S 222.188.

00 en

CJ409:01

Installation

SANDVIK MINING AND CONSTRUCTION

Sandvik SRP AB SE-233 81 Svedala, Sweden
 CJ409:01 S 222.188.00 en 1 (1)

Installation
2007-08-03

Contents
1. Safety regulations S 222.071

2. Installation and operation S 222.066

3. Installation drawing 400.0550

 CJ Chapter 1 1 (6)
Safety regulations and noise emmission
MB 124 S 222.071.02 en
Jaw Crushers 2004-06-30

Jaw Crusher
1. The feed hopper is normally equipped with a pivoted stone guard. The stone guard
must not be raised during operation.

Wear protective goggles and a safety helmet. This is

Warning !!! especially important in cases where stones and stone
fragments can be thrown up out of the crusher.

2. The feed system must be amply dimensioned so that the crusher can recieve a
sufficient quantity of material. The material should be approximately level with the
top edges of the cheek plate.

3. A metal detector should be installed if this is possible, to prevent tramp iron entering
the crusher.

There should be a level monitor installed in the feed hopper

Caution !! to stop the feed to the crusher if the material level rises too
high.

4. The feed system must be electrically connected in such a way that it cannot be started
before the crusher and its discharge system are running.

5. When crushing in a jaw

crusher it is inevitable that –
sooner or later - a large stone
will jam in the feed opening.
It is also possible that a hang
up can occur inside the
crushing chamber.

To correct such a situation in a quick and - for the plant personnel - safe way, we
recommend that a hydraulic hammer is included in the installation right at the planning
stage.

Sandvik do not recommend blasting. The

Warning !!! use of explosives is at the customers own risk. Sandvik
takes no responsibility for damage to personnel or
to the crusher.

The use of wedges etc. to clear a material blockage is very

Warning !!! dangerous.
 CJ Chapter 1 2 (6)
Safety regulations and noise emmission
MB 124 S 222.071.02 en
Jaw Crushers 2004-01-08

6. To make work around the crusher easier, platforms with guardrails should be
installed around the crusher’s feed opening.

7. The discharge arrangement must be designed in such a way that there is no

possibility of material building up beneath the crusher. There is otherwise a risk that
the discharge system can be damaged. In addition, too many stoppages will
undermine plant efficiency.

8. Guards

The flywheels and other parts of the V-belt drive must always
Caution !! have robust guards.

The guards should cover all rotating parts including the V-

belts. There should also be a possibility to check the belt
tension.

These guards must be designed so that they comply with the

applicable safety regulations.

9. When welding is to be carried out during repairs or other work on the crusher, it is
important that the working area is earthed in a correct way.

The welding current must not pass through a roller bearing. If

Caution !! the working area is earthed on the wrong side of the bearing,
the bearing can be so seriously damaged that bearing
replacement is necessary.

Welding must not be carried out on the toggle plate as cracks

Warning !!! may occur in the material.
 CJ Chapter 1 3 (6)
Safety regulations and noise emmission
MB 124 S 222.071.02 en
Jaw Crushers 2004-01-08

10. Make sure there is no risk of falling into the crushing chamber. Remember that when
a blockage is broken up, any objects in the crushing chamber may be pulled sharply
downwards.

Protect yourself against the risk of injury from stones and

Warning !!! ragments which can be thrown up at high speed out of the
crushing chamber. Remember that stone dust can caus lung
damage.

11. Whenever work or inspection is carried out on the retraction system there is a risk of
injury if you are behind or below the retraction.

Stress fatigue can cause the retraction rod or the spring to fail
Caution !! and be thrown backwards. Always replace the safety guard
right away.

12. Retraction rods and springs suffer from fatigue and should therefore be replaced after
2-3 years.

Be aware that a broken spring or rod can cause serious injury.

Warning !!! Make sure that the safety wires and guards are in place.

13. When the moving jaw has been swung forwards, always position a block between the
moving jaw and the frame cross-member.

Hydraulic pressure could suddenly disappear, allowing the

Warning !!! moving jaw to cause serious damage.
 CJ Chapter 1 4 (6)
Safety regulations and noise emmission
MB 124 S 222.071.02 en
Jaw Crushers 2004-01-08

14. Maintenance work underneath the crusher.

Before anybody goes in underneath the crusher, make sure

Caution !! that all relevant isolating switches have been locked in the
open position. Make sure that no stones can fall down - from
a feeder, for example. Wear a safety helmet and protective
gloves.

15. If it is desired to rotate the flywheels with the help of the motor - during repair work,
or for some other reason - this must only be done by the foreman responsible.

16. Do not forget to fix the toggle seat holder in position before you remove the toggle
plate.

17. When removing or installing jaw plates it is vital that the lifting gear used is in good
condition.

Never stand inside the crushing chamber when jaw plates or

Warning !!! cheek plates are being lifted out or in.

When jaw plates are to be removed it may in some cases be necessary to burn off part of
the plate to avoid jamming against the cheek plates. When gas-cutting is necessary, make
sure that there is good ventilation and use a fresh air mask.

18. It is important that the cheek plates are properly clamped as there is a risk that they
can come loose.
 CJ Chapter 1 5 (6)
Safety regulations and noise emmission
MB 124 S 222.071.02 en
Jaw Crushers 2004-01-08

19. When removing a flywheel mounted on a tapered seating it is important to use tools
which are intended for this purpose.

There is otherwise a major risk that the flywheel can suddenly

Warning !!! come off the end of the shaft when it comes loose. If the proper
tool is not available, it is important that shaft nut A is used as a
stop.
20. Crushing always creates dust. Such dust can be more or less dangerous to health,
depending on the type of material. Use a breathing mask.
To reduce the risks caused by dust, water sprays can be fitted around the feed
opening and the discharge area can be encapsulated and fitted with a dust-extraction
system.
(Dust encapsulation, dust extraction and/or water-spraying equipment are not
included in the crusher’s standard specification).
 CJ Chapter 1 6 (6)
Safety regulations and noise emmission
MB 124 S 222.071.02 en
Jaw Crushers 2004-01-08

Noise levels and measuring conditions

Dangerous noise levels occur during crushing.
Caution !! Use ear protection!

Dust encapsulation results in lower noise levels. (Dust encapsulation is not included in the
crusher’s standard specification.)

Machine Test running in the factory Typical values when

(without material) crushing
dB(A) dB(A)
Jaw crusher - CJ ≤ 87 102 - 108

The values given above are equivalent continuous sound levels (Leq) measured during a
period of 60 seconds with an integrating sound level meter. The values are measured at a
distance of approx. 1 m from the machine and approx. 1.6 m above ground level or above a
platform alongside the machine.

The sound levels given are approximate values. The sound level depends on many factors,
e.g. whether or not the crusher has dust encapsulation, how the equipment is installed, how
the feed arrangement is designed, the size and impact strength of the feed material, the size
of the drive motor, etc.

Training
The plant personnel must be trained for their duties and must be given safety instructions.
 CJ Chapter 2 1 (6)
Single Toggle Jaw crusher MB 124 S 222.066.00 en

2005-06-28
Installation and operation

Contents Page

Installation and operation general 2

Erection 2

Welding work 3

Feed arrangement 3

Initial start-up 4

Checks during operation 5

General 5

Feeding 5

Bearings 6
 CJ Chapter 2 2 (6)
Single Toggle Jaw crusher MB 124 S 222.066.00 en

2005-06-28
Installation and operation

Installation and operation

General
For every crusher we supply a dimension drawing, a table of weights and an installation
outline drawing.

These drawings and the table give information about the space required for dismantling
and handling and the weights of the heaviest components. Install lifting gear suitable for
the heaviest lift, laid out so that the installation and removal of wearing parts can be carried
out quickly. Ensure that there is sufficient space on the ground for wearing parts when
replacement is to be carried out.

The stone guard must not be swung up during operation. Use

Warning !!! protective goggles and a safety helmet. This is especially
important in cases where stones and stone fragments can be
thrown out of the crusher.

Before anybody goes in underneath the crusher, make sure

Warning !!! that all relevant isolating switches have been locked in the
open position. Make sure that no stones can fall down – from
a feeder, for example. Wear a safety helmet and protective
gloves.

If the shaft is turned by using the drive motor, this must only
Warning !!! be done under the direction of a qualified foreman.

Erection
1. Erect the crusher on its foundation. Use a level to check that it is horizontal, specially in
the transverse direction, by placing the level on the flat flywheel rim.

2. Install the drive motor and the V-belt drive. When the drive is correctly installed, the
top of the flywheel will rotate toward the crushing chamber. The crusher is factory
shipped with right hand drive. Hand of drive is determined from the feed end facing the
crusher in the direction of material flow. Drive hand can be switched to left by
interchanging the two flywheels. Check V-belt drive alignment. Be sure that the motor
and eccentric shafts are parallel and that the motor sheave is in line with the grooved
crusher flywheel.
3. Install all belt guards.
 CJ Chapter 2 3 (6)
Single Toggle Jaw crusher MB 124 S 222.066.00 en

2005-06-28
Installation and operation

Do not operate the crusher without having a suitable drive

Warning !!! guard, conforming to staturory requirements, in place.

4. Install other auxiliary equipment.

Welding work
When welding on the crusher during installation or repairs, be sure that the working area is
grounded correctly.

The welding current must never pass through a roller or plain

bearing. When welding on the swing jaw, for example, do not
Note !
attach the ground cable to be frame or flywheels, since the
current would then be forced to pass through the bearings.
Grounding the work area on the wrong side of a bearing can
cause serious damage and require bearing replacement.

When welding an item to the crusher, attach the ground cable to the item itself. If a crusher
component is to be welded, attach the ground cable as near as possible to the welding area.

Feed arrangement
One of the most important factors for uniform jaw plate wear and thus the lowest possible
operating costs is that the feed arrangement is designed so that the material is evenly
distributed across the width of the feed opening and the crushing chamber is kept full. If
you have any doubts about the feed and discharge arrangements, contact Sandvik Rock
Processing.

The feed system must be amply dimensioned so that the

Note ! crusher can receive a suffient quantity of material. The
material should be approximately level with the top edges of
the side liners (cheek plates).

A metal detector should be installed, if this is possible, to

prevent tramp iron entering the crusher.

There should be a level monitor installed in the feed hopper to

stop the feed to the crusher if the material level rises too high.

The feed system must be electrically connected in such a way

Caution !! that it cannot be started before crusher and its discharge
system are running.
 CJ Chapter 2 4 (6)
Single Toggle Jaw crusher MB 124 S 222.066.00 en

2005-06-28
Installation and operation

With crushing in a jaw crusher it is invetiable that – sooner or

Warning !!! later – a large stone will jam in the feed opening. It is also
possible that a “hang” can occur inside the crushing chamber.
To correct such a situation in a quick and – for the plant
personnel – safe way, we recommend that a hydraulic
hammer is included in the installation right at the planning
tage. The hydraulic hammer must be used only to knock off
corners and edges from the stones and to poke at the stones if
a “hang” occurs.

To facilitate work around the crusher there must be platforms

with guard rails around the feed opening.

The use of wedges etc., to clear a "hang" is very

dangerous. Blasting must never be carried out in the
crusher.

The noise level close to the crusher exceeds 95 dB (A) when

crushing is taking place, so ear protectors must be worn.

Initial start-up
1. Check that all threaded joints are tight.
2. Check that all bearings are lubricated. See lubrication instructions.
3. Run the crusher with an empty chamber. Check to be sure that no abnormal noises are
heard and that bearings do not heat excessively. Tighten tension rods as recommended.
At initial start-up it is recommended that the crusher be run unloaded until the bearing
temperatures level off, and then be allowed to cool down prior to restarting to begin
crushing. This start-up method is also suggested after a bearing replacement.
4. Check the crusher speed, it must not exceed the value given in the table below:

Other speeds may be recommended by Sandvik Rock

Note ! Processing for special applications.
 CJ Chapter 2 5 (6)
Single Toggle Jaw crusher MB 124 S 222.066.00 en

2005-06-28
Installation and operation

ROTATION
CRUSHER ECCENTRIC SHAFT SPEED
See the Installation drawing
(r.p.m.)

CJ408 286-301

CJ409 249-281

After break-in, retighten threaded joints and other retaining devices, and check V-belt
tension.

Checks during operation

General
Check that no abnormal noises are heard when the crusher is in operation. Investigate noise
sources immediately, and take corrective measures.

The crusher must be standing still when adjustments are

Warning !!! made.

All nuts and bolts should frequently be checked for proper

Note ! tightness. Any looseness should be corrected.

Feeding
Feed the crusher uniformly for optimum crushing capacity. A controlled rate scalping
feeder is recommended for most applications. Adjust feed rate to avoid covering the top
edge of the stationary jaw plate.
 CJ Chapter 2 6 (6)
Single Toggle Jaw crusher MB 124 S 222.066.00 en

2005-06-28
Installation and operation

The largest feed material should be at least 3 to 4 inches smaller than the opening between
the upper jaw plate wedges.

Never resort to blasting to remove blocks of stone which may

Caution !! become wedged in the crusher chamber. The shock of
blasting will be transmitted to bearings and other vital
components and cause severe damage.

Do not exceed maximum recommended motor horsepower as measured by current

indicated on an ammeter. Avoid machine overloads, which may result from:

1. Formation of cavities in the jaw plate.

2. Worn jaw plates.
3. Too small a discharge setting or
4. Too high a proportion of fine material in the feed.

Bearings
Check bearing temperatures regularly. Investigate causes of unusually high bearing
temperatures (over 80oC = 176oF) immediately, and take corrective measures.

Grease lubrication of bearings is critical, as a bearing can overheat due to either a lack of
lubricant or an excessive amount of lubricant. Excess grease is purged through the
labyrinth seals and, based on observation of the seals, the lubrication procedure should be
altered accordingly when an abnormally high bearing temperature is incurred. Bearing
temperature should be closely monitored when changing the lubrication procedure.