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TRIO

E N G I N E E R E D

P R O D U C T S

Trio Engineered Products, Inc. 12823 Schabarum Ave. Irwindale, CA 91706 Telephone 626-851-3966 Fax 626-851-9526

Parts and Operation Manual

CT Series
20 x36
Jaw Crusher

CT2036 Jaw Crusher Manual

HAZARD WARNING
Any machinery may be hazardous to the user if it is not maintained and
operated properly. The following precautions should always be observed:

CRUSHING MACHINERY
1. Take special care to see that all parts of your body are clear of moving parts
and pinch points before starting or operating machinery.
2. Make sure that all rotating sheaves, pulleys and belts are properly guarded
to prevent being caught by them.
3. Be sure that the feed and discharge systems for material processing
equipment are designed and maintained so that processed materials (rocks,
gravel, coal, etc.) are retained within the system. Do not allow any part of
your body to enter in or near the material flow.
4. Never sit or stand on any component of the machinery while it is in operation
to prevent injuries arising from vibration.
5. Verify that the supporting structure(s) provided by your company for the
machinery is sufficient to support both the total weight of the equipment and
the dynamic load and stresses created by the equipment.

CONVEYING MACHINERY
1. Be sure that all parts of your body are kept clear of moving conveyor belts,
especially at pinch points.
2. Do NOT lubricate machinery while it is in motion.
3. Never lean over a moving conveyor belt, or ride on a conveyor belt
intended only for material transport.
4. Always keep clear of feed or discharge points of all material conveyor
systems.
5. Be sure that all guards are securely fastened in place on sheaves, pulleys,
and belts before and during equipment operation.

SAFETY EQUIPMENT
Trio Engineered Products, Inc. provides only such safety equipment and guards
as are specified by the Purchaser on the Shop Order or the Customer Order
Acknowledgment. The Purchaser must furnish all other required safety devices.

CT2036 Jaw Crusher Manual

GENERAL SAFETY PRACTICES


Safety Practices affect everyone. Any and all personnel who operate or
maintain your equipment are expected to comply with the basic safety
practices that follow.
This manual contains the best available information on proper installation,
operation and maintenance of the equipment that it addresses. It does NOT
replace or supersede applicable federal, state, or local regulations, your
company safety rules, or insurance carrier requirements. It definitely is not
intended to replace good judgment or common sense!
Equipment operators, plant management and safety engineers are required
and expected to be aware of potential hazards that may exist in the specific
workplace where the equipment is installed and operated. All personnel are
expected to develop, implement and maintain a safe work environment
compatible with operating conditions, requirements, and practices.
Additional safety precautions suited to the specific conditions of the work site
and the equipment installations are the responsibility of the user.
Experience has demonstrated that the greatest numbers of workplace
accidents are caused by failure to follow established safety rules. Be sure that
you are fully familiar with the safety program requirements applicable to
operating this type of equipment. Consult your supervisor concerning any
operating procedure that you are not sure about before operating or working
on this equipment.
Note: It is strongly recommended that properly constructed and guarded
access platforms be erected at convenient locations on the equipment
installation site to allow safe inspection, adjustment, maintenance and repair of
the equipment described in this manual. It is the responsibility of the purchaser
of this equipment to ensure that such platforms comply with applicable federal,
state, and local standards and regulations.

PERSONAL SAFETY PRACTICES


ARRANGEMENTS FOR EMERGENCY SITUATIONS
Supervisory and operating personnel should develop an emergency response
profile for possible emergencies on the worksite. All personnel should know the
location of fire-extinguishers, where to obtain first-aid assistance and supplies,
emergency report telephone numbers, power shut-off points, and other
equipment shut-down control locations. Appropriate tools and equipment
should be available to allow immediate response to emergency situations.

CT2036 Jaw Crusher Manual

Always follow the requirements and regulations of your companys Emergency


Action Plan.

CT2036 Jaw Crusher Manual

SAFE MACHINERY INSTALLATION


1. Read and understand all parts of this manual including General Dimension
Drawings.
2. Review your Plant Engineers Installation Drawings for this equipment.
3. Select, Assemble, and Test the correct hoisting and rigging equipment
required to move the equipment to the installation site in your family.
If there is any question regarding the proper rigging of the equipment or
necessary hardware to make the lift/movement of the equipment to its
designated mounting location, contact your local representative or Trio
Engineered Products, Inc. to resolve the questions prior to beginning installation
activities.

KNOW AND UNDERSTAND HOW THE EQUIPMENT WORKS


It is absolutely essential that machine operators understand completely how the
crusher works. The operator must know the location and function of all controls,
gauges, indicators and alarms included with the unit.
Operators and
maintenance personnel must be completely familiar with maintenance
procedures and schedules. Only if the equipment is given maintenance on the
prescribed schedule can costly and time-consuming breakdowns be
prevented.
DO NOT OPERATE THE MACHINE WHEN ITS PARTS ARE WORN BEYOND DESIGNATED TOLERANCES.
REPAIR OR REPLACE THEM BEFORE TROUBLE OCCURS.

INSPECT YOUR MACHINE BEFORE START-UP


Make a visual inspection of the machine for loose, worn, or damaged parts or
faulty safety devices. Inspect all drive belts and pulleys for excessive wear. Test
alarm systems and check fluid levels. Make sure that hydraulic, air, and
lubrication systems and their respective valves, drains, and fittings are in proper
working order. Report or repair any problem before starting the machine.

FOLLOW THE RECOMMENDED EQUIPMENT START-UP INSTRUCTIONS


Be sure that control systems and alarms are working properly. Check gauges for
proper readings. Check for any unusual noises that may indicate bearing failure
or other mechanical problems. Check for sudden rises in lubricant temperature.
Shut the equipment down immediately if problems are detected, and report the
problem(s) to your supervisor. Always refer to the Operating Section of this
manual if you are unsure about a start-up procedure or for additional
information.

CT2036 Jaw Crusher Manual

STOP THE MACHINE PROPERLY AND SAFELY


The machine must be completely stopped with power off and locked-out with
controls tagged before any cleaning, repairs, adjustments, or service is
performed. All provisions of your companys Control of Hazardous Energy (LockOut/Tag-Out) program must be followed.

REPORT THE NEED FOR NECESSARY REPAIRS IMMEDIATELY


Report any situation involving the need for repair, replacement or adjustment of
an equipment component immediately. Remember, the most minor defect
could result in injuries to yourself or others or serious damage to the machinery if
it is not corrected promptly.
Do NOT work on the equipment unless you have been properly and completely
trained to do the work involved.

PREVENT FIRE HAZARDS


Never weld or use a cutting torch near open or exposed fuels, lubricants, or
other flammable materials. Follow your companys Hot Work Policy.
Do not let greasy or oily rags accumulate in poorly ventilated areas. Store oily
rags and other combustible materials in an approved storage container and
dispose of them properly.
Never use an open flame to check for fluid leaks in the equipment. Use an
approved low voltage electric light or flashlight.
Never smoke in undesignated areas. Follow your companys Smoking Rules.
Always extinguish smoking materials properly. Know where the nearest fire
extinguisher is located, how to operate it, and what types of fires it can be used
to extinguish. Make sure that fire extinguishers are in place, are in proper
working condition, and have a current, valid inspection tag. If a fire extinguisher
is not readily available, or does not meet these requirements, report the situation
to your supervisor.

KEEP YOUR WORK AREA CLEAN


Become fully familiar with the worksite where the equipment is installed. Inspect
the area daily and see that unsafe conditions are corrected. Make sure that all
equipment guards are securely fastened in place, that steps, stairways, work
platforms and barrier rails are sound and free of spills or obstructions. Keep the
floor/work surface clean and free of oil, greasy rags, cables, chains, buckets and
other obstructions. Keep tools and loose parts in a toolbox or appropriate
storage areas. Use high flashpoint/low toxicity solutions for cleaning.

CT2036 Jaw Crusher Manual

HANDLE TOOLS, HEAVY PARTS, AND MACHINE COMPONENTS PROPERLY


Do not toss parts or tools or drop them off platforms. Do not lower or swing
electric or air power tools by their power cords or air lines. Use a suitable rope
and/or container to lower tools or parts to the floor. Review job activities and
arrange to get help before you attempt to lift, carry or move heavy parts. For
heavy or awkward lifts use proper hoisting devices.

DRESS PROPERLY FOR THE JOB AND USE APPROPRIATE PERSONAL


PROTECTIVE EQUIPMENT
Follow your company Personal Protective Equipment Policy. Discuss personal
protective equipment requirements with your supervisor before operating
equipment or performing service, repair or adjustment work. Dont wear loose
clothes or jewelry, and restrain long hair.

FOLLOW YOUR COMPANY SUBSTANCE ABUSE CONTROL POLICY


Report any use of prescription or over-the-counter medications to your
supervisor prior to operating this equipment or making any adjustments or
repairs to it.
ALCOHOL OR OTHER CONTROLLED SUBSTANCES SHOULD NOT BE USED PRIOR TO OR DURING WORK
ON THIS EQUIPMENT.

AVOID SERIOUS EYE/SKIN INJURIES


Hydraulic fluid or compressed air can penetrate or burn the skin or damage the
eyes causing serious injury, blindness, or death.
Mineral-based hydraulic oil is hazardous. Always wear goggles when working
with hydraulic fluid. Flush your skin or eyes thoroughly with water if you spill or
splash hydraulic fluid on yourself. Remove clothing on which hydraulic fluid has
splashed. Get immediate assistance and report the matter to your supervisor.
Get appropriated medical care.
Wear appropriate personal protective
equipment as set forth in your companys Personal Protective Equipment Policy
when handling hydraulic fluid. Wash your hands with soap and water after
handling hydraulic fluid. Never eat, drink or smoke while handling hydraulic
fluid.
Make sure that all compressed air lines and couplings are in proper operating
condition at all times. Be sure that all compressed air lines intended for chip or
dust removal are fitted with OSHA compliant pressure relief nozzles. Never use
compressed air to clean your clothing or any part of your body.

CT2036 Jaw Crusher Manual

DISPOSE OF ALL WASTE MATERIALS PROPERLY


Dispose of all waste materials such as fuels, lubricants, hydraulic fluid, etc. in
accordance with your company waste management policies, and federal,
state, and local regulations. If you have a question concerning proper
procedures to be followed, consult with your supervisor, or the company safety
administrator.

SAFETY AND MAINTENANCE PRACTICES


REPLACE LOOSE OR DEFECTIVE PARTS
Keep the equipment clean and free of dirt and oil so that loose, broken,
defective, or worn parts can be easily identified. Make daily visual checks for
missing, cracked, or frayed V-belts. Also check daily for frayed, broken or kinked
cables. Inspect end connections for wear. Replace sheaves with cracked rims
or spokes immediately. Report suspected defects to your supervisor.

PROPERLY GROUND MACHINE ELECTRICAL COMPONENTS


Check frequently to ensure that the equipment is properly grounded as
stipulated in your company electrical safety rules. Prevent any electric cable
from coming in contact with water in puddles, drainage channels, etc. Protect
power cables from vehicular traffic such as forklifts and other motor vehicles.
Power cables should be bridged over traffic lanes. All permanent electric
cables should be in proper conduit or other approved insulation. Follow your
company electrical safety rules with regard to periodic inspection of the
condition of electric line insulation and couplings. Do NOT use portable, flexible
electric cords to deliver electric power to the equipment.

CONTROL OF HAZARDOUS ENERGY (LOCK-OUT/TAG-OUT)


PROGRAM
CAUTION: Purchaser must implement a Control of Hazardous Energy (LockOut/Tag-Out) Program that complies with 29 CFR 1910.147 and 133 regulations.
It is the responsibility of the purchaser to provide a suitable Control of Hazardous
Energy program for the protection of its employees while they are engaged in
the installation, maintenance, repair, or modification of equipment powered by
electricity, hydraulic, pneumatic or mechanical energy in order to meet the
regulations of the U.S. Dept. of Labor, Occupational Health and Safety
Administration (OSHA).
Under certain conditions and in certain operating environments, the Federal
Mine Safety and Health Administration (MSHA) governs regulations concerning
this subject. Certain state, county, or local regulations may also apply.
CT2036 Jaw Crusher Manual

Assistance in establishing regulatory obligations may be obtained from


regulatory agencies, insurance carriers, or private consultants.
Specific information concerning electrical operating characteristics such as
output, rated capacity, etc. of electrical motors supplied with the equipment
may be obtained by review of the technical data contained in this manual or
from the specific equipment supplier stipulated in the Shop Order.

OBTAINING CONTROL OF HAZARDOUS ENERGY PROGRAM MATERIALS


Listed below are three possible suppliers of materials to aid you in development,
documentation and maintenance of your program. Inclusion of the names of
these firms in this manual does not represent an endorsement of them by Trio
Engineered Products, Inc.. These firms provide some of the materials required for
a comprehensive program.
1.

SETON Name Plate Company


P. O. Box BD - 1331
New Haven, CT 06505-9770
Telephone
203-488-8059
Toll Free
800-243-6624
Fax Toll Free 800-345-7819

2.

EMED Co., Inc. Telephone


Graphic Communications Products
Buffalo, NY 14240-0369
P. O. Box 369
Toll Free
800-442-3363
Fax Toll Free 800-344-2578

3.

D & G Sign and Label


P. O. Box LA - 157
Toll Free
800-356-9269
Northford, CT 06472
Telephone
203-483-0491
Fax
203-488-4770

The Purchaser has sole responsibility for safe operation of this equipment. The
Purchaser is responsible for ensuring that on-site machine operation is in
compliance with any and all applicable federal, state, county or city safety
standards and regulations.
The equipment may be moved from one site to another a number of times by
various purchasers, lessees, etc. Consequently, responsibility for compliance
with applicable safety and environmental codes lies with the entity responsible
for operating the equipment within each jurisdiction.
Purchaser is wholly responsible for any ancillary or support equipment such as,
but not limited to, processed material receiving devices, and inspection or
service platforms.

CT2036 Jaw Crusher Manual

10

Purchaser is required to perform periodic maintenance of the type and on the


recommended schedules set forth in this manual. Maintenance shall include,
but is not limited to safety devices delivered with the equipment set forth in the
Shop Order, and Warning and Instruction labels affixed to the equipment.
Replacement parts including warning and instructional labels are available from
Trio Engineered Products, Inc.. Purchaser is invited to call for availability and
current price of such parts and labels at 1-626-851-3966.
Any modifications or machinery as designed, manufactured, and delivered by
Trio Engineered Products, Inc. without the express written approval and consent
of Trio Engineered Products, Inc. will void all warranties and remove all
responsibility of Trio Engineered Products, Inc. for any and all damages to
persons or property.

Forward
This parts section of this manual is intended to assist the informed installer and user of
this jaw crusher in identifying wear and replacement parts that will be required during
the operating of this equipment. Because of the extreme nature of crushing, parts
replacement is an expected occurrence. The prepared operator should have certain
parts on hand to minimize operating down time.
Specific questions regarding the operation and maintenance should be addressed to
your distributor. The manufacturer will constantly try to improve their equipment and
there will therefore be changes from time to time that may require you to request up
dates from the factory or your local representative.

Safety
The manufacturer may not always know exactly how their equipment is installed,
applied and used, and cautions all prospective operators that they must exercise the
greatest care for the safety of individuals that happen in and around the machinery.
Equipment used in the United States must be installed and operated with regard to
safety either, per OSHA or MSHA regulations, or both.
Operating the equipment beyond its published ratings or without the proper guards and
protection for personnel is foolhardy and subjects the operator to potentially numerous
penalties or imprisonment or both.

General Information
This Operation and Maintenance Manual has been prepared to assist in the installation,
operation, and maintenance of Trio jaw crushers. The information contained in this
manual is intended to familiarize the operator with the general configuration and
assembly of this equipment. It should aid in providing the necessary information for
efficient operation and maintenance of this machine.

CT2036 Jaw Crusher Manual

11

Each crusher is delivered with this manual that illustrates the specific components
comprising the jaw crusher. When ordering parts, please have the following information
available:
Crusher Size
Crusher Serial Number
Part name and reference number (from appendix)
Complete shipping instructions (type of shipping required)
Number of parts required

Recommended Spare Parts


The following parts are recommended to have on hand for problems resulting from
normal wear and tear on the machine.
Stationary Jaw

Movable Jaw

Stationary Jaw Bolts

Movable Jaw Wedges & Bolts

Cheek Plates & Bolts

Toggle Plates

Recommended Tools
The following tools are recommended for storage with the crusher, as they will be
required for use during normal maintenance and repair.
Jaw Lifting Cable

Metric Allen Head Wrenches

Hydraulic Jack

Box Wrench

Complete Set of Metric Tools

Machine Shipping Condition


The crusher is assembled prior to delivery. However, a careful inspection of the
machinery should be performed upon delivery in order to identify any damage that may
have occurred during transportation.
The following checklist should be reviewed to ensure that the crusher is received in
proper operating condition.

Examine the crusher for significant damage.

There should not be any abnormal conditions, such as scarring and wear on
all frictional surfaces.

Verify that all removable plates are fastened tightly. Verify that the toggle
plate is seated correctly.

Verify that the shims are seated correctly and that the pull rod bolt is
adequately tightened.

CT2036 Jaw Crusher Manual

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Rotate the flywheel to determine if rotation appears trouble free, the pulley
and flywheel should turn smoothly.

Verify that the eccentric shaft and associated bearings are adequately
lubricated.

General Installation Information


Crusher Component Weights (Lbs)
Complete
Crusher

24,180

Frame
and
Cheek
Plates

Fixed

Swing

Pitman

Jaw

Cheek
Plates
(Total)

Jaw

8,686

1,430

1,430

590

3,877

Eccentric
Shaft

1,151

Toggle
Plate

247

Flywheel
(Total)

Pitman,
Eccentric
Shaft and
Swing Jaw

3,865

6,458

Horsepower Requirements
Electric motors are available for special duty crusher applications and are
recommended over standard frame motors.
MODEL

OPERATING SPEED
(FULL LOAD RPM)

MOTOR
HORSEPOWER (MIN.)

CT20x36

250

75

Flywheel Rotation Direction

CT2036 Jaw Crusher Manual

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CT Jaw Capacity (TPH) Analysis for Given Closed Side Setting of Crusher
Model

C.S.S. (Inch)
C.S.S. (mm)

1"

1-1/2"

2"

2-1/2"

3"

3-1/2"

4"

5"

6"

7"

8"

9"

10"

12"

25

40

50

63

75

90

100

125

150

180

200

230

250

300

10x20

1"--3-1/2"

25-90

12

15

22

26

32

35

10x30

1"--3-1/2"

25-90

17

22

27

32

39

45

10x40

1"--3-1/2"

25-90

23

30

37

43

52

63

10x48

1"--3-1/2"

25-90

28

35

44

52

64

76

12x52

1"--3-1/2"

25-90

50

63

77

90

105

130

17x26

1-1/2"--5"

40-125

35

45

55

70

95

105

135

20x36

2"--5"

50-125

80

92

110

133

148

180

24x36

3"---7"

75-180

120

147

165

190

30x42

3"---7"

75-180

150

175

36x48

4"---9"

100-230

42x54

5"---10"

125-250

230

275

190

220

280

340

240

295

360

450

500

570

330

390

515

575

630

700

650

740

800

48x64

6"---12"

150-300

500

590

26x46

2"---7"

50-180

90

103

125

155

175

210

250

340

32x54

2"---7"

50-180

105

118

135

170

185

235

310

420

950

1.

The above information is based on average feed material that weighs approximately 100 lbs/ft crushed of a size which is readily fed into the crushing chamber without clogging.

2.

Capacities shown may vary depending on the type, size, moisture content, and clay content of material, the bulk density, method of material feeding. Undersize material should be
removed from the crusher feed to eliminate packing and excess wear.

SETTINGS GREATER THAN INDICATED ARE WITHIN DESIGN CAPABILITIES OF THE MACHINES BUT ARE NOT SHOWN DUE TO ANTICIPATED HIGHER OPERATING
COSTS.

The above tables are based on results obtained during actual operation and could vary depending on the type of material, gradation of feed, method of feeding, moisture and clay
content, and other material characteristics. The indicated top size, also influenced by the above conditions, is provided to assist in the selection of the crushing equipment to follow.
Contact your dealer for more details.

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CT Jaw Product Grading Analysis (% Passing) for Given Closed Side Setting of Crusher
Product Size
>250mm

>10"

250

10"

225

9"

200

8"

180

7"

150

6"

125

5"

100

4"

1"

1-1/2"

2"

2-1/2"

3"

3-1/2"

4"

5"

6"

7"

8"

9"

10"

12"

25mm

40mm

50mm

63mm

75mm

90mm

100mm

125mm

150mm

180mm

200mm

230mm

250mm

300mm

100
100

100

100

100

100

100

90

85

75

65

90

83

75

70

60

100

90

83

75

70

65

55

90

83

75

70

63

60

52

100

95

83

75

68

63

58

55

47

100

90

85

75

68

60

58

48

45

40

100

90

83

75

65

60

55

48

45

40

35

90

3-1/2"

75

3"

63

2-1/2"

50

2"

90

75

65

58

55

50

40

35

30

25

22

20

17

45

1-3/4"

85

70

60

55

50

45

35

30

25

22

20

17

13

40

1-1/2"

100

75

65

55

50

45

40

30

25

22

20

17

12

10

30

1-1/4"

95

70

55

50

40

35

30

25

22

20

17

15

10

25

1"

75

65

45

43

35

30

25

20

17

15

12

10

20

3/4"

70

55

40

30

25

22

20

17

15

12

10

100

95

83

75

70

60

55

50

45

40

35

30

100

83

75

70

65

55

50

45

35

30

25

25

90

75

68

60

55

50

42

35

30

25

22

22

15

5/8"

60

45

35

25

20

17

15

13

10

10

3/8"

45

30

25

20

15

13

10

3/16"

30

20

15

10

THE ABOVE TABLES ARE BASED ON RESULTS OBTAINED DURING ACTUAL OPERATION AND COULD VARY DEPENDING ON THE TYPE OF MATERIAL, GRADATION OF FEED, METHOD OF FEEDING,
MOISTURE AND CLAY CONTENT, AND OTHER MATERIAL CHARACTERISTICS. THE INDICATED TOP SIZE, ALSO INFLUENCED BY THE ABOVE CONDITIONS, IS PROVIDED TO ASSIST IN THE SELECTION OF
THE CRUSHING EQUIPMENT TO FOLLOW. CONTACT YOUR DEALER FOR MORE DETAILS. Jaw crushers reduce large rock to smaller stone using exceptional force. The

foundation therefore must be substantial enough to support the crusher without distortion.

CT2036 Jaw Crusher Manual

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Foundation Recommendations
Jaw crushers reduce large rock to smaller stone using exceptional force. The foundation therefore must
be substantial enough to support the crusher without distortion.
Jaw crushers may be installed on permanent concrete or steel structures or mobile equipment.
Regardless of the application the foundation must withstand the forces of material impact and drive line
loads. The design task is usually best handled by a qualified engineer.
The interface between the crusher and foundation must be flat so that the crusher is given proper
support. Where a flat surface cannot be obtained it may be necessary to use machinery grout between
the two surfaces. The grout used of course must be adequate to the task when considering the impact
and dimensional requirements.
The installer will have to consider the configuration of chutes, hoppers, structural supports, etc., when
designing the crusher foundation. In order to minimize the noise and vibration to the surrounding
buildings as a result of the operating machinery, it maybe advisable to insert wooden planks, rubber
sheets or other padding materials between the crusher and its foundation.

Feed Configuration
In order to achieve the maximum operating efficiency for the crusher, an optimal feed arrangement must
be utilized. This crusher can reach its maximum efficiency only when the feed is supplied in the correct
amount and distributed evenly into the crushing chamber. The feed equipment should also allow for easy
access to the crushing chamber in the event of material blockage, part replacement, or other
maintenance.

Discharge Configuration
The crusher discharge compartment can be manufactured out of metal or wood. The compartment should
be readily accessible for cleaning, maintenance, and inspection. The compartment should also have a
shelf or ledge to provide a bed of crushed material for falling material to impact on. This bed will absorb
much of the impact of the falling material before it reaches the conveying belt. If a discharge chute is
used, its slope must be at least 45 from the horizontal and increased if the material is sticky in nature.

V-Belt Drive Installation


The crusher is powered by conventional 8V or C section V-Belts. The drive sheaf on the machine
carries the correct number of grooves to transmit the maximum allowable horsepower for the crusher.
The size and number of belts should not be reduced. Refer to a table of electrical power requirements for
recommended horsepower ratings.
The crusher installer will determine the V-Belt drive installation, so the following notes are provided for
general reference only.
Clean all oil, dirt, grease or rust from the sheaf grooves.
Verify the proper alignment of the sheaves and that the shafts are parallel.
Shorten the center distance until the belts can be slipped on easily.
Determine the minimum allowances for shortening or lengthening the center distance between
sheaves after referencing and a V-belt installation manual.
Always used a match set of belts from the same manufacturer. Never use a combination of warn
and new belts.

CT2036 Jaw Crusher Manual

16

After placing the belts on the sheaves, run the drive for a few minutes. Tension the drive until only slight
sag appears on the slack side of the belts when the drive is running. The slack side depends on the
motor position and rotation of the crusher.

V-Belt Precautions
V-Belt stretching and wear are potential problems for the user and frequent careful inspections are
recommended in order to identify problem belts before the belts fail. This will serve to reduce the potential
injuries that could result when belts break and give way.

Rust Protection
A crusher is comprised of iron and steel parts; it is particularly vulnerable to rust corrosion. Once rust
develops, the resulting porosity on the metal surfaces can cause an increased degradation of the crusher
due to water and moisture collection. Rust could be a major cause of downtime, high maintenance costs,
production loss, production waste, and short equipment life. It also could cause a potential safety risk to
operating personnel.
Because of the significant effects of rust on this machines operation, good service maintenance should
be practiced. If the crusher is in storage or not being used for more than a significant period of time, the
crusher should be operated for at least 10 minutes on a monthly basis. If there is no power supply to the
crusher during this period, the flywheel must be manually rotated 5 to 10 times to ensure that the
bearings to not deform and to ensure a proper disbursement of bearing grease.
Moisture condensation will cause corrosion at the contact point between the bearing rollers and the inner
and outer rings. This will degrade the finished surfaces of both the rollers and rings. When the crusher is
operating, this surface wear will cause the bearings to become rough and fail prematurely.

Tension Rod and Toggle Plate Information


The closed side setting of a Jaw Crusher is determined by the position of the toggle seat located within
the transverse header. The toggle seat may be positioned closer or further away from the pitman by
shims inserted at the rear of the seat. To decrease the closed side setting a larger shim pack is used,
conversely to increase the opening shims are removed.
Since the toggle plate is not mechanically attached to the pitman or the toggle seat tension rods and
springs are used to hold it in position. In operation the toggle plate acts like a pivot that holds the closed
side setting relatively fixed as the top of the pitman opens or closes by the amount of pitman eccentric.

Initial Assembly
The toggle plate, toggle seat, buffer plates and tension rod assembly, as shipped, will be installed in the
frame and should require no further attention other than final adjustment as explained in the operating
instructions section of this manual.
The toggle plate protects the pitman from the serious damage that could result if an uncrushable object
enters the crushing chamber. The toggle plate is intended to bend or fracture when an overload occurs
against the pitman die plate. The failure will result in an increase in the size discharge chute that will
allow the uncrushable object to pass through the chamber.
The tension spring on the toggle plate supplies the force required to prevent the pitman from pulling away
from the toggle plate upon reaching its furthest point forward.

Removal and Installation


During normal operation, the toggle plate, tension rod, or any of their respective components may require
repair or replacement. Care should be taken when removing those parts to ensure that no personal injury
results from the procedure.

CT2036 Jaw Crusher Manual

17

Flywheel and Pitman Information


Maintenance personnel that are familiar with large diameter spherical roller bearings should accomplish
removal and replacement of the flywheels and pitman. Work should be performed in a clean environment
free of dust and moisture. Smart tips include:
1. Plan ahead and have all necessary tools on hand before work begins in order to minimize the
bearings exposure to moisture and dirt.
2. Have all the required parts on hand as well.
3. Make sure that all shaft surfaces are clean and free of scarring or nicks.
4. Do not remove the bearing packaging until you are ready for immediate installation.

Jaw Dies and Side Plates


Fixed Jaw Die Replacement
The stationary jaw die plate is reversible and can be rotated 180 in order to distribute the wear over both
ends that will extend the total life of the plate. The plate should be rotated before excessive wear on the
lower end occurs.
Swing Jaw Die Replacement
Similar to the stationary plate, the movable jaw die plate, mounted on the pitman is reversible and can be
rotated 180 to distribute wear across the entire plate.

Lubrication
Lubrication procedures are performed primarily to deliver grease or oil to rotating or sliding surfaces to
reduce friction and carry away heat. Pressure lubrication is also used to expel contaminants from seals
and other openings. Certain lubricants are used to protect parts from corrosion.
When grease lubrication is used, the grease should be packed into the bearing making sure it gets
between the rollers and the cage not just on the outside of these parts. When hand-packing bearings,
force grease through the bearing under the cage from the large end to the small end to ensure proper
grease distribution. Mechanical grease packers are also available which force grease through the
bearing, filling the space between the roller and the cage. Grease should also be smeared on the outside
of the rollers.
Basic Lubricant Functions
Lubrication can be defined as the control of friction and wear between adjacent bearing surfaces by the
development of a lubricant film between them.
A bearing lubricant must perform three fundamental functions:
1. To provide a suitable film which separates the moving parts in a bearing.
2. As a heat transfer medium (to carry away heat)
3. To protect the bearing surfaces from corrosion and contamination.
Lube Recommendation
Trio recommends daily lubrication application at the close of the shift (Refer to the appendix B); the
grease will flow smoothly and allow easy purging around seals or out of the drain plug.
NEW CRUSHER lubrication It is recommended to completely purge bearings after the first 200 hrs.
after that 10 hr. intervals or shift intervals should be followed. Trio recommends a maintenance book be
used to keep a good account of activity on all aspects of the crusher.

CT2036 Jaw Crusher Manual

18

Self-Aligning Spherical Roller Bearing

Lubrication of the spherical roller bearings is accomplished by using a manual type grease gun or an
automatic lubricating system through four grease fittings. One grease fitting is located on each of the
side bearing housings and two grease fittings are located on the pitman, one at each pitman bearing.
If the grease gun method of lubrication is used, add the grease immediately after shut down while the
bearings are still warm.
Normally, a manual type grease gun requires 20 strokes to discharge one ounce of grease.
AVOID USING TOO MUCH GREASE AS EXCESSIVE GREASE WILL CAUSE OVERHEATING AND
SHORTEN THE BEARING LIFE.
Grease Specifications
Trio recognizes there are many factors that go into choosing a grease, a brand and a supplier, what we
wish to do is select the proper grade and additive that best fits the machinery and application. The brand,
the supplier (i.e. Texaco, Shell and so on) and the type (i.e. synthetic vs. non-synthetic) we will leave to
the end user.
Bearing greases must withstand high pressures and temperatures. Some bearing manufacturers can
supply a high quality premium grease that may prolong the life of the equipment, however satisfactory
performance can be obtained by using an NLGI #2. Choose type EP rated, ASTM D2509. Use the
proper grade for the ambient temperature expected.
The selection of the correct lubricant for ant application requires careful study of operational and
environmental conditions. In the selection of the proper lubricant there are trade-offs and concerns other
than fatigue life to consider. For instance changing lubricant viscosities will affect the bearing operating
temperature.
When severe operating conditions are anticipated the use of a lubricant with an extreme pressure
additive may help prevent scoring damage in the cone-rib / roller-end contact area. EP additives are
chemically complex material which, when activated by localized high temperatures, forms a low shear
strength film at the contact area on the bearing thus preventing scoring.
Grease life is dependent upon such factors as speed, environmental conditions and operating
temperature. The higher the temperature the more rapid is the grease oxidation. Grease life is reduced by
approximately one-half for every 18 degrees Fahrenheit rise in temperature. Therefore the higher the
operating temperature the often the grease must be replenished. Past experience is the best guide to
CT2036 Jaw Crusher Manual

19

republication frequency. Obviously, seal leakage will dictate frequent relubrication and every attempt
should be made to maintain seals at top efficiency.
Bearing Temperature
A properly adjusted bearing should run at about 140 to 160 degrees Fahrenheit. If a bearing is suspected
of running to hot it should be checked with a surface mount thermometer and checked to see if it is over
165 degrees Fahrenheit. A bearing that develops high temperature after it has been running satisfactorily
for some time may be caused by over greasing. A newly installed bearing that overheats is usually
caused by improper adjustments of the running clearance. A failed bearing that is overheating will
probably be accompanied by some other indication such as grinding noises.

Dust Seals
As stated above the bearings are protected from outside contamination by labyrinth seals that depend on
sloughing grease to shed the dust, dirt and moisture.

Operating Instructions
Pre-Starting Instructions
Adhering to strict inspection habits will serve to help insure years of successful operation of this crusher.
Memory alone will not ensure that proper maintenance is performed. Consequently, a written record book
is recommended. By regularly performing pre-startup maintenance inspections, the operator will minimize
down time and prolong the crushers useful life. Before starting the crusher, the following steps should be
followed:
1. Check that the correct hydraulic oil is being used and is correctly installed in the hydraulic adjustment
assembly.
2. Inspect to ensure that the crusher is free of tools and other potential mechanical obstructions.
3. Verify that all joints, bolts and fasteners are tightened properly and that there are no leakages in the
lubricant system.
4. Before starting, pump several ounces of fresh grease into each bearing. Let the machine run for one
half hour and add grease in intervals until grease appears on the bearing grease seals.
5. Listen carefully for any unusual sounds. When satisfied that all parts are running correctly, begin
feeding a small amount of material and begin increasing the feed rate until the crusher is operating at
its full capacity.
6. During this startup period, check the bearing temperature frequently. If temperatures are above the
recommended levels, lubricate according to the instructions provided in the lubrication section.
7. Check to ensure that the tension spring on the crusher does not need re-adjustment. If an adjustment
is required, make sure that all necessary parts are available.
8. After all of these steps have been followed, start the crusher according to the crusher start-up
section.

Crusher Speed
The correct speed (revolutions per minute - RPM) is very important for proper crusher operation. The
sheave sizes recommended for driving the crusher are designed for maximum load operation -- therefore
the crusher speed may be somewhat higher during lessened load periods.
By operating at the recommended speeds, the crusher will produce its maximum output with uniform
production size.

CT2036 Jaw Crusher Manual

20

Parts: Tension Rod and Toggle Plate Assembly


Illustration
The following illustration identifies the essential parts comprising the tension rod and
toggle seat assembly.

CT2036 Jaw Crusher Manual

21

Parts List
Item

Part #

12
13
14
15
16
18
19
20
21
22
24
25
26
27
28
30
31
32
33
34
35
36
37
38
39
40
89
90
91
92

C2036-8
C2036-9
C2036-10
GB5782/M12X35
GB93/12
C2036-11
C2036-12
C2036-13
GB91
GB6170/M30
C2036-14
C2036-15
GB70/M20X70
GB7244/20
C2036-16
C2036-17
C2036-18
C2036-19
GB6170/M12x35
GB93/12
C2036-20
GB5782/M20x60
GB7244/20
C2036-21
C2036-22
GB6170/M36
T6090-20
T6090-18
GB5782/M16x45
GB93/16

Description
Buffer (Lower)
Rubber Dust Apron
Clamp Plate for Rubber Dust Apron
Bolt M12X35 For Rubber Dust Apron
Lock Washer 12
Toggle Plate
Pin
Washer
Split Cotter 8x75
Nut M30
Buffer (Upper)
Toggle Dog
Bolt M20x70
Lock Washer 20
Rubber Dust Cover
Tension Rod
Spring Keeper (Lower)
Clamp Plate
Bolt M12x35
Lock Washer 12
Plate
Bolt M20x60
Lock Washer 20
Spring
Spring Keeper (Upper)
Nut M36
Lower Guider
Plate
Bolt M16x45
Lock Washer 16

CT2036 Jaw Crusher Manual

QTY

Unit Weight Lbs

1
1
1
5
5
1
1
1
1
16
1
1
2
2
1
1
1
1
4
4
1
2
2
1
1
2
2
2
2
2

63.8
4.4
2.2
.088
.0022
246.4
4.84
.11
.0066
.66
171.6
1.76
.40
.11
21.78
37.4
7.04
3.52
.077
.002
45.1
.33
.011
26.4
4.84
1.1
12.1
.33
.154
.0044

22

Parts: Bearings and Eccentric Shaft Assembly


Illustration
The following illustrations identify the essential parts of the bearing and eccentric shaft
assembly.

CT2036 Jaw Crusher Manual

23

Parts List
Item
56
57
58
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

Part #
C2036.4
C2036-27
GB825/M16
GB5782/M24X70
GB7244/24
C2036-29
C2036-30
GB1095/12x30
GB//T288
C2036-31
GB32.1/M20X65
GB7244/20
C2036-32
C2036-33
GB/T288
AH2244
KM48
C2036-34
GB812/M190X3
GB858/190
GB1152/M10x1
C2036-35
GB1095/12x35
C2036.5
GB5867/Z2-170x225
C2036-36
GB32.1/M16x65
GB7244/16
GB32.1/M36x130
C2036-37

CT2036 Jaw Crusher Manual

Description

QTY

Flywheel
Bearing Housing Cover (LH)
Eyebolt M16
Bolt M24x70
Lock Washer 24
Eccentric Shaft
Spacer
Key 12x30
Pitman Bearing 23148CA/W33 C3
Pitman Seal
Bolt M20x65
Lock Washer 20
Middle Seal
Bearing Housing
Frame Bearing 22244 CAK/W33 C3
Adapter AH2244
Round Nut
Bearing Housing Cover (RH)
Lock Nut M190x3
Lock Washer 190
Grease Fitting
Outer Seal
Key 12x35
Sheave
Ringfeder Z2-170x225
Cover
Bolt M16x65
Lock Washer 16
Bolt M36x130
Washer

1
1
2
4
4
1
2
2
2
2
32
32
2
2
2
2
1
1
L, R Each
2
4
2
2
1
2
2
6
6
12
12

Unit Weight Lbs


2008.6
66
.506
.66
.0374
1150.6
19.8
.05
150
46.2
.35
.011
44
350
116
16.28
13.64
66
8.36
.44
.044
35.2
.044
1,855
12.7
18.7
.22
.01
1.98
.396

24

Parts: Jaw Dies and Side Plates


Illustration
The following illustrations identify the essential components comprising the jaw dies and
cheek plates.

CT2036 Jaw Crusher Manual

25

Parts List
Item
1
2
3
4
5
6
7
8
9
10
11
17
22
59
60
61

Part #
C2036.1
C2036-1
C2036-2
T6090-4
T6090-1
GB7244/30
C2036-3
C2036-4
C2036-5
C2036-6
C2036-7
C2036.2
GB6170/M30
GB97/30
C2036.6
GB6170/M24
C2036-28

Description
Frame
Fixed Jaw Die
Upper Cheek Plate (LH & RH Each)
Bolt for Cheek Plate
Washer
Lock Washer 30
Lower Cheek Plate (LH & RH Each)
Swing Jaw Die
Wedge for Swing Jaw Die
Pitman Protection Plate
Bolt for Swing Jaw Wedge
Pitman
Nut M30 for Swing Jaw Wedge
Washer 30
Wedge for Fixed Jaw Die
Nut M24 for Fixed Jaw Die Wedges
Washer

CT2036 Jaw Crusher Manual

QTY

Unit Weight Lbs

1
1
Total 2
8
8
8
Total 2
1
1
1
4
1
8
4
2
4
2

8,096
1,430
143
2.42
.22
.07
152
1,430
86
226.6
8.36
3,876.4
.396
6.6
.22
.33

26

Parts: Lubrication
Illustration
The following illustration identifies the location of each grease fittings on the jaw
crushers.

Parts List
Item
Part #
23 Q/ZB220-77
29 C2036.3

Description
Drain Plug M24X2
Lubrication System

CT2036 Jaw Crusher Manual

QTY
2
1

Weight
.319
16

27

APPENDIX A: DISCHARGE SETTING ADJUSTING PROCEDURE

CT2036 Jaw Crusher Manual

28

PUMP STATION

Parts List
Item
40
41
42
43
44
45
46
47
48
49
50
51
52
55
59
60
61

Part #
GB6170/M36
C2036-23
C2036-24
GB5782/M16x45
GB7244/12
T6090-31
GB5867/Z2-90x130
T6090-32
GB6170/M30

T6090-34
C2036-25
C2036-26
C2036.6
GB6170/M24
C2036-28

CT2036 Jaw Crusher Manual

Description
Nut M36
Rear Wedge for Discharge Adjustment
Guider (I)
Bolt M16x45
Lock Washer 12
Pin (I)
Ringfeder Z2-90x130
Washer
Nut M30
Hydra. Cylinder 390+125
Hydra. Cylinder 404+137
Pin (II)
Guider (II)
Front Wedge for Discharge Adjustment
Wedge for Fixed Jaw Die
Nut M24 for Fixed Jaw Die Wedges
Washer

QTY

Unit Weight Lbs

2
1
1
12
12
2
2
4
4
1
1
2
1
1
2
4
2

1.1
358.6
2.2
.154
26.4
3.37
.154
.40

7.7
2.2
358.6
6.6
.22
.33

29

Adjusting the Discharge Setting

Be sure the pump station is connected to the adjustment hydraulic cylinder properly (refer to
the diagram below).
Loosen the tension spring retainer nuts (item 40).
Switch the valve to the desired flow direction (Bigger End of Wedge Out Increase the
discharge opening or Bigger End of Wedge In Decrease the discharge opening).
Use pump through the hydraulic cylinders to push/pull the wedges out/in to the desired
discharge opening position.
Tighten the tension spring retainer nuts (item 40).

Switch the valve back to the Hold position.

Hydraulic Control Connection Diagram

CT2036 Jaw Crusher Manual

30

Hydraulic Fitting Parts Details


CT2036 Jaw Crusher Manual

31

Appendix A: Jaw Crusher Bearing Greased Quantity per Day


(8 Hrs.)
Jaw Size

Grease for Pitman Bearing

Grease for Frame Bearing

Weight (Ounce)

Volume (Quart)

Weight (Ounce)

Volume (Quart)

SJ10X16

.43

.015

.43

.015

SJ16X24

.57

.02

.57

.02

SJ20X30

.74

.026

.74

.026

SJ24X36

.81

.029

.81

.029

SJ30X42

1.69

.059

1.69

.059

CT/SJ10X30

.44

.015

.44

.015

CT/SJ10X40

.44

.015

.44

.015

CT/SJ10X48

.50

.018

.50

.018

CT/SJ12X52

.94

.033

.94

.033

CT/C20X36

.70

..025

.61

.021

CT/C24X36

.89

.031

.72

.025

CT30X42

1.62

.057

1.55

.055

CT32X54

1.55

.055

1.34

.047

CT24X36

.89

.031

.72

.025

The grease is to be totally replaced when the machines have worked number of hours
respectively as shown below:

Grease Replace
Period (Hrs)

CT/SJ10X48

2,200

CT/SJ12X52

2,200

SJ10X16

3,500

CT/C20X36

2,000

SJ16X24

2,600

CT/C24X36

1,900

SJ20X30

2,000

CT30X42

1,600

SJ24X36

2,500

CT32X54

1,700

SJ30X42

1,500

CT24X36

1,900

CT/SJ10X30

2,600

CT/SJ10X40

2,600

Jaw Size

CT2036 Jaw Crusher Manual

The quantity is free room in the bearing


housing.
32

WARRANTY TERMS AND CONDITIONS


Seller warrants all new equipment manufactured or imported by Trio Engineered Products, Inc.
(Trio) against defects in material or workmanship attributed to the original machine
manufacturing. No other warranties are expressed or implied.
Warranty claims must be made through the dealer or agent responsible for the original
equipment sale, as the equipment will have been registered with them at the time of sale from
Trio. Claims must be made within twelve (12) months from the date of readiness for operation,
but not more than fifteen (15) months from the date of shipment from Trio. All parts claimed to
be defective shall be returned to Trio, freight prepaid, for inspection to determine that the said
part or parts are defective.
If it is determined that the fault lies with Trio, Trio will ship a replacement part or parts at no cost,
but freight charges will be paid by customer. If it is determined that the fault does not lie with
Trio, a replacement part or parts will be shipped, freight collect, to the customer with the receipt
of a purchase order from the dealer or agent. Trio will not be responsible for freight costs
associated with warranty claims.
When petitioning for a warranty item, the serial number of the equipment must be referenced.
The serial number must be clearly identifiable on the Trio nameplate on the equipment. This
warranty is void if:

The serial number plate and/or other markings identifying the machine as Trio have
been altered or removed.

The machine was not sold under the Trio brand name or another brand name approved
by Trio.

Parts have been used other than those supplied by Trio.

Trio makes no warranty with respect to damages or defects in any product caused by improper
installation, operation, maintenance, and storage or caused by negligence or accident. In
addition, any product repaired or altered in any way as reasonably determined by Trio, that
affects the performance or purpose for which the equipment was originally manufactured, will
not be covered under this warranty.
Under this warranty, the buyer will not be entitled to any labor charges involving the repair of the
equipment involving warranty items, unless authorized by Trio in writing.
Warranties of merchantability or of fitness for any particular purpose or arising from the course
of dealing or usage of trade are specifically excluded. Any affirmation of fact, description of
goods, or sample or model referred to in this agreement or elsewhere, whether or not the same
relate to production or capability of the goods to perform, are not the basis of this agreement,
unless specifically made a party of the agreement in writing.
Under no circumstances will Trio be responsible for consequential or punitive damages of any
nature, whether based on contract or tort, including but not limited to lost profits, loss of
production, delays or other expenses. Under no circumstances shall the liability of Trio exceed
the purchase price of the equipment furnished.
The laws of the state of California shall govern the warranty. The parties agree that exclusive
jurisdiction for any claim for breach of this warranty shall rest in the Los Angeles County
Superior Court in the State of California.

CT2036 Jaw Crusher Manual

33