Chancadora Trio

Weir Minerals Latin America
Vulco Per S.A.
Installation, Operation and Maintenance Manual
JAW CRUSHER
MODEL CT3042
SAN RAFAEL PROJECT
MINSUR S.A.
PO: 4600017596
OF: 103774
Av. Separadora Industrial 2201
Ate Lima, Per
T: +51 (1) 6187575
E: ventas@weirminerals.com.pe
UNIDAD SAN RAFAEL
W: www.weirminerals.com
Rev.0
Aprobado A
Aprobado con Comentarios AWC
Revisado por:
Luis Prez Abad
Revisado y Comentado - RWC

Rechazado - RS
Fecha:
23-feb-2016
Operation & Maintenance Manual
To the Owner & Operator

We have tried to provide information that gives our customers a clear understanding of equipment
construction, function, capabilities and requirements. This information is based on the knowledge and
experience of qualified people at our company and in our field organization. Proper use of this information
provides users of our equipment with high efficiency, maximum service life and low maintenance costs.
That is why we strongly recommend that anyone using our equipment be familiar with this manual.
Information presented here should not be considered authoritative in every situation. Users will as a matter
of course encounter problems and circumstances that raise questions not anticipated here. Such questions
should be directed to their distributor or the manufacturer.
Anyone who uses this equipment for any purpose other than that for which it was intended assumes sole
responsibility for dangers encountered and injuries sustained as a result of such misuse.
DANGER
Federal, state and local safety regulations aim to protect both people and property from
accident, injury and harmful exposure. When complied with, such regulations are often
effective. Hazards to personnel and property are further reduced when this equipment is
used in accordance with all operation and maintenance instructions. Generally:
(1) Read and heed all danger, warning, caution, and notice decals. Know what guards and protective
devices are included and see that each is installed and in operational condition. Additional guards and
protective devices may be required and must be installed by the user (owner) before operating.
(2) Never attempt to maintain, lubricate or adjust this equipment while it is running. Lock out and tag
out all energy sources before doing maintenance, cleaning, adjusting or repairing this equipment. Make it
impossible for anyone to start this machine while others are working on it or in it.
(3) Wear personal protective equipment such as hard hats, ear plugs, safety glasses and safety shoes
when operating this equipment. Do not wear loose clothing or long hair.
(4) Think safety and act safely. Stay alert at all times. Eliminate or neutralize potential hazards as soon
as you spot them. Never allow anyone to engage in horseplay when near this equipment.
DANGER
Failure to take these precautions will result in death or severe personal injury.
CRSH-OM-0003ENG(OCT-2014)
Model CT-Series Jaw Crushers
The following warning applies to equipment supplied with lead-acid batteries:
WARNING
Battery posts, terminals and related accessories contain lead and lead compounds,
chemicals known to the State of California to cause cancer and reproductive harm.
Wash hands after handling.
The following warning applies to equipment supplied with diesel powered engines:
WARNING
Diesel engine exhaust and some of its constituents are known to the State of California to
cause cancer, birth defects, and other reproductive harm.
NOTICE
Product Registration:
All equipment must be registered within 14 days of start-up to receive warranty coverage.
Registration information will only be accepted from the end-users of the equipment, however dealers can
register the equipment for the end-user provided the information registered is the end-users information.
In addition to this registration, all cone crushers, vertical shaft impact crushers, and all screens using
urethane media must have an application data sheet on file and approved by Trio.
After completion of the registration and application data sheet, if required, all submitted information will
be reviewed and a confirmation email sent to the email address provided to Trio.
Warranty will be fully enforced upon confirmation of payment and receipt of the above information.
Register online at: http://www.trioproducts.com/register/form
or call Trio at +1 626 851 3966.
Warranty Terms & 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 or 2,000 working hours, whichever occurs first, 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.
This Page Intentionally Left Blank

Table of Contents
Copyright 2014 Trio Engineered Products, Inc. All rights reserved. . . . Cover Back Page
To the Owner & Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a
Warranty Terms & Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . c
Section 1 - Introduction
About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 1
Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 1
Safety Alert Symbol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 1
Section 2 - Safety
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 1
Symbols and Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 1
Hazard Classification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 1
Safety Signs and Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 2
Safety Sign Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 2
Personal Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 3
Management Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 3
Operator Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 3
Work Area Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 4
Equipment & Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 4
Training and Knowledge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 4
What is Lockout & Tagout? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 5
When is Lockout & Tagout required? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 5
Who must apply a lock & tag? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 5
When can a lock and tag be removed? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 5
Who can remove a lock and tag? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 5
Section 3 - General Information

Jaw Crusher Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 1
Serial Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 1
Flywheel Rotation Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 1
Jaw Crusher Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 2
Jaw Crusher Capacities Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 3
Jaw Crusher Gradation Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 4
Jaw Crusher Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 5
Jaw Crusher Weight & Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 5

Table of Contents
Section 4 - Set-Up & Installation

Crusher Receiving and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 1
Level the Crusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 1
Lifting the Crusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 1
Positioning the Crusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 2
Crusher Auxiliary Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 2
Hydraulic Line Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 2
Section 5 - Inspection, Lubrication & Maintenance Checks

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 1
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 1
Inspection Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 1
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 2
General Lubrication Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 2
Lubricant Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 2
Lubrication Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 3
Bearing Daily Lubrication Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 4
Jaw Crusher Seal Lubrication Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 5
Jaw Crusher Bearing Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 6
Jaw Crusher Seal Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 6
Changing Grease in Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 7
Maintenance Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 9
Exterior Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 9
Interior Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 9
Jaw Crusher Daily Inspection Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 11
Pre-Start-up Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 11
Start-up Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 12
Jaw Crusher Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 13
Section 6 - Start-Up & Operation

Start-Up & Operation Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 1
Crusher Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 2
Oversize Feed Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 2
Unblocking Jammed Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 2
Section 7 - Adjustments & Wear Parts Replacement

Adjustments & Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 1
Jaw Crusher Crushing Chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 1
Closed Side Setting (CSS) Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 1
Shim-Type CSS Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 2
Shim-Type CSS Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 2
ii

Table of Contents
Hydraulic Wedge-Type CSS Adjustment (Manual Hyd. Pump) . . . . . . . . . . . . . . . . . . . . . .7 - 3

Hydraulic Wedge-Type CSS Adjustment (Manual Hyd. Pump) Procedure . . . . . . . . . . . . .7 - 3
Power Hydraulic Pump Unit for CSS Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 4
Power Hydraulic Pump Unit With Electrical Control Box . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 5
Power Hydraulic Pump Unit Hydraulic Schematic Type 1 Connections . . . . . . . . . . . . . . . .7 - 6
Power Hydraulic Pump Unit Hydraulic Schematic Type 2 Connections . . . . . . . . . . . . . . . .7 - 8
Hyd. Wedge-Type CSS Adjustment (Power Hyd. Pump Type 1 Connections) . . . . . . . . . .7 - 10
Hyd. Wedge-Type CSS Adjustment (Power Hyd. Pump Type 1 Connections) Procedure . .7 - 11
Hyd. Wedge-Type CSS Adjustment (Power Hyd. Pump Type 2 Connections) . . . . . . . . . .7 - 12
Hyd. Wedge-Type CSS Adjustment (Power Hyd. Pump Type 2 Connections) Procedure . .7 - 13
Direct Hydraulic Toggle Plate-Type CSS Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 14
Direct Hydraulic Toggle Plate-Type CSS Adjustment Procedure . . . . . . . . . . . . . . . . . . . . .7 - 14
Standard Toggle Seat Tension Rod Spring Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 17
Fully Hydraulic Toggle Plate-Type CSS Adjustment System . . . . . . . . . . . . . . . . . . . . . . .7 - 19
Hydraulic Pump Control Unit Hose Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 20
Hydraulic Control Unit Standby Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 21
CSS Decrease Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 21
CSS Increase Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 21
Tension Rod Spring Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 22
Toggle Cylinders Oil Supplement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 22
Tension Cylinders Oil Supplement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 22
Tramp Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 22
Toggle and Tension Cylinder Fast Reset After Tramp Release . . . . . . . . . . . . . . . . . . . . . . .7 - 23
Hydraulic Unit Valve Pressure Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 23
Toggle Cylinder Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 24
Fully Hydraulic Toggle Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 24
Fully Hydraulic Toggle Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 25
Jaw Die Lifting Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 26
Cheek Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 28
Upper Cheek Plate Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 28
Lower Cheek Plate Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 29
Installation of Lower Cheek Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 29
Installation of Upper Cheek Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 30
Tightening Cheek Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 31
Stationary Jaw Die . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 31
Stationary Jaw Die Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 32
Stationary Jaw Die Rotation or Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 33
Stationary Jaw Die Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 33
Swing Jaw Die . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 34
Swing Jaw Die Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 34
Swing Jaw Die Rotation or Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 36
Swing Jaw Die Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 36
Check & Tighten Jaw Dies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 36
Re-adjust Crusher Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 36
iii

Table of Contents
Toggle Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 37
Toggle Plate Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 37
Toggle Plate Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 39
Jaw Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 40
Frame Bearing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 40
Frame Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 42
Pitman Bearing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 44
Pitman Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 46
Appendix A - Torque Specs

Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standard Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Metric Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standard Bolt Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Metric Bolt Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-1
A-1
A-1
A-2
A-3
Appendix B - V-Belt Drive Information

General Belt Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Belt Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Belt Drive Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintaining V-Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tension-Deflection Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Belt Type Cross-Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Belt Idlers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inside Idler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Backside Idler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Kiss Idler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
iv
B-1
B-1
B-2
B-4
B-4
B-6
B-6
B-6
B-6
B-6

About This Manual
Section 1 - Introduction
DANGER
About This Manual

This book is an operation and maintenance manual
for the owner or operator of the equipment
described within.
Figure 1 - 2 Safety Alert Hazard Level Symbol
This manual contains information

necessary for proper and safe
operation. Carefully read this
manual before attempting to
operate. Failure to read and heed
instructions preceded by a safetyalert symbol (Figure 1 - 2) can
cause death or severe personal
injury as well as equipment and
environmental damage.
We strongly recommend that anyone working with

this equipment become familiar with the manual,
whether or not you have experience with similar
equipment.
This manual will help you understand how to
install your equipment, prepare it for operation,
and perform normal operation and maintenance
tasks.
Intended Use
Experience has shown it is to your advantage to

keep a copy of this manual where operators can
consult it as needed and to have a copy on file in
your office, so that shift leaders or supervisors can
conveniently refer to it. Additional copies can be
ordered through your distributor.
The Jaw Crusher described within is designed to

crush rock, recycle concrete, and also a wide range
of other products and materials. Use of this
machinery in any other way is prohibited and
contrary to its intended use.
This equipment is precisely engineered, highly

functional, and heavy-duty designed to provide
years of excellent service performing to customer
specifications. We are proud to manufacture this
equipment for your use and profit. We also take
pride in the quality of our service and replacement
parts.
Safety Alert Symbol

The safety alert symbol (Figure 1 - 1) is used to
alert you to potential personal injury hazards.
Obey all safety messages that follow this symbol
to avoid possible injury or death.
Only your Parts Catalog, identified with your

machines serial number, is an authoritative source
of part numbers and part descriptions for your
equipment.
Figure 1 - 1 Safety Alert Symbol
Ongoing improvement of product design may in

the future result in changes to some parts. Use part
numbers, model numbers and serial numbers from
your Parts Catalog to communicate with your
distributor.
1-1

About This Manual
1-2

Introduction
Section 2 - Safety
Hazard Classification
A multi-tier hazard classification system is used to
communicate potential personal injury hazards.
The following signal words used with the safety
alert symbol indicate a specific level of severity of
the potential hazard (Figure 2 - 1). Signal words
used without the safety alert symbol relate to
property damage and protection only. All are used
as attention-getting devices throughout this
manual as well as on decals and labels fixed to the
machinery to assist in potential hazard recognition
and prevention.
Introduction
The Jaw Crusher is designed to crush rock, recycle
concrete, and also a wide range of other products
and materials. Use of this machinery in any other
way is prohibited and contrary to its intended use.
When our equipment is used for purposes other
than those for which it was designed, user assumes
sole responsibility for any injuries or damage that
may result from said misuse. We emphatically
recommend that this equipment be operated only
by personnel who are trained in its use.
We make no guarantee, either expressly or by
implication, that this equipment meets all local or
federal safety regulations. It is the responsibility of
those individuals who own and/or operate this
equipment to verify that all safety regulations are
complied with before starting either this unit or
any associated equipment.
DANGER
DANGER indicates an imminently

hazardous situation which, if not
avoided, will result in death or
serious injury.
WARNING
WARNING indicates a potentially

avoided, could result in death or
serious injury.
CAUTION
CAUTION indicates a potentially

avoided, may result in minor or
moderate injury.
Symbols and Standards

Important symbols and hazard classification
standards relating to safe equipment operation are
used throughout this manual. Make sure you read,
understand and follow all DANGER, WARNING
and CAUTION decals on equipment.
CAUTION
CAUTION used without the safety

alert
symbol
indicates
a
potentially hazardous situation
which, if not avoided, may result
in property damage.
NOTICE
NOTICE indicates information or

a company policy that relates
directly or indirectly to the safety
or protection of property.
Figure 2 - 1 Hazard Classification
2-1

Symbols and Standards
Safety Signs and Icons

Beneath all safety regulations lies a set of
common-sense rules. Everyone who works with or
near heavy equipment must be aware of those
rules. To foster and maintain such an awareness in
our customers, safety signs are fixed on our
equipment.
Read manual.
Safety alert symbol.
Icons on our safety signs remind both workers and

supervisors of common hazards and procedures
that, in the course of a busy day, they might
otherwise forget. The language of the icons is
simple and direct (Figure 2 - 2).
Lock out power before servicing

machine.
Wear hearing protection when youre

near this equipment.
Safety Sign Maintenance

Replace any missing or damaged safety signs.
Keep operator safety in mind at all times. Use mild
soap and water to clean safety signs. Do not use
solvent-based cleaners because they may damage
the safety sign material.
Wear eye protection when youre

Wear respiratory protection when

youre near this equipment.
Wear head protection when youre

Entanglement hazard. Death or

serious injury can result by getting
caught in belting.
Ensure all guards are in place.
Figure 2 - 2 Safety Pictograms Explained
2-2

Personal Safety
Personal Safety
This equipment is designed with the safety of all
personnel in mind. Never attempt to change,
modify, eliminate or bypass any of the safety
devices installed at the factory. Guards, covers and
shields installed around moving parts at the factory
are meant to prevent accidental injury to operators
and other personnel. Do not remove them.
Replace guards, covers and shields when the

task for which you removed them is finished.
Block parts as necessary to prevent their

sudden movement while people are working
on the machine.
Never attempt to clear away jammed feed

material, discharge material or other stoppage
while the machine is running. Stop the
equipment, lock out and tag out before
touching this machine with your tools or your
hands.
Wear proper personal protective equipment,

including eye protection, hard hat and safety
shoes, whenever youre near this machine
while it is running.
Dress appropriately in every way. Never wear

loose clothes, long hair, coat tails, jewelry,
pockets full of tools or any other item that
could get caught in moving parts.
Know where your fellow workers are. Always

look around and inside this machine before
starting it. Make sure nobody is in the way of
moving parts or working on the machine.
Lift with your legs, not with your back. Keep

the weight close to your body. If the load is
more than 40 lbs., get someone to help you.
Never engage in horseplay when near this

machine, or any other.
Report any defective machinery or equipment

and unsafe conditions or activity to your boss
immediately.
Dont limit safety practices to the few rules

listed here. Think safety and act safely at all
times.
Most of all, know your equipment. Understand

the machinery, the conditions under which it
operates and what it is capable of doing.
DANGER
Sometimes, at a customers
request, equipment is shipped
without certain features such as a
drive sheave. In such cases it is the
customers responsibility to guard
the machine properly.
We recommend the following basic safety
practices:
Management Responsibilities
Make sure that everyone working on or near

this equipment is familiar with safety
precautions. Have a supervisor at the job site
responsible for job safety.
Give crew members specific safety
responsibilities and instruct them to report any
unsafe conditions to their supervisor
Operator Responsibilities
Read all danger, warning, caution and notice

signs.
Always lock out and tag out involved energy

sources before performing maintenance or
adjustments on this equipment. Make it
impossible for anyone to start this machine
while others work on it or in it.
Never remove any guard, cover or shield when

this equipment is in motion.
2-3

Personal Safety
Work Area Safety
Equipment & Tools
Keep the work area as neat and clean as

practical.
Clean tools that are properly labeled and stored

are safer tools. Keep your tools in good order.
Keep all product safety signs clean, clear and

current.
Make sure all electrical equipment is properly

grounded. Wet spots near electrical current are
especially dangerous.
Keep drive belts and sheaves in good

condition. Frayed belts or cracked sheaves are
not only dangerous, they cost you downtime.
Always use mechanical assistance to lift heavy

loads. Never overload a hoist, crane, jack or
other lifting device. Check lifting tackle
regularly; replace it at the first sign of stretch,
fraying or other wear.
Keep your equipment clean, free of dirt and

grease, so that loose, cracked or broken parts
are more easily spotted. Replace defective
parts as soon as they are discovered.
Store hazardous materials in restricted access

areas and mark them clearly. Federal
regulations require special labeling of certain
materials.
Never start an engine in an enclosed space

without properly venting the exhaust.
Do not smoke or allow smoking near fuels and

solvents. Never strike a spark or use an open
flame near fuels and solvents.
Store flammable fuels, solvents and gases in

secure, well ventilated areas. Never allow
fumes to accumulate in the storage area. Use
nonflammable solvents for cleaning parts and
equipment whenever possible.
Know where fire extinguishers and other firesuppression equipment are located. Learn how
to use them effectively.
Training and Knowledge

Proper training and equipment knowledge is
essential to the safe operation of this machine.
Carefully read the entire manual before attempting
to operate. Keep this manual for future reference.
WARNING
Do not operate this equipment until
you have been trained in its
operation or maintenance. This
equipment may only be operated or
maintained by trained personnel,
who have demonstrated their
ability to do so safely.
Be alert and wary around any pressurized

system, hydraulic or pneumatic. High-pressure
oils and gases are very dangerous.
2-4

What is Lockout & Tagout?
When can a lock and tag be removed?
Lockout & Tagout is a procedure thats designed

to prevent the unexpected or accidental startup of
equipment and to alert all workers whenever it is
unsafe to operate any piece of equipment. When
used as intended, Lockout & Tagout also protects
personnel from energy stored in devices such as
springs, accumulators, batteries, hydraulic
systems, etc.
After performing these six steps:

1) All safety guards are back in place.
2) All work is complete and tools are put away.
3) All workers are notified that a lock is being
removed.
4) All workers are positioned safely for startup.
5) Controls are positioned for safe startup.
When is Lockout & Tagout required?
6) The machine is ready for safe operation.
Any time anyone is maintaining, repairing,

lubricating, or, for whatever reason, working
on the equipment.
When the equipment is broken or, for whatever

reason, unfit or unsafe to operate.
While clearing
mechanisms.
Whenever the equipment is left unattended.
blocked
or
Who can remove a lock and tag?
Only the person who applied a lock and tag is

permitted to remove them.
Lockout & Tagout rules laid out here are generic.

To get instructions for your particular workplace,
consult your employers lockout/tagout procedure.
jammed
Who must apply a lock & tag?
Any person working on the equipment.
Foreman or other person responsible for the

work being done.
If several people are working on a machine at

the same time, each person must apply his or
her own lock and tag.
2-5

2-6

Jaw Crusher Description
Section 3 - General Information
Serial Numbers
Jaw Crusher Description
Crushers are assigned a serial number which is

stamped on a plate on the machine.
The Jaw Crusher is a high-capacity compressiontype crusher that fractures material along its
natural fault lines.
Other components on the crusher may have

separate serial numbers or identifying numbers.
Always give the model and serial number or
identifying number of your crusher when ordering
parts or requesting information. If parts are
required for the other certain components, you
should supply that serial number or identifying
number as well as the crusher numbers.
Product size is controlled by adjusting the distance

between the fixed jaw die and the moveable
(swing) jaw die fastened to the pitman assembly.
These jaw dies are replaceable and come in several
different profiles depending upon the type of
material to be crushed and customer preference.
Flywheel Rotation Direction
The pitman is protected from damage by the toggle

plate. The toggle plate is intended to bend or
fracture if an uncrushable object enters the
crushing chamber, and thus opens the chamber
allowing the object to pass through.
Crushers are fitted with two flywheels, one of

which acts as the driven sheave. The direction of
rotation and orientation to the crusher is shown in
(Figure 3 - 2).
The Jaw Crusher may be mounted or installed in

static stationary, modular skid, as well as portable
wheel or mobile track plant applications. No
matter which type application the Jaw Crusher is
used in, it must be level to operate properly.
Figure 3 - 2 Flywheel Rotation Direction
Figure 3 - 1 Typical Jaw Crusher
3-1

Jaw Crusher Components
Jaw Crusher Components
Each model/size jaw crusher consists of similar

components, however certain models/sizes may
not have all the same components as other models/
sizes.
Be familiar with the crushers components. See

(Figure 3 - 3)
To be certain your machine has the proper

components, check to ensure it was equipped as
ordered.
8
4
3
21
7
9
10
11
20
12
19
13
18
17
16
15
1 2 3 4 5 6 7 8 9 101112131415161718192021-
Crusher Frame
Stationary Jaw Die
Cheek Plate (Key Plate)
Flywheel
Swing Jaw Die
Pitman Liner
Frame Bearing
Pitman
Pitman Bearing
Eccentric Shaft
Spring Guards
Adjustment Hydraulic Ram
Tension Rod Spring
Tension Rod
Shims
Upper Buffer
Toggle Plate
Lower Buffer
Rubber Dust Apron
Wedges for Stationary Jaw
Wedges for Swing Jaw
14
Figure 3 - 3 Typical Jaw Crusher Components
3-2

Jaw Crusher Capacities Chart
Jaw Crusher Capacities Chart

.
CT SERIES JAW CRUSHERS OPEN CIRCUIT MAXIMUM CAPABILITIES (STPH)
Jaw
Model
C.S.S. Size
Opening
1"
25 mm
1-1/2"
38mm
2"
50mm
2-1/2"
64mm
3"
76mm
3-1/2"
90mm
4"
100mm
5"
127mm
6"
150mm
7"
175mm
8"
200mm
9"
225mm
10"
250mm
11"
280mm
12"
305mm
CT1030
CT1040
CT1048
CT1252
CT2036
23
30
35
50
28
37
44
63
34
45
55
77
90
42
56
68
90
110
50
66
80
105
60
79
95
130
CT2436
CT2645
CT3042
NCT3042
CT3254
CT3648
CT4254
CT4763
CT6080
96
250
150
126
300
140
170
155
200
220
340
170
190
189
230
240
370
190
210
218
260
280
400
330
230
250
300
300
320
440
310-400
380-500
250-300
391
300-400
320-420
400-500
370-470
450-580
500-650
320-400
522
350-460
380-500
470-570
430-540
520-650
590-750
490-610
575-730
650-840 780-1100
550-700
630-810
740-930 860-1215
675-980
700-900 800-1010 950-1340

880-1100 1030-1455
950-1180 1120-1575
1.
The above information is bas ed 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 G REATER THAN INDICATED MAY BE WITHIN DESIGN CAPABILITIES OF THE MACHINES BUT ARE NOT
SHOWN DUE TO ANTICIPATED HIG HER OPERATING CO STS.
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 c onditions, is provided to assist in the selection of the c rushing equipment to follow. Contact your dealer for more details.
3-3

Jaw Crusher Gradation Chart
Jaw Crusher Gradation Chart

.
CT SERIES JAW CRUSHERS PRODUCT GRADATIONS (PERCENT PASSING)
C.S.S. Size Opening
Product
Size
15"
380mm
14"
356mm
13"
330mm
12"
305mm
11"
280mm
10"
250mm
9"
225mm
8"
200mm
7"
175mm
6"
150mm
5"
127mm
4"
100mm
3-1/2"
90mm
3"
76mm
2-1/2"
64mm
2"
50mm
1-3/4"
45mm
1-1/2"
38mm
1-1/4"
32mm
1"
25mm
3/4"
19mm
5/8"
13mm
3/8"
10mm
1/4"
6mm
1"
25 mm
1-1/2"
38mm
2"
50mm
2-1/2"
64mm
3"
76mm
3-1/2"
90mm
4"
100mm
5"
127mm
6"
150mm
7"
175mm
8"
200mm
9"
225mm
10"
250mm
11"
280mm
12"
305mm
100
100
90
100
90
85
100
90
85
75
100
90
85
75
70
100
90
83
75
70
65
100
90
83
75
70
65
60
100
90
83
75
70
65
60
55
100
90
83
75
70
63
60
55
45
100
95
83
75
68
63
58
55
45
40
100
90
85
75
68
60
58
48
45
40
35
100
90
83
75
65
60
55
48
45
40
35
25
95
83
75
70
60
55
50
45
40
35
25
22
100
83
75
70
65
55
50
45
35
30
25
22
20
100
90
75
68
60
55
50
42
35
30
25
22
20
17
90
75
65
58
55
50
40
35
30
25
22
20
17
12
85
70
60
55
50
45
35
30
25
22
20
17
12
10
100
75
65
55
50
45
40
30
25
22
20
17
12
10
95
70
55
50
40
35
30
25
22
20
17
15
10
75
65
45
43
35
30
25
20
17
15
12
10
70
55
40
30
25
22
20
17
15
12
10
60
45
35
25
20
17
15
13
10
45
30
25
20
15
13
10
30
20
15
10
TH E ABOV E TABL ES
AR E BAS ED ON R ES UL TS OBTA INE D D U RIN G AC TUA L OP ER ATION AN D CO UL D V AR Y D EPE ND IN G ON TH E TYPE
OF MA TER IA L, GR AD ATION OF FEED , M ETH OD OF FEE DIN G , MOISTU R E AN D CL AY C ON TEN T , AN D OTH ER MA TER IAL
C HA RA CTE RISTIC S. TH E IN DIC ATED TOP S IZE , AL SO INFL U EN CE D B Y THE ABOV E CO ND ITIO NS , IS PR OVID ED TO A SSIST IN TH E
SE LE CTION OF TH E C R US HIN G EQU IPME NT TO FOL LOW . C ONTA CT YOU R DE AL ER FOR MOR E D ETA IL S.
Jaw crushers reduce large rock to smaller stone using exceptional force. The foundation
therefore must be substantial enough to support the crusher without distortion.
3-4

Jaw Crusher Specifications
Jaw Crusher Specifications
Jaw Crusher Weight & Dimensions
Specifications for the jaw crusher are found in the

serial specific parts manual.
Weights and dimensions for the jaw crusher are

found in the serial specific parts manual.
3-5

Jaw Crusher Weight & Dimensions
3-6

Crusher Receiving and Inspection
Section 4 - Set-Up & Installation
Level the Crusher
Wherever the crusher is installed, it must be

mounted level. For stationary units, the supporting
structure must be level when completed. For skidmounted, mobile, or portable plant units, the frame
must be leveled. Use leveling jacks or suitable
blocking as needed to bring the unit to a level
position.
Crusher Receiving and Inspection

When the crusher is delivered, thoroughly check
for damage that might have occurred during
transport. Do not set up the unit until the
inspection is complete.
Note any damage on the shippers bill of lading
and have the deliverer sign your description of any
problem(s). Keep a copy of the marked-up bill of
lading for your files. Take photos if possible. File
a claim with the carrier within 30 days of receipt of
the equipment.
Lifting the Crusher
To lift the crusher, use machinery, lifting slings,

and equipment of sufficient size to safely handle
the load. When hooking lifting slings to the
crusher, always attach to the crusher frame. Never
lift complete crusher by attaching to flywheels or
pitman. If only pitman, shaft, and bearing
assembly is to be removed from crusher frame,
fasten lifting slings and equipment to lifting lugs
provided on top of pitman housing.
See (Figure 4 - 1)
Check loose parts, small parts boxes, and tools

against the packing list to ensure all items shipped
are present.
Installation
To operate correctly, the crusher must be installed
on a firm, level foundation. Make sure the
foundation and supporting structures are strong
enough to support the dynamic load of the
operating crusher and related equipment with
material moving through it.
Lifting Lugs
Lifting Lugs
Figure 4 - 1 Typical Jaw Crusher Lifting Lugs
4-1

Installation
Hydraulic Line Connections
Positioning the Crusher
Allow enough room around the crusher for

conveyors, loaders, and maintenance equipment
and personnel. Allow enough clearance below
crusher for discharge material conveyor and also
clearance above and behind the unit for access.
NOTICE
While making line connections
between the hydraulic power unit
and the crusher, air may become
trapped in the lines. It is necessary
to purge the trapped air. This can
usually be accomplished by
opening and closing the jaw several
times before initial operation.
Crusher Auxiliary Equipment
The crusher utilizes a system to provide hydraulic

power to adjust the jaw die opening. Make sure
this systems hydraulic lines are properly
connected and tightened as well as the electrical
drive motor (if used) is properly connected and
runs in the correct direction.
4-2

General
Section 5 - Inspection, Lubrication &

Maintenance Checks
Inspection Procedures
The following are major steps in a daily inspection

of your crusher:
General
1) Lockout & Tagout all power to crusher before
any lubrication or maintenance is performed.
To insure efficient operation, the crusher should be

inspected, lubricated, and have necessary
maintenance adjustments and repairs made at
regular intervals.
2) Look the complete crusher over carefully.

When sure that everything is in good order
and safe, the crusher should be ready to
operate.
Inspection
Performing a daily inspection is a good way to
keep your crusher performing safely and
efficiently. Utilizing the Daily Inspection Form at
the end of this section as a guide will help you
establish a maintenance routine, provide a
maintenance record, and help monitor the
condition of the equipment.
3) Remove the lock and tag.

4) Clear the area and prepare to start the crusher.
5-1

Lubrication
Lubrication
fittings and openings are cleaned thoroughly

before starting to inject lubricant. In using a grease
gun make sure the nozzle makes proper contact
with the cleaned fittings or openings and that the
nozzle has not been allowed to touch uncleaned
surfaces.
General Lubrication Information
The greatest single factor governing the life and

efficiency of any piece of machinery, where
friction is encountered, is proper lubrication.
While it is generally known that insufficient
lubrication will enable friction to reduce the
efficiency and service life of key parts, it is also
true that the presence of too large a quantity of
grease in a bearing housing usually results in high
operating temperatures and subsequent loss of
efficiency.
Never mix different brands or types of lubricant

within the crusher. Always drain and flush out old
lubricant before changing to a different brand as
chemical breakdown can occur in lubricant
mixtures.
Cleanliness in the handling of lubricants, fittings,

grease guns, and the openings and plugs of
housings is of vital importance.
Foreign
substances contaminate lubricant. Be sure all
Refer to (Table 5 - 1) as a guide for the proper

lubricants used on the crusher. If you do not have
access to the brands shown, see your lubricant
distributor for an equivalent.
Lubricant Specifications
Table 5 - 1 Jaw Crusher Lubricant Specifications

Lubricant Type
Ambient
Temperature
F (C)
Specification
Recommended
Standard Lubricant
Recommended
Synthetic Lubricant
Below 100
(Below 38)
NLGI 2, with EP
Additives
Mobil Delvac Xtreme
Mobilith SHC 220
Above 100
(Above 38)
NLGI 2, with EP
Additives
Mobilith SHC 460
Below 40
(Below 4)
ISO 32, HVI AW

Low Pour Point
Mobil DTE 13M
Mobil SHC 524
Above 40
(Above 4)
ISO 68,
Antiwear
Mobil DTE 26
Mobil SHC 526
Grease
Hydraulic Oil
(Used in Adjusting or
Controls Hydraulic
Systems)
5-2

Lubrication
Lubrication Intervals
The bearings and seals should use the specified

lubricant shown in (Table 5 - 1). See (Table 5 - 2)
for recommended lube intervals.
Table 5 - 2 Jaw Crusher Lubrication Intervals
ITEM
DAILY or
Every 8
Hours
WEEKLY or
Every 40
Hours
MONTHLY
or Every 160
Hours
YEARLY or
Every 2000
Hours
Shaft Labyrinth
Seals
--
--
Add Grease
to Each Seal
Check
Pitman Bearings
Add Grease
to Each
Bearing
Add Grease
to Each
Bearing
--
Change
Grease
Frame Bearings
Add Grease
to Each
Bearing
Add Grease
to Each
Bearing
--
Change
Grease
Hydraulic Oil
Check
Check
--
Change as
Required
5-3

Lubrication
Bearing Daily Lubrication Quantity
NOTICE
The following table shows the approximate

amount of grease to be added daily to each bearing
for the particular model jaw crusher.
Note that it takes approximately 20

strokes from a manual type grease
gun to discharge 1 ounce of grease.
Table 5 - 3 Jaw Crusher Bearing Daily Lubrication Quantity

Pitman Bearing
MODEL
Volume
Frame Bearing
Weight
Volume
Weight
Quart
gram
Ounce
Quart
gram
Ounce
CT1030
0.014
0.015
12.5
0.44
0.014
0.015
12.5
0.44
CT1040
0.014
0.015
12.5
0.44
0.014
0.015
12.5
0.44
CT1048
0.017
0.018
14.2
0.50
0.017
0.018
14.2
0.50
CT1252
0.031
0.033
26.6
0.94
0.031
0.033
26.6
0.94
CT2036
0.024
0.025
19.8
0.70
0.020
0.021
17.3
0.61
CT2436
0.029
0.031
25.2
0.89
0.024
0.025
20.4
0.72
CT2645
0.036
0.038
31.7
1.12
0.029
0.031
25.6
0.88
CT3042
0.054
0.057
45.9
1.62
0.052
0.055
43.9
1.55
NCT3042
0.045
0.048
36.9
1.30
0.043
0.045
34.0
1.20
CT3254
0.052
0.055
43.9
1.55
0.044
0.047
38.0
1.34
CT3648
0.054
0.057
45.9
1.62
0.052
0.055
43.9
1.55
CT4254
0.063
0.067
53.9
1.90
0.057
0.060
47.6
1.68
CT4763
0.086
0.091
73.7
2.60
0.085
0.090
70.9
2.50
CT6080
0.158
0.167
139.2
4.88
0.141
0.149
123.7
4.4
5-4

Lubrication
Jaw Crusher Seal Lubrication Quantity
NOTICE
The following table shows the approximate

amount of grease to be added to each seal for the
particular model jaw crusher.
Note that it takes approximately 20

strokes from a manual type grease
gun to discharge 1 ounce of grease.
Table 5 - 4 Jaw Crusher Seal Lubrication Quantity

Middle Labyrinth Seal
MODEL
Volume
Outer Labyrinth Seal
Weight
Volume
Weight
Quart
gram
Ounce
Quart
gram
Ounce
CT1030
0.016
0.017
14.2
0.5
0.016
0.017
14.2
0.5
CT1040
0.016
0.017
14.2
0.5
0.016
0.017
14.2
0.5
CT1048
0.018
0.019
17.0
0.6
0.018
0.019
17.0
0.6
CT1252
0.032
0.034
25.5
0.9
0.032
0.034
25.5
0.9
CT2036
0.035
0.037
28.3
1.0
0.035
0.037
28.3
1.0
CT2436
0.039
0.041
31.2
1.1
0.039
0.041
31.2
1.1
CT2645
0.039
0.041
31.2
1.1
0.039
0.041
31.2
1.1
CT3042
0.045
0.048
36.9
1.3
0.045
0.048
36.9
1.3
NCT3042
0.043
0.045
34.0
1.2
0.043
0.045
34.0
1.2
CT3254
0.052
0.055
42.5
1.5
0.052
0.055
42.5
1.5
CT3648
0.056
0.059
45.4
1.6
0.056
0.059
45.4
1.6
CT4254
0.060
0.063
51.0
1.8
0.060
0.063
51.0
1.8
CT4763
0.067
0.071
56.7
2.0
0.067
0.071
56.7
2.0
CT6080
0.074
0.078
62.4
2.2
0.074
0.078
62.4
2.2
5-5

Lubrication
Jaw Crusher Bearing Lubrication Points
Jaw Crusher Seal Lubrication Points
Do not over-grease bearings. Too much grease in

bearings will cause overheating and premature
bearing failure.
Grease should be added to seals until a fresh bead

of grease appears around the seals to provide a
moisture and dust barrier.
See (Figure 5 - 1) illustration showing the bearing

lubrication points on a jaw crusher.
See (Figure 5 - 2) illustration showing the seal

lubrication points on a jaw crusher.
Hoses to Grease
the Bearings
Grease Fittings
Figure 5 - 1 Typical Jaw Crusher Bearing Lubrication

Points
Grease Fittings
Figure 5 - 2 Typical Jaw Crusher Seal Lubrication
Points
5-6

Changing Grease in Bearings
4) Replace the grease fittings.
Under normal conditions, it is recommended that

grease be changed at least once each year or every
2000 hours of operation, which ever comes first.
See (Figure 5 - 3)
5) Run the crusher empty for at least 10 minutes.

6) Stop unit and remove drain plugs to drain
flushing oil.
7) Replace drain plugs when bearings have been
sufficiently flushed.
8) Install the recommended amount of grease
into each bearing. See (Table 5 - 5)
NOTICE
Frame bearings do not have drains
on the bearing housings. Purging
may require care to avoid a mess.
Drain Plugs
Figure 5 - 3 Typical Jaw Crusher Pitman Bearing
Grease Drain Points
1) Before changing lubricant, run crusher long

enough to heat the existing lubricant to a
consistency that allows it to flow freely.
2) Clean area around drain plugs and grease
fittings then remove plugs and fittings to drain
free flowing lubricant.
3) Replace drain plugs and inject flushing oil in
each bearing to fill pitman barrel and frame
bearing housing to top of fitting holes. An
extreme pressure 150 viscosity, Grade 46
flushing oil can be used.
5-7

Table 5 - 5 Jaw Crusher Bearing Lubrication Replacement Quantity

Pitman Bearing
MODEL
Volume
Frame Bearing
Weight
Volume
Weight
Gal.
Kg
Lbs.
Gal.
Kg
Lbs.
CT1030
1.06
0.28
0.93
2.06
0.94
0.25
0.83
1.83
CT1040
1.06
0.28
0.93
2.06
0.94
0.25
0.83
1.83
CT1048
1.32
0.35
1.16
2.55
1.06
0.28
0.93
2.06
CT1252
3.19
0.84
2.81
6.18
3.19
0.84
2.81
6.18
CT2036
1.89
0.50
1.66
3.66
1.71
0.45
1.50
3.30
CT2436
2.64
0.70
2.32
5.11
1.89
0.50
1.66
3.66
CT2645
3.70
0.98
3.26
7.17
2.54
0.67
2.24
4.92
CT3042
6.01
1.59
5.29
11.63
4.99
1.32
4.39
9.65
NCT3042
3.44
0.91
3.02
6.65
2.82
0.74
2.48
5.46
CT3254
6.01
1.59
5.29
11.63
4.99
1.32
4.39
9.65
CT3648
7.24
1.91
6.37
14.01
7.06
1.87
6.21
13.67
CT4254
10.27
2.72
9.04
19.89
7.24
1.91
6.37
14.01
CT4763
16.60
4.39
14.61
32.14
14.47
3.83
12.73
28.01
CT6080
35.51
9.40
31.25
68.75
31.02
8.21
27.30
60.06
5-8

Maintenance Checks
Maintenance Checks
Interior Inspection
The jaw crusher does not have an enclosed,

interior crushing chamber, but does have items
underneath or inside the frame which may require
close inspection. Care must be taken to do this.
Exterior Inspection
1) Lockout & Tagout power to crusher drive,

crusher hydraulic unit, and all other associated
equipment.
1) Verify Lockout & Tagout of crusher drive.
DANGER
DANGER
Failure to Lockout & Tagout all

energy sources will result in death
or severe personal injury. Make it
impossible to start this machine or
associated equipment while people
are working on or in it.
Failure to Lockout & Tagout will

result in death or severe personal
injury.
2) Inspect all crushing chamber components,
including stationary jaw die, swing jaw die,
cheek plates, pitman shaft housing liner to
make sure all are in good condition.
2) Check all exterior components, including

drives, belts, guards, covers and inspection
doors, bearings, seals, hardware and hydraulic
parts to make sure all are in good condition.
3) Repair or replace as necessary any parts that

are damaged, missing, excessively worn, or in
faulty condition. See Section 7 for wear items
adjustment and replacement information.
3) Repair or replace as necessary any parts that

are missing or in faulty condition.
Start-Up
4) Tighten any loose hardware or loose hydraulic

fittings. See Appendix A for hardware torque
specifications.
When all inspection and repairs or necessary

replacements are complete, perform the following
to prepare crusher for start-up.
5) See Appendix B for v-belt drive information.

1) Remove Lockout & Tagout from crusher
drive.
2) Make sure everyone is clear of crusher.
3) Crusher should now be ready for start-up.
5-9

Maintenance Checks
5 - 10

Jaw Crusher Daily Inspection Form

Date __________
Signature _______________________________
7) Flywheel bolts - tight

OK Not OK See Notes
8) Flywheel counterweights - tight
OK Not OK See Notes
Pre-Start-up Checklist
1) Lockout & Tagout - crusher & assoc. equip.

OK Initials ______________________
9) Jaw dies and cheek plate bolts - tight &

jaw dies in good condition
OK Not OK See Notes
2) Under-crusher discharge area - clear of debris

OK Not OK See Notes
10) Pitman tension rod springs tensioned properly

OK Not OK See Notes
3) Belt guards - present, in good condition

OK Not OK See Notes
11) Crusher setting (C.S.S.) checked & adjusted

properly _________Inches _________mm
OK Not OK See Notes
4) Belts - tensioned, clean, in good condition

OK Not OK See Notes
5) Sheaves - aligned, clean, in good condition
OK Not OK See Notes
6) Pitman Shaft:
a. Seals - good condition
OK Not OK See Notes
b. Seals - greased properly
OK Not OK See Notes
c. Bearings - housing bolts tight
OK Not OK See Notes
d. Bearings - greased properly
OK Not OK See Notes
Last Greased at _______________________
Initials ______________________________
Notes:
_____________________________________
_____________________________________
_____________________________________
_____________________________________
_____________________________________
12) Hydraulic System:

a. Breather cap, control levers & valves - in
place, secure & tight, no leaks, no damage
OK Not OK See Notes
b. Lines & hoses - in place, secure & tight, no
leaks, no damage
OK Not OK See Notes
c. Cylinder(s) - securely pinned, no leaks, no
damage
OK Not OK See Notes
d. Cylinder hydraulic pressure is adequate and
replenished.
OK Not OK See Notes
e. Reservoir - oil clean and at proper level
OK Not OK See Notes
Oil Added - Qts. ______________________
Initials ______________________________
f. Oil & Filter Changed - Qts._____________
Initials ______________________________
Notes:
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
5 - 11

Start-up Checklist
13) Remove Lockout & Tagout - crusher &

associated equipment
OK Initials ______________________
14) Jog crusher drive motor to verify pitman shaft
rotates in proper direction (See Diagram)
OK Not OK See Notes
20) Crusher run 50% load - 2 hours minimum

OK Not OK See Notes
21) 50% load bearing temperatures checked
(140-160F. / 60-70C.)
OK Not OK See Notes
22) 50% load power draw _____________Amps
OK Not OK See Notes
23) 50% load crusher balance is good
OK Not OK See Notes
24) Crusher run 75% load - 4 hours minimum
OK Not OK See Notes
(140-160F. / 60-70C.)
OK Not OK See Notes
OK Not OK See Notes
15) Crusher shaft runs at ______________RPM

OK Not OK See Notes
16) Crusher run no load - 2 hours minimum
OK Not OK See Notes
17) No load bearing temperatures checked
(140-160F. / 60-70C.)
OK Not OK See Notes
18) No load power draw _____________Amps
OK Not OK See Notes
19) No load crusher balance is good
OK Not OK See Notes
Notes:
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
27) 75% load crusher balance is good

OK Not OK See Notes
OK Not OK See Notes
(140-160F. / 60-70C.)
OK Not OK See Notes
30) Crusher at work
Diesel Engine RPM ____________________
Electric Motor Amps ___________________
Total Crushing Hours Today _____________
Downtime Today ______________________
Notes:
________________________________________
________________________________________
________________________________________
________________________________________
5 - 12

Jaw Crusher Troubleshooting Chart

The following chart outlines some of the issues,
possible causes, and solutions to those issues you
may encounter with the jaw crusher.
Table 5 - 6 Jaw Crusher Troubleshooting
ISSUE
POSSIBLE CAUSE
SOLUTION
Crusher will not start
Incorrect wiring
Check wiring diagram
No power
Check power source
Defective motor
Check motor. Replace if defective.
Soft start issues
Ensure soft start is functioning properly
Crushing chamber full
Clear crushing chamber
Excessive amp draw
Possible voltage drop. Check power source.
Excessive fines in feed
Remove fines from feed.
Un-crushable object in
crushing chamber
Clear crushing chamber
Damaged or worn bearings
Replace bearings
Discharge opening set too

close
Adjust discharge opening to within specifications
Flywheel/Drive sheave turned

on shaft
Re-mount flywheel/drive sheave in proper position
Excessive fines build up in

flywheels
Clean dust or material build up from flywheels
Crusher running too fast
Ensure crusher is running at proper RPM
Crusher not secured to

mounting structure
Ensure crusher foot mounting bolts are secure to

structure
Loose toggle plate
Check tension springs. Adjust as required.
Gap between upper buffer

and upper buffer guide too
large
Add shims to close gap to between .5 ~ 1.0 mm
Loose die bolts
Tighten die bolts as required
Dirt/material buildup in toggle

plate seats
Remove dirt/material buildup
Loose bolts
Tighten all loose bolts as required
Crusher stops under

load
Crusher shakes/
vibrates
Excessive noise
(knocking,
squeaking,
rattling, etc.)
5 - 13


ISSUE
POSSIBLE CAUSE
SOLUTION
Crusher loses RPM
Excessive fines in crushing

chamber
Check material feed and remove fines
Low voltage
Check power source
Loose or worn drive belts
Adjust belt tension and replace belts as required
Worn drive sheave
Replace drive sheave as required
Improper jaw dies for

application
Check with TRIO for jaw die options
Electrical power issues
Check power source, wire size, drive motor
Drive belt issue
Check and adjust belt tension and replace belts as

required
Tension springs not equally

adjusted
Worn buffer(s)
Inspect and replace buffer(s) as required
Worn toggle plate
Inspect both ends of toggle plate to check wear
Crusher not level
Check and make sure crusher is level
Material build up on top of

toggle entering lower buffer
Keep toggle plate area free of material build up and

debris
Tension springs not equally

adjusted
Crushing on one side only
Ensure feed is centered and not segregated
Un-crushable object(s) went

through machine
Remove un-crushable object(s) from feed
Exceeding recommended
reduction ratio
Adjust feed size or adjust C.S.S.
Uneven jaw die wear
Improper feed to crusher
Ensure feed is centered and not segregated
Cracked jaw dies
Jaw dies excessively worn
Replace jaw dies at 80% wear
Crusher frame parent steel

worn
Remove dies, inspect and repair crusher frame as

required
Un-crushable object(s) went

through machine
Remove un-crushable object(s) from feed
Application issues
Evaluate crusher application
Poor crusher
performance
Toggle plate drift
Uneven toggle plate

wear
Cracked/broken
toggle plate
5 - 14


ISSUE
POSSIBLE CAUSE
SOLUTION
Bearings overheating
Incorrect grease
Use specified type grease
Over greasing or under

greasing
Use proper quantity of lubricating grease
Crusher is overloaded
Eliminate overload condition
Low oil level in system
Ensure oil reservoir is at proper level
Hydraulic pump not operating
Ensure hydraulic pump has power and is activated
Low hydraulic pressure
Ensure hydraulic system pressure is adequate
Hydraulic lines incorrectly

connected
Check and ensure lines are correctly connected
Air in hydraulic system
Bleed air by removing tension spring tension and

attempting to open and close C.S.S. two full cycles
Damaged wedge surface(s)
Ensure wedge surface(s) are smooth and clear of

debris. Replace as required.
Hydraulic leak
Check and repair leaks
Hydraulic lines incorrectly

connected
Check and ensure lines are correctly connected
Adjustment wedges
will not move
Adjustment wedges
open during
operation
5 - 15

5 - 16

Start-Up & Operation Information
Section 6 - Start-Up & Operation
3) Start up all other components on the plant in

the proper sequence prescribed for your
particular plant system. If no prescribed
sequence is available, start with the last piece
of equipment to discharge material and work
back toward the initial feed point until all
components are operating empty.
Start-Up & Operation Information

The jaw crusher is generally used as a component
of an overall plant system. Specific equipment
start-up procedures will depend on the particular
plant and the material flow as well as the type of
controls used. Always refer to controls schematics
and information received with your particular
equipment for start-up and operation.
4) Make sure crusher is running at the proper

RPM. See (Table 6 - 1)
Table 6 - 1 Jaw Crusher Operating Speeds
The following steps should be used as a guide to

operation of the jaw crusher:
1) Check the surrounding area to ensure no
personnel are in a dangerous position prior to
start-up.
WARNING
Always sound horn or other warning
device to warn others that you are about to
start up the equipment.
2) If the crusher is part of a plant system, make
sure it is started in proper sequence with other
components.
Jaw Model
RPM
CT1030
300
CT1040
300
CT1048
300
CT1252
300
CT2036
250
CT2436
250
CT2645
300
CT3042
250
NCT3042
250
CT3254
250
CT3648
225
CT4254
220
CT4763
200
CT6080
200
5) Begin material flow to the plant. Keep safety

in mind.
6) Record any observation about plant operating
conditions in the plant log book.
6-1

Crusher Feed
Crusher Feed
DANGER
The most efficient operation of the crusher results

when the crushing chamber is kept full of material
and when a uniform method of feed is used. The
crusher should ideally be kept full of material but
it should not be allowed to build up above the top
of the jaws.

injury.
3) Use extreme caution when attempting to
dislodge or remove jammed objects. These
objects are under tremendous pressure and can
fracture or dislodge and be thrown out at high
speeds at any time.
During normal operations, the flow of material to

the machine and crushed material out of the
machine forms a steady stream of product from the
crusher.
Oversize Feed Material
DANGER
Avoid feeding material into the crusher that is too

large to pass through the crushing chamber. If a
piece of material is too large, it should be broken
down before it gets to the crushing chamber. A
hydraulic breaker may be installed to assist in this
process.
Never use explosives in a crusher to

clear jammed objects. The crushing
chamber and machine components
are not designed to withstand the
forces generated by explosives.
CAUTION
WARNING
If a hydraulic breaker is installed, it should
never be used to fracture rocks inside the
crushing chamber. Damage to bearings or
other parts may occur. Never use a
hydraulic breaker to break rocks on the
apparatus feeding the crusher.
Never attempt to walk or stand on

jammed or bridged material. The
material could break free at any
time.
4) Remove as much loose material from the top
of the crushing chamber as possible. When the
jammed object becomes accessible, try to
loosen it with a pole, rock hook or breaker bar.
If necessary, use a grappling device to remove
the object out of the feed opening.
Unblocking Jammed Material
If material becomes jammed in the machinery:

1) Stop the machinery immediately!
2) Lockout & Tagout power.
WARNING
Never attempt to dislodge a
jammed object directly by hand.
6-2

Crusher Feed
CAUTION
If a hydraulic breaker is used when the feed
opening is blocked, extreme care must be
taken to break the jammed rock only.
Never directly hammer on any part of the
crusher or its components. Never pry
against the crusher to free the blockage.
5) After unblocking and clearing is completed,
remove any objects, loose material or debris
from the crusher discharge area.
6) Remove the Lockout & Tagout from the
power source.
Crusher should now be able to be restarted.
6-3

Crusher Feed
6-4

Adjustments & Replacement
Section 7 - Adjustments & Wear

Parts Replacement
Closed Side Setting (CSS) Adjustment

The jaw crushers crushing chamber discharge
opening governs the size of finished material
produced.
Adjustments & Replacement

As equipment is used, wear parts must be adjusted
and/or replaced to keep the machinery operating
efficiently and properly. The following will give
guidance to adjustment procedures and
replacement for wear items on your jaw crusher.
The CSS is the closest distance the stationary and

swing jaw die faces come measured peak to peak
at the bottom of the chamber. See (Figure 7 - 2)
While the crusher is at rest, the opening at the
bottom of the chamber is somewhat larger and
known as the open measurement. To determine
the CSS, deduct the amount shown in the table
below from the open measurement .
Jaw Crusher Crushing Chamber

The jaw crushers crushing chamber consists of
the stationary jaw die, the swing jaw die
(sometimes called the moveable jaw), and the
cheek plates (sometimes called key plates). The
pitman shaft housing area is also protected by a
replaceable liner. See (Figure 7 - 1)
Table 7 - 1 Deduction To Determine CSS
Jaw Model
Inches
Metric
CT1030
0.394
10mm
CT1040
0.394
10mm
CT1048
0.394
10mm
CT1252
0.591
15mm
CT2036
1.000
25mm
CT2436
1.260
32mm
CT2645
N/A
N/A
CT3042
1.417
36mm
NCT3042
1.181
30mm
CT3254
1.023
26mm
CT3648
1.929
49mm
CT4254
2.087
53mm
CT4763
1.653
42mm
CT6080
N/A
N/A
1 - Swing Jaw Die

2 - Stationary Jaw Die
3 - Cheek Plates (Key Plates)
Figure 7 - 1 Typical Jaw Die & Cheek Plate
Arrangement
7-1

Shim-Type CSS Adjustment Procedure
1) Lockout & Tagout crusher drive.
DANGER
injury.
2) Loosen bolts on both sides of machine that
secure the shims.
3) Loosen tension rod spring nuts on both sides
of machine.
Measure peak to peak when
crusher is at rest, then deduct
amount from table to get CSS.
4) Activate hydraulic hand pump to extend

cylinder to push the pitman forward and
relieve the weight off the stack of shims.
Figure 7 - 2 Jaw Crusher Closed Side Setting (CSS)
5) Add or subtract shims as required to achieve

the desired CSS.
Shim-Type CSS Adjustment
On smaller model jaws, the size of the opening is

changed by adding or subtracting shims between
the upper buffer and the frame housing.
See (Figure 7 - 3).
6) With the desired number of shims seated,

retract the hydraulic cylinder to allow the
pitman to rest against the shim stack.
7) Re-tighten the bolts on both sides of machine
securing the shims.
8) Re-set tension rod spring tension on both sides
of machine.
9) Once complete, remove Lockout & Tagout.
Figure 7 - 3 Shim-Type CSS Adjustment
7-2

Hydraulic Wedge-Type CSS Adjustment

(Manual Hyd. Pump) Procedure
Hydraulic Wedge-Type CSS Adjustment

(Manual Hyd. Pump)
On some larger model jaws, the size of the opening

is changed by operating a manual hydraulic pump
connected to cylinders moving wedges between
See (Figure 7 - 4).
DANGER
injury.
6
5
2) Ensure the hydraulic pump unit is properly

connected to the hydraulic cylinders on the
wedges.
NOTICE
1
2
2
1
2
3
4
5
6
Wedges In
Wedges Out
Manual Hand Pump
Valve Direction - Wedges In
Valve Direction - Wedges Out
Valve Direction - Hold Position

of machine.
4) Move the valve to the desired flow direction
(Wedge Out - Increases Opening)
(Wedge In - Decreases Opening)
5) Activate hydraulic hand pump to push or pull
the wedges in or out to the desired CSS.
Figure 7 - 4 Hydraulic Wedge-Type CSS Adjustment

(Manual Hyd. Pump)
6) Move the valve back to the Hold position.

of machine.
7-3

Power Hydraulic Pump Unit for CSS

Adjustment
The powered hydraulic pump unit may or may not

have the electrical control box mounted on the
unit. Either unit contains the same hydraulic
components.
Some larger model jaw crushers utilize a powered

hydraulic pump unit to supply power for the CSS
adjustment mechanism.
See (Figure 7 - 5)
Unit Without Electrical Control Box
15 7 17
18 16 13
14
5
16
17
15
12
18
19
9
6 1
11
17
11
10
16
20
1
2
3
4
5
6
7
Unit With Electrical Control Box

Motor
8 - Reservoir Cap / Breather
Coupling
9 - Check Valve
Gear Pump
10- One-way Throttle Valve
Relief Valve
11- Synchronous Valve
Directional Control Valve
12- Pressure Gauge
Oil Level Gauge
13- Gauge Fitting
Return Oil Filter
14- Gauge Hose
151617181920-
P Port / High Pressure Hose

B Port / High Pressure Hose
A Port / High Pressure Hose
T Port / Low Pressure Hose
Electrical Control Buttons
Electrical Control Box
Figure 7 - 5 Power Hydraulic Pump Unit Components
7-4

Power Hydraulic Pump Unit With Electrical

Control Box
The electrical schematics below are for reference

when the power hydraulic pump unit used has the
electrical control box mounted.
Circuit Breaker
Pump Motor
Transformer Control and Protection
Pump Motor Control
Stop
Start
Electric Schematic (380V)

Circuit Breaker
Pump Motor
Transformer Control and Protection
Pump Motor Control
Stop
Start
Electric Schematic (460V)

Figure 7 - 6 Power Hydraulic Pump Unit Electrical Schematics
7-5

Power Hydraulic Pump Unit Hydraulic

Schematic Type 1 Connections
CT2036, CT2036SA, CT2036T, CT2036TA
The hydraulic schematic below is for reference

when the power hydraulic pump unit is used on the
following model jaw crushers.
CT2436, CT2436J, CT2436JS, CT2436JT,

CT2436TB, CT2436TC, CT2436S
CT2645A
CT3042, CT3042T, CT3042TAC, CT3042S,
CT3042SB, CT3042SC, CT3042SD, CT3042TA,
CT3042TP
CT3254, CT3254PN, CT3254TA, CT3254TB,
CT3254TC, CT3254TD, CT3254TE, CT3254TS
CT3648, CT3648HT, CT3648HTS
CT4254, CT4254S, CT4254SA, CT4254SB,
CT4254T, CT4254U
CT4763, CT4763T, CT4763U, CT4763Y
CT6080
7-6

Rated Flow
Rated Pressure
Motor Power
Motor Speed RPM
Filtration
Oil Reservoir Volume
1
2
3
4
5
Motor
Coupling
Gear Pump
Relief Valve
6 7 8 9 10-
Oil Level Gauge

Return Oil Filter
Reservoir Cap / Breather
Check Valve
One-way Throttle Valve
111213141516-
4 ml/r
21 MPa
3KW / 380V or
3.6KW / 460V
1410 / 380V or
1710 / 460V
20 m
65L (17 Gal.)
Synchronous Valve
Pressure Gauge
Gauge Fitting
Gauge Hose
Figure 7 - 7 Power Hydraulic Pump Unit Hydraulic Schematic Type 1 Connections & Specifications
7-7

Power Hydraulic Pump Unit Hydraulic

Schematic Type 2 Connections
CT3254A, CT3254C, CT3254D
The hydraulic schematic below is for reference

when the power hydraulic pump unit is used on the
following model jaw crushers.
CT4254B, CT4254HA
7-8

Rated Flow
Rated Pressure
Motor Power
Motor Speed RPM
Filtration
Oil Reservoir Volume
1
2
3
4
5
6
Motor
Coupling
Gear Pump
Relief Valve
Oil Level Gauge
7 8 9 101112-
Return Oil Filter

Reservoir Cap / Breather
Check Valve
One-way Throttle Valve
Synchronous Valve
Pressure Gauge
131415161718-
4 ml/r
21 MPa
3KW / 380V or
3.6KW / 460V
1410 / 380V or
1710 / 460V
20 m
65L (17 Gal.)
Gauge Fitting
Gauge Hose
A Port / High Pressure Hose
T Port / Low Pressure Hose
Figure 7 - 8 Power Hydraulic Pump Unit Hydraulic Schematic Type 2 Connections & Specifications
7-9

Hyd. Wedge-Type CSS Adjustment (Power

Hyd. Pump Type 1 Connections)

is changed by operating a power hydraulic pump
See (Figure 7 - 9).
1
1
2
3
4
5
6
7
Wedges In
Wedges Out
Power Hydraulic Pump Unit
Pressure Gauge

(Power Hyd. Pump - Type 1 Connections)
7 - 10


Hyd. Pump Type 1 Connections) Procedure
DANGER
injury.
2) Ensure the power hydraulic pump unit is
properly connected to the hydraulic cylinders
on the wedges. See (Figure 7 - 9)
4) Engage power to the hydraulic pump unit.

5) Move the control valve lever in the desired
flow direction to move the wedges in or out to
the desired CSS.
6) Once the desired CSS has been achieved,
move the control valve lever back to the Hold
position.
7) Disengage power to the hydraulic pump unit.
of machine.
NOTICE
of machine.
7 - 11


Hyd. Pump Type 2 Connections)

is changed by operating a power hydraulic pump
See (Figure 7 - 10).
1
1
2
3
4
5
6
7
Wedges In
Wedges Out
Power Hydraulic Pump Unit
Pressure Gauge

(Power Hyd. Pump - Type 2 Connections)
7 - 12


Hyd. Pump Type 2 Connections) Procedure
DANGER
injury.
2) Ensure the power hydraulic pump unit is
properly connected to the hydraulic cylinders
on the wedges. See (Figure 7 - 10)
4) Engage power to the hydraulic pump unit.

5) Move the control valve lever in the desired
flow direction to move the wedges in or out to
the desired CSS.
6) Once the desired CSS has been achieved,
move the control valve lever back to the Hold
position.
7) Disengage power to the hydraulic pump unit.
of machine.
NOTICE
of machine.
7 - 13

Direct Hydraulic Toggle Plate-Type CSS

Adjustment
On certain model jaws, the size of the opening is

changed by adding or subtracting shims between
the upper buffer and a hydraulic cylinder
mechanism directly acting against the frame
housing.
Figure 7 - 11 Direct Hydraulic Toggle Plate-Type CSS

Adjustment
The toggle plate hydraulic cylinder mechanism as

well as the tension rod spring cylinder mechanisms
are powered and held hydraulically by a separate
hydraulic pump control unit. See (Figure 7 - 12)
Make sure the hydraulic pump control unit is
properly connected to the crusher hydraulic
cylinders. See (Figure 7 - 15) schematic.
Figure 7 - 12 Direct Hydraulic Toggle Plate-Type

Hydraulic Pump Control Unit
Direct Hydraulic Toggle Plate-Type CSS

Adjustment Procedure
DANGER
Operating hydraulic pressure on toggle cylinder

mechanism is 16.5 Mpa (2393 psi) and the tension
rod spring cylinders is 12 Mpa (1740.5 psi).
During normal operation, hydraulic unit should be
turned on and running before crusher is started and
the Auto/Manual Switch should be set to Auto.

injury.
2) Place a Safety Block between the pitman
and the back cross member as shown.
See (Figure 7 - 13)
7 - 14

Shims

Adjustment Shims
Safety block installed between

pitman and frame cross member.
Safety block should be made
from solid hardwood material.
Shim Bolt
8) Add or remove shims as required to achieve

the desired CSS. Each shim removed will
reduce the CSS by approximately 23mm.

Adjustment Safety Block Installed
9) Re-install bolts on both sides of machine to

secure the shims.
3) Turn Auto/Manual Switch to Manual
10) Turn the Auto/Manual Switch to Auto. This

allows the hydraulic control unit to pressurize
the Toggle Cylinder set and Tension
Cylinders.
4) Push the Tension Cylinder Relief button to

release tension cylinder hydraulic pressure.
5) Push the Toggle Cylinder Relief button to
release toggle cylinder set hydraulic pressure.
6) Remove the adjustment mechanism covers
from both sides of machine.
7) Loosen bolts on both sides of machine that
secure the shims. See (Figure 7 - 14)
11) Once pressurized, remove the Safety Block.

12) Re-install adjustment mechanism covers on
both sides of machine.
13) Once complete, remove crusher drive Lockout
& Tagout.
7 - 15

.
Tension
Toggle
Release
Rated Pressure
Max. Pressure
Rated Flow
Operating Voltage
Operating Temp
Filtration
Oil Volume
Motor Power
1 2 3 4 5 6 7 8 9 1011-
Oil Pump
Pump Coupling
Electric Pump Motor
Motor Pump Joint Flange
Reservoir Breather
Oil Level Gauge
Return Line Filter
Hose
Fitting
Accumulator
Pressure Gauge
20MPa
21MPa
18 L/Min.
24V
60 + or - 5 C
10um
200L
7.5Kw/380V/50Hz
12- Pressure Gauge

13- Check Valve
14- Solenoid Valve
15- Valve Block
16- Solenoid Valve
17- Flow Control Valve
18- Check Valve
19- Ball Valve
20- Tension Rod Cylinders
21- Toggle Cylinder Assembly
22- Oil Reservoir
Figure 7 - 15 Direct Hydraulic Toggle Plate-Type Hydraulic Controls Schematic
7 - 16

Standard Toggle Seat Tension Rod Spring Adjustment
Standard Toggle Seat Tension Rod

Spring Adjustment
1) Completely loosen spring tension rod nuts

until springs are at their full, no-load length.
See A above.
After crusher CSS is set, the toggle seat tension rod

springs must be adjusted to apply the proper
amount of spring tension to keep the toggle plate
contained in its seats.
See (Figure 7 - 16)
2) Record this length A.
NOTICE
When measuring spring free length, each
spring length may vary. It is important to
compress each spring the same amount as
shown in (Table 7 - 2) even though this
may make the spring overall lengths differ.
The important issue is that the compression
amount be equal on each side to ensure the
toggle plate remains centered during
operation.
B
A
A - Spring Free Length
3) See (Table 7 - 2) for the amount to compress

springs for your particular model crusher.
See B above.
4) When springs are compressed the amount
specified in (Table 7 - 2), that length will be
dimension B subtracted from dimension A.
B - Spring Compression Deduction Amount

Figure 7 - 16 Typical Toggle Seat Tension Rod Spring
Adjustment
7 - 17

Standard Toggle Seat Tension Rod Spring Adjustment
Table 7 - 2 Tension Rod Spring Length Deduction

Jaw Model
Initial mm (inch)
Range mm (inch)
CT1030
21 (0.826)
20~30
(0.787~1.181)
CT1040
31 (1.220)
25~37
(0.984~1.456)
CT1048
57 (2.244)
50~62
(1.968~2.440)
CT1252
64 (2.519)
50~65
(1.968~2.559)
CT2036
39 (1.535)
35~45
(1.377~1.771)
CT2436
35 (1.377)
30~40
(1.181~1.574)
CT2645
N/A
N/A
CT3042
55 (2.165)
50~60
(1.968~2.362)
NCT3042
22 (0.866)
18~27
(0.708~1.062)
CT3254
34 (1.338)
30~40
(1.181~1.574)
CT3648
32 (1.259)
30~38
(1.181~1.496)
CT4254
35 (1.377)
35~50
(1.377~1.968)
CT4763
65 (2.559)
65~100
(2.559~3.936)
CT6080
55 (2.165)
53~60
(2.086~2.362)
5) When the springs are adjusted on both sides,

start the crusher.
6) Listen for a knocking sound. If a knocking is
heard, the toggle is not held tight enough by
the springs.
7) Further tighten (compress) the tension springs
a slight amount.
8) Run the crusher again and repeat until no
toggle plate knocking sound is detected.
NOTICE
For proper operation and optimum toggle
plate wear performance, the tension rod
springs must be adjusted evenly on both
sides so the toggle plate will run in the
center of the upper and lower buffer seats.
The important issue is that the compression
amount be equal on each side to ensure the
toggle plate remains centered during
operation.
7 - 18

Fully Hydraulic Toggle Plate-Type CSS Adjustment System
Fully Hydraulic Toggle Plate-Type CSS

Adjustment System
On certain model jaws, the size of the opening is
changed by a fully hydraulic cylinder mechanism
directly acting against the frame housing and the
swing jaw. The toggle plate tension mechanism is
accomplished by having dual-acting cylinders
between the frame housing and the swing jaw in
addition to tension rods and springs.
1
2
3
7
9
1
2
3
4
4
7
5
6
Toggle Cylinder 5 - Adapter
Toggle Beam
6 - Tension Rod
Toggle Plate
7 - Tension Spring
Tension Cylinder
Figure 7 - 17 Fully Hydraulic Toggle Plate-Type CSS

Adjustment
The toggle plate hydraulic cylinder mechanism as

well as the tension cylinder mechanisms are
powered and held hydraulically by a separate
hydraulic pump control unit. See (Figure 7 - 18)
1 - Power
2 - Pump Start
3 - Filter Blocked
Indicator
4 - Pump Stop
5 - CSS Increase
7 - 19
8
6 - CSS Decrease
7 - Adjust/Operate
Mode Switch
8 - E-Stop
9 - Main Power
Switch
Figure 7 - 18 Fully Hydraulic Toggle Plate-Type

Hydraulic Control Unit

Hydraulic Pump Control Unit Hose

Connections
Make sure the hydraulic pump control unit is

properly connected to the crusher hydraulic
components and cylinders. See (Figure 7 - 19) and
(Figure 7 - 24) schematic.
Figure 7 - 19 Fully Hydraulic Toggle Plate-Type Hydraulic Pump Unit Hose Connections
7 - 20

CSS Increase Adjustment Procedure
Hydraulic Control Unit Standby Mode
When the control unit is first started, no matter if

the panel switch is in Adjustment Mode or
Operation Mode, the unit will be in a Standby
Mode.
CSS Decrease Adjustment Procedure
1) Turn control unit on.
1) Turn control unit on.

2) Turn control panel switch to Adjustment
Mode.
3) Push the CSS Increase button on the control
panel to move the toggle cylinders in until the
desired position is reached.
2) Turn control panel switch to Adjustment

Mode.
NOTICE
3) Push the CSS Decrease button on the control

panel to move the toggle cylinders out until
the desired position is reached.
The displacement of the toggle cylinder is

measured by the sensor ST1 or ST2 on the
toggle cylinders. Output current ranges
from 4 to 20mA. See (Figure 7 - 24)
schematic.
If pressure measured by
pressure sensor (32) is below its upper
limit of 12 MPa (1740 psi), oil will be
supplied to the tension cylinder rod side
chamber until it reaches the upper limit.
NOTICE
The displacement of the toggle cylinder is
measured by the sensor ST1 or ST2 on the
toggle cylinders. Output current ranges
from 4 to 20mA. See (Figure 7 - 24)
schematic.
If pressure measured by
pressure sensor (32) is below its upper
limit of 12 MPa (1740 psi), oil will be
supplied to the tension cylinder rod side
chamber until it reaches the upper limit.
4) The toggle cylinder displacement is now
recorded as the default value for cylinder
reset.
4) The toggle cylinder displacement is now

recorded as the default value for cylinder
reset.
5) CSS adjustment is complete and now control
panel switch can be moved to Operation Mode
and tension rod spring adjustment should now
be made.
5) CSS adjustment is complete and now control

panel switch can be moved to Operation Mode
and tension rod spring adjustment should now
be made.
7 - 21

Tension Rod Spring Adjustment
Toggle Cylinders Oil Supplement
When the crusher CSS has been set or changed as

described above, the tension rod springs must be
adjusted.
While the hydraulic control unit is in operation, the

toggle cylinders must maintain their default value
(CSS setting) described above.
When the
difference between toggle cylinders actual
displacement and the default displacement reaches
the maximum deviation, the valve will be actuated
to move the cylinders to maintain position. This
will continue through the entire crushing process.
1
Tension Cylinders Oil Supplement
2
3
4
1
2
3
4
5
6
7
Toggle Cylinder
Toggle Beam
Toggle Plate
Tension Cylinder
Adapter
Tension Rod
Tension Spring:
Compress springs 28mm (1 - 1/8 in.)
Compressed length 312mm (12 - 3/8 in.)
Both springs should be equally adjusted.

Tension Rod Spring Adjustment
While the hydraulic control unit is in operation, the

tension cylinders must maintain their position and
pressure relative to (CSS setting) described above.
Tension cylinder oil supplement depends on the
pressure measured by the sensor (32). If the
measured pressure is below the lower limit of
5MPa (725 psi), the valve will be actuated to move
the cylinder rod side until the measured pressure
reaches the upper limit of 12MPa (1740 psi). This
will continue through the entire crushing process.
When both toggle cylinders and tension cylinders
need oil supplement, the tension cylinders have
priority.
Tramp Release
If an uncrushable piece of material in the crushing

chamber causing the pressure in safety valve
(29.2) to rise above its setting of 25MPa (3625
psi), it will allow most of the oil to flow across
check valve in (29.1) to toggle cylinder rod side
chamber and the remaining oil to flow back to
tank. See (Figure 7 - 21) and (Figure 7 - 24)
1) Completely loosen spring tension rod nuts

until springs are at their full, no-load length.
Response time is 2 milliseconds and the cylinder

maximum retract speed is 15mm/s.
2) See (Figure 7 - 20) for the amount to compress

springs.
Once the tramp release has occurred, according to

the displacement sensor signal, the hydraulic
control unit will ready itself for cylinder reset.
3) When springs are compressed the amount

specified, tighten tension rod jam nuts.
7 - 22

Hydraulic Unit Valve Pressure Adjustments
Toggle and Tension Cylinder Fast Reset After

Tramp Release
The fast reset is the follow-up movement after

tramp release. If the toggle cylinders stop their
retracting and the pistons do not bottom (according
to the signal from the displacement sensor), once
the tramp release is finished, the toggle cylinders
will need to be reset. Reset as outlined above in
CSS Decrease procedure.
If the toggle cylinders pistons bottom, or the
displacement sensor reading does not change and
motor current overloads when toggle cylinders are
resetting, it is a tramp release failure. To protect
the crusher and hydraulic unit, the crusher motor
should be shut down. Manual tramp release
should be performed.
8
The default system pressure setting is

24MPa (3481 psi). See (Figure 7 - 22)
The tension cylinder maximum pressure setting is
13MPa (1885 psi). See (Figure 7 - 22)
The toggle cylinder rod side default pressure
setting is 7 - 8MPa (1015 - 1160 psi) Generally
there is no need to adjust it. See (Figure 7 - 21)
The toggle cylinder piston side pressure should be
adjusted according to the material strength being
crushed. The adjustment range on the valve is
5.5 - 25MPa (798 - 3626 psi). See (Figure 7 - 21)
2
10
6
5
1
4
3
1 - Rod Side Pressure Setting

2 - Piston Side Pressure Setting
3 - Piston Side Connect Between Cylinders
4 - To Piston Side - From Valve
5 - To Rod Side - From Valve
6 - Piston Side Test Point
7 - Displacement Sensor (Inside)
8 - Rod Side Test Point
9 - Rod Side Connect Between Cylinders
10 - To Tank
1 - System Pressure Setting

2 - Tension Cylinder Pressure Setting
3 - Manual Unloading Relief Valve
Adjustment Manifold Valve Pressure Setting

Adjustment Toggle Cylinder and Valve
7 - 23

Toggle Cylinder Maintenance
2) Shut off hydraulic control unit.
Make sure all hoses, valves and fittings are

checked regularly.
DANGER
3) Open manual unloading relief valve to release

hydraulic pressure. See (Figure 7 - 22)
4) If pressure gauge reading is 0, close unloading
relief valve.
Extreme care should be taken due

to the toggle cylinder large oil
capacity and the hydraulic lock
valves.
5) If pressure is not 0, release the pressure by

carefully loosening pressure hose to the piston
side of cylinder.
If it becomes necessary to disconnect hoses, valves

or fittings from the cylinders, make sure to relieve
all hydraulic pressure before service.
6) Once pressure is relieved, make sure hoses,

valves and fittings are re-tightened.
Fully Hydraulic Toggle Electrical Schematic
1) Retract cylinders to the maximum CSS.
Figure 7 - 23 Fully Hydraulic Toggle Plate-Type Electrical Controls Schematic
7 - 24

Fully Hydraulic Toggle Hydraulic Schematic

.
A2
DT4 B2
DT3
21.1
A1 DT1
DT2 B1
14
20
23
17
13MPa
33
19
21.2
24MPa
16
13
18
22
DT6 B3
A3 DT5
32
P
I
DPI1 26
15
12
24.1
25.1
27.2
27.1
24.2
8MPa
29.2
29.1
25.2
28
31
30.1
PDS1
3, 4, 5, 6
9
Rod Side Chamber Pressure: 35-210Bar
10
Max. Pressure
25MPa, adjust as need
30.2
ST1
ST2
Piston Side Chamber

Pressure: 55-315Bar
11
1, 2
Specifications:
1 2 3 4 5 6 7 8 9 101112-
1. Rated Pressure: 25MPa

2. Rated Flow: 36L/min
3. Operation Voltage: 24V DC
4. Operation Hydraulic Oil Temp. : 605 C
5. Filtration: 10m
6. Tank Volume: 240L
7. Motor: 18.5 kW, 575V AC, 60HZ
Reservoir
13- Relief Valve
Cabinet
14- Solenoid Valve
Pump Motor Mount
15- Fitting
Pump Coupling
16- Gauge Hose
Gear Pump
17- Pressure Gauge
Pump Drive Motor
18- Manual Relief Valve
Hose
19- Relief Valve
Oil Return Filter
20- Hydraulic Lock
Reservoir Breather Cap
21- Solenoid Valve
Oil Level Gauge
22- Hose
Ball Valve
23- Accumulator
Valve Manifold
24- Hose
252627282930-
Tension Cylinder
Bi-directional Hydraulic Lock
Hose
Valve Manifold
Unidirectional Sequence Valve
Toggle Cylinder
(with Displacement Sensor)
31- Hose
32- Pressure Sensor
33- Check Valve
Figure 7 - 24 Fully Hydraulic Toggle Plate-Type Hydraulic Controls Schematic
7 - 25

Jaw Die Lifting Tools

For replacement or rotating jaw dies, it will be
necessary to have a sufficient lifting tool attached
to the dies. Trio manufactures its jaw dies with
wedge slots in each end to facilitate this lifting.
The following drawings give general illustrations
as to these lifting tool attachments.
See (Figure 7 - 25) and (Figure 7 - 26)
1 - Lifting Eye
2 - Steel Plate
3 - Wedge-Shaped
Steel Block
4 - Tack Weld Area
1
2
3
These tools may be fabricated locally. Contact

Trio for details regarding the lifting tools for your
specific size machine.
1 - Lifting Eye
2 - Steel Plate
3 - Wedge-Shaped
Steel Block
4 - Tack Weld Area
1
2
3
Figure 7 - 26 Typical Swing Jaw Die Lifting Tool

Arrangement
Figure 7 - 25 Typical Stationary Jaw Die Lifting Tool

Arrangement
7 - 26

Make sure wedge-shaped steel blocks are made

from at least 1 inch (25 mm) thick steel and lifting
eyes are large enough to hold the weight of the jaw
die.
The wedge-shaped steel blocks must be drilled and
tapped to accept the size threads of the lifting eye
used.
7 - 27
WARNING
When welding mild steel to
manganese jaw dies or cheek
plates, proper welding procedures
and standards are to be observed
(such as ASTM A128 / A128M).
In particular, use a stainless 310
welding rod (or equivalent), 5/32
inch (3.97 mm) in diameter; make a
number of passes rather than one
large pass; no pre-heating or afterwelding heating (keep welded
surfaces below 500F (260C);
follow all safety precautions when
lifting.

Cheek Plates
Cheek Plates
Upper Cheek Plate Removal
The cheek plates, in addition to acting as wear

liners for the crushing chamber, also hold the
stationary jaw die in place on the frame by pressing
on the sides of the die and holding it up tight
against the frame.
If the crusher is left to operate with loose cheek

plates, the stationary jaw will move, causing
excessive wear on the jaw and frame as well as
reducing the capacity of the crusher. To operate
properly, the cheek plates should be driven down
tight and the bolts be kept well tightened to hold
them firmly against the sides of the frame and the
stationary jaw.
DANGER
injury.
2) Install chains or slings to upper cheek plate
using holes on the top of plate or, if no holes
are present, fashion a hook and eye assembly
to fasten to each plate. This may require
welding a lifting hook or eye to the plate.
The crusher may have both upper cheek plates and

one or more lower cheek plates while other
crushers may have a single cheek plate on each
side (depending upon the crusher size). Generally
more wearing action occurs on the lower cheek
plates and they will have to be replaced more often
than the upper plates. Never allow the plates to
become worn completely through or let wear take
place on the crusher frame.
WARNING
Caution should be used during the

following procedures and proper
personal protection equipment and
tools are to be used to ensure
personnel and equipment safety.

lifting.
NOTICE
3) With a suitable lifting device, put slight

tension on chains or slings to keep cheek plate
in place.
CAUTION
Before replacement of cheek plates, it is

best to adjust the machine to its most open
adjustment setting as this will allow the
most room to work.
4) Remove bolts from cheek plate.
7 - 28

Cheek Plates
5) Remove upper cheek plate from crusher

frame. If it does not come free when bolts are
removed, it may be necessary to strike the
plate to jar it loose.
5) Remove lower cheek plate from crusher

frame. If it does not come free when bolts are
removed, it may be necessary to strike the
plate to jar it loose.
6) Set upper cheek plate aside.
6) Set lower cheek plate aside.
7) Repeat above procedure to remove each upper

plate.
7) Repeat above procedure to remove each lower

plate.
Lower Cheek Plate Removal
Installation of Lower Cheek Plate
1) Once upper cheek plate is removed, fashion a

hook and eye assembly to fasten to each lower
cheek plate. This may require welding a
lifting hook or eye to the plate.
Before installation of lower cheek plates into

crusher, make sure stationary jaw die is aligned
properly in the frame in relationship to swing jaw
die. For installation of stationary jaw, see
procedure in this section.
WARNING
lifting.
1) Fashion a hook and eye assembly to fasten to

each lower cheek plate. This may require
welding a lifting hook or eye to the plate.
WARNING
lifting.
2) Install chains or slings to lower cheek plate

using the hook or eye assembly fastened to
plate.
tension on chains or slings to keep cheek plate
in place.
2) Install chains or slings to lower cheek plate

plate.
4) Remove bolts from cheek plate.
7 - 29

Cheek Plates
3) With a suitable lifting device, lift cheek plate

into place in crusher frame.
4) Using a suitable driver and bar, drive plate
into place tight up against jaw die.
5) Install bolts and snug them up to keep plate in
place.
6) Using the same methods listed above, install
remaining lower cheek plate.
7) When both side lower cheek plates are in
place and tight against the stationary jaw die,
tighten all bolts to the proper torque.
8) With both lower cheek plates in place, proceed
to installation of upper cheek plates.
Installation of Upper Cheek Plate
1) Install chains or slings to upper cheek plate

using holes on the top.
2) With a suitable lifting device, lift cheek plate
into place.
3) Install bolts and snug them up to keep plate in
place.
4) Using a suitable driver, drive plate into place
tight up against jaw die.
5) Repeat above procedure to install each upper
plate.
6) When both side upper cheek plates are in
place and tight against the stationary jaw die,
tighten all bolts to the proper torque.
7) When all cheek plates are in place and tight,
remove crusher drive Lockout & Tagout.
7 - 30

Stationary Jaw Die
Tightening Cheek Plates
Cheek plates may become loose, permitting the

stationary jaw die to move and cause wear to both
the die and crusher frame. Check periodically to
make sure the cheek plates are tight against the
stationary jaw die. If the stationary jaw die moves
during crushing operation, the cheek plates should
be tightened. The following method permits
tightening of the lower plates without removing
the upper plates.
DANGER
injury.
2) Loosen bolts on the upper cheek plates until
they are loose enough to allow the plates to be
lifted up.
8) Using a suitable driver, drive upper plate

down until very tight against the jaw die.
9) Tighten bolts on the upper cheek plate to the
proper torque.
10) Repeat these steps for each side.
11) When all cheek plates are in place and tight,
remove crusher drive Lockout & Tagout.
Stationary Jaw Die

The stationary jaw die is locked in a rigid position
against the back of the crusher frame by the cheek
plates and tapered wedges at the top of the crusher
frame. See (Figure 7 - 27) The stationary jaw die
may be reversed by rotating it top-to-bottom to
gain additional wear life. The worn side of the jaw
die must not be allowed to wear too thin as this will
weaken that side of the die and could potentially
cause damage to the crusher.
3) With a suitable lifting device, lift upper cheek

plate approximately 1/2 inch (12.7 mm) and
place a piece of steel plate or bar as a spacer
between it and the lower cheek plate.
4) Loosen the lower cheek plate bolts slightly

until they are snug, but not tight, and will
allow the plate to be driven down.
5) Using a suitable driver, drive upper plate

down until the lower plate is driven down very
tight against the jaw die.
6) Tighten bolts on the lower cheek plate to the

proper torque.
1 - Stationary Jaw Die

2 - Stationary Jaw Die Wedges
3 - Cheek Plates
7) Remove the steel spacer from between the

plates.
Figure 7 - 27 Typical Stationary Jaw Die & Wedge

Arrangement
7 - 31

Stationary Jaw Die
Stationary Jaw Die Removal
WARNING
Failure to replace jaw dies when
corrugations are worn or running
crusher until die concave sections
are worn will reduce capacity of the
crusher. Jaw dies not replaced at
the proper time can cause
compaction of material in the
crushing chamber and could result
in premature bearing failure,
excessive toggle plate breakage or
other damage to crusher.
2) Cheek plates must be removed prior to

removal of the stationary jaw die. See
procedures in this section for removal.
the top of the stationary jaw die. See jaw die
lifting tool information in this section.
WARNING
lifting.
CAUTION
NOTICE
Before replacement of the stationary jaw
die, it is best to adjust the machine to its
most open adjustment setting as this will
allow the most room to work.
DANGER
injury.
4) Install chains or slings to stationary jaw die

die.
tension on chains or slings to keep jaw die in
place.
6) Loosen stationary jaw die wedge bolts and
hammer wedges toward center of crusher
frame to loosen the die.
7) Lower slightly the jaw die and move it toward
the pitman until it clears the crusher frame.
8) Lift the stationary jaw die out of the crusher
frame and set aside.
7 - 32

Stationary Jaw Die
3) Lift the jaw die enough to slide stationary jaw

die top over the wedges and so the bottom of
jaw die is up tight and seated on bottom of
crusher frame.
9) Remove the hook or eye assembly fastened to

the jaw die.
Stationary Jaw Die Rotation or Replacement
If stationary jaw die has enough wear life left to

accommodate rotating it, the hook or eye assembly
removed from it as described above should be
attached to the opposite end at the top. Use the
same steps also described above to fasten the hook
or eye assembly to the jaw die.
If stationary jaw die is to be replaced with a new
one, use the same steps also described above to
fasten the hook or eye assembly to the top of jaw
die.
Both the back of the jaw die and the mating surface
of the crusher frame must be clean and free of
debris before installation into crusher.
Stationary Jaw Die Installation
1) Install chains or slings to stationary jaw die

die.
4) Tighten wedge bolts on each side evenly just

enough to hold jaw die fully seated along the
bottom edge of crusher frame while making
sure the die is centered in the crusher frame.
5) Cheek plates can now be re-installed in the
crusher frame per procedures outlined in this
section.
6) Wedge bolts on each side can now be fully
tightened.
7) Check to make sure the bottom of the
stationary jaw die has remained fully seated
along the bottom edge of the crusher frame.
8) Once jaw die and cheek plates are in place,
remove the Lockout & Tagout.
2) With a suitable lifting device, lift jaw die into

crusher frame and lower it until the bottom of
the die slides over the bottom of the crusher
frame.
7 - 33

Swing Jaw Die
Swing Jaw Die
Swing Jaw Die Removal
The swing jaw die is held in position against the

face of the pitman by the swing jaw wedges bolted
through at the upper end of the pitman.See (Figure
7 - 28) There may be two types of pitman design,
one which has a replaceable lower wedge bolted to
the pitman or the wedge area machined into the
pitman itself. The swing jaw die may be reversed
by rotating it top-to-bottom to gain additional wear
life. The worn side of the jaw die must not be
allowed to wear too thin as this will weaken that
side of the die and could potentially cause damage
to the crusher.
3
WARNING
Failure to replace jaw dies when
corrugations are worn or running
crusher until die concave sections
are worn will reduce capacity of the
crusher. Jaw dies not replaced at
the proper time can cause
compaction of material in the
crushing chamber and could result
in premature bearing failure,
excessive toggle plate breakage or
other damage to crusher.
CAUTION
2
1
1 - Swing Jaw Die
2 - Swing Jaw Die Wedges
3 - Swing Jaw Bolts
Pitman Design Types
Figure 7 - 28 Typical Swing Jaw Die & Wedge

Arrangement
7 - 34

Swing Jaw Die
NOTICE
Before replacement of the swing jaw die, it
is best to adjust the machine to its most
open adjustment setting as this will allow
the most room to work.
3) Install chains or slings to swing jaw die using

the hook or eye assembly fastened to die.
tension on chains or slings to keep jaw die in
place.
5) Remove jaw die wedge bolts from through the
pitman and remove the jaw die wedge
block(s).
DANGER
DANGER

injury.
the top of the swing jaw die. See jaw die
lifting tool information in this section.
WARNING
lifting.
Care must be taken to stay clear of

inside of crusher while performing
jaw die replacement as falling jaw
die will result in death or severe
personal injury.
6) Lift the swing jaw die up off the pitman and
out of the crusher frame and set aside.
the jaw die.
7 - 35

Swing Jaw Die
Swing Jaw Die Rotation or Replacement
Check & Tighten Jaw Dies
If swing jaw die has enough wear life left to

accommodate rotating it, the hook or eye assembly
removed from it as described above should be
attached to the opposite end at the top. Use the
same steps also described above to fasten the hook
or eye assembly to the jaw die.
Both the stationary and swing jaw dies should be

checked periodically to make sure they are kept
tight within the crusher.
If swing jaw die is to be replaced with a new one,

use the same steps also described above to fasten
the hook or eye assembly to the top of jaw die.
Both the back of the jaw die and the mating surface
of the pitman must be clean and free of debris
before installation into crusher.
In addition to making sure the stationary jaw die

wedges are kept tight, the cheek plates must be
kept tight as well as described above in this
section. The wedge bolts should be checked daily
after a new die is installed due to the die stretching.
The swing jaw die wedge bolts have spring
washers installed to prevent the bolts from
breaking when the new die stretches. The bolts
should also be checked for tightness.
Swing Jaw Die Installation
1
1) Install chains or slings to swing jaw die using
the hook or eye assembly fastened to die.
2) With a suitable lifting device, lift jaw die into

crusher frame and lower it until the bottom of
the die slides over the bottom seating area of
the pitman.
3
1 - Wedge Block
2 - Retaining Bolt
3 - Spring Washers
3) Center the jaw die on the pitman.

4) Install the jaw die wedge block(s) and the
retaining bolts with spring washers through
the pitman and tighten to proper torque.
See (Figure 7 - 29)
the jaw die.
6) Once jaw die is in place, remove the Lockout
& Tagout.
Figure 7 - 29 Typical Swing Jaw Die Retaining Bolt

Arrangement
Re-adjust Crusher Setting
Once all jaw dies and/or cheek plates have been

replaced or rotated and tightened, then crusher
closed side setting should be re-adjusted to the
desired setting.
7 - 36

Toggle Plate
Toggle Plate
Toggle Plate Removal
The pitman is protected from damage by the toggle

plate. See (Figure 7 - 30) The toggle plate is
intended to bend or fracture if an uncrushable
object enters the crushing chamber, and thus opens
the chamber allowing the object to pass through. If
the toggle plate becomes damaged or wears out at
the seat areas, it will be necessary to replace it.
CAUTION
DANGER
injury.
DANGER
3

inside of crusher as well as
underneath the crusher while
performing
toggle
plate
replacement as falling plate will
injury.
1 - Tension Rod Spring

2 - Tension Rod
3 - Toggle Plate
Figure 7 - 30 Typical Jaw Tension Rod &Toggle Plate
Arrangement
2) Install chains or slings through toggle plate

and run up the back side of the pitman to
support toggle plate. See (Figure 7 - 31)
3) Loosen tension rod springs completely and
remove tension rods, springs and nuts from
machine.
4) Install chains or slings to pitman at the tension
rod connection point.
5) Move crusher adjustment wedges to
maximum possible open setting.
7 - 37

Toggle Plate
Hold & Lower Toggle Plate

tension on chains or slings to hold toggle plate
in place.
7) With a suitable device, pull pitman forward
and hold in place until toggle plate can be
lowered free from seats.
8) Lower toggle out of frame of machine until it
can safely be handled and set aside.
Pull Pitman Forward

Figure 7 - 31 Toggle Plate Removal
7 - 38

Toggle Plate
Toggle Plate Installation
CAUTION
DANGER
injury.
DANGER
performing
toggle
plate
replacement as falling plate will
injury.
2) Maintain the installed chains or slings to

pitman at the tension rod connection point as
in the removal procedure.
3) Place new toggle plate in an area close enough
so it can be lifted up into machine frame.
4) Install chains or slings through toggle plate
and run up the back side of the pitman to
support toggle plate. See (Figure 7 - 31)
5) With a suitable lifting device, lift toggle plate
into place taking care it is completely engaged
into upper seat in the frame.
6) With toggle plate fitted into upper seat, slowly
release pitman and allow it to move backward
to engage toggle plate into the lower seat.
7) Remove chains or slings from tension rod
attachment points.
8) Install tension rods, springs and nuts back
onto machine.
9) Re-adjust crusher to desired closed side
setting and re-set tension rod spring tension.
10) Finally, finish by removing Lockout & Tagout
of crusher drive.
7 - 39

Jaw Bearings
Jaw Bearings
Frame Bearing Removal
The jaw crusher is equipped with double row,

spherical roller, self-aligning bearings. Both
frame and pitman bearings are protected against
loss of lubricant and entrance of dirt, sand and grit
by labyrinth-type grease seals.
When bearings are determined to need

replacement, it is recommended to remove as
much of the lubricant from the bearing housings by
draining them while still warm from operation.
The following procedures should then be
followed:
12
11
10
7 8
CAUTION
9
16 17
15

DANGER
3
injury.
13
14
6
5
DANGER
123456789-
Flywheel/Drive Sheave
Outside Seal
Lock Nut
Lock Washer
Frame Bearing Housing
Crusher Frame
Frame Bearing
Withdrawl Sleeve
Frame Bearing Cover
1011121314151617-
Pitman Seal
Pitman Bearing Cover
Pitman Bearing
Grease Keeper
Pitman
Pitman Shaft
Ringfeder
Pitman Cover
Figure 7 - 32 Typical Jaw Bearing Arrangement

performing bearing replacement as
falling parts will result in death or
severe personal injury.
2) Mark the flywheel/drive sheave and pitman
shaft so it can be re-installed in the same
location.
3) Install appropriate lifting slings and use an
adequate lifting device to support flywheel/
drive sheave.
7 - 40

Jaw Bearings
4) Remove pitman shaft cover and remove

ringfeder that retains flywheel/drive sheave to
pitman shaft. See (Figure 7 - 32)
5) Remove flywheel/drive sheave from shaft and
set aside.
6) Slide outside seal and key off of pitman shaft
and set aside.
7) Remove the frame bearing cover from the
frame bearing housing and set aside. This will
expose the bearing lock nut and lock washer
that retains the frame bearing to the pitman
shaft.
8) The pitman housing should now be supported
by an adequate method of blocking or lifting
so the pitman shaft will not drop or lower
during the next steps.
12) Using a spanner wrench or suitable special

tool, tighten the withdrawl nut against the
frame bearing to force the withdrawl sleeve
from between the pitman shaft and frame
bearing inner race. Remove the sleeve and nut
and set aside.
13) With adequate lifting device and slings to
support the frame bearing housing, slide the
bearing housing with the bearing out off of the
pitman shaft.
14) The frame bearing will now be able to be
removed from the housing.
15) Place the frame bearing housing on suitable
blocking and push bearing out of housing
using a press, dead blow hammer or other
appropriate driver. See (Figure 7 - 33)
9) Once the pitman is supported, remove the

bolts holding the frame bearing housing to the
crusher frame.
10) Straighten the lock washer tab(s) on the
bearing lock nut then remove the nut and
washer with a spanner wrench or suitable
special tool.
11) Install a withdrawl nut (not shown) onto the
withdrawl sleeve on the frame bearing.
Figure 7 - 33 Frame Bearing Removal From Housing
16) Clean and inspect all parts to replace as

necessary.
7 - 41

Jaw Bearings
Frame Bearing Installation
Replacement with a new bearing requires

determining the bearings unmounted radial
internal clearance before installation.
See (Figure 7 - 34)
This clearance measurement should be taken and
recorded to be referenced later when setting
bearing final clearance after mounting in crusher.
Feeler Gauge Blade
Internal
Clearance
4) Install the withdrawl sleeve onto pitman shaft

and slide it into bearing inner race as far as
possible.
5) At this time, install the lock nut without the
lock washer and screw the nut up snug against
the withdrawl sleeve.
6) Using a spanner wrench or suitable special
tool, tighten the lock nut against the withdrawl
sleeve until the final bearing clearance
measurement is reached. See the following
tables for reduction in unmounted clearance as
well as the final mounted clearance listed by
machine model.
Table 7 - 3 Frame Bearing Reduction in Radial
Internal Clearance
Jaw
Model
Figure 7 - 34 Jaw Bearing Radial Internal Clearance

Measurement
1) After recording unmounted bearing radial

internal clearance described above, install
bearing into frame bearing housing.
2) With adequate lifting device and slings to
support the frame bearing housing, slide the
bearing housing with the bearing onto the
pitman shaft taking care that labyrinth seal
fingers are aligned and slide toghether with no
interference.
3) Bolt frame bearing housing securely to
crusher frame and tighten bolts.
7 - 42
Min.
Max.
mm
in.
mm
in.
CT1030
0.08
0.0031
0.11
0.0043
CT1040
0.08
0.0031
0.11
0.0043
CT1048
0.09
0.0035
0.13
0.0051
CT1252
0.10
0.0039
0.14
0.0055
CT2036
0.10
0.0039
0.14
0.0055
CT2436
0.11
0.0043
0.15
0.0059
CT2645
0.11
0.0043
0.15
0.0059
CT3042
0.15
0.0059
0.21
0.0083
NCT3042
0.12
0.0047
0.17
0.0067
CT3254
0.15
0.0059
0.21
0.0083
CT3648
0.17
0.0067
0.23
0.0091
CT4254
0.17
0.0067
0.23
0.0091
CT4763
0.21
0.0083
0.28
0.0110
CT6080
0.21
0.0083
0.28
0.0110

Jaw Bearings
Table 7 - 4 Frame Bearing Allowable Final Mounted

Clearance
Jaw
Model
Min.
10) Install the frame bearing cover and tighten

bolts to secure it to the frame bearing housing.
Max.
mm
in.
mm
in.
CT1030
0.10
0.0040
0.18
0.0071
CT1040
0.10
0.0040
0.18
0.0071
CT1048
0.10
0.0040
0.20
0.0079
CT1252
0.12
0.0045
0.22
0.0087
CT2036
0.12
0.0045
0.22
0.0087
CT2436
0.13
0.0050
0.24
0.0094
CT2645
0.13
0.0050
0.24
0.0094
CT3042
0.17
0.0065
0.32
0.0126
NCT3042
0.14
0.0055
0.27
0.0106
CT3254
0.17
0.0065
0.32
0.0126
CT3648
0.19
0.0075
0.35
0.0138
CT4254
0.19
0.0075
0.35
0.0138
CT4763
0.23
0.0090
0.42
0.0165
CT6080
0.23
0.0090
0.42
0.0165
Example: Model CT1030

Unmounted clearance = 0.010 in.
Minus max. reduction = 0.0043 in.
Equals - 0.0057 in.
This falls within the min. of 0.0040 in. and
the max. of 0.0071 in.
9) Re-check the bearing mounted clearance again

to make sure the proper clearance was
maintained.
11) Install the outside seal and key onto the

pitman shaft making sure the labyrinth seal
fingers are aligned and slide together with no
interference.
12) Using appropriate lifting slings and an
adequate lifting device, re-install the flywheel/
drive sheave and ringfeder onto the pitman
shaft using the marks made during
disassembly.
13) Re-tighten the ringfeder to lock the flywheel/
drive sheave onto the pitman shaft.
14) Re-install the pitman cover on the end of the
shaft and tighten bolts.
15) Remove blocking or supports from under the
pitman used to hold it in place.
16) Replenish grease into the bearing and seals
using the appropriate quantity as described in
the tables in the Lubrication Section of this
manual.
crusher drive.
Crusher should now be ready to re-start.
6) Once the bearing clearance has been reached,

remove lock nut, install the lock washer and
lock nut back on shaft.
7) Re-tighten lock nut.
8) Bend a tab of the lock washer into one of the
slots in the lock nut.
7 - 43

Jaw Bearings
Pitman Bearing Removal
To remove and replace pitman bearings it will be

necessary to remove the pitman and shaft
assembly from the crusher frame.
When bearings are determined to need
replacement, it is recommended to remove as
much of the lubricant from the bearing housings by
draining them while still warm from operation.
The following procedures should then be
followed:
CAUTION
DANGER
injury.
DANGER
performing bearing replacement as
falling parts will result in death or
severe personal injury.
2) Using the procedure shown earlier in this

section, remove the toggle plate from the
crusher.
3) Mark the flywheel/drive sheave and pitman
shaft so it can be re-installed in the same
location.
adequate lifting device to support flywheel/
drive sheave.
5) Remove pitman shaft cover and remove
ringfeder that retains flywheel/drive sheave to
pitman shaft. See (Figure 7 - 32)
6) Remove flywheel/drive sheave from shaft and
set aside.
7) Slide outside seal and key off of pitman shaft
and set aside.
8) Repeat this for the opposite side flywheel/
drive sheave so that both sides have been
removed.
adequate lifting device to support the entire
pitman and shaft assembly.
10) Once the pitman and shaft assembly is
supported, remove the bolts holding both side
frame bearing housings to the crusher frame.
11) Once the bolts are removed, lift the pitman
and shaft assembly from the crusher frame.
See (Figure 7 - 35)
7 - 44

Jaw Bearings
16) Remove bolts from both pitman bearing

covers, remove covers and set aside. See
(Figure 7 - 37)
Figure 7 - 35 Pitman and Shaft Assembly Removal

From Crusher Frame
12) Lift pitman and shaft assembly and place it

onto cribbing or platform on the ground.
See (Figure 7 - 36)
Figure 7 - 37 Pitman Bearing Covers
17) Next, support pitman shaft at outer ends and

fasten slings from a suitable lifting device.
18) While supported, press shaft with bearings
through and out of the bore of the pitman
housing. See (Figure 7 - 38)
Figure 7 - 36 Pitman and Shaft Assembly Placed on

Ground
13) The frame bearings and housings will now be

able to be removed from the pitman shaft
using the procedure found earlier in this
section.
14) Once the frame bearings and housings are
removed from the shaft, proceed to the next
steps to remove the shaft with bearings from
the pitman housing.
15) Remove pitman seals from the shaft.
Figure 7 - 38 Pitman Shaft and Bearings Being Pressed
from Housing
7 - 45

Jaw Bearings
19) Place shaft with bearings onto suitable

cribbing or platform supported at the outer
ends of the shaft. See (Figure 7 - 39)
Pitman Bearing Installation
Replacement with a new bearing requires

determining the bearings unmounted radial
internal clearance before installation.
See (Figure 7 - 41)
This clearance measurement should be taken and
recorded to be referenced later when checking
bearing final clearance after mounting in the
pitman housing.
Figure 7 - 39 Pitman Shaft and Bearings Removed from

Housing
Thoroughly clean the pitman housing, shaft and all

parts that are to be re-used.
20) Press or pull each bearing and grease keeper

from shaft while maintaining support on the
shaft. See (Figure 7 - 40)
Feeler Gauge Blade
Internal
Clearance
Figure 7 - 40 Pitman Shaft Bearings Being Pressed Off

Shaft
21) To fully remove each bearing and grease

keeper from the shaft, it will be necessary to
lift each end of the shaft from its support so
bearings and grease keepers can be slid off
shaft.
Figure 7 - 41 Jaw Bearing Radial Internal Clearance

Measurement
7 - 46

Jaw Bearings
1) Lift and slide grease keepers onto shaft

making sure they seat fully against the
machined surfaces of the shaft.
See (Figure 7 - 42)
Figure 7 - 43 Pitman Shaft Bearings On Shaft
Figure 7 - 42 Pitman Shaft Grease Keepers On Shaft
2) Bearing installation onto the shaft will be

easier if they are first heated to expand
slightly. The bearings can be heated using
several methods. One method is using an oil
bath. Maximum temperature of the oil bath
should not exceed 120 C (250 F).
4) With adequate lifting device and slings lift the

shaft assembly and start the bearing into the
pitman housing bore, making sure it is square
with the face of the pitman housing.
5) Apply pressure on the shaft assembly and
press it into the pitman housing until each
bearing race is the same distance from the
edge of the pitman housing.
See (Figure 7 - 44)
NOTICE
Bearings should be allowed to heat
long enough to fully expand. Do
not allow bearings to come into
direct contact with the heat source.
3) With adequate lifting device and slings lift
each of the heated bearings into place against
the grease keepers and hold them firmly in
postition until they cool enough to seat on the
shaft. See (Figure 7 - 43)
Figure 7 - 44 Pitman Shaft and Bearings Pressed into

Housing
7 - 47

Jaw Bearings
6) Measure each bearings internal installed

clearance to assure that the bearings have the
proper amount of clearance once installed.
See (Table 7 - 5)
Table 7 - 5 Pitman Bearing Radial Internal Installed
Clearance
Jaw
Model
Min.
7) Using the proper type grease shown in the

tables in the Lubrication Section of this
manual, inject grease into the voids between
the rollers in the bearing, making certain that
it is forced into the center of the bearing. Note
the amount of grease injected into each of the
pitman bearings.
8) Install each side pitman bearing cover and
torque bolts to proper torque.
See (Figure 7 - 45)
Max.
mm
in.
mm
in.
CT1030
0.20
0.0079
0.26
0.0102
CT1040
0.20
0.0079
0.26
0.0102
CT1048
0.20
0.0079
0.26
0.0102
CT1252
0.22
0.0087
0.29
0.0114
CT2036
0.24
0.0094
0.32
0.0126
CT2436
0.26
0.0102
0.35
0.0138
CT2645
0.26
0.0102
0.35
0.0138
CT3042
0.31
0.0122
0.41
0.0161
NCT3042
0.26
0.0102
0.35
0.0138
CT3254
0.31
0.0122
0.41
0.0161
CT3648
0.34
0.0134
0.45
0.0177
CT4254
0.37
0.0146
0.50
0.0197
9) Re-install pitman seals onto shaft.
CT4763
0.41
0.0161
0.55
0.0217
CT6080
0.44
0.0173
0.60
0.0236
10) Re-install frame bearings onto shaft using

procedures shown earlier in this section.
Figure 7 - 45 Pitman Bearing Covers Installed
7 - 48

Jaw Bearings

adequate lifting device to support the entire
pitman and shaft assembly.
12) Lift pitman and shaft assembly into crusher
frame, align frame bearing housings with
crusher frame and install bolts.
See (Figure 7 - 46)
13) Torque frame bearing housing bolts to proper

torque.
14) Reinstall each side flywheel/drive sheave
using the procedures shown earlier in this
section.
15) Reinstall toggle plate using the procedures
shown earlier in this section.
16) Once pitman and shaft is re-assembled into the
crusher, complete grease replenishment into
each pitman and frame bearing and seals using
the quantities listed in the tables in the
Lubrication Section of this manual. Take into
consideration also the amount of grease put
into each pitman bearing initially.
crusher drive.
Crusher should now be ready to re-start.
Figure 7 - 46 Pitman and Shaft Assembly Installed Into

Crusher Frame
7 - 49

Jaw Bearings
7 - 50

Torque Charts
Appendix A - Torque Specs
maximum torque values are based on 75% of the

specified minimum proof strength of the bolt steel
in order to provide a safety factor. The term "lube"
applies to cadmium plating and/or application of
thread lubricants. Hardened washers should
always be used, regardless of whether standard
nuts or lock nuts are employed.
Torque Charts
The following pages contain charts for use as
guides when tightening bolts and nuts. These
specifications should be followed unless specific
torques are given elsewhere in this manual.
Metric Bolt Torque

Standard Bolt Torque
Table A - 2 is a list of torque values recommended

for metric bolts. The maximum torque values are
based on 75% of the specified minimum proof
strength. The term "lube" includes the application
of thread lubricants, cadmium plating and the use
of hardened washers regardless of whether
standard or lock nuts are used.
Table A - 1 is a list of recommended torque values

for standard bolts. Use this torque chart to avoid
overstressing standard nuts and bolts used on
equipment. These specifications should be
followed unless specific torques are given. Trio
uses various bolts Grades 2, 5, and 8. The
A-1

Torque Charts
Standard Bolt Torque Chart

S.A.E Grade 2
dia.
(in.)
Dry
pitch
(thd/in.) (ft-lbs) N-M
S.A.E Grade 5
Lube
Dry
S.A.E Grade 8
Lube
Dry
Lube
(ft-lbs)
N-M
(ft-lbs)
N-M
(ft-lbs)
N-M
(ft-lbs)
N-M
(ft-lbs)
N-M
1/4
20
11
12
16
12
1/4
28
10
14
14
19
11
15
5/16
18
11
15
12
17
23
13
18
25
34
19
26
5/16
24
12
16
10
14
19
26
15
20
27
37
21
28
3/8
16
20
27
15
20
31
42
24
33
44
60
34
46
3/8
24
23
31
17
23
35
47
27
37
49
66
38
52
7/16
14
32
43
25
34
49
66
38
52
70
95
54
73
7/16
20
36
49
27
37
55
75
42
57
78
106
60
81
1/2
13
49
66
38
52
75
102
58
79
106
144
82
111
1/2
20
55
75
42
57
85
115
65
88
120
163
92
125
9/16
12
70
95
54
73
109
148
84
114
154
209
118
160
9/16
18
79
107
60
81
121
164
93
126
171
232
132
179
5/8
11
97
132
75
102
150
203
115
156
212
287
163
221
5/8
18
110
149
85
115
170
231
131
178
240
325
185
251
3/4
10
157
213
121
164
266
361
205
278
376
510
289
392
3/4
16
180
244
133
180
297
403
229
311
420
570
323
438
7/8
210
285
160
217
430
583
330
447
606
822
466
632
7/8
14
230
312
177
240
473
641
364
494
668
906
514
697
320
434
240
325
644
873
495
671
909
1233
699
948
14
340
461
255
346
704
955
542
735
995
1349
765
1037
1-1/8
350
475
270
366
794
1077
611
829
1288
1747
990
1342
1-1/8
12
395
536
305
414
891
1208
685
929
1445
1959
1111
1507
1-1/4
495
671
380
515
1120
1519
862
1169
1817
2464
1398
1896
1-1/4
12
550
746
425
576
1241
1683
954
1294
2012
2728
1548
2099
1-3/8
655
888
500
678
1469
1992
1130
1532
2382
3230
1832
2484
1-3/8
12
745
1010
570
773
1673
2269
1287
1745
2712
3677
2086
2829
1-1/2
865
1173
665
902
1949
2643
1500
2034
3161
4286
2432
3298
1-1/2
12
975
1322
750
1017
2194
2975
1687
2288
3557
4823
2736
3710
1-3/4
1370
1857
1055
1430
2286
3100
1758
2384
4988
6764
3837
5203
4.5
2060
2793
1585
2149
3438
4662
2644
3585
7500
10170
5769
7823
2-1/4
4.5
3015
4088
2320
3146
5027
6817
3867
5244
10969 14874
8438
11442
2-1/2
4125
5593
3170
4298
6875
9323
5288
7171
15000 20340 11538 15646
2-3/4
5590
7579
4300
5830
9321
12639
7170
9723
17794 24129 13688 18561
7385
10013
5680
7701
12313 16696
9472
12844 23507 31875 18082 24519
Table A - 1: Torque Values for Standard Hardware
A-2

Torque Charts
Metric Bolt Torque Chart

Property Class = 8.8
Dry
dia pitch
(mm) (mm) (ft-lbs) N-M
Lube
Dry
Lube
Dry
Lube
(ft-lbs)
N-M
(ft-lbs)
N-M
(ft-lbs)
N-M
(ft-lbs)
N-M
(ft-lbs)
N-M
6.9
9.3
5.2
9.7
13.2
7.3
9.9
11.6
15.7
8.7
11.8
17.7
23.9
13.3
18
24.9
33.8
18.7
25.4
29.8
40.4
22.4
30.4
10
1.5
30
41
24
32
44
60
34
46
52
71
40
54
10
1.25
32
43
24
33
46
63
36
49
55
74
42
57
12
1.75
53
72
41
55
77
105
60
81
91
123
70
95
12
1.25
58
78
44
60
85
115
65
88
99
134
76
103
14
85
115
65
88
124
168
95
129
145
196
111
151
14
1.5
91
124
70
95
134
181
103
139
156
212
120
163
16
131
178
101
137
192
260
148
200
225
305
173
234
16
1.5
140
190
108
146
204
277
157
213
240
325
184
250
18
2.50
181
246
139
189
265
359
204
276
311
421
239
324
18
1.5
204
276
156
212
297
403
229
310
349
473
268
364
20
2.5
256
347
197
267
374
507
288
390
439
595
338
458
20
1.5
284
385
218
296
415
563
319
433
487
660
375
508
22
2.5
349
473
268
364
510
692
392
532
599
812
460
624
22
1.5
383
519
294
399
560
759
431
584
657
891
505
685
24
443
600
340
461
647
877
497
674
759
1029
583
791
24
482
654
371
503
705
956
543
736
828
1122
637
863
27
648
879
499
676
949
1286
729
989
1112
1508
856
1160
27
700
949
538
730
1023
1387
787
1067
1200
1627
923
1252
30
985
1335
741
1004
1389
1883
1044
1416
1665
2257
1252
1697
36
1716
2326
1290
1749
2419
3280
1819
2466
2900
3931
2180
2956
42
2753
3732
2070
2806
3882
5263
2919
3957
4652
6307
3498
4742
48
4156
5634
3124
4236
5860
7944
4406
5973
7023
9521
5280
7159
56
6662
9032
5009
6791
9393
12735
7063
9575
11259 15264
8465
11477
64
9954
13496
7484
10147 14035 19028 10553 14307 16822 22807 12648 17148
72
14410 19536 10835 14689 20319 27547 15277 20712 24353 33016 18310 24824
Table A - 2: Torque Values for Metric Hardware
A-3

Torque Charts
A-4

General Belt Care
Appendix B - V-Belt Drive

Information
5) Do not overtighten belts. Overtightening

shortens the useful life of belts and sheaves.
This can also cause premature bearing
failures. Ideal belt tension is the lowest at
which belts wont slip under peak loads.
General Belt Care

V-belts achieve more service life if kept clean and
dry. Rock dust and rust from metals are abrasive.
Oils and acids deteriorate belt material. Dust and
moisture on belts can cause slippage. Dust buildup
in sheaves can cause harmful vibration.
6) Periodically inspect v-belt drives for wear on

belts or sheaves. See (Figure B - 1) and
(Figure B - 2) Replace worn sheaves.
Worn
Sheave
Belt dressing compounds are available and are

sometimes used for various reasons. While they
may be used, belt dressing may actually shorten
belt life. Clean, well cared for belts are the best
way to care for belt problems. Daily cleaning of
belts and sheaves by blowing them off with
compressed air can increase their useful life.
Worn Belt
or Sheave
Normal
Store un-used belts in a cool and dry environment

with no direct sunlight. Store on shelves or in
original containers. Do not allow belts to be bent
to diameters smaller that what is recommended for
the belt cross section.
Figure B - 1 Typical Belt & Sheave Wear
General Belt Recommendations

1) Keep belts and sheaves clean.
2) Avoid belt or sheave rubbing. Dont let belts
or sheaves rub against a guard (or anything
else) while they are running.
3) Drive belts with motors mounted on
adjustable bases. This allows convenient and
proper installation of belts without prying on
belts.
4) Keep belts properly tightened. Most belt
stretch occurs in the first 30-40 hours of
operation. Check belt tension frequently
during this period.
Figure B - 2 Sheave Gauge Shows Wear
B-1

Belt Drive Troubleshooting
8) If a drive uses multiple belts, use only

matched belts. A matched set of belts last
longer and loading is evenly divided among
all the belts. Belts from different
manufacturers should not be mixed in a set
because material differences could reduce belt
life. Always replace belts in full sets.
7) Keep belts straight. Dont allow v-belts to run

out of alignment. To run properly, sheaves
must be parallel and grooves must be in line.
See (Figure B - 3)
9) Dont overload belts. If the drive has 10

sheave grooves, use 10 belts. Using less than
the designed number puts stress on the
remaining ones. This can cause premature
failure.

Good maintenance practices should help you
experience minimal trouble with belts and
sheaves, however there may be times when
troubles are experienced. The following table can
be used as a troubleshooting tool.
Figure B - 3 Sheave Alignment
B-2

Table B - 1 Belt Drive Troubleshooting

Trouble
Cause
Correction
Belt Slip (sidewalls glazed)
Insufficient tension
Replace belts; increase tension
Drive squeals
Overloaded drive
Arc of contact too short
Heavy starting load
Find cause and correct

Increase distance between hubs
Increase tension
Broken cord caused by prying

Overloaded drive
Impulse loads
Replace belt correctly

Redesign drive
Apply proper tension
Misalignment
Worn sheave grooves
Flat idler sheave
Realign drive
Replace sheave
Align and reposition
Excessive vibration
Check drive design, mounting

Consider banded belts
New belts installed with old
Replace belts with matched set
Sheave grooves worn unevenly

Improper groove angle
Replace sheaves
Shafts not parallel
Align drive
Shock loads
Heavy starting load

Use compensator starting
Belt pried over sheaves

Foreign object in drive
Replace belt correctly

Determine source of object,
design guard to correct problem
Sheave grooves worn

Sheave diameter too small
Mismatched belts
Drive overloaded
Belt slips
Sheaves misaligned
Oil present
Excessive heat present
Replace sheaves
Redesign drive
Replace with matched set
Redesign drive
Increase tension
Align sheaves
Eliminate oil
Ventilate drive
Belts roll over
Mismatched belts
Belt breaks
Belt wears prematurely
B-3

Maintaining V-Belt Tension
1/64 inch per each inch of span length.

Example:
For a 100 inch span, the deflection would be
100/64, or approximately 1-1/2 inches.
V-belt tension must be maintained to provide

proper drive effectiveness. The following method
of tensioning v-belts has been established as an
acceptable and preferred method.
4) Compare the force measurement to the

recommended ranges shown in (Table B - 2)
below for the appropriate belt cross section
type shown in.
Tension-Deflection Method
1) Place a straightedge across the top of both

sheaves. See (Figure B - 4)
5) Tighten or loosen belt to bring it into the

recommended range.
2) Measure the span length.
6) When installing new belts, tighten them to

Initial Installation tension. This tension will
drop during the run-in period.
3) Using a spring scale at right angle to belt at

1/2 of span length, apply a force to the scale
on one of the belts enough to deflect the belt
1
2
3
7
9
8
6
1 - Straightedge
5 - Motor Drive Sheave
2 - Span Length
6 - V-belt
3 - 1/2 Span
7 - Spring Scale
4 - Deflection Measurement - 1/64 Inch for each

Inch of Span Length
8 - Force Measurement
9 - Driven Sheave
Figure B - 4 Tension-Deflection Diagram
B-4

Table B - 2 Belt Deflection Forces

Recommended Belt Deflection Force (Pounds)
V-Belt
Cross
Section
Smallest Sheave
Diameter Range
(Inches)
Initial
Installation
- 3.0
3.1 - 4.0
4.1 - 5.0
5.1 -
Retensioning
Maximum
Minimum
3.6
4.2
5.2
6.1
3.1
3.6
4.6
5.3
2.4
2.8
3.5
4.1
- 4.6
4.7 - 5.6
5.7 - 7.0
7.1 -
7.3
8.7
9.3
10.0
6.4
7.5
8.1
8.8
4.9
5.8
6.2
6.8
- 7.0
7.1 - 9.0
9.1 - 12.0
12.1 -
12.5
15.0
18.0
19.5
10.7
13.0
16.3
16.9
8.2
10.0
12.5
13.0
12.0 - 13.0
13.1 - 15.5
15.6 - 22.0
25.5*
30.0*
32.0*
22.1
26.0*
28.0*
17.0
20.0
21.5
18.0 - 22.0
22.1 -
45.0*
52.5*
39.0*
45.5*
30.0*
35.0*
AX
- 3.0
3.1 - 4.0
4.1 - 5.0
5.1 -
5.1
5.5
6.0
6.7
4.4
4.8
5.2
5.9
3.4
3.7
4.0
4.5
BX
- 4.6
4.7 - 5.6
5.7 - 7.0
7.1 - 12.0
10.0
11.0
11.5
10.1
8.7
9.5
9.9
7.8
6.7
7.3
7.6
CX
- 7.0
7.1 - 9.0
9.1 - 12.0
12.1 -
18.0
19.5
20.0
21.0
15.6
16.9
17.6
18.2
12.0
13.0
13.5
14.0
3V
2.65 - 3.35
3.65 - 4.50
4.75 - 6.0
6.5 - 10.6
4.6
5.5
6.4
7.3
4.0
4.8
5.6
6.4
3.1
3.7
4.3
4.9
5V
7.1 - 10.3
10.9 - 11.8
12.5 - 16.0
16.5
19.5
21.0
14.3
16.9
18.2
11.0
13.0
14.0
8V
12.5 - 16.0
17.0 - 20.0
21.2 - 24.4
39.0*
45.0*
51.0*
33.8*
39.0*
44.2*
26.0*
30.0*
34.0*
3VX
2.2 - 2.5
2.65 - 4.75
5.0 - 6.5
6.9 -
4.8
5.7
7.2
8.7
4.2
4.9
6.2
7.5
3.2
3.8
4.8
5.8
5VX
- 5.5
5.9 - 8.0
8.5 - 10.9
11.8 -
15.0
19.0
21.0
22.0
13.0
16.9
18.2
19.5
10.0
13.0
14.0
15.0
* Note: For banded belts, multiply the force in table by

the number of belts in the band.
B-5

Belt Type Cross-Sections
Belt Type Cross-Sections
Backside Idler
A backside idler increases the arc of contact on

both sheaves. However, it forces a backward bend
in the v-belt that can contribute to premature
failure. The idler puts additional stress on the
bottom portion of the belt which will result in
bottom cracking. If a backside idler must be used,
the diameter should be at least 1 - 1/2 times the
diameter of the small sheave. It should also be
located as close as possible to the small sheave.
Figure B - 5 Belt Type Cross-Sections

Figure B - 7 Backside Idler
Belt Idlers
Kiss Idler
A properly designed v-belt drive does not require

and idler to deliver full horsepower if proper belt
tension can be maintained. Idlers should be
avoided if possible because it puts additional
bending stress points on the belt. Due to drive
design parameters, idlers are sometimes used. The
following are general descriptions of the types of
idlers that may be used.
A kiss idler differs from the backside idler because

the kiss idler does not penetrate the belt span and
create a backward bend on the belt. A kiss idler
does not contribute to premature belt failure. Use
of a kiss idler can help control belt vibration and
whip on drives subject to shock and pulsating
loads. If a kiss idler is used, the diameter should
be at least 1 - 1/2 times the diameter of the small
sheave.
Inside Idler
A v-grooved idler located on the inside of the belts

on the slack side of drive would be recommended
over a backside idler. The idler should be located
near the large sheave to minimize reduction of the
arc of contact on the small sheave. The diameter
should be equal to or larger than that of the small
sheave.
Figure B - 8 Kiss Idler
Figure B - 6 Inside Idler
B-6
Trio Engineered Products, Inc. 12823 Schabarum Ave. Irwindale, CA 91706 Telephone 626-851-3966 Fax 626-851-9526
CT Series 30 x42A
Jaw Crusher
Parts Manual
30 x 42
Size:
Serial Number:
CT3042-346-AU1078
2015.12.08
CT3042A Jaw Crusher Manual
Parts: Jaw Crusher(With Drive)
CT3042AJaw Crusher Manual
Parts List
Item
Part #
Description
QTY. STOCK CODE
CT3042A-AU1078
30"42" Jaw Crusher(With Drive)
C3042A.00
CT3042 Jaw Crusher Assembly
101711000
T7510-1
Fixed Jaw Die
301701053
T7510-6
Swing Jaw Die
301701058
C3042FHZ.3
Guard For Sheave
301711008
C3042FHZ.4
Guard For Flywheel
301711009
GB13575.2
V-Belt 25N 6980mm
424001185
NEP447T-6
Motor 150HP/460V/60HZ +5000m
421300032
GB5782-zn/M2090/GD8.8
Bolt M2090
401022055
GB93/20
Lock Washer 20
403015010
10
GB97.1/20
Washer 20
403020008
11
GB6170-zn/M20/GD8
Nut M20
402011006
12
CMS132A.2
Motor Mount
101750074
13
CT.APP.WEG.6
Hydraulic Unit
102000251
14
T7510P-2
Drive Sheave
101750013
15
T7510P-3
Bushing
101750014
16
GB5782-zn /M16220/GD8.8
Bolt M16220
401022090
17
GB93/16
Lock Washer 16
403015008
Parts: Tension Rod and Toggle Plate Assembly

Illustration
The following illustration identifies the essential parts comprising the tension rod and toggle
seat assembly.
Parts List
Item
Part #
Description
QTY. STOCK CODE
41
T7510-15
Guard
101701070
42
GB5782-zn/M2465/GD8.8
Bolt For Guard
401022098
43
GB7244/24
Lock Washer For Guard
403005005
44
T7510-29
Tension Rod
101701084
45
GB6170-zn/M48/GD8
Nut For Tension Rod
402011016
46
GB56-zn/M48/GD8
Nut For Tension Rod
402009010
47
T7510-30A
Spring Keeper (Upper)
101701086
48
T7510-31
Spring
301701087
49
T7510-32A
Spring Keeper (Lower)
101701089
52
C3042A-1
Buffer (Upper)
101711002
53
T7510-34A
Buffer Retainer For Buffer (Upper)
101701093
54
GB70.1-zn/M2465/GD8.8
Bolt For Buffer (Upper)
405009056
55
T7510-35
Limit Plate
101701094
56
GB5782-zn/M1645/GD8.8
Bolt M1645
401022025
57
GB93/16
Lock Washer 16
403015008
58
T7510A-12
Rubber Dust Cover
101710004
59
T7510-14
Rubber Clamping For Rubber Dust Cover
101701069
60
GB5782-zn/M1030/GD8.8
Bolt For Rubber Dust Cover
401022143
61
GB93/10
Lock Washer For Rubber Dust Cover
403015005
62
T7510-38
Pin Shaft For Tension Rod
301701097
63
1380-49
Washer
301301146
64
GB91-zn/870
Split Cotter For Tension Rod
410011026
65
T7510-11B
Toggle Plate
101701066
102
T7510-36
Rubber Dust Apron
101701095
103
T7510-37
Clamping Plate For Rubber Dust Apron
101701096
104
GB93/10
Lock Washer For Rubber Dust Apron
403015005
105
GB5782-zn/M1030/GD8.8
Bolt For Rubber Dust Apron
401022143
106
C3042A.DE-1
Buffer (Lower)
101711003
107
T7510.6-2
Buffer Retainer For Buffer (Lower)
101701048
108
GB70.1-zn/M1025/GD8.8
Bolt M1025
405011006
Parts: Bearings and Eccentric Shaft Assembly

Illustration
The following illustrations identify the essential parts of the bearing and eccentric shaft assembly.
Parts List
Item
12
13
14
15
16
17
18
19
20
21
22
23
24
25
69
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
(86)
99
100
101
Part #
T7510A.3
T7510.4A
T7510-16
GB1972/A80-2
GB6170-zn/M36/GD8
T7510A.5
GB5867/Z2-280355
T7510-20
GB32.1-zn/M3090/GD8.8
GB7244/30
GB343-zn
GB32.1-zn/M42165/GD10.9
JB/ZQ4335-86
GB343-zn
T7510-39B
T7510-9A
1380-27-R
1380-27-L
GB825-zn/M20
GB1152/M101
1380-33
GB1096/1635
GB288/23168CA/W33C3
T7510-17
T7510-49
T7510-18
GB288/23164 CAK/W33C3
GB6584/AH3164
1380-28A
1380-50
GB32.1-zn/M2065/GD10.9
GB7244/20
GB343-zn
1380-31
GB1096/1635
1380-30
C3254A.2-2RH
C3254A.2-2LH
1380-51
Description
Flywheel Assembly
Wedge For Fixed Jaw Die
Washer For Fixed Jaw Wedge
Belleville Washer For Fixed Jaw Wedge
Nut For Fixed Jaw Wedge
Sheave Assembly
Locking Assembly Z2-280355
Shaft Cover
Bolt For Shaft Cover
Lock Washer For Shaft Cover
Steel Wire 3 L=800
Bolt For Bearing Housing
Washer 42
Steel Wire 5 L=1450
Pitman
Eccentric Shaft
Bearing Housing(RH)
Bearing Housing(LH)
Eyebolt M20
Grease Fitting M101
Grease Retainer
Key 1635
Pitman Bearing
Pitman Seal (Bearing Cover)
Shim 5867180.2
Middle Labyrinth Seal
Frame Bearing
Withdraw Sleeve
Bearing Housing Seal (RH)
Shim 5506800.2
Bolt M2065
Lock Washer 20
Steel Wire 3 L=1200
Outer Labyrinth Seal
Key 1635
Lock Washer For Round Nut
Round Lock Nut For Round Nut (RH)
Round Lock Nut For Round Nut (LH )
Bearing Housing Seal (LH)
Qty.
Stock Code
1
2
2
4
4
1
2
2
6
6
2
16
16
2
1
1
1
1
2
6
2
2
2
2
2
2
2
2
1
2
48
48
4
2
2
2
1
1
1
101710012
101701043
301701071
425004007
402011011
101710016
411002009
101701075
401012019
403005007
401014029
403023004
101701100
101701061
101301204
101301118
405031003
428001000
101301124
409001008
407003040
101701072
101701120
101701073
407003039
412001005
101301182
101301148
401014017
403005003
101301122
409001008
301301121
101314035
101314018
101301183
Parts: Jaw Dies and Cheek Plates

Illustration
The following illustrations identify the essential components comprising the jaw dies and cheek
plates.
Parts List
Item
Part #
Description
Qty.
Stock Code
T7510A.1
Frame
101710001
T7510-1
Fixed Jaw Die
301701053
T7510-2-L
Upper Cheek Plate(LH)
301701054
T7510-2-R
Upper Cheek Plate(RH)
301701123
1380-5
Bolt For Cheek Plate
301301084
T6090-53
Washer For Cheek Plate
301250123
GB1972/A63-2
Belleville Washer For Cheek Plate
16
425004005
GB6170-zn/M30/GD8
Nut For Cheek Plate
402011010
GB6172.1-zn/M30
Nut M30
402020003
T7510-3-L
Lower Cheek Plate(LH)
301701055
T7510-3-R
Lower Cheek Plate(RH)
301701124
10
C3042A.DE
Pitman Assembly
101711001
13
T7510.4A
Wedge For Fixed Jaw Die
101701043
14
T7510-16
Washer For Fixed Jaw Wedge
301701071
15
GB1972/A80-2
Belleville Washer For Swing Jaw Wedge
425004007
16
GB6170-zn/M36/GD8
Nut For Swing Jaw Wedge
402011011
70
T7510-6
Swing Jaw Die
301701058
T7510-5A-L
Wedge For Swing Jaw Die(LH)
301701057
T7510-5A-R
Wedge For Swing Jaw Die(RH)
301701125
72
T7510-7
Bolt For Swing Jaw Wedge
301701059
73
C1048-29
Washer For Swing Jaw Wedge
301101076
74
GB1972/A80-2
Belleville Washer For Fixed Jaw Wedge
16
425004007
75
GB6170-zn/M36/GD8
Nut For Fixed Jaw Wedge
402011011
76
T7510-4
Pitman Guard
101701056
77
GB5782-zn/M2480/GD8.8
Bolt For Pitman Guard
401022087
78
GB7244/24
Lock Washer For Pitman Guard
403005005
71
10
Parts: Lubrication
Illustration
The following illustration identifies the location of each grease fittings on the jaw crushers.
Parts List
Item
Part #
Description
Qty.
Stock Code
69
T7510-39B
Pitman
101701100
79
JB/ZQ4450/M201.5
Drain Plug M201.5
432250001
80
JB982/20
Washer
499001205
84
GB1152/M101
Grease Fitting M101
428001000
11
T7510A.7
Lubrication System
101710003
11
Lubrication System
T7510A.7
Parts List
Item
Part #
Description
Qty.
Stock Code
T7510A.7
Lubrication System
101710003
1380.7.1
Connector
101301071
GB9065.3/DN8/M161.5, L=1400mm
Hose DN8/M161.5, L=1400mm
426001017
GB9065.3/DN8/M161.5, L=1050mm
Hose DN8/M161.5, L=1050mm
426001009
JB984/M141.5/161.5
Connector M141.5/161.5
427420000
GB3452.1/ 8x1.8
O Ring
413003072
1380.7-3A
Distributor
101301179
GB1152/M101
Grease Fitting M101
428001000
GB5783-zn/M1280/GD8.8
Bolt M1280
401034092
GB93/12
Lock Washer 12
403015006
12
Appendix A: Discharge Setting Adjusting Procedure
13
Parts List
Item
Part #
Description
Qty.
Stock Code
16
GB6170-zn/M36/GD8
Nut M36
402011011
26
T7510-27
Rear Wedge For Discharge Adjustment
101701082
27
T7510-28
Front Wedge For Discharge Adjustment
101701083
28
GB5782-zn/M2495/GD8.8
Bolt M2495
401022088
29
GB7244/24
Lock Washer 24
403005005
30
T7510-25
Guider (II)
101701080
31
GB5782-zn/M1645/GD8.8
Bolt M1645
12
401022025
32
GB7244/16
Lock Washer 16
12
403005002
33
T7510-13
Pin (I)
101701068
34
GB5867/Z2-90130
Locking Assembly Z2-90130
411002013
35
T7510-24
Washer
301701079
36
T7510-YYG-X
Hydraulic Cylinder 431+183
301710009
37
T7510-YYG-Z
Hydraulic Cylinder 416+167.5
301710010
38
T7510-23
Pin (II)
101701078
39
T7510-22
Guider (I)
101701077
50
T7510-21
Support Plate (I)
101701076
51
T7510-26
Support Plate (II)
101701081
14
CT.APP-WEG.6
Hydraulic Unit Parts
15
Parts List
ITEM
PART #
DESCRIPTION
QTY.
STOCK CODE
CT.APP.WEG.6
Hydraulic Unit
102000251
CT.APP 100
Valve Subassembly
102000027
CT.LM 010
Valve Base
102000107
6C-18LN/RN
Connector
427120139
CT.APP 200
Box
102000028
A-1416SC
Control Box
433050012
GB70.1-zn/M820/GD8.8
Bolt M820
405009003
GB93/8
Lock Washer 8
403015004
GB97.1/8
Washer 8
403020002
PT-7
Fitting
437001392
10
GB70.1-zn/M865/GD8.8
Bolt M865
405009082
11
SD5/1-P(KG-3)/28LAET
Valve
434001143
12
RSO-31TN/36M4-1000
Hose
437001389
13
Y-60ZT
Pressure Gauge
434005024
14
1CB-18-06WD/RN
Connector
427120177
15
1CM-18WD/RN
Connector
427070011
16
CT.APP 500
Hose
102000163
17
CT.APP 600
Hose
102000164
18
CT.APP 700
Hose
102000165
19
5B-06-04WD
Connector
480001506
20
CT.APP 300A
Tank Cover Assembly
102000188
21
GB70.1-zn/M825/GD8.8
Bolt M825
405009070
22
GB93-zn/8
Lock Washer 8
403014002
23
GB97.1/8
Washer 8
403020002
24
CT.APP 001
Seal For Tank Cover
102000031
25
CT.APP 400
Tank
102000032
26
GB70.1-zn/M1225/GD8.8
Bolt M1225
405009080
27
GB97.1/12
Washer 12
403020004
28
W21-100L-4
Motor 3kW/WV/BT5/IE2
421150060
QTY.
STOCK CODE
ITEM
PART #
DESCRIPTION
29
CT.APP.PP.1
Hose
102000045
30
CT.APP.PP.2
Hose
102000046
16
17
Parts List
ITEM
PART #
DESCRIPTION
QTY.
STOCK CODE
CT.APP 300A
Tank Cover Assembly
102000188
CT. APP 310
Cover Assembly
102000036
RFA-4020LY
Filter
480002469
GB70.1-zn/M825/GD8.8
Bolt M825
405009070
VST-M272WD
Plug
427150013
GB5782-zn/M1260/GD8.8
Bolt 1260
401022012
GB93-zn/12
Lock Washer 12
403014004
GB97.1/12
Washer 12
403020004
CT.APP 301
Gasket
102000037
2MC-14-16WD
Connector
480001483
10
1C-16-22
Connector
427070101
11
2C9-22RN
Connecter
427070032
12
152CF
Steel Pipe
0.2m
480002593
13
CBWmb-F4.0-ALP
Pump
416005024
14
GB70.1-zn/M1030/GD8.8
Bolt M1030
405009007
15
GB97.1/10
Washer 10
403020003
16
1CM-18-14WD/RN
Connector
427070100
17
121.5CF
Steel Pipe
0.3m
480003075
18
1CM-18WD/RN
Connector
427070011
19
PAF2-0.02-0.75-20-F
Air Filter
480002470
20
BR250
Guard
422300263
21
CR24 2850/1230
Coupling
480002471
18

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Weir Minerals Latin America

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Installation, Operation and Maintenance Manual

Luis Prez Abad

Revisado y Comentado - RWC

Operation & Maintenance Manual

To the Owner & Operator

Model CT-Series Jaw Crushers

Operation & Maintenance Manual

The following warning applies to equipment supplied with lead-acid batteries:

Model CT-Series Jaw Crushers

Operation & Maintenance Manual

Warranty Terms & Conditions

Model CT-Series Jaw Crushers

Operation & Maintenance Manual

This Page Intentionally Left Blank

Model CT-Series Jaw Crushers

Operation & Maintenance Manual

Section 3 - General Information

Model CT-Series Jaw Crushers

Operation & Maintenance Manual

Section 4 - Set-Up & Installation

Section 5 - Inspection, Lubrication & Maintenance Checks

Section 6 - Start-Up & Operation

Section 7 - Adjustments & Wear Parts Replacement

Model CT-Series Jaw Crushers

Operation & Maintenance Manual

Hydraulic Wedge-Type CSS Adjustment (Manual Hyd. Pump) . . . . . . . . . . . . . . . . . . . . . .7 - 3

Model CT-Series Jaw Crushers

Operation & Maintenance Manual

Appendix A - Torque Specs

Appendix B - V-Belt Drive Information

Model CT-Series Jaw Crushers

Operation & Maintenance Manual

About This Manual

Figure 1 - 2 Safety Alert Hazard Level Symbol

This manual contains information

We strongly recommend that anyone working with

Experience has shown it is to your advantage to

The Jaw Crusher described within is designed to

This equipment is precisely engineered, highly

Safety Alert Symbol

Only your Parts Catalog, identified with your

Ongoing improvement of product design may in

Model CT-Series Jaw Crushers

Operation & Maintenance Manual

This Page Intentionally Left Blank

Model CT-Series Jaw Crushers

Operation & Maintenance Manual

DANGER indicates an imminently

WARNING indicates a potentially

CAUTION indicates a potentially

Symbols and Standards

CAUTION used without the safety

NOTICE indicates information or

Figure 2 - 1 Hazard Classification

Model CT-Series Jaw Crushers

Operation & Maintenance Manual

Safety Signs and Icons

Safety alert symbol.

Icons on our safety signs remind both workers and

Lock out power before servicing

Wear hearing protection when youre

Safety Sign Maintenance