Reference Manual

Reference Manual

Service Manual
Service Manual

Symons Cone
Symons Cone Crusher
Crusher
4Aly,
1
5/2
/4’, 5 1
& 7’
/2’ & 7’

metso
minerals
 FOREWORD
This book is an Instruction Manual for the new operator and a refresher for the experi-
enced one. Read — study — and keep it handy.
Hlustrations and instructions guide the operator through correct procedures for check-
ing, starting and operating the Crusher and accessories.
Operating techniques outlined in the book are basic. Operating skills and additional tech-
niques will develop as the operator gains knowledge of the Crusher and its capabilities.
Continuing improvement and advancement of product design may result in changes to
your new machine which may not be included in this publication, however each publica-
tion is reviewed and revised, as required, to up-date and include appropriate changes
in the later editions.
The description and specifications in this manual were in effect at the time this manual
was approved for printing. Nordberg reserves the right to discontinue models at any
time and to change specifications or design, without notice and without incurring obliga-
tion.
Whenever a question arises regarding your Crusher, or this publication, please consult
your Nordberg representative for the latest available information.
This manual is to be used as a general guide concerning technical information. All
technical information required for correct installation of your crusher must be obtained
from the installation drawings and technical data furnished for your particular crusher.

SAFETY
BASIC RULES REGARDING SAFETY IN AND AROUND A CRUSHING
PLANT ARE OUTLINED IN SECTION 0, ENTITLED “SAFETY”.
OPERATOR SAFETY AND THE SAFETY OF OTHERS DEPENDS UPON
REASONABLE CARE AND JUDGEMENT IN THE OPERATION OF THIS
CRUSHER. A CAREFUL OPERATOR IS GOOD INSURANCE AGAINST AN
ACCIDENT.
MOST ACCIDENTS, NO MATTER WHERE THEY OCCUR, ARE CAUSED
BY FAILURE TO OBSERVE AND FOLLOW SIMPLE FUNDAMENTAL
RULES OR PRECAUTIONS. FOR THIS REASON MOST ACCIDENTS CAN
BE PREVENTED BY RECOGNIZING HAZARDS AND TAKING STEPS TO
AVOID THEM BEFORE AN ACCIDENT OCCURS.
REGARDLESS OF THE CARE USED IN THE DESIGN AND CONSTRUC-
TION OF THIS TYPE OF EQUIPMENT, THERE ARE CONDITIONS THAT
CANNOT BE COMPLETELY SAFEGUARDED AGAINST WITHOUT INTER-
FERING WITH REASONABLE ACCESSIBILITY AND EFFICIENT OPERA-
TION. WARNINGS ARE INCLUDED IN THIS INSTRUCTION MANUAL TO
HIGHLIGHT THESE CONDITIONS.

1st Printing, 1995

 TABLE OF CONTENTS

SAFETY 2.0... 0c eee ee eee eee beeen eee neeneaaaee SECTION 0

GENERAL CRUSHER INFORMATION ..... 22.0...
eeeennnaes SECTION 1
GENERAL INSTALLATION INFORMATION ee nen eee ee eens SECTION 2

MAIN FRAME, ADJUSTMENT RING AND SPRING RING ASSEMBLIES ............... SECTION 3

COUNTERSHAFT BOX, COUNTERSHAFT AND SHEAVE ASSEMBLIES ............... SECTION 4

THRUST BEARING AND ECCENTRIC ASSEMBLIES ............ccc eeeeeeae SECTION 5

...000

SOCKET ASSEMBLY ..... 0... cece

tee cece nee e een eeneeens SECTION 6
MAIN SHAFT, MANTLE AND FEED DISTRIBUTOR ASSEMBLIES .................... SECTION 7
BOWL, BOWL LINER AND ADJUSTMENT CAP ASSEMBLIES ....................0005 SECTION 8

FEED PLATFORM ASSEMBLY ............ ccc cc cece tenet e eee tee e teenies SECTION 9

LUBRICATING SYSTEM... ee ene treet vn eenae SECTION 10

cece

OPERATING INSTRUCTIONS 2.0...e nena SECTION 11

HYDRAULIC SYSTEMS teen nee e teen ens SECTION 12

.... 1... cence
 Section 0

SAFETY

PERSONNEL SAFETY .......... 00.20 cece c cece nee cece eee e nee eens 0-1

GENERAL ... 1... cece cen nent ee een e nett eeennaes 0-1

STOP ACCIDENTS BEFORE THEY STOP YOU! oo eee eee 0-1

DO YOU KNOW YOUR EMPLOYER’S SAFETY PROGRAM? ............... 0-1

ARE YOU DRESSED PROPERLY FOR THE JOB? 2.0 0-1

DO YOU UNDERSTAND YOUR MACHINERY? wenn e eet e eee e eens 0-1

DO YOU HAVE KNOWLEDGE OF WORKING AREAS? ..............000005 0-2

ARE YOU PREPARED FOR EMERGENCIES? .............cccccececueees 0-2

BEFORE STARTING CHECK .......... 0. ccc cece cece eee ence eee eneeas 0-2

START UP SAFELY ............ ccc eee ene eee e eee eee enneees 0-2

REPORT A DEFECTIVE MACHINE ..............c0ccceeeeececeeeeeeeees 0-3

STOPPING SAFELY ...... 0.0.00 c ccc eect

t eee eee eeeenes 0-3

TIPS FOR SAFE MAINTENANCE ..... 0... ee ccc cee eet ene nes 0-3

READ AND UNDERSTAND ......0.... 0. ccc ccc cece eee een eeennees 0-3

WARNING TAGS ... 0... eee ene beeen eee n eens 0-3

LOCKOUT ELECTRICAL SERVICE ....... 0... cece cece n eee eeenees 0-3

CLOTHING — SAFE PRACTICE ....... 2... cece eect eee eee eee anes 0-3

ALCOHOLIC BEVERAGES AND MEDICATION ................

00000 e ee eue 0-3

WORK AREA ... 06.0.

ene e enn e eee t eee e ete eees 0-3

EQUIPMENT ..... 0... ccc cnn eee eee n eee ete nnes 0-4

FIRE HAZARDS .... 2. cetee eee eeeeees 0-4

PRESSURIZED SYSTEMS — HYDRAULIC ORAIR ...........

000 c cee eae 0-4

USE QUALITY PARTS «2.00... cece cece centr eee teen ne eennee 0-4
PLANT SAFETY 00... . cece ccc eeer ene eet eens 0-5

GENERAL «one
neeeee een eens 0-5

DRIVE GUARDS .... 0... eereet tenn etna 0-5

OPERATOR’S PLATFORM ......... 0... cece cece ee ce tee eee nee 0-5

ELECTRICAL LOCKOUT 3... 1... ccc cece

tenn e ent enes 0-5

CRANES 2.0... cc
ene eee ee teen ent n eens 0-5

MOBILE CRANES ....... 0... cc cece cee cee nnn nents 0-6

WELDING EQUIPMENT .......... 0... c ccc cece tte cent eee 0-6

CONVEYOR BELTS .......... 00. c cece tent e ete eeeee 0-6

PORTABLE PLANTS ..... 0... ccc cee eee eee e nee nnee 0-6

CRUSHING PLANT “NOISE” 20...

tence eens 0-6

EPOXY VERSUS ZING 2.0...

cece eee ene e nes 0-7

SPRING RING ASSEMBLIES .... 01...

ee eee eens 0-7

CLEARING A CRUSHER......... 0... cece eter teen eens 0-7

TRAMP IRON REMOVAL............

0. cece cece teen eens 0-7

GENERAL MAINTENANCE WORK .... 00.0.0: cece cece eee eens 0-7
 Section 0

SAFETY

PERSONNEL SAFETY The safest machine must still be operated with care
and with knowledge of its performance capabilities.
GENERAL
The most comprehensive safety program must still
This portion of the instruction manual is intended to be followed.
illustrate only basic safety procedures. Additional Remember that on any job, YOU are the key to
precautions may be necessary for the safe opera- safety. Good safety practices not only protect the
tion of a Crusher. The information contained in this men around you, they are your own best protection.
manual is not intended to replace safety codes, Study this manual and any manufacturer's opera-
insurance requirements, federal, state and local tor's manuals covering your specific equipment.
laws, rules and regulations. Read all warning and caution instructions. Practice
SAFETY of the operator and maintenance person- safe operation.
nel is of prime concern. These paragraphs are pre- INSIST THAT YOUR FELLOW WORKERS DO,
sented as a helpful guide to construction equipment TOO. BE ALERT TO POSSIBLE HAZARDS
personnel and to show some of the daily work BEFORE THEY CAUSE TROUBLE, AND REMEM-
problems which they may encounter. BER... SAFETY IS UP TO YOU!!!
It is the responsibility of the operator to know what DO YOU KNOW YOUR EMPLOYER'S
specific requirements, precautions and work area SAFETY PROGRAM?
hazards exist and to discuss them with his supervi- Company safety records show that the greatest
sor. A common understanding should be reached percentage of accidents are caused by disregard of
by all personnel to assure safe performance in op- simple safety rules. Know — observe! — the overall
erating the equipment. program . . . and consult your supervisor for specif-
The operator is the key to safe job performance ic instructions when starting a job.
and should study these safety tips to be aware of ARE YOU DRESSED PROPERLY
basic safety precautions to help prevent serious FOR THE JOB?
injury and damage to property.
You may need any number of special items — safe-
STOP ACCIDENTS BEFORE ty hat, safety shoes, safety glasses, goggles, heavy
THEY STOP YOU! gloves, ear protective devices, etc. — for your own
protection. Find out what items are required and
In order to alert you, the user, and those entrusted
wear them!
as operators and maintenance personnel, danger-
ous or hazardous operations are shown in this in- Loose clothing can catch in moving parts. Keep
struction manual with WARNING notes. sleeves buttoned, jackets belted and wear your
special safety equipment. Keep warm without re-
stricting your movement. Wrist watches and rings
can be dangerous. Keep your pockets free of ob-
jects which may fall out.
DO YOU UNDERSTAND YOUR
MACHINERY?
READ THE MANUAL furnished with your equip-
ment to learn its operating and maintenance char-
acteristics, capacities and limitations. Learn the
location and function of ALL controls, indicators,
warning devices and caution instructions. Learn to
recognize the machine's warning and safety de-
vices. They will alert you to conditions such as
LOW PRESSURE or HIGH TEMPERATURE that
may make it hazardous to continue operating.

0-1
DO YOU HAVE KNOWLEDGE OF . CHECK every drain cock, valve and fitting to be
WORKING AREAS? sure it is in place and secure.
Learn — beforehand — as much about your work- . LOSS of pressure from tow fluid levels may
ing area as possible: lead to serious hydraulic failures.
Be a good housekeeper . . . keep the floor clean, . CRUSHER SEIZURE from lack of oil or grease
free of oil, grease, rags, cables, chains, buckets, is a problem that may cause accidents.
rocks and other hazards. Keep loose parts in a tool . NEVER adjust pressure relief vaives to get
box. Use only non-flammable solutions for cleaning. higher operating pressures. The manufacturer's
Know the weight limitations for any floors on which recommended pressures give the safest perfor-
you will operate. mance with the longest life.
Know the clearances in the work area. A little time 8. NEVER tamper with safety devices.
spent checking side and overhead clearances, in-
9. CHECK the Crusher thoroughly for visual de-
cluding power lines, can save a lot of trouble later.
fects, such as leaks, worn hoses or loose parts.
Be careful of dust, smoke or fog, which may obscure 10. INSPECT your machine according to the oper-
your vision. ator's manual and your supervisor's instruc-
tions.
11. BEFORE STARTING walk completely around
ARE YOU PREPARED FOR
your machine. Make sure there is no one next
EMERGENCIES?
to, under or on the machine. Warn any person-
Plan ahead — stay alert — operate sensibly — and nel nearby that you are starting up.
you will avoid both having and causing personal
REPORT ANY DEFECTS TO YOUR SUPER-
injury and accidental equipment damage. If a care-
VISOR.
less moment does cause an emergency — react
quickly with the tools and skills at hand. Know the
location of and how to use a fire extinguisher and a
START UP SAFELY
first aid kit.
1. CHECK equipment for warning tags.
Know where to get prompt assistance.
2. FOLLOW the recommended starting proce-
An emergency calls for fast action.
dures as outlined in Section 11, OPERATING
DON’T STOP YOUR SAFETY PROGRAM WITH INSTRUCTIONS.
THESE GENERAL RULES. BE EQUALLY CON-
. AFTER Crusher has been started, check all
SCIOUS THAT SPECIFIC WORKING CONDI-
gauges and instruments to be sure that every-
TIONS — AND YOUR PARTICULAR EQUIPMENT
thing is operating properly.
— CAN REQUIRE ADDITIONAL PRECAUTIONS.
. SHUT DOWN immediately if any improper read-
ings are observed.
BEFORE STARTING CHECK 5. TEST all controls for proper functioning.
Equipment not properly prepared for operation is 6. LISTEN for and report any unusual noises.
unsafe equipment. Run a careful check at the be-
ginning of your shift. If you find something that 7. RECHECK alarms or other warning and safety
needs attention, THINK TWICE before deciding to devices.
“let it go this time”. Even minor mechanical defects . DO NOT stand on the adjustment ring while the
can lead to personal injury and accidents. Crusher is running.
1. DO NOT allow unauthorized personnel to oper- . DO NOT lean or place your hands on or against
ate the Crusher! the spring clusters while the Crusher is in opera-
2. MAKE SURE all guards and other protective tion.
devices are in place, secured and not damaged. 10. DO NOT take a chance with a defective ma-
3. CHECK fluid systems: Are they at the correct chine. REPORT IT TO YOUR SUPERVISOR.
level and completely leak free?
REPORT A DEFECTIVE MACHINE ing and adjustment mechanisms, lockout the
electrical service to the power unit as
Inspect your machine daily . . . check for loose,
depressing the “STOP” button will only stop the
worn or damaged parts. Report or correct any un-
motor.
safe conditions immediately . . . and do. not operate
the machine until they have been corrected. . Provide each maintenance man with his own
personal padlock and ONE key.
Even a minor defect can become serious . . . report
any machine defects to your supervisor.
CLOTHING — SAFE PRACTICE
STOPPING SAFELY
1. KEEP HANDS AND CLOTHING AWAY FROM
Be sure Crusher is stopped before .. . cleaning, MOVING PARTS. Do not take chances by
servicing, lubricating . . . checking belt tension. . . wearing loose sleeves, floppy ties, watches and
removing housing covers . . . working on the hy- rings.
draulic system ... making repairs . . . or attempting
. WEAR EYE PROTECTION when handling fuel,
to clear a plugged cavity. MAKE NO CHECKS,
cleaning fluid, oil or brake fluid. THESE MATE-
ADJUSTMENTS OR REPAIRS OF ANY KIND
RIALS CAN DAMAGE YOUR EYES.
WHILE THE CRUSHER IS IN OPERATION.
. WEAR A RESPIRATOR when required.
4. WEAR SAFETY GLASSES when drilling, grind-
TIPS FOR SAFE MAINTENANCE ing or hammering metal.
Perform maintenance with care. . KEEP YOUR POCKETS FREE of objects which
READ AND UNDERSTAND can fall out and into machinery.

1. Instruction manual furnished with the Crusher, . WEAR HARD HAT AND SAFETY SHOES,
especially Section 11, OPERATING INSTRUC- when required .
TIONS. . WEAR GLOVES to protect your hands when
. Instructions for inspection and maintenance lIo- changing cables.
cated at the rear of Section 11, OPERATING . WEAR SAFETY GLASSES AND PROTECTIVE
INSTRUCTIONS. CLOTHING when using high pressure air.
. Warning plates and caution plates provided on . WEAR GOGGLES AND PROTECTIVE CLOTH-
the machine. ING when handling molten metals; zinc, babbitt,
4. Warning notes in the instruction manual. lead, etc.

5. Lubrication guides for periodic servicing also at 10. WEAR EAR PROTECTIVE DEVICES when re-
the rear of Section 11. quired or REDUCE exposure time as required.

WARNING TAGS ALCOHOLIC BEVERAGES AND

Before working inside a Crusher, be sure to tag and MEDICATION
lockout the electrical controls so no one else will 1. DO NOT use alcoholic beverages before com-
start it. ing to work or while on the job.
Attach warning tags to prevent accidents: 2. BEWARE of medicines, tranquilizers or other
1. If Crusher is unsafe for operation. drugs which can make you sleepy or less alert.

2. If controls are being serviced. WORK AREA

3. If machine is being repaired. 1. PROMOTE GOOD HOUSEKEEPING, keep the
floor clean and dry, free of debris and tools.
LOCKOUT ELECTRICAL SERVICE
Oily and wet floors, steps and hand rails are
1. Always lockout all electrical controls before per- slippery. In winter, watch out for ice and snow.
forming any type of maintenance work on the Wet spots, especially near electrical equip-
Crusher. ment, are dangerous.
2. When servicing the electrical power unit on . DO NOT let material lay and build up on or
those Crushers equipped with hydraulic clamp- around the Crusher.
3. STORE dangerous fluids in a suitable place — 5. DO NOT smoke while using cleaning solvents.
away from unauthorized personnel. ALLOW
6. DO NOT let greasy, oily rags accumulate in a
NO SMOKING IN THE AREA! poorly ventilated area. Store oily rags and other
4. NEVER start a diesel or gasoline engine within combustible material in a safe place.
an enclosed area unless there is adequate ven- . NEVER use an open flame to check fuel, bat-
tilation. Exhaust fumes can kill! tery electrolyte or coolant levels . . . or to look
EQUIPMENT for hydraulic leaks anywhere on the equipment.
Use a flashlight!
1. Use the proper tools; handle tools and heavy
parts sensibly. . KNOW where fire extinguishers are kept — and
how they operate — and for what type of fire.
. Keep all tools and equipment free of dirt, oil Check regularly — at least monthly — to be
and grease. Do not drop or toss them. sure it is in the working area.
. Use hoisting equipment for heavy lifting. Save
your back. PRESSURIZED SYSTEMS —
HYDRAULIC OR AIR
. Lower parts, do not drop them.
1. Relieve ALL pressure before opening or remov-
To prevent slipping, wipe hand levers and knobs ing any hydraulic or air pressure lines, valves,
clean of oil or grease. fittings, etc.
. Do not use sheaves with cracked rims or
2. Check for worn hoses or damaged lines.
spokes.
3. High pressure oil can be dangerous.
7. Check for missing, cracked or frayed V-belts.
. Check for broken, defective or missing parts USE QUALITY PARTS
and replace them. Keep equipment clean and A replacement part for any item should always be
free of dirt and oil so you can spot loose or of comparable SIZE, TYPE AND QUALITY — as
defective parts. the part being discarded.
. When using cables to move a load, be sure
cables are of adequate size and replace any REPORT NECESSARY REPAIRS
worn, badly frayed, broken or kinked ones. lf your daily check uncovers any item that needs
Check end connections for wear. attention — repair, replacement or adjustment —
FIRE HAZARDS REPORT IT NOW!

1. DO NOT smoke while refueling — or when The most minor defect could result in more serious
handling fuel containers. trouble — IF THE MACHINE IS OPERATED.

SHUT OFF engine when refueling — and use Only perform the work you're authorized to do. Do
extra caution if engine is hot. not attempt repairs you do not understand.

. WHEN pouring fuel into the tank, ground the Only work on equipment you thoroughly under-
funnel or spout against the filler neck to avoid stand — a pressure-loaded part, if carelessly re-
static electric spark. leased, could injure anyone in its path.

. DO NOT use gasoline or diesel fuel for clean- Remember you are entrusted with the operation
ing parts. Good commercial, non-flammable and maintenance of a highly valuable piece of
solvents are preferred. equipment. TREAT IT AS SUCH!

0-4
PLANT SAFETY ON THE CRUSHER. A good operator's platform
constructed of “solid” floor plate should have hand
GENERAL
railings, toe plates and wire mesh or expanded
The safety procedures mentioned here do not elim- metal between the platform and the top of the hand
inate all safety hazards found in the area of crush- railing to prevent tools from dropping off the plat-
ing plants. However, they do highlight some of the form and hitting someone working below. Do not
procedures which have been found through long fasten the operator's platform to the adjustment ring
experience to improve safety conditions around as the entire adjustment ring raises or lifts very
Crushers and crushing plants. Nordberg will wel- quickly when tramp iron passes through the Crusher.
come inquiries regarding other suggested safety
procedures to use around their Crushers and relat- ELECTRICAL LOCKOUT
ed equipment. THE ELECTRICAL POWER SOURCE FOR THE
CRUSHING EQUIPMENT SHOULD BE LOCKED
OUT WHENEVER ANYONE IS WORKING ON IT.
Each maintenance man who normally works on a
Crusher should be provided with his own personal
padlock with only one key. When he works on any
assembly of the Crusher, he should use this pad-
lock to lock out the electrical controls for the
Crusher. It is most important that only one key be
provided for the lock and that key must be in the
pocket of the person who is working on the
Crusher. If more than one person works on the
Crusher, each should have his own lock and key at
separate lockout stations for the controls of the
Crusher. Accidental start-up of crushing equipment
with men in the immediate area can be responsible
for many accidents on what was supposedly a
“clear” machine.
DRIVE GUARDS
CRANES
Proper safety precautions start with the initial instal-
lation of the Crusher. Crushers are driven either by Crushers, like any other type of mechanical equip-
V-belts or by direct couplings to motors. THE BELT ment, require normal periodic maintenance if the
DRIVE OR COUPLING SHOULD HAVE A PRO- operator is to get the most for his money from the
TECTIVE GUARD AROUND IT. use of the machine. One of the most flagrant crush-
er safety violations is the use of inadequate and
Crusher sheaves in particular are designed for
unsafe lifting equipment. Although a Crusher is not
maximum rim speeds. If these speeds are exceed-
a finely tuned piece of equipment, such as an auto-
ed, it is possible that the sheave could explode and
mobile engine, the internal parts of a Crusher
cause severe injury or even death.
should be assembled and disassembled with crane
Since the speed of the Crusher is quite important facilities that have the capability of gently and slow-
for proper operation, most V-belt drive guards usu- ly lifting and lowering the various parts that make
ally have a small opening immediately opposite the up a Crusher. WHEN USING A CRANE, ALWAYS
center of the crusher drive shaft so that a tachome- OPERATE WITHIN THE RATED CAPACITY OF
ter can be inserted to occasionally check the speed THE CRANE. THE SAFE RATED CAPACITY
of the countershaft. This opening should be cov- INCLUDES WEIGHT OF HOOK, BLOCK AND
ered with an access door or hatch. ANY MATERIALS HANDLING DEVICES SUCH AS
CABLES, SLINGS, SPREADER BARS, ETC. SUB-
OPERATOR’S PLATFORM
TRACT THE WEIGHT OF ALL THESE TO FIND
Since periodic inspection and maintenance must be THE TRUE WEIGHT OF THE LOAD THAT CAN
performed on each Crusher, IT IS IMPORTANT BE HANDLED SAFELY. Chain falls should be con-
THAT SOME TYPE OF PLATFORM BE ERECTED sidered only as a last resort to assemble and disas-
AT A LEVEL CONVENIENT FOR THE MAINTE- semble a Crusher. When it comes to safety, the
NANCE MEN WHO MUST INSPECT AND WORK best should be used.
MOBILE CRANES extremely important for safe operation. Check your
footing. Your machine should be on as solid and
WHEN USING A MOBILE CRANE, ALWAYS
level a footing as possible. Use heavy timber mats
OPERATE WITHIN THE RATED CAPACITY OF
THE MACHINE TO AVOID BUCKLING THE BOOM as needed. Trailers must be raised so that trailer
OR TIPPING. Safe ratings are based on operating wheels do not touch the ground. Place screw jacks
at each corner of the trailer or as near the corner
the crane on firm, level ground; outriggers should
as possible. All four jacks must be an equal dis-
be properly extended and/or lowered whenever
tance from each end. Adjust each jack until the
possible. Avoid fast swings, hoists or sudden brak-
unsupported portion of the trailer beams stop
ing; these can cause overloads. Do not handle
vibrating or until vibrations are reduced to a mini-
large, heavy loads in strong winds.
mum. NEVER leave your trailer in a low spot where
When moving your crane, check bridges before rains may wash out your footing. PERIODICALLY
crossing, make sure they will support the weight of RECHECK TRAILER FOOTING FOR STABILITY.
the machine. Check clearances under bridges, for
When moving your trailer, check bridges before
overhead electrical lines or any overhead obstruc-
crossing, make sure they will support the weight of
tion.
the machine. Check clearances under bridges, for
Check your hitcher, be sure he's clear before start- overhead lines or any overhead obstruction.
ing lift. Make certain he securely attaches the load. NEVER TRAVEL WITH NEAR CAPACITY LOADS,
CHECK LOCAL LAWS, ESPECIALLY ON WEIGHT
WELDING EQUIPMENT
LIMITATIONS. When traveling on the highway make
One of the most frequently used tools around the sure all headlights, clearance lights and tail lights
Crusher is the cutting torch. Crushers which are are on. Use proper traffic warning flags and signs.
equipped with hydraulic components should have
these components depressurized and adequately
CRUSHING PLANT “NOISE”
covered with flame-proof material so that sparks,
weld spatter, etc., cannot reach these areas. Rup- Crushing equipment by its very nature is noisy and
tured high pressure hydraulic lines will quickly the auxiliary equipment found in and around crush-
vaporize the hydraulic fluid as it reaches the atmos- ing equipment such as chutes, transfer stations,
phere. This vaporized fluid can quickly become a screens, etc., can at times be noisier than the
mass of flames, resulting in severe burns for per- Crusher itself. EAR PROTECTIVE DEVICES MAY
sonnel in the immediate area. ALL MAINTENANCE BE REQUIRED IF NOISE LEVELS ARE HIGHER
PERSONNEL WHO NORMALLY USE TORCH THAN THOSE ALLOWED BY LAW. If ear protec-
CUTTING EQUIPMENT SHOULD BE ADVISED IF tive devices are undesirable, consideration should
THERE ARE HYDRAULIC COMPONENTS IN THE be given to reducing the amount of noise exposure
IMMEDIATE AREA IN WHICH THEY ARE WORK- that an operator or maintenance man may be sub-
ING. Then adequate precautions should be made jected to. In other words, shorter working hours.
to avoid contact with these components. Rubber
Although alteration of the machinery to change its
lined hoses are not immune to the torch cutting
noise characteristics may be economically impossi-
equipment which is used in normal plant mainte-
ble, many operators have found that the installation
nance procedures.
of a relatively inexpensive operator's station can
CONVEYOR BELTS improve noise conditions. The operator can see the
equipment in operation and still be protected from
DO NOT USE CONVEYOR BELTS AS WALK-
the noise through the installation of acoustical tile,
WAYS. Conveyor belts leading to and from the
double windows, air conditioning equipment, etc.
Crusher should be provided with walkways along-
These working conditions will normally result in a
side the conveyor. Always provide hand rails along
more efficient operation and reduce potential in-
the conveyor belt walkway as an added safety pre-
juries from noise.
caution.
Many plant operators are finding that an operator's
PORTABLE PLANTS
tower erected at an elevation above most of the
If your crushing plant consists of portable equip- equipment provides both safety features for the
ment, that is, crushing and screening equipment operator and increased efficiency in plant opera-
mounted on trailers, trailer footing or cribbing is tion.

0-6
EPOXY VERSUS ZINC handled pruning saw can be used to "saw away"
All Crushers require some type of backing when the material which is jamming the Crusher.
replacing the crushing members. Epoxy resins In some cases, hydraulic jacks have been used on
backing compound have all but eliminated the pos- the outside of the Crusher to overcome the spring
sibility of workmen being accidentally burned due to load holding the jammed material in place in the
molten zine either spilling or exploding when it crushing cavity. Excessive loading from a hydraulic
comes in contact with wet surfaces. THE ENOR- jack on the external parts of a Crusher can cause
MOUS DEGREE OF CONVENIENCE AS WELL severe stresses within the Crusher and initiate
AS THE HIGH SAFETY FACTOR INVOLVED cracks in some of the more expensive assemblies.
WHEN USING PLASTIC BACKING AGENTS HAS
MADE THE USE OF MOLTEN ZINC FOR CRUSH- TRAMP IRON REMOVAL
ER LINER BACKING OBSOLETE |
- Without question, the MOST DANGEROUS OPER-
When epoxy backings are used, care should also ATION around a Crusher is the REMOVAL OF
be taken when removing the liners with a cutting TRAMP IRON which has jammed in the crushing
torch. THE AREA SHOULD BE WELL VENTILAT- chamber. Extremely severe injuries, can occur try-
ED BECAUSE EPOXY FUMES CAN CAUSE NAU- ing to remove tramp iron. ABSOLUTELY NO
SEA OR POSSIBLE EYE OR SKIN IRRITATION. WORK SHOULD BE DONE IN TRYING TO
REMOVE TRAMP IRON LODGED IN THE
SPRING RING ASSEMBLIES CRUSHING CAVITY WITHOUT FIRST READING
THOROUGHLY THE PARAGRAPH TRAMP IRON
For those Crushers which use springs as a means
REMOVAL IN SECTION 11.
of protecting the Crusher from tramp iron overload,
it is recommended that the hydraulic jacks used to
GENERAL MAINTENANCE WORK
assemble and disassemble spring clusters be tight-
ly secured to the Crusher itself by means of a chain A certain amount of work must be done in the
or cable. IF PROPERLY SECURED, ANY UNEX- immediate area of the Crusher during the normal
PECTED AND SUDDEN MOVEMENTS WILL NOT course of operations on a day-to-day basis. The fol-
CAUSE THE JACKS TO BE FORCEFULLY lowing are some of the do’s and don'ts to be fol-
EJECTED TOWARD THE PERSONNEL WORK- lowed as part of normal crusher operating proce-
ING ON THE CRUSHER. It is also recommended dures.
to wrap a cable around the springs themselves to
1. DO NOT perform maintenance on moving ma-
keep them from being ejected away from the
chinery. This includes such items as adding
Crusher.
lubricating oil or greasing parts of the Crusher
while it is in operation.
CLEARING A CRUSHER
. DO NOT put hands or feet on the spring clus-
There are many unforeseen events such as power ters which protect the Crusher from tramp iron
failures, sudden surge of materials, etc., which can overloads while the Crusher is in operation.
cause a Crusher to become plugged with material
and stall. UNPLUGGING THE CRUSHER CAN . DO check the manufacturer’s recommenda-
BECOME A VERY SERIOUS POTENTIAL tions for periodic maintenance procedures.
SOURCE OF ACCIDENTS. In many instances, the These maintenance procedures are designed
only way in which the Crusher can be restarted is to not only avoid damage to the equipment but
to literally dig the material out of the crushing cavity also avoid harm to the operator as well.
by hand. Sometimes, however, alternate methods . DO avoid spillage around the Crusher. Crush-
may be used which make clearing the machine ers seem to attract odd size pieces of rock,
both easier and safer. gravel, etc. Plant operators should make it a
In those machines which are crushing relatively fine habit to keep the area immediately adjacent to
material, a plugged Crusher can sometimes be the Crusher free from this type of spillage
cleared by inserting a high pressure water hose which could cause unsuspecting personnel to
trip and fall.
into the crushing chamber and washing away the
material which has jammed itself into the cavity. In . NEVER look into the crushing cavity while the
machines which are crushing a relatively coarse Crusher is in operation without protection from
material, some operators have found that a long possible flying material.
REMEMBER — SAFETY IS UP TO YOU!

0-8
 Section 1

GENERAL CRUSHER INFORMATION

INTRODUCTION 0... cece cece cece ee eeu eeeeeenneenbaeueunnas 1-1
CRUSHER SIZES 2.0... e cece nee e teen cent ec eetrenereennns 1-1
INITIAL INSPECTION 2.0.0... ccc cece ccc cece e eee e eee e vent eeneenerennees 1-1
INFORMATION FURNISHED ........... 0... c cece cece nese eee eee eneeuanes 1-1
REPAIR PARTS .... 0.60. ccc cece ec ene nee etn teteetcneeeneeenreaens 1-1
CRUSHER TERMINOLOGY .......... 2... cece eee cee eee eeenenteneees 1-1
ESTIMATING CRUSHER CAPACITY ......... 0c cece cece cn ceeeeeeneeneees 1-2
 Section 1

GENERAL CRUSHER INFORMATION

INTRODUCTION 4. Drawings and Auxiliary Bulletins when the hy-
draulic clamping and adjustment mechanism is
This Instruction Book has been prepared to assist
furnished.
you, the user, and those entrusted as operators, in
the installation, operation, and maintenance of the 5. All other drawings or informational data that
Symons Cone Crushers, Standard and Short Head. might be required for your specific installation.
The information contained herein will serve to A Parts Manual containing the various assembly
acquaint you with the construction of the Crusher - drawings pertaining to your Crusher will be sent
and as an aid in gaining the general knowledge under separate cover at a later date; usually imme-
necessary for efficient operation and maintenance. diately after the Crusher has been shipped. This
manual illustrates and identifies each and every
Each Crusher is completely assembled and test run
part used in the assembly of the machine and is to
prior to shipment, however, certain safeguards
be used when ordering spare or replacement parts.
must be taken during use. These precautions are
defined in the following instructions, and will help to REPAIR PARTS
prevent the problems that arise because of improp-
er operation or maintenance. Nordberg endeavors to carry an ample supply of
parts in stock to provide prompt and efficient ser-
It is strongly recommended that the contents of this
vice on all orders for repairs and replacements.
book be read, understood and put in practice prior
to installation and during operation of the Crusher. To avoid delay, and the possibility of incorrect parts
being furnished, the following information should be
CRUSHER SIZES given:
These instructions, in general, cover the following 1. Crusher Size and Type (Standard or Short
Symons cone crushers; 4-1/4 Ft., 5-1/2 Ft. and 7 Head).
Ft. sizes.
2. The Serial Number of the Crusher which is
INITIAL INSPECTION stamped on the crusher name plate as well as
It is recommended that as soon as possible after on the cover of the Parts Manual.
receipt of the Crusher, a careful check be made for 3. Exact quantity of each part ordered.
any possible damage which might have been in-
curred during transit. A careful check should also 4. Complete name and part code number as
be made to be sure that nothing has been lost and shown in the Parts Manual.
that all items on the Bill of Lading, Freight Bill or 5. Complete shipping instructions. Advise whether
Manifest can be accounted for. If any shortages or shipment is desired by Mail, Express, Surface,
damages are discovered, these should immediately or Air Freight.
be brought to the attention of the respective carrier
so that necessary claims can be processed without If your Crusher Parts Manuals have been lost,
any undue delay. destroyed, or misplaced, an additional set will be
supplied without charge upon application.
INFORMATION FURNISHED
For proper operation, only genuine factory parts
The following drawings and data for your particular should be installed. These are guaranteed as to
Crusher will be found in a separate book entitled accuracy, workmanship, and material.
INSTALLATION DRAWINGS.
1. Foundation Drawing.
CRUSHER TERMINOLOGY
Throughout this manual certain terms will be used
2. Oil Piping Drawings for the Crusher and lubri-
in describing the Crusher and its operation. In order
cating system.
that there will be no possibility of confusion or mis-
3. Water Piping Drawings when the water seal is understanding, these terms are defined as to their
furnished. usage in the manual.

1-1
FEED: The raw material that is to be crushed. discharged and the material which does not pass
LINERS: The bowl liner and mantle are the crush- through the screen is returned to the Crusher.
ing members and are commonly referred to as liners.
CAVITY: The internal contour formed by the two
ESTIMATING CRUSHER CAPACITY
crushing members. Symons Cone Crushers have three separate and
distinct capacities (see the tables STANDARD
PARALLEL ZONE: With the liners in their closest
CONE CRUSHER CAPACITIES or SHORT HEAD
relationship during the gyrating cycle, the lower
CONE CRUSHER CAPACITIES). The difference
portion of both the bowl liner and mantle, for some
between these is the point in the circuit at which the
distance, will be parallel to each other. This area is
measure is taken in either open circuit or closed cir-
known as the parallel zone.
cuit operation. The crusher is one component of the
FEED OPENING (Closed Side): The smallest dis- circuit. As such, its performance is in part depen-
tance between the top of the crushing members as dent on the proper selection and operation of feed-
measured when the two crushing members are at ers, conveyors, screens, supporting structure, elec-
their closest relationship during their gyrating cycle. tric motors, drive components and surge bins.
Where used, attention to the following factors will
FEED OPENING (Open Side): The largest distance
enhance crusher capacity and performance.
between the top of the crushing members as mea-
sured when the two crushing members are at their 1. Proper selection of crushing chamber for mate-
farthest relationship during their gyrating cycle. The rial to be crushed.
feed opening (open side) determines the maximum
. A feed grading containing proper distribution of
size of feed. As a general rule, the maximum size
the particle sizes.
of feed should not exceed the closed side feed
opening. 3. Controlled feed rate.
DISCHARGE SETTING: The distance between the 4. Proper feed distribution 360° around the crush-
bottom of the crushing members as measured at ing chamber.
the point where the two crushing members are at
5. Discharge conveyor sized to carry maximum
their closest relationship during their gyrating cycle.
crusher capacity.
This discharge setting regulates product size.
. Properly sized scalping and closed circuit
MINIMUM DISCHARGE SETTING: The smallest
screens.
permissible distance between the bottom of the
crushing members as measured when the two 7. Automation controls.
crushing members are at their closest relationship
8. Adequate crusher discharge area.
during the gyrating cycle.
The following factors will detract from crusher ca-
DISCHARGE OPENING: The distance between the
pacity and performance.
bottom of the crushing members as measured at
the point where the two crushing members are at 1. Sticky material in crusher feed.
their farthest relationship during their gyrating
2. Fines in crusher feed (smaller than crusher set-
cycle. This wide opening permits rapid discharge of
ting) exceeding 10% of crusher capacity.
the crushed material.
3. Excessive feed moisture.
PRODUCT SIZE: The size of the screened material
after it has been crushed. 4, Feed segregation in crushing cavity.
CAPACITY: The output of the Crusher computed in 5. Improper feed distribution around circumfer-
tons per hour. ence of crushing capacity.
OPEN CIRCUIT OPERATION: The type of opera- . Lack of feed control.
tion where precise uniformity of product size is not
. Inefficient use of recommended connected
considered to be of prime importance and the feed
horsepower.
is run through the Crusher but once.
8. Insufficient conveyor capacity.
CLOSED CIRCUIT OPERATION: The type of oper-
ation where precise uniformity of product size is 9. Insufficient scalper and closed circuit screen
important and the product is screened as it is being capacities.
10. Insufficient crusher discharge area. gested that the bowl liner and mantle be torch cut
open so that the contour of the bowl liner and man-
11. Extremely hard or tough material.
tle can be traced onto a sheet of card board or
12. Operation of crusher at less than recommend- heavy paper and the traced contours sent to the
ed full load countershaft speed. factory, in order that the exact concentration of
wear can be determined.
Capacities are based on results obtained from thou-
sands of installations worldwide, crushing the broad- Another bowl liner and mantle can then be recom-
est range of ores, rocks and minerals to determine mended which will have a different contour at these
effect of individual conditions. wear points,

SELECTION OF PROPER LINERS In order to properly answer any inquiry, it is impor-

tant that the following information be included:
Through extensive research and study, Nordberg has
developed a varied line of crushing members cov- 1. Size of feed.
ering a wide range of feed and product sizes. Since 2. Type of feed.
there are so many variable conditions and types of
operation to be considered, it would be difficult to list 3. Product size desired.
each type of liner that would be best suited for each
To operate continuously with liners having a crush-
individual condition and type of operation.
ing cavity unsuited to the operation, results in uneco- —
If for any reason, it is felt that unsatisfactory wear nomical wear of the liners, poor crushing efficiency
life was obtained from the original liners, it is sug- and, in some instances, abuse to the Crusher.

1-3
 NEW FEED
CIRCULATING LOAD

SSL
_

<
| CLOSED CIRCUIT OPEN CIRCUIT

CLOSED CIRCUIT/OPEN CIRCUIT STANDARD CRUSHER

1-4
 NEW FEED

yO
Vi \
L. NN
CIRCULATING LOAD

CLOSED CIRCUIT OPEN CIRCUIT

CLOSED CIRCUIT/OPEN CIRCUIT SHORT HEAD CRUSHER

1-5
 Section 2

GENERAL INSTALLATION INFORMATION

FOUNDATION... 0.0... cece eee eee eee e ene een e eens 2-1

CRUSHER CLEARANCE DIMENSIONS .............

0... cece cee ee eee eee 2-1

CRUSHER AND SUB-ASSEMBLY WEIGHTS ..... 00... c cece eens 2-1

FEED ARRANGEMENT ........... 0... ccc cece eee eee eens 2-1

DISCHARGE ARRANGEMENT ...............

cece eee eee eee nes 2-3

TYPE OF DRIVE ....... cece cece cece

eee eee eee 2-3

CRUSHER MOTOR ....... ccc ccc cect eee nee eet cent ee ee nnene 2-3

PIPELINE INFORMATION ....... 0.0. e cece eee nent eens 2-4

GENERAL ASSEMBLY AND DISASSEMBLY INFORMATION ................. 2-4

GENERAL MAINTENANCE INFORMATION ...........0.

0c cess eee eee eee 2-5

MINIMUM RECOMMENDED SPARE PARTS LIST ............0

000 cece eens 2-5

SPECIAL TOOLS wo. cece nee e ene 2-5

PROTECTING THE CRUSHER AGAINST RUST CORROSION ............... 2-7

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TYPICAL MOUNTING ARRANGEMENT

IF FURNISHED (7) ceserve ninnes SPACE REQUIREMENTS TO ALLOW FOR FREE. AND

i
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UNIMPEDED DISCHARGE OF CRUSHED MATERIAL

2. FOR THE PROPER SELECTION OF HOISTING EQUIPMENT ASOVE THE CRUSFER.
CRUSHER FOUNDATION DISCHARGE 1245 an
1
lL *. {3 REFER TG TO7-003 OR TD7-004 FOR THE COMPLETE CRUSPER WEIGHT AS
OPENING DIMENSIONS a°-2 WELL AS THE WEIGHTS OF VARIOUS SUB-ASSEMALIES THAT REQUIRE

to sl tes iff
FREQUENT HANDLING

3. IN ORDER TO ACCURATELY DETERMINE CRUSHER CLEARANCE DIMENSIONS

REFER TO 1D7-001
Lit
L ] C } o- — HOLES IN EACH 4. THIS ORAWING IS BASED ON TYPICAL CONDITIONS OF INSTALLATION AND ~
t SLIDE RAIL OPERATION - NORDSERG CAN NOT BE RESPONSIBLE FOR ASSUMPTIONS KADE
[res ee | 27SLIDE RAILS FURNISHED

stze fev) (5) iF crusser 1s COUIPPED WITH A WATER SEAL ARRANGEMENT, AND IS TO BE
PLACED ON A SLAB TYPE FOUNDATION, PROVIDE THREE 6° WIDE BY 6° DEEP
QUTSIDE OTA, HOSE TRENCHES IN FOUNDATION AS SHOWN IN PLAN VIEW. REFER TO FEED
MOTOR SHEAVE AND CRAIN PIPING ORAWING NUMBER 94399005.

CRUSHER ORIVE MOTOR IS NOT FURNISHED BY

NORDBERG UNLESS OTHERWISE INDICATED || «OUTSIDE OIA OF
FOR THE PROPER SELECTION
OF THE ELECTRIC MOTOR
REFER TQ ELECTRIC ORIVE
MOTOR SPECIFICATIONS
TD6-043.

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CRUSHER
(4) © 43°, OIA CRUSHER ANCHOR BOLTS. rey
ANNOYS

THREADED (3° AT THE TOP WITH (1) PLAIN

WASHER AND (2) HEX NUTS. ANCHOR BOLTS TO
BE FURNISHED BY CUSTOMER PET TET HEAVY DUTY -
NARROW “V"
AXOdZ

V-SELT INSTALLATION
V-BELT DRIVE
FOR V-BELT STRETCH
WH

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CLEARANCE DIMENSIONS
 CRUSHER SIZE
WEIGHT OF COMPLETE
CRUSHER AND WEIGHTS 7 FT.
OF ASSEMBLIES THAT 7 FT. SUPER
REQUIRE FREQUENT HEAVY HEAVY
HANDLING 4-1/4 FT. 5-1/2 FT. DUTY DUTY
CRUSHER COMPLETE 49,500 95,400 148,500 191,200
MAIN FRAME, ADJUSTMENT
RING, SPRINGS, STEP BEARING
PLATES, ECCENTRIC, SOCKET,
COUNTERSHAFT BOX, 30,700 56,100 85,000 127,200
COUNTERSHAFT AND
CRUSHER SHEAVE
MAIN FRAME, ADJUSTMENT
RING AND SPRINGS 24,200 43,400 63,800 106,000

MAIN FRAME, INCLUDING

MAIN FRAME CAP, OUTER
ECCENTRIC BUSHING AND 12,100 25,500 40,000 55,300
MAIN FRAME LINER
BOWL, BOWL LINER AND
ADJUSTMENT CAP 10,800 22,600 32,700 33,200

HEAD, MAIN SHAFT, MANTLE ;

AND FEED PLATE 8,000 16,700 30,800 30,800

COUNTERSHAFT BOX,
COUNTERSHAFT AND CRUSHER 2,800 4,700 7,000 7,000
SHEAVE
ECCENTRIC 2,300 4,200 7,600 7,600
SOCKET 1,400 3,800 6,600 6,600
MANTLE 1,700 4,300 6,700 6,700
BOWL LINER 2,000 4,500 7,800 7,800

SINCE VARIOUS ASSEMBLY COMBINATIONS ARE AVAILABLE IN EACH CRUSHER

SIZE AND BECAUSE OF MANUFACTURING VARIATIONS,
THE WEIGHTS SHOWN ABOVE ARE APPROXIMATE.
ALL WEIGHTS CAN VARY + 5%.
ALL WEIGHTS IN POUNDS.

STANDARD CRUSHER AND SUB-ASSEMBLY WEIGHTS

 CRUSHER SIZE
WEIGHT OF COMPLETE
CRUSHER AND WEIGHTS 7 FT.
OF ASSEMBLIES THAT 7 FT. SUPER
REQUIRE FREQUENT HEAVY HEAVY
HANDLING 4-1/4 FT. 5-1/2 FT. DUTY DUTY
CRUSHER COMPLETE 49,800 96,700 154,600 197,300
MAIN FRAME, ADJUSTMENT
RING, SPRINGS, STEP BEARING
PLATES, ECCENTRIC, SOCKET,
COUNTERSHAFT BOX, 30,700 56,100 85,000 127,200
COUNTERSHAFT AND
CRUSHER SHEAVE
MAIN FRAME, ADJUSTMENT
RING AND SPRINGS 24,200 43,400 63,800 106,000

MAIN FRAME, INCLUDING

MAIN FRAME CAP, OUTER
ECCENTRIC BUSHING AND 12,100 25,500 40,000 55,300
MAIN FRAME LINER
BOWL, BOWL LINER
ADJUSTMENT CAP AND 9,600 20,200 31,600 32,100

HEAD, MAIN SHAFT, MANTLE

AND FEED PLATE 9,500 20,400 38,000 38,000

COUNTERSHAFT BOX,
COUNTERSHAFT AND CRUSHER 2,800 4,700 7,000 7,000
SHEAVE
ECCENTRIC 2,300 4,200 7,600 7,600
SOCKET 1,400 3,800 6,600 6,600
MANTLE 1,300 3,100 5,000 5,000
BOWL LINER 1,500 3,400 6,000 6,000

SINCE VARIOUS ASSEMBLY COMBINATIONS ARE AVAILABLE IN EACH CRUSHER

SIZE AND BECAUSE OF MANUFACTURING VARIATIONS,
THE WEIGHTS SHOWN ABOVE ARE APPROXIMATE.
ALL WEIGHTS CAN VARY + 5%.
ALL WEIGHTS IN POUNDS.

SHORT HEAD CRUSHER AND SUB-ASSEMBLY WEIGHTS

 Section 2

GENERAL INSTALLATION INFORMATION

FOUNDATION FEED ARRANGEMENT
The foundation drawing which is furnished will, in The maximum efficiency which can be obtained
most instances, govern the installation of the from the Crusher is directly dependent on the feed
Crusher. The foundation should conform wherever arrangement. The Crusher can only reach maxi-
possible, to the size and type of construction rec- mum efficiency if the feed is supplied in the correct
ommended on the drawing. A TYPICAL FOUNDA- amount and is evenly distributed around the entire
TION ARRANGEMENT is shown at the beginning crushing cavity. By carefully checking the founda-
of this section. A solid level foundation of proper tion drawing and crusher clearance dimensions,
proportion and durability is of utmost importance to certain precautions can be taken regarding the
the successful operation of the Crusher. installation of the feed equipment. The construction
should permit the easy removal of this equipment
when servicing the Crusher. The feed arrangement,
CRUSHER CLEARANCE therefore, deserves a great deal of thought in the
DIMENSIONS planning prior to its eventual construction.
A well planned installation is an absolute necessity Each Crusher can be furnished with a feed platform
for the ultimate success of the Crusher. One of the and spout which should be used whenever condi-
major considerations to be given the construction of tions permit. The feed platform can be adjusted
the foundation is crusher clearances. Sufficient vertically by turning the feed adjustment nuts which
head room should be provided above the Crusher support the platform. On the 7 Ft. Crushers, the
for the removal of the main shaft and bowl assem- feed platform is a rigid structure without feed spout,
blies. Enough room should be provided at the side and is furnished on the large machines due to the
of the foundation for the removal of the countershaft type of feed and the wide variation of feeding
box assembly. Consideration should also be given equipment available for these Crushers. A properly
to the additional clearance required for the feeding constructed feed box mounted on top of the feed
arrangement, such as; chuting, feed hopper and platform provides a backstop for the feed as it
other auxiliary equipment. Adequate clearance comes from the chute so that the feed will rebound
should also be provided for the discharge compart- and fall vertically through the feed spout. The feed
ment, conveyor and related equipment. In order to will then drop onto the feed plate in a more uniform
accurately determine crusher clearances, refer to manner. The feed box, when correctly fed in con-
the table CLEARANCE DIMENSIONS as well as junction with the feed distributing plate on the
the foundation drawing. Crusher, will help to assure a uniform distribution of
thoroughly mixed feed around the entire crushing
cavity. Segregation of fine and coarse material
CRUSHER AND SUB ASSEMBLY should be kept to a minimum to achieve maximum
WEIGHTS liner wear. For best results on the “Standard”
Crushers the feed should be regulated so that the
Another factor to be considered when designing the crushing cavity is not entirely filled and that the
foundation and also a factor to be considered when feed does not build up under the feed plate. On the
planning overhead lifting equipment is crusher “Short Head” Crushers the feed should be regulat-
weights. An overhead crane, a rubber or track ed so that there is a build-up of material below the
mounted mobile crane, a chain hoist or other suit- feed plate and above the crushing cavity. This
able equipment must be provided for handling bridge of material should extend around the entire
heavy crusher components during erection or dur- cavity and serve as a limiting means to prevent
ing the replacement of the crushing members or overfeeding. With this type of feeding, a greater
other worn parts. Size requirements for hoisting output can be realized with a product of a finer and
equipment including cables, slings and hooks can more uniform size and also a substantial reduction
be calculated by referring to the table CRUSHER in power consumption. A feed box is not furnished
AND SUB-ASSEMBLY WEIGHTS. This table gives with the Crusher, since the type of feed will deter-
the complete crusher weight as well as the weights mine how the feed box is to be constructed and of
of sub-assemblies that require frequent handling. what material.

2-1
WHENEVER POSSIBLE, IT IS ADVISABLE TO The feeding equipment must be of adequate size
PLACE A SCREEN AHEAD OF THE CRUSHER so as to maintain maximum feed conditions to the
TO REMOVE FINE OR STICKY MATERIAL FROM Crusher.
THE FEED PRIOR TO CRUSHING. THIS WILL The correct and incorrect method of feed and feed
ELIMINATE PACKING, EXCESSIVE SPRING box construction are shown in the illustration FEED
ACTION AND INEFFICIENT OPERATION. A MET- ARRANGEMENTS.
AL DETECTOR CAN ALSO BE INSTALLED TO
REMOVE METALLIC OBJECTS, SUCH AS TRAMP
IRON WHICH WOULD CAUSE SPRING ACTION.

Here the incoming material passes through one Here’ the incoming material falls on the feed plate
side of the feed opening, causing uneven distribu- properly.
tion. Results of even distribution:
Results of uneven distribution: 1. Maximum capacity.
1. Reduced capacity. Uniform product.

PF oN
2. Oversize product. Minimum spring action.
3. Excessive spring action. Minimum bearing pressures.
4. Maximum bearing pressure. a
Minimum power consumption.
5 . Maximum power consumption.

INCORRECT METHOD OF FEED CORRECT METHOD OF FEED

FEED ARRANGEMENTS
DISCHARGE ARRANGEMENT Should the motor sheave be located directly ABOVE
the countershaft or within 30° of the crusher vertical
Since the discharge arrangement varies with each
centerline, the factory must be informed as to the
installation, a discharge compartment or chute is
position of the drive sheave, so that the OUTER
not furnished with the Crusher. The construction
countershaft bushing can be properly installed.
should, however, follow the recommendations as
shown on the foundation drawing. Either metal or Power may be furnished by either an electric motor
wood may be used for the discharge compartment. or diesel engine.
An inspection door should be provided in the com-
The Crusher may also be direct driven, that is, cou-
partment so that the inside of the compartment is
pling connected to a driving motor or engine.
readily accessible for cleaning or inspection. A shelf
or ledge should be constructed within the discharge Any problems related to the crusher drive should
compartment. The shelf will provide a “dead bed” of be submitted to the factory for suggestions.
crushed material on which the falling material will
hit. The shelf will absorb much of the impact before
the material falls onto the conveying equipment,
adding considerable life to such equipment.
lf a chute is to be used, the slope of the chute must
be more than 45° with the horizontal and, if materi-
al is very sticky, the angle of inclination should be
increased.
There should be sufficient clearance, as shown on NARROW 8V BELT BANDED BELTS
the foundation drawing, between the main frame
BELT CROSS SECTIONS
cap and the bottom of the discharge compartment
and between the discharge opening or chute and
the conveying belt or elevator. Adequate clearance
at these points will prevent material from clogging
CRUSHER MOTOR
the discharge area and causing it to build up under The electrical driving motor is to be a squirrel cage
the head and interfere with the operation of the induction motor; continuous rated, with normal start-
Crusher. This will insure a free unimpeded dis- ing torque (approximately 125 percent) and normal
charge of crushed material. breakdown torque (approximately 200 percent) with
+10 percent acceptable voltage variance.
Abrasive resistant insulation and stator thermostats
TYPE OF DRIVE
(an internal protective device) are suggested. The
The standard recommendation for driving the motor can either be open dripproof or totally en-
Crusher is through a V-belt drive. The V-belt drive is closed fan cooled.
particularly desirable because of, first its feature
To maintain continuous service of the recommend-
which prevents Crusher shock loads from being
ed operating horsepower level shown on the foun-
transferred to the crusher motor and, secondly, its
dation drawing, an electric motor with a 1.15 ser-
ability to carry surge loads without a resultant loss
vice factor is required. If a service factor of 1.0 is
in crusher speed.
used, the horsepower rating appearing on the
The V-belt drive can consist of narrow 8V belts or motor’s nameplate should be approximately15 per-
banded belts. See the illustration BELT CROSS cent higher than the recommended operating horse-
SECTIONS. power. However, the crusher power draw is to be
held to the horsepower shown on the foundation
The narrower 8V belts are designed for compact-
drawing.
ness of drive, drive economy and reduced over-
hung load. Banded belts are single belts unitized If a V-belt drive is used, care should be taken when
with a common cover to prevent belt whip or turn- ordering the motor that the motor bearings are ade-
over. Banded belts fit all standard sheaves, how- quately sized for the overhung sheave weight and
ever, banded belts should be limited to only 2 or 3 belt pull. The motor must also have a O° radial belt
individual belts banded together. pull capacity. Motor shaft diameter must be able to

2-3
withstand peak torque and simultaneous bending All piping connections should be checked for leaks.
due to belt pull and sheave weight. The shaft It is very important that the oil suction line between
should be of sufficient length to accommodate the the pump and tank be absolutely tight, since any
entire length of the motor sheave bushing or hub as leakage in this line will be reflected in the lowering
well as provide clearance between the motor hous- of pump efficiency, that is, oil capacity and oil pres-
ing and the rim of the sheave. sure will be considerably lower and may endanger
the crusher lubrication. Leakage in the suction line
With the V-belt drive, slide rails under the motor are is especially dangerous since it does not reveal
required to provide allowance for V-belt take-up due itself by an oil leakage as would be the case in the
to belt stretch and for belt installation. oil pressure line.
If a direct drive is used, care should be taken when Attention should be given as to the direction of rota-
ordering the motor, that the motor shaft extension tion of the crusher countershaft, as it is important
and bearings are adequately sized for a direct drive that suction and feed lines be connected properly
application. The motor shaft diameter must be able to the crusher driven integral pump. For the correct
to withstand peak torque. arrangement of the integral pump piping consult the
All horsepower ratings referred to on foundation piping drawings furnished.
drawings are based on electric horsepower. There-
fore, when using a diesel engine as the driving unit,
the engine manufacturer must be contacted in order GENERAL ASSEMBLY AND
to find out what diesel horsepower is equivalent to DISASSEMBLY INFORMATION
the electric horsepower at the speed (RPM) shown
Symons cone crushers are shipped either as a
on the foundation drawing.
complete unit or in sub-assemblies, depending on
crusher size. For domestic shipment, the smaller
size Crushers are usually shipped as a complete
PIPELINE INFORMATION unit, ready to be set on the foundation. In some
The LUBRICATING SYSTEM, Section 10, describes instances these smaller machines will be disman-
in detail the proper type of oil, its temperature and tled into sub-assemblies for export shipment or for
regulation, as well as the equipment that is used or domestic shipment where shipping or handling re-
could be used in the Crusher lubricating system. It strictions so demand. The larger size Crushers are,
should be noted that the lubricating system for the in most instances dismantled for shipment.
Crusher is designed for 125 PSI MAXIMUM operat- In succeeding sections detailed instructions will be
ing pressure. given covering the assembly and disassembly of
Consult piping drawings furnished to show the pipe the various crusher components. Starting with the
and pipe fittings supplied with the Crusher and any main frame, the remaining components are dis-
other lubricating equipment. Pipeline layout will cussed in their normal assembly sequence. Wheth-
vary to suit local conditions. Two influencing factors er the Crusher is shipped as a complete assembled
should be considered in the layout of both feed and unit or whether it is completely dismantled, the
drain lines; the pipeline should be as short and as Crusher can be assembled by referring to those
direct as possible, without dead pockets or other sections which apply to the Crusher depending on
flow obstructions and the drain line should have a the extent of dismantling.
minimum pitch of 1" (25 mm) for every 12" (305 Before installing any of these crusher parts, check
mm) of pipe used. that the protective coating applied to all machined
It is necessary that all piping be checked for inter- surfaces for shipment has been removed, and that
nal cleanliness, that all chips and cuttings at thread- all parts are clean and free from grit and dirt, espe-
ed ends be removed to safeguard the oil pump. cially oil passages and pipes.

Unions should be installed in suitable locations to All machined surfaces and threads that may have
facilitate removal of any of the lubricating equip- possibly been damaged in shipment must be re-
ment: oi! pump, filter, cooler, etc. stored to the proper condition before assembly.
After cleaning, lightly oil all bearing surfaces and
machined surfaces of mating parts.
GENERAL MAINTENANCE MINIMUM RECOMMENDED
INFORMATION SPARE PARTS LIST
When performing any maintenance work on the The following is a list of the minimum spare parts
Crusher, the following general precautions should which should be on hand at all times to insure a
be observed: minimum of down time.

1. When removing parts with machined or bearing Bowl liner.

=
surfaces which may rust, they should be well
Mantle.
oiled or covered with a rust preventative, if they

fF oN
oa
are to be kept out of the Crusher for any length Integral oil pump (if so equipped).
of time.
Step bearing plate shims (1 Set) .
. Use additional caution when handling any parts
Socket sealing ring springs (1 Set).
which have bearing surfaces or a machined
surface that has close tolerances. Socket sealing ring spring housings (1 Set).
. When disassembling any parts with bearing or SPRINGS AND HOUSINGS ARE USED ONLY
machined surfaces, protect these surfaces from ON CRUSHERS EQUIPPED WITH THE STAN-
coming in contact with the ground by using DARD HEAD SEALING ARRANGEMENT.
wooden blocking.
It is to be understood that this list contains only the
. Bronze liners or bushings should be handled minimum compliment of spare parts and if the crush-
with extreme care. Excessive ramming or pound- er installation is either in a remote location or con-
ing on this soft material may cause warping or sists of several Crushers, this list should be expand-
springing of such parts. ed. Therefore, consult the factory for a suggested
list of spare parts for your particular operation.
. Clean thoroughly and oil, all machined parts
before installing them in the Crusher. Do not Before storing any spare parts, check that the pro-
replace a bearing surface without coating it with tective coating applied before shipment is still
oil. intact.
When assembling two mating parts that require Finally, when replacing any bushings, bearings or
either a press or sliding fit, coat the contacting major parts and when the Crusher is being started
surfaces with a light coating of oil. This will act for the first time, it is advisable to “run the parts in’.
as a lubricant and prevent rusting in place. Refer to the information described in the paragraph
When pressing the main shaft into the head or entitled BREAK-IN PROCEDURE in Section 11.
the pinion onto the countershaft use a white
lead and oil mixture.
. Inner and outer eccentric bushings are to be
SPECIAL TOOLS
stored vertically, stored in any other position Only tools which are not readily available through
could cause the bushings to become out-of- commercial supply houses can be furnished with
round or elliptical. Great difficulty could conse- your Crusher.
quently be encountered when installing them in
These tools consist of all the eyebolts necessary for
the Crusher. In some instances installation
handling the equipment; a few special wrenches;
would be impossible.
cables for turning and adjusting the bowl; a mandrel
. All bowl, adjustment ring, main shaft, main for pouring backing; and special capscrews for in-
shaft nut, locking collar, locking nut and. locking stalling and removing the countershaft box.
nut cover thread surfaces are to be rubbed with
All of the tools are painted the same color as the
a cloth impregnated with powdered molybde-
Crusher for immediate identification and shipped in
num disulfide and then coated with grease or
a separate box.
oil. Again, should this powder be unobtainable,
grease applied liberally is a good substitute. The illustration SPECIAL TOOLS shows the type of
tools usually furnished, but will vary slightly with
each size of Crusher.
 SOCKET ECCENTRIC JACKING SCREW FOR
EYEBOLT EYEBOLT INSTALLING AND REMOVING
COUNTERSHAFT BOX

SOCKET SEALING
RING EYEBOLT
| 4 ~ MAIN SHAFT
EYEBOLT

o 2
STEP BEARING
PLATE EYEBOLT

coy rT WINDLASS
wn
ADJUSTMENT
CABLE
SHACKLE

WRENCH FOR BOWL

MH 4) LINER U-BOLT NUT AND
LOCKING COLLAR
WA CAPSCREW
UPPER STEP BEARING
PLATE ROD @

ADJUSTMENT CAP
SCREW WRENCH BACKING MANDREL
FOR MANTLE
SPECIAL TOOLS

2-6
PROTECTING THE CRUSHER hydraulic assemblies. The rust preventives func-
AGAINST RUST CORROSION tion by displacing water from metal surfaces, by
forming strong water-resistant films on the sur-
Rusting is a specific type of corrosion that occurs faces, and by absorbing water in the system
on iron and steel surfaces when both water and into a water-in-oil emulsion. These products
oxygen are present. ' provide as much as 30 to 40 times the protec-
tion against rust as high-quality lubricating oils
Rusting can occur even if the amount of water pres-
that have not been especially formulated to
ent is only a very thin film that may not even be visi-
prevent rust.
ble. In fact, rusting of iron and steel in humid at-
mospheres is a common experience. Since air, the In most applications, the residual rust-preven-
normal source of oxygen, usually contains some tive film left by these products need not be
moisture, and ordinary water contains dissolved air, flushed away or otherwise removed when the
the elements required for rusting are practically al- Crusher is to be filled with lubricating oil and
ways present. Corrosion of some metals, for exam- put into normal service.
ple copper and aluminum, results in the formation
Generally, one (1) barrel (55 U.S. gallons) is
of a tight oxide film that protects the surfaces from
sufficient to coat a Crusher. The viscosity of the
further corrosion. On the other hand, rust on iron or
oil should be in the 150 to 300 SSU at 100°F
steel is porous so that water and oxygen can siill
(38°C) range.
get at the underlying surface. Therefore, rusting
continues and penetrates deeper into the metal. . Fill the countershaft box with oil through the
1/2" tapped hole in the top of the box casting.
Rust is dangerous and expensive. Rusting causes
Some leaking will occur from the end of the
industry several billions of dollars annually. In many
countershaft box, this is normal.
plants rusting is the major cause of:
. Turn the main shaft assembly upside down and
Downtime
fill the lubricating hole in the bottom of the shaft
Lost Production
until the oil flows out of the hole in. the head,
Wasted Production
then drain. Brush or spray a light-bodied petro-
- High Maintenance Costs
leum solvent containing a substantial amount of
Early Replacement of Equipment
a polar rust-preventive additive having strong
Rusting also creates: attraction for metal surfaces, on the entire main
shaft and underside of the head.
Safety Hazards to Personnel
The additive should have excellent ability to wet
This cost can be greatly reduced:
metal surfaces in the presence of water; as a
Through a rust prevention program result it strongly resists displacement from the
Through proper use of rust preventives surface by water. The solvent should evaporate
quickly and leave a thin, transparent, greasy
To protect your Crusher from rust corrosion during
film. The material should be suitable for light
seasonal shut down or for foreign shipment or for
and moderate service, for example, protected
outdoor storage (winter or summer), the following
outdoor storage. It should be applied at plant
protective measures are recommended:
operating temperature by any convenient means
1. Remove the bowl and main shaft assemblies (brushing, rolling, spraying) and the film need
and fill the entire eccentric bore with a rust pre- not be removed when the Crusher is placed in
ventive lubricating oil until the oil is level with operation.
the top of the socket liner.
. Brush or spray this same greasy solution on
Make sure that all piping and the breather hole the bowl and adjustment ring threads. Then
in the side of the countershaft box are sealed cover the threads with a liberal amount of a
with pipe plugs to assure that the entire inside lithium base grease NLGI No. 1 containing 5-
of the Crusher can be filled. 10% of molybdenum disulfide.
Use a lubricating oil which has a rust preven- . Pack the socket sealing ring (standard seal
tive blend that is designed for the protection of only) with this same grease, making sure the
internal parts of enclosed assemblies such as wipers are completely covered. If the Crusher
engines, compressors, pumps, gear sets, and has a water sealing arrangement, fill the water

2-7
 chamber with the same oil as used in the rest Where it is necessary that the Crusher be shipped
of the Crusher. or stored dismantled, the various sub-assemblies
must be protected more thoroughly, as the previ-
. If the Crusher is equipped with a hydraulic ously described procedures are for metal surfaces
clamping and adjustment mechanism, fill the oil that are NOT directly exposed to the elements; sun,
tank on the power unit with a similar rust pre- wind, rain, snow, etc.
ventive oil but having a viscosity of 150 SSU at
100°F (38°C), 25 U.S. gallons are required for The following protective measures are recommend-
the entire hydraulic system. Make sure the oil is ed in those instances where a Crusher must be
compatible with such a hydraulic system where shipped or stored dismantled and the various sub-
neoprene, polyurethane, bronze, nickel, chrome, assemblies exposed to the elements:
steel and iron is used. 1. Cover the entire top of the socket liner, the ad-
The hydraulic clamping and adjustment system justment ring, and end of the countershaft box
must be operated to assure that the power unit, with the black polyethylene sheeting to protect
lock posts and rams have been thoroughly coat- the inside of the Crusher after the Crusher itself
ed with the rust preventive. was prepared as previously described with a
rust preventive oil. The sheeting must be ade-
. After the Crusher has been completely filled quately braced to prevent sagging.
with the special rust preventive oil, the Crusher
. Spray or paint the machined surfaces of the
is to be drained before placing it in storage, as
various sub-assemblies; bowl, main shaft and
the remaining film is all that is required for ade-
head, etc. with a specially processed asphaltic
quate rust protection.
material that is made fluid by means of a petro-
DO NOT USE THIS OIL TO OPERATE THE leum solvent. It is a medium-body, black liquid
CRUSHER AS IT IS DESIGNED ONLY FOR that can be applied at room temperature by any
RUST PREVENTION. convenient method. The solvent evaporates and
leaves a hard strong dry acid-resistant film. This
. Then reassemble the bow! and main shaft as- coating provides long-time protection under
semblies into the Crusher and cover the entire severe conditions such as unprotected outdoor
adjustment cap and bowl hopper with a sheet storage and presence of corrosive fumes. It is
of 8 mil BLACK polyethylene to prevent water especially suitable for unpainted external sur-
from seeping into the Crusher and corroding faces. The treated parts will withstand consid-
the bowl and adjustment ring threads. This erable scuffing and moderately rough handling,
sheeting is available in 20 ft. by 100 ft. rolls. but they should be protected against severe
Black is recommended as transparent sheeting physical damage, since the hard, dry film is not
will deteriorate four (4) times faster than black. self-repairing. The film is somewhat similar to
The end of the countershaft box and counter- paint and although semi-permanent, can be
shaft should also be covered. Steel strapping removed even after prolonged aging by vigor-
or banding is an ideal method of holding the ous rubbing with solvent soaked rags.
polyethylene sheeting in place.
FOR THOSE PARTS STORED OUTDOORS
IF THE ABOVE RECOMMENDATIONS ARE FOL- UNPROTECTED, THE ABOVE RECOMMEN-
LOWED, A CRUSHER STORED OUTDOORS DATIONS SHOULD PROVIDE 24 MONTHS
SHOULD HAVE 6-12 MONTHS OF RUST PRO- OF PROTECTION AGAINST RUST CORRO-
TECTION. SION.
 Section 3

MAIN FRAME, ADJUSTMENT RING AND

SPRING RING ASSEMBLIES

DESCRIPTION ....... 2c cc ener e neers nent enenen 3-1

ASSEMBLY INSTRUCTIONS ..... 0. ccc cece tenet tenets 3-1

GENERAL ....... 0... eee

cece nett ence ene e ees 3-1

CRUSHER INSTALLATION ............ een

nee e ete nents 3-1

MAINTENANCE .... 2. ec ccc een ee eee nee n eens 3-2

MAIN FRAME LINER AND ARM GUARDS .............

00: cece eee eee ee 3-2

OUTER ECCENTRIC BUSHING REMOVAL .............

0: cece eee eee eee 3-3

INSPECTION OF MAIN FRAME BORE ..........

00. ce eee ee eee e ene nen 3-4

OUTER ECCENTRIC BUSHING INSTALLATION ...........

0. eee eee 3-5

POURING THE BUSHING LOCK......... 0... e cece

eee eee teens 3-6

~ REPLACING THE BUSHING LOCK...... 0.02. c ccc ccc eee ee 3-7

CAVITY RELEASE CYLINDER REMOVAL............

00... eee ee cece eee 3-8

CAVITY RELEASE CYLINDER INSTALLATION. ............0

02 e cece ee eee 3-10

ACCUMULATOR REPLACEMENT..........2...200:e
cece cece eee ence en ees 3-10

SPRING ASSEMBLIES ......... 2. cece ccc eee tenets 3-11

OFFSET SPRING ARRANGEMENT DISASSEMBLY....................05- 3-12

OFFSET SPRING ARRANGEMENT ASSEMBLY ...... cece

eee teen eee 3-12

CENTERED SPRING ARRANGEMENT DISASSEMBLY.................... 3-14

CENTERED SPRING ARRANGEMENT ASSEMBLY .................0.505- 3-14

DETERMINING CORRECT SPRING LENGTH ............

00.0.0 cece eee 3-16

REMOVING RUSTED OR DAMAGED SPRING BOLTS..................005 3-16

SPRING BOLT INSPECTION .......... cece enter ee eens 3-17

SPRING ADJUSTMENT ............ 00. cece tence tere e erences 3-17

MAIN FRAME PINS............ 002: ec cece eee t ee eee e eee eae 3-18

EXTERNAL MAIN FRAME PIN BUSHINGS..............

000. cece ee eee eee 3-18

MAIN FRAME SEAT .......... 000s cece eee eee eee e eens 3-18

7 FT. SUPER HEAVY DUTY CRUSHER SEAT LINER

 ADJUSTMENT
RING PIN A NOE
COVER

GREASE
FITTING
Sw) (ey
ey,

nm

-'7 DUST COLLAR

e SEAL
ae
ro)
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\a cate|
\
(Tite

OCG \/

LOWER \ fH
SPRING ae:
SEGMENT EE

ARM OUTER
GUARD ECCENTRIC
BUSHING
MAIN
FRAME
PIPE PLUG
1/32 f MAIN
GASKET FRAME
 Section 3
MAIN FRAME, ADJUSTMENT RING AND
SPRING RING ASSEMBLIES

DESCRIPTION ASSEMBLY INSTRUCTIONS

This section covers the main frame, adjustment ring GENERAL
and spring assemblies.
In most instances, these components will be
The main frame, which is securely bolted to a foun-
shipped already assembled. However, in some rare
dation, transmits the crushing force to the founda-
cases, shipping restrictions or space limitations
tion and provides a rigid support for the remaining may require that the unit be disassembled Com-
crusher components.
plete procedures, for assembling the main frame
A main frame liner welded to the inside of the frame components, are given in the MAINTENANCE por-
as well as arm guards are replaceable and protect tion of this section.
the inside of the frame from wear. An adjustment
ring, which seats on a conical machined surface at
the top of the main frame is threaded on its inside CRUSHER INSTALLATION
diameter to provide the means of adjusting the
bowl assembly. If the main frame assembly or the entire Crusher is
to be placed on a concrete foundation, the main
Hydraulic cylinders or heavy duty helical compres- frame must be grouted into place. There are two
sion springs seating against the underside of the types of grouting material in usage today; these are
frame and bolted to the adjustment ring allows concrete and epoxy. Concrete has been used al-
tramp iron to pass through the crushing cavity with- most exclusively as grouting material over the past
out damage to the Crusher. When hydraulic cylin- years, however, more recently, concrete grout has
ders are used and excessive forces created by been replaced by epoxy in most crusher installa-
improper operation or by passing non-crushable tions.
material will cause the adjustment ring to lift which
in turn will pull the cylinder rods within the hydraulic The preparations, properties of concrete, and equip-
cylinders upward. Oil will be displaced from the ment involved, in most cases makes epoxy a pre-
upper cylinder chamber into the accumulators fur- ferable material. Epoxy is a tough, resilient, vibra-
ther compressing the nitrogen gas within the accu- tion resistant epoxy material which is readily avail-
mulator. Once the overload or tramp iron has able in kit form in various sizes. Each kit consists of
passed and crushing forces normalize, the com- an epoxy and a hardener that are mixed together
pressed nitrogen will return the oil to the cylinder, right at the job site; the simple directions are includ-
the cylinder rods will retract, and the adjustment ed in each kit. The use of epoxy requires no special
ring will again seat itself on the main frame. equipment, preparation or handling. Once mixed,
the epoxy must be poured without delay, but subse-
When springs are used and a non-crushable object
quent mixes can be poured at any convenient time.
enters the crushing cavity and spring pressure is
exceeded, the springs compress and permit the To install either the main frame assembly or
adjustment ring to lift, allowing such material to be the entire Crusher on a concrete foundation or to
readily discharged. Main frame pins projecting from grout a steel structure to a concrete slab proceed
the top of the frame prevent the adjustment ring as follows:
from rotating and serve as a guide to return the ring
to its original position when the adjustment ring lifts 1. Torch cut four large diameter washers from 3/8"
or tilts. (10 mm) plate and place them over the founda-
tion bolts.
The outer eccentric bushing, which is locked to the
frame, provides the bearing surface for the eccen- 2. Attach a suitable sling or slings through the
tric assembly. A main frame cap bolted to the bot- holes in the four ribs at the lower corners of the
tom of the frame gives access to this portion of the main frame flange. On the 7 Ft. super heavy
Crusher as well as provides the support for the duty Crusher lifting hooks near the top of the
thrust bearing and eccentric assemblies. frame are to be used for this purpose.

3-1
 will prevent the wood strips from sticking to the
A wornne grout. All joints and seams must be sealed with
a caulking compound to prevent leakage of the
DO NOT USE THE LIFTING HOOKS ON epoxy during pouring.
THE ADJUSTMENT CAP FOR LIFTING THE
7. Mix and pour the epoxy following instructions
ENTIRE MACHINE. THESE HOOKS ARE
on the kit. When cold temperatures prevail,
NOT STRONG ENOUGH TO LIFT THE warm the epoxy and crusher flange to 65°-80°F
ENTIRE CRUSHER. SERIOUS PERSONAL (18°-27°C). For best results the epoxy kits
INJURY OR SEVERE DAMAGE TO THE should be stored in a warm area before mixing.
CRUSHER COULD RESULT. To prevent air entrapment under the Crusher,
pour the epoxy from one place at a time, allow-
3. Carefully lift the main frame and lightly oil the ing the epoxy to cover an area of approximately
underside of the frame flange to prevent adhe- 2 feet (.6 meters) on either side of the pouring
sion of the epoxy to the Crusher. spot. Then move to a position where the previ-
. Place the main frame in position on the founda- ous pour flow has stopped and pour again.
tion on top of the 3/8" (10 mm) thick washers. Continue this procedure until grouting is com-
pleted.
When using concrete grout place the main
frame on hardwood blocks positioned beneath DO NOT POUR EPOXY INTO MORE THAN
each of the four corners of the frame rather ONE AREA AT A TIME.
than on the steel washers. Wood is used in this For the average number of pounds required to
instance as concrete grout shrinks when it sets grout the Crusher with either 1/2" or 3/4" (12
and the wood will shrink with the concrete. mm or 20 mm) of grout thickness refer to the
The blocks should support the main frame table EPOXY GROUTING REQUIREMENTS.
approximately 2" to 2-1/2" (560 mm to 60 mm) 8. After the grouting has hardened, tighten the
above the top of the concrete foundation to Crusher firmly to the foundation.
allow for the proper thickness of concrete.
9. When a Crusher is mounted on a steel struc-
The surface of the foundation where the con- ture the Crusher is simply leveled and tight-
crete grouting will be poured, should be left ened firmly to the structure.
rough and be carefully cleaned before grouting.
This surface should be thoroughly saturated POUNDS (KG) OF EPOXY*
with water and kept wet to prevent any rapid CRUSHER SIZE REQUIRED FOR:
absorption of water from the grout mix. How- 12" (12 mm) | 3/4" (20 mm)
ever, remove any excess water from the top of GROUT GROUT
the foundation just prior to pouring the grout.
4-1/4 Ft. 110 (50) 165 (75)
Use a grout mixture which contains a non-
shrink additive to minimize shrinkage. 5-1/2 Ft. 176 (80) 265 (120)
. Level the Crusher by inserting “C” shaped 7 Ft. 187 (85) 286 (130)
shims around the foundation bolts on top of the * All quantities include enough grout for an extra
steel washers. This will give approximately 1/2" 1/2" (12 mm) between forms and frame flange. If
to 3/4" (12 mm to 20 mm) grout area between is irregular, increase amounts by
the foundation
the main frame and the foundation, which is the 10%.
desired epoxy thickness.
the inside and EPOXY GROUTING REQUIREMENTS
. Next, construct a form around
outside of the main frame flange that will con-
tain the epoxy during pouring. Use 1" x 2" (25 MAINTENANCE
mm x 50 mm) wood furring strips for the forms.
MAIN FRAME LINER AND ARM GUARDS
Locate and fasten the furring strips 1/2" (12
mm) from the outside of the crusher flange, on When the Crusher is “down” for a liner change,
the inside, place the forms against the side of inspect the main frame liner and arm guards for
the foundation and the underside of the main wear.
frame flange. See the illustration GROUTING
WITH EPOXY. All forms must be thoroughly With the head removed from the Crusher, lower the
waxed with 3 coats of ordinary paste wax. This arm guards from the top onto the main frame arms.
 OUTLINE OF EPOXY GROUT
CRUSHER AS IT APPEARS AFTER

N
WOOD FORMS ARE
REMOVED. = FOUNDATION
( BOLT
WOoD FORMS
1
|

FOUNDATION

GROUTING WITH EPOXY

An arm guard could be slipped in place from be- 1. Drill a series of 3/8" (10 mm) diameter holes,
neath the Crusher while the head is in place but spaced 4" (100 mm) apart, in the wall of the
with considerable difficulty. outer eccentric bushing. See the illustration
REMOVING BUSHING LOCK. Drill the holes to
A replacement main frame liner is sometimes
a depth corresponding to the shoulder width of
shipped in sections, making the installation of the
the replacement bushing.
liner a somewhat easier task. Should a liner be
received in one piece, the ends of the liner must be 2. Hold a steel bar at a 45° angle against the out-
overlapped until the liner is smaller in diameter side of the bushing and break the top of the
than the adjustment ring threads. Clamp the over- bushing into pieces by hitting the steel bar with
lapped ends tightly together with heavy duty “C” a sledge hammer.
clamps, lower the liner in place in the frame and
3. Break the top of the bushing away from the
remove the clamps, allowing the liner to spring
bushing lock all around the circumference of
back to its original shape. The height at which the
the bushing, cleaning out all chips and frag-
liner is to be welded inside the frame is readily
ments.
noticeable by the remaining weld from the old liner.
4. Remove the main frame cap at the bottom of
OUTER ECCENTRIC BUSHING REMOVAL the frame to give access to the bushing.
The outer eccentric bushing is held in the main
5. Cut a steel plate, to a diameter slightly smaller
frame by a bushing lock at the top. This lock must
than the main frame bore. A plate 2" (50 mm)
be removed before the bushing can be pressed
thick is required; several plates of thinner mate-
out. It is by far easier to break out the top of the
rials can be used to obtain this 2" (50 mm)
bushing than it is to remove the lock. Should it be
thickness. Place the plate against the bottom of
desired to remove a bushing in one piece, the
the bushing as shown in the illustration
bushing lock must be drilled and chipped out. Even
REMOVING OUTER ECCENTRIC BUSHING.
the smallest piece of broken zinc or epoxy locking
compound must be cleaned out before pressing A HEX NUT CAN BE WELDED TO THE TOP
can begin. If the outer eccentric bushing is to be OF THIS PLATE AND WITH AN EYEBOLT
removed for replacement, proceed as follows: THREADED INTO THE NUT, CONNECT THE

3-3
 BREAK OUT MAIN FRAME OUTER
AS SHOWN ECCENTRIC
DRILL HOLES BUSHING
AROUND
CIRCUMFERENCE

_ BLOCKING
e
5 HYDRAULIC “|
“4 JACK
OUTE
ECCENTRIC
BUSHING
sey X 8
STEEL
REMOVING BUSHING LOCK PLATE

EYEBOLT TO A CRANE OR SUITABLE REMOVING OUTER ECCENTRIC BUSHING

HOIST. PULLING FROM THE TOP, WHILE
JACKING FROM THE BOTTOM, WILL HELP
Aliso check the bore to be sure that it has not worn
CONSIDERABLY IN REMOVAL.
oversize or shrunk undersize, due to the presence
. Then cut a plate the same diameter as the of heat. Measure the main frame bore from bottom
main frame cap also from 2" (50 mm) material. to top.
Torch cut three holes in the plate the same
Removing the main frame cap will expose an area
diameter and on the same bolt circle as those
in the bore that has been unaffected by wear or
in the main frame cap. The three holes must be
heat, since the cap projects about 1/2" (12 mm)
spaced 120° apart. | inside. Using an inside micrometer placed in the
. Suspend the plate from the bottom of the main bore, about 1/4" to 3/8" (6 mm to 10 mm) from the
frame by three long studs. Place a 50 ton bottom of the frame, will give the original bore
hydraulic jack between this plate and the one diameter.
placed against the bottom of the bushing. A Once this dimension has been recorded measure
substitute arrangement can be utilized by plac- the entire length of the bore, checking about every
ing a steel rail or beam across the discharge 6" (150 mm). At the same time check for out-of-
compartment to provide a support for the jack. roundness by swinging the micrometer 90° to the
. Force the bushing from the frame by exerting first measurement and measure this diameter. It
pressure with the jack and adding blocking must be pointed out that on the 7 Ft. heavy and
whenever necessary. super heavy duty Crushers, a stepped outer eccen-
tric bushing is used, making the measuring some-
INSPECTION OF MAIN FRAME BORE what complicated. The lower bore is to be mea-
|
Before installing a new outer eccentric bushing, sured as mentioned previously. Then add 0. 062
inspect the main frame bore for scoring or rough inch to the lower bore dimension, this would be the
spots, these must be my out. correct dimension for the middle bore. Add 0.125
inch to the lower bore for obtaining the correct
upper bore dimension. A warnine
THE STEPPED BUSHING ON THESE LARGER USE HEAVY, WELL INSULATED GLOVES
MACHINES PERMITS THE BUSHING TO SLIDE WHEN HANDLING THE DRY ICE
TWO-THIRDS OF THE WAY INTO THE FRAME HANDLING DRY ICE WITHOUT PROTEC-
BEFORE COMING INTO ANY POSSIBLE INTER- TION COULD RESULT IN SEVERE BURNS.
FERENCE, CONSEQUENTLY AIDING IN INSTAL-
LATION. Wrap the outside of the bushing with several
layers of burlap to prevent the external build up
With a bore that has shrunk unevenly, the high
of frost which would hinder the installation of
spots can be ground off to the correct diameter. If the bushing in the main frame. Wrapping also
the bore has pulled in to the extent where hand helps to achieve a more thorough cooling.
grinding is no longer practical, the entire main
frame bore must be machined out to the original DO NOT USE THIS METHOD OF INSTALLA-
diameter. Also, in case the frame bore has worn TION TO OVERCOME A MAIN FRAME BORE
out-of-round, it should be remachined concentric, THAT HAS CLOSED-IN.
even though the diameter would be increased. . Measure the outside diameter of the bushing
Remachining drawings are available showing the and the bore of the main frame to determine
correct bore dimensions and their tolerances. when the bushing has cooled sufficiently.
When a bore has either been worn or machined
. Lift the bushing into position and center it in the
oversize, contact the factory for the purchase of a
top of the main frame bore. Use the line on the
special oversize bushing, giving remachined bore
side of the bushing for aligning the bushing with
dimensions so that the bushing can be machined to
the cored pockets in the frame.
the proper tolerances.
OUTER ECCENTRIC BUSHING 5. Quickly lower the bushing into the main frame.
INSTALLATION 6. The top of the bushing must be flush with the
Outer eccentric bushings are machined to provide top of the frame when properly installed.
a metal-to-metal or a few thousandths loose fit in . Pour the bushing lock. Follow the procedure as
the main frame bore. Should a bushing have such a outlined under POURING THE BUSHING
metal-to-metal fit or be out of round because of LOCK.
improper storage or shipment, the following proce-
dure using dry ice is recommended. QUANTITY OF DRY
To install a replacement outer eccentric bushing, CRUSHER SIZE ICE IN POUNDS
using dry ice proceed as follows: : (KILOGRAMS)
1. Paint or scribe a line down the side of the bush- 4-1/4 Ft. 250 (115)
ing starting from one of the cast lugs. 5-1/2 Ft. 400 (180)
THE OUTER ECCENTRIC BUSHING ON THE 7 Ft. 600 (270)
7 FT. CRUSHER HAS CORED POCKETS
RATHER THAN CAST LUGS TO FORM THE DRY ICE REQUIREMENTS
BUSHING LOCK WITH THE FRAME.
If dry ice is not available an alternate method using
. Pack the bore of the replacement bushing with ramming can be employed. To install the bushing
dry ice to shrink the bushing. The table DRY by ramming, proceed as follows:
ICE REQUIREMENTS gives the approximate
1. Paint or scribe a line down the side of the bush-
amount of dry ice necessary to adequately
ing starting from one of the cast lugs.
pack the inside of the bushing providing some
sort of filler is used in the center of the bushing. THE OUTER ECCENTRIC BUSHING ON THE
As an example, a 6" x 6" wooden timber leaves 7 FT. CRUSHER HAS CORED POCKETS
sufficient area around it in a 4-1/4 Ft. outer RATHER THAN CAST LUGS TO FORM THE
eccentric bushing to allow for an adequate BUSHING LOCK WITH THE FRAME.
amount of dry ice to shrink the bushing.
. Lift the bushing into position and center it in the
Cooling time should be approximately two top of the main frame bore. Use the line on the
hours on all size bushings.

3-5
 side of the bushing for aligning the bushing with To pour an outer eccentric bushing lock, proceed
the cored pockets in the frame. as follows:
3. Place the steel plate used in removal, on top of 1. The top of the bushing must be flush with the
the bushing and force the bushing into the top of the frame when properly installed.
frame by ramming against the top of the steel
The bushing and frame and, if used, the epoxy
plate.
locking compound should be at room tempera-
4. The top of the bushing must be flush with the ture prior to pouring — 60° to 90°F (16° to
top of the frame when properly installed. 32°C).
5. Pour the bushing lock. Follow the procedure as 3. When using epoxy locking compound, the outer
outlined under POURING THE BUSHING eccentric bushing is prepared by forming a
LOCK. dam of putty around the top of the bushing as
shown in the illustration POURING EPOXY
LOCK. This putty dam helps direct the flow of
POURING THE BUSHING LOCK the locking compound into the opening be-
tween the bushing and frame. It also prevents
The cast lugs around the top of the outer eccentric
the epoxy from spilling down the inside of the
bushing which engage the cored pockets in the
bushing.
main frame are dovetailed to provide a lock when
the remaining space between the lugs and the
A warnne
frame is filled with epoxy locking compound or zinc.
This lock prevents the bushing from moving. CAREFULLY FOLLOW THE INSTRUC-
THE OUTER ECCENTRIC BUSHING ON THE 7 TIONS AS WELL AS THE PRECAUTIONS
FT. CRUSHER HAS CORED POCKETS RATHER THAT ARE PRINTED ON THE INDIVIDUAL
THAN CAST LUGS TO FORM THE LOCK WITH CANS OF EPOXY LOCKING COMPOUND
THE FRAME. BEFORE MIXING AND POURING.
Application of epoxy locking compound requires no 4. Refer to the table, LOCKING MATERIAL RE-
special training or experience. Melting and pouring
QUIREMENTS for the number of locking com-
equipment and special protective gear are eliminat- pound kits or the approximate amount of zinc to
ed because the locking compound is mixed and
prepare.
poured at room temperature.

THE USE OF EPOXY BACKING MATERIAL 1S

NOT RECOMMENDED IN THIS APPLICATION.
oar eee
the main frame
bushinga
7 FEET
7 FEET SUPER
CRUSHER SIZE 4-1/4 FEET 5-1/2 FEET HEAVY HEAVY
DUTY DUTY
Volume Required
Quantity of Cubic Inches 75 (1229) 160 (2622) 45 (737) 45 (737)
Locking Material (cm?)
Required for Fine in
OuterBushing
Eccentric Pounds
;
20 (9) 42 (19) 12 (5.4) 12 (5.4)
(Kilograms)
; Volume Required
Quantity of Cubic Inches 70 (1147) 65 (1065) 80 (1311) 80 (1311)
Locking Material (cm’)
Required for Zino in
oe ushing Pounds 18 (8.2) 47 (7.7) 21 (9.5) 21 (9.5)
(Kilograms)

LOCKING MATERIAL REQUIREMENTS

 6. After the locking material has fully hardened,
A warwine grind off flush any excess material.

WHEN POURING THE BUSHING LOCK REPLACING THE BUSHING LOCK

WITH 800°F (425°C) MOLTEN ZINC, GOG- If the outer eccentric bushing ever becomes loose,
GLES AND PROTECTIVE CLOTHING MUST repouring of the lock is all that is required. Drill,
BE WORN. CONTACT WITH MOLTEN ZINC chip and clean out all the zinc or epoxy locking
WILL RESULT IN SERIOUS BURNS. compound. Reset the bushing, if necessary, and
then repour the lock.

USE A 1"x 2" STEEL BAR BOLTED ACROSS THE

TOP OF THE OUTER ECCENTRIC BUSHING
TO HOLD THE BUSHING FLUSH WITH THE
TOP OF THE FRAME UNTIL THE BUSHING IS
LOCKED INTO THE MAIN FRAME

BUSHING
LOCK

HEX
HEAD
CAPSCREW

OUTER
MAIN FRAME ECCENTRIC
BUSHING

POURING EPOXY LOCK

3-7
CAVITY RELEASE CYLINDER REMOVAL tem pressure gauge. If the system looses pressure
and requires repeated repressurizing, an oil leak
A leaking cylinder is a condition which requires
should be suspected. To remove a leaking cylinder
immediate attention. A leaking cylinder either exter-
for replacement or repair, proceed as follows:
nally around the piston rod or past the gland seals
or past the piston of the cylinder will result in exces- 1. Perform a clearing operation as stated in Sec-
sive adjustment ring movement. External leakage tion 11 under the heading CLEARING THE
will be visible by oil seepage around the piston rod CRUSHER but DO NOT repressurize the cavity
area at the top of the cylinder or at the junction release cylinders.
between the cylinder and the gland. An external
2. Shut the power OFF to the power unit motor
leakage, will show itself at the cavity release sys-
and LOCK OUT the motor. Then follow the

hh UPPER AND LOWER

SPHERICAL WASHER
i}
1

___.. UPPER AND LOWER

aS ee ee ee SPHERICAL WASHER

' i)

law aw ELBOW
NSE NEE

__ CVLINDER
CAPSCREW |
LOCKWASHER !
D NUT
AN HOSE
PL Ly : _t_

| Lae @ CAPSCREW
ACCUMULATOR _———L_| dy & ; LOCKWASHER
BRACKET $7 AND PLAIN
| WASHER
a ee
ACCUMULATOR
1

P
prised ELBOW
cane ltt
a i __ ,
© (an, AON © Bl A
MANIFOLD

CAVITY RELEASE CYLINDER ASSEMBLY

7 FT. HEAVY DUTY
 DEPRESSURIZING paragraphs in Section 12. 11. See Section 12 for cavity release cylinder
This will vent the pressurized oil at the accumu- repair instructions.
lator side of the cylinders back to tank. Make
7 FT. SUPER HEAVY DUTY (SEE ILLUSTRATION
sure the pressure gauge in the CAVITY RE-
CAVITY RELEASE CYLINDER ASSEMBLY —
LEASE PRESSURIZE circuit reaches zero (0
7 FT. SUPER HEAVY DUTY)
psi).

A waanne UPPER AND LOWER

SPHERICAL WASHER
DO NOT UNDER ANY CIRCUMSTANCES
ATTEMPT TO DISCONNECT ANY OF THE
HYDRAULIC CONNECTIONS WITHOUT
FIRST INSURING THAT THE SYSTEM HAS
BEEN DEPRESSURIZED. DISCONNECT-
ING A HOSE WHILE UNDER HIGH PRES-
SURE IS DANGEROUS DUE TO THE HIGH
VELOCITY OF THE ESCAPING OIL AND
DUE TO THE POSSIBILITY OF BEING
STRUCK BY THE FREE END OF A WHIP-
PING HOSE.
- 7" UPPER AND
7 FT. HEAVY DUTY (SEE ILLUSTRATION CAVITY (— LOWER
RELEASE CYLINDER ASSEMBLY — 7 FT. HEAVY SPHERICAL
DUTY) WASHER

3 . Disconnect the release circuit hose fitting at the

accumulator manifold and cap or plug all fit- HOSE
tings, hoses, etc. CYLINDER
Attach a sling around the accumulator and to a
suitable lifting device.
. Remove the accumulator mounting bracket
ACCUMULATOR
capscrews. BRACKET
. Then disconnect the two large diameter hoses
from the elbows at the TOP of each cylinder.
| p
Alternately back out the hose swivel connec-
tions a little at a time to keep the manifold par- XQ CAPSCREW
allel with the main frame flange. Continue to
LOCKWASHER
AND PLAIN
alternately back out the hose connections until _ WASHER
the hoses are free and the accumulator is sup-
ported by the sling. Lower the accumulator ACCUMULATOR
being careful not to damage any of the hoses
or fittings.
CAVITY RELEASE CYLINDER ASSEMBLY
. Screw a lifting eye into the end of the cylinder 7 FT. SUPER HEAVY DUTY
rod and attach a sling.
. Raise and block the cylinder enough to expose 1. Disconnect the release circuit hose fittings at
the flats on the cylinder rod just below the nut. the tee on the cavity release cylinder assembly
and plug all fittings, hoses, etc.
. Using a wrench on the rod flats, heat the nut to
break the Loctite bond and remove the nut. 2. Attach a sling around the cylinder and to a suit-
able lifting device.
10. Lift the cylinder clear of the Crusher while slid-
ing the piston rod down through the hole in the 3. Raise and block the cylinder assembly enough
adjustment ring. Be careful not to damage the to expose the flats on the cylinder rod just
threads on the rod or the fitting. below the nut.

3-9
 . Using a wrench on the rod flats, unscrew the 6. After the cylinder is installed and all connec-
nut. tions completed, bleed the system to remove
. Lift the cylinder assembly clear of the Crusher any entrapped air. Then pressurize the system
while sliding the piston rod down through the and check for leaks. See Section 12 for instruc-
hole in the adjustment ring. Be careful not to tions on charging, bleeding and checking the
damage the threads on the rod. system.

. Remove the accumulator bracket and accumu- ACCUMULATOR REPLACEMENT

lator from the cylinder. A faulty accumulator, either the nitrogen gas escap-
7. See Section 12 for cavity release cylinder re- ing to atmosphere or a leak in the internal bladder,
pair instructions. is a serious condition that requires immediate at-
tention. In either instance, the accumulator will
CAVITY RELEASE CYLINDER completely fill with oil. Since the gas or pre-charge
INSTALLATION has escaped or leaked from the bladder, the tramp
Install a new or repaired cylinder as follows: release arrangement will not function properly. Oil
which is normally displaced from the tramp release
7 FT. HEAVY DUTY
cylinders into the accumulators when uncrushable
1. Pull the piston rod out of the cylinder about 4" material or overloads are encountered, cannot
(100 mm) and install the special spherical compress the nitrogen gas within the accumulator
washers. bladders, thereby creating excessive forces within
. Connect a lifting device to the cylinder so that it the crushers components.
will hang vertically with the piston rod end up- The accumulator gas pressure should be checked
ward and the hose port facing outward. Lift the every 200 hours of every month. If the accumulator
cylinder while sliding the rod up through the gas pressure is not at its normal pre-charge level or
hole in the adjustment ring. is unable to sustain the recommended level of nor-
. Install the special spherical washers, apply mal operating pressure, the accumulator should be
Loctite to the threads and turn the hex nut on removed and replaced. Replace a faulty accumula-
the piston rod until the nut is 1/4" (6 mm) below tor as follows:
the threaded end of the rod. 1. Shut the power OFF to the power unit motor
. Reinstall the accumulator and connect all hy- and LOCK OUT the motor. Then follow the
draulic and accumulator hoses. DEPRESSURIZING paragraphs in Section 12.
This will vent the pressurized oil at the accumu-
. After the cylinder is installed and all connec- lator side of the cylinders back to tank. Make
tions completed, bleed the system to remove
sure the pressure gauge in the CAVITY RE-
any entrapped air. Then pressurize the system
LEASE PRESSURIZE circuit reaches zero (0
and check for leaks. See Section 12 for instruc-
psi).
tions on charging, bleeding and checking the
system.
A WARNING
7 FT. SUPER HEAVY DUTY
DO NOT UNDER ANY CIRCUMSTANCES
1. Pull the piston rod out of the cylinder about 4"
ATTEMPT TO DISCONNECT ANY OF THE
(100 mm) and install the special spherical
HYDRAULIC CONNECTIONS WITHOUT
washers.
FIRST INSURING THAT THE SYSTEM HAS
. Install the accumulator and accumulator brack- BEEN DEPRESSURIZED. DISCONNECT-
et to the cylinder. ING A HOSE WHILE UNDER HIGH PRES-
. Connect a lifting device to the cylinder assem- SURE IS DANGEROUS DUE TO THE HIGH
bly so that it will hang vertically. Lift the cylinder VELOCITY OF THE ESCAPING OIL AND
assembly while sliding the rod up through the DUE TO THE POSSIBILITY OF BEING
hole in the adjustment ring. STRUCK BY THE FREE END OF A WHIP-
PING HOSE.
. Install the special spherical washers and turn
the hex nut on the piston rod until the nut bot- 2. Remove the valve guard from the accumulator
toms against the shoulder on the rod. and then the valve cap and washer from the
. Connect all hydraulic hoses. valve stem. Using the charging and gauging
 assembly furnished with the tools, mount the 7. Pre-charge the replacement accumulator ac-
gauging assembly with the 10' hose removed, cording to the instructions in the CHECKING
to the accumulator. First, turn the T-handle on PRE-CHARGE PRESSURE AND CHARGING
the air chuck OPEN, until the handle can no THE ACCUMULATOR paragraphs in Section
longer be turned. The screw on the bottom of 12. The accumulator can be damaged if oil
the bleeder valve must be CLOSED. Then pressure is applied before correctly pre-charg-
thread the swivel portion of the air chuck onto ing with nitrogen.
the accumulator’s gas valve stem. Tighten the
. After the accumulator is installed and all con-
swivel hand tight and then tighten an additional
nections completed, bleed the system to re-
quarter turn to compress the sealing washer in
move any entrapped air. Then pressurize the
the swivel to prevent gas leakage.
system and check for leaks. See Section 12 for
DO NOT OVERTIGHTEN THE SWIVEL. EX- instructions on bleeding and pressure testing
CESS TORQUE CAN TWIST OFF THE VALVE the hydraulic system.
STEM AND/OR DISTORT THE COPPER
SEALING WASHER IN THE SWIVEL CAUS- SPRING ASSEMBLIES
ING LEAKAGE.
The spring cluster assemblies ordinarily will not
Turn the T-handie on the air chuck DOWN until require any maintenance. However, it may become
the shaft inside the chuck fully depresses the necessary to remove the springs in order to main-
valve core in the gas valve on the accumulator. tain other crusher components.
Then slowly OPEN the screw at the bottom of
the bleeder valve until the nitrogen gas begins
to escape from the threaded opening in the A WARNING
side of the gas charging valve. Allow all of the
SPRING DISASSEMBLY/ASSEMBLY IS
gas to escape to the atmosphere. When the
EXTREMELY HAZARDOUS. FOLLOW ALL
pressure gauge on top of the gas charging
INSTRUCTIONS WITH CARE.
valve “reads” 0 psi, the accumulator is consid-
ered empty. Remove the gauging assembly
There are two different types of spring arrange-
from the accumulator and proceed to Step 3.
ments over the countershaft box housing, which we
. Remove the hex nuts, lockwashers and cap- will refer to as offset and centered, each of which
screws from the clamp segment around the requires a different procedure for disassembling
accumulator body and remove the clamp seg- and assembling. The offset spring arrangement will
ment. Attach a sling around the accumulator have a spring cluster on each side of the counter-
and to a suitable lifting device. shaft box housing. The centered spring arrange-
ment will have one spring cluster, directly over the
. Position a large pipe or adjustable wrench
countershaft box housing. See the illustrations
around the flats of the accumulator and turn the
OFFSET SPRING ARRANGEMENT and CEN-
accumulator counterclockwise until it is free.
TERED SPRING ARRANGEMENT. Because of the
. Carefully position the replacement accumulator equipment involved, these spring clusters are to be
being careful that the accumulator is going on removed last and installed first.
straight and is not cross threaded. Tighten
AFTER REMOVING OR INSTALLING ONE
firmly.
SPRING CLUSTER, THE NEXT CLUSTER TO BE
. Install the clamp segment and attaching hard- DISASSEMBLED OR ASSEMBLED IS THE ONE
ware. DIRECTLY OPPOSITE. STAGGERING IN THIS

7 FT.
CRUSHER SIZE 4-1/4 FT. 5-1/2 FT. 7FT.
HEAVY SUPER
Sea
DUTY DUTY
Jack Capacities in
Tons (2000 Lbs.) 20 30 30 50
JACK CAPACITIES

3-11
MANNER WILL ALLOW THE ADJUSTMENT RING 9. Removing the remaining springs around the
TO SEAT EVENLY ON THE MAIN FRAME. circumference of the main frame requires the
use of two hydraulic jacks, simply to balance
The correct jack capacity for lowering or raising one
the cluster. Place a jack on the frame flange
spring cluster can be determined by referring to the
just under each side of the lower spring seg-
table, JACK CAPACITIES.
ment and remove the clusters by unscrewing
OFFSET SPRING ARRANGEMENT the spring bolt nuts and lowering the jacks.
DISASSEMBLY
To remove the springs, spring bolts and spring seg- OFFSET SPRING ARRANGEMENT
ments, proceed as follows: ASSEMBLY
1. Place a hydraulic jack on the main frame flange To install the springs, spring bolts and spring seg-
at one side of the countershaft box housing. ments, proceed as follows:
1. Place a hydraulic jack on the main frame flange
A warnine and block where necessary to make the jack
THE JACK SHOULD BE SHIMMED SO THAT IT solid and level.
IS SOLID AND LEVEL. A LOGGING CHAIN OR . Place a 1" x 3" x 36" steel bar across the top of
STEEL CABLE SHOULD BE WRAPPED the jack and the main frame. See the illustra-
AROUND THE ENTIRE CIRCUMFERENCE OF tion OFFSET SPRING ARRANGEMENT.
THE MAIN FRAME AND JACKS TO HOLD THE
JACKS IN POSITION. SERIOUS PERSONAL . Place the lower spring segment on top of the
INJURY MAY RESULT IF A JACK SHOULD bar in a position so that the spring bolt holes
SLIP. extend on each side of the bar enough to en-
able the hex nuts to be turned on. Position the
2. Place a 2" x 3" x 36" steel bar across the top of springs on top of the lower spring segment.
the jack and the main frame as shown in the
. Carefully lower the spring bolts through the
illustration OFFSET SPRING ARRANGEMENT.
adjustment ring and spring cluster assembly.
3. Place a 2" x 3" x 3" steel block on the bar mid- Do not drop the bolts in, as the threads could
way between the middle spring bolt and the be damaged, making the installation of the nuts
inner bolt and relieve the spring pressure on difficult.
the bolts by jacking.
. Raise the spring cluster by jacking and turn the
4. Slowly unscrew the spring bolt nuts while low- outer spring bolt nut up tight against the spring
ering the jack. Do not remove the spring bolt segment as the springs are being compressed.
nuts at this point.
. Lower the jack and insert a 1" x 3" x 3” steel
5. Lower the jack and slide the 2" block on the bar block between the steel bar and the segment,
mid-way between the outer spring bolt and the wedge the block mid-way between the middle
middle spring bolt. Raise the jack to relieve the bolt and the inner bolt.
pressure on the bolts and slowly unscrew the
outer spring bolt nut. . Raise the jack until the segment is level, turn-
ing up the remaining nuts against the segment
6. Lower the jack and replace the 2" thick bar with as the springs are being compressed.
a 1" x 3" x 36" bar, then place a 1" x 3" x 3"
block on the bar mid-way between the middle . Lower the jack and replace the 1" thick bar with
bolt and the inner bolt. Raise the jack to relieve a 2" x 3" x 36" bar, then place a 2” x 3" x 3"
pressure and slowly unscrew the remaining block on the bar mid-way between the outer
spring bolt nuts. spring bolt and the middle spring bolt.

7. Lower the jack and remove only the block, then . Raise the jack again and turn the outer spring
raise the jack once again and remove the bolt nut up tight as the springs are com-
spring bolt nuts entirely. pressed.
8. Slowly lower the jack until all spring pressure 10. Lower the jack and wedge the 2" block on the
has been relieved and remove the spring com- bar mid-way between the middle bolt and inner
ponents. bolt.

3-12
 2" x 3" x
2" x 3" x 3" BLOCK 3" BLOCK

2" x 3" x 36” BAR

[\ 2" x 3" x 36” BAR

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iat
$ | 4

JACK
JACK RAISED JACK JACK RAISED LOWERED
TO RELIEVE LOWERED TO RELIEVE AFTER FURTHER
SPRING AFTER LOOSENING SPRING LOOSENING
PRESSURE NUTS PRESSURE OF NUTS
STEP 1 STEP 2 STEP 3 STEP 4

1"x 3"x 3" BLOCK

\ 1"x 3" x 36” BAR

j.

Neal eke taal VEE [S| PS) PAN

iY

Z
z
Wh

="
Wh

pom
ATT

WN
ca

f
JACK RAISED
Lote WITH BLOCK
JACK RAISED REMOVED TO JACK
TO RELIEVE
AFTER REMOVING RELIEVE SPRING LOWERED
SPRING PRESSURE AFTER REMOVING
PRESSURE CENTER NUT REMAINING NUTS
STEP 5 STEP 6 STEP 7 STEP 8

OFFSET SPRING ARRANGEMENT

3-13
11 . Raise the jack until the segment is again level, lower the springs until the entire spring force is
turning up the remaining nuts tight against the held by the 1-1/2" steel block. Remove the 1"
segment. See SPRING ADJUSTMENT TABLE steel blocks and the spring bolt nuts at this
for correct spring installation length. time.
12. Repeat this procedure with the spring cluster . Move the steel bars outward slightly. Jack the
on the opposite side of the countershaft box spring cluster upwards once again and remove
housing. the 1-1/2" steel block.
13. The remaining spring assemblies are to be . Lower the jacks and remove the special
installed by using two jacks to balance the clus- tapered bars. With all spring pressure relieved,
ter. Place a jack on the frame flange just under the jacks and the spring assembly can be
each side of the cluster. Alternately compress removed. It may be necessary to pry the clus-
the springs and tighten the spring bolt nuts until ter outward with a long section of pipe or heavy
the correct spring installation length is reached. board in order to free it.
CENTERED SPRING ARRANGEMENT . Removing the remaining springs around the
DI SASSEMBLY circumference of the main frame requires the
use of two hydraulic jacks, simply to balance
To remove the springs, spring bolts and spring seg-
the cluster. Place a jack on the frame flange
ments, proceed as follows: just under each side of the lower spring seg-
1 ment and remove the cluster by alternating
. Place a hydraulic jack on the main frame flange
at each side of the countershaft box housing. unscrewing the spring bolt nuts and lowering
the jacks.
A warnine CENTERED SPRING ARRANGEMENT
ASSEMBLY
THE JACK SHOULD BE SHIMMED SO
THAT IT IS SOLID AND LEVEL. A LOG- To assemble the springs, spring bolts and spring
GING CHAIN OR STEEL CABLE SHOULD segments, proceed as follows:
BE WRAPPED AROUND THE ENTIRE CIR-
1. Place the spring cluster assembly in position
CUMFERENCE OF THE MAIN FRAME AND
over the countershaft box housing, then care-
JACKS TO HOLD THE JACKS IN POSI-
fully lower the spring bolts through the adjust-
TION. SERIOUS PERSONAL INJURY MAY
ment ring and spring cluster assembly. Do not
RESULT IF A JACK SHOULD SLIP.
drop the bolts in, as the threads could be dam-
aged, making the installation of the nuts diffi-
. Place a 1" x 3" x 36" steel bar, tapered or cult. See the illustration CENTERED SPRING
wedge shaped at one end, across the top of ARRANGEMENT.
the jack and main frame, as shown in the illus-
tration CENTERED SPRING ARRANGEMENT. . Place a hydraulic jack on the main frame flange
at each side of the countershaft box housing.
. Place a 2" x 3" x 3" steel block on top of each The jack should be blocked so that it is solid
steel bar directly under each edge of the lower and level. Place the special tapered bars, used
spring segment and relieve the spring pressure in disassembly on top of the jacks.
on the bolts by jacking.
. Drive the special bars between the lower spring
. Alternate unscrewing the spring bolt nuts and segment and main frame as far as they will go,
lowering the jacks. Lower the cluster about then raise the spring cluster by jacking under
1/2", the ends of the bars until a 1-1/2" x 3” x 3" steel
. With the spring bolt nuts supporting the cluster, block can be inserted between the lower spring
lower the jacks and replace the 2" steel blocks segment and the frame.
with 1" x 3" x 3" blocks. Then jack the springs . Lower the jacks and thread the spring bolt nuts
upward to relieve the weight, and slowly on the spring bolts.
unscrew the spring bolt nuts and lower the
jacks. . Place 1" x 3" x 3" steel blocks on top of the
bars under each edge of the lower spring seg-
. Insert a 1-1/2" x 3" x 3" steel block between the ment and compress the springs by jacking,
lower spring segment and the main frame and while at the same time tightening the nuts.
 9" xX Q" x q"
1"x3"x 3"
STEEL BLOCK STEEL BLOCK

<
1"x 3"x 36" BAR 1"x 3" x 36" BAR

\ RZ LENS
z
i" \ Spee S NS J

TOU
SUT
aa

Be JA\
RG cach |
JACK LOWERED
‘ BOTH JACKS FOR INSERTING
1" x 3" x 3"
SIMULTANEOUSLY
RAISED TO STEEL BLOCK
RELIEVE SPRING AFTER NUTS
PRESSURE STEP 2 ARE LOOSENED
STEP 1

ma TIOTTTIT |

LL

a
RAISED TO
RELIEVE SPRING
PRESSURE

YS
1-1/2" x 3" x 3" STEEL BLOCK STEP 3

22/2:
MULT

Z=|=:
1 AN

= a Ee Za
“ “al

STEEL BLOCK : : | j

SUPPORTING JACKS RAISED

SPRING PRESSURE * SLIGHTLY TO
FOR REMOVAL OF REMOVE 1-1/2"
SPRING BOLT NUTS STEEL BLOCK
STEP 4 STEP 5

CENTERED SPRING ARRANGEMENT

3-15
 6. Lower the jacks and replace the 1" blocks with glance. This method is much more accurate than
2" x 3" x 3" blocks. Continue jacking until the using a ruled tape measure for checking. Check
springs are compressed to the correct length. each spring cluster for the correct spring length at
See SPRING ADJUSTMENT TABLE. three locations, thereby insuring that the cluster
was not installed in a tilted position.
7. The remaining spring assemblies are to be
installed by using two jacks to balance the clus- Should the installed length be too great or too
ter. Place a jack on the frame flange just under small, repeat the previous steps wherever neces-
each side of the cluster. Alternately compress sary. Once the correct length has been attained,
the springs and tighten the spring bolt nuts until remove the jacking equipment; spring pressure will
the correct spring installation length is reached. hold the spring bolt nuts tightly in place. When all of
the springs have been hung, recheck each ciuster
for the correct installation length.
All size Crushers now use shorter springs in the
DETERMINING CORRECT SPRING
cluster immediately over the countershaft box as a
LENGTH safety measure and for easier installation and re-
At this point it is advisable to check the spring set- moval. The shorter springs can be readily identified
ting. Refer to the SPRING ADJUSTMENT TABLE by measuring the free length of the spring. Refer to
for correct spring installation length for your particu- the SPRING ADJUSTMENT TABLE.
lar Crusher. DO NOT USE THE SHORTER SPRINGS IN THE
* SINCE ONLY THE LATEST DESIGN SPRINGS SAME CLUSTER WITH THE LONGER SPRINGS.
ARE SHOWN IN THE TABLE, CONTACT THE
FACTORY FOR THE CORRECT INSTALLED REMOVING RUSTED OR DAMAGED
LENGTH IF YOUR CRUSHER IS MORE THAN
SPRING BOLTS
SEVERAL YEARS OLD OR IF THE SPRING
LENGTHS ON YOUR CRUSHER ARE DIFFER- Difficulty can be encountered when there has been
ENT THAN THOSE SHOWN. a lot of spring action or when the Crusher has been
exposed to the weather. The threads on the spring
Once this length is known, a spring gauge can be bolts could distort or stretch from continual spring
made in the following manner: take two welding action or corrode when exposed to the elements. If
rods and remove the coating, then cut each rod to
this takes place, torch cutting of the spring bolts
one-half (1/2) the spring installed length. When this
might become necessary.
has been done, take one of these rods and place
one end against the underside of the upper spring
segment or the underside of the main frame where A warnine
applicable. While holding this rod in place, take the EXTREME CARE MUST BE USED WHEN
other rod and place one end of it against the top of REMOVING THE CLUSTERS BY TORCH
the lower spring segment. Whether or not the cor- CUTTING OF THE SPRING BOLTS.
rect length has been reached can then be seen at a

7 FT.
. 7 FT.
HEAVY
SUPER
HEAVY
CRUSHER SIZE 4-1/4 FT. 5-1/2 FT. DUTY
DUTY

Free Length 17-1/2 23-1/2 20 27-1/4 23-1/2 34-1/8 30-1/2

installed Length 15-1/16 22 18-3/4 24-1/4 21-3/4 31 28-1/4
Minimum Working Length 14-13/16 21-3/4 18-1/2 24 21-1/2 30-5/8 28
**For Spring Clusters Over Countershaft Box (All Dimensions Are In Inches)

SPRING ADJUSTMENT TABLE

 The spring clusters are to be raised in the same SPRING ADJUSTMENT
manner as previously described. Compress the
In the crushing of material of ordinary hardness,
cluster about 1/2". This will expose part of the
the springs will not work. If due to abnormal condi-
spring bolt below the segment. These are to be
tions or materials of exceptional hardness, the
torch cut at this point. A logging chain or steel cable
springs work only occasionally, this action need not
wrapped around the entire circumference of the
cause any alarm. Refer to the illustration SPRING
springs and jacks will offer some degree of protec-
ACTION.
tion should the jacks begin to slip when the com-
pression on the cluster is removed. Once the bolts Excessive spring action, such as sustained cyclic
have been torch cut, carefully lower the entire clus- or rhythmic action, indicates a faulty crushing con-
ter still keeping the chain or cable wrapped around dition that should be investigated and corrected
them. As each cluster is removed, take up the slack before any serious damage is done to the Crusher.
on the chain or cable before lowering the next cluster. Irregular feed, excessive fines in the feed, too close
a crusher setting and overloading may be some of
the causes of spring action. The springs should
A warnwe never be further compressed to overcome exces-
sive spring action because added compression of
USE EXTREME CARE IN REMOVING these springs will only impose excessive strain on
SPRING ASSEMBLIES IN THIS MANNER. the Crusher without correcting or eliminating the
SERIOUS PERSONAL INJURY MAY cause of the faulty condition.
RESULT.
Refer to the SPRING ADJUSTMENT TABLE which
shows the correct installed length of the springs for
SPRING BOLT INSPECTION the various size Crushers when compressed for
If the clusters have been taken down in the conven- normal operation. Shown also is the minimum work-
tional manner by simply unscrewing the spring bolt ing length to which the springs can be safely com-
nuts, examine the spring bolts for wear, both at the pressed. All springs, when adjusted, should be the
top of the bolt, where they pass through the adjust- same length.
ment ring and frame, and at the threads on the bot- The springs should never be compressed beyond
tom. Smooth out any nicks or burrs or remove any the recommended minimum length. Should any
rust which would hinder the turning of the nuts abnormal spring difficulty be encountered, the
when reassembling the springs. Replace any bolts problem should be submitted to the factory for sug-
which are permanently damaged. gestions and recommendations.

BOWL fe | ADJUSTMENT ADJUSTMENT RING

= LINER | RING _IN RAISED POSITION

| SPRINGS.
CLOSED SIDE | COMPRESSED

As a piece of tramp iron enters the cavity, the springs allow the bowl and the adjustment ring to rise,
thus preventing damage. Immediately upon passage of the tramp iron, the springs automatically return
the bowl and adjustment ring to the normal operating position.
SPRING ACTION

3-17
 l-
During normal Crusher operation the main frame ADJUSTMENT
and adjustment ring seating surfaces will wear; the RING
more the spring action, the more the wear. As the
EXTERNAL
seating surfaces wear, the adjustment ring moves MAIN FRAME
downward which causes each spring cluster to PIN
lengthen which in turn means the initial spring force ~<A
holding the adjustment ring to the main frame has
been reduced. Therefore, periodically, check the
springs for the correct installed length and readjust
if necessary. CORRECT SPRING LENGTH IS
IMPORTANT!

MAIN FRAME PINS

The main frame pins prevent the adjustment ring
from rotating in respect to the main frame and also
guide the adjustment ring back to its original posi- RETAINING
tion, when the ring lifts, due to tramp iron or packed RING
material. Due to the rotation of the head in respect
to the bowl, the adjustment ring will want to rotate
in the direction of machine rotation. Since this force
will be acting on the adjustment ring in one direc-
tion only, the external main frame pin bushings will
EXTERNAL MAIN FRAME PINS
have a tendency to wear on one side only. Spring
action is the main cause of bushing wear.
MAIN FRAME SEAT
Any wear on the external main frame pin bushing is
Once the spring ring assemblies have been remov-
easily checked since the bushings are readily visi-
ed from the Crusher, the adjustment ring can be lift-
ble at all times.
ed from the main frame to inspect the main frame
Excessive bushing wear will result in a concentra- seat for wear. Due to irregularity in feed to a Crush-
tion of wear on the spring bolts in the area where er and the slight rubbing action between the adjust-
the bolt passes through the main frame. The exter- ment ring and main frame seat, there is a certain
nal main frame pin bushings should be replaced amount of wear. Should there be an excessive
when they show signs of excessive wear. Since amount of spring action, this wear could be in-
excessive wear is unusual, the main frame pins will creased.
rarely require replacement.
As standard equipment on ail 7 Ft. Crushers, a
EXTERNAL MAIN FRAME PIN BUSHINGS bronze inner main frame seat liner is welded to the
frame as shown in the illustration MAIN FRAME
To replace the external main frame pin bushings, SEAT LINERS.
refer to the illustration EXTERNAL MAIN FRAME
PINS and proceed as follows: The use of a bronze alloy which forms the seating
surface for the adjustment ring of these machines,
1. Lower, but do not remove, the spring clusters provides a replaceable wearing surface. The bronze
as described under SPRING ASSEMBLIES. alloy being of a softer metal than either the frame or
2. Rotate the adjustment ring slightly to center the the ring does the wearing.
main frame pin in the bushing. Seat liners can be provided on the other size Crush-
ers, but at an additional cost. The smaller size
Once the pin is centered, remove the bushing
Crushers are not subjected to the same type of
by first removing the retaining ring and then
hard use, except in extreme cases, as the larger
prying the bushing out.
machines, thereby not warranting the need for seat
Simply slide the new bushing into the adjust- liners.
ment ring and lock in place with the retaining
In conjunction with the bronze inner main frame
ring.
seat liners, a steel outer seat liner is also added.
When the bushings have been replaced, raise This outer liner simply fills in the space or void that
the springs to the correct length. occurs when the adjustment ring is raised due to
the addition of the inner liner. The outer liner is very 3. Measure from the bottom of the adjustment
important as it permits the adjustment ring to tilt ring to the ground areas on the top of the upper
and recenter properly when the ring raises due to a spring segment and record the dimensions.
piece of tramp iron passing through the crushing
. At periodic intervals remeasure these points
cavity.
and compare them to the original dimensions.
Because of the different type of seating on the 7 Ft. Comparing the two sets of dimensions will show
Super Heavy Duty Crusher, no outer seat liner is at a glance how much wear has taken place
possible. See the illustration, MAIN FRAME SEAT and if the wear is even all the way around the
LINERS. Crusher. Due to casting and machining varia-
tions this is the only accurate method wear can
To determine exactly how much wear is taking
be determined.
place on the seat liners, proceed as follows:
. When any one of the four check dimensions
1. Starting at the countershaft box, grind four flat
measures less than the initial recorded dimen-
areas, 90° apart, on the side of the adjustment
sions by the amount shown on the table SEAT
ring and on top of the upper spring segment
LINER WEAR, the seat liners need replacing.
as shown on the illustration, DETERMINING
This much vertical wear means that only 1/16"
SEATING SURFACE WEAR.
(1.5 mm) of material is left on the INNER seat
ON CRUSHERS WHICH HAVE NO UPPER liner.
SPRING SEGMENTS GRIND THE MATCHING
AREAS ON TOP OF THE MAIN FRAME MAXIMUM
UPPER FLANGE. CRUSHER SIZE VERTICAL
WEAR
The flat areas on the upper spring segments or
on the frame must be directly below those on All Sizes
the adjustment ring. Crushers Except 3/8" (10 mm)
7 Ft. Super Heavy Duty ,
2. In a clockwise direction, number these areas by
7 Ft. Super Heavy Duty 3/4" (19 mm)
stamping or painting 1, 2, 3 and 4 on both the
adjustment ring and the spring segments. SEAT LINER WEAR

OUTER MAIN
FRAME SEAT INNER MAIN MAIN FRAME

|
LINER FRAME SEAT
LINER

A,
4-1/4 FT., 5-1/2 FT.
AND
7 FT. SUPER HEAVY DUTY
7 FT, HEAVY DUTY

MAIN FRAME SEAT LINERS

Example: Crusher Size: 4-1/4 Ft. Short Head RING AND ALSO SUBJECT THAT PORTION OF
THE RING TO EXCESSIVE WEAR.
Original recorded measurement ....... 1-1/4"
Should the seating be on the outer liner, the main
Periodic dimensional check .............. 1"
frame and/or adjustment ring must be reworked.
Difference ....... Lecce eee 1/4"
The 1/4" difference between the two measurements
indicates the seating surface has worn but, accord-
ing to the table SEAT LINER WEAR the seat liner
still has. some wear life left. If the difference had
been 3/8", the seat liner would have required GRIND FLAT AREAS ON
replacing. SIDE OF ADJUSTMENT
RING AND ON TOP OF
WHENEVER REPLACING WORN SEAT LINERS, MAIN FRAME AS SHOWN
BOTH INNER AND OUTER LINERS MUST BE
ADJUSTMENT
REPLACED AT THE SAME TIME. INSTALLATION RING
AND WELDING PROCEDURES ARE SHOWN

MEASURE WEAR HERE

ON THE DRAWING FURNISHED WITH EACH
SET OF SEAT LINERS. THE DRAWING IS EN-
TITLED, FIELD WELDING OF MAIN FRAME SEAT
LINERS.
The above method can also be used for determin-
ing how much wear is taking place between the
adjustment ring and main frame if the Crusher is
NOT equipped with seat liners.
If, when inspecting the adjustment ring and the
main frame for seating surface wear, it is found that
the seat is worn or the present liners need replac-
ing, remachining and installation drawings as well
as welding procedures can be furnished.
BEFORE A SEAT LINER CAN BE INSTALLED ON
AN OLDER CRUSHER THE MAIN FRAME AND
ADJUSTMENT RING SEAT MUST BE RESTORED
TO ITS ORIGINAL CONDITION.
When assembling the adjustment ring onto new
seat liners, contact must be all around on the
bronze INNER liner and a clearance of 1/32" (.75
mm) must exist at the OUTER liner as shown in the
illustration, SEATING SURFACE.
WHEN ASSEMBLING THE ADJUSTMENT RING
ONTO A MAIN FRAME WITHOUT SEAT LINERS,
CONTACT MUST ALSO BE ALL AROUND ON
THE INNER SEATING SURFACE AND A GAP
MUST EXIST AT THE OUTER SEATING SURFACE.
To determine if the adjustment ring is seating prop-
erly, place balls of clay or putty on the seat liners,
then lower the adjustment ring on the frame. The
clay or putty will compress and show where the ring
is seating.
SEATING ON THE OUTER SEAT LINE COULD
CAUSE PREMATURE FAILURE OF THE ADJUST-
MENT RING BY ABNORMAL BENDING OF THE DETERMINING SEATING SURFACE WEAR
 ADJUSTMENT RING

1/32" CLEARANCE MUST

\
EXIST BETWEEN THE CONTACT MUST BE
OUTER SEAT LINER ALL AROUND ON THE
AND THE ADJUSTMENT RING INNER SEAT LINER
AND THE ADJUSTMENT
RING

Hi é
3
“— MAIN FRAME

meet
RANAY

SEATING SURFACE

7 FT. SUPER HEAVY DUTY CRUSHER wears along with the bronze inner seat liner. The
SEAT LINER thickness of this fulcrum bar will vary according to
seat liner wear.
Because of the different type of seating on the 7 Ft.
Super Heavy Duty Crusher, no outer seat liner is To determine the proper thickness of the new ful-
possible. See the illustration, MAIN FRAME SEAT crum bar, proceed as follows:
LINERS. 1. Place balls of clay or putty around the top of
After installing a new seat liner, a fulcrum bar must the main frame.
also be added to the top of the main frame as 2. Then lower the adjustment ring on the frame.
shown in the illustration 7 FT. SUPER HEAVY
When the adjustment ring is properly seated
DUTY SEAT LINER. the clay or putty will compress, showing the
The fulcrum bar is required as the top of the main exact amount of clearance remaining between
frame and the underside of the adjustment ring the adjustment ring and the main frame.

3-21
3. Measure the thickness of the compressed clay SEATING ON TOP OF THE MAIN FRAME
or putty, then subtract 3/16" (5 mm) to obtain COULD CAUSE PREMATURE FAILURE OF
the correct thickness of the fulcrum bar. Round THE ADJUSTMENT RING BY ABNORMAL
off this dimension to a standard plate or bar BENDING OF THE RING AND ALSO SUB-
stock size, such as 7/8" (23 mm) or 1" (25 mm) JECT THAT PORTION OF THE RING TO
or 1-1/8" (29 mm) . EXCESSIVE WEAR.
4. Weld the fulcrum bar to the top of the main 6. Should the seating be on top of the main frame,
frame as shown in the illustration, 7 FT. SUPER the fulcrum bar must be reworked.
HEAVY DUTY SEAT LINER. WHENEVER A SEAT LINER IS REPLACED, THE
5. When assembling the adjustment ring onto the TOP OF THE MAIN FRAME MUST HAVE A FUL-
new seat liner, contact must be all around on CRUM BAR ADDED TO THE FRAME . INSTALLA-
the seat liner. A clearance of 1/8" to 3/16” (3 TION AND WELDING PROCEDURES ARE
mm to 5 mm) between the top of the main SHOWN ON THE DRAWING FURNISHED WITH
frame and the underside of the adjustment ring THE SEAT LINER. THE DRAWING IS ENTITLED,
is required. FIELD WELDING OF MAIN FRAME SEAT LINER.

ORIGINAL OUTLINE OF FULCRUM BAR ADJUSTMENT RING

MAIN FRAME

1/4 [YY 12 24-1/2 D.

THICKNESS
O SUIT WEAR :
CONDITION

I
MAIN FRAME
WORN TO
THIS HEIGHT

| SEAT LINER

MAIN FRAME

7 FT. SUPER HEAVY DUTY CRUSHER SEAT LINER

 Section 4
COUNTERSHAFT BOX, COUNTERSHAFT
AND SHEAVE ASSEMBLIES

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De ee ee ee ee ee eh ee

ASSEMBLING THE COUNTERSHAFT BOX

REPLACING THE PINION .......... 0... cece cece eee e eee eee eee ee eens
 INNER COUNTERSHAFT COUNTERSHAFT
BUSHING BOX GUARD
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THRUST COUNTERSHAFT
WASHER BOX SEAL
 Section 4

COUNTERSHAFT BOX, COUNTERSHAFT

AND SHEAVE ASSEMBLIES

DESCRIPTION tershaft box which is exposed to wear from falling

material.
This section covers the countershaft box, counter-
shaft and crusher sheave assemblies. Power is ASSEMBLY INSTRUCTIONS
transmitted from the initial power source to the Refer to the illustration INSTALLING COUNTER-
countershaft through a V-belt or a direct drive. The SHAFT BOX ASSEMBLY. A complete procedure for
countershaft, which has a bevel pinion pressed and - assembling the various components is given in the
keyed to it, in turn drives the gear on the eccentric maintenance portion of this section. If the counter-
assembly. The countershaft is supported within two shaft box assembly was removed for shipment, the
sleeve bearings or bushings. These bushings are countershaft box is to be installed in the main frame
pinned to the countershaft box to prevent any pos- as follows: )
sibility of bearing rotation. The flange on the inner
countershaft bushing assumes all thrust wear from 1. Carefully stretch the large diameter “O” ring,
the pinion thrust washer. The oil flinger keyed to the which can be found in one of the packing
other end of the countershaft removes the oil from boxes, over the machined diameter at the pin-
within the countershaft box by centrifugal! force. A ion end of the countershaft box. This “O” ring
housing covering the flinger is so designed as to prevents oil leakage from between the counter-
allow the oil to drain back to the oil tank for re-use. shaft box and main frame.
The countershaft box has a force fit in the main 2. Lower the countershaft box guard into position
frame and is firmly held in place with large diameter on the pinion end of the box.
capscrews. An “O” ring between the inner mating
surfaces of the box and frame provides an oil tight Slide a long section of pipe over the sheave
seal. A box guard protects that portion of the coun- end of the countershaft to offset the much

COUNTERSHAFT
BOX HL
_ GUARD nN
“O” RING iHe Sh N
a Mea tM ae
Dorrososse
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sss.) . “A er FEN, ho ae
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~

COUNTERBALANCING
PIPE
id
4 a”
ae a

CENTERING
LUG
Newrerrececne

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o oe
SLIDE
4s
s

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4

INSTALLING COUNTERSHAFT BOX ASSEMBLY

4-1
 COUNTERSHAFT
BOX REGULAR
JACKSCREW JACKSCREW COUNTERSHAFT
WASHER BOX HEX HEAD
MAIN SPACERS MAIN CAPSCREWS
FRAME FRAME TIGHT

{ | __\ \

COUNTERSHAFT
BOX
STEP 1 STEP 2 STEP 3

FORCING COUNTERSHAPFT BOX INTO MAIN FRAME

heavier pinion end of the assembly. See the illus-

tration INSTALLING COUNTERSHAFT BOX “O” RING
MAIN
ASSEMBLY. FRAME
TIGHT
. With an overhead crane or other suitable lifting WITH “O”
device, carefully position the countershaft box RING SEAL
centering lug on the slide within the main frame
and slide the assembly in as far as it will go.
. Insert the three special hex head jacking
screws, found in the box with the tools, through
the holes in the box flange, space 120° apart,
and then into the threaded holes in the frame.
See the illustration FORCING COUNTER-
SHAFT BOX INTO MAIN FRAME.
. As the countershaft box has an interference fit
on both flanges with the main frame, alternately
tighten each jackscrew a small amount, to pre-
vent binding, until they have bottomed in the
threaded holes in the frame.
. Remove the jackscrews and install washers or
spacers between the head of the jackscrews
and the flange as shown. Again tighten each
jackscrew a small amount until they have bot-
tomed in the threaded holes .
. The jackscrews are now removed and replaced
with the regular hex head capscrews that will
finally hold the box in the frame.
. Continue forcing the countershaft box into the
frame by alternately tightening these standard COUNTERSHAFT BOX SEALS
COMBINATION TAKE-UP CLAMPING
AND BACK OFF BOLTS SCREW

FLANGE
\
COUNTERSHAFT
DIAMETER

SHEAVE HUB

SHEAVE ASSEMBLY

capscrews until the box is tight against the 7. Place the sheave key in the countershaft key-
frame at the outer flange. See the illustration way.
COUNTERSHAFT BOX SEALS.
. Loosen the clamping screw and setscrew on
the sheave bushing sufficiently to permit the
MOUNTING CRUSHER SHEAVE bushing to be slid onto the shaft.
To mount a crusher sheave with a removable bush- DO NOT USE ANY LUBRICANTS DURING
ing, proceed as follows: Refer to the illustration, THE FOLLOWING ASSEMBLY PROCE-
SHEAVE ASSEMBLY. DURES.
1. Refer to the oil piping drawing and install all oil . Slide the bushing over the end of the shaft,
piping. flange first.
. Remove the split tapered bushing from the 10. Position the sheave bushing on the shaft so
sheave by unscrewing the combination take-up that there is 1/82" to 1/16" (1.0 mm to 1.5 mm)
and back-off bolts. clearance between the bushing and the oil
. Check that the tapered surface and bore of the flinger. Firmly tighten the clamping screw, how-
bushing, the tapered bore of the sheave and ever, avoid overtightening.
the countershaft, are clean and free of burrs, 11. Using a wooden 4" x 4" block, ram the counter-
scratches and all foreign matter, such as paint, shaft toward the Crusher until the sheave bush-
dirt and lubricants. ing contacts the oil flinger, thereby providing
. Pull the countershaft toward the drive end until the necessary end float or running clearance.
the pinion thrust washer is tight against the See the illustration END FLOAT — V-BELT
INNER countershaft bushing as shown in the DRIVE.
illustration END FLOAT — V-BELT DRIVE.
RECHECK THE 1/32" TO 1/16" (.75 mm to 1.5
. Bump the oil flinger against the OUTER coun- m) END FLOAT BY MOVING THE COUN-
tershaft bushing using a 4" x 4" block of wood TERSHAFT AXIALLY, IN AND OUT.
as a ram.
12. Slide the sheave over the bushing being careful
. Check the shaft to be sure that it cannot be to keep the boit holes lined up with the tapped
moved axially, in or out. If slight movement is holes in the bushing flange.
still possible, exert a pulling force on the coun- 13. Insert the take-up bolts through the bolt holes
tershaft while simultaneously bumping the oil and alternately tighten each bolt a small
flinger against the outer countershaft bushing. amount, until all bolts are tight. Refer to the
table, TAKE-UP BOLTS TORQUE REQUIRE-

4-3
 PINION THRUST
WASHER OIL
COUNTERSHAFT
FLINGER
OUTER COUNTERSHAFT
BUSHING

37 COUNTERSHAFT
BOX
CRUSHER
SHEAVE
1/32” to 1/16” END FLOAT —+||-—.
INNER COUNTERSHAFT * » SHEAVE
PINION BUSHING BUSHING
TIGHT

END FLOAT — V-BELT DRIVE

MENTS. Do not lubricate the bolt threads or ance as this clearance assures the proper fit
the tapped holes. When the sheave is finally and grip between sheave bushing and counter-
positioned, a clearance of 1/8" to 1/4" (3 mm to shaft. Follow the torque requirements closely:
6 mm) should exist between the face of the over tightening the take-up bolts will create
sheave hub and the flange of the bushing. No bursting pressures in the hub of the sheave
attempt should be made to take up this clear- and could cause the sheave to crack.

IDENTIFYING SIZE OR SHEAVE DO NOT USE ANY LUBRICANTS

BUSHING FOR PROPER TORQUE PROPER WRENCH PULL WHEN
REQUIREMENTS PROPER TORQUE USING OPEN END OR SOCKET
WHEN USING WRENCH
BUSHING SIZE AND THREAD TORQUE WRENCH
FLANGE OF TAKE-UP (FOOT POUNDS) WRENCH LENGTH WRENCH PULL
DIAMETER BOLTS (INCHES) (POUNDS)
2 #10-24 5 4 15
2-11/16 1/4-20 9 4 27
3-3/16 1/4-20 9 A 7
2-3/16 1/4-20 9 4 27
3-7/8 5/16-18 15 6 30
4-5/8 3/8-16 30 6 60
6 1/2-13 60 12 60
6-5/8 9/16-12 75 12 75
7-1/4 5/8-11 135 12 135

9 3/4-10 225 15 180

10 7/8-9 300 15 240

15 1-1/8-7 600 24 300

TAKE-UP BOLT TORQUE REQUIREMENTS
CRUSHER SHEAVE REMOVAL . Measure the shaft diameter and the bore of the
coupling as it is being heated to be sure the
To remove the crusher sheave proceed as follows:
bore is slightly larger than the shaft. If the cou-
1. Remove the take-up bolts and thread two of pling has been heated properly, no trouble
them into the tapped holes in the hub of the should be encountered in positioning the cou-
sheave. Using the two bolts as back-off bolts, pling on the shaft. Make sure the keyways are
exert pressure by tightening the bolts against properly aligned.
the flange of the bushing, breaking the sheave . Drive in the keys.
grip on the bushing cone.
. Pull the countershaft toward the drive end until
SHOULD THERE BE DIFFICULTY “BREAK- the pinion thrust washer is tight against the
ING” THE FIT BETWEEN THE SHEAVE AND INNER countershaft bushing as shown in the
BUSHING, TAP THE END OF THE SHAFT OR illustration END FLOAT — DIRECT DRIVE .
BUSHING WITH A BABBITT HAMMER WHILE
MAINTAINING BACK-OFF BOLT PRESSURE, . Bump the oil flinger against the OUTER coun-
UNTIL THE SHEAVE IS LOOSE ENOUGH TO tershaft bushing using a 4" x 4" block of wood
as aram.
REMOVE.
. Check the shaft to be sure that it cannot be
. Loosen the clamping screw and set screw on
moved axially, in or out. If slight movement is
the bushing.
still possible, exert a pulling force on the coun-
. If necessary, insert a wedge such as a screw- tershaft while simultaneously bumping the oil
driver, into the split in the bushing flange and flinger against the outer countershaft bushing.
remove the bushing.
. In order to provide the proper countershaft end
MOUNTING FLEXIBLE COUPLING float using a direct drive arrangement, a safety
set collar must be installed on the countershaft.
For the initial installation or when reassembling the
Since a set collar is usually split in two halves
flexible coupling on a direct drive arrangement, pro-
for easier installation, position the halves on the
ceed as follows:
shaft and firmly tighten the two clamping screws,
‘1. Disassemble the coupling. however, avoid overtightening.
2. Inspect both the driving and driven shafts and The safety set collar should be positioned so
coupling bores, making sure they are free from that there is 1/32" to 1/16” (.75 mm to 1.5 mm)
burrs, scratches and all foreign matter. Be sure clearance between the collar and the oil flinger.
the keys fit the shafts and coupling halves Using a wooden 4" x 4" block, ram the counter-
properly. shaft toward the Crusher until the collar con-
tacts the oil flinger, thereby providing the nec-
. Since the coupling halves are mounted on both essary end float or running clearance. See the
the crusher countershaft and motor or engine illustration END FLOAT — DIRECT DRIVE.
shafts with an interference fit, heat the coupling
hub to a temperature of approximately 175°F RECHECK THE 1/32" TO 1/16" (.75 MM TO
(79°C) above the ambient temperature and 1.5 MM) END FLOAT BY MOVING THE
install on the shaft as quickly as possible. COUNTERSHAFT AXIALLY, IN AND OUT.
DO NOT HEAT THE COUPLING HUB OVER 10. Tighten the setscrew in the safety set collar to
275°F (135°C) AS THE FLANGE OR GAP lock the collar in place.
PORTION OF THE COUPLING COULD 11. Align the coupling as described in Section 2,
BECOME DAMAGED FROM EXCESSIVE INITIAL ALIGNMENT OF FLEXIBLE COU-
HEAT. A CHEMICAL MARKING DEVICE, PLING.
WHICH MELTS AT A PREDETERMINED TEM-
PERATURE, SHOULD BE USED TO INSURE
CHECKING END FLOAT
UNIFORM AND SAFE HEATING. lf the Crusher was shipped completely assembled,
the end float was set correctly at the factory; but, as
A WARNING it is important for the proper operation of the
Crusher, recheck the end float. The countershaft
USE HEAVY, WELL INSULATED ASBES- must be free to move in and out 1/32" to 1/16" (.75
TOS GLOVES WHEN HANDLING THE mm to 1.5 mm). DO NOT ALLOW END FLOAT TO
HEATED COUPLING HALVES. EXCEED 1/16" (1.5 MM).

4-5
 PINION COUNTERSHAFT
THRUST OUTER COUNTERSHAFT
WASHER BUSHING
OIL
FLINGER

COUNTERSHAFT SAFETY
BOX SET
COLLAR
PINION FLEXIBLE
TIGHT 1/32” to 1/16” END FLOAT — — COUPLING
INNER
a

COUNTERSHAFT
BUSHING

END FLOAT — DIRECT DRIVE

MAINTENANCE FRAME HOUSING TO APPROXIMATELY

100°F (38°C) ABOVE AMBIENT.
DISASSEMBLY OF COUNTERSHAFT BOX
6. Continue tightening them until the box is free of
To disassemble the countershaft box and counter- the frame.
shaft assembly for replacement of bushings, pinion
or other wear parts, proceed as follows: . Slide a long section of pipe over the sheave
end of the countershaft to counterbalance the
1. Remove all oil piping that would interfere with assembly and remove the assembly by using
the removal of the box. an overhead crane or other suitable lifting
2. Remove the crusher sheave at this point, as device. See the illustration INSTALLING
described under CRUSHER SHEAVE RE- COUNTERSHAFT BOX ASSEMBLY.
MOVAL. This is done primarily to prevent dam- . Remove the flinger housing.
aging or breaking the sheave during box
removal. . Heat the oil flinger to a temperature of approxi-
mately 50°F (10°C) above the ambient temper-
. Remove the capscrews holding the counter- ature.
shaft box to the main frame.
10. Place a pry bar between the flinger and the
. Install the special jacking screws, that are fur- countershaft box and exert moderate pressure.
nished with the machine, into the three equally
spaced tapped holes in the outer flange of the 11. Once the flinger starts to move, grasp each
box. See the illustration COUNTERSHAFT side of the flinger and pull the flinger straight off
BOX REMOVAL. the shaft.

. Alternately tighten each jackscrew a small

amount to prevent binding in the frame. A warnnc
IF THERE IS AN EXCEPTIONALLY TIGHT FIT, USE HEAVY, WELL INSULATED GLOVES
HEAT MAY BE APPLIED TO THE MAIN
WHEN HANDLING THE HEATED OIL
FRAME AT THE OUTER COUNTERSHAFT
FLINGER.
BOX FIT TO ASSIST IN REMOVAL. HEAT THE
 JACKING SCREWS (3 ) —
COUNTERSHAFT
> Cayo
BOX 79
OIL
FLINGER
NY C\ \ Y

ne

\
(mp | f-
COUNTERSHAFT 4

a
OIL FLINGER
HOUSING

COUNTERSHAFT BOX REMOVAL

INSIDE THE BORE OF SOME OIL FLINGERS 3. Place the oil flinger key in the keyway in the
IS EITHER AN “O” RING OR A GRAPHITE countershaft. In some countershafts the flinger
IMPREGNATED PACKING, WHICH PRE- keyway is a small keyway just for the flinger
VENTS OIL FROM LEAKING OUT ALONG key, while in other countershafts the flinger key
THE COUNTERSHAFT. CARE SHOULD BE fits in the same keyway as the crusher sheave
TAKEN THAT THIS SEAL IS NOT DAMAGED key.
DURING REMOVAL OF THE FLINGER. IF
THE SEAL IS DAMAGED, IT MUST BE . Check the condition of the seal inside the oil
REPLACED BEFORE THE UNIT IS flinger bore, if the flinger is so equipped. Re-
REASSEMBLED. place the seal if necessary.
12. Pull the countershaft assembly out of the coun- . Heat the oil flinger to a temperature of approxi-
tershaft box. mately 50°F (10°C) above the ambient temper-
ature and install on the countershaft as quickly
ASSEMBLING THE COUNTERSHAFT BOX as possible.
Assembly is the reverse procedure of disassembly DO NOT APPLY TOO MUCH HEAT TO THE
with the following exceptions: FLINGER AS THE “O” RING OR THE
1. Insert the countershaft assembly in the coun- GRAPHITE IMPREGNATED PACKING WHICH
tershaft box. PREVENTS OIL FROM LEAKING OUT
ALONG THE COUNTERSHAFT, COULD
2. To hold the countershaft stationary, place a BECOME DAMAGED FROM THE HEAT .
large “C” clamp so that the pinion is clamped to
the countershaft box flange. See the illustration . When resistance is encountered, place a block
HOLDING THE COUNTERSHAFT ASSEMBLY. of wood across the face of the flinger and force
An alternate method for holding the counter- the flinger on the shaft by ramming against the
shaft would be to place the pinion against a timber. The flinger is properly installed when it
firm bearing wall or similar support. is tight against the outer countershaft bushing.

4-7
 ‘c” 7. On some countershaft box assemblies the oil
CLAMP flinger key cannot be installed until the oil fling-
er has been properly installed on the counter-
shaft. In this case the key must be welded to
PINION the flinger to hold the key in place. If the flinger
being installed already has the key welded to it,
check that the weld did not crack during remov-
al of the flinger.
. If the oil flinger is equipped with a piston ring to
provide the oil seal between the flinger and the
flinger housing, check that the piston ring can
be freely turned in the specially machined
groove in the flinger. Carefully file off any nicks
or burrs that may have formed on the piston
ring, causing the piston ring to bind in the fling-
er. Replace the piston ring if necessary.
. Check the bore inside the flinger housing be-
fore assembling the housing to the countershaft
box, the bore must be SMOOTH! If a groove is
BEGINNING to wear into the bore of the flinger
housing from the piston ring, the bore must be
machined smooth. A groove worn in the hous-
ing can cause the piston ring to “lock” in the
flinger housing and make future removal of the
flinger housing extremely difficult, if not impos-
Ff
sible, without damaging some part on this end
COUNTERSHAFT of the countershaft box assembly. Replace the
BOX flinger housing if the groove worn in the hous-
ing is too deep.
HOLDING THE COUNTERSHAFT ASSEMBLY

CRUSHER SIZE PINION LOCATION ere 000 La)

4-1/4 Ft. 3/8" 25
5-1/2 Ft. 1/2" 40
7 Ft. 1/4" 65
PINION LOCATION AND PRESS FIT
 REPLACING THE PINION . Place the pinion and shaft assembly in a suit-
Whenever the countershaft box is out of the Crush- able hydraulic press and force the pinion free of
er for inspection or replacement of parts, it is advis- the shaft. The table, PINION LOCATION AND
able to inspect the pinion for wear or broken teeth. PRESS FIT lists the capacity of press required
Pitting or galling on the face of the teeth are good for both removal and installation of the pinion.
indications of excessive wear. This can be due to . Lubricate the end of the shaft and the bore of
improper tooth contact resulting from an incorrect the new pinion with a suitable pressing lubri-
quantity of shims being placed under the lower step cant.
bearing plate, by overloading the Crusher, or by . Place the pinion on the end of the shaft and
using excessively dirty oil. align the keyways.
Also check the pinion thrust washer for wear or . Press the new pinion onto the shaft so that the
scoring. If the pinion is worn to the point where re- - end of the shaft protrudes from the pinion the
placement is necessary, the pinion is to be remov- distance specified in the table PINION LOCA-
ed as follows: TION AND PRESS FIT.
1. Remove the countershaft assembly from the REMOVAL OF COUNTERSHAFT BUSHINGS
countershaft box as described under DISAS-
SEMBLY OF COUNTERSHAFT BOX. On occasions when a bushing becomes worn and
replacement is necessary, the bushing will be loose
2. Slide off the pinion thrust washer. in the box. In instances such as this, the bushing is
simply slid from the box without difficulty. Due to
3. Drive out the tapered key, from the rear of the
extreme limits of manufacturing tolerances, the
pinion.
countershaft bushings may have had a slight inter-
ference fit within the countershaft box. If such is the
| FLATS ARE TO case, removal will be more difficult. To replace the
BE SMALLER countershaft bushings, that have such a press fit or
THAN INSIDE those that have “seized” in the box because of a
WELD 1” DIA. OF BUSHING build up of heat due to inadequate lubrication or
HEX NUT from overloading the Crusher, proceed as follows:
TO PLATE SG
1. Remove the countershaft box from the main
frame and the countershaft from the counter-
shaft box as described under DISASSEMBLY
' DIA. OF PLATE OF COUNTERSHAFT BOX.
TO BE LARGER
f THAN INSIDE . Construct a steel centering plate as shown in
ia OF BUSHING the illustration, CENTERING PLATE.
. Slide the narrow portion of the plate horizontal-
ly through the bushing until the plate is behind
the bushing.
COUNTERSHAFT . Turn the centering plate 90° so that the outer
BUSHING
edge of the plate will bear against the bushing.
See the illustration COUNTERSHAFT BUSH-
ING REMOVAL BY RAMMING.
. While holding the plate in position thread a 1"
diameter rod into the nut which is welded to the
center of the plate. The rod must be a few inch-
es longer than the bushing and threaded on
both ends.
. Place a 1" x 3" x 12" steel bar over the other
end of the rod and hold firmly in place with a
hex nut.
. Insert a long timber or pipe through the opposite
end of the countershaft box and ram against
CENTERING PLATE the centering plate.

4-9
 INNER
COUNTERSHAFT ONO
BUSHING

CENTENiwG
PLATE

TIMBER

OUTER COUNTERSHAFT
BUSHING

COUNTERSHAFT BUSHING REMOVAL BY RAMMING

INNER COUNTERSHAFT COUNT!

BUSHING BOX |
CENTERING
PLATE
/ OUTER
COUNTERSHAFT
BUSHING

BLOCKING
THREADED ROD
FLAT BAR
TIMBER

COUNTERSHAFT BUSHING REMOVAL BY JACKING

4-10
 OUTER.
COUNTERSHAFT
BUSHING

DOWELS

COUNTERSHAFT
BOX
COUNTERSHAFT BUSHING INSTALLATION

INNER OUTER
COUNTERSHAFT OIL COUNTERSHAFT
GROOVE BUSHING

OlL GROOVE

END VIEW
OF
INNER
BUSHING ieee COUNTERSHAFT
BOX

LOCATION OF INNER COUNTERSHAFT BUSHING OIL GROOVE

4-11
Should the bushing remain tight within the counter- INSTALLING COUNTERSHAFT BUSHINGS
shaft box an alternate method utilizing a jacking
When both the countershaft and countershaft box
procedure is suggested to remove bushings which
have been thoroughly inspected and found to be
are very difficult to remove, proceed as follows:
satisfactory, the new bushings can be installed.
1. Using the same centering device as previously Should the bushings have a loose fit within the box
described and in the same manner except for a just slide the bushings in, over the dowels, taking
much longer rod and steel bar, place wooden care that the oil groove in the bore is positioned as
blocking between the steel bar and the counter- described in Step 3. If an interference fit occurs,
shaft box flange as shown in the illustration proceed as follows:
COUNTERSHAFT BUSHING REMOVAL BY 1. Remove two of the four dowels or pins that are
JACKING. in the face of the box flange.
. Using the threaded rod as a jackscrew, tighten 2. Insert two rods which are slightly longer than
the hex nut until the flange of the bushing is the bushing into these two dowel holes. See
pulled against the steel bar. the illustration COUNTERSHAFT BUSHING
. Unscrew the nut and place additional blocking INSTALLATION. These rods will make certain
under the bar and tighten the hex nut until the that the holes in the bushing flange line up with
bushing is again pulled against the bar. the dowels in the box.
. Both countershaft bushings, inner and outer
4. Repeat this procedure until the bushing is free.
are identical. However, their position in the bore
may differ. Determine the proper location of the
INSPECTION PRIOR TO BUSHING bushing oil groove in relation to the counter-
INSTALLATION shaft box as follows:
As a precautionary measure prior to pressing in a A. The longitudinal oil groove in the INNER
new bushing, check the diameter of the bore in the countershaft bushing is properly located at
countershaft box. The bushings are machined to the top of the countershaft. See the illustra-
provide a fit of 0.001" (0.030 mm) tight, to 0. 002" tion, LOCATION OF INNER COUNTER-
(0.050 mm) loose. The inside diameter of the bore SHAFT BUSHING OIL GROOVE.
and the outside diameter of the bushing should be B. The OUTER countershaft bushing is normal-
checked to make certain their diameters meet ly installed with the longitudinal oil groove
these tolerances. Should the interference be more located at the top. However, its position will
than the 0.001" (0.025 mm), the box must be rema- differ if the motor sheave is located ABOVE
chined to meet these limits. An excessive interfer- the Crusher, either directly over the crusher
ence fit can cause the bushing to collapse or the sheave or within 30° of each side of the
bushing bore to become smaller thereby reducing crusher vertical centerline. See the illustra-
the clearance between countershaft and bushing. If tion VERTICAL DRIVE.
the bore is found to be smaller than when originally
machined, this bore shrinkage can usually be The outer countershaft bushing groove must
attributed to extreme heat. then be rotated 90° from top center in either
direction depending on the rotation of the
Check the shaft itself for straightness or run out. crusher countershaft. See the iilustration
With the shaft between centers, the run out should POSITIONS OF OUTER COUNTERSHAFT
not exceed a total of 0. 004" (0.102 mm). If more BUSHING OIL GROOVE. Rotating the
than 0.004" (0.102 mm), the countershaft should be bushing 90° when using such a vertical
replaced. drive will prevent the pull of the countershaft
If the bore of the bushing has become smaller from from slightly closing this groove and restrict-
excessive pressure when pressing into an under- ing the flow of lubricating oil through it.
size countershaft box bore or if a bent countershaft . Pack the bore of the replacement bushings with
is used, the bushing could seize onto the shaft. dry ice for 2-3 hours to shrink the bushings to
permit easy installation into the countershaft box.
Should the shaft be twisted, as indicated by com-
parison of alignment between keyways, it is to be Approximately 50 Ibs. (22 kg) of dry ice will be
discarded and a new one installed. required for BOTH countershaft bushings on
 VERTICAL
CRUSHER the 4-1/4 Ft. size Crushers, while 100 Ibs. (44
CENTERLINE kg) will be required on the 5-1/2 Ft. and 7 Ft.
J machines.
= — WRAP THE OUTSIDE OF THE BUSHING IN A
| : i] FEW LAYERS OF BURLAP TO PREVENT
THE EXTERNAL BUILD UP OF FROST
WHICH COULD HINDER THE INSTALLATION
OF THE BUSHING IN THE COUNTERSHAFT
BOX. THIS ALSO HELPS TO ACHIEVE A
MORE THOROUGH COOLING.

A wornne
USE HEAVY, WELL INSULATED GLOVES
WHEN HANDLING THE DRY ICE.
HANDLING DRY ICE WITHOUT PROTEC-
TION COULD RESULT IN SEVERE BURNS.

IF THE COUNTERSHAFT BOX IS AT A TEM-

VERTICAL DRIVE PERATURE OF 75°F (24°C) OR HIGHER,
PLAIN [CE CAN BE USED AS A SUBSTI-
TUTE. MEASURE THE OUTSIDE DIAMETER
OF THE BUSHING AND THE BORE OF THE
COUNTERSHAFT BOX TO DETERMINE
WHEN THE BUSHING HAS COOLED SUFFI-
CIENTLY.

OIL

cS
OIL
wg GROO VE
|

+ +

A, 9
9:00 O'CLOCK POSITION NORMAL OR 3:00 O’CLOCK POSITION
FOR CLOCKWISE 12:00 O'CLOCK POSITION FOR COUNTERCLOCKWISE
ROTATION WITH ROTATION WITH
VERTICAL DRIVE VERTICAL DRIVE
OR WITHIN OR WITHIN
30° OF VERTICAL 30° OF VERTICAL ~

POSITIONS OF OUTER COUNTERSHAFT BUSHING OIL GROOVE

(END VIEW OF COUNTERSHAFT BUSHING)

4-13
 5. Very quickly slide the bushing into the bore of from the oil flinger housing, especially when the oil
the countershaft box using the rods inserted in is cold. This type of oil leak is probably due to insuf-
the box as guides. ficient pitch in the main drain line or incorrect piping
. If installation did not proceed rapidly and the coming from the flinger housing. See the illustration
bushing expanded when part way in the bore or OIL PIPING CONNECTIONS. Minimum pitch is 1"
if installation by freezing is not available, ram
(25 mm) for every 12" (305 mm) of drain pipe used.
the bushing into place using a block of wood Also check the inside of the hose or piping coming
across the face of the bushing to protect it. The from the oil flinger housing for any obstructions,
guide rods will help considerably in this type of such as dirt build-up or a collapsed hose that may
assembly. restrict oil flow. Any of these items just described
DO NOT USE EXCESSIVE FORCE WHEN can cause the oil to back up and leak out of the
flinger housing.
RAMMING AS THE BUSHING CAN BE-COME
COCKED IN THE BORE CAUSING GREAT Before doing any disassembly work on the counter-
DIFFICULTY. shaft box itself, or any repiping of the main drain
line, all of which means considerable down time, it
. Replace the two dowels that were previously
removed. is recommended to “break” the drain line from the
flinger housing where it joins the main drain line
and run a separate line from this housing directly
OIL LEAKAGE FROM DRIVE END OF
COUNTERSHAFT BOX back to the oil tank. This procedure has eliminated
this kind of oil leak in most cases and has resulted
Should oil begin to leak out of the oil flinger housing in the least amount of down time because of work-
at the drive end of the countershaft box, it may be ing with small pipe diameters — 3/4" to 1-1/4" (9
that either an “O” ring or a graphite packing inside mm mm to 31 mm). See the illustration SEPARATE
the oil flinger has become damaged or worn and DRAIN LINE.
requires replacing. See the paragraph DISASSEM-
The majority of oil leaks from the drive end of the
BLY OF COUNTERSHAFT BOX in this section.
countershaft box have been on portable plants
It is also possible that the cause of the oil leakage where drain lines do not have sufficient pitch due to
is the inability of the oil to drain away fast enough space limitations in such installations.
 REDUCING
TEE DRAIN LINE
FROM OIL ™~
DRAIN LINE BAFFLE PLATE FLINGER
FROM CRUSHER WELDED INSIDE HOUSING
\ REDUCING TEE

DRAIN LINE
FROM CRUSHER

DRAIN LINE
FROM OIL a
FLINGER )
HOUSING 45° Y

i
TO
CHECK FOR PROPER OIL FLINGER OL
HOUSING TO CRUSHER DRAIN LINE PIPING! TANK
ALL OF THESE OIL PIPING CONNECTIONS DRAIN LINE
DRAIN LINE ARE CORRECT FROM OIL
FROM CRUSHER
FLINGER
HOUSING
DRAIN LINE t
FROM OIL
FLINGER DRAIN LINE = | an
HOUSING FROM CRUSHER

45°
Y ~.

OIL PIPING CONNECTIONS

4-15
 DRAIN LINE
FROM CRUSHER EXISTING DRAIN
LINE FROM OIL
\ FLINGER HOUSING
INSTALL PIPE
PLUG AS
») SHOWN

Lo Yo
/ Y REPIPE EXSITING
DRAIN LINE SO
N/ “~~ THAT A SEPARATE
DRAIN LINE FROM
45° Y j THE OIL FLINGER
™ 4 —— HOUSING CAN BE
INSTALLED TO THE
rH OIL TANK

NEW DRAIN LINE

-—— FROM OIL
FLINGER
HOUSING
TO
OIL
TANK

SEPARATE DRAIN LINES

 Section 5

THRUST BEARING AND ECCENTRIC ASSEMBLIES

DESCRIPTION 2.0... ccc ete ne t eee ee n eee een eens 5-1

ASSEMBLY INSTRUCTIONS ....... vec eeeeeeveeeeeeeeseeueututeeeeeeenees 5-1

CHECKING OR ADJUSTING BACKLASH AND ROOT CLEARANCE ........ 5-2

MAINTENANCE .... 2... ccc eee cern e eet e ene e eens 5-4

REMOVING ECCENTRIC ASSEMBLY _

4-1/4 FT., 5-1/2 FT. AND 7 FT. CRUSHERS .......................00
00008 5-4

REPLACING GEAR.... 2... ccc cc cree eee cnet e teen eennees 5-5

TWO PIECE GEAR REMOVAL .......... 00. cece cece ect eee eee nee 5-5

TWO PIECE GEAR INSTALLATION ..... 00... ccc bec e cee e eee ee 5-5

REMOVAL OF COUNTERWEIGHT ...........

0.0. c cece eee ences 5-6

ADJUSTING GEAR BACKLASH FOR WEAR ...........

0-0 cece eee eens 5-6

INNER ECCENTRIC BUSHING ...... 00.0.0 cece cece cee eee eee eee 5-6

INNER ECCENTRIC BUSHING REMOVAL —

4-1/4 FT. CRUSHERS ... 1. cc eens 5-6

INNER ECCENTRIC BUSHING REMOVAL —

5-1/2 FT. AND 7 FT. CRUSHERS ... 0c
ccc eee eens 5-7

INSTALLING INNER ECCENTRIC BUSHING .........

0... 0c cece eee eee 5-7

REPOURING BUSHING LOCK ..... 00... ccc ccc cece eee eee 5-7

EMERGENCY REPAIR OF GEAR AND

ECCENTRIC INTERFERENCE KIT .... cece
eee eee eens 5-8
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 Section 5

THRUST BEARING AND ECCENTRIC ASSEMBLIES

DESCRIPTION the pin is fully in the cored hole. Also check that
the plate which has a shoulder on it is centered
This section covers the thrust bearing and eccentric in the eccentric. Thread the step bearing plate
assemblies. The eccentric (which has a tapered, rod into the bearing plate and check to be cer-
offset bore) provides the means whereby the head tain the rod does not protrude beyond the bot-
and main shaft follows an eccentric path during tom of the plate.
each cycle of rotation. An inner eccentric bushing
locked into the eccentric bore provides the bearing . Place the steel cross bar over the other end of
surface for the main shaft. A large bevel gear the rod and rest the bar across the eccentric.
(pressed and keyed to the top of the eccentric) is The rod will be held firmly in place by tightening
driven by the pinion on the countershaft. The ec- the nut against the cross bar. See the illustra-
centric, in turn, rotates within the outer eccentric tion INSTALLING ECCENTRIC ASSEMBLY.
bushing in the main frame bore. The entire assem-

O
bly is supported by a series of thrust plates which
rest on top of the main frame cap. This series of
thrust or step bearing plates reduces the frictional
wear of the eccentric assembly. Backlash and root
SPECIAL
clearance between gear and pinion teeth are main- LONG
tained in this assembly by the addition or subtrac- EYEBOLT I
tion of step bearing plate shims.
ASSEMBLY INSTRUCTIONS
If the eccentric assembly was removed from the
Crusher due to weight limitations, the various parts
of this assembly are to be installed as follows:
1. Stack the step bearing plates with the bronze
lower bearing plate at the bottom, the steel
inner bearing plate in the middle, and the
bronze center bearing plate at the top. See the
illustration INSTALLING STEP BEARING
PLATES. Apply a light coat of oil to all bearing
plates and the eccentric. BRONZE }
CENTER #8
ON SOME MACHINES THE STEEL INNER STEEL BEARING }
BEARING PLATE AND BRONZE CENTER INNER PLATE i
BEARING PLATE HAVE BEEN OMITTED, : BEARING ;
THERE ARE ONLY TWO STEP BEARING
PLATES; THE BRONZE LOWER AND STEEL
UPPER WHICH HAS A PIN PRESSED INTO
THE TOP OF THE PLATE AS DESCRIBED IN
WHMULLUUE
STEP 3
Se PD LLL LLLLL ALLL
SS SSM
ALLL LL
SILStd\
2. Thread the special long eyebolt into the bronze
lower bearing plate and lower the plates into $~— AN, :
position in the main frame bore making sure
the lugs on the bottom plate engage the slots in BRONZE
the main frame cap. LOWER
BEARING
3. Place the steel upper step bearing plate (which PLATE
has a pin pressed into the top of the plate)
against the bottom of the eccentric being sure INSTALLING STEP BEARING PLATES

5-1
 EYEBOLT STEEL
CROSS factory tooth backlash and root clearance
has been established, the step bearing plate
BAR STEP rod is to be removed.
BEARING
PLATE CHECKING OR ADJUSTING BACKLASH
ROD outer AND ROOT CLEARANCE
END OF There are two styles of gears used, non-shifted and
TEETH shifted. “Shift” refers to the gear bore. To determine
if the Crusher has a shifted gear refer to the eccen-
tric assembly parts list. “2-piece shifted gear’ indi-
cates a shifted gear. If this “2-piece shifted gear”
notation is not included in the parts list, then the
gear is a non-shifted.
To check or adjust backlash and root clearance of a
shifted gear, proceed as follows:
1. Position the counterweight or heavy portion of
the gear directly over the pinion.

UPPER MAIN 2. Pull the countershaft toward the driven end

STEP SORE FRAME until the pinion thrust washer is tight against
BEARING the INNER countershaft bushing.
PLATE
3. Turn the countershaft slightly, until a gear tooth
is in a vertical position.
MAIN PIN 4. Remove all clearance between the eccentric
FRAME
CAP and the outer eccentric bushing by jacking or
prying the eccentric assembly toward the pin-
INSTALLING ECCENTRIC ASSEMBLY ion so that the teeth on the gear are in their
closest relationship to the pinion. This is best
5. Install the eyebolts into the top of the eccentric accomplished by jacking the gear horizontally
and lower the eccentric assembly into the toward the pinion. A pry bar inserted between
Crusher. the socket portion of the frame and the gear
can also be used.
6. Be sure the gear and pinion have properly
meshed and are in their correct relationship to Hold the gear in this position while taking the
each other. The backlash and root clearance measurements. Use only enough force re-
should be set in accordance with the specifica- quired to slide the eccentric assembly toward
tions listed in the table BACKLASH AND ROOT the pinion. Using excessive force could “tip” the
CLEARANCE MEASUREMENTS. After satis- eccentric assembly and give incorrect readings.

BACKLASH AND ROOT CLEARANCE MEASUREMENTS BAC

CRUSHER BACKLASH
ROOT CLEARANCE KLASH
SIZE ACTUAL | MINIMUM | MAXIMUM
.030
4-1/4 Ft. 050 125 .094 156
040
5-1/2 Ft. “060 156 125 188
050
7 Ft. “070 .203 125 312 PINION
All Dimensions !n inches — MEASUREMENTS TO BE TAKEN
AT OUTER END OF TEETH ONLY ROOT CLEARANCE

5-2
5. To check the backlash, rotate the countershaft ON SOME OF THE SMALLER SIZE CRUSH-
until the pinion tooth just “touches” the gear ERS THERE IS NOT ENOUGH ROOM TO
tooth. Measure the clearance on the opposite CHECK BACKLASH OR ROOT CLEARANCE
side of the teeth with a feeler gauge. Then WHEN THE COUNTERWEIGHT OF THE
measure the root clearance as shown in the GEAR IS DIRECTLY OVER THE PINION . IN
table BACKLASH AND ROOT CLEARANCE THIS CASE, STEP 1 MUST BE OMITTED.
MEASUREMENTS. . Pull the countershaft toward the drive end until
. If the backlash and root clearance is found to the pinion thrust washer is tight against the
be less than that which is specified in the table, INNER countershaft bushing as shown in the
the eccentric assembly is to be removed and illustration END FLOAT found in Section 4.
metal shims of the proper thickness are to be V-BELTS OR FLEXIBLE COUPLING MUST BE
added. “LOOSE” BEFORE PROCEEDING WITH THE
The shims are to be inserted under the bottom MEASUREMENTS.
bronze bearing plate and directly on top of the . Turn the countershaft slightly, until a GEAR
main frame cap. Adding shims will raise the tooth is in a vertical position as shown in the
eccentric assembly and move the gear away illustration BACKLASH AND ROOT CLEAR-
from the pinion, thereby increasing the back- ANCE MEASUREMENTS.
lash and root clearance. Should the measure-
ments be more than that specified, metal shims . Remove all clearance between the eccentric
of the proper thickness must be removed. and the outer eccentric bushing by jacking or
prying the eccentric assembly toward the pin-
Whenever installing shims on top of the main ion so that the teeth on the gear are in their
frame cap, always place the thinnest shims on closest relationship to the pinion. This is best
the bottom and the thickest shims on top. accomplished by jacking the gear horizontally
SHIMS PLACED BENEATH THE BEARING toward the pinion. A pry bar inserted between
PLATES WHEN THE CRUSHER LEFT THE the socket portion. of the frame and the gear
FACTORY ARE OF THE REQUIRED THICK- can also be used.
NESS TO PROVIDE PROPER BACKLASH Hold the gear in this position while taking the
AND ROOT CLEARANCE. THESE SHIMS, measurements. Use only enough force as is
WHILE PLACED IN THE CRUSHER INITIALLY required to slide the eccentric assembly toward
FOR BACKLASH ADJUSTMENT ARE PRI- the pinion. Using excessive force could “tip” the
MARILY USED FOR WEAR COMPENSATION. eccentric assembly and give incorrect readings.
REFER TO THE MAINTENANCE PORTION
OF THIS SECTION. . To check the backlash, rotate the countershaft
until the pinion tooth just "touches" the gear
Always use a minimum quantity of shims; if two tooth. Measure the clearance on the opposite
1/32" (.75 mm) shims are required, use one side of the teeth with a feeler gauge. Then
1/16" (1.5 mm) shim instead. Do not use shims measure the root clearance as shown in the
thinner than 1/32" (.75 mm). All shims must be table BACKLASH AND ROOT CLEARANCE
FLAT, without rough edges, kinks or bends. MEASUREMENTS.
If the above procedure is not followed and the . Mark the gear where the backlash and root
lightside of the counterweight is placed over the clearance measurements were taken. Rotate
pinion, excessive clearance will occur when the the gear by turning the countershaft and check
gear is operating under load. This excessive the measurements again with the gear in a dif-
clearance will result in the gear not running on ferent position. Do this several times and find
the pitch diameters. It will also result in the gear the average readings.
tooth load being applied more toward the tip of
the tooth which will cause higher stress on the . If the average backlash and root clearance is
gear teeth. . found to be less than that which is specified in
the table, the eccentric assembly is to be re-
To check or adjust backlash and root clearance of a moved and metal shims of the proper thickness
non-shifted gear, proceed as follows: are to be added. The shims can be lowered in
1. Position the counterweight or heavy portion of place by using a tool such as shown in the illus-
the gear directly over the pinion if possible. tration INSTALLING SHIMS.

5-3
The shims are to be inserted under the bottom Whenever installing shims on top of the main
bronze bearing plate and directly on top of the frame cap, always place the thinnest shims on
main frame cap as shown in the illustration the bottom and the thickest shims on top.
STEP BEARING PLATE SHIMS. Adding shims
will raise the eccentric assembly and move the SHIMS PLACED BENEATH THE BEARING
gear away from the pinion thereby increasing PLATES WHEN THE CRUSHER LEFT THE
the backlash and root clearance. Should the FACTORY ARE OF THE REQUIRED THICK-
measurements be more than that specified, NESS TO PROVIDE PROPER BACKLASH
metal shims of the proper thickness must be AND ROOT CLEARANCE. THESE SHIMS,
removed. WHILE PLACED IN THE CRUSHER INITIALLY
FOR BACKLASH ADJUSTMENT ARE PRI-
LOWERING MARILY USED FOR WEAR COMPENSATION.
TO
ns SHIMS
REFER TO THE MAINTENANCE PORTION
OF THIS SECTION.
Always use a minimum quantity of shims; if two
1/32" (.75 mm) shims are required, use one
1/16" (1.5 mm) shim instead. Do not use shims
thinner than 1/32" (.75 mm). All shims must be
FLAT, without rough edges, kinks or bends.

MAINTENANCE
REMOVING ECCENTRIC ASSEMBLY —
4-1/4 FT., 5-1/2 FT. AND 7 FT. CRUSHERS
To remove the eccentric assembly on these Crush-
ers, for servicing or replacement of parts, proceed
as follows:
1. Thread the eyebolts into the top of the eccen-
tric and lift the eccentric assembly out of the
INSTALLING SHIMS Crusher.

A,

MAIN
1/32” GASKET FRAME
SHIMS LOWER OF BOTTOM CAP
BRONZE BEARING
PLATE

STEP BEARING PLATE SHIMS

 Place blocking under the gear in such a posi-
A warnwe tion that the gear will not fall a great distance
and possibly damage the outside of the eccen-
CARE SHOULD BE TAKEN THAT THE tric. The blocking however, should be low
STEP BEARING PLATES DO NOT STICK enough to permit the gear to drop clear of the
TO THE BOTTOM OF THE ECCENTRIC shoulder on the counterweight. See the illustra-
DURING ECCENTRIC REMOVAL, AS tion TWO PIECE GEAR REMOVAL.
THESE PLATES COULD “BREAK” LOOSE . Remove the hex head capscrews and lock-
FROM THE BOTTOM OF THE ECCENTRIC washers bolting the gear to the counterweight.
DURING THE LIFTING PROCEDURE AND
CAUSE PERSONAL INJURY. RAISE THE . Ram downward on the outer surface of the
ASSEMBLY SLIGHTLY, THEN PUSH DOWN gear until the gear drops free of the counter-
ON THE BEARING PLATES WITH A LONG weight.
PIPE OR POLE TO BREAK THE PLATES
LOOSE FROM THE ECCENTRIC. COUNTERWEIGHT
\
—_—_—
—> ~”AY
2. Screw the special long eyebolt into the bottom
step bearing plate and remove all the step
bearing plates at one time. See the illustration
INSTALLING STEP BEARING PLATES .
REPLACING GEAR
The bevel gear which is mounted at the top of the
eccentric should be inspected whenever the eccen-
tric is removed for servicing other related parts or if
broken or excessively worn teeth are suspected.
Pitting or galling on the face of the teeth are a good
indication of excessive wear . This can originate
from an incorrect quantity of shims being placed
under the lower step bearing plate or by overioad-
ing the Crusher or by using excessively dirty oil. If it
has been determined that the gear is worn to the a BLOCKING
point where replacement is necessary, removal is
best accomplished as follows:

PRESS FIT
\
CRUSHER SIZE IN TONS (2000 LBS.) \
4-1/4 Ft. 15 ECCENTRIC
5-1/2 Ft. 20 TWO PIECE GEAR REMOVAL
7 Ft. 25
GEAR PRESS FIT TWO PIECE GEAR INSTALLATION
When installing a new gear, proceed as follows:
TWO PIECE GEAR REMOVAL
1. Remove the tapped dowel from the worn gear
This arrangement consists of a separate ring gear and drive it into the dowel hole of the new gear.
bolted to a counterweight. Only the gear needs
replacing as the counterweight remains pressed Thoroughly clean the threads on the capscrews
and keyed to the eccentric. For removal of this type that hold the gear to the counterweight and the
of gear, proceed as follows: tapped holes in the gear. It is recommended to
use Loctite Locquic Primer T as a cleaning
1. Remove the eccentric assembly from the agent. The use of this primer deposits various
Crusher as described under REMOVING EC- activating chemicals on the surface of the
CENTRIC ASSEMBLY. threads. However, xylol or trichloroethylene can
also be used.

5-5
 DO NOT USE GASOLINE, KEROSENE OR REMOVAL OF COUNTERWEIGHT
ANY OTHER OILY (PETROLEUM BASE)
In the event the counterweight on the two piece
CLEANING AGENTS OR THE EFFECTIVE-
gear arrangement must be removed from the ec-
NESS OF THE LOCTITE WILL BE REDUCED
centric use the same removal and installation meth-
CONSIDERABLY.
od as described in the ONE PIECE GEAR RE-
3. Place the gear on blocking and carefully lower MOVAL AND INSTALLATION procedures.
the eccentric assembly inside the gear with the ADJUSTING GEAR BACKLASH FOR WEAR
dowel projecting inside the dowel hole in the
counterweight. When step bearing plate and tooth wear reaches a
point where the proper backlash can no longer be
4, Liberally coat the capscrew threads with Loctite maintained, the backlash must be adjusted. This is
277, before assembling the capscrews into the accomplished by adding or removing the correct
gear. combination of shims which will give the proper
DO NOT USE ANY LUBRICANT EXCEPT backlash as specified in the table BACKLASH AND
LOCTITE . ROOT CLEARANCE MEASUREMENTS under
ASSEMBLY INSTRUCTIONS. Adding shims raises
5. Insert the capscrews and lockwashers into the the entire assembly, thereby moving the gear and
holes in the counterweight. Turn the capscrews pinion farther apart, while removing shims lowers
into the tapped holes in the gear and check that the assembly to bring the gear and pinion closer
the gear is properly centered on the counter- together. Be certain the plates and shims are reas-
weight fit. sembled correctly.
THERE ARE TWO DIFFERENT LENGTH BOTTOMING OF GEAR TEETH SHOULD BE
CAPSCREWS USED. THE LONGER CAP- AVOIDED AT ALL TIMES. CLEARANCE MUST BE
SCREWS ARE TO BE USED IN THE HEAV- PROVIDED AT THE BOTTOM OF THE TEETH,
IER PORTION OF THE COUNTERWEIGHT. REGARDLESS OF TOOTH WEAR. THEREFORE,
6. Alternately tighten each capscrew a small WHEN TEETH BECOME WORN TO THE EXTENT
amount to prevent the gear from binding on the THAT THE MINIMUM ROOT CLEARANCE AS
counterweight. Tighten each capscrew to the SHOWN IN THE TABLE CANNOT BE MAIN-
torque value shown in the table TWO PIECE TAINED WITH THE PROPER BACKLASH, THEN
GEAR TORQUE REQUIREMENTS . BACKLASH FIGURES MUST BE DISREGARDED.

GRADE 5 CAPSCREWS MUST BE USED. INNER ECCENTRIC BUSHING

THE HEAD OF A GRADE 5 CAPSCREW IS Whenever the eccentric is removed, the inner
IDENTIFIED WITH THREE RADIAL MARKS eccentric bushing should be checked for looseness
AS SHOWN. and excessive wear. When the bushing is found to
be loose in the eccentric, follow the instructions
under REPOURING BUSHING LOCK.
A BUSHING WITH NORMAL USE TENDS TO
WEAR MORE AT THE HEAVIEST SIDE OF THE
ECCENTRIC. THIS IS NO CAUSE FOR CON-
7. When all capscrews have been tightened, CERN SINCE IT IS A NORMAL AND EXPECTED
check with a feeler gauge that the gear is tight CONDITION. A BUSHING WHICH IS WORN
against the underside of the counterweight. EXCESSIVELY THIN OR CRACKED WILL, OF
The gear is now properly installed. COURSE, REQUIRE REPLACEMENT.
INNER ECCENTRIC BUSHING REMOVAL —
4-1/4 FT. CRUSHERS
PROPER TORQUE
CRUSHER | CAPSCREW WHEN USING A Eccentrics on these Crushers have two integrally
SIZE SIZE TORQUE WRENCH cast flat areas that engage similar flats on the
(FOOT POUNDS) bushing for preventing the bushing from turning. Do
not disturb these cast flat areas which are located
5-1/2 Ft. 1" 560-610
in the upper portion of the eccentric bore unless
7 Ft. 1-1/4" 1050-1150 they are ineffective through wear. See REPOUR-
TWO PIECE GEAR TORQUE REQUIREMENTS ING BUSHING LOCK.
To remove the inner eccentric bushing from the 4. Place a steel plate against the bottom of the
eccentric, simply turn the eccentric upside down, bushing and ram against the plate. The bush-
place a steel plate against the bottom of the bush- ing should now drop out of the eccentric.
ing and jar the bushing free by ramming against the
plate.
INSTALLING INNER ECCENTRIC
BUSHING
Position the eccentric on wooden blocking in such a
To install a replacement inner eccentric bushing,
manner so as to enable the bushing to drop free of
proceed as follows:
the eccentric when rammed loose.
1. Chip out any epoxy or zinc which might remain
INNER ECCENTRIC BUSHING REMOVAL — in the cored pockets in the eccentric on the 5-
5-1/2 FT. AND 7 FT. CRUSHERS 1/2 Ft. and 7 Ft. Crushers. Do not disturb the
On the 5-1/2 Ft. and 7 Ft. machines the bushing cast flats in the eccentric bore on the 4-1/4 Ft.
lock is found only at the top of the bushing and con- Crushers.
sists of mating tapered pockets, in both the bushing . Check to be sure the flats on the bushings are
and eccentric, which are filled with epoxy locking in alignment with the cast flats in the eccentric
compound or zinc, to prevent the bushing from turn- or the pockets in the bushings are across from
ing. If the inner eccentric bushing requires replace- the ones in the eccentric.
ment, proceed as follows:
. Lower the bushing into the eccentric and, using
1. Drill a series of holes in the locking material, a wooden timber, ram the bushing down. For
only in the pockets that are directly across from the APPROXIMATE location of the bushing
the cored pockets in the eccentric, See the within the eccentric, refer to the illustration and
illustration, 5-1/2 Ft. AND 7 Ft. BUSHING table INNER ECCENTRIC BUSHING LOCA-
LOCK. TION. Measurements are to be taken from the
. Chisel through the material adjoining the drilled top of the eccentric down to the bushing at the
holes. gear key. Ram the bushing down until a feeler
gauge of no more than 0.004 inch can be
. Turn the eccentric upside down positioned on inserted at the bottom, between the outside of
wooden blocking in such a manner so as to the bushing and the bore of the eccentric.
enable the bushing to drop free of the eccentric
when rammed loose. DO NOT USE DRY ICE TO INSTALL AN
INNER ECCENTRIC BUSHING. BOTH BUSH-
DRILL OUT THE
NORDBAK OR ZINC ING AND ECCENTRIC MUST BE AT THE
ECCENTRIC IN THESE CORED SAME TEMPERATURE WHEN INSTALLING

\ POCKETS THE BUSHING.

. Pour the bushing lock at the top of the eccentric
on the 5-1/2 Ft. and 7 Ft. Crushers. On the 4-
1/4 Ft. Crushers no further bushing locks are
required. Refer to the table LOCKING MATERI-
AL REQUIREMENTS in Section 3 for the
approximate amount of locking material to pre-
pare.
USE ONLY EPOXY LOCKING COMPOUND
WHEN REPOURING THE BUSHING LOCKS.
DO NOT USE EPOXY BACKING MATERIAL .
EPOXY LOCKING COMPOUND USES A SPE-
CIAL FILLER WHICH OFFERS MORE
BUSHING STRENGTH AND HEAT TRANSFER PROP-
LOCK ERTIES THAN CONVENTIONAL EPOXY
BACKING MATERIAL.
INNER REPOURING BUSHING LOCK
ECCENTRIC
BUSHING “ Should a bushing become free to rotate within the
eccentric by wearing through the bushing lock, it is
5-1/2 FT. AND 7 FT. BUSHING LOCK

5-7
 INNER
ECCENTRIC EYEBOLT
BUSHING
ECCENTRIC

FEELER
GAUGE

CRUSHER SIZE 4-1/4 FT. 5-1/2 FT. 7 FT.

A 19/32 7/8 1-3/16
ALL DIMENSIONS IN INCHES
INNER ECCENTRIC BUSHING LOCATION

then necessary to repour these locks. On the 4-1/4 MENTS in Section 3 for the approximate amount of
Ft. Crushers see the illustration REPOURING locking material to prepare.
BUSHING LOCKS. Remove the bushing and chip
EMERGENCY REPAIR OF GEAR AND
out the cast flats in the eccentric bore, especially
ECCENTRIC INTERFERENCE FIT
the dovetailing cast into the eccentric. Once this is
done, the loosened bushing can be lowered back To offset downtime during critical operating periods,
into position and the epoxy locking compound or the use of Loctite is recommended as an emer-
zinc repoured from the top of the eccentric. Care gency “field” repair to correct for the loss of interfer-
should be taken when repouring these flats that the ence fit between the gear and eccentric, until a
flats on the bushing are directly opposite the dove- more appropriate time is available for normal repair
tailing in the eccentric bore. On the 5-1/2 Ft. and 7 or replacement of parts. When using Loctite to hold
Ft. Crushers, drill, chip and clean out the epoxy or the gear to the eccentric proceed as follows:
zinc from the pockets and pour in an additional
1. Measure the outside diameter of the eccentric
quantity, taking care that the bushing pockets are
and the bore of the gear. If the fit is less than
located directly across from the pockets in the
0.010 inch loose on the diameter, Loctite can
eccentric. See the illustration REPOURING BUSH-
be used.
ING LOCKS.
IF THE CRUSHER IS EQUIPPED WITH A
BEFORE REPOURING ANY LOCK, CHECK THAT
TWO-PIECE GEAR ARRANGEMENT, THE
THE BUSHING IS PROPERLY INSTALLED AS
BORE OF THE COUNTERWEIGHT MUST BE
DESCRIBED UNDER INSTALLING INNER
MEASURED INSTEAD OF THE GEAR AS
ECCENTRIC BUSHING.
THE COUNTERWEIGHT IS THE PART
Refer to the table LOCKING MATERIAL REQUIRE- PRESSED ON TO THE ECCENTRIC.
2. Thoroughly clean the outside of the eccentric DO NOT USE A HYDRAULIC PRESS TO
and the bore of the gear or counterweight. It is INSTALL THE GEAR OR COUNTERWEIGHT
recommended to use Loctite Locquic Primer T TO THE ECCENTRIC WHEN USING THE
as a cleaning agent. The use of this primer LOCTITE REPAIR PROCEDURE.
deposits various activating chemicals on the
. After the gear or counterweight has been coat-
surface of the gear or counterweight and ec-
ed with Loctite and it is properly positioned on
centric. However, xylol or trichloroethylene can
the eccentric, allow at least 2 to 3 hours before
also be used.
moving the assembly. Refer to the installation
DO NOT USE GASOLINE, KEROSENE OR method as described in the ONE-PIECE GEAR
ANY OTHER OILY (PETROLEUM BASE) INSTALLATION procedure to properly position
CLEANING AGENTS OR THE EFFECTIVE- the gear or counterweight on the eccentric.
NESS OF THE LOCTITE WILL BE REDUCED
PLACE BLOCKING UNDER THE GEAR OR
CONSIDERABLY.
COUNTERWEIGHT IN SUCH A MANNER AS
3. Liberally coat the surfaces of both the gear or TO HOLD THE ENTIRE ASSEMBLY IN ITS
counterweight and eccentric with Loctite CORRECT RELATIONSHIP WITH EACH
RC/680 (High Strength Retaining Compound) OTHER UNTIL THE LOCTITE HAS CURED.
using a CLEAN brush. Make sure the entire fit
. Curing of the Loctite can be speeded up by
surfaces are coated with the Loctite.
heating the gear or counterweight to 200°F
4. lf necessary the gear or counterweight can be (93°C). The assembly can then he used imme-
heated to permit assembly to the eccentric. diately after cooling to room temperature.

- ECCENTRIC EPOXY
\ OR ZINC

ZA | |F
|
Ky

FLATS ON : FLATS CAST

OUTSIDE OF : INTO THE
INNER : ECCENTRIC
ECCENTRIC
BUSHING

= CORED
e ; POCKETS
4 i: N ECCENTRIC BUSHING
LOCK
ECCENTRIC |

t INNER :
ECCENTRIC
BUSHING

»t

5-1/2 FT. AND 7 FT CRUSHER

2 FT., 3 FT., 4 FT., 5100 AND
4-1/4 FT. CRUSHER

REPOURING BUSHING LOCKS

 Section 6

SOCKET ASSEMBLY
DESCRIPTION ... 0... cece etree eee teen tte nee b tebe nenees 6-1

ASSEMBLY INSTRUCTIONS ...... 0.0... ccc cece eee nee teenies 6-1

GENERAL INFORMATION. ......... 00.0000. eect eee eee eens 6-1

INSTALLING THE BOLTED SOCKET ......... 0... eee eee tees 6-1

INSTALLING THE 4-1/4 FT. DOWELED SOCKET...........00..ccceeveeees 6-2

INSTALLING THE 7 FT. DOWELED SOCKET .....................

ccc enue 6-3

WATER SEAL PIPING... 0... 0c ccc eeet eee ener n ene t ene enees 6-5

GENERAL INFORMATION. ...... 0.0. cece cece eee eet e eee n ene ees 6-5

CONTINUOUS WATER SYSTEM........ 0... ccc cece cece cece teen eenes 6-5

LIMITED WATER SYSTEM ......... 2... cece eee eee eee tee tenn eens 6-5

WATER PRESSURE REQUIRED........ 0.0... ccc cece 6-5

INSTALLATION. 2.0... . cere eee net nett eee eneeeeee 6-5

OPERATION .. 0... cece

en ee teeter te tee ee tent eee eae 6-8

SEASONAL STORAGE ......... 00ers 6-8

MAINTENANCE .... 0... ccc cere tence nen n ene e ens 6-8

SERVICING THE STANDARD OR AIR SEAL ARRANGEMENT ............. 6-8

SERVICING THE WATER SEAL ARRANGEMENT.................2000000s 6-11

WATER PRESENT IN THE LUBRICATING OIL..............

02. c cee eee 6-13

LEAKING WATER ...... 00.0 ccc cece cece eee eee tebe beeen et eeee 6-13

REPLACING THE WATER CHAMBER GASKET..................0002e

eee 6-13

SOCKET LINER... eee ete enna 6-15

GENERAL INFORMATION. .........0. 00.0. e cece erect eens 6-15

REPLACING SOCKET LINER...........

0... cece cence eee 6-16

REMOVAL OF BOLTED SOCKET ...........00.0 0... 6-17

REMOVAL OF 4-1/4 FT. AND 7 FT. DOWELED SOCKET................... 6-17

SHIMMING LOOSE SOCKET ...... 0... c cece ee eee cent ene ees 6-19
 SOCKET
DOWEL
SOCKET SOCKET
SEALING LINER
RING
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et Se ean
SOCKET SEALING

ott
RING SPRINGS
AND HOUSING
PACKING LOCKING -
KEY
SOCKET
 Section 6

SOCKET ASSEMBLY
DESCRIPTION For extremely dusty crushing conditions a water
seal which has a water chamber bolted to the sock-
This section covers the socket assembly. The sock-
et, in conjunction with a baffle ring welded to the
et with the socket liner supports the main shaft
head, uses constantly circulating water as the seal.
assembly and transmits the crushing force to the
This baffle arrangement requires that dust particles
main frame. The socket is held rigidly in the frame
become trapped and suspended in the water flow-
by an interference fit and a series of capscrews
ing through the chamber.
installed around the perimeter of the socket.
Either of these types of seals provides a very effec-
In the case of a 4-1/4 Ft. or 7 Ft. Crusher equipped
tive seal against dust infiltration.
with a doweled socket, an interference fit and a
series of dowels provide the means of holding the
socket rigidly to the frame. ASSEMBLY INSTRUCTIONS
The socket liner mounted on top of the socket pro- GENERAL INFORMATION
vides the bearing surface for the head. The spheri-
cal bearing surface of the socket liner is thoroughly Although the socket is usually shipped completely as-
sembled in the main frame, the occasion may arise
lubricated from an oil passage through the center of
the main shaft and through the head. A retaining where weight or shipping restrictions prohibit this
ring welded to the socket prevents the oil which is degree of assembly. If the socket assembly was re-
circulating on the surface of the socket liner from moved for shipment, it will be necessary to partially
disassemble the unit in order that the tapped holes
spilling into the sealing arrangement. An oil groove
for the lifting eyebolts and the holes which are used
in the liner and a series of drilled holes in both the
for holding or pulling in the socket are accessible. Re-
liner and socket allows the oil to drain back inside
move the sealing ring components (if equipped with
the Crusher.
the standard seal or air seal arrangement) or the
It is very important that dust and abrasive particles water chamber components (if equipped with the
which result from the crushing process be kept water seal arrangement) as described in the MAIN-
from entering the lubricating system or damaging TENANCE portion of this section, then proceed to
the highly machined internal portions of the Crush- install the socket.
er. Since the head moves with an eccentric or gy-
INSTALLING THE BOLTED SOCKET
rating motion a seal must be provided that is flexible
in order that continuous contact or sealing is possible. To install the bolted socket, proceed as follows:
This flexibility is provided in three types of sealing 1. Lower the socket into the approximate position
arrangements; the standard seal, air seal and water on the main frame and align the holes in the
seal. socket with the tapped holes in the frame. See
the illustration LIFTING SOCKET ASSEMBLY.
The standard sea! utilizes a sealing ring packed
with grease, which is constantly held against the ONE HOLE IN BOTH THE SOCKET AND THE
head wipers by a series of small helical compres- MAIN FRAME IS OFFSET TO INSURE PROP-
sion springs. This wiper arrangement allows the ER ASSEMBLY.
dust particles that enter the seal to become trapped
2. Insert the socket head capscrews through the
and embedded in the grease. The standard seal is
used in most plant installations with average crush- holes in the socket and then into the tapped
holes in the main frame.
ing conditions, where the supply of water is limited
and on portable plant installations. 3. As the socket has an interference fit with the
For extremely dusty crushing conditions the air seal main frame, uniformly heat the frame around
the socket fit to 100°F (88°C) above ambient
using a similar type of wiper arrangement as the
temperature.
standard seal is furnished. This seal uses an air
blower to pressurize the seal area and force the 4. With a wrench, alternately tighten each cap-
dust out. screw a small amount to prevent binding. See

6-1
 EYEBOLT

»
SOCKET
HEAD
CAPSCREW

SOCKET

SOCKET

TIGHTENING SOCKET HEAD CAPSCREWS

INSTALLING THE 4-1/4 FT. DOWELED

SOCKET
To instail the doweled socket, proceed as follows:
1. Lower the socket into the approximate position
on the main frame and align the holes in the
LIFTING SOCKET ASSEMBLY socket with the four dowels in the frame. See
the illustration LIFTING SOCKET ASSEMBLY
the illustration TIGHTENING SOCKET HEAD — DOWELED SOCKET.
CAPSCREWS. . With the socket in the proper position on the
. Tighten all capscrews until the socket is firmly main frame, insert the four special hex head
seated in the main frame. On all sizes of Crush- jacking screws, found in the box with the tools,
ers the socket must seat without any clearance. through the holes in the socket and then into
See the illustration BOLTED SOCKET SEAT- the tapped holes in the main frame.
ING SURFACES. . As the socket has an interference fit with the
. Clean, lubricate and install the sealing ring or main frame, uniformly heat the frame around
water chamber components, depending on how the socket fit to 100°F (38°C) above ambient
equipped, as instructed under SERVICING temperature.
THE STANDARD SEAL, AIR SEAL or WATER . Alternately tighten each jacking screw a small
SEAL ARRANGEMENT in the MAINTENANCE amount to prevent binding. See the illustration
portion of this section. TIGHTENING JACKING SCREWS.
 SOCKET ae
EYEBOLT

TIGHT

| tl
CLEARANCE me

MAIN _—
FRAME SOCKET

4-1/4 FT., 5-1/2 FT. & 7 FT.

SEATING SURFACE

BOLTED SOCKET SEATING SURFACES

5. Tighten all jacking screws until the socket is

firmly seated in the main frame. The socket
must seat with a clearance of 1/8" (3 mm)
between the socket and frame, at the outside
flange of the socket. See the illustration DOW-
ELED SOCKET SEATING SURFACE.
6. The jacking screws are then removed. All
drilled and tapped holes in the socket are to be
sealed with the plastic tapered plugs that are
furnished. FRAME
7. Clean, lubricate and install the sealing ring as
instructed under SERVICING THE STANDARD
OR AIR SEAL ARRANGEMENT in the MAIN- LIFTING SOCKET ASSEMBLY
TENANCE portion of this section. DOWELED SOCKET
INSTALLING THE 7 FT. DOWELED
SOCKET
IS TO BE ALIGNED WITH A LOCATING PIN
To install the doweled socket, proceed as follows:
IN THE MAIN FRAME TO INSURE PROPER
1. Lower the socket into the approximate position ASSEMBLY . THIS PIN IS LOCATED OPPO-
on the main frame and align the holes in the SITE THE COUNTERSHAFT BOX.
socket with the four dowels in the frame. See
. With the socket in the proper position on the
the illustration LIFTING SOCKET ASSEMBLY
main frame insert the four special hex head
— DOWELED SOCKET.
jacking screws, found in the box with the tools,
ON THE WATER SEAL DOWELED SOCKET through the holes in the socket and then into
THERE IS ONE HOLE IN THE SOCKET THAT the tapped holes in the main frame.

6-3
 SOCKET SOCKET
™
Ve

1/8" CLEARANCE

JACKING
SCREW

MAIN ~*~
FRAME

DOWELED SOCKET SEATING SURFACE

. Tighten all jacking screws until the socket is

firmly seated in the main frame. The socket
must seat with a clearance of 1/8" (3 mm)
between the socket and frame, at the outside
flange of the socket. See the illustration DOW-
TIGHTENING JACKING SCREWS ELED SOCKET SEATING SURFACE.
. The jacking screws are then removed. The
tapped holes are to be sealed with cotton
. As the socket has an interference fit with the waste saturated with oil or grease.
main frame, uniformly heat the frame around
. Clean, lubricate and install the sealing ring or
the socket fit to 100°F (38°C) above ambient
water chamber components, depending on how
temperature.
equipped, as instructed under SERVICING
. Alternately tighten each jacking screw a small THE STANDARD, or WATER SEAL ARRANGE-
amount to prevent binding. See the illustration MENT in the MAINTENANCE portion of this
TIGHTENING JACKING SCREWS. section.
WATER SEAL PIPING settling tank should be drained off periodically and
water added to maintain the correct level. Refer to
GENERAL INFORMATION the table PIPING AND WATER REQUIREMENTS
The main consideration when deciding on a water for the correct capacity of the tank and the horse-
type seal, is the quantity and quality of water that power required for the water pump motor. Since
will be available. The water should be clean and this is a closed system, an anti-freeze solution or a
free from foreign matter and excessive sediment. light grade of fuel oil can be substituted in place of
The quantity of water must be in accordance with the water to keep the system from freezing in cold
the amount specified in the table PIPING AND weather.
WATER REQUIREMENTS.
Two types of water systems which can be used, are WATER PRESSURE REQUIRED
the CONTINUOUS and the LIMITED. The merits _ The amount of water pressure required for the
and requirements for each system are discussed in water type seal is dependent upon the quantity
the following paragraphs. (GPM) of water that is necessary to adequately
flush out the water chamber, however, the pressure
CONTINUOUS WATER SYSTEM
loss within the water chamber is minimal, approxi-
A continuous water system is that which can be mately 10 PSI.
obtained from a plant water system. With a continu-
ous system, water is simply circulated through the INSTALLATION
Crusher and discharged. The dirt and dust is col-
lected in the water and washed away and not recir- Whenever a water seal arrangement is furnished
culated through the system. When using a continu- with the Crusher, drawings are provided showing
ous system avoid operating in freezing tempera- hose and pipe fittings, of both the feed and drain
tures unless precautions are taken to prevent the lines, which are furnished with the Crusher. A typi-
water from freezing. This type of water system is cal arrangement of the continuous and the limited
the most popular and is used on most water seal water system is shown in the illustrations CONTIN-
installations. See the illustration CONTINUOUS UOUS WATER SYSTEM and LIMITED WATER
WATER SYSTEM . SYSTEM. Drain lines should have a minimum pitch
of 1/2" for every 12" of pipe used.
LIMITED WATER SYSTEM
After the piping has been installed, the system
if a continuous water supply is not available, a stor- should be tested to determine if the amount of
age settling tank for the water supply can be used. water circulated conforms to that given in the table
The water in this type of system is continually being for the various size Crushers. The flow valve, which
circulated from a storage tank to the Crusher and is furnished, should be installed in the feed line, to
back again. A baffle separates the tank and the control the amount of water to the Crusher. The
dust contaminated water drains into one side of the quantity of water and the water pressure must
baffle while the pump suction line is connected to remain constant for the proper operation of the
the other side of the baffle. The heavier particles of water seal arrangement.
dust will settle on the one side of the baffle before
mixing with the water on the other side. See the All hose and pipe fittings are to be placed directly
illustration LIMITED WATER SYSTEM, for the loca- under the arms of the main frame or countershaft
tion of this baffle. Sediment at the bottom of the box to prevent wear from the crushed material.

RECOMMENDED MINIMUM HP REQUIRED

CRUSHER a ATER Sek QUANTITY RECOMMENDED FOR PUMP
usH VATE | WATE | OF WATER TO BE SETTLING TANK | MOTOR WHEN
Al UFFLY | CIRCULATED INGALS. | CAPACITYIN | USING SETTLING
PER MINUTE U.S. GALLONS TANK
4-1/4 Ft. 4-1/2" 1" 6 300 1/2
5-1/2 Ft. 1-1/2" 1" 8 300 1
7 Ft 1-1/2" 1 8 500 1
PIPING AND WATER REQUIREMENTS
 ooo 2 {a1}
on

|
—

|OEDoO
:

| A
— =
=i ed
beeeeram ie esmt

Le

WATER FEED
__ LINE
Cop CT a’,
fo = oy y
i ——___—_. i

|
' it
Jf,
: —
‘
1 0725, ne)

:i aE |
peor is

ore td
bb eeecligee FLOW VALVE TO
Kee GLOBE VALVE USED
bar TO REGULATE QUANTITY
tt GATE VALVE NORMALLY CLOSED. OF WATER
i USED FOR DRAINING SOCKET
| WHEN CRUSHER IS SHUT DOWN

Ld
WATER DRAIN LINES
(DRAIN LINES SHOULD HAVE
A MINIMUM PITCH OF 1/2"
FOR EVERY 12" OF PIPE USED)

CONTINUOUS WATER SYSTEMS

 ‘
rag| ae
Ss =
—

cc e i

ia Tm ={TT {Tk Ma =

yt tit | Wd od.
‘
' 1
| | | 1! | ' ' | | ' ' | f | ' | !
\ \ ‘ | ' | ' | y ‘ | 1 1 | ' ‘

i ste i PL hE Lt ht aa

FLOW VALVE
OR GLOBE VALVE
USED TO REGULATE
QUANTITY OF WATER
fH, a Tr} vs
Cat ‘ey —
ee
—H/") f
Lan
. {
".."s, WATER DRAIN '
aymy, LINES / GATE VALVE NORMALLY '
ae CLOSED. USED FOR Psp
a Ne?
., 4 a, DRAINING SOCKET 1
WHEN CRUSHER
Oe IS SHUT DOWN
rn (DRAIN LINES SHOULD HAVE
bh A MINIMUM PITCH OF 1/2"
iy} FOR EVERY 12" OF PIPE USED)

WATER 4} LEVEL . Betts 1.

ref (id4
MUST BE MAINTAINED 8s \ | MEEED
: | i!‘ V7, UNE
(
ye
(i)
Q if

7 / PUMP AND
DRAIN SETTLING BAFFLE MOTOR
PLUG TANK
LIMITED WATER SYSTEM

6-7
OPERATION ARRANGEMENT and LIFTING SOCKET
Do not allow the water level in the overflow trough SEALING RING.
of the water chamber to become too high. This is ON THE 7 FT. CRUSHER, CAST LUGS ON
caused by either an excessive amount of water THE SIDES OF THE SEALING RING ARE
being supplied to the chamber, or by the discharge USED FOR LIFTING PURPOSES.
pipe not draining freely due to being frozen or par- . Thoroughly clean all the components removing
tially clogged. Dirt or other foreign material such as all greased dirt. Check the drain holes or
precipitation from hard water may also partially clog chipped grooves just beneath the socket liner
the water outlet or drain manifold. are open. These holes or grooves permit the
A large concentration of dust will require more excess oil that flows over the socket liner to
water to flush out the seal. Sediment should not be run down between the socket liner and the
allowed to accumulate in the water chamber or the oil retaining ring and drain back into the Crush-
effectiveness of the seal will be reduced. If this er. See the illustration OIL DRAIN HOLES/
occurs, it may be caused by an insufficient supply GROOVES.
of water or an uneven overflow of water, which indi- . Inspect the wipers on both the head and seal-
cates the Crusher is not level on the foundation. ing for wear.
Also check for a dirty water supply or the crushed
. Inspect the wipers on both the head and seal-
material could be building up in the discharge chute
ing ring for possible damage, smooth up any
and interfering with the underside of the head. nicks, burrs or rough edges.
SEASONAL STORAGE . Inspect the springs for possible breakage and
At the end of the crushing season or during any weakness due to fatigue. Replace where nec-
long shutdown period, drain all the water from the essary. Use a new spring as a guide to deter-
Crusher. To assure complete drainage of the water mine whether a spring has lost its compres-
chamber, both the feed and drain lines are to be sion.
pitched away from the Crusher and the feed line is . Clean the holes in the socket or main frame
to be drained using the valve furnished. It is also which accommodate the springs and spring
advisable to remove the head and main shaft housings.
assembly and fill the inner portion of the water . Insert the springs in the spring housings and
chamber with a light grade of oil to prevent the lightly lubricate the housings with oil, then
water jet ports from clogging or corroding. insert them in the holes in the socket or the
main frame.
EYEBOLT
MAINTENANCE ~ SOCKET
SERVICING THE STANDARD OR
SEALING
RING
AIR SEAL ARRANGEMENT
With the main shaft assembly out of the Crusher for
a liner change, it is advisable to replace the grease
in the sealing ring chambers and check the socket
sealing components for proper operation and wear.
lf the socket sealing ring is excessively worn to the
point where it has lost its effectiveness as a seal, it
should be replaced. If any of the springs have be-
come weakened and no jonger can exert the nec-
essary pressure to maintain continuous contact
between the head wipers and the sealing ring
wipers, they also should be replaced. To service or
replace the parts on a standard or air seal arrange-
ment, proceed as follows:
1. Remove the socket sealing ring, springs, spring PACKING
housings, and locking keys (If so equipped).
See the illustration STANDARD and AIR SEAL
LIFTING SOCKET SEALING RING
 OIL RETAINING SOCKET MAIN HEAD
RING LINER SHAFT SOCKET
|—~ / DOWEL

SOCKET
~ LOCKING SEALING
KEY RING

SOCKET
SOCKET SEALING
SOCKET RING SPRING
HEAD
CAPSREW
AND HOUSING
BOLTED OR KEYED SOCKET

MAIN
OIL RETAINING SOCKET SHAFT

Lemme!
RING LINER HEAD

SOCKET
SEALING
RING

SOCKET
J) SOCKET
KEY
OrRING Ma SOCKET SEALING
MAIN FRAME RING SPRING
DOWEL AND AND HOUSING
SOCKET BUSHING DOWELLED SOCKET
STANDARD AND AIR SEAL ARRANGEMENT

6-9
 LOCKING
KEYS SOCKET SOCKET
— SEALING SEALING
RING
}—____.

v2

LOCKING KEYS

8. Check each spring and spring housing to be

sure it has adequate freedom of movement
within the hole in the socket.
. Install the locking keys at the side of the socket. GUIDE PINS
See the illustration LOCKING KEYS. Check
that the locking keys move freely within the 11. Carefully aligning the slots in the sealing ring
hole in the socket.
with the locking keys or the guide pins in the
ON THE 7 FT. DOWELED SOCKET GUIDE sealing ring with the guide bushings in the
PINS ARE USED IN PLACE OF THE LOCK- socket, lower the ring over the socket onto the
ING KEYS. CLEAN THE GUIDE PINS spring housings.
PRESSED INTO THE UNDERSIDE OF THE 12. Check to be certain that the ring is free on the
SOCKET SEALING RING THOROUGHLY. socket, that no binding of the seal is evident
SEE THE ILLUSTRATION GUIDE PINS. and that free movement on the springs is possi-
10. Remove the felt packing from inside the socket ble. If the sealing ring is not “free” on the sock-
sealing ring flange or on the side of the socket et, trim the inside diameter of the felt packing,
and soak the packing thoroughly in lubricating using a sharp knife.
oil. The felt is then to be reinserted in the 13. Remove the lifting eyebolts and seal the tapped
groove. holes with cotton waste saturated in oil or
grease.
ON THE 7 FT. DOWELED SOCKET A LARGE
DIAMETER “O” RING IS USED IN PLACE OF ON THE 4-1/4 FT. DOWELED SOCKET ALL
THE FELT PACKING. REMOVE THE “O” RING DRILLED AND TAPPED HOLES IN THE
FROM THE GROOVE IN THE MAIN FRAME SOCKET ARE TO BE SEALED WITH THE
AND CLEAN THE GROOVE THOROUGHLY. PLASTIC TAPERED PLUGS THAT ARE FUR-
LIGHTLY GREASE THE “O” RING AND THEN NISHED.
REINSTALL IN THE GROOVE. IF THE SEAL 14. If this is a STANDARD SEAL ARRANGEMENT
IS DAMAGED, IT MUST BE REPLACED BE- pack the sealing ring with a lithium base grease
FORE THE SEALING RING IS REASSEMBLED. such as NLGI No. 1 or equivalent, to the level
THE FELT PACKING OR “O” RING SEALS shown on the illustration SOCKET SEALING
AGAINST DUST INFILTRATING BETWEEN RING GREASE CHAMBERS. The sealing ring
SOCKET AND RING. IF DUST IS ALLOWED on the 4-1/4 Ft. and 7 Ft. doweled socket has
TO ENTER THIS AREA, FREE MOVEMENT only one chamber that has to be filled with
OF THE SEALING RING CAN BE IMPAIRED. grease, while the 5-1/2 Ft. bolted socket has
THEREFORE, IF THIS PACKING OR “O” two chambers that are to be filled with grease.
RING SHOULD BECOME DAMAGED OR 15. Lightly oil the surface of the socket liner and
INEFFECTIVE THROUGH LONG USE, coat both ring and head wipers with a liberal
REPLACEMENT IS NECESSARY. amount of grease.
 GREASE
(TWO CHAMBERS)
GREASE
(ONE CHAMBERS)

/
SOCKET
SEALING
SOCKET
SOCKET
SEALING
RING
SOCKET

RING

5-1/2 FT. BOLTED SOCKET 4-1/4 FT. AND 7 FT. DOWELLED SOCKET

SOCKET SEALING RING GREASE CHAMBERS

16. Install the main shaft assembly in the Crusher necessary, adjust each water jet so that the
’ and check that the springs lightly force the slots or holes will all point in the same direction
sealing ring against the wipers on the head. so that the water will circulate in a clockwise
direction. This will prevent sediment from set-
17. After the main shaft assembly is in its proper
tling in the chamber. See the illustration AD-
position, lift the assembly approximately 1/2"
JUSTING WATER JETS.
(13 mm) and again check that the sealing ring
is free to move on the springs. . Check that the drain holes or chipped grooves
just beneath the socket liner are open. These
holes or grooves permit the excess oil that
SERVICING THE WATER SEAL flows over the socket liner to run down between
ARRANGEMENT the socket liner and the oil retaining ring and
drain back into the Crusher. See the illustration
With the main shaft assembly out of the Crusher for OIL DRAIN HOLES/GROOVES
a liner change, it is advisable to clean the water
chamber and check the socket sealing arrange- . On the 7 Ft. Crusher, check that the vent pipes
ment for proper operation. For disassembly and are open thereby allowing the water chamber
replacement of the various socket sealing compo- and baffle ring area to maintain atmospheric
nents refer to the instructions as described under pressure. The 4-1/4 Ft. and 5-1/2 Ft. Crushers
REPLACING THE WATER CHAMBER GASKET. have similar venting arrangements. These larg-
er machines are equipped with vents because
To service the parts on a water seal arrangement, of the large quantity of water being circulated
proceed as follows: through the water chamber. See the illustration
1. Thoroughly clean al!l the parts, removing all WATER SOCKET VENTING.
grease, dirt and sediment. See the illustration . Fill the chamber with water and test for leaks
WATER SEAL ARRANGEMENT. and proper operation. See the table PIPING
2. Clean the slots or holes in the water jets to be AND WATER REQUIREMENTS.
sure there will be unrestricted water flow. If . Install the main shaft assembly in the Crusher.
 SOCKET
LINER
BAFFLE |
RING MAIN SHAFT HEAD

-\. SOCKET DOWEL

OIL
RETAINING
RING

1/16" GASKET WATER our

SOCKET
WATER INLET VET
HEAD
CAPSCREW BOLTED SOCKET

SOCKET MAIN
VENT MEAD
SHAFT OIL
| \ RETAINING RING

=\\. BAFFLE RING

SOCKET
LINER

WATER
CHAMBER SOCKET
KEY ; an
GASKET AND
MAIN FRAME SPACER WATER
WATER INLET DOWEL AND OUTLET
SOCKET BUSHING

7 FT. DOWELLED SOCKET

WATER SEAL ARRANGEMENT

 SOCKET
LINER DRILLED
> HOLE
OIL
RETAINING
HEAD RING CHIPPED
GROOVE
OIL
RETAINING
RING
HEAD

OIL DRAIN
HOLES \
SOCKET SOCKET
OIL LINER
DRAIN
HOLES
SOCKET OIL DRAIN HOLES OIL DRAIN GROOVES

OIL DRAIN HOLES/GROOVES

WATER PRESENT IN THE supplied in greater amounts than what is recom-

LUBRICATING OIL mended. See the table PIPING AND WATER
REQUIREMENTS.
There may be occasions when water may be pres-
ent in the lubricating oil, either from condensation,
LEAKING WATER
or a plugged air breather or if the Crusher is so
equipped, from a faulty water seal arrangement. Should water begin to leak from beneath the Crush-
AN IMPORTANT FACTOR TO CONSIDER IS THAT er, it could be caused by either an excessive
THE AIR BREATHER CONNECTING INTO THE amount of water being supplied to the chamber, or
SIDE OF THE COUNTERSHAFT BOX MUST BE by the discharge pipe not draining freely due to
CLEAN TO MAINTAIN ATMOSPHERIC PRES- being frozen or partially clogged. Dirt or other for-
SURE INSIDE THE CRUSHER TO ASSURE FREE eign material such as precipitation from hard water
DRAINAGE OF THE LUBRICATING OIL AND CIR- may also partially clog the water outlet or drain
CULATION OF WATER. manifold. See the table PIPING AND WATER
REQUIREMENTS. Also check all pipe connections
A natural cause of water in the lubricating oil is con- for tightness. Leakage could occur from the gasket
densation, in which case, it need only to be drained joint between the water chamber and socket, see
off. If the water which is present in the lubricating the instructions REPLACING THE WATER CHAM-
oil is due to condensation or other natural causes, BER GASKET.
allow the oil to remain motionless in the tank for a
day so that the water will have a chance to settle to
the bottom of the tank. Since the water is the heav- REPLACING THE WATER
ier liquid, it can now be drained off without losing a CHAMBER GASKET
great deal of oil. When water is present in the oil in If there is evidence of water leakage from beneath
' any appreciable amount, the oil will foam. This con- the Crusher or as indicated by foam in the oil level
dition is readily visible in the oil level gauge on the gauge on the oil tank, the Crusher should be disas-
oi] tank. See the instructions REPLACING THE sembled to determine whether there is a leaking
WATER CHAMBER GASKET. Another cause of water chamber gasket or the vents and drain holes
water in the lubricating oil is that water is being are plugged.

6-13
 WATER
CHAMBER
BAFFLE HEAD
VENT RETAINER RING
AND OIL BAFFLE
RETAINING RING OIL
RETAINING
HEAD RING
peskNG
\ BAFFLE
[RING

WATER ~~
CHAMBER

=)\
—_
——

6"GASKET
AND DRAIN |
SPACER MANIFOLD i

SOCKET Vs
MAIN f (t 5
WATER FRAME FRAME
CHAMBER WATER
OUTLET
7 FT. CRUSHER
4-1/4 FT. AND 5-1/2 FT. CRUSHER
WATER SOCKET VENTING

To replace the gasket or other related parts, pro- 2. Disconnect the pipe couplings in the water pip-
ceed as follows: ing at the inlet and the drain side of the water
chamber. See the illustration WATER SEAL
1. With the main shaft assembly removed, thor-
ARRANGEMENT.
oughly clean the water chamber, removing any
grease or other sealing.agent which might be 3. Remove the socket head or hex head cap-
packed around the socket head capscrews. screws which bolt the water chamber to the
socket.
ON THE 7 FT. DOWELED SOCKET THE WA-
TER CHAMBER IS HELD TO THE SOCKET ON THE 7 FT. MACHINE THE VENTS AND
BY HEX HEAD CAPSCREWS BOLTED FROM VENT RETAINERS MUST BE UNSCREWED
BENEATH THE SOCKET. AT THE SIDE OF THE SOCKET BEFORE THE
 ONE HOLE IN BOTH THE WATER CHAMBER
AND THE SOCKET IS OFFSET TO INSURE
ADJUST WATER JETS
TO THATWATER FLOWS THE PROPER LOCATION OF WATER INLET
IN A CLOCKWISE DIRECTION AND DRAIN CONNECTIONS.
. Bolt the water chamber to the socket with the
socket head or hex head capscrews. Be sure
that each capscrew is tight enough to effect a
seal, however, do not overtighten.
10, After the capscrews have been tightened se-
curely, the area around the head of the cap-
screw should be sealed to prevent corrosion.
This sealing can be done with a tube of silicone
sealant. Any tapped holes are to be sealed with

[
cotton waste saturated with oil or grease.
INSTALL THE VENTS AND RETAINERS ON
THE 7 FT. CRUSHER.
LIFTING NAA
1/16" WATER 11. Connect the water seal piping to the inlet and
LUG CHAMBER outlet side of the water chamber by referring to
WATER CHAMBER GASKET the piping drawings furnished.
ADJUSTING WATER JETS 12. Fill the chamber with water and test for leaks
and proper operation. See the table PIPING
AND WATER REQUIREMENTS.
CHAMBER CAN BE LIFTED OFF. SEE THE 13. Install the main shaft assembly in the Crusher.
ILLUSTRATION WATER SOCKET VENTING.
. Using the lifting lugs or eyebolts, lift the water SOCKET LINER
chamber, together with the short sections of GENERAL INFORMATION
inlet and drain piping, clear of the Crusher. A portion of the spherical surface of the socket liner
. With a putty knife or other thin bladed instru- is relieved or undercut to a depth of 3/16" (5 mm) or
ment, scrape the old gasket off the socket. 1/4" (6 mm) depending on crusher size. This under-
Clean the surface of the chamber and the sock- cut is shown in the illustration SOCKET LINER
et thoroughly so that all traces of gasket or gas- UNDERCUT DIMENSIONS. The socket liner is
ket cement are removed. Be careful not to machined so that normally the outer edges of the
damage the gasket surfaces. socket liner are the only portion which will be in
contact with the head. As the socket liner wears,
. Clean the slots or holes in the water jets to be the main shaft assembly slowly drops, causing the
sure there will be unrestricted water flow. If running clearance between the main shaft and
necessary, adjust each water jet so that the inner eccentric bushing to be reduced. When this
slots or holes will all point in the same direction wear occurs it may cause the head to revolve at an
so that the water will circulate in a clockwise abnormally fast rate. (0 to 10 RPM is considered
direction. See the illustration ADJUSTING normal with Crusher running empty.) A careful
WATER JETS. This will prevent sediment from inspection of the socket liner will show if the bear-
settling in the chamber. ing area has worn away where it is flush with the
. On those Crushers using a water chamber gas- undercut. In conjunction with the spinning head,
ket, cement the 1/16" gasket to the spacer there will be a possible loss of oil and an increase
using a suitable gasket cement such as Per- in oil temperature. When a spinning head condition
matex No. 2. Do not cement the chamber to the is noticed, the socket liner most likely must be
replaced.
gasket.
WHEN THE SOCKET LINER WEARS DOWN TO
. Carefully position the water chamber on the THE UNDERCUT, THIS WILL BE READILY
socket so as not to disturb the gasket. Then NOTICEABLE BY THE SHALLOW OIL GROOVE,
align the holes in the chamber with the tapped THE LINER MUST BE REPLACED. OTHERWISE
holes in the socket.
DAMAGE TO PARTS OF THE SOCKET SEALING HOLDING THE KEY TO SEE IF THERE ARE
ARRANGEMENT AS WELL AS DAMAGE TO THE ANY CRACKS, REWELD IF NECESSARY.
CRUSHER ITSELF, MAY OCCUR. SEE THE ILLUSTRATION SOCKET LINER
REPLACING SOCKET LINER KEYS.
When the socket liner has worn to a point where . Place a wooden block directly over the top of
replacement is required, proceed as follows: the socket fit, as the liner has an interference fit
1. Remove the socket from the Crusher as with the socket, and hit against the block with a
described under REMOVAL OF BOLTED or sledge hammer or heavy ram. Force the liner in
DOWELED or KEYED SOCKETS. place a little at a time, moving around the
perimeter of the bore and alternately hitting the
2. Place the socket upside down on timbers or liner at one point and then at a point on the
other suitable supports as shown in the illustra- opposite side. See the illustration SOCKET
tion SOCKET LINER REMOVAL LINER INSTALLATION.
CARE SHOULD BE TAKEN WHEN SUS- . Pour babbitt into the counterbored dowel holes,
PENDING THE SOCKET THAT NO OB- after the liner has been firmly seated.
STRUCTIONS WILL INTERFERE WITH THE
REMOVAL OF THE WORN LINER.
3. Place a 4" x 4" wooden block against the sock-
A warnine
et liner and hit against the wooden block with a WHEN HANDLING THE 650°F (343°C)
heavy hammer. See the illustration SOCKET MOLTEN BABBITT, GOGGLES AND PRO-
LINER REMOVAL. Keep hitting the liner mov- TECTIVE CLOTHING MUST BE WORN.
ing around the bore and alternately hitting the CONTACT WITH MOLTEN BABBITT WILL
liner at one point and then at a point on the RESULT IN SERIOUS BURNS.
opposite side, until the liner drops free.
7. Once the babbitt has hardened, remove all
4. Then turn the socket over and center the new
excess babbitt by scraping, being sure that
liner over the brass dowels in the socket. If nec-
there are no high spots and that the surface of
essary, replace any dowels that have become
the babbitted area is smooth and blends into
worn. These dowels prevent the socket liner
the spherical surface of the liner. See the illus-
from turning should the liner lose its interfer- tration SOCKET DOWELS.
ence fit. See the table SOCKET LINER INTER-
FERENCE FIT for the proper amount of inter-
ference between socket liner and socket. CRUSHER A B
SIZE DIAMETER UNDERCUT
ON THE 7 FT. DOWELED SOCKET, TWO
KEYS ARE USED TO PREVENT THE SOCK- 4-1/4 Ft. 22-1/2 (572) 3/16 (5)
ET LINER FROM TURNING SHOULD THE 5-1/2 Ft. 30 (762) 3/16 (5)
LINER LOSE ITS INTERFERENCE FIT. IT IS 7 Ft. 38 (965) 1/4 (6)
ADVISABLE WHENEVER REPLACING THE
SOCKET LINER TO CHECK THE WELDS All Dimensions In Inches (Millimeters)

UNDER CUT
A DIAMETER

SOCKET LINER UNDERCUT DIMENSIONS

 ; SLEDGE
«—~ HAMMER

WOODEN SOCKET
BLOCK
\ BLOCKING

SOCKET LINER

SOCKET LINER REMOVAL

8. Thoroughly clean and lightly oil the surface of 7. Back out the capscrews far enough to insert a
the liner. steel block under each capscrew.

THE PROCEDURE AS OUTLINED IN STEPS 8. Again alternately tighten each capscrew a

6 AND 7 DO NOT APPLY TO THE 7 FT. DOW- small amount against the steel block until the
ELED SOCKET. socket is free of the frame.

REMOVAL OF BOLTED SOCKET THE TAPPED HOLES SHOULD BE FILLED

WITH COTTON WASTE SATURATED WITH
To remove the bolted socket for maintenance or the OIL OR GREASE IMMEDIATELY AFTER USE
replacement of related parts, proceed as follows: TO PREVENT CORROSION AND PLUGGING
WITH DIRT.
1. Lift off the socket sealing ring or unbolt the
water chamber to give access to the socket 9. Screw the lifting eyebolts into the socket and
head capscrews which bolt the socket to the remove the socket from the Crusher.
main frame. REMOVAL OF 4-1/4 FT. AND 7 FT.
DOWELED SOCKET
Using a wrench, remove these capscrews.
To remove the doweled socket for maintenance
. Use four of the capscrews as jacking screws by or the replacement of related parts, proceed as
installing them into the tapped holes provided follows:
in the socket.
1. Lift off the socket sealing ring or unbolt the
. Uniformly heat the main frame around the water chamber to give access to the dowels
socket fit to 100°F (88°C) above ambient tem- which prevent the socket from turning in the
perature. main frame.
. Using a wrench, alternately tighten each cap- 2. Use the four special hex head jacking screws
screw a small amount. See the illustration found in the box with the tools by installing
REMOVING BOLTED SOCKET. The socket will them into the tapped holes provided in the
be slowly withdrawn from its interference fit in socket.
the frame. 3. Uniformly heat the main frame around the
. Continue tightening the capscrews until the socket fit to. 100°F (38°C) above ambient tem-
capscrews bottom in the threaded holes. perature.

6-17
 SLEDGE HAMMER

WOODEN

SOCKET

\
LINER

SOCKET

BLOCKING

SOCKET LINER INSTALLATION

SOCKET
LINER
KEY

SOCKET

SOCKET LINER
TO SOCKET
INTERFERENCE
CRUSHER SIZE MINIMUM | MAXIMUM* TWO KEYS
4-1/4 Ft. .001 .004 180° APART

5-1/2 Ft. .001 .005

7 Ft. Doweled Socket .002 .006
*Maximum Interference Fit Desired
All Dimensions In Inches

SOCKET LINER INTERFERENCE FIT SOCKET LINER KEYS

 SCRAPE BABBITT SMOOTH
IN THIS AREA TO BLEND
_ INTO THE SPHERICAL
SURFACE OF THE SOCKET LINER

OIL RETAINING RING

™

SOCKET

NER
BABBITT -

SOCKET
SOCKET
DOWEL

SOCKET DOWELS

4. Using a wrench, alternately tighten each jack-

ing screw a small amount. See the illustration
REMOVING DOWELED SOCKET . The socket
will be slowly withdrawn from its interference fit
CAPSCREW in the frame.
OR
JACKING Tighten each jacking screw a small amount
SCREW until the socket is free of the frame.
. The tapped holes should be filled with cotton
waste saturated with oil or grease immediately
after use to prevent corrosion and plugging with
dirt.
. Screw the lifting eyebolts into the socket and
remove the socket from the Crusher.

SHIMMING LOOSE SOCKET

On rare occasions, after prolonged or continuous
hard use, it is possible for the socket to become
loose from its press or interference fit in the frame.
In the case of the bolted socket, if this condition is
not discovered and corrected as soon as possible,
breakage of the socket head capscrews may occur.
On a keyed socket the continual pounding can
cause the key and main frame bore to wear. The
correct interference fit between the socket and
main frame is extremely important! See the table
REMOVING BOLTED SOCKET SOCKET INTERFERENCE FIT.

6-19
This condition is usually indicated by oil leakage
from beneath the Crusher. Other factors can also
bring about oil leakage in the same region, such as
SOCKET
a worn socket liner or head. Regardless of the
cause of the leakage the Crusher should be disas-
sembled to accurately pin point where the leakage
is occurring. If it is discovered that the leakage is
due to a loose socket, the condition can be reme- JACKING
SCREW
died as follows:
1. Match mark the socket and frame at two places,
180° apart. Repeat this procedure four times
each time rotating 45°.
2. Remove the socket and measure the diameter
of the socket and the diameter of the main
frame bore at the places indicated by the match
marks.
3. Compute the average total clearance or inter-
ference.
4. Make up eight shims of a thickness which will
give a total interference fit as specified in the
table SOCKET INTERFERENCE FIT Be sure
the shims are long enough to be lapped over
the top of the main frame.
5. Place the eight shims at the points indicated by
match marks. Hold the shims in place by bend-
ing the shims around the top of the main frame
bore. See the illustration INSTALLING SOCK-
ET SHIMS.
6. Force or drive the socket into place in the frame
following the procedures under ASSEMBLY
INSTRUCTIONS.

SOCKET TO
MAIN FRAME
INTERFERENCE FIT
CRUSHER SIZE MINIMUM | MAXIMUM*
4-1/4 Ft. Bolted Socket .003 .007
REMOVING DOWELED SOCKET
4-1/4 Ft. Doweled
Socket .005 .009

5-1/2 Ft. .003 .008

7 Ft. Doweled Socket .010 .015

*Maximum Interference Fit Desired
All Dimensions In inches
SOCKET INTERFERENCE FIT
 STEEL
WEDGES SOCKET
LINER

ECCENTRIC
MAIN
FRAME
AN” eee
_/

la
J, iN =z en

REMOVING KEYED SOCKET

SOCKET AND ECCENTRIC CLEARANCE

Whenever installing the socket in the Crusher, there SOCKET
must be clearance between the underside of the HEAD
socket and the top of the eccentric and gear as CAPSCREW
shown in the table SOCKET AND ECCENTRIC
CLEARANCES.
Care should be taken when the socket is assem-
bled in the main frame that the minimum clearance
between the underside of the socket and the top of BEND THIS PORTION
the eccentric and gear as shown in the table be OF SHIM OFF AFTER
SOCKET HAS BEEN
carefully observed. INSTALLED
Operating the Crusher without such clearance re-
duces the running clearance between the inner ec-
centric bushing and the main shaft and could cause
the Crusher to overheat. SHIM— |
Should little or no clearance exist after the socket is
installed, remove the socket and check the table
BACKLASH AND ROOT CLEARANCE MEASURE-
MAIN
MENTS in Section 5. If these measurements are in FRAME
accordance with the table, the reduced clearance
between the socket and eccentric may be due to
wear on the main frame and socket seating sur-
faces. Reworking the main frame and/or socket to
restore the original dimensions is recommended. INSTALLING SOCKET SHIMS

6-21
 CLEARANCE

CRUSHER SIZE CLEARANCE CLEARANCE CLEARANCE

4-1/4 Ft. 1/4 (6) 1/8 (3) 5/16 (8)
5-1/2 Ft. 5/16 (8) 3/16 (5) 3/8 (10)
7 Ft. 5/16 (8) 3/16 (5) 3/8 (10)
All Dimensions In Inches (Meters)
SOCKET AND ECCENTRIC CLEARANCES