Jaw Rock Crusher

Jaw Crusher Repair and Overhaul
Models 2044 and 3042
SAFETY
Read and fully understand the precautions contained on the inside front cover of this manual before operating or servicing the crusher. Also refer to Chapter 1 for important quarry safety information.
WARNING !!!
Failure to follow the safety precautions shown below may result in serious personal injury or death!
Never attempt to work on quarry equipment while it is in operation. Always stop the machinery, lockout power and tag controls. . . 1. Before performing any lubrication, maintenance, adjustments or repairs. 2. Before removing spilled materials. 3. Before clearing jams or working inside the machinery. 4. If any unusual noises or sudden changes in operation are noticed. Stay clear of feed and dischar ge areas and other places where f alling rock is present. K eep away from loading vehicles. Wear and use personal protective equipment in accordance with all applicable health and safety regulations. Safety goggles, hard hat, ear plugs and steel toe shoes are mandatory when w orking near machinery. Wear and use additional personal protective equipment as required. Stay clear of springs and other pinch points. Never reach in-between vibrating equipment and its support structure. Keep a safe distance from all moving components. Never attempt to enter the crushing chamber when tramp iron or other uncrushable objects are wedged inside. These materials are under tremendous pressure and may be propelled upw ards through the feed opening at any time. On crushers not equipped with hydraulic clearing, use a pole, hook, grappling device or breaker bar to safely dislodge uncrushable objects. Do not make equipment modifications that will result in a safety hazard or create a dangerous situation Never remove or disable safety de vices. Maintain all machinery in accordance with manuf acturers instructions and maintenance schedules. Read the operator s manuals for the equipment that you operate. Be sure that you fully understand all phases of operation for each machine. A careful and well-trained operator is the best insurance against an accident. Refer to the Telsmith Quarry Equipment Safely Guide for important quarry safety information. If your copy of the Safety Guide is missing, replacement copies may be obtained from your local Telsmith dealer or the Telsmith Parts Department. All rotating power products are potentially dangerous and must be properly guarded. Placement of guards and other safety equipment is the user s responsibility. Such equipment must be installed where ver appropriate and maintained as required. It is the purchaser responsibility to ensure that quarry equipment is installed and used in a safe and wful s la manner. All machinery must be operated in compliance with applicable health and safety la s and general w standards of reasonable care.
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Telsmith H-Series Gyrasphere
Table of Contents
Table of Contents
Forword. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v Chapter 1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 Chapter 2 General Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1 Chapter 3 Repair and Overhaul Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1 Chapter 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1 Chapter 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
APPENDICES Torque Specifications Appendix A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 Conversion Chart Appendix B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1 Crusher Weights Appendix C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1 Lubricant Specifications Appendix D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1 Expendable Supplies Appendix E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1
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INTRODUCTION
This manual contains complete repair and o verhaul instructions for Telsmith D-Series jaw crushers, models 2044 and 3042. The procedures included in this manual are based on the latest information a vailable at the time of publication. However, due to Telsmiths polic y of continuous improvement, features and specifications are subject t change without notice. Actual dimensions, weights, and clearances may be dif ferent than shown, due to fabrication variables, custom engineering or optional equipment. Finally, please note that some features shown in this manual may not be present on your crusher . Some equipment described may be optional at extra cost, or available only on selected models.
FINDING MODEL AND SERIAL NUMBERS

Model and serial numbers are located on a data plate attached to the crusher frame. Always lockout power and tag controls before reading data plate!
HOW TO CONTACT TELSMITH

Please use the follo wing phone numbers to contact the Telsmith factory for product support: Service Department: (414) 242-6600 Parts Department: (800) 688-6601 Fax: (414) 242-7861 Note: If calling from outside the U.S.A. or Canada, please use the Service Department phone number when ordering parts. Please send all written correspondence to: Telsmith, Inc. 10910 N. Industrial Drive P.O. Box 539 Mequon, WI 53092-0539 U.S.A. Please send all e-mail correspondence to: parts@telsmith.com
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REPAIR AND OVERHAUL PROCEDURES
This manual includes procedures for crusher repair and overhaul procedures only . For detailed operation and maintenance instructions, please refer to the Telsmith Jaw Crusher Operation & Maintenance Manual. The Operation & Maintenance Manual is provided with all new jaw crushers. If this manual is lost, ne w copies are available from your local Telsmith dealer or the Telsmith Parts Department.
REQUESTING SERVICE ASSISTANCE

If you have questions about the procedures contained in this manual, please contact your local Telsmith dealer. Their knowledgeable factory-trained personnel are prepared to address any concerns you may have regarding your Telsmith equipment. If additional assistance is required, please contact the Telsmith Service Department. Service technicians are available by telephone from 8:00 a.m. to 4:30 p.m. CST , Monday through Friday, except holidays. To ensure f aster response, always have your machines model and serial numbers ready when calling.
ORDERING REPLACEMENT PARTS

For replacement parts information, please refer to the Jaw Crusher Parts Catalog . This booklet contains e xploded diagrams and parts lists to help you quickly identify the major components and subassemblies used on your crusher.
The Parts Catalog is pro vided with all ne w Telsmith jaw crushers. If the Parts Catalog is lost, new copies are available from your local Telsmith dealer or the Telsmith Parts Department. To ensure that the correct parts are recei ved, always have your crushers model and serial numbers ready when placing your order.
personal injury or death, be certain that all such equipment is properly reinstalled before operating the crusher.
SERVICE BULLETINS
Telsmith periodically issues service b ulletins to inform customers of the latest repair and maintenance procedures. Service bulletins may have been included separately with this manual. Always read and understand all service b ulletins (if present) before starting any maintenance or service work.
INSTALLATION & ASSEMBLY DRAWINGS

The follo wing installation and assembly dra wings (blueprints) are included with all new Telsmith jaw crushers: Crusher Sectional Assembly Drawing Oil System Assembly Drawing (if equipped) The drawings include specifications, dimensions and othe technical information that may be helpful during repair and overhaul procedures. Contact your local Telsmith dealer or the Telsmith Service Department if you ha ve any questions about information contained on the drawings. As required, additional dra wings may be pro vided to sho w model-specific design features and equipmen configurations If the drawings are lost, replacement copies may be ordered from your local Telsmith dealer or the Telsmith Parts Department.
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SAFETY
All quarry personnel operating or servicing the crusher must read and fully understand the safety information included in Chapter 1 of this manual. In addition, all quarry personnel must read and fully understand the safety information presented in the Telsmith Quarry Equipment Safety Guide. The Safety Guide is pro vided with all ne w crushers. Additional copies of the Safety Guide are available from your local Telsmith dealer or the Telsmith Parts Department.
ILLUSTRATIONS
This manual contains some illustrations in which guards, access panels and other safety equipment has been remo ved to provide greater clarity . However, to pre vent serious
Telsmith 2044 & 3042 Jaw Crushers
Chapter 1
Chapter 1 Safety
SAFETY OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 HAZARD AND ADVISORY STATEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Hazard Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Advisory Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 LOCKOUT/TAGOUT. . . . . . . . . . . . . . . . . . Who Must Use Lockout/Tagout? . . . . . . . . . . What is Lockout/Tagout? . . . . . . . . . . . . . . When Must Lockout/Tagout Occur? . . . . . . . . How is Lockout/Tagout Performed? . . . . . . . . When Can Lockout/Tagout Devices be Removed?. Lockout/Tagout Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 1-3 1-3 1-4 1-4 1-5 1-5
Lockout/Tagout Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Additional Lockout/Tagout Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 JAW CRUSHER SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 QUARRY SAFETY SUMMARY. . . . . . . . Know Your Machinery . . . . . . . . . . . Be Prepared for Emergencies . . . . . . . . Wear Personal Protective Equipment (PPE) Observe Personal Safety Precautions . . . . Help Prevent Accidents . . . . . . . . . . . Avoid Alcohol and Other Drugs . . . . . . Be Aware of Your Surroundings . . . . . . Practise Good Housekeeping . . . . . . . . Inspect And Maintain Machinery. . . . . . MACHINERY INSTALLATION SAFETY Foundations . . . . . . . . . . . . . . . Guarding . . . . . . . . . . . . . . . . Customer Modifications . . . . . . . . Electrical Hook-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 1-6 1-6 1-7 1-7 1-7 1-8 1-8 1-8 1-8 1-8 1-8 1-8 1-9 1-9
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MAINTENANCE AND REPAIR SAFETY . . . . . . General Precautions. . . . . . . . . . . . . . . . . Electrical Systems . . . . . . . . . . . . . . . . . Pressurized Systems (hydraulic and air) . . . . . . Welding On Machinery . . . . . . . . . . . . . . . Clearing Jammed Material . . . . . . . . . . . . . Hazardous Materials . . . . . . . . . . . . . . . . Disposal Of Excess Fuels, Lubricants And Liquids Flammable and Combustible Liquids. . . . . . . . HOISTING AND HANDLING SAFETY . . . . . General Precautions. . . . . . . . . . . . . . . . . Wire Rope. . . . . . . . . . . . . . . . . . . . . . Connecting Or Clamping Wire Ropes . . . . . . . Chains . . . . . . . . . . . . . . . . . . . . . . . . Fiber Or Synthetic Slings . . . . . . . . . . . . . .
. 1-9 . 1-9 . 1-9 . 1-10 . 1-10 . 1-10 . 1-11 . 1-11 . 1-11 . 1-11 . 1-11 . 1-11 . 1-12 . 1-12 . 1-12
TRANSPORTING MACHINERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
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SAFETY OVERVIEW
It is the responsibility of the quarry management team to develop a comprehensive safety a wareness program, and to ensure that all quarry workers and support personnel receive appropriate safety training as required by federal, state and local regulations. Safety is basically common sense. There are standard safety rules, but each situation has its o wn peculiarities which can not always be covered by rules. Therefore, quarry personnel must continually w atch for possible safety hazards and be prepared to take prompt corrective action when necessary. Failure to observ e the precautions contained in this chapter can result in serious personal injury and even loss of life. As with most industrial work environments, a careful operator is the best insurance against an accident. The complete observance of one simple rule w ould prevent many unnecessary injuries and deaths each year This rule is: . Never attempt to clean, lubricate, repair or adjust any machinery unless it is stopped and properly locked out. Please note that this chapter is only intended as a brief re view of basic quarry safety precautions and procedures. The general guidelines included in the follo wing paragraphs are not intended to supersede of ficial quarry safety procedures insurance company requirements, or applicable federal, state and local regulations.
A Note is a basic informational statement or helpful suggestion. An Important is used to dra w attention to a procedure that must be observed to prevent machine damage or malfunction .
! DANGER
Hazard Statements
! WARNING!!! DANGER ! CAUTION !!! DANGER
Important Note
Advisory Statements
HAZARD AND ADVISORY STATEMENTS

Throughout this manual, the use of hazard and advisory statements has been emphasized. Examples of these are shown in Figure 1-1. Figure 11. Hazard and Advisory Statements
LOCKOUT/TAGOUT Who Must Use Lockout/Tagout?

Quarry owners, managers, and safety officers must be ware of OSHAs lockout/tagout standard: CRF Section 29 1910.147, The Control of Hazardous Energy. This standard is also recognized by MSHA. All mechanics, maintenance personnel, operators, and electricians must fully understand and comply with this standard to ensure the safety of all employees.
Hazard Statements
The Caution, Warning and Danger statements are hazard statements used to alert w orkers of unsafe practises and potentially harmful or life-threatening situations. Each of these statements is preceded by the Safety Alert Symbol. Failure to follow the instructions contained in a Caution statement may result in MINOR PERSONAL INJURY. Failure to follow the instructions contained in a Warning statement could result in SERIOUS PERSON AL INJURY or DEATH. Failure to follo w the instructions contained in a Danger statement will result in SEVERE PERSON AL INJURY or DEATH.
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What is Lockout/Tagout?
Lockout/tagout is a means to ensure that personnel who install, operate, repair, maintain, service or otherwise disable machines, equipment, or electrical ener gy systems are protected from harm due to une xpected energizing, or the release of stored energy by...
Advisory Statements
The Note and Important statements are advisory statements which relate to equipment operation, maintenance and service procedures. They are used to draw attention to proper procedures and practises.
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1. Lockout Placing a disconnect switch, circuit breaker, valve, or other ener gy-isolating mechanism in the of f or safe position and securing it with a lock so the ener gyisolating mechanism cannot be activated. 2. Tagout A prominent written w arning (tag or label) placed on the ener gy-isolating mechanism indicating the name of the indi vidual placing the mechanism out-ofservice, and stating that the ener gy isolating mechanism cannot be activated until the tagout device is removed.
How is Lockout/Tagout Performed?

OSHA has identified the foll wing step-by-step lock out/ tagout procedure: 1. Prepare for shutdown Before shutting down a piece of equipment, kno w the type and magnitude of the ener gy that powers it, the hazards of that energy, and how to control it. Warn all employees that the machinery is about to be shut down. 2. Shutdown the equipment After w arning all employees, shut down the machine, equipment, or electrical system by the normal stopping procedure. 3. Control stored energy an y potentially hazardous stored energy (electrical, mechanical, h ydraulic, pneumatic, etc.) that remains must be released, dissipated, restrained, or otherwise rendered safe. If stored ener gy reaccumulates, monitor it until the possibility of accumulation no longer exists. 4. Isolate the equipment Diseng age all isolating devices, both primary and secondary so that the equipment is , isolated from all of its ener y sources (electrical, mechanical, g hydraulic, pneumatic, etc.). 5. Apply lockout/tagout devices Attach lockout tagout devices (according to your compan ys safety program) in such a manner that the isolating de vice (circuit break er, control, etc.) will be held in a safe or off position. Attach tags to alert others that the machinery is being serviced.
When Must Lockout/Tagout Occur?

Lockout/tagout must occur whenever service or maintenance is performed, and injury could occur due to the une xpected start-up of equipment, or the release of stored ener gy. See Figure 1-2.
In general, lock out/tagout procedures must be performed under the following circumstances: Before cleaning, lubricating, adjusting or repairing machinery or equipment. Before w orking on electrical, h ydraulic or pneumatic circuits or devices. Before clearing jammed mechanisms, machinery or equipment. Before removing guards or other protective devices. Whenever a machine or its controls will be left unattended.
LOCKOUT/TAGOUT POWER
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Before making inspections or adjustments. Before performing any lubrication, maintenance or repairs.
1. Always lockout/tagout power to the crusher drive motor. 2. Always lockout/tagout controls for diesel engine (if equipped). Disconnect batteries and shut-off fuel supply. 3. Always lockout/tagout power to the crusher lubrication and hydraulic systems. 4. Always lockout/tagout power to all crusher feed and discharge equipment, such as feeders, conveyors and screens.
! WARNING!!! DANGER
Failure to perform lockout/tagout procedures in accordance with OSHA/MSHA regulations will likely result in serious personal injury or death! Figure 1-2. Lockout/Tagout
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6. Verify that equipment is isolated After warning all employees to stay clear , engage the start b utton to confir the machine is inoperable. Return the control to the of f position before proceeding with servicing.
Lockout/Tagout Rules
Always lockout/tagout any machinery before performing any adjustment, inspection, lubrication, maintenance or repair procedures. Failure to observe this precaution may result in serious personal injury or death. Your compan ys lock out/tagout program may be somewhat different than described in this manual. If so, be sure to completely follo your companys official policie w and procedures when lockout/tagout is necessary. Consult your companys safety officer if you h ve any questions. A lock must have only one user and one key. Anyone who installs a lock must keep the key in their possession at all times. Except in an emergency situation, only the person that installs a lock is authorized to remove it. To prevent accidental start-up, never give your lock or its key to another employee. Your key must open your lock only . Your key should not be capable of opening an y other locks. K eys for other locks should not be capable of opening your lock. Except in an emer gency situation, ne ver attempt to remove anyone elses lock. Do not allow others to remove your lock. When disconnecting po wer, be sure that the circuit breaker handle (or other isolating de vice) is in the OFF position. Accidentally locking a control in the ON position could result in serious personal injury or death. If tw o or more people are w orking on a machine, a multiple lock out de vice must be used to pre vent accidental start-up in the e vent that one person finishe working before another. Each lock must ha ve a tag. If tw o or more people are working on a machine, each person must attach a separate tag to their lock. Never attach a lock without a tag. Never use tags alone. A tag should al ways be accompanied by a lock which pre vents the isolating device from becoming energized.
When Can Lockout/Tagout Devices be Removed?

Lockout/tagout devices can only be remo ved after the following conditions are met: All guards and protecti installed. ve de vices are properly reved from the
All tools and repair equipment are remo equipment and the immediate area.
All mechanics and other personnel are clear of the equipment and its immediate area. All personnel ha ve been w arned that the equipment is about to be restarted (sound w arning horn or acti vate warning lights). After removing lockout/tagout devices, always use the normal start-up procedure as described in the operator s manual for the machinery.
Lockout/Tagout Devices
Lockout/tagout devices include: 1) locks 2) tags and labels 3) multiple lockout devices A lock must be suf ficiently durable, so it can withstand th environmental conditions (heat, cold, moisture, etc.) around it. A lock must also be strong enough so that it cannot be easily removed or forced open. A tag or label must be affi ed to each lock to alert others that service work is in progress. Each tag or label must ha ve the following characteristics: Be sufficiently durable to withstand wear and a use, even if used in dirty or damp environments. Be securely attached with a cable that is dif remove, cut or tear. Contain the name of the person that applied it. Contain a w arning or other precautionary statement that briefly indicates w y the machine is locked out and what hazards could result if the equipment is started while service work is in progress. When tw o or more people are w orking on a piece of equipment, a multiple lock out device must be used. This allows each person to install their o wn lock, pre venting accidental start-up. ficult t
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Additional Lockout/Tagout Requirements

Be sure that the po wer is COMPLETELY turned of f. A motor may be stopped and lock ed out. Ho wever, interlocks, starters, and other supplemental electrical components may still be energized. Use a voltmeter and/ or ammeter to v erify that all electrical circuits are completely dead. Always be sure that all peripheral equipment, such as feed conveyors, grizzly feeders and dischar ge conveyors, is also tagged and lock ed out. Serious personal injury or death can result if an y of these items starts une xpectedly while the crusher is being serviced.
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Although lockout/tagout procedures are most commonly associated with electrical systems, be a ware that hydraulic, pneumatic and mechanical systems must also be tagged and lock ed out before servicing. This may involve the lockout/tagout of valves, levers and other nonelectrical devices. For machinery po wered by internal comb ustion engines (diesel, gas, etc.), always disconnect batteries and shut-of f fuel supply before servicing the machinery . Lockout/ tagout engine controls to ensure that engine is not accidentally started while the machinery is being serviced. Always be sure that all h ydraulic or air pressure is completely relieved before w orking on h ydraulic or pneumatic systems. Dangerous pressures can be present, even when equipment is turned off and locked out. After maintenance or repairs are completed, always warn all employees that the machinery is about to be restarted. Be sure no one is on or near the equipment before a lock and tag is removed. As a precaution, al ways activate a w arning horn or light before restarting the machinery . This will pro vide additional w arning for personnel to stay clear of machinery that is about to be started.
Do not tamper with crusher alarm components (if equipped). Never attempt to defeat electrical interlocks or to disable crusher protective devices. Stay clear of pinch-point areas. Never stand on h ydraulic hoses or use them as steps. If hoses rupture, serious injury or death could result. As required, use a safety harness during servicing. Always lockout/tagout power to the crusher drive motor and crusher oil lubrication system before performing an y inspection, adjustment lubrication, maintenance or repair procedures. Also lockout power to all crusher feed and discharge equipment. Be sure pressure is fully relie ved before servicing the crusher hydraulic system. If the crusher is po wered by a diesel engine, al ways disconnect batteries and shut-of f fuel supply before performing any inspection, adjustment, lubrication, maintenance or repair procedures. Lockout/tagout engine controls to pre vent the engine from being accidentally started while the crusher is being serviced. Always stop the crusher immediately if an y gauges show abnormal readings, or if there is a sudden obvious change in operation. Be alert for noises that might indicate trouble. Inspect, lubricate, maintain and repair the crusher in accordance with the instructions contained in this manual and any additional manuals or documentation pro vided with the crusher.
JAW CRUSHER SAFETY

Perform a complete inspection before starting the crusher . Be sure that the crushing chamber is clear . Refer to the Jaw Crusher Operation and Maintenance Manual for crusher daily start-up procedures. Be sure that all guards and other safety de vices are correctly installed and tightly secured before starting the crusher. Stay clear of rotating or mo ving parts during crusher operation. Do not allow personnel to be on or near the crusher during operation. Stay clear of feed and dischar ge areas to prevent being injured or killed by flying or alling rock. Rock projected upw ards through the feed opening can injure or kill. Do not look directly into the feed opening while the crusher is operating. Use mirrors or closedcircuit cameras if close observ ation of the feed arrangement is necessary for troubleshooting or evaluation purposes. Never attempt to clear jammed material from the crushing chamber while the crusher is operating. Serious injury or death could result if you are pulled into, or fall inside, the crushing chamber. Never attempt to adjust the dischar ge setting during crusher operation. Always w ait until the crusher is completely stopped before making any adjustments.
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QUARRY SAFETY SUMMARY Know Your Machinery

Read the manuf acturers operation and maintenance manuals for all machinery and equipment that you operate. Be sure that all hazard statements contained within the manuals are completely understood. Become familiar with the controls, functions and settings of each machine. Fully understand all phases of each machines operation. Be sure that you completely understand and follo w all start-up and shut-do wn procedures as described in the manufacturers manuals. Be familiar with the safety signs on your equipment, and the hazards against which they warn. Check the le gibility of all safety signs e very day. Order new signs from the machinery manuf acturer if the y become illegible or worn.
7F
Be Prepared for Emergencies

Know the proper emergency shut-down procedures for the equipment you operate.
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Know where fire xtinguishers are k ept and ho w to use them. Be sure that fire xtinguishers are properly rated, and that they remain fully charged and ready for use at all times. Know the procedure for contacting emer gency medical personnel. Keep a list of emer gency phone numbers handy at all times. Know where first-aid kit, stretcher and other eme gency supplies are k ept. Be sure that first aid supplies ar properly maintained and ready for use. Make sure that a clear path to emer gency equipment and exits is al ways maintained. Do not allo w equipment, spilled materials or other obstructions to get in the way. Know how to report accidents.Always report all accidents immediately to the appropriate supervisor.
Use walkways and ladders when w orking near machinery, or observing its operation. Use a safety harness when necessary. Keep handrails and machine contact surf aces clean. To a void back injuries, al ways use proper lifting techniques to safely lift heavy objects. Lift with your legs and keep your back straight. Keep the materials or object close to your body Have a co-worker assist you if the load . cannot be lifted safely by one person. Never attempt to catch falling materials or objects. Be a ware of flammable liquids and other potential fi hazards. Do not smok e when refilling engines or usin cleaning solvents. Do not stand under equipment or components that are being hoisted or suspended. Ne ver allow other quarry personnel to do so. Before you assemble, operate, clean, lubricate, or adjust machinery, be sure to read and understand all procedures contained in the machinery manufacturers manual. Be sure to operate quarry machinery in compliance with current OSHA and MSHA regulations, and all applicable federal, state or local regulations.
Wear Personal Protective Equipment (PPE)

Wear safety glasses or goggles whene ver outside of an approved operators enclosure. F ailure to wear appropriate eye protection can result in permanent e ye injuries and loss of sight. Wear appropriate ear protection when working within 50 feet of any operating quarry machinery, and in other areas where noise le vels are high. Prolonged e xposure to high noise levels can cause permanent hearing loss. Wear steel-toe safety boots, heavy-duty gloves and a hard hat. This equipment is mandatory in most areas of the quarry. Use respirators in dusty locations and when working with hazardous substances. Prolonged exposure to rock dust or chemical fumes can cause permanent respiratory illness. Other personal protecti ve equipment may be necessary for your specific job assignment, such as a full ace shield and safety harness. Wear or use these items when necessary and as required by applicable federal state and local regulations.
Help Prevent Accidents

Do not allow unauthorized personnel in or near the w ork area. Never allow unauthorized personnel to operate, adjust, maintain or repair machinery. Allow only properly trained and experienced personnel to operate machinery. Be sure ine xperienced operators are carefully supervised at all times. Before starting the machinery check that no personnel are , inside, on, under or beside the equipment. Unless absolutely necessary, do not allow anyone to be on or near the equipment while it is operating. Do not allo w personnel to be near loading areas, or anywhere else that f alling or ejected material could hit them. Before starting machinery , be sure that the surrounding area is clear of people, equipment and tools. Use warning horns, warning lights or other signal device to alert other workers that the equipment is about to be started. Use extreme caution if the machinery must be operated for inspection or observ ation purposes. Stay a safe distance and wear appropriate personal protecti ve devices. Before making repairs to the machinery , always clear all quarry material from the feed and dischar ge devices (feeders, conveyors, chutes, etc.).
7F
Observe Personal Safety Precautions

Never wear loose or ragged clothing when working on or around rotating po wer equipment. Avoid wearing necklaces, rings or other je welry. These items can become caught or tangled in the machinery , resulting in se vere personal injury or death. Keep hair short, if possible. Keep long hair securely tiedup to prevent it from becoming caught in the machinery. Be especially careful whene ver using wet w alkways, platforms, or ramps. The combination of rock dust and wet metal can create an extremely slippery surface. Keep all walkways and other access structures clean, dry and free of grease or oil.
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Safety
In areas which present a danger of f alling, use an appropriate fall protection device, such as a safety harness and lifeline. Always report an y unsafe conditions or defecti equipment to the appropriate supervisor. ve
Inspect And Maintain Machinery

Always perform a safety inspection at the be ginning of each shift. Refer to the machinery manuf acturers operation and maintenance manuals for detailed pre-startup inspection and maintenance procedures. Test all warning devices before starting the machinery to ensure that the y are w orking properly. Never disable or bypass any alarm systems or interlocks. Be sure that an y defecti ve components or systems are properly repaired by a qualified technician before th machinery is started. Immediately report an y serious problems to the appropriate supervisor. Before performing inspections or maintenance, al ways lock out power and tag controls to the machine drive, and to all feed and dischar ge equipment. Warn all personnel that the equipment is being serviced. Refer to theLockout/ Tagout section of this chapter for additional information. Maintenance inspection procedures are included throughout this manual. Although maintenance is not typically a safety concern, machinery that is re gularly maintained and in proper w orking condition will minimize the occurrence of safety hazards and emer ency g situations.
Avoid Alcohol and Other Drugs

Do not operate or w ork near quarry machinery when under the influence of alcohol or other drugs.These items can result in reduced alertness and impaired judgement. Serious personal injury or death could result. Some prescription and non-prescription medications can cause drowsiness or other adv erse side ef fects. Do not operate or w ork near quarry machinery when under the influence of such medications
Be Aware of Your Surroundings

The quarry environment contains many situations that are potentially hazardous. Use extreme caution to avoid being struck by haul trucks, loaders and other quarry mobile equipment. Be a ware of idle machinery that could start-up without warning. Stay clear of such machinery and the immediate area. Be a ware of o verhead obstructions, such as con veyors, support structures or power lines.
MACHINERY INSTALLATION SAFETY Foundations

Proper foundations and support structures are essential to ensure the safe and efficient operation of quarry equipment Crushing machinery needs a firm foundation on which t operate. This does not need to be a poured pad, but it may not be on unstable ground.When selecting the location, be sure that the entire area is as level as possible. Follow all manuf acturers installation dra wings and specifications when constructing the base pads fo permanent plants. If any questions arise re garding foundation requirements or modifications necessary forTelsmith machinery, please contact the Telsmith Service Department. Customer-designed support structures for Telsmith equipment must meet Telsmiths engineering standards. All plans must be submitted in adv ance to the Telsmith Engineering Department for approval.
Practise Good Housekeeping

Do not store tools or equipment on walkways. Be sure that all walkways, platforms, stairs and ramps are kept free of spilled material and trash. A build-up of material in these areas can cause slips and f alls. Make repairs as required in areas where spillage is present. Do not allow machinery to become b uried under piles of spilled material. This will mak e the machinery more difficult to inspect and may hide bro en welds, loose fasteners and other serious problems that could cause a safety hazard. Keep the areas around control panels and machinery free of spilled material. Free access must be maintained at all times. In the e vent of an emer gency, quick access to controls could prevent injury or death. Clean up spilled fuel or oil immediately to eliminate slipping hazards. If necessary, use an oil absorbent. Always be sure that po wer is tagged and locked out before cleaning spilled material or oils. Ne ver clean-up these items while the machinery is operating.
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Guarding
Quarry management is responsible for the proper installation and placement of guards to prevent personnel from coming in contact with rotating or moving parts.
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Safety
In addition to the guards supplied with the machinery , additional guards and related safety equipment may be required to comply with OSHA, MSHA and an y applicable local re gulations. The proper f abrication, installation and placement of these items is quarry managements responsibility. When f abricating guards, refer to MSHA s Guide to Equipment Guarding at Metal and Nonmetal Mines. Additional information can also be provided by the safety officer at your orksite. Never remo ve guards until the machinery is stopped, power is locked out, and controls are tagged. Be sure that guards are properly re-installed before reconnecting power.
All Telsmith machinery is designed with electrical components of the proper size and v oltage. Any modifications to these components or to the p wer supply must be approved in writing by the Telsmith Engineering Department. Be sure that all connections are in accordance with the National Electric Code and an y applicable state or local codes.
MAINTENANCE AND REPAIR SAFETY
! WARNING!!! DANGER
Always lockout/tagout power to machinery and conveying equipment before performing any maintenance or repairs. Warn all personnel that the machinery is being serviced.
Customer Modications
Do not modify quarry machinery in an way without prior y approval from the manufacturer. Such modifications ma include (but are not limited to) changing machine speed or direction of rotation, drilling additional holes and welding or bolting additional equipment to the machinery. All customer modifications to Telsmith machinery must be appro ved in writing in writing by the Telsmith Engineering Department.
General Precautions
To help ensure safe machine operation, use only genuine OEM replacement parts that are sold or appro ved by the machines manufacturer. Use of non-OEM parts may adversely affect machine operation and could result in an a hazardous situation. Always tighten all f asteners to the proper torque as described in the repair procedures. When torque specifications are not listed, use the alues in the torque chart at the back of this manual. Refer to Appendix B of this manual. Be sure all replacement f asteners are of the proper grade and specifications. Replace a y w orn or damaged fasteners.
Electrical Hook-up
! WARNING!!! DANGER
When installing any electrical equipment, be sure t o c o m p l e t e l y f o l l o w t h e m a n u f a c t u r e r s instructions. Failure to observe this precaution could result in a dangerous electrical shock hazard. Be sure that all electrical equipment is properly grounded. Lay out the po wer lines, especially those for portable plants, so that contact with standing water is minimized. Do not place po wer lines in an area where the y will be driven o ver by transport v ehicles or other quarry equipment. If it is absolutely necessary to extend a power line across a traf fic area, protect the cable with properl rated bridging. Be sure that all auxiliary control panels or po wer supply panels can be securely lock ed out. This type of panel is mandatary. Maintain adequate o verhead clearance from po wer lines or other obstructions, particularly when planning to use stacking conveyors for stockpiles. Be sure that electrical po wer supplies are located in an area that will be safe from accidental contact during crushing operations.
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Electrical Systems
Always read, understand and follo appropriate electrical w system troubleshooting, maintenance and repair instructions in the machinery manufacturers manuals. Allow only trained and licensed electricians to install, troubleshoot and repair electrical equipment. All procedures must be in compliance with the National Electric Code and an y applicable state or local regulations. When servicing an electrical system, w with the power ork locked out and tagged. Always assume that an electrical system is live until it has been locked out. Always tag and lock out po wer before remo ving cables with quick-disconnect plugs. Repair an y ob viously w orn or damaged wires and connectors.
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Safety
Inspect power cables and connections daily for signs of wear, crack ed insulation and w orn or damaged connectors. Repair or replace as required. Do not store tools inside electrical cabinets. Verify that all tools are grounded with a three wire plug or double insulated. Be sure that all e xtension cords are grounded with a three wire plug.
Do not operate any hydraulic or air system with ob viously worn or damaged, or leaking components.Always replace any defective components immediately. Never place hands on h ydraulic c ylinder rods while equipment is in operation. Do not step on the h ydraulic relief cylinder hoses when climbing on the crusher. Refer to manuf acturers instructions when rechar ging hydraulic accumulators or checking accumulator pressure. Allow only trained hydraulic system technicians to depressurize, rechar ge or repair h ydraulic accumulators.
Pressurized Systems (hydraulic and air)

Adjust, maintain and repair all pressurized systems only in accordance with the instructions contained in the manufacturers manuals provided with the machinery. Never attempt to work on a pressurized system while it is pressurized or in operation.
Welding On Machinery
Be sure to pro vide adequate v entilation when welding inside enclosed areas to prevent the buildup of hazardous fumes. Special concern should be e xercised when welding chromium, manganese, cadmium, copper, cobalt, lead and nickel, as these materials are considered to be potentially carcinogenic. Be sure to wear the proper welding shield, welding glo ves and clothing. Do not wear synthetic f abric clothing or clothing which could be easily ignited by sparks. Always follo w all standard safety procedures when welding. Be sure that all systems are shut down, power is locked out, and controls are tagged. Pro vide welding screens to protect other employees working in the area. Relieve all h ydraulic pressure before welding near hydraulic components and lines. Co ver h ydraulic components to protect them from weld spatter and sparks. Do not weld near flammable liquids or ydraulic oils. Welding lifting eyes or hooks to manganese steel castings is strongly discouraged, and should be done only if absolutely necessary. Always use a stainless steel or manganese weld rod. Ne ver allow personnel to w alk or work underneath castings being lifted or supported. Never ground the welder so that the electrical po wer will fl w through bearings, hydraulic components or electrical equipment. Serious damage could result. Be sure all compressed g as cylinders are stored upright, chained and capped. Turn-off all c ylinders when not in use.
Before performing maintenance or repairs on an pressurized system: - Cycle the controls through all operating positions to relieve any trapped pressure.
- Check that ALL pressure is relie ved from the system. Pressure gauges must read zero (0) PSI. - Lockout and tag all controls. Be sure electrical power is properly locked out and tagged. Allow time for hot hydraulic oil to cool before performing any maintenance or repairs. Hot oil can cause burns. Before loosening fittings or rem ving components, always recheck that ALL pressure is relie ved from the system. Pressure gauges must read zero (0) PSI. Never attempt to crack a h ydraulic fitting while hydraulic system is pressurized. You could be injured or killed by a stream of high pressure oil. Never have your face near, or stand directly in front of a hydraulic line when cracking a fitting, ven after system pressure has been relie ved. Always assume that the line has pressure. Use a piece of cardboard to check for hydraulic oil leaks, not your hand. Escaping fluid under pressure ca penetrate the skin, resulting in serious personal injury. Clean-up an y spilled h ydraulic fluid. Hydraulic fluid extremely slippery, and can be especially dangerous if spilled on an elevated walkway or platform. Repair an y leaks immediately . Always relie ve system pressure and lockout/tagout power before tightening fittings or making repairs Never attempt to adjust pressure relief valves to above the machinery manuf acturers recommended settings. Serious personal injury and/or equipment damage could result.
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7F
Clearing Jammed Material

If material becomes jammed in the machinery: - Immediately stop the machinery. - Lockout/tagout power. Warn others that the machinery is being serviced. - Follow the instructions in the operation and maintenance manual of the affected equipment.
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Safety
To prevent serious personal injury or death, never attempt to remove jammed material while the machinery is in operation. Always remove all jammed material before restarting the machinery. To prevent damage, never attempt to restart a stalled machine without first rem ving the jammed material. Never use dynamite or other e xplosives to clear jams. Explosives are dangerous and can injure or kill personnel. Damage to machinery could also occur.
Flammable and Combustible Liquids

Store flammable liquids in a safe place, way from quarry machinery and personnel. Use approved safety containers and be sure that they are clearly marked. Containers must be covered when not in use. Keep flammable liquids way from sparks, open flame and other ignition sources. Do not smok e around flammable liquids. Always obey posted no smoking signs. Be f amiliar with the locations of fire xtinguishers throughout the quarry. Be sure the y remain accessible at all times, and are not blocked by obstructions. Do not use g asoline or other flammable liquids to clea tools or parts. Use only appro ved non-flammabl solvents. Always shut-of f engines before refueling. Ground fuel spout against the filler neck to pr vent static electricity. Never smoke while refueling. Use only appro ved safety containers for storing and transporting small quantities of flammable liquids. eep containers covered when not in use.
Hazardous Materials
Be a ware potentially hazardous chemicals or materials. Such items can be harmful if the y are improperly used, stored, mixed or transported, or if the y are inhaled, swallowed or allowed to contact the skin. Consult your employers hazard communications plan for instructions regarding the proper handling and use of hazardous materials. Read and understand the labels attached to the product containers. Always follow the instructions carefully. Consult the manuf acturers material data sheet (MMD) for potential hazards and appropriate medical procedures should an accident occur. Store hazardous materials only in appro containers. Be ved sure containers are clearly labeled. To a void potential health hazards, persons in re gular contact with h ydraulic oils must be a ware of the importance of thorough hygiene, and the proper methods for handling mineral oils. Mineral-based hydraulic oils act as solv ents on the natural oils of the skin. Frequent and prolonged skin contact can cause dermatitis or severe irritation. Always wear suitable protecti ve clothing when handling hydraulic oil. Be sure protective clothing and proper w ash-up facilities are available to all personnel that may come in contact with mineral-based hydraulic oils. Always dispose of used rags or paper to wels in the correct and safe fashion.
HOISTING AND HANDLING SAFETY General Precautions

Do not allo w personnel to w ork or w alk under loads supported by a crane or hoist. Use appropriate lifting de vices to secure the load to the crane. See the follo wing paragraphs of this section for additional information. Use the correct lifting hooks to support the load. Refer to the equipment manuf acturers manuals for lifting points and procedures. Use extreme caution when operating a crane near po wer lines or electrical equipment. Do not e xceed the crane s rated load capacity . Always subtract the weight of the hook block, slings, chains, spreader bars and any additional equipment to determine the maximum load that can be safely lifted.
7F
Disposal Of Excess Fuels, Lubricants And Liquids

Quarry personnel are responsible for the proper disposal of unused fuels, used lubricating oils, used h ydraulic oils, and other toxic materials. DO NOT dispose of these materials in an unapproved manner. Follow all applicable federal, state and local regulations.
Wire Rope
Wire rope requires careful use, handling and maintenance to ensure long life and safe operation. Always observe the following precautions. Be sure to use the correct wire rope for the application. Be sure that the wire rope is inspected re gularly following the manufacturers guidelines.
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Safety
Avoid sudden loading in cold weather . Never use frozen wire rope. Use suitable padding to protect wire rope from sharp corners or edges. Avoid dragging wire rope underneath loads or o obstacles. ver
Be sure that all connections between chain sections are completed with properly sized hardw are and lifting hooks.
! CAUTION !!! DANGER

Always follow proper rigging procedures as provided by the chain manufacturer. The angle of rigging may decrease the rated lifting capacity.
Never use wire rope that has is cut, badly kink ed, frayed or crushed. Avoid reverse bends. Be sure that rope ends are properly sized. Use thimbles in eye fittings at all times Watch for local wear. Reposition or shorten wire rope to remove the worn section from the area of lifting tension.
Fiber Or Synthetic Slings

Slings require careful use, handling and maintenance to ensure long life and safe operation. Be sure that slings are rated or coded for the hitch or application. Be sure that slings are inspected re gularly following the manufacturers guidelines. Slings may be safely used in a temperature range of 20 to 180 F (-6 to 82C) without decreasing load limits. F or temperatures beyond this range or for wet/frozen slings, follow manufacturers instructions for load reductions. Do not use synthetic slings in temperatures e 180F (82C). Avoid sudden or shock loading (DO NO upright). xceeding T jerk load
Follow the manuf acturers instructions for lubrication if using wire rope for lifting purposes.
Connecting Or Clamping Wire Ropes

When connecting or clamping wire ropes, use one of the following: Clamp and thimble connections combine both the clamp and thimble in one unit. Clamp and thimble connections are capable of supporting 80% of the rated wire rope load. Cable clips are the most common way to secure a rope to a piece of equipment or to make an eye. The cable clip or Crosby Clip is made of a U-bolt and saddle. If this type of clip is used to make an eye, the use of a properly sized thimble is mandatory. If not, the cable may kink, forming a permanent weak spot.
TRANSPORTING MACHINERY
Be sure that the machinery is properly secured so that it cannot vibrate or move during transport. Remove any dirt, stones or other loose material from the machinery. Install shipping brackets, wood blocking or other shipping materials as directed in the machinery manuf acturers manuals. Perform any shipment preparation procedures as indicated in the manuals. Plan your route carefully . Know the clearance height of the machinery. Be aware of bridges, power lines and steep or uneven grades. Be aware of any other conditions which may present hazards or obstructions. Be sure that all tractor trailer components are working and in good condition. Test all systems (brak es, steering, lights, etc.) for proper operation and/or adjustment before beginning the mo ve. Check air pressure in all tires and replace any tires that are worn or damaged. After the machinery has been transported, block the tires if the trailer will remain stationary for an extended period of time. Refer to the Telsmith Portable Plant Installation and Maintenance Manual for additional portable plant transport instructions.
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7F
Chains
Chains require careful use, handling and maintenance to ensure long life and safe operation. Be sure that the correct size chain is being used for the application. Be sure that the chain is inspected regularly following the manufacturers guidelines. Avoid sudden or shock loading (DO NO T jerk load upright). Use suitable padding to protect the chain from sharp corners or edges. Avoid dragging the chain under loads or over obstacles. Use the proper fittings at all times Watch for local wear . Reposition or shorten chain (as required) to remo ve the w orn section from the area of tension. Inspect links to determine the amount of wear . Refer to manufacturers specifications for wear tolerance ranges
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Chapter 2
Chapter 2 General Instructions

WORK SAFELY AND USE COMMON SENSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 TOOLS AND SUPPLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 LUBRICANTS & SEALANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 PARTS IDENTIFICATION & INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 HANDLING SEALS & MACHINED PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 HANDLING BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 USING HEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Removing Hydraulic Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
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General Instructions
7F
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WORK SAFELY AND USE COMMON SENSE

Refer to Chapter 1 of this manual for important quarry safety information. Also refer to the Telsmith Quarry Equipment Safety Guide for additional safety precautions. Observe all precautionary statements (D ANGER, WARNING, CAUTION, IMPORTANT, and NOTE) that are included within the repair and overhaul procedures. Be sure all lifting devices, slings and supports are in good condition and of adequate rated capacity . Refer to Appendix C for component weights. Keep cleaning solvents and other combustibles away from heat and open flame. Do not smo e around flammabl liquids. Wear appropriate personal protecti ve equipment (PPE). Keep the work area clean and well organized. If service assistance is needed, contact your local Telsmith dealer or the Telsmith Service Department.
PARTS IDENTIFICATION & INSPECTION

Tag and mark all parts during remo val and disassembly procedures. Clean all parts as remo ved. Verify that the y are free of cracks, nicks, burrs and other imperfections. Check clearances and dimensions as instructed in the procedures. Replace any excessively worn or damaged parts. If possible, take reference photographs of the machinery as it is disassembled. During reassembly , use the photographs to v erify that all parts are correctly reinstalled.
HANDLING SEALS & MACHINED PARTS

Be careful not to cut or damage seals during installation. Handle shafts carefully to prevent damage. Do not nick or mar finished sur aces. If shafts, bearings or other machined items are to be removed from the machinery for more than a fe w days, cover them with a protecti ve coating of rust-preventative lubricant.
TOOLS AND SUPPLIES

The following common tools, shop equipment and supplies are required to complete most repair and o verhaul procedures: Chain puller (6000 lb. capacity). Impact wrench with a 3/4 inch dri ve minimum, 1 inch preferred. Set of sockets and breaker bars, minimum 3/4 inch dri ve with sockets up to 3-1/2 inches. Cold chisel, 3/4 inch. Hammers (various sizes). Cables, slings, and chains. Crane or hoist of adequate capacity. (Refer to Appendix C for component weights) Feeler gauge and inside/outside micrometers. Cleaning solvent. Flushing oil. Refer to the Tools and Supplies Required heading at the beginning of each chapter for additional items needed to perform specific repair and verhaul procedures.
HANDLING BEARINGS
Remove an y loose dirt from the machinery before exposing bearings. Handle bearings with clean, dry hands. Use only clean lint-free rags. Use clean tools in clean surroundings. Use clean solvents and flushing oils. Install new bearings as removed from packaging without washing. Do not remo ve bearings from packaging until ready to use. Soak used bearings in solv ent. Then w ash the bearings and blo w them dry with filtered, moisture-fre compressed air. Dip the bearings in oil immediately after drying to prevent rust.
7F
! WARNING!!! DANGER
Always wear eye protection and face shield when using compressed air. Do not spin the bearings by hand or by air pressure after the bearing surfaces have dried.
LUBRICANTS & SEALANTS

Required lubricants and sealants are listed at the beinning of g each chapter under the Tools and Supplies Required heading. Detailed specifications for these items are located i Appendixes D and E.
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USING HEAT
When using an oil bath, avoid contact with hot oil. Use an acetylene torch if heat is required to remo ve an interference-fit part and it is not practical to use hot oil
23
Keep flame m ving continuously. Do not let flame touc the part being removed. If a part is to be destro yed by heat, be careful not to damage other reusable parts nearby. Be careful when using heat and handling hot parts. To prevent burns, always wear appropriate hand, f and eye ace protection.
Removing Hydraulic Lines
! WARNING!!! DANGER
Failure to observe the following precautions may result in serious personal injury or death. Before loosening an y h ydraulic fittings or rem ving hydraulic lines, be sure that pressure is fully relieved and that all pressure g auges indicate zero (0) PSI. Lockout/ tagout power if the system is po wered by an electric pump. Never attempt to loosen a h ydraulic fitting while th system is pressurized. If hydraulic oil penetrates the skin, serious personal injury or death can result. Never have your face near, or stand directly in front of a hydraulic line when cracking a fitting, ven after system pressure has been relie ved. Always assume that the line has pressure. Before removing a hydraulic hose, check that the hose is relaxed and not stiff. A stiff hydraulic hose indicates that system pressure has not been fully relie ved. If a hose feels stiff, do not attempt to loosen the hose fittings unti pressure has been relieved.
7F
Be sure to wear appropriate personal protecti ve equipment, such as safety goggles or f ace shield. Some residual pressure may still be present in the system, e ven when all gauges indicate zero (0) PSI. Have a suitable container ready to catch an y spilled hydraulic oil when hydraulic lines are removed. To pre vent contamination of h ydraulic systems, cap all ports and hose fittings immediately after rem ving any hydraulic lines.
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Chapter 3
Chapter 3 Repair and Overhaul Procedures

Preliminary Instructions and Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 General Shutdown Procedure (Before Working on Crusher) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Stationary Jaw Die Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Stationary Jaw Die Key Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Swing Jaw Die Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Swing Jaw Guard Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Cheek Plate Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Flywheel Pulley/Sheave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 Tension Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 Toggle and Toggle Seat Replacement . . . . . Toggle Removal . . . . . . . . . . . . . Toggle Seat Replacement (Toggle Beam) Toggle Seat Replacement (Swing Jaw). . Toggle Installation . . . . . . . . . . . . Thrust Shaft (Model 3042 Only) . . . . . . Removal. . . . . . . . . . . . . . . . . Bronze Thrust Shaft End Replacement . Installation . . . . . . . . . . . . . . . Hydraulic Adjusting Cylinder Replacement. Removal. . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23 . 3-23 . 3-24 . 3-24 . 3-25 . 3-29 . 3-30 . 3-31 . 3-31 . 3-32 . 3-33 . 3-34 . 3-34
7F
Swing Jaw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
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Repair and Overhaul Procedures
7F
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REPAIR AND OVERHAUL PROCEDURES Preliminary Instructions and Precautions
Stationary Jaw Die Replacement

TOOLS AND SUPPLIES REQUIRED Suitable rigging and hoisting equipment Lifting hook 1-inch drive impact wrench or torque wrench with 2-1/4" socket for stationary jaw die fasteners Hand grinder Prybar Tape measure Appropriate equipment and materials for cleaning mating surfaces of crusher and stationary die Lubricant (refer to specifications New fabric washers Appendix D for lubricant
! WARNING!!! DANGER
Failure to follow the instructions and precautions below may result in serious personal injury or DEATH! Read the General Instructions in Chapter 2. Lock out po wer source and tag crusher dri ve controls. Warn all personnel that crusher is being serviced. Lock out power source and tag controls for crusher feed and discharge equipment. Always use suitable rigging and hoisting equipment to stabilize and lift heavy objects. Lifting heavy components with inadequate hoisting apparatus can damage machinery and result in serious personnel injury or death. Refer to Appendix C for component weights.
General Shutdown Procedure (Before Working on Crusher)
! WARNING!!! DANGER
Failure to follow the instructions and precautions below may result in serious personal injury or DEATH! 1. 2. Be sure there is no material lodged inside the crushing chamber. Lockout/Tagout power to the crusher drive motor. Shut off fuel supply if the crusher is po wered by a diesel engine. Refer to Chapter 1 for detailed lock out/tagout procedures. Lockout/Tagout power to the oil lubrication system, if equipped.
7F
3.
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33
02 01 03
2044
04
05 06 07 08
09 10 11 02
01
03
3042
7F
04
01 - Die (stationary jaw) 02 - Bolt 03 - Lifting hook pocket 04 - Key 05 - Fabric washer 06 - Steel washer 07 - Hex nut 08 - Jam nut 09 - Bushing 10 - Washer 11 - Bolt Do not remove jaw die hardware unless jaw die is worn or broken 09 10
05 06 07 08
11
Figure 31. Stationary Jaw Exploded View

34 03/99
! WARNING!!! DANGER
Lock out power source and tag controls for crusher drive motor, feed and discharge equipment before performing any maintenance or repairs. Always secure drive pulley if it is necessary to enter the crushing chamber. Warn all personnel that crusher is being serviced. Also, read and adhere to the instructions at the be ginning of this chapter entitled Preliminary Instructions and Precautions and General Shutdo wn Procedure (Before Working on Crusher) before performing an y maintenance or repairs.
IMPORTANT: Mating surfaces must make solid contact. Always remove any dirt, nicks or burrs before replacing or reversing die. Clean all surfaces as required. Using a straightedge, check contact surfaces of both stationary jaw and jaw die for atness. Check surfaces both longitudinally and diagonally to assure that 100 percent contact is accomplished.
! WARNING!!! DANGER
A lw ay s u s e s u i t a b l e r i g g i n g a n d h o i s t i n g equipment to stabilize and lift heavy objects. Lifting heavy components with inadequate hoisting apparatus can damage machinery and result in serious personnel injury or death. Refer to Appendix C for component weights. Figure 3-2. Clean Mating Surfaces of Die and Frame 2. Inspect key [04] and replace if worn or broken. Refer to the Stationary Ja w Die K ey Replacement section of this manual. Rotate die [01] 180 (if opposite end is not w orn) or place ne w die on lifting hook. Refer to Figure 3-3. Lower die [01] into position aligning k eyways of die with keys [04] of crusher frame. Refer to Figure 3-4.
Removal
NOTE: See Figure 3-1 for exploded view and numbered callouts [01 - 11]. Also refer to other gures as indicated. 1. 2. Loosen (but do not remove) nuts [07, 08] on lowest row of jaw die bolts [02]. Remove nuts [07, 08] and w ashers [05 and 06] from upper ro w of ja w die bolts [02]. Refer to Figure 3-5. Remove upper row of jaw die bolts [02]. Carefully pry top of ja w die [01] from crusher frame. Insert lifting hook into pocket located at back of die and support using an appropriate lifting de vice. Refer to Figure 3-3. Remove nuts [07, 08] and w ashers [05, 06] from lo wer row of jaw die bolts [02]. Refer to Figure 3-5. Remo ve lower row of jaw die bolts [02]. Lift die [01] from crusher frame and mo ve to an appropriate work area.
3.
3
LIFTING HOOK
3.
7F
LIFTING POCKET STATIONARY JAW DIE
4.
5.
Installation
NOTE: See Figure 3-1 for exploded view and numbered callouts [01 - 11]. Also refer to other gures as indicated. 1. Whether replacing or reversing the die [01], clean and check for nicks and burrs on the mating surfaces. Using a hand grinder, make sure all mating surfaces of frame and die are smooth. Refer to Figure 3-2.
35
Figure 3-3. Lift Stationary Jaw Die
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FABRIC WASHER LIFTING HOOK STATIONARY JAW DIE
STEEL WASHER
HEX NUT JAM NUT DIE KEYWAY FABRIC WASHERS STEEL WASHER HEX NUTS
DIE KEY
JAM NUTS
Figure 3-4. Install Stationary Jaw Die
4.
Position die [01] on crusher frame. Install a jaw die bolt [02] into each of the upper corners of the die. Loosely secure the two jaw die bolts [02] with nuts [08].
Figure 3-5. Install Stationary Jaw Die Fastening Hardware 6. Remove lifting hook and install upper ro w of ja w die bolts [02]. Coat threads of ja w die bolts with lubricant. Loosely secure bolts [02] with fabric washers [05], steel washers [06] and nuts [07, 08]. Refer to Figure 3-5.
IMPORTANT: Install new fabric washers during Steps 5 and 6. Do not reuse old fabric washers. 5.
7F
Install lower row of ja w die bolts [02]. Coat threads of jaw die bolts with lubricant. Loosely secure bolts [02] with f abric w ashers [05], steel w ashers [06] and nuts [07, 08]. Refer to Figure 3-5.
IMPORTANT: In Step 7, the corrugations of the stationary jaw die must line up perfectly with the corrugations of the swing jaw die. 7. Center jaw die [01] in main frame. Measure the distance between the edge of the jaw die [01] and the side wall of the main frame. Do this on both sides of the ja w die. Refer to Figure 3-6. Using a prybar, slide the jaw die so that it is perfectly centered in the main frame. Mak e sure that the measurement is equal on both sides. Corrugations of the stationary ja w and swing ja w must be meshed as illustrated in Figure 3-7.
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Stationary Jaw Die Key Replacement

SIDE WALLS OF CRUSHER
TOOLS AND SUPPLIES REQUIRED

STATIONARY DIE
1-inch dri ve impact wrench or torque wrench with ?" socket Hammer Brass bar Mallot Appropriate equipment and materials for cleaning mating surfaces Lubricant (refer to specifications Appendix D for lubricant
! WARNING!!! DANGER
CENTER DIE BETWEEN WALLS (Measurement Must Be Equal on Both Sides)
Figure 3-6. Measure Distance Between Die and Wall

SWING JAW DIE
! WARNING!!! DANGER
CORROGRATIONS MUST BE MESHED STATIONARY JAW DIE
Figure 3-7. Check that Stationary and Swing Jaw Dies are Meshed 8. Tighten all nuts [07, 08] e venly using a 1-inch dri ve impact wrench or torque wrench with 2-1/4" sock et. If the keys [04] were remo ved and/or replaced, install the washers [10] and bolts [11]. Refer to Figure 3-8. Torque all fasteners to the value specified in Appendix A.
A lw ay s u s e s u i t a b l e r i g g i n g a n d h o i s t i n g equipment to stabilize and lift heavy objects. Lifting heavy components with inadequate hoisting apparatus can damage machinery and result in serious personnel injury or death. Refer to Appendix C for component weights. The following procedures may be performed after the stationary jaw die is remo ved from the crusher . Refer to Stationary Jaw Die Replacement instructions in this section.
7F
IMPORTANT: After starting crushing with the machine, it is very important to go back every 8 hours for at least 3 days and retighten the bolts to ensure they are, in fact, staying tight.
Removal
NOTE: See Figure 3-1 for exploded view and numbered callouts [01 - 11]. Also refer to other gures as indicated. 1. Remove bolts [11] and washers [10] from the stationary jaw die locating keys [04]. Refer to Figure 3-8. Remove keys [04] from the main frame. If replacing the b ushings [09], remo ve them from the main frame using a hammer and brass bar.
2.
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Installation
NOTE: See Figure 3-1 for exploded view and numbered callouts [01 - 11]. Also refer to other gures as indicated. 1. Clean all mating surfaces of the new bushings [09] and main frame. Apply a light coat of lubricant to the bushing bores of the main frame. Align a ne w b ushing [09] (be vel end f acing inside of crusher) with the bore of the main frame. Using a mallot, tap the bushing [09] evenly around its entire circumference until it is partly installed in the bore. Continue
tapping the b ushing [09] e venly around its entire cir cumference until it is flush with the all of the main frame. Install the second bushing [09] in the same manner. Refer to Figure 3-8. 3. Apply a light coat of lubricant to the bores of the b ushings [09]. Install the new keys [04] into the bores of the bushings [09].
2.
NOTE: Do not install the bolts [11] and washers [10] at this time. This is completed after the stationary jaw is installed.
CRUSHER HOUSING WASHER BUSHING
DIE KEY
BOLT
DEVELED END OF BUSHING
7F
Figure 3-8. Stationary Jaw Die Key Components
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Swing Jaw Die Replacement

TOOLS AND SUPPLIES REQUIRED Suitable rigging and hoisting equipment Lifting hook 1-inch dri ve impact wrench or torque wrench with the following socket for swing jaw die fasteners: 2-1/4" socket (2044 crusher) 2-3/4" socket (3042 crusher) Hand grinder Prybar Appropriate equipment and materials for cleaning mating surfaces of swing jaw and swing jaw die Lubricant (refer to specifications New fabric washers Appendix D for lubricant
08
08 07 06 05 09
07 06 05 09
04 03
04 03 10
02
02 01
01
10
3
11
11 12
13 01 - Fabric washer 02 - Steel washer 03 - Hex nut 04 - Jam nut 05 - Fabric washer 06 - Steel washer 07 - Hex nut 08 - Jam nut 09 - Swing jaw 10 - Guard 11 - Capscrew 12 - Wedges 13 - Bolt 14 - Die (swing jaw) 15 - Key 15 15 14
13
7F
14
2044
3042
Figure 3-9. Swing Jaw Exploded View
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39
! WARNING!!! DANGER
Lock out power source and tag controls for crusher drive motor, feed and discharge equipment before performing any maintenance or repairs. Always secure drive pulley if it is necessary to enter the crushing chamber. Warn all personnel that crusher is being serviced. Also, read and adhere to the instructions at the be ginning of this chapter entitled Preliminary Instructions and Precautions and General Shutdo wn Procedure (Before Working on Crusher) before performing an maintenance or y repairs.
LIFTING HOOK
LIFTING POCKET
SWING JAW DIE
! WARNING!!! DANGER
A lw ay s u s e s u i t a b l e r i g g i n g a n d h o i s t i n g equipment to stabilize and lift heavy objects. Lifting heavy components with inadequate hoisting apparatus can damage machinery and result in serious personnel injury or death. Refer to Appendix C for component weights. Figure 3-10. Support Jaw Die with Lifting Hook 3. Lift die [14] from swing jaw [09] and move to an appropriate work area.
Removal
NOTE: See Figure 3-9 for exploded view and numbered callouts [01 - 15]. Also refer to other gures as indicated. 1. 2. Remove nuts [03, 04], washers [01, 02], wedge bolts [13] and wedges [12]. Carefully pry top of die [14] from swing jaw [09]. Insert lifting hook in pock et and support die with hoist. Refer to Figure 3-10.
Installation
NOTE: See Figure 3-9 for exploded view and numbered callouts [01 - 15]. Also refer to other gures as indicated. 1. Whether replacing or reversing the die [14], clean and check for nicks and burrs on the mating surfaces. Using a hand grinder, make sure all mating surfaces of swing jaw and die are smooth. Refer to Figure 3-2.
7F
IMPORTANT: Mating surfaces must make solid contact. Always remove any dirt, nicks or burrs before replacing or reversing die. Clean all surfaces as required. Using a straightedge, check contact surfaces of both swing jaw and jaw die for atness. Check surfaces both longitudinally and diagonally to assure that 100 percent contact is accomplished. 2. Inspect k ey [15] and replace if w orn or brok en. Also check welds around key [15]; reweld if necessary. Refer to Figure 3-11. Rotate die [14] 180 (if opposite end is not w orn) or place new die on lifting hook. Refer to Figure 3-10. Align die [14] with swing ja w [09], making sure die is properly seated o ver centering k ey [15] and supported by ledge. Refer to Figure 3-11.
3. 4.
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WELD KEY INTO KEYWAY AT ALL JOINTS
WELD
DIE
KEY SWING JAW LEDGE
DIE SWING JAW LEDGE
7F
WELD
KEY
Figure 3-11. Position Die into Jaw
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311
5.
Remove lifting hook from pock et. Carefully place top of die [14] against swing jaw [09].
! WARNING!!! DANGER
A lw ay s u s e s u i t a b l e r i g g i n g a n d h o i s t i n g equipment to stabilize and lift heavy objects. Lifting heavy components with inadequate hoisting apparatus can damage machinery and result in serious personnel injury or death. Refer to Appendix C for component weights.
IMPORTANT: Mating surfaces must make solid contact. Always remove any dirt, nicks or burrs before installing wedges. Clean all surfaces as required. IMPORTANT: Install new fabric washers during Step 6. Do not reuse old fabric washers. 6. Position wedges [12] at top of die [14] and install wedge bolts [13]. Coat threads of wedge bolts [13] with lubricant. Secure bolts [13] with f abric w ashers [01], steel washers [02] and nuts [03, 04]. Tighten all nuts [03, 04] e venly using a 1-inch dri ve impact wrench or torque wrench with 2-1/4" sock et (2044 crusher) or 2-3/4" sock et (3042 crusher). Torque all fasteners to the value specified in Appendix A.
Removal
NOTE: See Figure 3-9 for exploded view and numbered callouts [01 - 15]. Also refer to other gures as indicated. 1. 2. Remove nuts [03, 04], washers [01, 02], wedge bolts [13] and wedges [12]. Remove nuts [07, 08], washers [05, 06] and guard bolts [11]. Lift guard [10] from swing jaw 09].
7.
Swing Jaw Guard Replacement

TOOLS AND SUPPLIES REQUIRED Suitable rigging and hoisting equipment 1-inch dri ve impact wrench or torque wrench with the following socket for swing jaw die fasteners: 2-1/4" socket (2044 crusher) 2-3/4" socket (3042 crusher) 1-inch dri ve impact wrench or torque wrench with the following socket for swing jaw guard fasteners: ?-?/?" socket (2044 crusher) ?-?/?" socket (3042 crusher) Appropriate equipment and materials for cleaning mating surfaces of swing jaw, die and guard 3.
Installation
NOTE: See Figure 3-9 for exploded view and numbered callouts [01 - 15]. Also refer to other gures as indicated. IMPORTANT: Mating surfaces must make solid contact. Always remove any dirt, nicks or burrs before installing guard. Clean all surfaces as required. 1. Lift guard [10] into position aligning mounting holes of guard [10] and swing jaw [09].
7F
Lubricant (refer to specifications New fabric washers
Appendix D for lubricant
IMPORTANT: Install new fabric washers during Steps 2 and 4. Do not reuse old fabric washers. 2. Coat threads of guard bolts [11] with lubricant. Install guard bolts [11], fabric washers [05], steel washers [06] and nuts [07, 08] hand tight. Position wedges [12] at top of die [14]. Coat threads of wedge bolts [13] with lubricant. Install wedge bolts [13], f abric w ashers [01], steel w ashers [02] and nuts [03, 04]. Torque all nuts [03, 04, 07, 08] to the v alue specified i Appendix A.
! WARNING!!! DANGER
3. 4.
5.
Cheek Plate Replacement

TOOLS AND SUPPLIES REQUIRED Suitable rigging and hoisting equipment 1-inch drive impact wrench or torque wrench with 1-7/8" socket for cheek plate fasteners Appropriate equipment and materials for cleaning mating surfaces of crusher and cheek plates Lubricant (refer to Appendix D for lubricant specifications
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312
01
02
03 04
2044
01
3
03
02
7F
06 05 04
3042
01 - Upper cheek plate 02 - Lower cheek plate 03 - Bolt 04 - Washer 05 - Hex nut 06 - Jam nut
Figure 3-12. Cheek Plate Exploded View

03/99 313
Installation
! WARNING!!! DANGER
NOTE: See Figure 3-12 for exploded view and numbered callouts [01 - 06]. Also refer to other gures as indicated. IMPORTANT: Mating surfaces must make solid contact. Always remove any dirt, nicks or burrs before replacing or exchanging cheek plates. Clean all surfaces as required. 1. Place new (or exchanged) check plate [01, 02] on hook or strap. Align cheek plate [01, 02] with bolt holes on crusher frame. Refer to Figure 3-13. 2044 CRUSHER: Coat threads of bolt [03] with lubricant. Slide bolt [03] with w asher [04] through crusher frame and loosely install into lo wer open hole of cheek plate [01, 02]. Refer to Figure 3-14. 3042 CR USHER: Slide bolt [03] through lo wer open hole of cheek plate [01, 02] and crusher frame. Coat threads of bolt [03] with lubricant. Loosely install washer [04] and nut [05] on bolt end. Refer to Figure 314.
2.
! WARNING!!! DANGER
Removal
NOTE: See Figure 3-12 for exploded view and numbered callouts [01 - 06]. Also refer to other gures as indicated. 1. 2044 CRUSHER: Completely remove bolt [03] and washer [04] from one bolt hole at top of cheek plate. Refer to Figure 3-14. 3042 CRUSHER: Completely remove bolt [03], washer [04] and nuts [05, 06] from one bolt hole at top of cheek plate. (For upper cheek plate, remove both bolts [03], washers [04] and nuts [05, 06].) Refer to Figure 3-14. 2. 2044 CRUSHER: Loosen (but do not remove) the lower bolt [03] to provide room for lifting hook or strap. Insert lifting hook or strap through open bolt hole. Refer to Figure 3-13. 3044 CRUSHER: Loosen (but do not remove) nuts [05, 06] on other bolts [03] to pro vide room for lifting hook or strap. Insert lifting hook or strap through open bolt hole(s). Refer to Figure 3-13. 3.2044 CRUSHER: Support cheek plate [01, 02] with hoist and remove the remaining bolt [03] and w asher [04]. Lift cheek plate [01, 02] from crusher. 3042 CRUSHER: Support cheek plate [01, 02] with hoist and remove all remaining bolts [03], nuts [05, 06], and w ashers [04]. Lift cheek plate [01, 02] from crusher.
SLING
7F
FASTENER (3042 Shown)
UPPER CHEEK PLATE
LOWER CHEEK PLATE
Figure 3-13. Installing Cheek Plate
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3.
CHEEK PLATE
3042
CRUSHER SIDE WALL WASHER JAM NUT
2044 CRUSHER: Coat threads of remaining bolt [03] with lubricant. Remove lifting hook or strap and install remaining bolt [03] and washer [04]. 3042 CR USHER: Remo ve lifting hook or strap and install remaining bolt(s) [03]. Coat threads of bolt(s) [03] with lubricant. Secure bolt(s) [03] with w asher [04] and nuts [05, 06]. Install remaining nut [06] on lower bolt.
HEX NUT
4.
2044 CRUSHER: Tighten all bolts [03] e venly using a 1-inch drive impact wrench or torque wrench with 1-7/8" socket. Torque all f asteners to the v alue specified i Appendix A. 3042 CRUSHER: Tighten all nuts [05, 06] evenly using a 1-inch dri ve impact wrench or torque wrench with 1-7/8" socket. Torque all fasteners to the value specifie in Appendix A.
BOLT CHEEK PLATE
CRUSHER SIDE WALL WASHER BOLT
2044
3
Figure 3-14. Installing Cheek Plate Fasteners
7F
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315
Flywheel Pulley/Sheave
TOOLS AND SUPPLIES REQUIRED Suitable rigging and hoisting equipment Torque wrench Standard socket or open end wrenches Hammer Wedges (2) Appropriate equipment and materials for cleaning eccentric shaft ends and flywheel pull y and/or flywhee sheave Lubricant (refer to specifications Appendix D for lubricant
FLYWHEEL PULLEY
18 15
30 19
20
21
3
17 31 16
7F
15
FLYWHEEL SHEAVE
34 35 30
15 - Bolt 16 - Jam nut 19 17 - Hex nut 20 18 - Flywheel pulley 21 19 - Washer 20 - Washer 21 - Capscrew 30 - Eccentric shaft 17 31 - Key 16 34 - Flywheel sheave (2044) 35 - Flywheel sheave (3042) Shaft component parts not shown are listed in Figures 4-1 & 5-1.
31
Figure 3-15. Flywheel Pulley and Sheave Exploded View

316 03/99
Installation
! WARNING!!! DANGER
NOTE: See Figure 3-15 for exploded view and numbered callouts [15 - 21, 30, 31, 34, 35]. Also refer to other gures as indicated. 1. 2. 3. Lubricate bore of flywheel pull y [18] or flywheel sheave [34, 35]. Install a wedge into the split at both sides of the bore. This will open the bore slightly for easier installation. Align keyway of flywheel pull y [18] and/or flywhee sheave [34, 35] with keyway of eccentric shaft [30] and install on eccentric shaft [30]. Install key [31]. Drive key [31] into place with hammer. Remove wedge from split at both sides of the bore. Install hub bolts [15] and secure with he x nut [17] and jam nut [16]. Torque nuts [16, 17] to the value specifie in Appendix A. Install shaft w asher [19], w ashers [20] and bolts [21]. Torque bolts to the value specified in Appendix A.
4. 5. 6.
! WARNING!!! DANGER
7.
Tension Rod
TOOLS AND SUPPLIES REQUIRED Standard socket or open end wrenches Pliers Tape measure Appropriate equipment and materials for cleaning tension rod components Grease (refer to Appendix D for lubricant specifications
Removal
NOTE: See Figure 3-15 for exploded view and numbered callouts [15 - 21, 30, 31, 35]. Also refer to other gures as indicated. 1. 2. Remove bolts [21], washers [20], and shaft washers [19] from appropriate end(s) of eccentric shaft [30]. Flywheel Pulle y Remo val: Remo ve nuts [16, 17] and hub bolts [15] from flywheel pull y hub [18]. Remo ve flywheel pull y [18] and k ey [31] from eccentric shaft [30]. Flywheel Sheave Removal: Remove nuts [16, 17] and hub bolts [15] from flywheel she ve hub [34, 35]. Remove flywheel she ve [34, 35] and k ey [31] from eccentric shaft [30]. NOTE: If ywheel and/or ywheel sheave cannot be removed by hand, use a wedge to expand the split hub.
3.
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317
01 02
03
04
05
06
07
3
09 01 - Nuts 02 - Spring washer 03 - Spring 04 - Sleeve 05 - Bracket 06 - Washer 07 - Bolt 08 - Tension rod 09 - Cotter pin 10 - Tension rod pin
08
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10
Figure 3-16. Tension Rod Exploded View
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1.
! WARNING!!! DANGER
Lock out power source and tag controls for crusher drive motor, feed and discharge equipment before performing any maintenance or repairs. Always secure drive pulley if it is necessary to enter the crushing chamber. Warn all personnel that crusher is being serviced. Also, read and adhere to the instructions at the be ginning of this chapter entitled Preliminary Instructions and Precautions and General Shutdo wn Procedure (Before Working on Crusher) before performing an y maintenance or repairs. 2.
Remove nuts [01], spring washer [02] and spring [03] from tension rod [08]. Remove tension rod sleeve [04]. NOTE: If sleeve bushings are worn, refer to the parts manual for replacement parts.
3.
Remove cotter pins [09], tension rod pin [10] and tension rod [08].
Installation
NOTE: See Figure 3-16 for exploded view and numbered callouts [01 - 10]. Also refer to other gures as indicated. NOTE: Model 2044 has one tension rod. Model 3042 has two tension rods. 1. Slide tension rod [08] through tension spring bracket [05] (bolted to bottom of toggle beam).
! WARNING!!! DANGER
IMPORTANT: A grease tting is located at the eye end of the tension rod. This tting provides lubrication to the tension rod bushing and should be facing downward so that it will be easily accessible. 2. Position tension rod [08] between brack et located at bottom of swing ja w. Install tension rod pin [10] through holes of brack et and tension rod [08]. Secure pin [10] with cotter pins [09]. Refer to Figure 3-17.
Removal
NOTE: See Figure 3-16 for exploded view and numbered callouts [01 - 10]. Also refer to other gures as indicated.

Never stand directly behind tension rod spring when removing nuts. Spring could accidentally release, causing serious Injury.
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319
SWING JAW
TENSION ROD PIN TENSION ROD COTTER PIN COTTER PIN BRACKET GREASE FITTING
Figure 3-17. Install Tension Rod IMPORTANT: A grease tting is located on the side of the tension rod sleeve. This tting provides lubrication to the tension rod. For Model 3042, this tting should be facing inward so that it will be easily accessible. For Model 2044, this tting may face either direction. 3. Slide tension rod slee ve [04] o ver threaded end of tension rod [08]. Position the tw o cast lugs between the mounting blocks of mounting brack et [05]. Refer to Figure 3-18.
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TENSION ROD SLEEVE MOUNTING BRACKET
SPRING SPRING WASHER MOUNTING BLOCKS
NUT CAST LUG TENSION ROD
7F
Figure 3-18. Install Tension Rod Spring Components 4. 5. Install spring [03] and spring w asher [02] on tension rod end [08]. Apply a light coating of grease to threads of tension rod [08]. Thread hex nut [01] onto tension rod [08] until it contacts the spring washer [02].

Never stand directly behind tension rod spring when tightening nuts. Spring could accidentally release, causing serious injury. 6. Measure the distance between the tw o spring w ashers [02, 04]. Refer to Figure 3- 19. Tighten nut [01] until spring [03] is compressed one (1) full inch.
IMPORTANT: For Model 3042 (dual tension rod models), the exact amount of pressure must be applied to both tension rods.
IMPORTANT: Never fully compress the spring. Springs must always have space in order to be effective.
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MEASURE DISTANCE BETWEEN WASHERS
Figure 3-19. Measure Distance Between Washers 7. Install the locknut [01] and lock it against the first nut [01]. Refer to Figure 3-20
7F
TENSION ROD LOCK NUT HEX NUT
SPRING SPRING WASHER
Figure 3-20. Install Locknut 8. Apply grease to fittings on tension rod [08] and tension rod sle ve [04]. Refer to Appendix D for grease specifications
IMPORTANT: If the crusher knocks when operating, tighten tension rod nuts [01] to the point where the knocking stops. Do not overtighten. For Model 3042 (dual tension rod models), tighten nuts [01] on both tension rods evenly.
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Toggle and Toggle Seat Replacement

TOOLS AND SUPPLIES REQUIRED Suitable rigging and hoisting equipment Standard socket or open end wrenches Optional auxiliary cylinder or hand winch Cutting torch (toggle seat replacement) Metal rod, hooked at end (see Figure 3-25) Appropriate equipment and materials for cleaning mating surfaces of toggle and toggle seats
crushing chamber. Warn all personnel that crusher is being serviced. Also, read and adhere to the instructions at the be ginning of this chapter entitled Preliminary Instructions and Precautions and General Shutdo wn Procedure (Before Working on Crusher) before performing an y maintenance or repairs.
! WARNING!!! DANGER
! WARNING!!! DANGER
Lock out power source and tag controls for crusher drive motor, feed and discharge equipment before performing any maintenance or repairs. Always secure drive pulley if it is necessary to enter the
Toggle Removal
01
3
02 03
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04 02 08 07 05
01 - Toggle beam 02 - Clamp 03 - Toggle seat (toggle beam) 04 - Toggle 05 - Toggle seat (swing jaw) 06 - Pin 07 - Bolt 08 - Washer
06
Figure 3-21. Toggle Assembly Exploded View

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5.
! WARNING!!! DANGER
DO NOT enter the crusher at any time when replacing the toggle. Perform all work from outside the crusher. Failure to follow this precaution may result in serious personal injury or DEATH! 1. 2. 3. Suspend hoist between cross member and swing jaw as illustrated in Figure 3-23. Lower sling through center ribs of toggle [04] and secure toggle to sling as illustrated in Figure 3-23. With the toggle [04] adequately supported, remo ve tension rod(s) as instructed in the section T ension Rod, Removal in this chapter. 6. 7.
Place four w ooden timbers inside rear of main frame. The wooden timbers will hold the lo wer portion of the swing ja w assembly in place when swing ja w is released during Step 6. Slowly release swing ja w assembly, allowing it to rest against wooden timbers. Check can vas protector (located abo ve toggle seat on swing jaw) for wear or damage; repair if necessary.
Toggle Seat Replacement (Toggle Beam)

! WARNING!!! DANGER ! CAUTION !!! DANGER

Use extreme caution when removing the toggle from the crusher. Personal injury can occur to people under the crusher if the toggle is accidentally dislodged from hoist and allowed to fall. 4. With the toggle [04] adequately supported, mo ve swing jaw forward as follows: a. If crusher is equipped with the optional auxiliary cylinder (Model 3042 only), install the c ylinder between the swing jaw and rear of crusher as illustrated in Figure 3-24. Attach the auxiliary c ylinder to the h ydraulic hand pump. Use the pump to extend the c ylinder and mo ve the swing ja w for ward. If crusher is not equipped with an auxiliary c ylinder, f asten a cable or other de vice to bottom of swing jaw pulling it forward to make room for toggle [04] remo val. Lo wer toggle [04] through bottom of crusher. Toggle seat replacement is most safely performed with the swing jaw removed from the crusher. Failure to follow this precaution may result in serious personal injury or DEATH! 1. 2. Remove bolts [07], washers [08] and clamps [02]. Using a cutting torch, cut the toggle seat [03] in half (along the full length). Remo ve both halv es of toggle seat [03] from toggle beam [01]. Clean and check new toggle seat [03] and toggle beam [01] for nicks and burrs and repair as necessary. Install new toggle seat [03] into toggle beam [01]. Secure with bolts [07], w ashers [08] and clamps [02]. Torque bolts [07] to the value specified in Appendix A.
3. 4.
3
b.
Toggle Seat Replacement (Swing Jaw)

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THRUST BRACKET SWING JAW
! WARNING!!! DANGER
Toggle seat replacement is most safely performed with the swing jaw removed from the crusher. Failure to follow this precaution may result in serious personal injury or DEATH! 1. Using a cutting torch, cut the toggle seat [05] in half (along the full length). Remove both halves of toggle seat [05] from the swing jaw. Remove pin [06] from swing jaw. Clean and check new toggle seat [05], pin [06] and swing jaw for nicks and burrs and repair as necessary. Install new pin [06] into new toggle seat [05] making sure it is completely seated.
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2.
AUXILIARY CYLINDER
3. 4.
Figure 3-22. Optional Auxiliary Cylinder (Model 3042 Only)

324
5. 6.
Install new toggle seat [05] into swing jaw aligning pin [06] with hole in swing jaw. Stake toggle seat at six (6) locations: one (1) at each end and in the center at both top and bottom.
2. 3.
Position the toggle [04] underneath the swing jaw. Suspend hoist between cross member and swing ja w as illustrated in Figure 3-23. Lower sling through center ribs of toggle [04] and secure toggle to sling. Refer to Figure 3-23. Position toggle as follows: a. Slowly raise toggle [04] into position fitting fir edge of toggle into toggle seat [03] located in toggle beam [01]. Refer to Figure 3-23. Continue lifting toggle [04] so that it pivots upward until second edge is aligned with toggle seat [05] located in swing jaw. Refer to Figure 3-24.
IMPORTANT: Refer to Appendix C for toggle weights. 4. 5.
Toggle Installation
NOTE: See Figure 3-21 for exploded view and numbered callouts [01 - 08]. Also refer to other gures as indicated. NOTE: The swing jaw must be moved forward before the toggle can be installed.
! WARNING!!! DANGER
DO NOT enter the crusher at any time when replacing the toggle. Perform all work from outside the crusher. Failure to follow this precaution may result in serious personal injury or DEATH! 1. Move swing jaw forward as follows: a. If the crusher is equipped with the optional auxiliary cylinder (Model 3042 only), install the c ylinder between the swing ja w and rear of crusher as illustrated in Figure 3-22. Attach the auxiliary c ylinder to the hydraulic hand pump. Use the pump to extend the c ylinder and mo ve the swing ja w for ward. If crusher is not equipped with an auxiliary c ylinder, f asten a cable or other de vice to bottom of swing jaw pulling it forward to make room for toggle [04].
b.
IMPORTANT: The canvas protecting apron must be lifted slightly so that when the toggle is seated in the toggle seat of the swing jaw, it forms a U with the top edge of the toggle. c. Slowly release swing ja w allo wing it to mo ve toward back of crusher. Make sure that toggle [04] is aligned with seat [05]. Lift can vas protecting apron to pre vent it from being wedged between toggle [04] and seat [05]. Refer to Figure 3-25.
b.
IMPORTANT: The toggle must be positioned between the two toggle seat clamps (bolted to toggle beam). The toggle must be fully seated in both toggle seats.
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3
SWING JAW SLING
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SWING JAW TOGGLE SEAT
TOGGLE BEAM
TOGGLE TOGGLE SEAT
Figure 3-23. Insert Toggle into Toggle Seat of Toggle Beam

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3
SLING SWING JAW
7F
TOGGLE BEAM
TOGGLE
TOGGLE SEAT
SWING JAW TOGGLE SEAT
Figure 3-24. Insert Toggle into Toggle Seat of Swing Jaw
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USE A HOOKED METAL ROD TO LIFT CANVAS APRON SLING TOGGLE CANVAS PROTECTING APRON
3
Figure 3-25. Position Canvas Protector on Top of Toggle 6. Install and adjust tension rod(s) as instructed in the section Tension Rod, Installation in this chapter.
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Thrust Shaft (Model 3042 Only)

TOOLS AND SUPPLIES REQUIRED Standard open end wrenches Standard hex wrenches Appropriate equipment and materials for cleaning mating surfaces of crusher and thrust shaft components Lubricant (refer to specifications Feeler gauge Appendix D for lubricant
3
09 10 11
7F
10 09 02 01 - Thrust shaft end (bronze) 02 - Thrust shaft 03 - Socket head capscrews 04 - Thrust washer 05 - Washer 06 - Bolt 07 - Bolt 08 - Nut 09 - Connector 10 - Adapter 11 - Hose 12 - Strap 13 - Bolt 14 - Fitting 01
13
12
08 07 04 06 05 03
Figure 3-26. Thrust Shaft Exploded View

03/99 329
Removal
! WARNING!!! DANGER
NOTE: See Figure 3-26 for exploded view and numbered callouts [01 - 14]. Also refer to other gures as indicated. 1. 2. 3. Remove grease lines [11] at fittings [09 and 10] at both sides of the crusher. Loosen adjustment bolt [07] and locknut [08] from thrust washer [04]. Refer to Figure 3-27. Remove bolts [06] and washers [05] from thrust washer [04]. Remove thrust washer [04].
! WARNING!!! DANGER
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CRUSHER SIDE WALL WASHER BOLT THRUST WASHER BRONZE THRUST SHAFT END
LOCK NUT BOLT
THRUST SHAFT
Figure 3-27. Thrust Washer Components 4. Slide thrust shaft [02] from thrust shaft holes on each side of crusher.
Installation
NOTE: See Figure 3-26 for exploded view and numbered callouts [01 - 14]. Also refer to other gures as indicated. IMPORTANT: Inspect bronze shaft end for wear. To r e p l a c e , r e fe r t o B r o n z e T h r u s t S h a f t E n d Replacement instructions in this section. 1. Clean and check thrush shaft components for nicks and burrs and repair as necessary. Also check mating surfaces on crusher frame for nicks and burrs and repair as necessary. Center swing jaw assembly so that clearance is equal on both sides between crusher frame bearing mountings and swing jaw retaining rings. Apply a light coat of lubricate to the thrust shaft hole on each side of crusher . Refer to Appendix D for grease specifications. Slide thrust shafts [02] (bronze end firs
331
7F
Bronze Thrust Shaft End Replacement

NOTE: See Figure 3-26 for exploded view and numbered callouts [01 - 14]. Also refer to other gures as indicated. 1. 2. 3. Remove socket head capscrews [03] from thrust shaft [02] and remove bronze thrust shaft end [01]. Clean and check thrush shaft components for nicks and burrs and repair as necessary. Install a ne w bronze thrust shaft end [01] onto thrust shaft [02] using the sock et head capscre ws [03] pre viously remo ved. Tighten capscre ws [03] to the v alue specified in Appendix A.
2.
3.
03/99
into thrust shaft holes on each side of crusher . Observe match marks (stamped on parts) to be sure that parts are installed on the correct side. Refer to Figure 3-27. 4. 5. 6. Secure thrust washers [04] with bolts [06] and w ashers [05]. Make sure lubrication hole faces rear of crusher. Install grease fitting parts [09 through 14] Install adjustment bolt [07] and locknut [08] into thrust washer [04], if remo ved. Turn the adjustment bolt [07] inward until a 0.025" clearance is achieved between the thrust shaft and thrust brack et. Use a feeler g auge for checking clearance. F ollow this procedure for both sides. The combined clearance for both sides should be 0.050". Tighten locknut [08]. Lubricate thrust shafts at grease fitting [14]. Refer t Appendix D for grease specifications
Hydraulic Adjusting Cylinder Replacement

TOOLS AND SUPPLIES REQUIRED Standard open end wrenches Standard hex wrenches Appropriate equipment and materials for cleaning mating surfaces of crusher and h ydraulic adjusting c ylinder components Screwdriver Pliers Lubricant (refer to specifications Appendix D for lubricant
7.
7F
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03/99
01
01 - Cylinder 02 - Clamp 03 - Boot 04 - Pin 05 - Clip pin 06 - Fitting 07 - Hydraulic Hose
Figure 3-28. Hydraulic Adjusting Cylinder
! WARNING!!! DANGER
! WARNING!!! DANGER
7F
Removal
NOTE: See Figure 3-28 for exploded view and numbered callouts [01 - 07]. Also refer to other gures as indicated. 1. Disconnect hydraulic lines [07] from c ylinder. Cap lines to prevent contaminants from entering the hydraulic system. Remove clip pins [05] from pins [04].
333
2.
03/99
3. 4. 1. 2.
Remove front and rear pins [04] from c ylinder [01] and remove cylinder [01]. Remove clamps [02] and boot [03] from cylinder [01]. Inspect cylinder rods for scoring and pitting; if damaged, replace cylinders [01]. Inspect cylinder seals for leakage. Check for h ydraulic fluid at bottom sur ace where c ylinder is mounted to crusher. If seals are leaking, replace as instructed in the manufacturer's repair instructions. Inspect pins [04] for wear or damage; replace if damaged. Inspect boot [03] for damage; replace if damaged.
Appropriate equipment and materials for cleaning mating surfaces of crusher, bearing mountings and bearing caps Lubricant (refer to specifications Appendix D for lubricant
Inspection
! WARNING!!! DANGER
3. 4.
Installation
NOTE: See Figure 3-28 for exploded view and numbered callouts [01 - 07]. Also refer to other gures as indicated. 1. 2. Install boot [03] onto cylinder [01] and secure with clamps [02]. Align cylinder [01] mounting holes with crusher mounting holes. Install front and rear pins [04] into mounting holes. Install clip pins [05] into each end of pins [04]. Connect h ydraulic lines [07] to c ylinder. Activate hydraulic hand pump and check for leaks; repair as necessary.
! WARNING!!! DANGER
3.
4.
Removal
1. On oil lubricated crushers, remove oil feed and return hoses from swing jaw. Cap hoses to prevent contaminants from entering the oil system. Mark bearing caps for proper reassembly . Remove jam nuts and hex nuts from bearing cap studs. Refer to Figure 3-29. Thread eyebolt into each bearing cap and remo ve bearing cap from main frame bearing cap studs.
Swing Jaw
7F
TOOLS AND SUPPLIES REQUIRED Suitable rigging and hoisting equipment 1-inch drive impact wrench or torque wrench with ?-?/?" socket for bearing cap fasteners Eyebolts (2)
2.
3.
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JAM NUT
HEX NUT STUD
BEARING CAP STUD
KEY (Welded in Keyway)
7F
Figure 3-29. Removing Bearing Caps 4. 5. Secure swing jaw to hoist with wire rope sling as illustrated in Figure 3-30. Attach a guide rope to the lo wer end of the swing ja w. Use the rope to help control swing ja w movement during Steps 6 and 7. Refer to Figure 3-30. IMPORTANT: See Appendix C for swing jaw weights. 6. Lift entire swing jaw assembly from crusher.
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335
NOTE: Arrange timbers so that lower portion of swing jaw will move towards front of crushing chamber when jaw is lowered into main frame.
LIFTING CABLE
IMPORTANT: See Appendix C for swing jaw weights. 2. Support the swing jaw assembly in a wire rope sling as illustrated in Figure 3-32. Install blocking as shown.
LIFTING CABLE
BLOCKING THRUST BRACKETS (Model 3042 Only)
BEARING MOUNTING BEARING HOUSING THRUST BRACKETS (Model 3042 Only)
3
7.
ATTACH GUIDE ROPE HERE
Figure 3-30. Hoisting Swing Jaw Lower swing jaw onto blocking with jaw die facing up.
SWING JAW ATTACH GUIDE ROPE HERE
7F
Figure 3-32. Swing Jaw in Sling 3. Attach a guide rope to the lo wer end of the swing ja w. Use the rope to control ja w movement during Steps 4 through 7. Hoist swing jaw assembly over the main frame, with the front of swing jaw facing stationary jaw die. Lower jaw until bearing mountings are suspended over openings in crusher frame. Refer to Figure 3-33. NOTE: The main frame bearing mountings are keyed in position with steel keys. Key #1 prevents bearing mountings from rotating in the main frame. Key #2 restricts the lateral movement of the swing jaw. Key #1 is installed during Step 7. Key #2 is welded to crusher frame.
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WOOD SUPPORTS
4.
Figure 3-31. Rest Swing Jaw on Blocking
Installation
If the swing jaw was shipped separately from the main frame, perform the following steps: 1. Place four hardwood timbers inside the main frame toward the rear of crusher.
336
6.
Position swing ja w so that k eys (#2) on frame are in alignment with the corresponding k eyways on bearing mountings. NOTE: As jaw is lowered during Step 7, have assistants install keys (#1). Rotate bearing mountings and reposition jaw as required so that all keyways and keys are precisely aligned. Refer to Figure 3-35.
Figure 3-33. Align Key #1 Keyways
3
Figure 3-35. Align Keys with Bearing Mountings 7. Slowly lo wer swing ja w until bearing mountings are seated in crusher frame openings. Model 3042 Only: As jaw is lowered, check that thrust brackets do not contact thrust shaft housings (in crusher frame). 8. Install an eyebolt into each bearing cap. Install bearing caps on studs.
7F
IMPORTANT: Bearing caps must be replaced on the same side and in the exact same position from which they were removed from shipment. Observe match marks on bearing caps and crusher frame. 9. Figure 3-34. Key and Keyway Locations 5. Rotate bearing mountings until k eyways for k eys (#1) are in alignment with the corresponding k eyways on crusher frame openings. Refer to Figure 3-33. Secure bearing caps with he x and jam nuts. Torque to the value specified in Appendix A.
10. Using a feeler g auge, check to mak e sure that bearing caps are seated tightly ag ainst crusher frame. Replace eyebolts with a bolt to k eep bearing cap lifting holes free of dirt.
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337
7F
338
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APPENDIX
APPENDIX
APPENDIX A - TORQUE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 APPENDIX B - CONVERSION TALBES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1 APPENDIX C - CRUSHER WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1 APPENDIX D - LUBRICANT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1 APPENDIX E - EXPENDABLE SUPPLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1
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Appendix1
Appendix
APPENDIX
Appendix
Appendix2
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RECOMMENDED MAXIMUM TORQUE VALIUES 5%
Identication Mark
Grade SAE J429 R898 Class 4.6

Torque** Dry Lube 5 6 11 13 20 23 32 36 49 55 70 78 92 105 165 180 200 225 300 340 430 480 605 670 795 905 1050 1186 1660 2500 4 5 8 10 15 17 25 27 38 42 54 60 71 81 125 140 155 170 230 260 330 370 465 515 610 670 810 915 1280 1920 1.31 1.50 2.16 2.39 3.19 3.61 4.37 4.89 5.83 6.59 7.07 7.90 8.79 9.95 13.20 14.52 13.82 15.25 18.15 20.35 22.85 25.60 29.00 32.10 34.60 39.40 42.20 47.30 56.80 75.00 8 10 17 19 31 35 49 55 75 85 110 120 150 170 270 295 395 435 590 660 795 890 1120 1240 1470 1670 1950 2190 3075 4620 6 7 13 15 24 27 38 42 58 65 84 93 115 130 205 230 305 335 455 510 610 685 860 955 1130 1290 1500 1690 2370 3550 2.02 2.31 3.33 3.69 4.93 5.58 6.76 7.55 9.03 10.20 11.58 12.93 14.40 16.30 21.31 23.75 27.00 29.80 35.40 39.70 42.30 47.50 53.80 59.59 64.20 73.00 78.00 87.70 105.50 138.50 10 12 21 24 38 43 61 68 93 105 135 150 185 210 330 365 530 585 795 890 1125 1260 1590 1765 2085 2370 2765 3110 4370 6550 8 9 16 18 29 33 47 52 72 80 105 115 145 160 250 280 405 450 610 685 865 970 1225 1355 1600 1830 2130 2400 3360 5050 2.49 2.85 4.11 4.56 6.08 6.90 8.35 9.33 11.15 12.58 14.30 15.95 17.75 20.10 26.30 29.30 36.30 40.00 47.70 53.50 60.00 67.30 76.30 84.40 91.00 103.50 110.80 124.50 149.50 196.70 **All torque values are given in foot-pounds. Clamp* Load # Torque** Dry Lube Clamp* Load # Torque** Dry Lube Clamp* Load #
2 ASTM A449 R898 Class 8.8 SAE J429 ASTM A354
ASTM/SAE Spec.
ISO Designation
R898 Class 10.9

Torque** Dry Lube 12 14 24 27 44 49 70 78 105 120 155 170 210 240 375 420 605 670 905 1030 1285 1440 1820 2010 2380 2710 3160 3555 4980 7480 9 11 18 21 34 38 54 60 82 90 120 132 165 185 290 320 455 515 695 785 990 1110 1400 1550 1830 2085 2430 2730 3810 5760 Clamp* Load # 2.86 3.26 4.70 5.21 6.95 7.88 9.55 10.68 12.75 14.38 16.35 18.25 20.30 23.00 30.00 33.50 41.50 45.80 54.50 61.20 68.70 77.00 87.20 96.50 104.00 118.30 126.50 142.20 171.00 225.00
Appendix A - Torque Table
Dia.
Thread Series
1/4 1/4 5/16 5/16 3/8 3/8 7/16 7/16 1/2 1/2 9/16 9/16 5/8 5/8 3/4 3/4 7/8 7/8 1 1 1-1/8 1-1/8 1-1/4 1-1/4 1-3/8 1-3/8 1-1/2 1-1/2 1-3/4 2
20 28 18 24 16 24 14 20 13 20 12 18 11 18 10 16 9 14 8 12 7 12 7 12 6 12 6 12 5 4-1/2
UNC UNF UNC UNF UNC UNF UNC UNF UNC UNF UNC UNF UNC UNF UNC UNF UNC UNF UNC UNF UNC UNF UNC UNF UNC UNF UNC UNF UNC UNC
A1
*Clamp loads are shown in 1000 pounds.
7F
Appendix A - Torque Table
7F
A2
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Appendix B- Conversion Tables
Appendix B- Conversion Tables

LINEAR MEASURE To Convert Inches Feet Centimeters Millimeters Meters Meters Info Centimeters Meters Inches Inches lnches Feet CUBIC MEASURE To Convert Cu. Inches Cu. Feet Cu. Centimeters Cu. Meters Cu. Meters Info Cu. Centimeters Cu. Meters Cu. Inches Cu. inches Cu. Feet Multiply by 16.387 0.0283 0.06102 610233779.0 35.314 To Convert Kilograms Pounds Pounds/Sq. Inch Pounds/Sq. Foot Multiply by 2.54 0.3048 0.3937 .0394 39.37 3.2808 To Convert Sq. Inches Sq. Miles Sq. Centimeters Sq. Meters Sq. Meters SQUARE MEASURE Info Sq. Centimeters Sq. Kilometers Sq. Inches Sq. Inches Sq. Feet WEIGHT Info Pounds Kilograms Kilograms/Sq. Centimeter Kilograms/Sq. Meter Multiply by 2.2046 0.4536 0.0703 4.8824 Multiply by 6.452 2.59 0.15499 1549.9 10.763
DEGREES FAHRENHEIT TO DEGREES CENTIGRADE F -30 -28 -26 -24 -22 -20 -18 -16 -14 -12 -10 -8 -6 -4 -2 0 +1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 03/99 C -34.44 -33.33 -32.22 -31.11 -30.00 -28.89 -27.78 -26.67 -25.56 -24.44 -23.33 -22.22 -21.11 -20.00 -18.89 -17.78 -17.22 -16.67 -16.11 -15.56 -15.00 -14.44 -13.89 -13.33 -12.78 -12.22 -11.67 -11.11 -10.56 -10.00 -9.44 -8.89 -8.33 -7.78 -7.22 F +20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 C -6.67 -6.11 -5.56 -5.00 -4.44 -3.89 -3.33 -2.78 -2.22 -1.67 -1.11 -0.56 0.00 +0.56 1.11 1.67 2.22 2.78 3.33 3.89 4.44 5.00 5.56 6.11 6.67 7.22 7.78 8.33 8.89 9.44 10.00 10.56 11.11 11.67 12.22 F +55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 C +12.78 13.33 13.89 14.44 15.00 15.56 16.11 16.67 17.22 17.78 18.33 18.89 19.44 20.00 20.56 21.11 21.67 22.22 22.78 23.33 23.89 24.44 25.00 25.56 26.11 26.67 27.22 27.78 28.33 28.89 29.44 30.00 30.56 31.11 31.67 F +90 91 92 93 94 95 96 97 98 99 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 C +32.22 32.78 33.33 33.89 34.44 35.00 35.56 36.11 36.67 37.22 37.78 40.55 43.33 46.11 48.89 51.67 54.44 57.22 60.00 62.78 65.56 68.33 71.11 73.89 76.67 79.44 82.22 85.00 87.78 90.55 93.33 96.11 98.89 101.67 104.44 F +225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320 325 330 335 340 345 350 355 360 365 370 375 380 385 390 395 C +107.22 110.00 112.78 115.56 118.33 121.11 123.89 126.67 129.44 132.22 135.00 137.78 140.55 143.33 146.11 148.89 151.67 154.44 157.22 160.00 162.78 165.56 168.33 171.11 173.89 176.67 179.44 182.22 185.00 187.78 190.55 193.33 196.11 198.89 201.67 B1
7F
7F
B2
03/99
Appendix C - Crusher Weights

IMPORTANT: Weights listed are approximate weights and may vary by +/- 5 percent. Always use suitable rigging and hoisting equipment to stabilize and lift heavy objects. Contact the Telsmith Parts Department for weights not shown.
Weights Pounds (Kilograms)

Description 2044 3042
7F
03/99
C1
7F
C2
03/99
Appendix D - Lubricant Specifications
Appendix D - Lubricant Specications

Lubricating Oil Specications (Oil System)
Ambient Temperature Description Viscosity ISO Grade Viscosity AGMA Grade #250.04 Viscosity SUS @ 100 F Viscosity SUS @ 210 F Viscosity Index Timken OK Load (lbs) Extreme Pressure Agent (EP) Rust and Oxidation Agent Anti-Foaming Agent Copper Strip Corrosion Test Below 40 F (4.5 C) CKC-100 3 EP 469 to 575 61 to 67 95 Min. 60 Min. Yes Yes Yes Pass Above 40 F (4.5 C) CKC-150 4 EP 709 to 871 74 to 82 95 Min. 60 Min. Yes Yes Yes Pass
Oil must not be corrosive to metals generally used in bearings, gears, shaftings, pumps and housings. Oil must have the least possible effect on rubber seals, synthetic seals, packings and hoses. Refer to the Jaw Crusher Operation & Maintenance Manual for detailed crusher lubrication procedures and oil capacities.
Hydraulic Oil Specications (Hydraulic Adjusting System)

Viscosity ISO Grade Viscosity SUS @ 100 F Viscosity SUS @ 210 F Viscosity Index API Gravity Pour Point, F Flash Point, F Anti-Wear Agent Anti-Foaming Agent Rust and Oxidation Inhibitor 68 317 53 to 57 95 Min. 29 Min. -10 to +10 400 to 425 Yes Yes Yes
7F
NOTE: Refer to the Jaw Crusher Operation and Maintenance Manual for detailed hydraulic system maintenance instructions and oil capacities.
11/97
D1
Appendix D - Lubricant Specifications
NLGI #2 Grease Specications

NLGI Grade Number 2 Worked Penetration @ 77 (60 Strokes) 285 Worked Penetration @ 77 (100,00 Strokes) 300 Dropping Point F 365 Copper Corrosion Test, 14 Days Pass Wheel Bearing Test @ 275 F Pass Timken OK Load (lbs) 50 The above grease must contain an extreme pressure (EP) agent that is not harmful to bronze, brass or lead. For satisfactory lubrication, grease must be absolutely free from any ingredients which could cause corrosion, and from gritty material which could produce wear. Grease should also be uniform in texture, consistency, structure, stability, ow characteristics and lubricating characteristics.
Moly Based EP-2 Grease Specications (Aluminum Complex with Molybdenum Disulde)
Worked Penetration Dropping Point F Rust Prevention (ASTM D-1743) Corrosion Prevention (ASTM D-1261) Oxidation Stability (ASTM D-942) Oxygen Absorption (PSI) After 100 Hours 200 Hours 300 Hours Oil Viscosity, SUS @ 100 F <3 <4 <5 1000 65 800 0.51 mm Aluminum Complex 0 to 450 F 3.0 265/295 510 Pass Pass
7F
Extreme Pressure Performance Timken OK Load (lbs) Four Ball Weld Point Wear Scar Type of Soap Operating Temperature MoS2 % by Weight
D2
11/97
Appendix E - Expendable Supplies

The following expndable supplies are used throughout the repair procedures of this manual. These supplies or their equivelents are commonly available at most local supply houses or distributors. Always read and understand manufacturers directions and safety precautions before using any expendable supplies.
Pipe Sealant
Description Loctite 592 PST Pipe Sealant, Medium Strength, Slow Cure, Anti-Galling. Part No. 59241. Manufacturer Loctite Corp
Thread Locking Compound

Description Loctite 242 Threadblocker, Removable Strength. Part No. 24241. Manufacturer Loctite Corp.
7F
03/98
E1
Spray Primer (for use with Loctite 242 thread locking compound)
Description Loctite 7471 Locquic Primer T, Aerosol, Part No. 22477. Manufacturer Loctite Corp.
Anti-Seize Compound
Description Bostik Never-Seez, Regular Grade, Copper Formula. Meets MIL SPEC A907E. Manufacturer Bostik Corp.
Silicone Sealant
Description Red Devil RD ProTM 100% Silicone Sealant. Meets MIL SPEC 46106A. Manufacturer Red Devil, Inc.
7F
E2
03/98
Shellac
Description Bulls Eye Shellac, Clear Sealer & Finish (Conforms to federal spec. TT-S-300A Manufacturer Wm. Zinsser & Co., Inc.
7F
03/98
E3
7F
E4
03/98

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Jaw Crusher Repair and Overhaul

Models 2044 and 3042

Telsmith H-Series Gyrasphere

Telsmith H-Series Gyrasphere

FINDING MODEL AND SERIAL NUMBERS

HOW TO CONTACT TELSMITH

REQUESTING SERVICE ASSISTANCE

ORDERING REPLACEMENT PARTS

INSTALLATION & ASSEMBLY DRAWINGS

Telsmith 2044 & 3042 Jaw Crushers

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

Telsmith 2044 & 3042 Jaw Crushers

Telsmith 2044 & 3042 Jaw Crushers

! WARNING!!! DANGER ! CAUTION !!! DANGER

HAZARD AND ADVISORY STATEMENTS

LOCKOUT/TAGOUT Who Must Use Lockout/Tagout?

Telsmith 2044 & 3042 Jaw Crushers

How is Lockout/Tagout Performed?

When Must Lockout/Tagout Occur?

Telsmith 2044 & 3042 Jaw Crushers

When Can Lockout/Tagout Devices be Removed?

Additional Lockout/Tagout Requirements

Telsmith 2044 & 3042 Jaw Crushers

JAW CRUSHER SAFETY

QUARRY SAFETY SUMMARY Know Your Machinery

Be Prepared for Emergencies

Telsmith 2044 & 3042 Jaw Crushers

Wear Personal Protective Equipment (PPE)

Help Prevent Accidents

Observe Personal Safety Precautions

Telsmith 2044 & 3042 Jaw Crushers

Inspect And Maintain Machinery

Avoid Alcohol and Other Drugs

Be Aware of Your Surroundings

MACHINERY INSTALLATION SAFETY Foundations

Practise Good Housekeeping

Telsmith 2044 & 3042 Jaw Crushers

MAINTENANCE AND REPAIR SAFETY

Telsmith 2044 & 3042 Jaw Crushers

Pressurized Systems (hydraulic and air)

Clearing Jammed Material

Telsmith 2044 & 3042 Jaw Crushers

Flammable and Combustible Liquids

HOISTING AND HANDLING SAFETY General Precautions

Disposal Of Excess Fuels, Lubricants And Liquids

Telsmith 2044 & 3042 Jaw Crushers

! CAUTION !!! DANGER

Fiber Or Synthetic Slings

Connecting Or Clamping Wire Ropes

Telsmith 2044 & 3042 Jaw Crushers

Chapter 2 General Instructions

Telsmith 2044 & 3042 Jaw Crushers

Telsmith 2044 & 3042 Jaw Crushers

WORK SAFELY AND USE COMMON SENSE

PARTS IDENTIFICATION & INSPECTION

HANDLING SEALS & MACHINED PARTS

TOOLS AND SUPPLIES

LUBRICANTS & SEALANTS

Telsmith 2044 & 3042 Jaw Crushers

Removing Hydraulic Lines

Telsmith 2044 & 3042 Jaw Crushers

Chapter 3 Repair and Overhaul Procedures

Repair and Overhaul Procedures