by hand as it weighs approximately 20 lb. (9
kg). It is suggested that the new style shaft nut cap on models
44-68 be lifted off using the lift lug supplied in the special
tools kit. Insert the lifting lug (Fig 4-28) through the slot in
the shaft nut cap and turn 90o to engage the lifting lug tangs
in the pockets of the cap. Use a properly rated lift device to
lift the lug and cap off the shaft nut.
07/09 417
A A
E
C
Figure 430. Head and Shaft Removal (C Style)
4 F
A. Shaft and Mantle Assembly
C. Bearing Cage
B. Upper Bearing Race
D. Lower Bearing Race
E. Eccentric Assembly
Figure 429. Head and Shaft Removal (A Style)

A. Shaft and Mantle Assembly B. Upper Bearing Race
IMPORTANT:
C. Bearing Cage D. Lower Bearing Race The upper bearing race (B, Fig. 4-29 & 4-30) may
E. Rotary Seal Ring F. Bakelite Seals temporarily stick to the inside of the taper head due to
oil adhesion. To prevent bearing damage, do not lift the
taper head more than 2 inches off the eccentric before
determining if the upper bearing race has detached
from the head.
11. Slowly lift the head and shaft assembly approximately
two inches off the eccentric. Stop and wait several minutes
while listening for the upper race to drop. A distinctive
clunk should be audible when the race drops down out of
the taper head.
418 07/09
Mantle Removal
! WARNING Remove the mantle from the head and shaft assembly as
Do Not reach or work under the taper head while detailed in MANTLE REMOVAL in this chapter.
it is suspended. If the race remains stuck to the
underside of the taper head, use a sling to retain
it as described below. Serious personal injury or ! CAUTION
death will result if the race loosens and falls on Make certain the head and shaft assembly is
personnel. securely supported when removing the mantle
(Fig. 4-31). A sledgehammer will be required to
12. If there is a question whether the race has dropped, lift the
break the mantle free. The head and shaft
head and shaft assembly up several more inches and check
assembly must be securely blocked to prevent
visually with a mirror to see if the race has dislodged. Do Not
the head and shaft assembly from moving while
under any circumstances place any portion of your body
the mantle is being broken loose.
under the shaft assembly while checking for the position of
the upper race.
! WARNING
NOTE: If the mantle must be removed by cutting with a
torch, provide adequate ventilation when
Hitting the side of the mantle with a sledge hammer may
removing Smithbond debris. Wear a certified
help loosen a stuck upper race.
respirator to prevent inhalation of fumes when
13. If the race still has not dropped down, loop a sling around torch cutting, grinding or breaking up
the lower end of the main shaft to form a noose. Do Not reach S m i t h b o n d o r c o m p o n e n ts b a c k e d w i t h
under the taper head while positioning the noose. Secure the Smithbond.
loose end of the sling to the eyebolt at the upper end of the
shaft. HEAD and SHAFT INSPECTION
14. Using the lift device, slowly lift the head and shaft When the head and shaft assembly is removed from the
assembly completely from the crusher and place on suitable crusher, the following checks and inspections should be
work supports (Fig.4-31). made. It is recommended that during the inspection
procedures the head and shaft assembly be turned over to
allow a more complete inspection of the underside of the
taper head.
1. Inspect the entire surface of the main shaft (Fig. 4-32) for
cracks, grooves, scratches, score marks, burn marks, pits or
rust. Attempt to polish out burn marks, scratches, rust and
scoring with an emery cloth or sandpaper. 4
IMPORTANT:
The shaft assembly has a 16 RMS finish that can be
damaged if handled improperly. NEVER attempt to
remove nicks, scratches or burrs by working in a vertical
motion with sandpaper, emery cloth or a file. If attempts
are made to remove imperfections, use only a fine file
and work horizontally when attempting to repair the
surface. If the shaft will not be reused immediately, coat
it with grease or oil to prevent rust.
2. If the shaft shows cracks, vertical grooves or surface
checking (fine cracks in an area on the surface) it is
Figure 431. Supporting the Head and Shaft Assembly recommended that the shaft be replaced.
15. If the upper bearing race remains stuck in the head, again
rap on the mantle with a sledgehammer to loosen the race and
get it to fall into the noose wrapped around the head.
07/09 419
B
A C
F
Figure 432. Shaft and Taper Head Inspection
A. Taper Head Machined Surface B. Taper Head Flange
C. Main Shaft
3. Check the taper head on both the inside and outside for
signs of cracks or other damage. Cracking on the taper head
G
will typically be visible on the flange (B, Fig. 4-32) or on the
inside of the taper at the main shaft junction. Check the inside
4 of the taper for signs of scoring that could indicate the upper
bearing has spun. If the taper head is cracked or badly scored,
it must be replaced.
Figure 433. Eccentric Assembly Components
4. Check the machined surface of the taper flange for
denting or gouging. Remove any surface imperfections with A. Upper Bearing Race B. Bearing Roller Cage
C. Lower Bearing Race D. Bakelite Seals
a grinder.
E. Rotary Seal Ring F. Inner Piston Ring
5. Check the taper flange for dents or caved in areas that G. Eccentric
could cause the flange to hang up on the eccentric assembly. 7. Inspect the inner piston ring (F, Fig. 4-33) for cracks or
If it is not possible to bend the flange back into position or damage. File or sand any rough areas on the ring and clean
into the correct shape, it will be necessary to replace the taper. out the piston ring groove thoroughly. If the piston ring is
6. Inspect the upper bakelite seals (D, Fig. 4-33) for wear. cracked or damaged, it must be replaced.
Replace the seals if worn or damaged. 8. Inspect the upper thrust bearing components (A, B and C,
Fig. 4-33) for wear, scratches, score marks, cracks in the
cages, roller wear or damage, pitting in rollers or races, rust,
etc. Replace the bearing if any damage is present or wear is
evident.
420 07/09
9. Inspect the inner bronze sleeve (located inside the 3. Prefit the inner piston ring in the groove on the eccentric
eccentric) for wear, burn marks, gouging or cracks. Replace assembly to check for fit. If the ring is a loose fit in the
the sleeve if damage is evident or the sleeve shows extensive groove, it will be necessary to shim the ends of the ring. Braze
wear. material on the ends of the ring to tighten the fit. If the ring is
a tight fit and does not enter the groove and seat correctly at
HEAD and SHAFT INSTALLATION all points around the circumference, it will be necessary to
file the ends of the ring to gain clearance.
IMPORTANT: 4. Thoroughly clean the underside of the taper head making

certain the labyrinth grooves are free of dust and dirt. Remove
If the main shaft, taper head, bearing components or the the piston ring from the eccentric and fit it in the groove on
bronze sleeve in the eccentric were replaced with new the underside of the taper head (Fig. 4-34).
components after the inspection procedure, it will be
necessary to check head and shaft tolerances before
re-installing the head and shaft in the crusher. Refer to A
the H or SBS service manual for the correct procedures
on measuring tolerances.
Mantle Installation
Install a new mantle on the taper head following the
C
instructions in MANTLE INSTALLATION in this chapter.
B
IMPORTANT:
Before installing the new mantle on the taper head,
D
make certain all old Smithbond and other debris has
been removed from the taper head. If it is necessary to
remove material using a grinder or hand chisels, be
careful not to nick or scratch the machined seat at the
bottom of the taper head.
Installation - Crushers Without Anti-Spin

1. Make certain that power to the crusher remains locked
out. Refer to Chapter 1 for complete lockout/tagout
instructions.
2. If the upper thrust bearing was removed from the 4
eccentric, install it at this time. Make certain the races are
aligned correctly with the large bevel facing away from the
E
roller cage (Fig. 4-34). The roller cage must be oriented with
the notched side of the cage facing down (Fig.4-34).
NOTE: Thrust bearings are supplied in two styles, TYPE 1 Figure 434. Bearing Component Orientation
and TYPE 2. If you have questions on bearing type and A. Top Race Large Bevel Facing Up
installation procedure, refer to the H or SBS service manual. B. Bottom Race Large Bevel Facing Down
C. Notches In Roller Cage Facing Down
D. This Side Of Cage Facing Up
! CAUTION E. This Side Of Cage Facing Down
Failure to properly install and align bearing 5. If the eyebolt was removed, reinstall the eyebolt into the
components will result in bearing failure which tapped hole at the top of the main shaft.
could damage other components on the crusher.
6. Lubricate the mating surfaces of the main shaft and the
inner bronze sleeve with crusher lube oil.
07/09 421
! WARNING NOTE:
Always use suitable rigging and hoisting If the taper head will not turn in Step 11 or is difficult to
equipment to stabilize and lift heavy objects. turn, the inner piston ring (F, Fig. 4-33) may not have
Lifting heavy components with inadequate seated correctly in the bore of the rotary seal ring.
hoisting apparatus can damage machinery and Attempt to seat the piston ring by rapping on the mantle
may result in serious personal injury or death. with a sledge hammer at several points on the
circumference. Check again for free rotation of the
7. Attach a lift cable or chain to the eyebolt. Using a properly
head. If the taper head is still difficult to turn, raise the
rated lifting device, carefully suspend the head and shaft
head and shaft and re-center the piston ring within its
assembly over the crusher.
groove. Re-seat the head and shaft assembly.
8. Align the bottom of the main shaft with the bore of the
12. Remove the eyebolt from the shaft and store for future
bronze sleeve in the eccentric (Fig. 4-35). Slowly lower the
use.
head and shaft assembly into the crusher. DO NOT rotate the
assembly as it is being lowered into the sleeve. 13. Install the shaft nut cap and secure with a capscrew and
flatwasher (Fig. 4-17). Torque the shaft nut to the correct
torque for your model crusher (Table 4-1).
A
14. Install the shaft nut bolt locking plate and weld the plate,
the burn ring and the shaft nut cap as shown in Figure 4-24.
A stainless steel weld rod E (R) 309L is required when
E making these welds.
15. Install the complete upper frame assembly to the crusher
following the instructions in Chapter 4 of this manual.
C
16. Install any chutes, conveyors or other feeding devices that
B
were removed previously.
Installation - Crushers with Anti-Spin

1. Make certain that power to the crusher remains locked
out. Refer to Ch. 1 for complete lockout/tagout instructions.
2. If the anti-spin assembly was removed, install it on the
lower frame at this time. Make certain the slider plate is
aligned with the input shaft and the inspection plug hole
(units built after 3/09 have inspection holes) on the front of
4 the anti-spin housing when bolting the unit to the bottom of
D F the crusher (Fig. 4-36).
Figure 435. Lowering Head and Shaft Assembly
A. Lift Eyebolt B. Main Shaft
C. Eccentric Assembly D. Bronze Sleeve
E. Taper Head F.Thrust Bearing Upper Race
9. Continue lowering the head and shaft assembly until the

underside of the taper head is seated on the top race of the A
thrust bearing.
10. Remove the lifting apparatus from the eyebolt when the
taper and shaft assembly is fully seated.
11. Block the flywheel sheave so it cannot move. Attempt to B
turn the taper head by hand. The assembly should turn freely
and smoothly in both directions. Figure 436. Aligning the Slider Plate
A. Slider Plate Groove B. Front Inspection Hole
422 07/09
3. If the upper thrust bearing was removed from the 6. Thoroughly clean the underside of the taper head making
eccentric, install it at this time. Make certain the races are certain the labyrinth grooves are free of dust and dirt. Remove
aligned correctly with the large bevel facing away from the the piston ring from the eccentric and fit it in the groove on
roller cage (Fig. 4-34). The roller cage must be oriented with the underside of the taper head (Fig. 4-37).
the notched side of the cage facing down (Fig. 4-34).
! CAUTION
Failure to properly install and align bearing
components will result in bearing failure which
could damage other components on the crusher.
4. Place a long bar down through the bore of the eccentric.
Using the bar, shift the slider plate from side to side until the
rectangular center hole is aligned with the round center hole
of the adapter plate (Fig.4-37).
Figure 438. Taper Head Labyrinth Grooves

A. Piston Ring Groove .
NOTE:
Crushers built after 3/09 have two threaded inspection
plugs on the anti-spin cover. These plugs should be
removed and used to help visually align anti-spin
components when installing the shaft drive tang into the
slider plate groove. Best results can be obtained by
shining a light in through the side hole (A, Fig. 4-39) and
viewing the tang and slider plate through the front 4
inspection hole (B).
Figure 437. Centering the Slider Plate

5. Prefit the inner piston ring in the groove on the eccentric
assembly to check for fit. If the ring is a loose fit in the A
B
groove, it will be necessary to shim the ends of the ring. Braze
material on the ends of the ring to tighten the fit. If the ring is
a tight fit and does not enter the groove and seat correctly at
all points around the circumference, it will be necessary to
file the ends of the ring to gain clearance.
Figure 439. Anti Spin Inspection Plugs
A. Side Inspection Plug B. Front Inspection Plug
07/09 423
7. Manually turn the eccentric until the highest and lowest 9. Lubricate the mating surfaces of the main shaft and the
points are aligned with the end of the slider plate tang groove inner bronze sleeve with crusher lube oil.
(Fig. 4-40). When the alignment is correct, the oil duct (52 &
57 models only) will be centered directly below the eccentric
high point and the counterweight will be centered over the
! WARNING
input shaft. Always use suitable rigging and hoisting
ECCENTRIC Lifting heavy components with inadequate
HIGH POINT hoisting apparatus can damage machinery and
B 10. Attach a lift cable or chain to the eyebolt. Using a properly
rated lifting device, carefully suspend the head and shaft
assembly over the crusher (Fig. 4-41).
ECCENTRIC D C
LOW POINT
Figure 441. Aligning The Head and Shaft

A. Drive Tang B. Main Shaft
11. Align the bottom end of the main shaft with the bore of the
inner bronze sleeve. With the shaft suspended above the bore,
4 slowly rotate the head and shaft assembly until the drive tang
is precisely aligned with the drive tang groove on the slider
plate (Fig. 4-42).
A
Figure 440. Aligning the Eccentric and Tang Groove

A. Align Tang Groove B. Oil Duct
C. Counterweight D. Countershaft
E. Eccentric High Side
8. If the eyebolt was removed, reinstall the eyebolt into the

tapped hole at the top of the main shaft.
424 07/09
B
C 1 1/4
Turn Turn
Figure 443. Rotation Check

17. Rotate the taper head slowly clockwise by hand. Verify
that it turns freely for at least 1/4 turn. Due to a one-way valve
inside the anti-spin unit, the amount of effort required will
increase gradually as the head is rotated in this direction.
D
NOTE:
Figure 442. Aligning Drive Tang with Groove
If the taper head is difficult to turn in steps 15 and 16,
A. Adapter Plate B. Slider Plate Groove raise the taper head and shaft and make the following
C. Drive Tang D. Inspection Hole (New Style Covers Only)
checks:
12. Slowly lower the head and shaft assembly into the - Check that the slider plate is properly positioned.
crusher. To ensure drive tang engagement, DO NOT rotate
the assembly as it is being lowered into the bronze sleeve. - Verify that the piston ring is correctly centered in the
groove on the inside of the taper head.
13. Continue lowering the head and shaft assembly until the
- Make certain the drive tang is aligned with the slider
4
underside of the taper head is seated on the top race of the
upper thrust bearing. plate groove (Fig. 4-39).
14. Remove the lifting chain from the eyebolt. Rock the head 18. Remove the blocking from the flywheel sheave.
slightly to check that the tang has seated in the tang groove. 19. From under the crusher, locate the match marks that were
15. Block the flywheel sheave so that the eccentric assembly made prior to head and shaft removal (Fig. 4-27).
cannot turn. 20. Verify that all match marks are aligned. If necessary,
16. Rotate the taper head slowly counter-clockwise by hand. rotate the taper head and rotary seal ring so that match marks
Verify that it turns freely for at least one full turn (Fig. 4-43). on these components are aligned with match marks on the
crusher main frame.
21. At the frame arm nearest the match marks, measure the
distance between the top of the frame arm and the bottom of
the taper head skirt (Fig. 4-26). Compare this measurement
with the measurement taken earlier during disassembly.
07/09 425
22. If the new measurement matches the measurement taken 27. When the shaft nut cap is correctly installed, install the
earlier this indicates that the head and shaft assembly is fully shaft nut cpascrew locking plate and weld the plate, the burn
seated and the drive tang is engaged in the slider plate groove. ring and the shaft nut cap as shown in Figure 4-45. A stainless
steel weld rod E (R) 309L is required when making these
welds.
IMPORTANT:
If the drive tang has not engaged the slider plate groove,
the measurement made in step 20 will be approximately
1
/2 to 1 inch (1.25 to 2.5 cm) longer than the earlier
measurement. If the measurement is too long, raise the WEL
shaft and head assembly and install the assembly again WELD D
re-aligning the drive tang and the slider plate groove C
(Fig. 4-39). A
B
! CAUTION
Never reach between the rotary seal ring and the
underside of the taper head to check clearance.
Serious personal injury will result if the rotary
seal ring is lowered onto hands or fingers.
23. Tang engagement can also be checked at the top of the
crusher. Lay a long straight edge or bar across the top of the
main frame (Fig. 4-44) parallel to the tang direction. Observe
the bar in relation to the taper head. The bar to head should
show a 3o gap on the eccentric low point side. If no gap is
present, this is an indication that the shaft tang has not
correctly seated in the slider groove.
WELD
Figure 445. Shaft Nut Welding Requirements
A. Capscrew B. Flat Washer
C. Capscrew Locking Plate
FINAL INSTALLATION and ASSEMBLY

4 B
1. On Anti-Spin equipped units, make certain all hydraulic
lines are correctly installed and that the anti-spin hydraulic
system has been successfully bled (See SBS Operation and
Maintenance Manual or TP405 Anti Spin Unit - Installation,
A Operation and Troubleshooting manual).
2. Re-install the upper frame assembly following the
Figure 444. Tang Engagement Check
instructions in Chapter 3 of this manual. Restore hydraulic
A. Check Gap At This Point B. Straight Bar and electrical power to the crusher.
24. On units with a new style anti-spin cover, re-install the 3. Install all chutes, hoppers and feed equipment that were
inspection plugs (Fig. 4-39) that were removed to visually removed previously to provide access to the crusher.
determine drive tang engagement.
4. Adjust the crusher discharge setting and resume crushing
25. Remove the lifting eyebolt from the shaft and store for with a normal feed of material.
future use.
26. Install the shaft nut cap, flatwasher and capscrew. Torque
the shaft nut capscrew to specification (Table 4-1).
426 07/09
Telsmith SBS Cone Crusher Appendix A - Torque Tables
Fastener Information SAE J429 Grade 2 SAE J429 Grade 5
Size Thread Threads Major Dia. Tensile Torque Torque Torque Torque
Type Per Inch (in) Stress Dry Lubricated Dry Lubricated
(n) Area in-lb/ft-lb in-lb/ft-lb in-lb/ft-lb in-lb/ft-lb
(in2) (Nm) (Nm) (Nm) (Nm)
1/4 UNC 20 0.2500 0.0318 66 (7.4) 49 (5.5) 100 (11.2) 76 (8.5)

UNF 28 0.2500 0.0364 75 (8.4) 56 (6.3) 120 (13.5) 87 (9.8)
5/16 UNC 18 0.3125 0.0524 11 (14.9) 8 (10.8) 17 (23.0) 13 (17.6)

UNF 24 0.3125 0.0581 13 (17.6) 9 (12.2) 19 (25.7) 14 (18.9)
3/8 UNC 16 0.3750 0.0775 20 (27.1) 15 (20) 31 (42.0) 23 (31.1)

UNF 24 0.3750 0.0878 23 (31.1) 17 (23) 35 (47.4) 26 (35.2)
7/16 UNC 14 0.4375 0.1063 32 (42.3) 24 (32.5) 49 (66.4) 37 (50.1)

UNF 20 0.4375 0.1187 36 (48.8) 27 (36.6) 55 (74.5) 41 (55.5)
1/2 UNC 13 0.5000 0.1419 49 (66.4) 37 (50.1) 75 (101) 57 (77.2)

UNF 20 0.5000 0.1600 55 (74.5) 41 (55.5) 85 (115) 64 (86.7)
9/16 UNC 12 0.5625 0.1819 70 (94.9) 53 (71.8) 110 (149) 82 (111)

UNF 18 0.5625 0.2030 78 (106) 59 (79.9) 120 (162) 91 (123)
5/8 UNC 11 0.6250 0.2260 97 (131) 73 (98.9) 150 (203) 110 (149)
UNF 18 0.6250 0.2560 110 (149) 83 (112) 170 (230) 130 (176)
3/4 UNC 10 0.7500 0.3345 170 (230) 130 176) 270 (366) 200 (271)
UNF 16 0.7500 0.3730 190 (258) 140 (188) 300 (407) 220 (298)
7/8 UNC 9 0.8750 0.4617 170 (230) 120 (163) 430 (583) 320 (434)
UNF 14 0.8750 0.5095 180 (244) 140 (190) 470 (630) 360 (488)
1 UNC 8 1.0000 0.6057 250 (339) 190 (258) 640 (868) 480 (651)
UNF 12 1.0000 0.6630 270 (366) 210 (285) 710 (963) 530 (719)
1 1/8 UNC 7 1.1250 0.7633 350 (474) 270 (366) 800 (1085) 600 (813)
UNF 12 1.1250 0.8557 400 (542) 300 (407) 890 (1207) 670 (908)
1 1/4 UNC
UNF
7
12
1.2500
1.2500
0.9691
1.0729
500 (677)
550 (746)
380 (515)
420 (569)
1,100 (1491)
1,200 (1627)
840 (1139)
930 (1260) 7F
1 3/8 UNC 6 1.3750 1.1549 660 (895) 490 (664) 1,500 (2033) 1,100 (1491)
UNF 12 1.3750 1.3147 740 (1003) 560 (760) 1,700 (2304) 1,300 (1762)
1 1/2 UNC 6 1.5000 1.4053 870 (1179) 650 (881) 2,000 (2711) 1,500 (2033)
UNF 12 1.5000 1.5810 980 (1328) 730 (989) 2,200 (2982) 1,600 (2169)
ASTM A307 Grade A ASTM A449
1 3/4 UNC 5 1.7500 1.8995 1,400 (1898) 1,000 (1355) 2,300 (3118) 1,700 (2304)
1 3/4 UN 12 1.7500 2.1873 1,600 (2169) 1,200 (1627) 2,600 (3525) 2,000 (2711)
2 UNC 4 1/2 2.0000 2.4982 2,100 (2847) 1,500 (2033) 3,400 (4609) 2,600 (3525)
2 UN 12 2.0000 2.8917 2,400 (3254) 1,800 (2440) 4,000 (5423) 3,000 (4067)
2 1/4 UNC 4 1/2 2.2500 3.2477 3,000 (4067) 2,300 (3118) 5,000 (6779) 3,800 (5152)
2 1/2 UNC 4 2.5000 3.9988 4,100 (5559) 3,100 (4203) 6,900 (9355) 5,200 (7050)
2 3/4 UNC 4 2.7500 4.9340 5,600 (7592) 4,200 (5694) 9,400 (12745 7,000 (9491)
3 UNC 4 3.0000 5.9674 7,400 (10033) 5,600 (7592) 12,000 (16270) 9,200 (12473)
Torque Coefficients Dry: 0.20

Lubricated: 0.15
07/09 A1
Torque Tables
Alloy Socket Head Cap

Fastener Information SAE J429 Grade 8
Screws ASTM A574
Size Thread Threads Major Dia. Tensile Torque Torque Torque Torque
Type Per Inch (in) Stress Dry Lubricated Dry Lubricated
(n) Area ft-lb ft-lb ft-lb ft-lb
(in2) (Nm) (Nm) (Nm) (Nm)
1/4 UNC 20 0.2500 0.0318 12 (16.2) 9 (12.2) 14 (18.9) 10 (13.5)

UNF 28 0.2500 0.0364 14 (18.9) 10 (13.5) 16 (21.6) 12 (16.2)
5/16 UNC 18 0.3125 0.0524 25 (33.8) 18 (24.4) 29 (39.3) 22 (29.8)

UNF 24 0.3125 0.0581 27 (36.6) 20 (27.1) 32 (43.3) 24 (32.5)
3/8 UNC 16 0.3750 0.0775 44 (59.6) 33 (44.7) 51 (69.1) 38 (51.5)

UNF 24 0.3750 0.0878 49 (66.4) 37 (50.1) 58 (78.6) 43 (58.3)
7/16 UNC 14 0.4375 0.1063 70 (94.9) 52 (71.8) 82 (111) 61 (82.7)

UNF 20 0.4375 0.1187 78 (106) 59 (79.9) 91 (123) 68 (92.1)
1/2 UNC 13 0.5000 0.1419 110 (149) 80 (109) 120 (162) 93 (126)
UNF 20 0.5000 0.1600 120 (163) 90 (122) 140 (188) 110 (149)
9/16 UNC 12 0.5625 0.1819 150 (203) 120 (162) --- ---
UNF 18 0.5625 0.2030 170 (230) 130 (176) --- ---
5/8 UNC 11 0.6250 0.2260 210 (285) 160 (217) 240 (325) 180 (244)
UNF 18 0.6250 0.2560 240 (325) 180 (244) 270 (366) 200 (271)
3/4 UNC 10 0.7500 0.3345 380 (515) 280 (379) 420 (569) 320 (434)
UNF 16 0.7500 0.3730 420 (569) 320 (433) 470 (637) 350 (474)
7/8 UNC 9 0.8750 0.4617 610 (827) 460 (624) 680 (922) 510 (691)
UNF 14 0.8750 0.5095 670 (908) 500 (677) 750 (1017) 560 (759)
1 UNC 8 1.0000 0.6057 910 (1234) 680 (922) 1,000 (1350) 770 (1044)
UNF 12 1.0000 0.6630 1,000 (1356) 750 (1017) 1,100 (1491) 840 (1139)
1 1/8 UNC 7 1.1250 0.7633 1,300 (1762) 970 (1315) 1,400 (1898) 1,100 (1491)
7F UNF 12 1.1250 0.8557 1,400 (1898) 1,100 (1491) 1,600 (2169) 1,200 (1627)
1 1/4 UNC 7 1.2500 0.9691 1,800 (2440) 1,400 (1898) 2,000 (2711) 1,500 (2003)
UNF 12 1.2500 1.0729 2,000 (2711) 1,500 (2003) 2,300 (3118) 1,700 (2305)
1 3/8 UNC 6 1.3750 1.1549 2,400 (3254) 1,800 (2440) 2,700 (3660) 2,000 (2711)
UNF 12 1.3750 1.3147 2,700 (3660) 2,000 (2711) 3,000 (4068) 2,300 (3118)
1 1/2 UNC 6 1.5000 1.4053 3,200 (4338) 2,400 (3254) 3,600 (4881) 2,700 (3660)
UNF 12 1.5000 1.5810 3,600 (4881) 2,700 (3660) 4,000 (5423) 3,000 (4068)
ASTM A354 Grade BD
1 3/4 UNC 5 1.7500 1.8995 5,000 (6779) 3,700 (5017) 5,600 (7592) 4,200 (5694)
1 3/4 UN 12 1.7500 2.1873 5,700 (7728) 4,300 (5830) 6,400 (8677) 4,800 (6508)
2 UNC 4 1/2 2.0000 2.4982 7,500 (10169) 5,600 (7593) 8,400 (11389) 6,300 (8541)
2 UN 12 2.0000 2.8917 8,700 (11796) 6,500 (8813) 10,000 (13588) 7,300 (9897)
2 1/4 UNC 4 1/2 2.2500 3.2477 11,000 (14914) 8,200 (11118) 12,000 (16270) 9,300 (12609)
2 1/2 UNC 4 2.5000 3.9988 15,000 (20338) 11,000 (14914) 17,000 (23049) 13,000 (17626)
2 3/4 UNC 4 2.7500 4.9340 18,000 (24405) 13,000 (17626) 23,000 (31184) 17,000 (23049)
3 UNC 4 3.0000 5.9674 24,000 (32540) 18,000 (24405) 30,000 (40676) 23,000 (31184)
Torque Coefficients Dry: 0.20

Lubricated: 0.15
A2 07/09
Wear Liner Replacement Appendix B - Conversion Tables
Appendix B - Conversion Tables
Telsmith SBS Cone Crusher Appendix B
LINEAR MEASURE SQUARE MEASURE
To Convert Info Multiply by To Convert Info Multiply by

Inches Centimeters 2.54 Sq. Inches Sq. Centimeters 6.452
Feet Meters 0.3048 Sq. Miles Sq. Kilometers 2.59
Centimeters Inches 0.3937 Sq. Centimeters Sq. Inches 0.15499
Millimeters Inches 0.0394 Sq. Meters Sq. Inches 1549.9
Meters lnches 39.37 Sq. Meters Sq. Feet 10.763
Meters Feet 3.2808
CUBIC MEASURE WEIGHT
To Convert Info Multiply by To Convert Info Multiply by

Kilograms Pounds 2.2046
Cu. Inches Cu. Centimeters 16.387
Pounds Kilograms 0.4536
Cu. Feet Cu. Meters 0.0283
Pounds/Sq. Kilograms/Sq. 0.0703
Cu. Centimeters Cu. Inches 0.06102
Inch Centimeter
Cu. Meters Cu. inches 610233779.0
Pounds/Sq. Kilograms/Sq. 4.8824
Cu. Meters Cu. Feet 35.314
Foot Meter
DEGREES FAHRENHEIT TO DEGREES CENTIGRADE
F C F C F C F C F C
-30 -34.44 +20 -6.67 +55 +12.78 +90 +32.22 +225 +107.22
-28 -33.33 21 -6.11 56 13.33 91 32.78 230 110.00
-26 -32.22 22 -5.56 57 13.89 92 33.33 235 112.78
-24 -31.11 23 -5.00 58 14.44 93 33.89 240 115.56
-22 -30.00 24 -4.44 59 15.00 94 34.44 245 118.33
-20 -28.89 25 -3.89 60 15.56 95 35.00 250 121.11
-18 -27.78 26 -3.33 61 16.11 96 35.56 255 123.89
-16 -26.67 27 -2.78 62 16.67 97 36.11 260 126.67
-14 -25.56 28 -2.22 63 17.22 98 36.67 265 129.44
-12 -24.44 29 -1.67 64 17.78 99 37.22 270 132.22
-10 -23.33 30 -1.11 65 18.33 100 37.78 275 135.00
-8 -22.22 31 -0.56 66 18.89 105 40.55 280 137.78
-6 -21.11 32 0.00 67 19.44 110 43.33 285 140.55
-4 -20.00 33 +0.56 68 20.00 115 46.11 290 143.33
-2
0
-18.89
-17.78
34
35
1.11
1.67
69
70
20.56
21.11
120
125
48.89
51.67
295
300
146.11
148.89 7F
+1 -17.22 36 2.22 71 21.67 130 54.44 305 151.67
2 -16.67 37 2.78 72 22.22 135 57.22 310 154.44
3 -16.11 38 3.33 73 22.78 140 60.00 315 157.22
4 -15.56 39 3.89 74 23.33 145 62.78 320 160.00
5 -15.00 40 4.44 75 23.89 150 65.56 325 162.78
6 -14.44 41 5.00 76 24.44 155 68.33 330 165.56
7 -13.89 42 5.56 77 25.00 160 71.11 335 168.33
8 -13.33 43 6.11 78 25.56 165 73.89 340 171.11
9 -12.78 44 6.67 79 26.11 170 76.67 345 173.89
10 -12.22 45 7.22 80 26.67 175 79.44 350 176.67
11 -11.67 46 7.78 81 27.22 180 82.22 355 179.44
12 -11.11 47 8.33 82 27.78 185 85.00 360 182.22
13 -10.56 48 8.89 83 28.33 190 87.78 365 185.00
14 -10.00 49 9.44 84 28.89 195 90.55 370 187.78
15 -9.44 50 10.00 85 29.44 200 93.33 375 190.55
16 -8.89 51 10.56 86 30.00 205 96.11 380 193.33
17 -8.33 52 11.11 87 30.56 210 98.89 385 196.11
18 -7.78 53 11.67 88 31.11 215 101.67 390 198.89
19 -7.22 54 12.22 89 31.67 220 104.44 395 201.67
07/09 B1
Appendix B - Conversion Tables Wear Liner Replacement
NOTES
7F
B2 07/09
Appendix C - Weights
Appendix C - Weights
Model 38 Weights Pounds (Kilograms)

Item 38
Crusher - complete and assembled w/o Anti-Spin 26,912 (12207)
Crusher - complete and assembled with Anti-Spin 27, 275 (12371)
Crusher - Base Unit
Including Mantle, Nut and Cap, Anti-Spin and Flywheel 16,389 (7433)
Including Mantle, Nut and Cap, Bottom Plate and Flywheel 16,026 (7269)
Crusher - Upper frame
Includes upper frame assembly, rotator, support bowl and 10, 885
concave ring. (4937)
Main (lower) frame only 8440
(3828)
Thrust bearing (each) 175
(79)
Rotary seal ring with lead 453
(205)
Inner bronze sleeve 40
(18)
Outer bronze sleeve 96
(44)
Eccentric 859
(390)
Main drive gear 263
(119)
Bottom cover plate (units without anti-spin only) 121
(55)
Anti-spin unit - Includes bottom plate, gearbox, hydraulic 508
motor, adapter plate, slider plate and gearbox cover. (230)
Upper frame only 4070
(1846)
Hydraulic relief cylinder (each) 94
(43)
Receiving hopper, outer 557
(253) 7F
Receiving hopper, inner 223
(101)
Locknut 1431
(649)
Hydraulic locking cylinder (each) 30
(14)
Support bowl with inner hopper and concave ring 4360
(1977)
Concave ring 1300
(590)
Smithbond for concave ring 44
(Typical - Refer to Chapter 3 for exact quantities) (20)
Head and shaft assembly, with mantle and nut. 3083
(1398)
07/09 C1
Appendix C - Weights Wear Liner Replacement

Item 38
Taper head only 1290
(585)
Main (tapered) shaft only 545
(247)
Mantle only 1022
(464)
Smithbond for mantle 44
Countershaft box assembly w/flywheel 1,475
(669)
Countershaft 125
(57)
Bevel pinion gear (countershaft) 60
(27)
Flywheel sheave 162
(73)
Power rotator assembly, including motor, gearbox and 200
adapter plate. (91)
Power rotator mounting bracket 54
(24)
Power rotator pinion gear 35
(16)
Crusher ring gear 780
(354)
Support Bowl Driver Forging (early models only - if equipped) 326
(148)
Drive ring weldment 509
(231)
Oil lubrication system with water cooler (empty - no oil in tank) 1380
7F (626)
Oil lubrication system with air-oil cooler (empty - no oil in tank) 1880
(853)
Hydraulic power unit (empty - no oil in tank) 600
(272)
V-belt drive guard 520
(236)
Important: All weights shown are estimated and may vary by +/-5 percent.
When available, always refer to the bill-of-lading or packing list for actual weights.
C2 07/09
Wear Liner Replacement Appendix C - Weights

Item 44
Crusher - complete and assembled with Anti-Spin 33,178 (15049
Crusher - Base Unit
Crusher - Upper Frame 12,744
Includes upper frame, locknut, locknut cover, support bowl, (5780)
concave ring, feed hoppers, Smithbond, and hyd. unlock cyl-
inders.
(4087)
(84)
(472)
(18)
(59)
Eccentric 1069
(485)
Main drive gear 263
(119)
(55)
(1506)
Hydraulic relief cylinder and manifold (each) 150
(68) 7F
(332)
(119)
Locknut 1664
(755)
(14)
Support bowl with inner hopper and concave ring 4791
(2173)
Concave ring - S 1600 (726)
Concave ring - FC 1700 (771)
Smithbond for concave ring S & FC 110 (50)
(Typical - Refer to Chapter 3 for exact quantities)
07/09 C3

Item 44
Head and shaft assembly, including mantle and nut 4380
(1986)
(1034)
(290)
Mantle only 1325
(601)
Countershaft box assembly w/flywheel 1,519
(689)
Countershaft 125
(57)
(27)
Flywheel sheave 320
(145)
adapter plate. (106)
(24)
(16)
(175)
(435)
7F (626)
(853)
(272)
(236)
When available, always refer to the bill-of-lading or packing list for actual
weights.
C4 07/09

Item 52
Crusher - complete and assembled with Anti-Spin 50,454(22886)
Crusher - Base Unit
Including Mantle, Nut and Cap, Anti-Spin and Flywheel. 31,857(14,454)
Including Mantle, Nut and Cap, Bottom Plate and Flywheel 31,465 (14,272)
Crusher - Upper Frame 16740
inders.
(6123)
(159)
(647)
(57)
(78)
Eccentric 1550
(703)
Main drive gear 486
(220)
(78)
(1851)
(92) 7F
(397)
(104)
Locknut 1663
(754)
Hydraulic Locking Cylinder (each) 30
(14)
Support bowl, with inner hopper and concave ring 8503
(3857)
Smithbond for concave ring S 176 (80)
Smithbond for concave ring FC 132 (60)
Head and shaft assembly, including mantle and nut. 8405
(3812)
07/09 C5

Item 52
(2357)
(571)
Mantle only 1626
(738)
Countershaft box assembly w/flywheel 2310
(1048)
Countershaft 223
(101)
(73)
Flywheel sheave 540
(245)
adapter plate. (91)
Power Rotator Mounting Bracket 54
(24)
(16)
(161)
(620)
(853)
7F Hydraulic power unit (empty - no oil in tank)
(1118)
1280
(581)
(353)
C6 07/09

Item 57
Crusher - complete and assembled with Anti-Spin 70, 523 (31787)
Crusher - Base Unit
Crusher - Upper Frame
Includes upper frame, locknut, locknut cover, support bowl, 29102
concave ring, feed hoppers, Smithbond, and hyd. unlock cyl- (13200)
inders.
(8940)
(215)
(1062)
(127)
(127)
Eccentric 2800
(1270)
Main drive gear 1040
(472)
(128)
(4167)
(95) 7F
Receiving hopper - outer 1292
(586)
Receiving hopper - inner 569
(258)
Locknut 5700
(2586)
(14)
Support bowl with inner hopper and concave ring 13,589
(6164)
Concave ring 4000
(1814)
Smithbond for concave ring (S & FC) 330 (150)
07/09 C7

Item 57
Head and shaft assembly, including mantle and nut. 10,662
(4,836)
(2668)
(777)
Mantle only 2653
(1203)
Countershaft box assembly with flywheel 2,243
(1,018)
Countershaft 240
(109)
(91)
Flywheel sheave 750
(340)
(35)
(16)
(562)
(782)
Support bowl driver forging (early models only - if equipped) 569
7F Oil lubrication system with air-oil cooler (empty - no oil in tank)
(258)
2680
(1216)
(581)
(230)
C8 07/09

Item 68
Crusher - complete and assembled w/o anti-spin 106,643 (48372)
Crusher - complete and assembled w/ anti-spin 107,102 (48581)
Crusher - Base Unit
Crusher - upper framey 40460
inders.
(13410)
(340)
(339)
(120)
(156)
Eccentric 4400
(1996)
Main drive gear 3270
(1483)
(134)
(5220)
(102) 7F
Receiving hopper - outer 1543
(700)
Receiving hopper - inner 306
(139)
Locknut 4896
(2221)
Hydraulic unlock cylinder (each) 122
(55)
Support bowl with Inner Hopper and Concave Ring 20,485
(9,292)
Concave ring 5120
(2322)
Smithbond for concave ring 68S 352 (160)
Smithbond for concave ring 68FC 484 (220)
07/09 C9

Item 68
Head and shaft assembly, including mantle and nut. 15882
(7177)
(3362)
(1338)
Mantle only 3280
(1488)
Countershaft box assembly with flywheel 3,728
(1,691)
Countershaft 373
(169)
(218)
Flywheel sheave 870
(395)
(35)
(16)
(1331)
(293)
Support bowl driver forging (early models only - if equipped) 647
7F Oil lubrication system with water cooler (empty - no oil in tank)
(293)
2760
(1252)
(1660)
(581)
(335)
C10 07/09
Wear Liner Replacement Appendix D - Lubricants
Appendix D - Lubricants
Lubricating Oil Specifications
Ambient Temperature
Below 40 F Above 40 F
(4.5 C) (4.5 C)
Viscosity ISO Grade C-100 C-150
Viscosity AGMA Grade #250.04 3 EP 4 EP
Viscosity SUS @ 100 F 469 to 575 709 to 871
Viscosity SUS @ 210 F 61 to 67 74 to 82
Viscosity Index 95 Min. 95 Min.
Timken OK Load (lbs) 60 Min. 60 Min.
Extreme Pressure Agent (EP) Yes Yes
Rust and Oxidation Agent Yes Yes
Anti-Foaming Agent Yes Yes
Copper Strip Corrosion Test Pass Pass
NOTE: Oil must not be corrosive to metals generally used in bearings, gears, shafts,
pumps and housings. Oil must have the least possible effect on rubber seals, synthetic
seals, packings and hoses. Refer to the Gyrasphere Operation & Maintenance Manual
for detailed crusher lubrication procedures and oil capacities.
7F
Hydraulic Oil Specifications
Viscosity ISO Grade 68

Viscosity SUS @ 100 F 317
Viscosity SUS @ 210 F 53 to 57
Viscosity Index 95 Min.
API Gravity 29 Min.
Pour Point, F -10 to +10
Flash Point, F 400 to 425
Anti-Wear Agent Yes
Anti-Foaming Agent Yes
Rust and Oxidation Inhibitor Yes
NOTE: Refer to the Gyrasphere Operation and Maintenance Manual for detailed
hydraulic system maintenance instructions and oil capacities.
07/09 D1
Appendix D - Lubricants Wear Liner Replacement
NLGI #2 Grease Specifications
NLGI Grade Number 2

Worked Penetration @ 77 (60 Strokes) 285
Worked Penetration @ 77 (100,00 Strokes) 300
Dropping Point F 365
Copper Corrosion Test, 14 Days Pass
Wheel Bearing Test @ 275 F Pass
Timken OK Load (lbs) 50
NOTE: The above grease must contain an extreme pressure (EP) agent that is not
harmful to bronze, brass or lead. For satisfactory lubrication, grease must be
absolutely free from any ingredients which could cause corrosion, and from gritty
material which could produce wear. Grease should also be uniform in texture,
consistency, structure, stability, flow characteristics and lubricating characteristics.
MOLY
EP-2
Moly Based EP-2 Grease Specifications

(Aluminum Complex with Molybdenum Disulfide)
Worked Penetration 265/295
7F Dropping Point F 510

Rust Prevention (ASTM D-1743) Pass
Corrosion Prevention (ASTM D-1261) Pass
Oxidation Stability (ASTM D-942)
Oxygen Absorption (PSI)
After 100 Hours <3
200 Hours <4
300 Hours <5
Oil Viscosity, SUS @ 100 F 1000
Extreme Pressure Performance
Timken OK Load (lbs) 65
Four Ball Weld Point 800
Wear Scar 0.51 mm
Type of Soap Aluminum Complex
Operating Temperature 0 to 450 F
MoS2 % by Weight 3.0
D2 07/09
Wear Liner Replacement Appendix E - Sealants and Compounds
Telsmith SBS Cone Crushers
Appendix E - Sealants and Compounds

The following sealants and compounds are used throughout the repair procedures of this manual. These items
or their equivalents are commonly available at most local supply houses or distributors. Always read and
understand manufacturers directions and safety precautions before using any items shown.
Pipe Sealant
Description Manufacturer
Loctite 592 PST Pipe Sealant, Medium Loctite Corp

Strength, Slow Cure, Anti-Galling.
Part No. 59241.
Thread Locking Compound

Loctite 242 Threadblocker, Removable Loctite Corp.

Strength. Part No. 24241.
Loctite 271 Threadlock, Permanent Loctite Corp.

Strength. Part No. 10T77.
7F
Spray Primer
(for use with Loctite 242 thread locking compound)
Loctite 7471 Locquic Primer T, Aerosol, Loctite Corp.

Part No. 22477.
07/09 E1
Appendix E - Sealants and Compounds Wear Liner Replacement
Telsmith SBS Cone Crushers
Anti-Seize Compound
Bostik Never-Seez, Regular Grade, Bostik Corp.

Copper Formula. Meets MIL SPEC A907E.
Silicone Sealant
Red Devil RD ProTM 100% Silicone Sealant. Red Devil, Inc.

Meets MIL SPEC 46106A.
Shellac
7F Bulls Eye Shellac, Clear Sealer & Finish Wm. Zinsser & Co., Inc.
(Conforms to federal spec. TT-S-300A)
E2 07/09
Wear Liner Replacement Appendix F - Removal Clearances
Appendix F - Removal Clearances
Type A Gear
C
Arrangement
A
B
Type B Gear
Arrangement
Note: Check crusher

gear arrangement
before using the table
below.
7F
Support Bowl Removal Clearances

Crusher Dimensions in inches (centimeters)
Crushers With Type A Gear Arrangement Crushers With Type B Gear Arrangement
Dimension A Dimension B Dimension C Dimension A Dimension B Dimension C
Model 38 104 (264) 67 (170) 5 (13) 106 (269) 67 (170) 5 (13)
Model 44 N/A N/A N/A 104 (264) 67 (170) 5 (13)
Model 52 N/A N/A N/A 116 (295) 76 (193) 5 (13)
Model 57 133 (338) 87 (221) 5 (13) 125 (318) 83 (211) 5 (13)
Model 68 144 (366) 96 (244) 5 (13) 142 (361) 94 (239) 5 (13)
NOTE: Measurements shown above are typical. Actual measurements may vary, due to product changes, custom engineering
or fabrication variables. See the inset views above to determine gear arrangement.
07/09 F1
Appendix F - Removal Clearances Wear Liner Replacement
Type A Upper
Frame Assembly
C
A
B
Type B Gear
Arrangement
Note: Check crusher

gear arrangement
before using the table
below.
7F
Head and Shaft Removal Clearances
Crusher Dimensions in inches (centimeters)
Crushers With Type A Gear Arrangement Crushers With Type B Gear Arraangement
Dimension A Dimension B Dimension C Dimension A Dimension B Dimension C
Model 38 136 (345) 130 (330) 5 (13) 136 (345) 130 (330) 5 (13)
Model 44 N/A N/A N/A 141 (358) 132 (335) 5 (13)
Model 52 N/A N/A N/A 161 (409) 151 (384) 5 (13)
Model 57 182 (462) 169 (429) 5 (13) 177 (450) 164 (417) 5 (13)
Model 68 203 (516) 188 (478) 5 (13) 201 (511) 186 (472) 5 (13)
NOTE: Measurements shown above are typical. Actual measurements may vary, due to product changes, custom
engineering or fabrication variables. See the inset views above to determine gear arrangement.
If crusher is NOT equipped with anti-spin, Dimensions A and B will be approximately 6 inches less than shown.
F2 07/09
Wear Liner Replacement Appendix G - Wear Liner Wear Limits
Appendix G - Wear Liner Wear Limits
7F
CONCAVE RING WEAR MEASUREMENT

1. Stop the crusher. Lockout/Tagout power to the crusher drive.
2. Raise the upper frame using the hydraulic clearing feature. Place hardwood blocks or safety spacers
between the upper and main frames. Refer to the crusher operators manual for instructions.
3. Lockout/Tagout Power to the hydraulic power unit.
4. At the bottom lip of the concave ring, measure dimension A.
5. Place a straight edge along the concave ring wear surface. Measure Dimension B.
6. Subtract Dimension B from Dimension A. This measurement should be 3/4 to 1 inch minimum.
7. If measurement is less than 1 inch, the concave ring should be replaced.
07/09 G1
Appendix G - Wear Liner Wear Limits Wear Liner Replacement
7F
MANTLE WEAR MEASUREMENT

1. Stop the crusher. Lockout/Tagout power to the crusher drive.
2. Raise the upper frame using the hydraulic clearing feature. Place hardwood blocks or safety spacers
between the upper and main frames. Refer to the crusher operators manual for instructions.
3. Lockout/Tagout Power to the hydraulic power unit.
4. At the bottom lip of the mantle, measure dimension A.
5. Place a straight edge along the mantle wear surface. Measure Dimension B.
6. Subtract Dimension B from Dimension A. This measurement should be 3/4 to 1 inch minimum.
7. If measurement is less than 1 inch, the mantle should be replaced.
G2 07/09

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TELSMI

ISSUE DATE: 07/09 (Rev 1) TP401

2. Before removing spilled materials.

3. Before clearing jams or working inside the machinery.

4. If any unusual noises or sudden changes in operation are noticed.

HOW TO CONTACT TELSMITH INC.

REQUESTING SERVICE ASSISTANCE

OPERATION AND MAINTENANCE CONTACTS

ILLUSTRATIONS TELSMITH APPROVED DISTRIBUTOR CONTACTS

INSTALLATION & ASSEMBLY DRAWINGS OTHER CONTACTS

SUPPORT BOWL AND CONCAVE RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

MANTLE AND HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Appendix A - Torque Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Appendix B - Conversion Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

Appendix C - Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1

Appendix D - Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1

Appendix E - Sealants and Compounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1

Appendix F - Removal Clearances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-1

Appendix G - Wear Liner Wear Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-1

(Continued on next page)

SAFETY OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

HAZARD AND ADVISORY STATEMENTS . . . . . . . . . . . . . . . . . . . . . . 1-2

QUARRY SAFETY SUMMARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

MACHINERY INSTALLATION SAFETY . . . . . . . . . . . . . . . . . . . . . . . . 1-8

MAINTENANCE AND REPAIR SAFETY. . . . . . . . . . . . . . . . . . . . . . . . 1-9

HOISTING AND HANDLING SAFETY . . . . . . . . . . . . . . . . . . . . . . . . 1-11

TRANSPORTING MACHINERY . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

SAFETY OVERVIEW A Note is a basic informational statement or helpful

1 The complete observance of one simple rule would prevent

HAZARD AND ADVISORY STATEMENTS

LOCKOUT / TAGOUT POWER...

Figure 12. Lockout/Tagout

When Can Lockout/Tagout Devices be Your companys lockout/tagout program may be

Additional Lockout/Tagout Requirements

7F properly maintained and ready for use.

Help Prevent Accidents Practice Good Housekeeping

MACHINERY INSTALLATION SAFETY Electrical Hook-up

MAINTENANCE AND REPAIR SAFETY Pressurized Systems (hydraulic and air)

- Immediately stop the machinery.

110 07/09 (Rev 1)

Disposal Of Excess Fuels, Lubricants And Wire Rope

07/09 (Rev 1) 111

Fiber Or Synthetic Slings

7F Do not use synthetic slings in temperatures exceeding

112 07/09 (Rev 1)

WORK SAFELY AND USE COMMON SENSE . . . . . . . . . . . . . . . . . . . . 2-2

TOOLS AND SUPPLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

LUBRICANTS & SEALANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

PART IDENTIFICATION & INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 2-2 2

HANDLING BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

USING HEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

HYDRAULIC SYSTEM SAFETY SUMMARY . . . . . . . . . . . . . . . . . . . . . 2-3

DISCONNECTING HYDRAULIC LINES . . . . . . . . . . . . . . . . . . . . . . . . 2-3

DEPRESSURIZING THE POWER ROTATOR CIRCUIT . . . . . . . . . . . . . . . 2-4

WORK SAFELY AND PART IDENTIFICATION & INSPECTION

USING HEAT Clean-up any spilled hydraulic oil. Hydraulic oil is

HYDRAULIC SYSTEM SAFETY SUMMARY ! WARNING!!!

Figure 23. Counterbalance Valve A Figure 25. Counterbalance Valve A 2

Figure 26. Counterbalance Valve B