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CJ409:01
Installation
Installation
2007-08-03
Contents
1. Safety regulations S 222.071
Jaw Crusher
1. The feed hopper is normally equipped with a pivoted stone guard. The stone guard
must not be raised during operation.
2. The feed system must be amply dimensioned so that the crusher can recieve a
sufficient quantity of material. The material should be approximately level with the
top edges of the cheek plate.
3. A metal detector should be installed if this is possible, to prevent tramp iron entering
the crusher.
4. The feed system must be electrically connected in such a way that it cannot be started
before the crusher and its discharge system are running.
To correct such a situation in a quick and - for the plant personnel - safe way, we
recommend that a hydraulic hammer is included in the installation right at the planning
stage.
6. To make work around the crusher easier, platforms with guardrails should be
installed around the crusher’s feed opening.
8. Guards
The flywheels and other parts of the V-belt drive must always
Caution !! have robust guards.
9. When welding is to be carried out during repairs or other work on the crusher, it is
important that the working area is earthed in a correct way.
10. Make sure there is no risk of falling into the crushing chamber. Remember that when
a blockage is broken up, any objects in the crushing chamber may be pulled sharply
downwards.
11. Whenever work or inspection is carried out on the retraction system there is a risk of
injury if you are behind or below the retraction.
Stress fatigue can cause the retraction rod or the spring to fail
Caution !! and be thrown backwards. Always replace the safety guard
right away.
12. Retraction rods and springs suffer from fatigue and should therefore be replaced after
2-3 years.
13. When the moving jaw has been swung forwards, always position a block between the
moving jaw and the frame cross-member.
15. If it is desired to rotate the flywheels with the help of the motor - during repair work,
or for some other reason - this must only be done by the foreman responsible.
16. Do not forget to fix the toggle seat holder in position before you remove the toggle
plate.
17. When removing or installing jaw plates it is vital that the lifting gear used is in good
condition.
When jaw plates are to be removed it may in some cases be necessary to burn off part of
the plate to avoid jamming against the cheek plates. When gas-cutting is necessary, make
sure that there is good ventilation and use a fresh air mask.
18. It is important that the cheek plates are properly clamped as there is a risk that they
can come loose.
CJ Chapter 1 5 (6)
Safety regulations and noise emmission
MB 124 S 222.071.02 en
Jaw Crushers 2004-01-08
19. When removing a flywheel mounted on a tapered seating it is important to use tools
which are intended for this purpose.
Dust encapsulation results in lower noise levels. (Dust encapsulation is not included in the
crusher’s standard specification.)
The values given above are equivalent continuous sound levels (Leq) measured during a
period of 60 seconds with an integrating sound level meter. The values are measured at a
distance of approx. 1 m from the machine and approx. 1.6 m above ground level or above a
platform alongside the machine.
The sound levels given are approximate values. The sound level depends on many factors,
e.g. whether or not the crusher has dust encapsulation, how the equipment is installed, how
the feed arrangement is designed, the size and impact strength of the feed material, the size
of the drive motor, etc.
Training
The plant personnel must be trained for their duties and must be given safety instructions.
CJ Chapter 2 1 (6)
Single Toggle Jaw crusher MB 124 S 222.066.00 en
2005-06-28
Installation and operation
Contents Page
Erection 2
Welding work 3
Feed arrangement 3
Initial start-up 4
General 5
Feeding 5
Bearings 6
CJ Chapter 2 2 (6)
Single Toggle Jaw crusher MB 124 S 222.066.00 en
2005-06-28
Installation and operation
General
For every crusher we supply a dimension drawing, a table of weights and an installation
outline drawing.
These drawings and the table give information about the space required for dismantling
and handling and the weights of the heaviest components. Install lifting gear suitable for
the heaviest lift, laid out so that the installation and removal of wearing parts can be carried
out quickly. Ensure that there is sufficient space on the ground for wearing parts when
replacement is to be carried out.
If the shaft is turned by using the drive motor, this must only
Warning !!! be done under the direction of a qualified foreman.
Erection
1. Erect the crusher on its foundation. Use a level to check that it is horizontal, specially in
the transverse direction, by placing the level on the flat flywheel rim.
2. Install the drive motor and the V-belt drive. When the drive is correctly installed, the
top of the flywheel will rotate toward the crushing chamber. The crusher is factory
shipped with right hand drive. Hand of drive is determined from the feed end facing the
crusher in the direction of material flow. Drive hand can be switched to left by
interchanging the two flywheels. Check V-belt drive alignment. Be sure that the motor
and eccentric shafts are parallel and that the motor sheave is in line with the grooved
crusher flywheel.
3. Install all belt guards.
CJ Chapter 2 3 (6)
Single Toggle Jaw crusher MB 124 S 222.066.00 en
2005-06-28
Installation and operation
Welding work
When welding on the crusher during installation or repairs, be sure that the working area is
grounded correctly.
When welding an item to the crusher, attach the ground cable to the item itself. If a crusher
component is to be welded, attach the ground cable as near as possible to the welding area.
Feed arrangement
One of the most important factors for uniform jaw plate wear and thus the lowest possible
operating costs is that the feed arrangement is designed so that the material is evenly
distributed across the width of the feed opening and the crushing chamber is kept full. If
you have any doubts about the feed and discharge arrangements, contact Sandvik Rock
Processing.
2005-06-28
Installation and operation
Initial start-up
1. Check that all threaded joints are tight.
2. Check that all bearings are lubricated. See lubrication instructions.
3. Run the crusher with an empty chamber. Check to be sure that no abnormal noises are
heard and that bearings do not heat excessively. Tighten tension rods as recommended.
At initial start-up it is recommended that the crusher be run unloaded until the bearing
temperatures level off, and then be allowed to cool down prior to restarting to begin
crushing. This start-up method is also suggested after a bearing replacement.
4. Check the crusher speed, it must not exceed the value given in the table below:
2005-06-28
Installation and operation
ROTATION
CRUSHER ECCENTRIC SHAFT SPEED
See the Installation drawing
(r.p.m.)
CJ408 286-301
CJ409 249-281
After break-in, retighten threaded joints and other retaining devices, and check V-belt
tension.
General
Check that no abnormal noises are heard when the crusher is in operation. Investigate noise
sources immediately, and take corrective measures.
Feeding
Feed the crusher uniformly for optimum crushing capacity. A controlled rate scalping
feeder is recommended for most applications. Adjust feed rate to avoid covering the top
edge of the stationary jaw plate.
CJ Chapter 2 6 (6)
Single Toggle Jaw crusher MB 124 S 222.066.00 en
2005-06-28
Installation and operation
The largest feed material should be at least 3 to 4 inches smaller than the opening between
the upper jaw plate wedges.
Bearings
Check bearing temperatures regularly. Investigate causes of unusually high bearing
temperatures (over 80oC = 176oF) immediately, and take corrective measures.
Grease lubrication of bearings is critical, as a bearing can overheat due to either a lack of
lubricant or an excessive amount of lubricant. Excess grease is purged through the
labyrinth seals and, based on observation of the seals, the lubrication procedure should be
altered accordingly when an abnormally high bearing temperature is incurred. Bearing
temperature should be closely monitored when changing the lubrication procedure.