TTM-2004-A

C SERIES JAW CRUSHER

Operating Guidelines Presentation

Operating Guidelines

TTM-2004-A

Dont Exceed Maximum Feed Size

The maximum feed size should be no larger than 80% of the crusher feed opening depth dimension. Trying to crush oversize material wastes time and reduces capacity and puts an undue strain on the crusher.

Operating Guidelines

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Oversized Feed Material

Oversized feed material should be set aside in the pit for secondary breaking. A piece too large for the crushing cavity can result in a premature failure of major crusher or feeder components. Trying to crush oversize material wastes time, reduces capacity and imposes unnecessary loads on the equipment!

Operating Guidelines

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Pitman Tipping Risk

Pitman tipping can occur if over-size feed material (larger then the feed opening) gets caught between the fixed jaw die and the pitman protector plate in addition to the lower portion of the crushing cavity being empty or lightly loaded. The over-size feed can cause the toe of the pitman to tip or pivot towards the fixed jaw die. This situation almost always causes the tension rod to break, the tension spring to break or the tension spring bracket to break.

Operating Guidelines

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Proper Feed Presentation

Feed should be directed straight into the crushing cavity, not into the pitman or side plates. The speed of the falling feed material must be controlled. If the speed of falling stones is too great, it should be slowed down with chains or other suitable arrangement as shown in the photo to the left. The maximum drop distance should be no greater than 39 (1m) The use of a horizontal grizzly feeder is recommended.

Operating Guidelines

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Proper Cavity Level

The proper cavity level for a C Series Jaw Crusher is to the top of the jaw dies. Unusually high cavity levels should be avoided as it presents the risk of premature failure of crusher components, feed hopper components or vibrating grizzly feeder components. High cavity levels can impose unnecessary loads on the equipment!

Operating Guidelines

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Never Start Under Load!

The C Series Jaw crusher should never be started under load The item that feeds the Jaw crusher (grizzly feeder, pan feeder, conveyor, dump box, etc.) should be electrically interlocked preventing it from starting unless the Jaw is operating. If the crusher stops under load, it must be dug out prior to restarting.

Operating Guidelines

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Prior to Starting the Crusher

Typical Pre-start Checks Before Starting
Pre-start checks are made after the crusher has been moved to a different location or after a maintenance repair. Remove all transporting brackets (if applicable). Make certain that all guarding is in place. Visually check that the crusher cavity is empty. Warn everyone in the immediate area that the crusher is being started (normally done with a horn or siren).

Operating Guidelines

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Daily Crusher Starting Sequence

Typical Daily Jaw Crusher Starting Sequence
Start the under-crusher conveyor (#1). Start the crusher (#2). The crusher should be interlocked with the undercrusher conveyor. As the crusher reaches full speed, listen and make certain that it sounds normal, and that there is no thumping sound. Start feeding material (#3).

#3

#2

#1

Operating Guidelines

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Daily Crusher Stopping Sequence

Typical Daily Jaw Crusher Stopping Sequence
Stopping the C Series Jaw Crusher will be the reverse of starting. Stop feeding material (#1). Continue running the Jaw crusher until all feed material has passed. Stop the Jaw crusher (#2). Stop the under-crusher conveyor (#3).

#1

#2

#3
Operating Guidelines

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Confirm Correct Crusher Rotation

After the crusher is started up, confirm that the flywheels are rotating the correct direction. The correct crusher rotation is when the flywheels rotate over the top towards the stationary jaw die. A crusher operating in the wrong direction will crush but not very well. An arrow cast into the flywheel counterweight serves as a reminder for correct rotation.

Operating Guidelines

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Proper Crusher Speed is a Must!

Crusher C63 C80 C100 C105 C110 C125 C140 C145 C160 C200 C3055 RPM 340 350 260 300 230 220 220 220 220 220 260

Correct crusher speed is very important. The speed of the crusher and the extent of pitman movement has been timed against gravity to hit the feed material in a succession of blows. A crusher can slow down and stall due to overload, high power draw, loose drive belts, tramp events, too tight of setting, sticky feed, etc. All crusher speeds listed are 10%. A crusher speed sensor can be used to prevent most stalls.

Operating Guidelines

TTM-2004-A

Dont Exceed Maximum Power!

The C Series Jaw Crusher is designed for a maximum horsepower draw. The operator needs to understand what the full load amp rating is for his / her particular crusher and every effort possible must be taken to operate at or below the full load amp rating. Operating at excessive power draw puts undue stree and stain on the crusher and can lead to premature crusher failure. Under no circumstance should a larger size horsepower motor be used. The exception would be if a larger size motor was used, it would have to be fused to the correct horsepower level.

Operating Guidelines

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Understand the Minimum Setting!

Know Your Crushers Minimum Setting
Crusher C63 C80 C100 C105 C110 C125 C140 C145 C160 C200 C3055 Inches (mm) 1.500" (38) 1.625" (42) 2.750" (70) 2.750" (70) 2.750" (70) 4.00" (102) 5.00" (127) 5.00" (127) 6.00" (150) 7.00" (180) 2.750" (70)

Minimum settings shown assume material with 22,000 - 60,000 PSI hardness. A tighter setting may be be allowed for material softer than 22,000 PSI (soft rock or recycle materials). Consult Metso Minerals for approval. The setting measured while the jaw crusher is at rest is not the closed side setting. It is very important to understand that when the crusher is at rest, the measurement taken is crushers open side setting.

Operating Guidelines

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Checking the Crusher Setting

Safety First - Lock Out Applicable Equipment
Prior to climbing underneath the crusher to measure or check the crusher setting, lock out the crusher, the under-crusher conveyor belt and the grizzly feeder to prevent injury. Each person should have his / her own lock and key.

STEP ONE

Operating Guidelines

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Checking the Crusher Setting

Confirm that the Crusher is Fully at Rest
Prior to checking the crusher setting, confirm that the crusher is fully at rest. The crusher is considered fully at rest when the flywheel keys are near the bottom as shown in the photo to the left. The setting of the crusher cannot be accurately checked if the flywheels are not at their correct resting point.

STEP TWO

Operating Guidelines

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Checking the Crusher Setting

Measure the Crusher Setting Peak to Peak
The Jaw Crusher discharge setting (closed side setting) is the shortest distance between the bottoms of the fixed and moveable jaw dies measuring "peak to peak". With a pull out tape, measure the distance between the top (peak) of the fixed jaw die and the top (peak) of the movable jaw die where the jaw dies are in closest relationship to each other. Remember that while the crusher is at rest (stopped), the measurement taken is close to the crusher's open side setting, not the crushers closed side setting!

STEP THREE

Operating Guidelines

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Checking the Crusher Setting

Remember - Measure at the Closest Point
In some applications, the jaw die wear might be a bit wavy or unusual as shown in the photo to the left. Keep in mind that when the measurement is made, it is taken where the jaw dies are in the closest relationship to each other. Failure to do this can result in crusher failure, i.e.: loose jaw dies, failed jaw die retaining hardware, failed toggle plate, etc.

STEP THREE - CONTINUED

Operating Guidelines

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Checking the Crusher Setting

Deduct the Proper Distance to Determine Actual Setting
Crusher C63 C80 C100 C105 C110 C125 C140 C145 C160 C200 C3055 1-1/4" (32) Inches (mm) 7/8" (22) 1" (24) 1-1/4" (32) 1-1/4" (32) 1-3/8" (36) 1-1/2" (39) 1-5/8" (42) 1-3/8" (36) 1-1/2" (39)

From the open side setting "peak to peak" measurement taken while the crusher was at rest, deduct the distance listed in the table to the left to determine the crusher's exact closed side setting. Always remember, that when the crusher is at rest, the measurement that you take peak to peak is the crushers open side setting.

STEP FOUR

Operating Guidelines

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Checking the Crusher Setting

Crusher Setting Example

C125 Jaw Crusher

Minimum Setting for a C125 = 4 6-3/4 1-1/2

Measurement Taken Peak to Peak Amount That you Must Deduct for a C125 -

6-3/4 minus 1-1/2 = 5-1/4 (Crushers True Closed Side Setting)

STEP FOUR - CONTINUED

Operating Guidelines

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Checking the Crusher Setting

Changing the Crusher Setting - Mechanical Adjusting
Prior to changing the crusher setting by turning the adjusting wedges in or out, loosen the tension spring.

Tension Spring Nut

Tension Spring

STEP FIVE

Operating Guidelines

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Checking the Crusher Setting

Changing the Crusher Setting - Mechanical Adjusting
Crusher C63 C80 C100 C105 C110 C125 C140 C145 C160 C200 C3055 0.09 (2.3) Inches (mm) 0.07" (1.9) 0.09" (2.3) 0.09" (2.3) 0.14" (3.5) 0.08" (2.0) 0.07" (1.7) 0.09" (2.3) 0.10" (2.5) 0.09" (2.3)

Turn each adjusting wedge in or out an equal amount. When turning the adjustment screw one rotation, the change in setting is shown in the table to the left.

Adjusting Wedge Action

STEP SIX

Operating Guidelines

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Checking the Crusher Setting

Changing the Crusher Setting - Mechanical Adjusting
Crusher C63 C80 C100 C105 C110 C125 C140 C145 C160 C200 C3055 14" (355) "L" Inches (mm) 12-1/4" (310) 12-1/4" (310) 14-1/2" (370) 14-3/8" (365) 14-3/8" (365) 16-3/4" (425) 21-1/4" (540) 21-1/4" (540) 21-1/4" (540)

Readjust the tension spring back to its correct length as shown in the table to the left.

L
Operating Guidelines

STEP SEVEN

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Checking the Crusher Setting

Changing the Crusher Setting - Mechanical Adjusting
Another method that can be used to tighten the tension spring is to listen to the crushers toggle plate area after the crusher has been started up and is operating no load. If a slight thumping is heard, the tension spring should be tightened up until the thumping has gone away. If a slight thumping is not heard, the tension spring should be loosened up until a slight thumping is heard, then tightened until the thumping goes away. Keep in mind that over tightening can result in failure of the spring and / or tension rod. The tension spring should be checked every day (8 hours).

STEP SEVEN- CONTINUED

Operating Guidelines

TTM-2004-A

Checking the Crusher Setting

Unlock the Equipment
After successfully checking and/or changing the crusher setting, unlock all the equipment that was previously locked out.

STEP EIGHT

Operating Guidelines

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Crushing at a Tight Setting

Intermediate Plate Option
When crushing at a tight setting, coupled with worn jaw dies, the nip angle between the two jaw dies might be less then prefect. This flatter nip angle can cause burping of the feed material which detracts from crusher capacity. In this case, an optional intermediate plate can be added behind the fixed jaw die to improve the nip angle, thus improve productivity.
Front Frame

Fixed Jaw Die

Intermediate Plate

Operating Guidelines

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Maximum Wedge Travel

There are stop blocks attached to the large end of each adjusting wedge. The stop blocks will be bolts with flat washers or could be L shaped angle brackets. The purpose of the stop blocks is to limit the distance that the wedge can travel. This prevents the adjusting screw from disengaging with each other.

Wedge Stops

Operating Guidelines

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Listen to the Toggle Plate Area

The toggle plate is a safety device which collapses in the event of an overload thus preventing damage to other crusher components. The toggle plate is held tight against the toggle seats with the tension rod on mechanical adjusted crushers or the hydraulic cylinder or hydraulically adjusted crushers. If the toggle plate is loose in the toggle seats, the toggle plate will make a thumping sound. This should be checked every day (8 hours).

Toggle Seat

Toggle Plate

Toggle Seat
Operating Guidelines

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Toggle Plate Failure Reasons

The C Series jaw crusher toggle plate is made of flexible steel. It is designed to bend in the event of overload. A failed toggle plate must be replaced. Typical reasons that the toggle plate could fail include: the crusher setting was tightened to the point that the movable jaw die touched the fixed jaw die (oops!), broken piece of drill steel, broken piece of a loader tooth, tramp debris in the pit, etc.

Operating Guidelines

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Perform a Walk Around Inspection

The operator should perform a walk around inspection at least once per shift but preferable twice per shift. During the walk around inspection, the operator will look for anything unusual, such as strange noises, loose fasteners, unusual vibrations, excessive temperatures, etc. Failure to perform a walk around inspection can lead to premature crusher failure.

Operating Guidelines

TTM-2004-A

Operating Guidelines