Jaw Crusher 2550-C50Fin09 PDF

2550 (C50) Jaw Crusher
Operation and Maintenance
ISSUE DATE: 04/09 TP527
SAFETY
Be sure to read and fully understand the precautions shown on the inside front cover of this manual before
operating or servicing your Telsmith product. Also refer to Chapter 1 for important safety information.
! WARNING
Failure to follow the safety precautions shown below may result
in serious personal injury or death!
• Never attempt to work on quarry equipment while it is in operation. Always stop the machinery, lockout power
and tag controls:
1. Before performing any lubrication, maintenance, adjustment, or repairs.
2. Before removing spilled materials.
3. Before clearing jams or working inside the machinery.
4. If any unusual noises or sudden changes in operation are noticed.
• Stay clear of feed and discharge areas and other places where falling rock is present. Keep away from loading
vehicles. Wear and use personal protective equipment in accordance with all applicable health and safety
regulations. Safety goggles, hard hat, ear plugs and steel-toed shoes are mandatory when working near
machinery. Wear and use additional personal protective equipment as required.
• Stay clear of springs and other pinch points. Never reach in-between vibrating equipment and its support
structure. Keep a safe distance from all moving components.
• Never attempt to enter the crushing chamber when tramp iron or other uncrushable objects are wedged inside.
These materials are under tremendous pressure and may be propelled upward through the feed opening at any
time. On crushers not equipped with hydraulic clearing, use a pole, hook, grappling device, or breaker bar to
safely dislodge uncrushable objects.
• Do not make equipment modifications that will result in a safety hazard or create a dangerous situation. Never
remove or disable safety devices. Maintain all machinery in accordance with manufacturer’s instructions and
maintenance schedules.
• Read the operator’s manual for the equipment that you operate. Be sure that you fully understand all phases of
operation for each machine. A careful and well-trained operator is the best insurance against an accident.
• Refer to Chapter 1, Safety, for important quarry safety information. If your copy is missing, replacement
copies may be obtained from your local Telsmith Dealer or the Telsmith Parts Department.
• All rotating power products are potentially dangerous and must be properly guarded. Placement of guards and
other safety equipment is the user’s responsibility. Such equipment must be installed wherever appropriate and
maintained as required.
• It is the purchaser’s responsibility to ensure that quarry equipment is installed and used in a safe and lawful
manner. All machinery must be operated in compliance with applicable health and safety laws and general
standards of reasonable care.
Foreword
INTRODUCTION ORDERING REPLACEMENT PARTS
The information, drawings, and pictures provided in this Refer to the prints supplied with your machine when ordering
manual will help you to achieve optimum performance from Telsmith parts. If your prints have been lost or damaged, new
your Telsmith, Inc. product. It contains safety, operation, copies are available from your local approved Telsmith
maintenance, service, and repair information on the machine Distributor or the Telsmith Parts Department.
to assist you in your operation.
To ensure that you receive the correct parts for your machine,
Please note that some features shown in this manual may not always include the model number and serial number when
be present on your machine. Some equipment described may ordering.
be optional at extra cost, or available only on selected
models. MODEL and SERIAL NUMBER PLATE
The data and instructions contained in this manual are based LOCATION
on the latest information at the time of publicaion. Telsmith's
policy of continuous improvem ents, features and
specifications are subject to change without notice.
Actual dimensions, weights, and clearances may be different
than shown, due to fabrication variables, custom engineering
or optional equipment.
HOW TO CONTACT TELSMITH INC.

Use the following information when you wish to contact
Telsmith:
• General: Phone (262) 242-6600
FAX (262) 242-5812
• Parts: Phone (800) 688-6601
FAX (262) 242-7861
• Written: Telsmith, Inc.
10910 N. Industrial Drive
P.O. Box 539
Mequon, WI 53092-0539
U.S.A.
• Send all e-mail to:
parts@telsmith.com
REQUESTING SERVICE ASSISTANCE

If service assistance is required or you have questions about
maintenance or repair procedures in this manual, please
contact your local approved Telsmith Distributor. If
additional assistance is necessary, contact the Telsmith
Service Department. Model and serial numbers are located on a data plate attached
Service technicians are available by telephone from 8:00 a.m. to the machine main frame. Always lockout power and tag
to 4:30 p.m. CST, Monday through Friday, except holidays. controls before reading data plate!
To ensure faster response, always have your machine’s model
and serial numbers ready when calling. SERVICE BULLETINS
Telsmith periodically issues service bulletins to inform
customers of the latest repair and maintenance procedures.
Service bulletins may have been included separately with this
manual. Always read and understand all service bulletins
before starting any maintenance or service work.
04/09 3
Foreword Operation and Maintenance
Telsmith 2550 Jaw Crusher
SAFETY CONTACTS
All quarry personnel operating or servicing the machine must TELSMITH PARTS DEPARTMENT CONTACTS
read and fully understand the information included in
Chapter 1, Safety of this manual.
Name:
ILLUSTRATIONS Phone (Office):
Phone (Cell):
This manual contains some illustrations in which guards,
access panels and other safety equipment have been removed FAX:
for instructional purposes or to provide greater clarity.
However, to prevent serious personal injury or death, always Name:
be sure all such equipment is installed before operating the
Phone (Office):
product.
Phone (Cell):
INSTALLATION & ASSEMBLY DRAWINGS FAX:
Installation and assembly drawings (blueprints) are provided

with all new Telsmith products. These drawings are normally TELSMITH SERVICE DEPARTMENT CONTACTS
included with the technical manuals but may be shipped
separately for some orders.
Name:
The drawings include specifications, dimensions and other Phone (Office):
information for use during installation and assembly
Phone (Cell):
procedures. Contact your local Telsmith dealer or the
Telsmith Service Department if you have any questions about FAX:
information contained on the drawings.
If the drawings are lost, replacement copies may be ordered TELSMITH APPROVED DISTRIBUTOR CONTACTS
from your local Telsmith dealer or the Telsmith Parts
Department. Name:
Phone (Office):
Phone (Cell):
FAX:
OTHER CONTACTS
Name:
Phone (Office):
Phone (Cell):
FAX:
Name:
Phone (Office):
Phone (Cell):
FAX:
4 04/09
Operation and Maintenance Safety
Telsmith Model 2550 Jaw Crusher
TABLE OF CONTENTS
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
FEATURES, DIMENSIONS and SPECIFICATIONS . . . . . . . . . . . . . . . 2
CRUSHER INSTALLATION and ASSEMBLY . . . . . . . . . . . . . . . . . . 3
CRUSHER OPERATION and ADJUSTMENTS . . . . . . . . . . . . . . . . . 4
CRUSHER LUBRICATION and MAINTENANCE SCHEDULE . . . . . . . . . 5
CRUSHER TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . 6
WEAR LINER and CHEEK PLATE REPLACEMENT . . . . . . . . . . . . . . 7
REPAIR and OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

7F
4/09 i
Foreword Operation and Maintenance
TABLE OF CONTENTS
(Continued)
APPENDICES
1
APPENDIX A - TORQUE TABLES - SAE Grades . . . . . . . . . . . . . . . . . . A-1
APPENDIX B - CONVERSION TABLES . . . . . . . . . . . . . . . . . . . . . . . B-1
APPENDIX C - TORQUE TABLES - ISO Grades . . . . . . . . . . . . . . . . . . C-1
ii 04/09
1
Chapter 1
Safety
CONTENTS
Page
GENERAL SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
PRECAUTIONARY STATEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Hazard Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Advisory Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
LOCKOUT/TAGOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Who Must Use Lockout/Tagout? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
What Is Lockout/Tagout? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
When Must Lockout/Tagout Occur? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
How Is Lockout/Tagout Performed? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
When Can Lockout/Tagout Devices Be Removed? . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Lockout/Tagout Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Lockout/Tagout Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Additional Lockout/Tagout Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
QUARRY SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Know Your Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Be Prepared for Emergencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Wear Personal Protective Equipment (PPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Observe Personal Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Help Prevent Accidents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
High Operating Temperatures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Avoid Alcohol and Other Drugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Be Aware of Your Surroundings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Practice Good Housekeeping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Falling Rocks or Material. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Inspect and Maintain Machinery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
EQUIPMENT INSTALLATION SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Equipment Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Foundations and Supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
04/09 1–1
Safety Operation and Maintenance
1 Operator Vantage Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Guarding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Customer Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Electrical Installation Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
MAINTENANCE AND REPAIR SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Electrical Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Pressurized Systems
(Hydraulic and Pneumatic) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Welding, Cutting or Grinding on Machinery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Clearing Jammed Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Hazardous Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Disposal of Excess Fuels, Lubricants and Liquids . . . . . . . . . . . . . . . . . . . . . . . 1-15
Flammable and Combustible Liquids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
HOISTING AND HANDLING SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Forming Wire Rope Eyes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Connecting Wire Ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Fiber or Synthetic Slings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
TRANSPORTATION SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

MAINTENANCE INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
SAFETY LABELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
Types of Safety Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
1–2 04/09
GENERAL SAFETY Hazard Statements 1

It is the responsibility of the quarry management team to
develop a comprehensive safety awareness program, and to ! DANGER
ensure that all quarry workers and support personnel receive Danger indicates an imminently hazardous situation
appropriate safety training as required by federal, state and which, if not avoided, will result in death or serious injury.
local regulations.
Be sure all operating, maintenance, service and support ! WARNING
personnel read and understand the contents of this manual,
including the safety information in this Chapter 1. Warning indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
There are standard safety rules, but each situation has its own injury.
conditions that cannot always be covered by these rules.
Therefore, quarry personnel must continually watch for
possible safety hazards and be prepared to take prompt ! CAUTION
corrective action when deficiencies in safety procedures are Caution indicates a potentially hazardous situation which, if
found. not avoided, may result in minor or moderate injury.
Failure to observe the precautions contained in this chapter
can result in serious personal injury and even loss of life. As Advisory Statements
with most industrial work environments, a careful operator is
the best insurance against an accident. NOTE:
The complete observance of one simple rule would prevent A statement used to draw attention to procedures and
many unnecessary injuries and deaths each year. This rule is: practices. Advisory in nature to the operation, maintenance,
service, and repair of the machinery.
“Never attempt to clean, lubricate, repair or adjust any
machinery or equipment unless it is stopped and properly
locked out and tagged out.” IMPORTANT:
Please note that this chapter is intended only as a brief review A statement used to draw attention to procedures and
of basic quarry safety precautions and procedures. The practices that need to be followed to prevent damage to the
general guidelines included in the following paragraphs machine.
should not be considered in lieu of a quarry’s official safety
procedures, insurance company requirements, or applicable
federal, state and local regulations.
PRECAUTIONARY STATEMENTS
Throughout this manual, you will see the following
Precautionary Statements listed below. These are used to
emphasize certain hazards or precautions related to
procedures in this manual.
04/09 1–3
1 There are many maintenance procedures contained LOCKOUT/TAGOUT

throughout this manual. All machinery that is maintained in
good working condition minimizes safety hazards and Who Must Use Lockout/Tagout?
emergencies.
Quarry owners, managers, and safety officers must be aware
Refer to Figure 1-1 for examples of Precautionary of OSHA’s “lockout/tagout” standard: 29 CFR, Section
Statements. 1910.147, The Control of Hazardous Energy. This standard is
also recognized by MSHA.
All mechanics, maintenance personnel, operators, and
electricians must fully understand and comply with this
NOTE: standard to ensure the safety of all employees.
Use a high impact type grout which contains a non-

shrink additive. Be sure to follow manufacturer’s
instructions when handling and pouring grout.
IMPORTANT:
If obvious signs of trouble or unusual noises occur
during start-up, stop the crusher as soon as
possible.
! CAUTION
Failure to install rotor locking pin after upper
rear frame has been opened will allow rotor
to turn. Serious personal injury may occur.
! WARNING
Failure to follow the instructions and
precautions below may result in serious
personal injury or death.
• Stop crusher and lockout/tagout main drive
p o w e r s o u r c e a n d c o n t r o l s . Wa r n a l l
personnel that crusher is being serviced.
! DANGER
HAZARDOUS VOLTAGE! Disconnect and
l o c k o u t / ta g o u t p o w e r s o u r c e b e f o r e
servicing. Failure to observe this precaution
will likely result in serious injury or death.
Figure 1–1. Sample Precautionary Statements
1–4 04/09
What Is Lockout/Tagout? 1
Lockout/tagout is a means to ensure that personnel who
install, operate, repair, maintain, service, or otherwise disable
machines, equipment, or electrical energy systems are
protected from harm due to unexpected energization or start-
up of equipment, or the release of stored energy by:
Lockout. The placement of a lockout device on an
energy isolating device, in accordance with an
established procedure, ensuring that the energy
isolating device and the equipment being controlled
cannot be operated until the lockout device is
removed.
Lockout device. A device that utilizes a positive
means such as a lock, either key or combination
type, to hold an energy isolating device in the safe
position and prevent the energizing of a machine or
equipment. Included are blank flanges and bolted
slip blinds.
Tagout. The placement of a tagout device on an
energy isolating device, in accordance with an
established procedure, to indicate that the energy
isolating device and the equipment being controlled
Figure 1–2. Lockout/Tagout
may not be operated until the tagout device is
removed.
When Must Lockout/Tagout Occur?
Tagout device. A prominent warning device, such
Lockout/tagout of equipment must occur whenever service
as a tag and a means of attachment, which can be
or maintenance is performed, and injury could occur due to
securely fastened to an energy isolating device in
the unexpected energization or start-up of equipment, or the
accordance with an established procedure, to
release of stored energy.
indicate that the energy isolating device and the
equipment being controlled may not be operated In general, lockout/tagout procedures must be performed
until the tagout device is removed. under the following circumstances:
• Before cleaning, lubricating, adjusting or repairing
machinery or equipment.
• Before working on electrical, hydraulic or pneumatic
circuits or devices.
• Before clearing jammed mechanisms, machinery or
equipment.
• Before removing guards or other protective devices.
• Whenever a machine or its controls will be left
unattended.
04/09 1–5
1 How Is Lockout/Tagout Performed? In situations in which lockout or tagout devices must be

temporarily removed to test or position the machinery or
OSHA has identified the following step-by-step lockout/
component thereof, the following sequence of actions shall be
tagout procedure:
followed:
1. Prepare for shutdown – Before shutting down a piece of
1. Clear the machine or equipment of tools and materials.
equipment, know the type and magnitude of the energy that
powers it, the hazards of that energy, and how to control it. 2. Remove employees from the equipment area.
Warn all employees that the machinery is about to be shut
3. Remove the lockout or tagout devices following proper
down.
procedures.
2. Shut down the equipment – After warning all
4. Energize and proceed with testing or positioning.
employees, shut down the machine, equipment, or electrical
system by the normal stopping procedure. 5. De-energize all systems and reapply lockout/tagout
devices to continue the servicing and/or maintenance.
3. Isolate the equipment – Disengage all isolating devices,
both primary and secondary, so that the equipment is isolated
from all of its energy sources (electrical, mechanical,
hydraulic, pneumatic, etc.).
4. Apply lockout/tagout devices – Attach lockout/tagout
devices (according to your company’s safety program) in
such a manner that the isolating device (circuit breaker,
control, etc.) will be held in a safe or off position. Attach tags
to alert others that the machinery is being serviced.
5. Control stored energy – any potentially hazardous
stored energy (electrical, mechanical, hydraulic, pneumatic,
etc.) that remains must be released, dissipated, restrained, or
otherwise rendered safe. If stored energy reaccumulates,
monitor it until the possibility of accumulation no longer
exists.
6. Verify that equipment is isolated – After warning all
employees to stay clear, engage the start button to confirm the
machine is inoperable. Return the control to the OFF position
before proceeding with servicing.
When Can Lockout/Tagout Devices Be

Removed?
Lockout/tagout devices can be removed only after the
following conditions are met:
• All guards and protective devices are properly reinstalled.
• All tools and repair equipment are removed from the
equipment and the immediate area.
• All mechanics and other personnel are clear of the
equipment and its immediate area.
• All personnel have been warned that the equipment is
about to be restarted (sound warning horn or activate
warning lights).
After removing lockout/tagout devices, always use the
normal start-up procedure as described in the operator’s
manual for the machinery.
1–6 04/09
Lockout/Tagout Devices • Your company’s lockout/tagout program may be 1

somewhat different than described in this manual. If so,
Lockout/tagout devices include:
be sure to completely follow your company’s official
1) locks policies and procedures when lockout/tagout is
2) tags and labels necessary. Consult your company’s safety officer if you
3) multiple lockout devices have any questions.
Lockout devices and tagout devices shall be singularly • A lock must have only one user and one key. Anyone who
identified, shall be the only device(s) used for controlling installs a lock must keep the key in their possession at all
energy, shall not be used for other purposes, and shall meet times. Except in an emergency situation, only the person
the following requirements: that installs a lock is authorized to remove it.
• Lockout and tagout devices shall be capable of • To prevent accidental start-up, never give your lock or its
withstanding the environment to which they are exposed key to another employee.
for the maximum period of time that exposure is
• Your key must open your lock only. Your key should not
expected. Tagout devices shall be constructed and printed
be capable of opening any other locks. Keys for other
so that exposure to weather conditions or wet and damp
locks should not be capable of opening your lock.
locations will not cause the tag to deteriorate or the
message on the tag to become illegible. • Except in an emergency situation, never attempt to
remove anyone else’s lock. Do not allow others to remove
• Lockout and tagout devices shall be standardized within
your lock.
the facility in at least one of the following criteria: color,
shape, or size, and additionally, in the case of tagout • When disconnecting power, be sure that the circuit
devices, print and format shall be standardized. breaker handle (or other isolating device) is in the OFF
position. Accidentally locking a control in the ON
• Lockout devices shall be substantial enough to prevent
position could result in serious personal injury or death.
removal without the use of excessive force or unusual
techniques, such as with the use of bolt cutters or other • If two or more people are working on a machine, a
metal cutting tools. multiple lockout device must be used to prevent
accidental start-up in the event that one person finishes
• Tagout devices, including their means of attachment, shall
working before another.
be substantial enough to prevent inadvertent or accidental
removal. Tagout device attachment means shall be of a • Each lock must have a tag. If two or more people are
non-reusable type, attachable by hand, self-locking, and working on a machine, each person must attach a separate
non-releasable with a minimum unlocking strength of no tag to their lock. Never attach a lock without a tag.
less than 50 pounds and having the general design and
• Never use tags alone. A tag should always be
basic characteristics of being at least equivalent to a one-
accompanied by a lock which prevents the isolating
piece, all-environment-tolerant nylon cable tie.
device from becoming energized.
• Lockout devices and tagout devices shall indicate the
identity of the employee applying the device(s).
• Tagout devices shall warn against hazardous conditions if
the machine or equipment is energized and shall include a
legend such as the following: Do Not Start. Do Not Open.
Do Not Close. Do Not Energize. Do Not Operate.
A multiple lockout device must be used when two or more
people are working on a piece of equipment. This allows each
person to install their own lock and tag.
Lockout/Tagout Rules
• Always lockout/tagout any machinery before
performing any adjustment, inspection, lubrication,
maintenance or repair procedures. Failure to observe this
precaution may result in serious personal injury or death.
04/09 1–7
1 Additional Lockout/Tagout Requirements • Become familiar with the controls, functions and settings
of each machine. Fully understand all phases of each
• Be sure that the power is COMPLETELY turned off. A
machine’s operation.
motor may be stopped and locked out. However,
interlocks, starters, and other supplemental electrical • Be sure that you completely understand and follow all
components may still be energized. Use a voltmeter and/ start-up and shutdown procedures as described in the
or ammeter to verify that all electrical circuits are manufacturer’s manuals.
completely dead.
• Be familiar with the safety labels on your equipment, and
• Always be sure that all peripheral equipment, such as feed the hazards against which they warn.
conveyors, grizzly feeders and discharge conveyors, have
• Check the legibility of all safety labels every day. Order
lockout/tagout devices attached. Serious personal injury
new labels from the machinery manufacturer if they
or death can result if any of these items starts
become illegible or worn.
unexpectedly while service work is in progress.
• Although lockout/tagout procedures are most commonly Be Prepared for Emergencies
associated with electrical systems, be aware that
• Know the proper emergency shutdown procedures for the
hydraulic, pneumatic and mechanical systems must also
equipment you operate.
be tagged and locked out before servicing. This may
involve the lockout/tagout of valves, levers and other • Know where fire extinguishers are kept and how to use
non-electrical devices. them. Be sure that fire extinguishers are properly rated,
and that they remain fully charged and ready for use at all
• For machinery powered by internal combustion engines
times.
(diesel, gas, etc.), always disconnect batteries and shut off
fuel supply before servicing the machinery. Lockout/ • Know the procedure for contacting emergency medical
tagout engine controls to ensure that engine is not personnel. Keep a list of emergency phone numbers
accidentally started while the machinery is being handy at all times.
serviced.
• Know where a first-aid kit, stretcher and other emergency
• Always be sure that all hydraulic or air pressure is supplies are kept. Be sure that first aid supplies are
completely relieved before working on hydraulic or properly maintained and ready for use.
pneumatic systems. Dangerous pressures can be present,
• Make sure that a clear path to emergency equipment and
even when equipment is turned off and locked out.
exits is always maintained. Do not allow equipment,
• After maintenance or repairs are completed, always warn spilled materials or other obstructions to get in the way.
all employees that the machinery is about to be restarted.
• Know how to report accidents. Always report all
Be sure no one is on or near the equipment before a lock
accidents immediately to the appropriate supervisor.
and tag is removed.
• As a precaution, always activate a warning horn or light
before restarting the machinery. This will provide
additional warning for personnel to stay clear of
machinery that is about to be started.
QUARRY SAFETY
Know Your Equipment
• Read and understand the manufacturer’s operation and
maintenance manuals for all machinery and equipment
that you operate. Be sure that all hazard statements
contained within the manuals are completely understood.
• Allow only trained and authorized personnel to operate
and maintain machinery.
1–8 04/09
Wear Personal Protective Equipment (PPE) • To avoid back injuries, always use proper lifting 1
techniques to safely lift heavy objects. Lift with your legs
Aggregate processing and handling can be a dangerous
and keep your back straight. Keep the materials or object
process. To reduce the risk of serious injury or death to
close to your body. Have a co-worker assist you if the load
personnel, observe the following precautions:
cannot be lifted safely by one person.
• Wear safety glasses or goggles whenever outside of an
• Before starting the machinery, check that no personnel are
approved operator ’s enclosure. Failure to wear
inside, on, under or beside the equipment. Unless
appropriate eye protection can result in permanent eye
absolutely necessary, do not allow anyone to be on or near
injuries and loss of sight.
the equipment while it is operating.
• During initial start-up of machine, sound pressure levels
• Never attempt to catch falling materials or objects.
should be taken near machine to determine what level of
hearing protection is required. Wear appropriate ear • Be aware of flammable liquids and other potential fire
protection when working within 50 feet of any operating hazards. Do not smoke when refilling engines or using
quarry machine and in other areas where noise levels are cleaning solvents.
high. Prolonged exposure to high noise levels can cause
• Do not stand under equipment or components that are
permanent hearing loss.
being hoisted or suspended. Never allow other quarry
• Wear steel-toe safety boots, heavy-duty gloves and a hard personnel to do so.
hat. This equipment is mandatory in most areas of the
• Before you assemble, operate, clean, lubricate, or adjust
quarry.
machinery, be sure to read and understand all procedures
• Always use authorized respirators when working in and contained in the machinery manufacturer’s manual.
around high-dust areas. Prolonged exposure to dust
• Be sure to operate quarry machinery in compliance with
particles can cause silicosis of the lungs. This, over a long
current OSHA and MSHA regulations, and all applicable
time period, can cause serious illness or death.
federal, state or local regulations.
• Other personal protective equipment may be necessary
• Be sure that all guards and other safety devices are
for your specific job assignment, such as a full face shield
correctly installed and tightly secured before starting the
and safety harness. Wear or use these items when
crusher. Stay clear of rotating or moving parts during
necessary and as required by applicable federal state and
crusher operation.
local regulations.
Observe Personal Safety Precautions

• Never wear loose or ragged clothing when working on or
around rotating power equipment. Avoid wearing
necklaces, rings or other jewelry. These items can become
caught or tangled in the machinery, resulting in severe
• Keep hair short, if possible. Keep long hair securely tied
up to prevent it from becoming caught in the machinery.
• Be especially careful whenever using wet walkways,
platforms, or ramps. The combination of rock dust and
wet metal can create an extremely slippery surface. Keep
all walkways and other access structures clean, dry and
free of grease or oil.
• Use walkways and ladders when working near machinery,
or observing its operation. Use a safety harness when
necessary. Keep handrails and machine contact surfaces
clean.
04/09 1–9
1 Help Prevent Accidents • Be aware of idle machinery that could start up without
warning. Stay clear of such machinery and the immediate
• Do not allow unauthorized personnel in or near the work
area.
area. Never allow unauthorized personnel to operate,
adjust, maintain or repair machinery. • Be aware of overhead obstructions, such as conveyors,
support structures or power lines.
• Allow only properly trained and experienced personnel to
operate machinery. Be sure inexperienced operators are
carefully supervised at all times. Practice Good Housekeeping
• Do not store tools or equipment on walkways.
• Do not allow personnel to be near loading areas, or
anywhere else that falling or ejected material could hit • Be sure that all walkways, platforms, stairs and ramps are
them. kept free of spilled material and trash. A build-up of
material in these areas can cause slips and falls. Make
• Use extreme caution if the machinery must be operated
repairs as required in areas where spillage is present.
for inspection or observation purposes. Stay a safe
distance from the machinery and wear appropriate • Do not allow machinery to become buried under piles of
personal protective devices. spilled material. This will make the machinery more
difficult to inspect and may hide broken welds, loose
• Before making repairs to the machinery, always clear all
fasteners and other serious problems that could cause a
quarry material from the feed and discharge devices
safety hazard.
(feeders, conveyors, chutes, etc.).
• Keep the areas around control panels and machinery free
• In areas that present a danger of falling, use an appropriate
of spilled material. Free access must be maintained at all
fall protection device, such as a safety harness and
times. In the event of an emergency, quick access to
lifeline.
controls could prevent injury or death.
• Always report any unsafe conditions or defective
• Clean up spilled fuel or oil immediately to eliminate
equipment to the appropriate supervisor.
slipping hazards. If necessary, use an oil absorbent.
High Operating Temperatures • Always be sure that power is tagged and locked out before
cleaning spilled material or oils. Never clean up these
• The equipment generates heat during operation resulting
items while the machinery is operating.
in surface temperatures that may sometimes exceed 140
°F (60 °C). For your safety, we recommend you let the
equipment cool before attempting to perform Falling Rocks or Material
maintenance. CAUTION - There is a risk of burn if the • Due to the unpredictable nature of aggregate and mineral
equipment is handled before cooling. handling, rocks may sometimes fall or be ejected from the
equipment. The user is cautioned to prevent potential
Avoid Alcohol and Other Drugs falling debris though intelligent design of the surrounding
structure by using guards and skirting where appropriate.
• Do not operate or work near quarry machinery when
CAUTION - A falling debris hazard exists around the
under the influence of alcohol or other drugs. These
equipment. Maintain a safe distance and wear Personal
substances can result in reduced alertness and impaired
Protective Equipment such as your hard hat, safety shoes
judgement. Serious personal injury or death could result.
and safety glasses. Additional safety warning decals have
• Some prescription and non-prescription medications can been provided for your convenience to post near the
cause drowsiness or other adverse side effects. Do not equipment.
operate or work near quarry machinery when under the
influence of such medications.
Be Aware of Your Surroundings

• The quarry environment contains many situations that are
potentially hazardous. Use extreme caution to avoid being
struck by haul trucks, loaders and other quarry mobile
equipment.
1–10 04/09
Inspect and Maintain Machinery • All support structures designed and manufactured by 1
others must be of adequate strength and size to resist the
• Always perform a safety inspection at the beginning of
weight of loaded machinery and any vibration which may
each shift. Refer to the machinery manufacturer’s
occur.
operation and maintenance manuals for detailed pre-start-
up inspection and maintenance procedures. • Structures and foundations should be designed and
constructed to handle dynamic forces up to 2.5 times the
• Test all warning devices before starting the machinery to
weight of the machinery.
ensure that they are working properly. Never disable or
bypass any alarm systems or interlocks. • All walkways, platforms, handrails, stairs and guards
designed by others must meet all local, state and federal
• Be sure that any defective components or systems are
regulations.
properly repaired by a qualified technician before the
machinery is started. Immediately report any serious Typical installations of Telsmith equipment will include an
problems to the appropriate supervisor. operator's platform. This may be furnished by Telsmith or by
the owner of the equipment. The operator's platform should
• Before performing inspections or maintenance, always
be positioned so that the operator has a clear view to control
lock out and tag power to the machinery, and to all feed
the feed of material to the equipment. Remote cameras can be
and discharge equipment for the machinery. Warn all
located to assist the viewing of feed points that are obstructed
personnel that the equipment is being serviced. Refer to
from the operator's view. An operator's cabin should be
the Lockout/Tagout section of this chapter for additional
provided in environments where the operator would be
information.
exposed to harmful dust, noise, and bad weather conditions.
• Maintenance inspection procedures are included The operator's platform should be isolated from any structure
throughout this manual. Although maintenance is not that might cause the operator to be exposed to excessive
typically a safety concern, machinery that is regularly vibrations.
maintained and in proper working condition will
Typical installations of Telsmith equipment will include
minimize the occurrence of safety hazards and emergency
service platforms. These may be furnished by Telsmith or by
situations.
the owner of the equipment. Since these platforms are
typically installation specific, Telsmith provides several
EQUIPMENT INSTALLATION SAFETY hazard decals to be located at the time of installation. The
placement of these decals is part of the initial start-up
Equipment Vibration checklist for the particular Telsmith equipment. Refer to
Some Telsmith equipment is designed to vibrate during specific Telsmith operator manual for proper placements.
operation. Vibrations are amplified during the start-up and The construction of any platforms shall conform to MSHA
shut-down cycles. There is a risk of a crushing injury if body and OSHA regulations for the area in which the equipment is
parts become pinched by the motion of the equipment. to be operated.
CAUTION - Be advised to keep hands and body parts away
from the moving equipment to avoid injury. Support structures Operator’s Vantage Point
must be suitably designed to accept these vibrational forces.
The dynamic loads generated by the equipment are • Telsmith suggests that the operator of the equipment
referenced on the installation drawing. should have a clear vantage point to view the flow of
material into the primary sections of large capacity plants
(250 tons per hour or more). This will ensure good control
Foundations and Supports
of material flow into the primary and into downstream
Your Telsmith equipment, along with any supporting components. It will also promote quicker reactions to
structure, must be installed on an adequate and proper problems, such as blockages, resulting in improved
foundation. Consider the following when preparing for the overall efficiency.
installation of the equipment:
• An adequate foundation on a solid footing is required.
The load-bearing capacity of the location for the
machinery must be 2500–3000 lb/ft2 ( 17.2- 20.7 MPa).
The location should be as level as possible.
04/09 1–11
1 Guarding • If power and control lines are run overhead, allow for
plenty of clearance for vehicle traffic of all sorts. If there
• Quarry management is responsible for the proper
are multiple cables, a cable tray should be used to support
installation and placement of guards to prevent personnel
all lines.
from coming in contact with rotating or moving parts.
• Maintain adequate overhead clearance from power lines
• In addition to the guards supplied with the machinery,
or other obstructions, particularly when planning to use
additional guards and related safety equipment may be
stacking conveyors for stockpiles.
required to comply with OSHA, MSHA and any
applicable local regulations. The proper fabrication, • Be sure that electrical power supplies are located in an
installation and placement of these items is quarry area that will be safe from accidental contact during
management’s responsibility. operation.
• When fabricating guards, refer to MSHA’s Guide to • All Telsmith machinery is designed with electrical
Equipment Guarding. Additional information can also be components of the proper size and voltage.
provided by the safety officer at your worksite.
• Be sure that all connections are in accordance with the
• Never remove guards until the machinery is stopped, National Electric Code (NEC) and any applicable state or
power is locked out and tagged. Be sure that guards are local codes.
properly reinstalled before reconnecting power. Refer to
• NEVER run computer cables in the same conduit as
the Lockout/Tagout section of this chapter for additional
electrical power cables. This will cause interference with
information.
the computer input/output data.
Customer Modifications • Incoming power and utility company transformers should
be located away from the crushing and screening
• Do not modify quarry machinery in any way without prior
equipment and vehicle travelways. Any modifications to
approval from the manufacturer. Such modifications may
these components or to the power supply must be
include (but are not limited to) changing machine speed or
approved in writing by the Telsmith Engineering
direction of rotation, drilling additional holes and welding
Department.
or bolting additional equipment to the machinery.
• All customer modifications to Telsmith machinery must
be approved in writing by the Telsmith Engineering
Department.
Electrical Installation Safety
! WARNING
When installing any electrical equipment, be
sure to completely follow the manufacturer’s
instructions. Failure to observe this precaution
could result in a dangerous electrical shock
hazard.
• Be sure that all electrical equipment is properly grounded.
• Lay out the power lines, especially those for portable
plants, so that contact with standing water is minimized.
• Do not place power lines in an area where they will be
driven over by transport vehicles or other quarry
equipment. If it is absolutely necessary to extend a power
line across a traffic area, protect the cable with properly
rated bridging.
• Be sure that all auxiliary control panels or power supply
panels can be securely locked out. This type of panel is
mandatary.
1–12 04/09
MAINTENANCE AND REPAIR SAFETY • Do not tamper with machinery alarm components. Never 1
attempt to defeat electrical interlocks or to disable
machine protective devices.
! WARNING
Always lockout/tagout power to the machinery Pressurized Systems
and to all feed and discharge equipment before (Hydraulic and Pneumatic)
performing any maintenance or repairs. Warn all
• Adjust, maintain and repair all pressurized systems only
personnel that the machinery is being serviced.
in accordance with the instructions contained in the
manufacturer’s manuals provided with the machinery.
General Precautions
• Never attempt to work on a pressurized system while it is
• To help ensure safe machine operation, use only genuine
pressurized or in operation.
OEM replacement parts that are sold or approved by the
machine’s manufacturer. Use of non-OEM parts may • Before performing maintenance or repairs on any
adversely affect machine operation and could result in a pressurized system:
hazardous situation.
— Cycle the controls through all operating positions to
• Always tighten all fasteners to the proper torque as relieve any trapped pressure.
described in the repair procedures. When torque
— Check that ALL pressure is relieved from the system.
specifications are not listed, use the values in the torque
Pressure gauges must read zero (0) psi.
table at the back of this manual. Refer to Appendix A of
this manual. — Lockout and tag all controls. Be sure electrical power
is properly locked out and tagged.
• Be sure all replacement fasteners are of the proper grade
and specifications. Replace any worn or damaged
fasteners.
Electrical Systems
• Always read, understand and follow appropriate electrical
system troubleshooting, maintenance and repair
instructions in the machinery manufacturer’s manuals.
• Allow only trained and licensed electricians to install,
troubleshoot and repair electrical equipment. All
procedures must be in compliance with the National
Electric Code and any applicable state or local
regulations.
• When servicing an electrical system, work with the power
locked out and tagged. Always assume that an electrical
system is live until it has been locked out.
• Always lockout and tag power before removing cables
with quick-disconnect plugs.
• Repair any obviously worn or damaged wires and
connectors.
• Inspect power cables and connections daily for signs of
wear, cracked insulation and worn or damaged
connectors. Repair or replace as required.
• Do not store tools inside electrical cabinets.
• Verify that all tools are grounded with a three-wire plug or
double insulated. Be sure that all extension cords are
grounded with a three-wire plug.
04/09 1–13
1 • Allow time for hot hydraulic oil to cool before performing • Be sure to wear the proper welding shield, welding gloves
any maintenance or repairs. Hot oil can cause burns. and clothing. Do not wear synthetic-fabric clothing or
clothing which could be easily ignited by sparks.
• Wear safety glasses or face shield when working on
pressurized systems. • Always follow all standard safety procedures when
welding. Be sure that all systems are locked out and
• Before loosening fittings or removing components,
tagged out. Provide welding screens to protect other
always recheck that ALL pressure is relieved from the
employees working in the area.
system. Pressure gauges must read zero (0) psi.
• Relieve all hydraulic pressure before welding near
• Never attempt to loosen a hydraulic fitting while a
hydraulic components and lines. Cover hydraulic
hydraulic system is pressurized. Serious personal injury
components to protect them from weld spatter and sparks.
could result.
• Do not weld near flammable liquids or hydraulic oils.
• Never have your face near, or stand directly in front of a
hydraulic line when loosening a fitting, even after system • DO NOT weld lifting eyes or hooks to any components.
pressure has been relieved. Always assume that the line Welding lifting eyes or hooks to components made of
has pressure. manganese, cast iron, ductile iron or other alloyed
materials may fail when being hoisted or moved. If it
• Use a piece of cardboard, not your hand, to check for
becomes absolutely necessary, use a stainless steel or
hydraulic oil leaks. Escaping fluid under pressure can
manganese welding rod. Use extreme caution when
penetrate the skin, resulting in serious personal injury.
lifting or moving these items and keep all personnel clear.
• Clean up any spilled hydraulic oil. Hydraulic oil is
• Never ground the welder so that the electrical power will
extremely slippery, and can be especially dangerous if
flow through bearings, hydraulic components or electrical
spilled on an elevated walkway or platform.
equipment. Serious damage could result.
• Repair any leaks immediately. Always relieve system
• Be sure all compressed gas cylinders are stored upright,
pressure and lockout/tagout power before tightening
chained and capped. Turn off all cylinders when not in
fittings or making repairs.
use.
• Never attempt to adjust pressure relief valves to above the
machinery manufacturer ’s recommended settings.
Serious personal injury and/or equipment damage could
result.
• Do not operate any hydraulic or air system with obviously
worn or damaged, or leaking components. Always replace
any defective components immediately.
• Never place hands on hydraulic cylinder rods while
equipment is in operation.
• Refer to manufacturer’s instructions when recharging
hydraulic accumulators or checking accumulator
pressure. Allow only trained hydraulic system technicians
t o d e p r e s s u r i z e , r e c h a rg e o r r e p a i r h y d r a u l i c
accumulators.
Welding, Cutting or Grinding on Machinery

• Be sure to provide adequate ventilation when welding,
cutting or grinding inside enclosed areas to prevent the
buildup of hazardous fumes or dust. Special concern
should be exercised when welding, cutting or grinding
chromium, manganese, cadmium, copper, cobalt, lead
and nickel, as these materials are considered to be
potentially carcinogenic.
1–14 04/09
Clearing Jammed Material Disposal of Excess Fuels, Lubricants and 1

• If material becomes jammed in the machinery: Liquids
— Immediately stop the machinery. Quarry personnel are responsible for the proper disposal of
unused fuels, used lubricating oils, used hydraulic oils, and
— Lockout/tagout power. Warn others that the other toxic materials. DO NOT dispose of these materials in
machinery is being serviced. an unapproved manner. Follow all applicable federal, state
— Follow the instructions in the operation and and local regulations.
maintenance manual of the affected equipment.
Flammable and Combustible Liquids
• To prevent serious personal injury or death, never attempt
to remove jammed material while the machinery is in • Store flammable liquids in a safe place, away from quarry
operation. machinery and personnel. Use approved safety containers
and be sure that they are clearly marked. Containers must
• Always remove all jammed material before restarting the be covered when not in use.
machinery. To prevent damage, never attempt to restart a
stalled machine without first removing the jammed • Keep flammable liquids away from sparks, open flame,
material. and other ignition sources. Do not smoke around
flammable liquids. Always obey posted “no smoking”
• Never use dynamite or other explosives to clear jams. signs.
Explosives are dangerous and can injure or kill personnel.
Damage to machinery could also occur. • Be familiar with the locations of fire extinguishers
throughout the quarry. Be sure they remain accessible at
all times, and are not blocked by obstructions.
Hazardous Materials
• Do not use gasoline or other flammable liquids to clean
• Be aware of potentially hazardous chemicals or materials.
tools or parts. Use only approved non-flammable
Such items can be harmful if they are improperly used,
solvents.
stored, mixed or transported, or if they are inhaled,
swallowed or allowed to contact the skin. • Always shut off engines before refueling. Ground fuel
spout against the filler neck to prevent static electricity.
• Consult your employer’s hazard communications plan for
Never smoke while refueling.
instructions regarding the proper handling and use of
hazardous materials. Read and understand the labels • Use only approved safety containers for storing and
attached to the product containers. Always follow the transporting small quantities of flammable liquids. Keep
instructions carefully. containers covered when not in use.
• Consult the manufacturer’s material safety data sheet
(MSDS) for potential hazards and appropriate medical
procedures should an accident occur.
• Store hazardous materials only in approved containers.
Be sure containers are clearly labeled.
• To avoid potential health hazards, persons in regular
contact with hydraulic oils must be aware of the
importance of thorough hygiene, and the proper methods
for handling mineral oils.
• Always wear suitable protective clothing when handling
hydraulic oil.
• Be sure protective clothing and proper washup facilities
are available to all personnel that may come in contact
with mineral-based hydraulic oils.
• Always dispose of used rags or paper towels in the correct
and safe manner.
04/09 1–15
1 HOISTING AND HANDLING SAFETY Forming Wire Rope Eyes

When forming eyes in wire ropes, use the following method:
General Precautions
• Use the correct size thimble as recommended by the
• Do not allow personnel to work or walk under loads supplier for the wire rope being used. DO NOT use under-
supported by a crane or hoist. or over-sized thimbles.
• Use appropriate lifting devices to secure the load to the • Use the correct size and number of U-bolt/saddle clamps
crane. See the following paragraphs of this section for to fasten the wire rope dead end to the live side of the wire
additional information. rope. Orient the saddle so it sits against the live side of the
• Use the correct lifting hooks to support the load. rope. DO NOT place the U-bolt against the live side of the
wire rope, as this will crush and deform the wire rope.
• Use extreme caution when operating a crane near power
lines or electrical equipment.
Connecting Wire Ropes
• Do not exceed the crane’s rated load capacity. Always When clamping or connecting two separate pieces of wire
include the weight of the hook block, slings, chains, rope together use the following method:
spreader bars and any additional equipment when
determining the maximum load that can be safely lifted. • Lay the two pieces of wire rope side by side with the spiral
of the strands facing or turning in the same direction.
Wire Rope • Have your supplier determine the number of U-bolt/
Wire rope requires careful use, handling and maintenance to saddle clamps required for your size of wire rope.
ensure long life and safe operation. Always observe the Normally, one complete clamp can carry approximately
following precautions. 75–80% of the wire rope capacity.
• Be sure to use the correct size wire rope for the • Install the clamps so that the saddle portion is alternated
application. from one side to the other.
• Be sure wire ropes are inspected regularly following the

manufacturer’s guidelines. Maintain an inspection log.
• When storing wire rope, follow the manufacturer’s
recommendations for applying a protective coating to the
wire ropes.
• Avoid sudden loading in cold weather. Never use frozen
wire rope in weather below 32°F (0°C).
• Do not use wire rope around sharp corners or edges that
may cause a cut or deformation of the wire rope.
• Use suitable padding to protect wire rope from sharp
corners or edges.
• Avoid dragging wire rope underneath loads or over
obstacles, as this may cause damage to the wire rope.
• Never use wire rope that is cut, badly kinked, frayed or
crushed.
• Avoid reverse bends.
• Be sure rope ends are properly sized.
• Use appropriate sized thimbles in eye fittings at all times.
NEVER attempt to use an undersized thimble in forming
a wire rope eye.
• Follow the manufacturer’s instructions for lubrication if
using wire rope for lifting purposes.
1–16 04/09
Chains • Keep slings clean and free of solvents, oils and grease. 1
Chains require careful use, handling and maintenance to • Wet or frozen slings should not be used until thoroughly
ensure long life and safe operation. dried. Have supplier inspect sling before using.
• Be sure to use the correct size chain for the application.
TRANSPORTATION SAFETY
• Be sure chains are inspected regularly following the
General Precautions
• Avoid sudden or shock loading. DO NOT jerk load • Be sure that the machinery or equipment is properly
upright or allow load to fall over if chains have too much secured so that it cannot vibrate or move during transport.
slack. Remove any dirt, stones or other loose material from the
• DO NOT use chains around sharp corners or edges that machinery.
may damage chain. • Install shipping brackets, wood blocking or other
• Use suitable padding to protect the chain from sharp shipping materials as directed in the machinery
corners or edges. manufacturer ’s manuals. Perform any shipment
preparation procedures as indicated in the manuals.
• Avoid dragging the chain under loads or over obstacles, as
this may cause damage to the chain. • Plan your route carefully. Know the clearance height of
the machinery. Be aware of bridges, power lines and steep
• Always place chain hooks over links with the hook point or uneven grades. Be aware of any other conditions which
facing downwards. may present hazards or obstructions.
• Inspect chains for wear. Refer to manufacturer’s • Be sure that all tractor-trailer components are working
recommendations for replacement. and in good condition. Test all systems (brakes, steering,
• Be sure all connections between chain sections are lights, etc.) for proper operation and/or adjustment before
completed with properly sized hardware and lifting beginning the move. Check air pressure in all tires and
hooks. replace any tires that are worn or damaged.
• When storing chains, follow the manufacturer’s • After the machinery has been transported, block the tires
recommendations for applying a protective coating to the if the trailer will remain stationary for an extended period
chains. of time.
! CAUTION MAINTENANCE INSPECTIONS

Always follow proper rigging procedures as • Routine maintenance inspections such as lubrication can
provided by the chain manufacturer. The angle often be conducted when performing a safety inspection.
of rigging may decrease the rated lifting This will help provide a good service routine and increase
capacity. the efficiency of your operation.
Fiber or Synthetic Slings

Slings require careful use, handling and maintenance to
ensure long life and safe operation.
• Be sure slings are rated or coded for the hitch or
application.
• Be sure slings are inspected regularly following the
• DO NOT use fiber or synthetic slings in temperatures
below 32°F (0°C) or temperatures exceeding 150°F
(65.5°C).
• Avoid sudden or shock loading (DO NOT jerk load
upright).
04/09 1–17
1 SAFETY LABELS It should be mentioned here that the ANSI Z535.4-2002

Standards are voluntary standards – they are not a legal
General requirement. However, from a legal point of view, product
manufacturers have the legal “duty to warn” about hazards
Each piece of equipment manufactured by Telsmith, Inc., has associated with the use or maintenance of their products.
undergone a Safety Audit to determine those areas that may
create a potential hazard. These audits were done under the To provide a comprehensive Safety Label, safety labels use
guidelines set forth by the ANSI Z535.4-2002 Standards, EN the “Harmonized” format. The Telsmith “Harmonized”
292-2 European Standards and ISO 3864 Part 2 International format uses the ISO Symbol in a center panel along with
Standards. Hazard audits performed are on file at our English text in the left side panel and the text translation for
facilities. the country of operation in the right side panel of the label.
Where possible, potential hazards have been designed out of To promote a better understanding of the Safety Labels
the equipment. However, when it is impractical to design out specifically designed and used by Telsmith, the following
a potential hazard Telsmith, Inc., applies various safety labels outlines the design of Safety Labels to meet or exceed the
to equipment manufactured to warn of the potential hazard. ANSI Z535.4-2002 and the ISO 3864 Part 2 Standards.
See Figure 1-3 to better understand the parts of a Safety
Types of Safety Labels Label.
Since Telsmith, Inc., furnishes equipment worldwide, Safety
Labels provided comply with the ANSI Z535.4-2002 and the
International ISO 3864 Part 2 Standards.
B C
A
E
H I
F G
Figure 1–3. Safety Label

A – Safety Alert Symbol D – Consequence of Interaction with Hazard G – ISO 3864-2 Symbol
B – Signal Word in Panel E – How to Avoid the Hazard H – Text Panel – Country of Operation
C – Nature of Hazard F – Text Panel – English I – Label Part Number for Ordering
1–18 04/09
A. “SAFETY ALERT SYMBOL” 1

This symbol is an exclamation mark enclosed in a triangle. It
is placed next to the Signal Word in the Panel and indicates
that a possible personal (human) injury hazard exists.
B. “SIGNAL WORD in PANEL”

The Signal Words for product Safety Labels are DANGER,
WARNING, CAUTION, and NOTICE. These words call
attention to the Safety Label and designate a level of hazard
seriousness. (ANSI 4.13 Standard.)
• ANSI 4.13.1 DANGER: Indicates an imminently
hazardous situation which, if not avoided, will result in
death or serious injury. The Signal Word is to be limited
to the most extreme situations.
• ANSI 4.13.2 WARNING: Indicates a potentially
hazardous situation which, if not avoided, could result in
death or serious injury.
• ANSI 4.13.3 CAUTION: Indicates a potentially
hazardous situation which, if not avoided, may result in
minor or moderate injury. It may also be used to alert
against unsafe practices.
• ANSI Z535.2 NOTICE: Indicates potential equipment
damage may occur if the Safety Label is ignored when
performing maintenance, repair or servicing of the
equipment.
NOTE:
When the Signal Word “NOTICE” is used on a Safety
Label the Safety Alert Symbol is removed from the
panel.
It is the responsibility of the quarry personnel to replace any
worn or illegible labels. Contact the Telsmith Parts
Department for replacement labels.
04/09 1–19
1 NOTES
1–20 04/09
Chapter 2
Features, Dimensions and Specifications 2
CONTENTS
Page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
MAJOR FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
MOUNTING ARRANGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
EXTERNAL DIMENSIONS DRAWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
04/09 2–1
Features, Dimensions and Specifications Operation and Maintenance
DESCRIPTION The Model 2550’s hydraulic relief feature automatically

allows passage of most uncrushable objects, such as tramp
The Telsmith Model 2550 is a primary jaw crusher intended iron and rebar, without jamming or stalling the crusher. If
for use as a mid-mount crusher on low profile applications needed, the crushing chamber can be manually cleared using
such as portable plants or track chassis. the hydraulic clearing function.
2 The 2550 crusher uses a single hydraulic cylinder (I, Fig 2-1) Discharge setting adjustments may be performed quickly and
to provide both crushing pressure and hydraulic relief action. easily, using the controls on the crusher’s hydraulic power
unit. Discharge settings of approximately 63.5 to 152 mm
(21/2 to 6 inches) are possible.
E
D
L
G
B H
I
J
Figure 2–1. 2550 Cutaway

A. Main Frame D. Cheek Plate G. Eccentric Shaft J. Toggle Seat
B. Maganese Stationary Die E. Swing Jaw Guard H. Swing Jaw K. Toggle End w/Compression Springs
C. Manganese Swing Jaw Die F. Flywheel, Pulley I. Toggle Cylinder L. Spherical Bearing
2–2 04/09
Operation and Maintenance Features, Dimensions and Specifications
MAJOR FEATURES OPTIONS

• A single oversize hydraulic cylinder (I, Fig. 2-1) allows • Linear Position Sensor which allows the crusher to
simple crusher adjustment and overload protection. automatically perform setpoint adjustments, eliminating
manual discharge setting adjustments required after
• The single hydraulic tensioning toggle cylinder assembly
replaces traditional tension springs, plus the associated
repairs or a manual clearing situation. 2
toggle beam and adjustment shims. • Automatic greasing system.
• AR 400 alloy steel cheek plates (D, Fig. 2-1) provide
extended wear. MOUNTING ARRANGEMENT
• Fabricated main frame (A, Fig. 2-1) is FEA designed and The Model 2550 is available as a stand-alone unit to be used
stress relieved for rugged durability. as a component of a complete portable crushing plant or as
part of a track mounted plant.
• Barrel protection is provided by a replaceable impact
plate (E, Fig. 2-1). If your crusher is mounted on a portable plant chassis:
• Reversible and interchangeable jaw dies (B & C, Fig. 2- • Refer to the Plant Assembly Drawing for the external
1) provide extended wear. dimensions of your portable plant.
• Shut down alarm automatically stops the crusher in the • Refer to any additional engineering drawings that have
event of low hydraulic pressure. been provided separately with this manual.
Some portable or track plants may include additional
equipment, such as vibrating screens or feeders. Separate
operation and maintenance manuals have been provided for
this equipment. Refer to these manuals for installation and
start-up procedures.
04/09 2–3
EXTERNAL DIMENSIONS DRAWING
EE GG
2
FF JJ
Top
HH
KK
LL
A B C MM
B
BB D
AA Z
Y E
U
T F
S G
R
X H
W P
O M I J
CC
Q K
L
N
V DD
NN
Front Side
Figure 2–2. 2550 Dimension in Millimeters (Inches)
A. 1422 mm. (56.0 in) O. 2289.7 mm (90.15 in.) CC. 303.9 mm (11.96 in.)
B. 1320.8 mm. (52.0 in.) Inside main frame P. 1700.0 mm (66.93 in.) DD. 50 - 180 mm (2-7 in.) Closed Side
C. 1270.0 mm. (50.00 in) Inside cheek plates Q. 40.0 mm (1.57 in.) Setting Range
D. 2661.8 mm. (104.79 in.) R. 150.0 mm (5.91 in.) EE. 50.8 mm (2.00 in.)
E. 950.0 mm (37.40 in.) S. 150.0 mm (5.91 in.) FF. 211.8 mm (8.34 in.)
F. 5.1 mm (0.20 in.) T. 150.0 mm (5.91 in. GG. 19.1 mm (0.75 in.)
G.320.0 mm (12.60 in.) U. 500.0 mm (19.69 in.) HH. 19.1 mm (0.75 in.)
H. 45.0 mm(1.77 in.) V. 1524.0 mm (60.00 in.) JJ. 302.4 mm (11.90 in.)
I. 2 x 19.0 mm (0.75 in.) W. 1700.0 mm (66.93 in.) KK. 1760.0 mm (69.29)
J. 1050.0 mm (41.34 in.) X. 1300.0 mm (51.18 in.) LL. 929.0 mm (36.57 in.)
K.1725.0 (67.91) Clearance for Swing Jaw Y. 137.5 mm (5.41 in.) MM. 1750.0 mm (68.90 in.)
L. 250.0 mm (9.84 in.) Z. 275.0 mm (10.83 in.) NN. 1877.4 mm (73.91 in.)
M. 45.0 mm (1.77 in.) AA.1591.0 mm (62.64 in.)
N. 589.7 mm (23.22 in.) BB. 2141.0 (84.29 in.)
2–4 04/09
Operation and Maintenance Features, Dimensions and Specifications
WEIGHTS
Model 2550 Kilograms Pounds
Jaw Crusher (kg) (Lbs)
Crusher, Assembled and Complete 15,875 35,000 2

Crusher Main Frame Assembly 5,490 12,103
Swing Jaw Assembly

(Complete weight of assembled swing jaw and shaft assembly, including swing jaw, swing jaw 4,662 10,279
die, eccentric shaft, swing jaw bearings, main frame bearings, and other related components.)
Flywheel Sheave 757 1668
Flywheel Pulley 833 1836
Swing Jaw Die 1332 2930
Stationary Jaw Die 1332 2930
Swing Jaw Guard Plate 126 277
Cheek Plate, Upper 80 177
Cheek Plate, Lower 53 116
Toggle Cylinder Assembly 963 2123
Toggle End, Cylinder Piston Side 52 114
Toggle End, Cylinder Rod Side 157 347
Toggle Cylinder (w/Relief) 636 1,404
Toggle Wear Bar 22 48
Die Wedge (Stationary) 118 260
Die Wedge (Swing Jaw) 65 144
IMPORTANT:
All weights shown are estimated and may vary by +/- 5
percent due to fabrication variables, optional equipment or
custom engineering. When available, always refer to the bill of
lading or packing list for actual weights.
04/09 2–5
2–6 04/09
Chapter 3
Crusher Installation and Assembly
3
CONTENTS
Page
RECEIVING THE SHIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Shipment Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Inspection & Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Reporting Damaged or Missing Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
CRUSHER LIFTING & HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
CLEARANCE REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
MOUNTING THE CRUSHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
LUBRICATION SYSTEM REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
HYDRAULIC SYSTEM PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Hydraulic Supply Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Hydraulic Line Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Hydraulic Control Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Hydraulic & Sensor Control Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . 3-7
SAFETY GUARD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

DIESEL ENGINE PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
FEED AND DISCHARGE ARRANGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
NEW CRUSHER START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
INITIAL START-UP CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
04/09 3–1
Crusher Installation and Assembly Operation and Maintenance
RECEIVING THE SHIPMENT 3. Check the crusher and any subassemblies for obvious
signs of damage.
Shipment Details
4. Remove all parts from the shipping crates and check
The 2550 Crusher is shipped completely assembled. The them against the packing list. Make a note of any damaged or
crusher will require final electrical control connections to the missing items.
3 hydraulic control assembly. Recommended crusher starter
circuitry and connections to the control assembly are detailed Reporting Damaged or Missing Items
in Chapter 3. Missing items or non-concealed damage must be noted in
The crusher will require a hydraulic pressure source capable writing on the delivery receipt when the shipment is
of delivering 3 GPM of hydraulic fluid at a minimum of 2500 delivered. The carrier will have the right to reject any future
psi. Hydraulic connections and requirements are detailed in damage claims if this is not done.
Chapter 3. Report any missing items or non-concealed shipping damage
The startup procedure for the grease lubrication system is as follows:
located in Chapter 3. 1. Provide a brief description of the missing or damaged
IMPORTANT: Do not connect electrical power to the items in writing on the delivery receipt. Make a copy of the
hydraulic power control assembly until all hydraulic and delivery receipt for your records.
lubrication hose connections have been made. 2. Notify the carrier immediately and request an inspection
Tools and loose parts are packed inside wooden crates or by an authorized representative. Save any damaged items or
fastened to pallets. Refer to the bill of lading and packing list shipping materials so that they are available for examination
for a complete description of the components and any during the inspection.
subassemblies supplied with your crusher. 3. File a damage claim with the carrier immediately after
Inspection & Unloading the inspection.
1. Always use proper lifting and handling procedures when IMPORTANT: Immediately report any concealed
unloading and unpacking the shipment. To avoid damage, shipping damage or parts shortages to the Telsmith
follow the instructions in the Crusher Lifting & Handling Service Department or your local Telsmith dealer.
section of this chapter.
2. Compare the total number of pieces received in the
shipment against the quantity shown on the bill of lading.
Check for any missing pieces.
CHECK THE ENTIRE SHIPMENT

FOR MISSING OR DAMAGED ITEMS
REFER TO THE BILL OF LADING AND PACKING

LIST WHEN UNLOADING THE SHIPMENT
3–2 04/09
Operation and Maintenance Crusher Installation and Assembly
CRUSHER LIFTING & HANDLING
Figure 3–1. Lifting The 2550 Jaw Crusher

2. Refer to the bill of lading or packing list for the actual
! WARNING weight of the complete 2550 crusher assembly. If these
Do not allow personnel under the crusher while it is documents are not available, refer to Chapter 2 for estimated
being supported by a crane or other lifting device. weights. Be sure that the lifting device and all other lifting
Always use suitable rigging and hoisting equipment equipment is of adequate capacity to support the entire load
to stabilize and lift heavy objects. Lifting heavy being lifted.
components with inadequate hoisting apparatus 3. Lift the crusher by installing lifting lugs or eyes of correct
can result in serious injury or death. capacity at the four mounting holes shown in Figure 3-2. Use
1. Read and understand the general hoisting and handling only these lift points and make certain that the crusher is
safety precautions contained in Chapter 1. evenly supported. Also note the following precautions:
04/09 3–3
• NEVER attempt to lift the crusher using the swing jaw • Allow adequate room beside the drive belt and drive
lifting lugs. These lugs are not designed to lift the entire sheave for routine inspection and maintenance. All belt
crusher. Serious damage could result! drive components must be easily accessible when the
flywheel and drive guards are removed.
• NEVER place slings around the flywheel sheaves or the
eccentric shaft. These components should never be used as • Allow adequate room around the grease lubrication
3 lifting points. system and the hydraulic control unit. All service points
must be easily accessible for routine inspection,
• Handle the crusher with care. Ensure that it remains
lubrication and maintenance activities.
upright and evenly supported at all times. Rough or
careless handling can cause serious damage.
MOUNTING THE CRUSHER
IMPORTANT: Improper lifting procedures can result in
permanent damage to the crusher and its components. • The crusher must be horizontally and vertically level when
Such damage is not covered under warranty! mounted. Damage to crusher internal components may
result if the crusher is not completely level.
A A • Install steel leveling shims as required between the crusher

mounting feet and the track plant frame. Then tighten the
crusher mounting nuts to firmly secure the crusher to the
frame.
Crusher must be horizontally and vertically level

(Check in both planes as shown)
Figure 3–2. 2550 Crusher Frame Lifting Points
A. Install lift eyes or lugs at these points only.

B. DO NOT use swing jaw eyes to lift complete 2550 crusher
CLEARANCE REQUIREMENTS
Note the following guidelines when planning the crusher
installation. Refer to Chapter 2 for crusher external
dimensions and required clearances. Figure 3–3. Checking Crusher Levelness
• Allow adequate room beside the crusher for walkways and
service platforms. Observe all federal, state and local
regulations when designing and constructing such
structures.
• Allow adequate room above the crusher for swing jaw
removal. Any structures or chutes mounted above the
crusher must be designed for easy removability when
repairs are necessary.
• Allow adequate room beside the flywheel sheaves to
permit removal of the sheaves when repairs are necessary.
3–4 04/09
visible at the grease seal shaft junction behind the

! CAUTION flywheels, grease intervals and amounts are probably
Check the position of the lock pins (Fig. 3-4) on correct. If a small amount of purged grease is not visible,
both sides of the crusher after the unit is the amount of grease applied at each service should be
mounted and before starting the crusher. Lock increased. If grease weepage at the seal junction is
excessive and grease is being thrown by the rotating parts,
pins must be in the storage position (Nose of pin
NOT protruding into the crushing chamber). decrease the grease amount applied at each interval. 3
Make certain the pins are firmly locked in the
storage position with the locking capscrews.
Sta r t i n g t h e c r u s h e r w i t h t h e l o c k p i n s B
B
protruding into the crushing chamber could
seriously damage the crusher drive A A
components.
D D
A
Figure 3–4. Locking Pin Storage Position

A. Locking Pin Storage Position
B. Nose of pin flush with side plates
LUBRICATION SYSTEM E
C C
REQUIREMENTS
• Start-Up - The 2550 Jaw Crusher uses four separate
Figure 3–5. Grease Fittings
grease zerks located on one central bracket (Fig. 3-5) to
supply lube to the swing jaw and main frame bearings. A. Swingjaw Fitting B. Main Frame Fitting
C. To Swingjaw Bearing D. To Main Frame Bearing
The grease lubrication system is delivered installed on the
E. Grease Zerk Block
crusher frame, with all hoses plumbed to grease zerks
(Fig. 3-5). Apply several strokes of a standard grease gun
at each zerk prior to starting the crusher to ensure the lines
are full.
• Daily Lubrication - Approximately 2.3 ml (.08 oz.) of
grease should be added at all zerks daily at shutdown
while the 2550 is warm. Add approximately 5 strokes
from a standard grease gun to each zerk. If the 2550
crusher is used for more than 1 shift a day, it should be
lubed at the end of each 8 hour shift. If grease is just
04/09 3–5
HYDRAULIC SYSTEM PREPARATION 2. The pressure supply line must be routed to fitting (P) on
the hydraulic control assembly (A, Fig. 3-7). A return line to
Hydraulic Supply Requirements the hydraulic tank must be connected to fitting (T) on the
hydraulic control assembly (B, Fig. 3-7). A clamp is provided
The 2550 Jaw Crusher will require a hydraulic pressure on the 2550 frame to route the hydraulic lines (Fig. 3-6).
supply capable of delivering a minimum of 172 bar (2500 psi)
3 at 11 LPM (3 GPM). A maximum of 206 bar (3000 psi) is
recommended. A steady hydraulic pressure supply under all
conditions is required, as the 2550 crusher must have 169 bar
(2450 psi) to start. If hydraulic pressure were to drop below C D
124 bar (1800 psi) but remain above 34 bar (500 psi) for four
minutes while the 2550 is running, the feeder will stop after
an additional 20 sec. If the pressure drops below 34 bar (500
psi), the jaw crusher will shut down after 20 seconds.
Hydraulic Line Installation

A B
The 2550 Crusher requires installation of three hydraulic
hoses and two (2) electrical connections to the hydraulic
control module. When completing the hydraulic connections.
3/ ” hydraulic hose is recommended for the two lines coming
8
from the “P” and “T” ports on the crusher valve block.
1. One 11/4“ hydraulic hose must be routed as a relief line
from the hydraulic cylinder relief manifold (A, Fig. 3-6) back
to the hydraulic tank. A hydraulic line clamp is supplied on
the 2550 frame to route the relief line. D
C
B
Figure 3–7. Hydraulic Line Connections

A. P Hydraulic Hose Connection B. T Hydraulic Hose Connection
C. 24V DIN Connector (Solenoid D. 24V DIN Connector (Solenoid
B A, Extend) B, Retract)
C
Figure 3–6. Hydraulic Relief Hose Mounting

A. Relief Hose B. Relief Hose Clamp
C. Hydraulic Hose Clamp D. Relief Manifold
3–6 04/09
Hydraulic Control Requirements disconnect switch that can be locked in the OFF position to
facilitate service of the 2550 Crusher. It is recommended that
Refer to the Hydraulic Control Requirements schematic (Fig.
the Stop/Start device controlling the feeder device be
3-8) and the Electrical Control and Interlocks schematic (Fig.
interlocked with the crusher Start/Stop (Fig. 3-9) to prevent
3-9) when planning your control switches and electrical
the feeder from continuing to deliver material in the event of
interlocks. Telsmith recommends that a hydraulic control
an emergency jaw crusher shut down situation.
switch with separate Start/Stop and Crush/Adjust functions 3
be used. The hydraulic control MUST incorporate a
2550 CRUSHER HYDRAULICS
b
HYDRAULIC ADJUST
ASSEMBLY
P A
T B
G4
HYDRAULIC CONTROL
ASSEMBLY
a G1 G2
30 psi 2000 psi

spring Charge
Pressure
P T 5000 psi B A 6000 psi P T P
4800
psi T
145 psi spring

EXT RET B A
G3
T2 T1 P
11 LPM (3 GPM) Minimum Recommended @ P
172 bar (2500 psi) Minimum Supply Pressure @ P
206 bar (3000 psi) Maximum Supply Pressure @ P
Supplied by Telsmith
Figure 3–8. Hydraulic Control Assembly, Hydraulic Schematic
Hydraulic & Sensor Control Electrical The ground wire from terminal #3 on the connector cable
Connections must be connected to the power supply grounding
connector. The jaw position sensor is delivered mounted
The 2550 Jaw Crusher requires electrical connection at both
and adjusted to give a 15.2 cm (6 in.) detection range. If
the hydraulic control assembly, and the jaw position sensor.
adjustments to the jaw position sensor become necessary,
• 24V must be supplied to the extend and retract solenoids refer to Chapter 4.
on the hydraulic control assembly (Fig. 3-9). DIN
connectors are supplied at both coils for the 24V supply.
• The position sensor (Fig. 3-9) uses a 4 pin, 12 mm euro
connector (Fig. 3-9) to both deliver the incoming 24VDC
power and return the position output signal (0.5 to 9.5
VDC). A compatible.250 cable with four (4) 22 ga
conductors will be required to connect the position sensor.
04/09 3–7
A C
B
Figure 3–9. Electrical Connections

A. Solenoid A (Extend) DIN connector B. Solenoid B (Retract) DIN connector
C. Jaw Position Sensor 4 Pin Euro Connector
2550 CRUSHER ELECTRICAL CONTROL & INTERLOCKS
+ -
FEEDER
CRUSH ADJUST ENABLE
PSI MEASURED AT P TR1 OFF
DELAY
XO
5 SEC
SET at 2450 PSI TR2
OX CRUSHER
RESET at 1800 PSI ENABLE
OFF
EXTEND RETRACT DELAY
25 SEC
TR2-1 SOL A
XOO
CYLINDER
EXTEND
OOX SOL B
CYLINDER
RETRACT
ANALOG OUTPUT PE
JAW POSITION
SENSOR 0.5 VDC = 0.00”
9.5 VDC = 7.00”
1 4 DISPLAY
2 3
PROGRAM
INPUT
PROVIDED BY TELSMITH
START START
STOP TR2-2 STOP TR1-1 MS1
RECOMMENDED CRUSHER RECOMMENDED STARTER CIRCUITRY

STARTER CIRCUITRY FOR DEVICE FEEDING CRUSHER
Figure 3–10. Hydraulic Control Assembly Electrical Schematic
3–8 04/09
SAFETY GUARD INSTALLATION DIESEL ENGINE PREPARATION

Installation of flywheel and drive belt safety guards is • Be certain that the diesel engine is properly sized for the
required after installation of the 2550 crusher and the jaw crusher. The 2550 Crusher requires 93 - 112 KW (125-150
power rotation system is complete. Guards must completely HP) to drive the swing jaw. Note that diesel horsepower is
cover the inner and outer face and the rim of each flywheel, rated differently than electric horsepower.
the complete belt run and the belt drive sheave to prevent
• Read and understand the operator’s manuals provided
3
accidental contact with the rotating surfaces by any service
with the engine. If present, also refer to any additional
personnel or operators. Flywheel and belt guards should be
operator’s manuals for engine accessories (power take-off,
designed to prevent accidental intrusion by tools, flying
auxiliary pump drive, etc.).
debris and any service equipment that could come in contact
with an operating jaw or the flywheel drive apparatus. • Follow the engine manufacturer’s instructions when
Threaded holes are provided in the 2550 frame for mounting preparing the diesel engine for use. Check all fluid levels.
flywheel guards (Fig. 3-11). If it is necessary to add fluids, use only recommended
fluids of the proper specifications.
! CAUTION • If the engine is equipped with a power take-off (PTO), read
Failure to properly guard Model 2550 Jaw the PTO operator’s manual for start-up checks and
Crusher flywheels and drive sheaves could adjustments.
result in entanglement risks to operators and • Prepare the engine for operation in accordance with the
service personnel. Serious injury or death could engine manufacturer’s initial start-up instructions.
result if contact is made with rotating flywheels, Completely follow all recommended break-in procedures.
sheaves or belts. Never operate the 2550 crusher Observe all safety precautions as outlined in the operator’s
with flywheel, sheave or drive belt guards manuals.
removed.
IMPORTANT: It is the user’s responsibility to install and
connect an appropriate fuel shut-off device if the
crusher is diesel powered.
FEED AND DISCHARGE

ARRANGEMENT
Adequate surge storage facilities must be provided to ensure
that the 2550 crusher receives a constant, steady feed at all
times. It is recommended that a feeder be installed between
the crusher and the surge storage to allow precise regulation
of the feed.
A vibrating grizzly feeder placed just ahead of the crusher is
mandatory for most crushing applications. A feeder will
remove most of the undersize or “fine” material from the
feed, resulting in improved crushing efficiency.
A feed hopper of appropriate size must be mounted above the
crusher. It is the customer’s responsibility to fabricate a
suitable feed hopper if one was not supplied with the crusher.
Hopper mounting holes are provided at the top of the crusher
frame. Refer to Chapter 2 for mounting hole locations and
dimensions.
A proper discharge arrangement is essential. Be certain that
the discharge chute will not restrict the free flow of material
through the crusher. Provide a sufficient amount of clearance
between the top of the jaw crusher foundation and the bottom
Figure 3–11. Flywheel Guard Mounting Holes of the discharge area so that crushed material can drop freely
as it exits the crusher.
04/09 3–9
Flat bottom boxes used as discharge chutes should be 10. Verify that hydraulic adjust cylinder position sensor LED
mounted low enough so that crushed material, when piled to remains green during complete crusher stroke.
the angle of repose, will not reach the lower portion of the
11. Listen for noise at the hydraulic adjust assembly. If a
swing jaw. Any material back-ups in this area can cause
“thumping” is heard during the test run, spring tension may
serious damage to the crusher.
need to be adjusted or balanced on the compression springs.
3 Crushed stone can be very abrasive. Whenever possible, Refer to Chapter 4 for complete spring adjustment
chutes should be constructed in the form of boxes so that instructions.
stone runs on stone and wear is reduced. For added durability,
it is recommended that chutes and hoppers be lined with
abrasion resistant steel plate.
NEW CRUSHER START-UP

1. Read and fully understand the crusher operating
instructions contained in this manual. Be familiar with all
crusher features and functions.
2. Perform all applicable installation and assembly
procedures as described in the previous sections of this
chapter.
3. Locate the Initial Start-up Checklist. This checklist is
shipped loose with all new crushers. Keep all checklists
handy during the initial start-up period.
NOTE: Refer to the back of this chapter for a duplicate
copy of the Initial Start-up Checklist.
NOTE: Perform all hydraulic system initial start-up
procedures as described in the OEM track plant
manufacturer instructions. Verify that all hydraulic
functions operate properly, and that there are no
obvious problems.
4. If not done previously, adjust the crusher discharge
setting. Refer to Chapter 4 for instructions.
5. Complete section I of the Initial Start-up Checklist.
6. Start the hydraulic pump. Verify that the main system
pressure gauge indicates approximately 172 - 206 bar (2500 -
3000 PSI). The hydraulic pump should turn on when main
system pressure falls below approximately 137 bar (2000 psi)
and turn off when main system pressure rises above (172 bar)
2500 psi.
7. Walk completely around the crusher. Check that no
personnel are on, inside or near the machine. Sound a
warning horn to alert others that the crusher is about to be
started.
8. Start the crusher drive motor or diesel engine.
9. Check crusher speed (RPM) during initial startup with a
handheld tachometer. Specified RPM is 250 RPM. If crusher
RPM is less than 242 RPM, or greater than 258 RPM,
adjustments to the flywheel drive apparatus will be required.
3–10 04/09
Mail to: Important:

Telsmith, Inc. Mail Signed Checklist
within 7 days of start-up
Attn.: Service Department
to maintain warranty.
P.O. Box 539
Mequon, WI 3
U.S.A.
INITIAL START-UP CHECKLIST

CUSTOMER INFORMATION: SECTION 1- Pre Start-Up Checks cont.
Customer Name / Address BELT DRIVE

Sheaves properly aligned and installed.
All sheave bolts tight.
Dealer Name / Address Drive belt tension adjusted correctly.

Drive and flywheel guards installed.
DIESEL ENGINE
Checklist completed by Engine properly installed and prepared for
operation.
Engine fluid levels checked.
Date Engine manufacturer’s manuals read and
Crusher Model understood.
Serial Number
HYDRAULIC SYSTEM
Customer Signature : Hydraulic reservoir filled
(Name and grade of fluid used _____________).
SECTION 1- Pre Start-Up Checks
Hydraulic supply and relief hoses properly
FOUNDATION connected at hydraulic unit and crusher.
Crusher solidly mounted on machine or Timed delay relay interlocked with crusher starter
structure. or diesel fuel shutoff.
Crusher shimmed level.
Hydraulic pump turns in correct direction.
Crusher mounting nuts tight.
Main system pressure indicator indicates 172 bar
CHUTES AND HOPPERS (2500 psi) to 206 bar (3000 psi).
Feed chute adequately sized and properly Hydraulic filter indicator(s) show no obstruction or
positioned. leaks.
Discharge hopper adequately sized and properly
positioned.
Chutes and hoppers have proper clearance.
Chutes and hoppers free of obstructions.
CRUSHER
Discharge setting correct (________ inches).
Crushing chamber clear.

Tension springs correctly adjusted.
(No knocking or thumping when initial run occurs)
04/09 3–11
START-UP CHECKLIST cont.

SECTION 2- CRUSHER INITIAL START-UP SECTION 3- MATERIAL INTRODUCTION
3 GREASE LUBRICATION SYSTEM FEED ARRANGEMENT
Grease Zerks Serviced. Feed evenly distributed across full width of
crushing chamber.
Swing jaw and eccentric shaft bearing temperatures
Feed free of clay and fines.
checked after 8 hour run-in:
Swing jaw bearings ______oC Crushing chamber remains adequately filled
Eccentric shaft bearings _______oC during normal operation.
No material back-ups or spillage evident in
CRUSHER DRIVE SYSTEM discharge area.
Top of drive side flywheel rotates toward feed
opening. HYDRAULIC SYSTEM
Flywheel speed is ______ RPM with crushing Hydraulic fluid temperature and pressure
chamber empty. remain within acceptable limits.
Jaw position sensor LED shows green. Hydraulic filter indicator(s) show green after fluid
is warm.
DIESEL ENGINE
Fluid heater (if equipped) turns on and off at
Engine starts and operates properly. correct temperatures.
Power take-off engages properly. CRUSHER
Engine gauges and indicators show normal readings. No unusual noises, vibrations or other signs that
would indicate jaw is making contact with solid
objects.
Engine heater turns off and on at the proper
temperature (if equipped). Hydraulic relief action does not occur during
processing of normal feed material.
Engine rpm is _____ rpm with crusher unloaded.
Flywheel sheave speed is ______ RPM after
material feed is started.
BELT DRIVE
Crusher RPM remains constant (within 5%) after
Drive belt tension correct after initial run. material feed is started.
Drive belt and sheave not contacting guards during Position sensor LED remains green during
operation. complete crusher stroke.
Mail to: Important:

Telsmith, Inc. Mail Signed Checklist
Attn: Service Department within 7 days of start-up
P.O. Box 539 to maintain warranty.
Mequon, WI
U.S.A.
3–12 04/09
Chapter 4
Crusher Operation and Adjustments
4
CONTENTS
DAILY START-UP PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Pre-Start Checks & Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Lubrication System Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Start-up Checks and inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Crusher Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
AFTER STARTING MATERIAL FEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
FEED RATE AND GRADATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
DAILY SHUTDOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
GOOD HOUSEKEEPING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
MEASURING THE DISCHARGE SETTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
SETPOINT ADJUSTMENT FEATURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
ADJUSTING THE DISCHARGE SETTING (Setpoint) . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
CLEARING OBSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Hydraulic Clearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Manual Clearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
POSITION SENSOR ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
HYDRAULIC ADJUST ASSEMBLY SPRING TENSION . . . . . . . . . . . . . . . . . . . . . . . 4-9
04/09 4–1
Crusher Operation and Adjustments Operation and Maintenance
DAILY START-UP PROCEDURES

Use the following steps as a guide when preparing the crusher
for operation at the beginning of each shift.
Pre-Start Checks and Inspections

Perform the following steps with the crusher OFF.
4 ! WARNING
Lockout/tagout power to the crusher drive before
making the following checks and inspections.
1. Remove any spillage and debris from around the crusher.
Remove any built up material from the crusher frame surfaces
Figure 4–1. 2550 Hydraulic Control Unit
and ledges.
2. Check that the crushing chamber is clear. Be sure that no
material is lodged inside. Crusher Start-Up
3. Check the discharge area for obstructions. If present, Perform the following steps when starting the crusher:
remove any trash or built-up material.
1. Walk completely around the crusher. Be sure no personnel
4. Inspect all chutes and hoppers for damage or excessive are on, inside or under the machine. Sound a warning horn to
wear. Remove any obstructions. alert others that the crusher is about to be started.
5. Remove any loose dirt or stones from the drive motor 2. Start the plant diesel engine and the hydraulic pump.
cooling fins. Be sure that the motor fan openings are clear.
3. Verify that the plant hydraulic system pressure gauge
Lubrication System indicates approximately 2500 PSI (172 bar).
Grease zerks for the 2550 swing jaw should be serviced when
the bearings are warm after a shift shutdown. Refer to Daily ! CAUTION
Shutdown in this chapter for suggested grease intervals. The jaw crusher jaw setpoint (discharge setting)
1. Remove any loose dirt or spillage from the grease zerk MUST be adjusted before running a new crusher
block. for the first time. The 2550 is delivered with the
jaws at a minimum clearance setting for
2. Check grease system hoses and fittings for leaks. Repair transport purposes. Follow the instructions in
any leaks before starting crusher. this chapter on adjusting the setpoint before
placing the crusher in the CRUSH mode for the
Start-Up Checks first time. Failure to set the setpoint (discharge
Perform the following steps with the crusher OFF. Refer to setting) at a 6.35 cm (21/2”) or greater setting
Chapter 9 for hydraulic system operation and maintenance before running the 2550 crusher could damage
instructions. the unit.
1. Remove loose dirt or spillage from the hydraulic control 4. If you are starting the 2550 Crusher for the first time,
unit (Fig. 4-1). adjust the crusher jaw setpoint (discharge setting) to the
desired setpoint as described in Measuring the Discharge
2. Wipe off all gauges and indicators. Setting and Adjusting the Discharge Setting in this chapter.
3. Check for hydraulic fluid leaks. Repair any leaks before An initial crusher jaw setpoint MUST be established before
starting the hydraulic pump. starting the 2550 crusher for the first time.
4. Check the plant hydraulic reservoir level indicator. Add 5. Place the selector switch controlling the 2550 crusher in
fluid if low. Refer to the plant manufacturers hydraulic fluid the CRUSH position.
specifications for correct hydraulic fluid type. 6. Verify that there are no unusual noises, vibrations or other
indications of improper operation. Stop the crusher
immediately if any obvious problems are detected.
4–2 04/09
Operation and Maintenance Crusher Operation and Adjustments
7. If swing jaw relief action occurs frequently, check the

material feed for excessive tramp iron or other uncrushable
AFTER STARTING THE MATERIAL objects.
FEED
1. Verify that the material feed is evenly distributed and well FEED RATE AND GRADATION
graded. The crusher should remain at least two thirds full
Regulate the feed rate so that the chamber remains at least
during crushing.
two-thirds filled while crushing. This will help ensure proper
2. Be sure there is no material spillage at the crusher feed work-hardening of the jaw dies and will help prevent uneven
hopper. Reduce feed rate if spillage occurs. wear from occurring. 4
3. Verify that material moves continuously through the A well-graded feed - evenly distributed across the full width
crusher without backing up. Check that the discharge of the crushing chamber - will help ensure maximum jaw die
conveyor is removing crushed material at an adequate rate. life and the highest quality product.
4. Check the ammeter at the drive motor. Power draw should The feed should be sized to a top dimension well within the
remain within normal limits and must not exceed the full effective receiving opening of the crusher. Large pieces that
rated amps of the crusher drive motor. cannot pass through the crusher without bridging should be
broken by other means or removed from the feed.
5. Recheck all gauges and indicators at least every 4 hours.
Stop the crusher immediately if any abnormal or rapidly Operating the crusher with a weak or intermittent feed is not
changing readings are observed. recommended. Underfeeding will result in a lower quality
product and greatly increased liner wear at the lower portion
6. When starting a new 2550 crusher for the first time, the
of the jaw dies.
swing jaw and eccentric shaft bearings temperatures should
be checked with a heat gun after 2 hours of operation and then Several times each day, check the discharge conveyor to
again after the first 4 hours of operation (Fig. 4-2). All verify that crushed material is being carried away without any
bearings should read 82 C (180oF) or less. After the crusher spillage or back-ups.
is broken in, bearing temperatures should be checked once a
week (40 hours). Excessive temperatures can be due to either DAILY SHUTDOWN
overgreased or undergreased bearings
1. Stop the material feed and allow time for the crushing
chamber to clear. Wait until there is no material remaining on
the discharge conveyor.
2. Stop the discharge conveyor.
3. Stop the crusher drive motor (or diesel engine) and allow
the swing jaw to come to a complete stop.
4. Lockout/tagout power to the crusher drive motor (or
diesel engine), and to all feed and discharge devices.
5. Lockout/tagout power to the hydraulic system and the
lubrication system.
6. Do a complete walk-around inspection of the crusher.
Note any maintenance or repair activities which must be
performed before the crusher is restarted.
7. Clean up any spilled material from walkways, stairways,
service platforms and other areas near the crusher.
8. Grease the swing jaw and eccentric shaft bearings while
the unit is still warm. Apply five strokes of a standard grease
gun to each zerk (Fig. 4-3). Use an NLGI #2 grease with EP
additives such as Mobil Delvac Xtreme Service if the crusher
is operating in a temperature range from 4oC (40oF) to 38oC
(100oF). Refer to Table 4-1 for grease recommendations if the
Figure 4–2. Checking 2550 Bearing Temperatures crusher will be operating in extreme heat or cold. If the
04/09 4–3
crusher is used for more than one 8 hour shift per day, grease and service points must remain accessible for routine
amounts will need to be adjusted. A properly greased crusher inspection and maintenance purposes.
should show a slight amount of grease seepage at the grease
• If possible, provide drainage away from the crusher.
seal/shaft junction behind the flywheels after eight hours of
use. • When not in use, properly store all spare parts and tools so
they are protected from dust and dirt.
MEASURING THE DISCHARGE

4 SETTING
Measure the discharge setting as described in the following
steps.
1. Lockout/tagout power to all feed and discharge devices.
Refer to Chapter 1 for complete lockout/tagout procedures.
2. Visually check that the crushing chamber is completely
empty.
3. Visually check that the flywheel weights are in the UP
position. This indicates that the eccentric shaft is in the
DOWN (at rest) position. If the weights are not in the up
position, the drive may need to be engaged momentarily to
rotate the weights.
4. Move the function switch to ADJUST, and then activate
the SET control to hold the jaw in position.
Figure 4–3. 2550 Grease Junction Block

! WARNING
Performing the discharge setting adjustment
Table 4–1. 2550 Grease Requirements requires working under or near the machine with
h y dra u l i c p o w e r a c ti ve . Ma k e ce r tai n al l
Recommended Recommended
Temperature
Specification Standard Synthetic personnel are aware that clearance settings are
Range
Lubricant Lubricant being adjusted. Rope off the work area and
install warning tags on the hydraulic control
Below 4oC NLGI 00, with - Mobilith SHC
40OF* EP Additives 007 panel to prevent inadvertent activation of
controls while service personnel are working
Below 38oC NLGI 2, with Mobil Delvac Mobilith SHC
100oF EP additives Xtreme Service 460 under or near the crusher.
Grease
5. From beneath the crusher, measure the PEAK to PEAK
Above 38oC NLGI 2, with - Mobilith SHC distance between the stationary die and the swing jaw die.
100oF EP additives 460
Make measurements in at least five different places across the
entire width of the discharge opening. See Figure 4-4.
* Recommended grade when crusher is supplied with an
Auto-Lube system.
GOOD HOUSEKEEPING
• Keep the crusher clean. Do not allow spilled material to
accumulate on or around the crusher. Be sure all
walkways, service platforms and stairways remain free of
tools and spilled material
• Do not allow spilled material to accumulate around the
hydraulic power or control units. All gauges, indicators
4–4 04/09
NOTE:
As wear occurs to the swing jaw and stationary
Swing Jaw Die
maganese crushing dies, the discharge setting will
gradually open beyond it’s original setting. As the
automatic reset feature controls the position of the
crushing cylinder, not the gap between the dies, it will be
necessary to manually check the discharge setting
periodically. Refer to Measuring The Discharge
Setting in this chapter for instructions on how to
4
Stationary Jaw Die
determine your current discharge setting.
Discharge
Opening
Measurement Note: Subtract approximately ADJUSTING THE DISCHARGE
25 mm (1 inch) from the discharge SETTING (Setpoint)
opening measurement to
determine the actual discharge If the discharge setting measured in the previous steps is not
setting. correct for your crushing application, or falls outside the 63.5
mm (2 1 /2 inch) minimum or 177mm (6 inch) maximum,
adjust the setting as follows:
Figure 4–4. Discharge Setting Measurement
To change the setpoint (Discharge Setting) on your 2550
6. Subtract approximately 25 mm (1 inch) from the shortest
crusher, adjust the jaw opening as follows:
measurement made in step 5. This dimension is the crusher
discharge setting. 1. Place the Manual/Auto switch in the AUTO position.
(Extend/Retract functions are not operational in Manual
IMPORTANT: The minimum discharge setting for this
mode.)
crusher is 63.5 mm (21/2”) or 87 mm (31/2”) as measured
at rest. DO NOT attempt to adjust the discharge setting 2. Place the Set/Adjust/Crush function selector switch in the
below this dimension. Crushing with an excessively ADJUST position.
close di scha rge setting may result in serious
3. Place the Extend/Retract control switch in the EXTEND
mechanical damage to the crusher. The maximum
position to close the setpoint. To open the setpoint, move the
discharge setting must not be set beyond 152 mm (6”)
control to the RETRACT position. The control must be held
or 177 mm (6”) as measured at rest.
in the Extend or Retract position while the adjustment is
performed, as the control will self center to the OFF position
! WARNING when released.
Once discharge settings are determined, all 4. Recheck the setpoint as detailed in MEASURING THE
personnel must clear the area beneath or near DISCHARGE SETTING, following all lockout/tagout and
the crusher before the discharge setting is warning directions while performing the measurement.
adjusted. Adjusting the discharge opening with
personnel under the crusher could result in 5. If necessary, perform additional adjustments to the
pinch point injuries or injuries due to dislodged setpoint using the Extend/Retract feature.
material falling unexpectedly. 6. When the correct setpoint is obtained, momentarily move
the function switch to SET. When the function switch is
SETPOINT ADJUSTMENT FEATURE moved back to the CRUSH position the new setpoint is
maintained.
Your crusher is equipped with a Linear Position Sensor that
automatically maintains the discharge (setpoint) setting. In 7. When a correct setpoint adjustment is obtained, restore all
the event of a relief action, the crusher will return the swing power to the crusher drive and all feed and discharge devices.
jaw to the previous discharge setting by controlling the Test the crusher for correct operation and correct size of
hydraulic cylinder position. crusher output.
04/09 4–5
CLEARING OBSTRUCTIONS 3. If the material will not dislodge, use the chisel feature to
break up the oversize material into crushable pieces. Use
Feed to the 2550 crusher should be sized to a top dimension caution when activating the chisel so that the breaker head
well within the effective receiving opening dimension of the does not plunge too deep into the chamber and contact the
crusher. Material that is 20 percent smaller than the full rated rotating or stationary jaw die.
receiving opening dimension is recommended. Feed should
be regulated so that the crushing chamber is always about 2/3 4. In some cases, uncrushable material (re-bar, tramp iron
full. In most cases, the hydraulic relief action should allow etc.) may be causing a bridge above the crushing dies. In this
oversize material or an overload to pass through the jaw. In type of obstruction situation it will be necessary to remove
4 some cases if an oversized piece of material is introduced, the the bridged material manually.
crusher could stall or cause a backup of input feed due to a 5. Before attempting to remove a bridged obstruction
bridging condition that is at the jaw intake above the crushing manually, read and understand all of the following warnings:
dies.
Hydraulic Clearing ! WARNING

Use the following procedure to remove excess material and Lockout/tagout power to the crusher drive, to all
jammed objects lodged inside the crushing chamber: feed and discharge devices and the hydraulic
power unit. Shut off the diesel engine on the
1. Immediately stop all feed devices. plant.
2. Move the SET/ADJUST/CRUSH function switch to the
ADJUST position. ! WARNING
3. Move the EXTEND/RETRACT control switch in the Use extreme caution when attempting to
RETRACT position and open the jaw to the fully retracted dislodge or remove jammed objects from the
position. If the oversize material does not drop immediately, 2550 crusher. These objects may be under
attempt to dislodge it by extending/retracting the jaw several tremendous pressure and could dislodge or
times. fracture at any time.
4. In most cases, fully opening the jaw should allow the
excess or oversize material to drop through the crusher onto ! WARNING
the discharge device where it can be removed. If this method
Never use dynamite or other explosives in an
clears the crusher, return the function switch to CRUSH and
attempt to clear a crusher jam. Explosives could
allow the 2550 jaw to run empty until the jaw returns to the
damage the crusher or eject material from the
pre-set setpoint.
crushing chamber at a high velocity that could
5. Restart the feed devices and observe the crusher operation cause injury or death.
as feed is re-introduced to the jaw.
6. If the crusher will not clear using the extend/retract ! WARNING
method, it maybe be necessary to manually break-up or
Always use a pole, rock hook (Fig. 4-5), breaker
remove the bridged material (See Manual Clearing in this
bar or grappling device to safely dislodge
chapter).
objects jammed inside the crushing chamber.
Always work from the top of the chamber. Never
Manual Clearing allow personnel to attempt to break up a jam
1. If your plant or machine is equipped with a rock breaker from beneath the 2550 crusher. Material could
chisel, it may be possible to breakup or dislodge the bridged suddenly release causing possible injury or
piece with the chisel. death. To prevent serious personal injury, do not
attempt to remove or dislodge jammed objects
2. Align the rock breaker chisel above the crusher jaw
by hand.
opening. Attempt to use the chisel head to bump or nudge
bridged material into the jaw opening.
4–6 04/09
4
A
7. Remove as much loose material from the top of the

crushing chamber as possible. When the uncrushable object
becomes accessible, try to loosen it with a pole, rock hook or
breaker bar. If necessary, use a grappling device to remove the
Figure 4–5. Using A Rock Hook To Dislodge Jams
uncrushable object up through the feed opening.
8. After clearing is complete, remove any objects, loose
! WARNING material or debris from the crusher discharge area.
Always use flywheel blocking to hold the swing
jaw in position. Do Not place timbers or other 9. Remove the blocking from the flywheel. Retract the
blocking devices in the crushing chamber in an locking pins to their storage position and secure with locking
attempt to hold the swing jaw open. Blocking bolts.
could crack or be ejected under tremendous 10. Reinstall the flywheel guard.
force causing personal injury or machine
damage.
! WARNING
Before restarting the crusher, verify that no
! WARNING personnel are working on, inside or under the
Never attempt to walk on jammed or bridged crusher or plant.
material. The material could break free at any
time sweeping you into the crusher and causing 11. Start the diesel engine, start the hydraulic pump and move
serious personal injury or death. the function switch to CRUSH. Allow the jaw to return to the
proper setpoint before resuming crushing.
6. Remove the V-belt drive guard to provide access to the
crusher flywheel. Block the flywheel sheaves to prevent the
jaw from turning during clearing procedures (Fig. 4-6).
Blocking must be installed so that the weighted portion of the
sheave does not rotate to the top as the chamber is cleared.
Block the flywheels by installing blocking through the
flywheel cutouts and contacting the top of the crusher frame
at two points on each flywheel.
Figure 4–6. Blocking Swing Jaw Sheaves

A. Blocking points (4 places) B. Blocking
C. Lock Pin (2)
04/09 4–7
POSITION SENSOR ADJUSTMENT • Loosen the six (6) clamp bolts on the position sensor (A,
Fig. 4-8) enough to allow the sensor body to be slid back
The 2550 Crusher is delivered with a linear position sensor and forth in relation to the slider magnet.
that tracks the hydraulic cylinder movement and position.
The sensor is set from the factory to track a cylinder stroke • Slide the sensor housing forward in relation to the magnet
from 0 mm (0”) to 177 mm (7”). until the LED is at the point where it just turns from yellow
to green.
If you require a different sensor range, or the indicators on the
sensor indicate that the position sensor is no longer tracking • When the LED reading is correct (green), tighten the
position sensor clamp bolts (A, Fig. 4-8) to 11 Nm (8 Ft.
4 the correct range, adjust the sensor as follows:
Lbs).
1. An LED located next to the electrical connector on the
end of the position sensor provides diagnostic readings to • Extend the swing jaw until the setpoint (discharge setting
determine current sensor condition (Fig. 4-7). This position is at 63.5 mm (21/2”). Note the color of the LED, it should
sensor LED can be used to help determine the sensor remain green indicating you are in the active zone.
operating range. When correctly set, the LED will show green • Retract and extend the jaw through the 63.5 mm (21/2 in.)
to indicate the zone that is currently programmed. If the to 158 mm (6 in.) range several times. Observe the LED as
swing jaw is retracted back past the 158 mm (6”) maximum the jaw runs through the range; if it reads green, the
setting, the LED will turn yellow to indicate you are out of the programmed stroke is correctly set.
programmed zone. If the swing jaw is closed past the 63.5
mm (21/2”) minimum setting the LED will again turn yellow.
A
2. When re-setting the linear position sensor, you must note B
the dead (null) areas on each end of the sensor. At the
connector end of the housing, a 76 mm (3”) dead (null) zone
is present. The back end of the housing has a 38 mm (11/2”)
dead (null) zone. When setting up the position sensor, the
magnet must be adjusted so it does not run in these zones. If
the magnet slides into these zones, the LED will turn red to
alert you that the position sensor cannot be programmed in
these areas. C
D
Figure 4–8. Position Sensor Components

A. Sensor Clamp Bolts (6) B. Sensor Body
A B C. Slider D. Mounting Bracket
E. Slider Magnet F. Slider Threaded Rod
4. If it is not possible to correctly program the sensor stroke

by positioning the sensor body, it may be necessary to adjust
Figure 4–7. Position Sensor LED Location the length of the threaded slider rod (F, Fig.4-8). Loosen the
A. Sensor Condition LED B. Electrical Connector fitting on one end of the rod and thread the rod in or out to
C. Sensor clamp bolt (2) change the length. If the sensor range cannot be programmed
to yield a green LED over the complete slider range, contact
3. To replace or reposition a linear position sensor the
the Telsmith Service Department.
following steps are required:
5. When all settings are correct and the sensor mounts are
tight, reset the jaw discharge setting to the desired opening.
4–8 04/09
HYDRAULIC ADJUST ASSEMBLY

SPRING TENSION
The hydraulic adjuster assembly springs should be checked
after the initial 8 hour shift has been run and then on a
monthly basis. As the toggle seats and wear bars wear over
time, spring tension will require adjustment. With the crusher
running, listen at the bottom of the unit to the hydraulic adjust
assembly (Fig 4-9). If a distinct “Thumping” sound is present,
the four springs on the unit need to be re-tensioned after their 4
initial run-in.
To re-tension springs:
1. Shut off all power to the crusher and plant including the
hydraulic system and the diesel engine. Lock/tagout all
controls.
A
! WARNING F C B
Lockout/tagout power to the crusher drive, to all
E D
feed and discharge devices and the hydraulic
power unit. Shut off the diesel engine on the
plant before performing any service on the Figure 4–9. Hydraulic Adjust Assembly
hydraulic adjust assembly. A. Upper Jam Nut (4) B. Lower Jam Nut (4)
C. Upper Spring Washer (4) D. Tension Spring (4)
2. From the bottom side of the crusher, measure the
E. Lower Spring Washer (4) F. Spring Pocket (4)
compressed length of each spring from the upper spring
washer to the face of the lower spring washer (Fig. 4-9). All 5. Do not compress the tension springs past 117 mm (45/8”)
four springs must have the same compressed length. If the dimension. Tightening the springs further could cause them
dimension of one spring is shorter or taller than the other 3 to coil bind or compress solid. If the hydraulic unit continues
springs it must be adjusted first. Remove the upper jam nut to make noise after tightening the springs to a matching
(A, Fig. 4-9) and tighten or loosen the lower jam nut (B, Fig. dimension, look for other sources for the noise such as the
4-9) until the out-of-dimension spring matches the others in tension pin action in the toggle ends or loose toggle wear bars
height. (Springs were adjusted new to a compressed height of in the toggle ends.
120 mm (43/4”)).
D A
NOTE:
120 mm (43/4”) is the ideal spring length. If knocking is
still heard with the springs adjusted to 120 mm, springs
may then be adjusted down to a minimum of 117 mm
(45/8”).
C
3. When all springs are showing the same compressed B
dimension, remove the upper jam nut from the remaining
springs. Adjust all four springs until they measure between
119 mm (411/16”) and (117 mm (45/8”) compressed height.
Measure the spring from the bottom (Fig. 4-10) which will
allow you access to measure the full length of the spring.
4. Check all four springs carefully, if it appears that coils are
binding (touching coil to coil) the springs are tightened too
much, or the spring has lost compression and is losing height
and must be replaced. Reinstall the upper jam nuts and tighten
Figure 4–10. Hydraulic Assembly (Bottom View)
firmly while holding the lower jam nut to prevent it from
rotating. Restart the crusher and run with no load for several A. Toggle Wear Bar (2) B. Jam Nuts (8)
C. Tension Spring (4) D. Tension Pin (4)
minutes to check for further abnormal noises.
04/09 4–9
4–10 04/09
Chapter 5
Crusher Lubrication
and Maintenance Schedule
Contents
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
TIME INTERVALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
CRUSHER LUBRICATION & MAINTENANCE SCHEDULE . . . . . . . . . . . . .5-3
04/09 5–1
Crusher Lubrication and Maintenance Schedule Operation and Maintenance
INTRODUCTION TIME INTERVALS

The crusher lubrication and maintenance schedule contains The time intervals shown in the schedule are based on an 8 to
important lubrication, maintenance and inspection 10 hour operating day and are applicable for most crushers.
procedures which must be performed on a routine basis to However, some maintenance items may require more
ensure proper crusher operation. frequent attention if one or more of the following conditions
are present.
All procedures should be performed at the proper time
intervals indicated in the schedule. Do not skip any - If the crusher is operated over 10 hours per day.
procedures that apply.
- If wet, dirty or sticky feed is being processed.
Always keep a written record of all maintenance activities.
- If the feed contains unusually hard or abrasive material.
Never rely on memory when performing scheduled
maintenance. - If the crusher operates in unusually hot or cold outside
ambient temperatures.
As indicated in the right hand column of the schedule, refer
to other chapters of this manual for detailed maintenance - If the jaw dies are nearing the end of their useful life.
instructions, lubricant specifications and other important
The lubrication and maintenance schedule should be
information.
considered only as a guide. Environmental conditions, the
5 type of material being processed and other factors specific to
! WARNING!!!
DANGER your crushing application will dictate the exact amount of
periodic maintenance required.
Always stop the crusher and lockout/tagout power
before performing any inspection, adjustment,
lubrication, maintenance or repair procedures.
Refer to Chapter 1 for complete lockout/tagout
instructions.
IMPORTANT: Before performing any service work, read
and completely understand all applicable maintenance
procedures. Always observe the safety precautions and
instructions included within the procedures.
Refer to Chapter 3 for additional

Lubrication System Maintenance
5–2 04/09
Operation and Maintenance Crusher Lubrication and Maintenance Schedule
CRUSHER LUBRICATION & MAINTENANCE SCHEDULE
Table: 5-1 Crusher Lubrication and Maintenance Schedule
Monthly
Chapter
Refer to
Weekly
Yearly
Daily
Lubrication or Maintenance Item:
REMOVE SPILLAGE AND DEBRIS FROM AREA AROUND CRUSHER. •
REMOVE ANY BUILT-UP MATERIAL FROM CRUSHER FRAME SURFACES. •
REMOVE DUST AND DIRT FROM CRUSHER DRIVE MOTOR. •
INSPECT ALL CHUTES AND HOPPERS FOR WEAR AND OBSTRUCTIONS. •
VERIFY THAT CRUSHING CHAMBER IS CLEAR. •
LUBRICATE GREASE FITTINGS • 3

5
CHECK JAW DIES AND CHEEK PLATES FOR LOOSENESS, CRACKS OR • 7
WEAR.
CHECK TIGHTNESS OF NUTS AND BOLTS. •
CHANGE HYDRAULIC SYSTEM FLUID •
MEASURE THE CRUSHER DISCHARGE SETTING. • 4
REMOVE DUST AND DIRT FROM SHEAVES. •
CHECK SHEAVES FOR DAMAGE OR LOOSENESS. • 8
INSPECT V-BELTS FOR WEAR OR DAMAGE. CHECK V-BELT TENSION. •
CHECK SUPPORT STRUCTURE FOR LOOSE OR DAMAGED MEMBERS. •
CHECK CRUSHER MAIN FRAME FOR CRACKS. •
CHECK CRUSHER SWING JAW FOR CRACKS. •
CHECK LINEAR POSITION SENSOR LED FOR CORRECT OPERATION. • 4
CHECK HYDRAULIC ADJUST ASSEMBLY SPRING TENSION. • 4
CHECK TOGGLE WEAR BARS AND TOGGLE SEATS. •
**PERFORM ENGINE MAINTENANCE (DIESEL ENGINE). (As Required)
CLEAN OUT ALL CHUTES, HOPPERS, AND ROCK BOXES •
CHECK HYDRAULIC SYSTEM OIL LEVEL (PLANT). •
*Re-lubricate daily or every 8 hours on machines operated more than one shift a day (Manual Grease Units).
**Refer to manufacturer’s service manuals for recommended time intervals.
Warning: Lockout/tagout power before performing any adjustment, inspection, lubrication, maintenance or repair procedures.
! Disconnect batteries, shut off fuel supply and lockout/tagout engine controls if crusher is powered by a diesel engine.
04/09 5-3
Crusher Lubrication and Maintenance Schedule Operation and Maintenance
NOTES
5–4 04/09
Chapter 6
Crusher Troubleshooting
CONTENTS
Page
CRUSHER TROUBLESHOOTING SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . 6-2
CRUSHER TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

1. Crusher will not start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
2. High power draw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
3. Crusher vibrates or shakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
4. Crusher makes knocking sounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
5. Crusher loses RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 6
6. Uneven die wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
7. Low production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
8. Broken toggle wear bar(s). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
9. High Bearing Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
POSITION SENSOR TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

1. Position Sensor LED does not light. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
2. Position Sensor LED remains RED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
3. Position Sensor LED remains YELLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
4. Position Sensor LED cycles from RED to GREEN . . . . . . . . . . . . . . . . . . . . . . . 6-6
5. Position Sensor Doesn’t Output Voltage Readings. . . . . . . . . . . . . . . . . . . . . . . 6-6
HYDRAULIC SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
01/09 6–1
Crusher Troubleshooting Operation and Maintenance
CRUSHER TROUBLESHOOTING SAFETY bridged material. The material could break free at any
PRECAUTIONS time.
• Fully retract the jaw when service will occur in the
crushing chamber. Always block the jaw sheaves and
! WARNING!!!
DANGER install swing jaw lock pins before allowing anyone inside
Stop the crusher and lockout/tagout power before the crushing chamber when the swing jaw is in the
performing any adjustment, lubrication, retracted position. Refer to Chapter 4 for procedure.
maintenance or repair procedures. Never attempt to • Do not place timbers or any other blocking devices inside
service the 2550 Jaw Crusher while it is operating. the crushing chamber to hold the swing jaw open. The
Refer to Chapter 1 for complete lockout/tagout blocking could crack or become dislodged. Serious
procedures. personal injury could result.
• Be sure that all guards and other safety devices are
! WARNING!!!
DANGER correctly reinstalled and tightly secured after
troubleshooting procedures are completed.
Failure to observe the following precautions may
result in serious personal injury or death!
CRUSHER TROUBLESHOOTING CHART
• Lockout/tagout power to the crusher drive motor, and all
Refer to Table 6-1 for general crusher troubleshooting
crusher systems before performing any inspection,
procedures. When indicated in the Corrective Action column,
adjustment, lubrication, maintenance or repair procedures.
refer to the other chapters of this manual for additional
Also lockout power to all crusher feed and discharge
maintenance instructions.
equipment. Refer to Chapter 1 for complete lockout/tagout
procedures. Refer to Table 6-2 for problems relating to the position
sensor.
• If the crusher is powered by a diesel engine, disconnect
6 batteries and shut off fuel supply before performing any
inspection, adjustment, lubrication, maintenance or repair
procedures. Lockout/tagout engine controls to prevent
the engine from being accidentally started while the
crusher is being serviced.
• Wear or use appropriate personal protective equipment
(PPE) as required by federal, state or local regulations,
such as hard hats, steel toe shoes, safety glasses and ear
protection.
• Use extreme caution if it is necessary to operate the
crusher for observation purposes. Stay clear of any
rotating or moving parts. Be aware of potential hazards at
all times.
• Allow only authorized personnel near the crusher during
troubleshooting procedures.
• Rock projected upwards through the feed opening can
injure or kill. Stay clear of the feed opening during crusher
operation. Use mirrors or closed-circuit cameras if close
observation of the feed arrangement is necessary for
troubleshooting or evaluation purposes.
• Never place hands on hydraulic cylinder body or rod.
Never stand on hydraulic hoses or use them as steps.
• Always use a safety belt, lifeline, body harness and/or
lanyard if it is necessary to enter the crushing chamber for
inspection purposes. Never attempt to walk on jammed or
6–2 04/09
Operation and Maintenance Crusher Troubleshooting
Table 6–1. Crusher Troubleshooting Chart
SYMPTOMS POSSIBLE CAUSE CORRECTIVE ACTION
1.Crusher will not start A. Material lodged in crushing Remove material from crushing chamber.
chamber.
Refer to Chapter 4 for chamber clearing
procedure.
B. No power to hydraulic Check diesel engine power source. Check

system. diesel output device to hydraulic pump.
C. Electrical interlocks or Verify that all interlocked doors (alarm and con-
switches preventing crusher trol panels) are closed.
startup.
Verify that the hydraulic system pump is on.
Verify that hydraulic system pressure is at least

2450 PSI (169 bar).
Verify that crusher selector switch is in CRUSH

position.
D. Incorrect wiring or loose Check electrical wiring at switches and

connections. hydraulic power control unit on crusher. 6
E. Hydraulic drive motor or drive Check the drive belt condition and tension.
belt defective. Remove belt if necessary and check whether
hydraulic drive motor runs with belt removed.
If motor runs without load, problem may be at
the swing jaw drive sheave or eccentric shaft
bearings. If hydraulic drive motor does not
operate with drive belt removed, a hydraulic
drive motor or hydraulic pressure problem may
be present on the plant.
2. High Power Draw A.Excessive fines in feed Remove excessive fines from feed.
(packing condition).
B. Uncrushable object in Clear the crushing chamber.

crushing chamber.
C. Discharge setting too small. Increase the discharge setting as required.
D. Defective drive motor. Have a licensed electrician test the drive motor
for proper operation.
E. Crusher bearings damaged or Replace bearings as required.

worn.
04/09 6–3
3. Crusher vibrates or A. Support structure bolts loose. Tighten any loose bolts. Check for missing
shakes bolts.
B. Swing Jaw bearing mounting Retorque bolts with Torque Multiplier tool.
flange bolts loose. Refer to Chapter 3.
C. Insufficient support structure. Rebuild or reinforce support structure as

required.
D. Crusher not level. Check crusher for levelness.

If necessary, add shims under the crusher
mounting flange.
E. Crusher speed incorrect. Check speed at the flywheel sheave. Refer to

Chapter 3 for recommended crusher RPM.
F. Dirt buildup on sheaves. Check for a buildup of dirt on the motor and
flywheel sheaves.
Remove dirt if present.
G. Wrong number of Add or remove counterweights as required.

counterweights on sheaves.
Contact Telsmith Service Department for
6 counterweight quantities and locations.
H. Swing jaw flywheel(s) not Remount flywheel(s) in correct position. Refer

correctly phased. to Chapter 8.
4. Crusher makes A. Hydraulic Adjustment Inspect the tension springs and adjust tension
knocking sounds Assembly tension springs not or replace springs as required. Refer to
providing adequate tension. Chapter 4.
B. Adjuster assembly wear bars Check wear bar mounting hardware. Tighten or
loose or extremely worn. replace as necessary. Check wear bar and
toggle seats for extreme wear or damage.
Replace as necessary.
5. Crusher loses RPM A. Excessive fines in crushing Check feed and remove fines.
chamber.
B. Loose or worn drive belts. Adjust tension and replace belts as required.
Refer to Chapter 12.
C. Sheave grooves worn. Inspect sheave grooves for wear. Replace

sheave(s) if grooves are excessively worn.
D. Swing Jaw Bearings Refer to Chapter 3 for swing jaw grease points
overheating due to insufficient and periodic grease intervals.
lube.
6–4 04/09
6. Uneven die wear A.Crushing chamber underfilled. The crushing chamber should be kept
approximately two-thirds full for best results.
Increase speed of feeding device as required.
B. Feed directed to one side. Reposition the feeding device so that material
is evenly distributed as it enters the crusher.
7. Low production A. Discharge setting too small. Check for proper discharge setting. Refer to
Chapter 4.
B. Crusher rotation incorrect. Check for proper rotation. Crusher flywheels

must turn towards crushing chamber. Refer to
Chapter 3.
C. Low Crusher RPM. Check crusher RPM at the flywheel.

Crusher RPM is a minimum of 242 RPM.
If RPM is below minimum, determine reason for
low RPM and make repairs or adjustment to
raise RPM to 250 RPM.
8. Broken toggle wear A. Excessive amount of Remove uncrushable objects from the feed.
bar(s) uncrushable objects entering the
crushing chamber.
B. Material build up in crusher Check discharge conveyor for proper

6
discharge area. operation.
Verify that the discharge chute is not restricting

the free flow of material.
C. Fines building up in the Remove fines from the feed.

bottom of crushing chamber
D. Hydraulic relief function not Troubleshoot the hydraulic relief circuit of the
working properly. hydraulic system.
9. High bearing A. Under or overlubricated Determine if grease is the correct volume and
temperatures at swing bearings or grease breakdown. type for current temperatures. Refer to Chapter
jaw and eccentric shaft 4 for grease specifications.
bearings
B.Drive belt is slipping on drive Check belt for contamination or damage that
sheave. may be causing slipping. Install new belt and
tension properly if necessary.
C. Discharge setting too small. Increase discharge setting.
D. Flywheel speed too high. Check speed at the flywheel sheave. Maximum
speed is 258 RPM. Correct if necessary.
E. Bearings worn or damaged. Replace crusher bearings as required.
04/09 6–5
Table 6–2. Position Sensor Troubleshooting
SYMPTOM POSSIBLE CAUSE CORRECTIVE ACTION
1. Position Sensor LED A. 24V input to position sensor Remove input cable and test for 24V input
does not light when connector is not present at pin 1 with a test meter. If voltage is not present,
crusher is started. of the connector. replace input cable and check 24V source.
B. Position sensor is defective. Replace position sensor and reset sensor

range. See Chapter 4.
C. Correct ground is not present Establish that ground path continuity is

at pin 3 (blue wire) on present from connector to the ground point.
connector.
2. Position Sensor LED A. The magnet is not delivering Replace magnet and reset sensor range.
remains RED when swing a signal to the linear
jaw is operating. displacement transducer.
B. Magnet is remaining in a null Check that mounting clamps on the

(dead) zone at the front or back transducer are tight and that the magnet
of the travel range. linkage has not broken or become
disconnected. Make repairs and adjustments
as needed.
3. Position Sensor LED A. “ZERO” and “SPAN” settings Follow instructions in Chapter 4 and set or
6 remains YELLOW or were not set when the linear reset span making certain that “ZERO” and
YELLOW and RED over transducer was mounted. “SPAN” settings are located in the active zone.
the complete span of
magnet while the crusher
is running.
4. Position sensor LED A. Magnet was set with either Reset sensor range, making certain that the
cycles from RED to the “ZERO” or “SPAN” setting in LED is in the active zone when the “ZERO”
GREEN while the jaw is a null zone when the unit was and “SPAN” settings are established.
running. programmed.
5. Position sensor is A. No voltage is being output at Position sensor defective, replace unit and
GREEN during complete pin 4 (black wire) on the position reprogram “ZERO” and “SPAN”.
jaw stroke, but no voltage sensor connector.
readings are being shown
on readout device. B. Correct voltage signals are Check the cable between the output
being output at the position connector and the display device for correct
sensor connector, but are not continuity. If cable checks OK, the display
being displayed at the output device may be defective.
device.
6–6 04/09
Telsmith SBS Cone Crusher
HYDRAULIC SYSTEM • Allow only trained and licensed electricians to

TROUBLESHOOTING troubleshoot hydraulic system electrical components and
wiring.
Hydraulic Troubleshooting Safety • Use common sense when observing hydraulic system
operation during troubleshooting. Be aware of potential
hazards at all times. Stay clear of all rotating or moving
! WARNING!!!
DANGER parts.
Lockout/tagout power to the hydraulic control • Wear or use appropriate personal protective equipment
assembly before performing any inspections, (PPE) as required by federal, state or local regulations,
adjustments, maintenance or repairs. Never such as hard hats, steel toe shoes, safety glasses, face
attempt to service the hydraulic system while it shield and ear protection.
is operating. Refer to Chapter 1 for complete
lockout/tagout procedures. • Never attempt to loosen a hydraulic fitting when the
hydraulic system is pressurized.
• When loosening a hydraulic fitting, keep your face and
! WARNING!!!
DANGER body away from the fitting as much as possible. Always
Pressures of up to 345 bar (5000 PSI) are present assume that the line has pressure.
in the hydraulic adjust assembly even when the • Use a piece of cardboard to check for hydraulic fluid
hydraulic pump is off and the hydraulic pressure leaks, not your hand. Escaping fluid under pressure can
gauge and sensors indicate zero (0) PSI. Never penetrate the skin, resulting in serious personal injury.
loosen any hydraulic fittings or disconnect any
hydraulic hoses until after the hydraulic system • Clean-up any spilled hydraulic fluid. Hydraulic fluid is
has been completely depressurized as extremely slippery and can be especially dangerous if
described later in this chapter. spilled on an elevated walkway or platform.
• Hot hydraulic fluid can cause burns. Wear appropriate 6
hand protection and protective clothing when servicing
! WARNING!!!
DANGER the hydraulic system. Avoid unnecessary contact with
Failure to observe the following safety hydraulic fluid.
precautions may result in serious injury or • Refer to Chapter 1 for additional safety precautions and
death. warnings which apply to pressurized systems and related
• Before beginning any troubleshooting procedures, machinery.
become familiar with hydraulic system operation for both
your plant and the 2550 crusher. Refer to Fig. 6-1 in this
chapter to identify hydraulic components and operating
pressure levels.
• Lockout/tagout power to the hydraulic control panel if it
is necessary to perform any adjustments, lubrication,
maintenance or repairs during troubleshooting. Refer to
Chapter 1 for complete lockout/tagout procedures.
• Always depressurize the hydraulic system before
loosening any hydraulic fittings or disconnecting any
hydraulic hoses. Refer to the Depressurizing the
Hydraulic System section of this chapter for additional
information.
• Allow only qualified hydraulic service technicians to
perform hydraulic system troubleshooting. All persons
working on the hydraulic system must have appropriate
training and certification.
04/09 6–7
2550 CRUSHER HYDRAULICS
b
HYDRAULIC ADJUST DIRECTIONAL
SOLENOID
ASSEMBLY CHECK
VALVE P A
T B
G4
HYDRAULIC CONTROL PRESSURE
ASSEMBLY REDUCING
VALVE
a G1 G2
2 Bar
(30 psi) 138 Bar
spring (2000 psi) CHECK
345 Bar 414 Bar Charge VALVE
P T (5000 psi) B A (6000 psi) P T Pressure P
331 Bar
(4800
psi) T
10 bar (145 psi) spring

EXT RET B A
G3
RELIEF
HYDRAULIC VALVE DIRECTIONAL CONTROL VALVE
CYLINDER
6
T2 T1 P
Supplied by Telsmith 11 LPM (3 GPM) Minimum Recommended @ P
172 bar (2500 psi) Minimum Supply Pressure @ P
206 bar (3000 psi) Maximum Supply Pressure @ P
G3
G4
G1
G2
HYDRAULIC ADJUST ASSEMBLY HYDRAULIC CONTROL ASSEMBLY
Figure 6–1. 2550 Hydraulic Schematic and Component Locations
6–8 04/09
DISCONNECTING HYDRAULIC HOSES DEPRESSURIZING THE 2550 CRUSHER

HYDRAULIC SYSTEM
! WARNING!!!
DANGER Depressurize the hydraulic system as described in the
following procedures before loosening any hydraulic fittings
Failure to properly depressurize the hydraulic or disconnecting any hydraulic hoses.
system before loosening hydraulic fittings or
disconnecting hydraulic hoses will result in the Perform all steps in the order shown. Do not skip any steps.
release of high pressure hydraulic fluid. Serious
personal injury or death can occur if hydraulic
fluid penetrates the skin.
! WARNING!!!
DANGER
• Up to 206 Bar (3000 PSI) may be present in the hydraulic Pressures of up to 345 bar (5000 PSI) may be
hoses, even when the plant hydraulic pump is off, and the present in the hydraulic system even when the
pressure gauge indicates zero (0) Bar (0 PSI). Up to 345 hydraulic pump is off and the hydraulic pressure
Bar (5000 PSI) may be present in the 2550 hydraulic gauge on the plant power unit indicates zero (0)
adjust assembly. PSI (0 bar). Never loosen any hydraulic fittings or
disconnect any hydraulic hoses until after the
• To prevent the release of high pressure hydraulic fluid, hydraulic system has been depressurized as
always completely depressurize the hydraulic system described in the following procedures:
before loosening any hydraulic fittings or disconnecting
any hydraulic hoses during troubleshooting procedures. 1. Retract the swing jaw to the fully retracted position.
Refer to the Depressurizing the Hydraulic System section 2. Stop the crusher. Lockout/tagout power to the crusher
of this chapter for instructions and additional information. drive, the hydraulic power unit and to all feed and discharge
• Before removing a hydraulic hose, check that the hose is equipment.
relaxed and not stiff. A stiff hose indicates that pressure 3. Be sure no personnel are on, inside or under the crusher.
has not been relieved. 6
• As hoses are removed, catch any hydraulic oil leakage in
an appropriate container.
! CAUTION
DANGER !!!
The swing jaw may move during the following
steps. To prevent serious personal injury, be
! WARNING!!!
DANGER sure no persons are on, inside or under the 2550
Always assume that the system is pressurized, crusher before activating the hydraulic
even if pressure appears to have been relieved. functions.
Wear appropriate eye protection and other 4. Check the pressure readout on the plant hydraulic power
personal protective equipment when loosening unit gauge. Pressure should now read 0 Bar (0 PSI).
hydraulic fittings and disconnecting hoses.
Serious personal injury or death can result if 5. Move the 2550 function switch from CRUSH to
hydraulic oil penetrates the skin. ADJUST. Attempt to move the swing jaw back and forth with
the EXTEND/RETRACT switch to check if all pressure is
exhausted.
6. Install a hydraulic test gauge at test port G2 (Fig. 6-1) on
the hydraulic control assembly to test for remaining pressure.
7. Move the test gauge to the G1 port on the hydraulic
control assembly (Fig. 6-1).
8. If pressure is indicated at either port, install a pressure test
line at the G1 port and bleed off any remaining pressure (and
fluid) into a catch receptacle. Install a pressure test line at the
G2 port and bleed off any remaining pressure (and fluid) into
a catch receptacle
04/09 6–9
9. Move the test gauge to the hydraulic adjust assembly and

install the test gauge at both port G3 and G4 (Fig. 6-1) to test Table 6–3. Hydraulic System Pressure Settings
for remaining residual pressure. If any pressure is indicated
on the gauge, install a pressure test line at the port in question Pressure
and bleed off any remaining pressure (and fluid) into a catch Port Component
Settings
receptacle.
G1 Supply Pressure 172 - 206 Bar
NOTE: An alternate method for draining off pressure at
Fig. 6-1 (2500 - 3000 psi)
G3 and G4 is to adjust both counterbalance valves all
the way out (turn LH screw adjusters clockwise) and G2 Charge Pressure 138 Bar
allow pressure to bleed. Count the number of turns Fig. 6-1 (Cyl Rod) (2000 PSI)
when turning screw adjusters and return the adjusters
G3 Piston Side 34 - 330 Bar
to the original settings. Recheck pressure at G3 and G4.
Fig. 6-1 Pressure (500 - 4800 PSI)
PRELIMINARY HYDRAULIC CHECKS G4 Rod Side 138 - 345 Bar

Fig. 6-1 Pressure (2000 - 5000 PSI)
AND ADJUSTMENTS
Make the following checks and inspections before
performing any hydraulic system troubleshooting
procedures:
• Check the plant hydraulic reservoir fluid level. Add
hydraulic fluid if low. Refer to plant manufacturer
documentation for fluid specifications.
• Check for visible external leakage on hydraulic system
fittings. Lockout/tagout power and depressurize the
6 hydraulic system before tightening or replacing any
fittings.
• Check for visible external leakage on valves, cylinders,
and other hydraulic components. Replace or repair
defective components as required to eliminate leaks.
Lockout/tagout power and depressurize the hydraulic
system before making repairs.
• Check that the hydraulic control assembly is securely
mounted. Loose mounting hardware could indicate
vibration problems in the system.
• Verify that proper voltage is connected to the solenoid
DIN fittings on control assembly. Be sure polarity is not
reversed.
• Hydraulic system electrical components must be correctly
wired and in proper working order. If electrical problems
are suspected, have a licensed electrician inspect and
troubleshoot the electrical components as required. Refer
to Chapter 3 for the hydraulic system wiring diagram.
• Check the system pressure at each major hydraulic
component (Table 6-3). Incorrect pressure settings or
readings can often help isolate hydraulic system problems
to a specific component.
6–10 04/09
Table 6-4: Hydraulic System Troubleshooting Chart
1. Hydraulic system con- A. Hydraulic pressure switch Check that hydraulic unit on plant is running and
trol relay (PS1) opens - open due to low pressure read- outputting sufficient pressure. If pressure reading
crusher stops ing (Less than 1800 PSI). is less than 124 Bar (1800 PSI) on plant pressure
gauge, determine cause and make repairs.
PS1 pressure switch opens when hydraulic pres-
sure falls below 124 Bar (1800 PSI). This causes
feeder relay (TR1) to open, stopping the crusher
feed device after approximately 5 seconds. If
hydraulic pressure remains below 124 Bar (1800
PSI) for an additional 20 seconds, control relay
(TR2) opens and the crusher stops.
B. Pressure switch or relay Check PS1 switch and relay TR2 for correct opera-
defective. tion. Replace as necessary.
2. High hydraulic fluid A. Low fluid level. Check fluid level. If fluid level is low, add additional
temperatures. hydraulic fluid as required.
Before checking fluid level, verify that hydraulic
fluid pump is off and that the hydraulic pressure
gauge indicates (0) PSI.
6
B. Fluid not the correct specifica- B. ISO 68 Hydraulic Fluid in synthetic formula may
tion for high ambient tempera- be required.
ture conditions.
C. Dirty or unchanged hydraulic C. Drain and flush the hydraulic reservoir. Replace
fluid. hydraulic filter element.
Refill hydraulic reservoir with new fluid of the
proper viscosity. Refer to your plant manual for
hydraulic fluid specifications and recommended
change intervals.
D. One or more relief valves are D. Check for heat build-up at individual relief
by-passing oil. valves in circuit. Clean or replace any suspect
valves.
3. Low hydraulic pressure A. Low fluid level. Check fluid level. If fluid level is low, add additional
hydraulic fluid as required.
Before checking fluid level, verify that the hydraulic
reservoir pump is off and that all gauges and sen-
sors indicate zero (0) PSI. For most accurate oil
level readings, the relief cylinders should be fully
retracted.
B. Hydraulic pump turning in Check direction of pump motor. Reverse electrical

wrong direction. leads if necessary.
04/09 6–11
Low hydraulic pressure C. Pump suction line clogged or Check for loose or cracked suction line fittings.
cont. leaking. Tighten or replace fittings as required.
Check suction line for obstructions. Remove if
present.
D. System relief valve stuck Check setting of system relief valves. Readjust or
open or set too low. replace valves as required.
E. Defective counterbalance Check valve setting. Replace valve if proper set-

valve, or improper valve setting. ting cannot be held.
F. Defective pressure gauge giv- Install a second pressure gauge at the pressure
ing false reading. test coupling (G1, Fig. 6-1) to verify that pressure
gauge is providing an accurate reading. Replace
pressure gauge if defective.
G. Low pump output Run a pump test with outlet hose removed. Pump
should flow approximately 3 gallons of fluid (11
LPM) in one minute. If GPM flow rate is less than 2
gallons (7.5 LPM), repair or replace the hydraulic
pump.
6 4. Low hydraulic flow A. Low oil level Check fluid level. If fluid level is low, add additional
hydraulic fluid as required.
Before checking fluid level, verify that reservoir
pump is off and that all gauges and sensors indi-
cate zero (0) PSI.
B. Pump suction line clogged or Check for loose or cracked suction line fittings.
leaking. Tighten or replace fittings as required.
Check suction line for obstructions. Remove if
present.
C. Low pump output Repair or replace the hydraulic pump or pump

motor.
6–12 04/09
5. EXTEND/RETRACT A. Obstruction preventing Check that the crushing chamber is free of tramp
functions do not operate hydraulic cylinder and swing jaw iron or jammed material. Clear the crushing cham-
movement. ber if necessary.
Verify that the adjust assembly hydraulic cylinder is
unobstructed. Remove obstructions if present.
B. No power to solenoid coils. Hydraulic control assembly contains two solenoid

coils. One coil activates the hydraulic RETRACT
function. The other activates the hydraulic
EXTEND function.
Check that voltage is present at the appropriate
solenoid coil terminals when the function selector
switch is in the EXTEND or RETRACT position.
Refer to Chapter 3 for hydraulic system wiring dia-
gram.
C. Solenoid coil is defective. Jog the selector switch several times between
EXTEND and RETRACT with the Function Switch
in the ADJUST position. Listen for the valve spool
to shift.
If spool does not shift when each function is acti-
vated, one or both solenoid coils may be defective.
6
To verify a defective solenoid coil, manually shift
the spool in both directions by depressing the
push-button at each end of the valve (Fig. 6-1).
When either button is depressed, the spool will
shift about 1/8 inch. Pressure should build immedi-
ately, and the relief cylinder rods should begin to
move.
D. Hydraulic control valve is Manually shift the valve spool as described in step
defective. 5C.
If the valve spool is stuck and cannot be manually
shifted, repair or replace hydraulic control valve.
E. System pressure too low. Check system pressure. Correct reading 172 to
206 bar (2500 - 3000 PSI) @ Port G1.
F. Cylinder relief valve stuck Check setting of cylinder relief valve. Valve must
open or set too low. be set 331 Bar (4800 PSI). Readjust or replace as
required.
04/09 6–13
5. EXTEND or RETRACT G. Low pump output or clogged 1. Lockout/tagout power to the hydraulic control
functions do not operate pump intake line. panel.
(cont.)
2. Verify that the pressure gauge indicates zero (0)
PSI.
3. Place a hydraulic flowmeter in the pump outlet
line. The flowmeter must be capable of operating
at pressures of at least 5000 PSI.
4. Place the selector switch in the EXTEND or
RETRACT position and hold. Reconnect power
and start the hydraulic pump.
The hydraulic cylinder must be moving (extending
or retracting) while the flowmeter reading is
checked in the next step.
5. Observe the flowmeter reading. The flow rate
should be approximately 11 LPM (3.0 GPM) or
greater. Go to next step of troubleshooting if the
flow rate is within acceptable limits.
6. If the flow rate is below acceptable limits:
6 Drain the hydraulic reservoir and inspect the pump
suction line for obstructions or leaks.
Refill the hydraulic reservoir with new oil. Check
the flow rate again as described in steps 4 and 5 of
this procedure. Repair or replace the pump if the
flow rate is still below acceptable limits.
I. Relief cylinder defective. Repair or replace the relief cylinder as required.
6. Adjust Assembly A. Pressure leaking down due to Check for leaks at Extend/Retract lines and fittings.
hydraulic cylinder does fluid loss. Check for hydraulic leak at cylinder. Repair fittings
not maintain adequate or replace seals as necessary.
tension.
B. Hydraulic cylinder defective. Check hydraulic cylinder and cylinder body for
signs of damage. (Cylinder plating peeling,
scratched, gouged etc., Cylinder body cracked or
dented etc.)
Replace adjust assembly if necessary.
C. Hydraulic cylinder relief valve Check setting of cylinder relief valve. Readjust or
stuck open or set too low. replace as required.
6–14 04/09
7. Low hydraulic fluid A. Fluid heater (If used) not Check that fluid heater is properly connected to a
temperature. working. power source of the correct voltage. Be sure that
power remains connected, even when crusher is
off.
Check that thermostat is set to between 70°F
(21°C) and 90°F (32°C).
Check for carbon build-up on heating element.
Clean as required.
Check for defective thermostat or burned-out heat-
ing element. Make repairs as required.
B. Hydraulic fluid heater thermo- Raise the temperature of the fluid heater thermo-
stat (if used) set too low. stat as required.
The heater thermostat is normally set at 21° to
32°C (70° to 90°F) depending on outside ambient
temperature. It can be set up to 100°F (38°C) for
especially cold climates.
8. Hydraulic system loses A. Hydraulic reservoir leaking. Inspect the hydraulic reservoir for leaks. Make
oil. repairs as required.
B. Leaking hydraulic hoses Check all hydraulic hoses and fittings for leaks.
6
and/or loose fittings. Tighten fittings or replace hoses as required.
C. Leaking hydraulic compo- Check hydraulic components for visible leakage.

nents.
Repair or replace leaking hydraulic components as
required.
9. Hydraulic cylinder A. Directional control valve is Try to manually shift the spool of directional control
extends or retracts when defective. valve in both directions by depressing the
EXTEND/RETRACT push-button at each end of the valve.
switch is in the center
When either push-button is released, the spool
(neutral) position.
should return to the center position and the relief
cylinders should not move.
If the valve spool is stuck in the EXTEND or
RETRACT position and cannot be manually
shifted, repair or replace the directional control
valve.
10. Excessive hydraulic A. Hydraulic relief cylinder valve Check setting of relief valve. Re-adjust or replace
relief action. set too low or stuck open. as required. Valve must be set to 331 bar (4800
PSI).
B. Crusher discharge setting is Check discharge setting and adjust within recom-
too low. mended limits.
04/09 6–15
6–16 04/09
Chapter 7
Wear Liner and Cheek Plate Replacement
CONTENTS
Page
REPLACEABLE WEAR COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
WEAR LINER REPLACEMENT PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Swing Jaw Die Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Swing Jaw Die Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Swing Jaw Hub Guard Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Swing Jaw Hub Guard Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Stationary Die Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Stationary Jaw Die Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
CHEEK PLATE REPLACEMENT PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

Cheek Plate Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Cheek Plate Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Cheek Plate Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
04/09 7–1
Wear Liner and Cheek Plate Replacement Operation, Maintenance and Repair
REPLACEABLE WEAR COMPONENTS
F G
A
7
B
Figure 7–1. 2550 Crusher Replaceable Wear Components

A.Cheek Plate Upper C. Stationary Maganese Die E. Swing Jaw Maganese Die G. Swing Jaw Guard
B. Cheek Plate Lower D. Stationary Die Retainer F. Swing Jaw Die Wedge
7–2 04/09
Operation, Maintenance and Repair Wear Liner and Cheek Plate Replacement
WEAR LINER REPLACEMENT

PROCEDURES ! CAUTION
Use extreme caution during jaw die removal
Swing Jaw Die Removal procedures. Work from the top of the crusher
only. Stay clear of areas where the die could tip
1. Retract the swing jaw completely using the hydraulic
or fall. Do not allow any personnel to be inside
controls.
the crushing chamber or under the crusher
during the lifting procedure.
! WARNING
Lockout/tagout power to the crusher drive, the
hydraulic system, and all feed and discharge
equipment before beginning wear liner A
replacement procedures. Refer to Chapter 1 for
complete lockout/tagout procedures.
2. With all power to the crusher locked out, attach chains to
the jaw at the lower cast in lugs (Fig. 7-2). Secure the chains
to the 2550 frame to prevent the swing jaw from moving
during jaw die removal and replacement. B
3. Install two (2) jaw die hooks in the upper pockets of the
maganese die (Fig. 7-3). Attach lift chains or harness capable
of lifting approximately 680 Kg (1,500 lbs) to the lift hooks.
4. Attach a hoist of suitable lifting capacity to the jaw die lift
apparatus (Jaw die weighs approx. 612 Kg (1350 lb.). Apply
slight pressure to the hooks to maintain the jaw die in position
while the retaining wedge is removed.
Figure 7–3. Swing Jaw Die Lift Hook Location

A. Lift Hook (pn AJ-273-2117) B. Die Lift Points (4)
C. Swing Jaw Maganese Die
5. Remove the four (4) hex head capscrews, washers and

locknuts holding the die wedge to the swing jaw (Fig. 7-4).
6. Install a lift strap through the two outer bolt holes on the
die wedge and lift it off the die with a hoist or crane (wedge
weighs 30 Kg (67 lb.)).
7. Tilt the top of the jaw die out slightly from the jaw casting
and lift the die straight up off the retaining lip on the bottom
edge of the jaw casting.
NOTE:
If the jaw die is only worn on one end it can be reversed
180 degrees and reused in the crusher. If wear is
Figure 7–2. Swing Jaw Chain Attachment Point
present on both ends, replace the die.
04/09 7–3
3. Insert two jaw die lift hooks (pn AJ-273-2117) into the
two upper pockets of the new or rotated die (Fig. 7-6). Install
E F a suitable lift harness or chains and connect a hoist capable of
supporting 1332 Kg (2930 Lb.).
D
A B
Figure 7–4. Die Wedge Removal

A. Swing Jaw Maganese Die B. Jaw Retaining Lip
C. Hex Head Capscrew Gr 8.8 (4) D. Jaw Die Wedge
E. Washer (4) F. Locknut (4)
8. Check the die retaining lip, the die wedge and the wedge
fasteners for wear and damage. If the wedge fasteners or the Figure 7–6. Lifting Jaw Die
wedge show substantial wear, replace the components.
4. Carefully lift the jaw die over the crusher feed opening.
Swing Jaw Die Installation Verify that the ribbed surface of the die is facing the
stationary die.
7 1. Examine the back side of the new or replacement jaw die
and the face of the jaw for any damage. Clean the mating 5. Slowly lower the bottom end of the jaw die straight down
surfaces and remove any nicks or burrs (Fig. 7-5). Remove into the crusher. Align the bottom edge of the die with the
any obvious high spots with a grinder. protruding jaw retainer lip. Seat the die on the lip and rotate
the die back until it is fully supported by the lip.
! CAUTION
Keep hands and fingers clear of the area
between the jaw die and the swing jaw during the
f o l l o w i n g s t e ps . F a i l u r e t o o b s e r v e t h i s
precaution may result in serious personal injury.
6. Continue to rotate the top of the die back until it seats
completely on the face of the jaw (Fig. 7-7). Make certain the
protruding key in the center of the die seats fully in the pocket
on the face of the swing jaw.
Figure 7–5. Die Surface Preparation

2. Be sure that all power to the crusher drive, hydraulic
system, oil lubrication system and all feed and discharge
devices remains tagged and locked out. Continue to keep the
jaw chained in the fully retracted position (Fig. 7-2).
7–4 04/09
Swing Jaw Hub Guard Removal

If the swing jaw (G, Fig. 7-1) on the 2550 is damaged or
E excessively worn on the bottom edge, it should be changed at
the same time as the swing jaw die. Remove the swing jaw
D
guard as described in the following steps
1. Lockout/tagout power to the crusher drive, hydraulic
power unit and all feed and discharge devices.
C
! WARNING
Always lock out power and tag controls before
F
performing any service on the swing jaw. Failure
B to observe this precaution may result in serious
2. Loosen the 6 capscrews (C, Fig. 7-8) holding the jaw
guard to the swing jaw casting, but Do Not remove.
A
! CAUTION
Failure to support the guard when fastening
Figure 7–7. Seating and Installing Jaw Die hardware is removed will allow it to drop into the
crusher.
A. Jaw Die Retaining Lip B. Jaw Die
C. Lower Jaw Die Retaining Lip D. Wedge Capscrew (4) 3. Using a prybar, pry the guard forward until it separates
E. Wedge F. Locknut and Washer (4)
from the face of the jaw. Remove only the two outer mounting
7. Carefully remove the lift apparatus and the two jaw die capscrews on the upper row. Replace the mounting capscrews
hooks while maintaining the die in position on the jaw. Lower with lift hooks or eyes.
the die wedge down into position on the die. 4. Support the guard with a lift device capable of supporting
8. Align the mounting holes in the wedge with the holes in 126 Kg (277 lbs). Remove the remaining four mounting
the jaw and install all four wedge hex head capscrews (D, Fig. capscrews and carefully lift the guard out of the crusher with
the lift device.
7
7-7 through the wedge and jaw. If the capscrew mounting
holes on the wedge will not align with jaw mounting holes,
the die is not correctly seated.
A B C
9. Lube the threads of the wedge capscrews with anti-seize
and install the washers and locknuts (F, Fig. 7-7) on the
capscrews. Work in an alternating pattern (1-3, 2-4) and
tighten the wedge capscrews to 2002 Nm (1477 Ft Lbs).
10. Remove the chain holding the jaw to the frame, and run
the hydraulic cylinder forward to the previous jaw crusher
setting before resuming crushing.
D
IMPORTANT:
Never attempt to run the crusher with the jaw retracted
past the 7” maximum jaw opening. Attempting to crush
material with a fully retracted jaw could damage the
hydraulic cylinder. Always re-establish your crusher jaw
setting before attempting to crush material.
11. Recheck the tightness of the wedge fasteners on a daily Figure 7–8. Jaw Guard Removal
basis during the first three days of operation. Re-torque if A. Swing Jaw B. Jaw Guard
necessary. C. Mounting Capscrew Gr 8 (6) D. Flat Washer (6)
04/09 7–5
Swing Jaw Guard Installation Stationary Die Removal

Install a new or refurbished swing jaw guard as follows: Remove the stationary die as follows:
1. Be sure that all power to the crusher drive, hydraulic 1. Fully retract the swing jaw to provide operating room for
system and all feed and discharge devices remain tagged and removal of the stationary die. Install a chain to the lower lugs
locked out. (Fig. 7-10) on the swing jaw and secure to the frame to hold
the swing jaw stationary.
2. Carefully inspect the mating surfaces of the jaw guard and
swing jaw. Thoroughly clean all surfaces and remove any
nicks or burrs. Check internal threads on mounting holes for
damage or debris. Clean and re-tap as necessary.
3. Install lift eyes or hooks into the two outside jaw guard
mounting holes on the top row (Fig. 7-9). Lift the guard into
position and align the mounting holes with the threaded holes
in the swing jaw casting.
7 Figure 7–10. Swing Jaw Locking Chain Installation
Figure 7–9. Swing Jaw Guard Mounting 2. Lockout/tagout power to the crusher drive, hydraulic
power unit and to all feed and discharge devices. Refer to
4. Coat the capscrews with medium thread locker and install Chapter 1 for complete lockout/tagout procedures.
the mounting capscrews and washer at the four open holes,
but Do Not tighten. With the guard correctly aligned and the
four mounting capscrews partially threaded into mounting ! CAUTION
holes, remove the lift apparatus and the lift hooks. Use extreme caution during stationary die
5. Install the two remaining mounting capscrews in the removal procedures. Work from the top of the
outside mounting holes and torque all fasteners to 576 Nm crusher only. Stay clear of areas where the die
(425 Ft.Lb.) in a cross pattern. could tip or fall. Do not allow personnel to be
inside the crushing chamber or under the
6. Recheck the tightness of the fasteners on a daily basis c r u s h e r d u ri n g r e mo v a l a n d i n s ta l l a t i on
during the first three days of operation. Re-torque if procedures.
necessary.
3. Install two lift hooks (pn AJ-273-2117 supplied with
crusher) in the two upper lift pockets on the face of the die.
4. Install a suitable lift harness or chains capable of lifting
approximately 1332 Kg (2930 lbs) to the stationary die lift
hooks and apply slight pressure to hold the die in position
while the retainer is removed.
7–6 04/09
5. Remove the five hex head capscrews, flat washers and

hex nuts holding the die retainer plate in position (Fig. 7-11). NOTE:
If the stationary die is worn only on one end, it can be
A reversed 180 degrees and reinstalled in the crusher.
However, the jaw die must be replaced if both ends are
worn.
B
NOTE:
C
Frame cheek plates should be examined for wear and
D damage while the stationary die is removed. Access to
cheek plates is improved with the stationary die
removed. Renewal and replacement of these parts
should be accomplished in tandem with a stationary die
replacement.
Stationary Jaw Die Installation

E
1. Be sure that power to the crusher drive, hydraulic system
and all feed and discharge devices remains tagged and
locked out and that the swing jaw is still fully retracted and
held in position.
2. Check the lower die retainer on the crusher frame for
damage before beginning installation of the new or
replacement die. If the retainer has pieces missing or has lost
the square edge and upward slant necessary to seat and hold
the die it will need to be repaired. Build up damaged or worn
areas by welding in material and re-establishing the required
shape with a grinder or cutting tool.
Figure 7–11. Stationary Die Retainer Plate Removal

7
A.Hex Nut (5) B. Washer (5)
C.Retainer Plate D. Stationary Die
E.Hex Head Capscrew (5)
6. Tip the retainer plate (C, Fig. 7-11) up on each end using
a pry bar, and install lift eyes in the two outside mounting
holes. Attach a lift apparatus capable of lifting approximately
120 Kg (265 Lb.) and remove the die retainer plate.
! CAUTION
The top of the stationary die could tip forward
suddenly when the upper die mounting plate is C
removed. Keep hands and arms away from the
B
area between the stationary die and the swing
jaw die. Injury to personnel could occur if the die
were to suddenly tip. A
7. Lift the die straight up out of the frame.

Figure 7–12. Lower Die Retainer Location
A. Lower Die Retainer B. Side Wall
C. Back Wall
04/09 7–7
3. Examine the upper die retainer plate (D, Fig. 7-13) for
wear and damage. An extremely worn or bent retainer should
be replaced.
F
E
D
Swing Jaw Removed For Clarity B
Figure 7–13. Stationary Die Installation

A. 2550 Frame B. Stationary Die C. Hex Head Capscrew & Washer (5)
D. Die Retainer Plate. E. Flat Washer (5) F. Hex Nut (5)
4. Carefully inspect the mating surface of the new or

replacement jaw die for nicks, burrs or high spots. Remove ! CAUTION
any high spots with a grinder (Fig. 7-5). Use extreme caution during die installation
procedures. Work from the top of the crusher
only. Stay clear of areas where the die could tip
or fall. Do not allow personnel to be inside the
crushing chamber or under the crusher.
7–8 04/09
5. Attach lift hooks to the two upper pockets on the front 1. Fully retract the swing jaw, and chain in position (Fig. 7-
side of the jaw (Fig. 7-13). Use an appropriate lifting device, 10) to prevent the swing jaw from moving during cheek plate
carefully lift the die over the crusher feed opening. Be sure replacement.
that the ribbed side faces the jaw die.
2. Lockout/tagout power to the crusher drive, the hydraulic
6. As the die is slowly lowered into the crusher, align the unit and all feed and discharge devices. Refer to Chapter 1 for
bottom of the die with the protruding edge of the lower die complete lockout/tagout procedures.
retainer. When the die is fully supported by the die retainer,
tip the die back so it fits flush against the back wall of the
crusher. Make certain the protruding key in the center of the
! CAUTION
die aligns with the keyway in the cruiser frame. Continue to Use extreme caution during cheek plate removal
support the die with the lifting hooks. and installation procedures. Stay clear of areas
where a cheek plate could tip or fall. Do not allow
7. Using an appropriate lifting device position the upper jaw personnel to be under the crusher while cheek
retaining plate (D, Fig. 7-13) over the stationary die. Lower plate removal/installation is in progress. A
the retaining plate into position aligning the mounting holes dislodged cheek plate could cause injury or
with the holes in the crusher frame. death.
8. Install the five (5) hex head capscrews with a washer on 3. Completely remove the top two flat head screws, washers
each head up through the frame and the retaining plate. Lube and crown nuts from the upper cheek plate (Fig. 7-15).
the threads on the capscrews with anti-seize compound.
Install a hex head nut and washer on each capscrew. Torque
fasteners to 1355 Nm (1000 Ft. lbs) working in an alternating
pattern (1-3, 5-2, 4).
C
1 2 3 4 5 D
Figure 7–14. Die Fastener Torque Sequence 7

9. Remove the lift hooks and lift device from the stationary
die.
10. Remove the chains holding the swing jaw in the retracted
position (Fig. 7-10). Restore power to the crusher.
11. Recheck the tightness of the fasteners on a daily basis
A
during the first three days of operation. Re-torque if
necessary.
B
CHEEK PLATE REPLACEMENT
PROCEDURES
Figure 7–15. 2550 Cheek Plates
Cheek Plate Removal
A. Upper Cheek Plate (2) B. Lower Cheek Plate (2)
C. Mounting Flathead Screw D. Locknut and Washer
NOTE:
Due to clearance issues, it is easier to remove and
install cheek plates when the stationary die is removed
from the back of the crusher frame.
04/09 7–9
4. Loosen (But Do Not Remove) the remaining crown nut on Cheek Plate Inspection
the bottom fastener of the plate. Tip the top of the cheek plate
towards the crushing chamber to allow a lift sling (Fig. 7-16)
or lift eyes to be installed in the top two holes. Attach the sling
NOTE:
to an appropriate lift device (plate weighs approximately 80 Cheek plates on the model 2550 crusher are NOT
Kg (177 Lb.)). reversible. Damaged or severely worn plates must be
replaced with new parts.
Cheek plates should be checked at each swing jaw and
stationary die change for wear or damage:
• Check the face of the plate for deep gouging, cracking
and trenching. Damaged or deeply grooved plates should
be replaced.
• Check the flat head mounting screws for wear on the
heads. If the head of the fastener is worn away to the point
it can no longer anchor the plate, both the flat head screw
and the cheek plate should be replaced.
• With the cheek plates removed from the crusher frame,
check the width of the plate at several points. If the plate
is worn to 1/2” (12 mm) or less at any point, replace the
cheek plate.
• Check the mounting side of the plate for flatness. Using
a straightedge, check the mating surface longitudinally
and diagonally for flatness. If any warping or high spots
1 2
are evident in the plate, replace it.
Cheek Plate Installation

1. Be sure that power to the crusher drive, hydraulic system,
oil lubrication system and all feed and discharge devices
7 Figure 7–16. Upper Cheek Plate Removal
remains tagged and locked out.
5. Support the cheek plate with the lifting device and sling.
2. Read and understand all precautionary statements at the
Remove the remaining flat head screw and lockwasher and
beginning of this chapter.
carefully lift the upper cheek plate from the crushing
chamber. 3. Carefully inspect the mating surfaces of the new or
replacement cheek plate and the crusher frame. Thoroughly
6. Completely remove the top flat head screw, washer and
clean all surfaces and remove any nicks or burrs.
locknut from the lower cheek plate.
7. Loosen (But Do Not Remove) the remaining locknut on
the bottom fastener of the plate. Tip the top of the cheek plate
! WARNING
towards the crushing chamber and install a lift strap or lift eye U s e e x tr e m e c a u t i o n d u r i n g c h e e k p l a te
in the top mounting hole. Attach the sling to an appropriate installation procedures. Stay clear of areas
lifting device (cheek plate weighs approximately 53 Kg (116 where the cheek plate could tip or fall. Do not
Lbs)). allow personnel to be under the crusher. A
dislodged cheek plate could cause injury or
8. Support the cheek plate with the lifting device and sling.
death.
Remove the remaining lower flat head screw, washer and
locknut from the cheek plate and carefully remove the plate 4. Insert a sling through the top bolt hole of the lower cheek
from the crushing chamber. plate. Attach the sling to an appropriate lifting device.
Carefully lift the cheek plate over the crusher feed opening.
5. Slowly lower the cheek plate into the crusher. Align the
mounting holes on the cheek plate with the mounting holes in
the crusher frame.
7–10 04/09
6. Insert a flat head screw through the open lower mounting

hole of the cheek plate and the crusher frame. Lube flat head
screw threads with anti-seize compound and loosely install
flat washer and locknut.
7. Remove the sling from the cheek plate. Lube the
remaining flat head screw threads with anti-seize compound
and loosely install the flat head screw, flat washer and lock
nut.
8. Alternately torque all locknuts to 576 Nm (425 Ft. lbs ).
9. Insert a sling through the top two bolt holes of the upper
cheek plate as shown in Figure 7-16. Attach the sling to an
appropriate lifting device. Carefully lift the cheek plate over
the crusher feed opening.
10. Slowly lower the upper cheek plate into the crusher. Align
the mounting holes on the cheek plate with the mounting
holes in the crusher frame.
11. Insert a flat head screw through the open lower mounting
hole of the upper cheek plate and the crusher frame. Lube the
capscrew threads with anti-seize compound and loosely
install flat washer and locknut.
12. Remove the sling from the cheek plate. Lube the
remaining flat head screw threads with anti-seize compound
and loosely install the flat head screws, flat washers and lock
nuts.
13. Alternately torque all locknuts to 576 Nm (425 Ft. lbs ).
14. Install the stationary jaw die if previously removed. Refer
to installation sequence in this chapter.
7
15. Recheck tightness of all nuts and bolts during the first
three days of operation. Retorque as required.
04/09 7–11
NOTES
7–12 04/09
Chapter 8
Repair and Overhaul
CONTENTS
Page
GENERAL OVERHAUL INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
SWING JAW REPAIR and OVERHAUL PROCEDURES . . . . . . . . . . . . . . . . . . . . . . 8-4

Flywheel Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Hydraulic Adjustment System Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Swing Jaw Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Eccentric Shaft Bearing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Main Frame Bearing Removal . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Eccentric Shaft Removal From Swing Jaw Housing. . . . . . . . . . . . . . 8-12
Swing Jaw Bearing Removal . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
Eccentric Shaft Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
Swing Jaw Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . 8-15
Eccentric Shaft Installation In Swing Jaw . . . . . . . . . . . . . . . . . . . 8-17
Swing Jaw Bearing Race Alignment. . . . . . . . . . . . . . . . . . . . . . 8-20
Main Frame Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . 8-20
Installing Swing Jaw in Main Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
Flywheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24 8
Sheave Flywheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . 8-24
Pulley Flywheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25
HYDRAULIC ADJUSTING ASSEMBLY SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25

Hydraulic Adjustment Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25
Hydraulic Adjustment Component Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 8-29
Toggle Wear Bar Replacement . . . . . . . . . . . . . . . . . . . . . . . . 8-29
Toggle End Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-29
Stationary End Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 8-31
Hydraulic Adjustment Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-32
04/09 8–1
Repair and Overhaul Operation, Maintenance and Repair
GENERAL OVERHAUL INSTRUCTIONS

Work Safety
• Refer to Chapter 1 of this manual for important quarry
safety information. Also refer to the Telsmith Quarry
Equipment Safety Guide for additional safety precautions.
• Observe all precautionary statements (DANGER,
WARNING, CAUTION, IMPORTANT, and NOTE) that
are included within the repair and overhaul procedures.
• Keep cleaning solvents and other combustibles away
from heat and open flame. Do not smoke around
flammable liquids.
• Wear appropriate personal protective equipment (PPE).
Keep the work area clean and well organized.
• If service assistance is needed, contact your local
Telsmith dealer or the Telsmith Service Department.
Lockout/Tagout
• Lockout/tagout power (Fig. 8-1) to the crusher drive
motor and to the crusher hydraulic system before
beginning any service work.
Figure 8–1. Lockout/Tagout
• If the crusher is powered by a diesel engine, disconnect
batteries and shut off fuel supply before beginning any Lifting Heavy Components
service work. Lockout/tagout engine controls to prevent
the engine from being accidentally started while the • Refer to Chapter 2 for the weights of major components
crusher is being serviced. and subassemblies. Know the total weight of the entire
load before beginning the lift.
• Lockout/tagout power to all other quarry equipment in
the area, such as feeders, conveyors and related • Always practice safe lifting procedures. Refer to the
machinery. Hoisting and Handling Safety section of Chapter 1 for
additional information.
• Refer to Chapter 1 for complete lockout/tagout
procedures. • Be sure all lifting devices, slings and supports are in good
condition and of adequate rated capacity.
8
! WARNING
! WARNING
Always lockout power and tag controls before
performing any lubrication, adjustments, Always use suitable rigging and hoisting
maintenance or repairs. Failure to observe this equipment to stabilize and lift heavy objects.
precaution may result in serious personal injury Lifting heavy components with inadequate
or death. hoisting apparatus can result in serious
Tools and Supplies

The following common tools, shop equipment and supplies
are required to complete swing jaw repair and overhaul
procedures:
• Chain puller (6000 lb. capacity)
• Impact wrench with a 3/4 inch drive minimum, 1 inch
preferred
8–2 04/09
Operation, Maintenance and Repair and Repair Repair and Overhaul
• Set of sockets and breaker bars, minimum 3/4 inch drive • If shafts, bearings or other machined items are to be
with sockets up to 3-1/2 inches removed from the equipment for more than a few days,
cover them with a protective coating of rust-preventative
• Cold chisel, 3/4 inch
lubricant.
• Hammers (various sizes)
• Be careful not to cut or tear seals as machined components
• Cables, slings, and chains are installed and removed.
• Crane or hoist of adequate capacity
(Refer to Chapter 2 for component weights) Handling Bearings
• Remove any loose dirt from the machinery before
• Feeler gauge and inside/outside micrometers
exposing bearings. Handle bearings with clean, dry
• Cleaning solvent hands.
• Heated Oil bath • Use only clean lint-free rags. Use clean tools in clean
surroundings. Use clean solvents and flushing oils.
• Bearing Induction Heater
• Install new bearings as removed from packaging without
• Portable Power Pack Jacking Unit
washing. Do not remove bearings from packaging until
ready to use.
Lubricants and Sealants
• Soak used bearings in solvent. Then wash the bearings
Various lubricants and sealants are used during the repair and
and blow them dry with filtered, moisture-free
overhaul procedures in this chapter. These items include:
compressed air. Dip the bearings in oil immediately after
• Lubricating oil drying to prevent rust.
• NLGI #2 Grease
• Thread locking compound
! WARNING
Always wear eye protection and face shield
• Gasket sealant when using compressed air.
• Anti-seize compound • To prevent bearing damage, do not spin the bearings by
• Pipe sealant hand or with compressed air after the bearing surfaces
have dried.
Part Identification and Inspection
Using Heat
• Tag and mark all parts during removal and disassembly
procedures. • Be careful when using heat and handling hot parts. To
prevent burns, always wear appropriate hand, face and
• Clean all parts as removed. Verify that they are free of
cracks, nicks, burrs and other imperfections.
eye protection. 8
• Avoid applying heat to nearby parts that could be
• Check clearances and dimensions as instructed in the damaged by excessive heat.
procedures.
• Replace any excessively worn or damaged parts.
• If possible, take reference photographs of the machinery
as it is disassembled. Use the photographs during
reassembly procedures to verify that all parts are correctly
reinstalled.
Handling Machined Parts

• Handle machined parts carefully to prevent damage. Do
not nick or mar finished surfaces.
04/09 8–3
SWING JAW REPAIR AND OVERHAUL

PROCEDURES ! WARNING
Always use suitable rigging and hoisting
Flywheel Removal equipment to stabilize and lift heavy objects.
Lifting heavy components with inadequate
1. Lockout/tagout power as described in the previous
hoisting apparatus can damage machinery and
section.
may result in serious personal injury or death.
2. If the crusher is equipped with flywheel guards, remove
4. Remove the two hex head capscrews holding the flywheel
the guards and all brackets and mounting apparatus.
retainer to the end of the swing jaw shaft (Fig. 8-2) and
3. Attach a suitable lifting device and lift chains to the remove the flywheel retainer from the shaft.
flywheel (Fig. 8-3). Flywheels weigh approximately 833 Kg
5. Remove the four mounting capscrews, washers and
(1833 Lbs) each.
locknuts (Fig. 8-2) holding the flywheel to the eccentric shaft.
D
D
B
E
A B
G
Figure 8–2. Flywheel Retaining Hardware Removal

A. Flywheel Retainer Capscrews (8) B. Flywheel Retainer (2) C. Shaft Key (2) D. Flywheel Mounting Capscrews (8)
E. Flywheel (Pulley) F. Eccentric Shaft G. Flywheel (Sheave)
NOTE:
It may be necessary to use wedges in the face and back
of the flywheel hub (Fig. 8-3) to spread the hub and help
separate the flywheel from the shaft.
8–4 04/09
Hydraulic Adjustment Assembly Removal

1. Disconnect the electrical connector at the position sensor.
Disconnect position sensor bracket and linkage to prevent
damage during handling (Fig. 8-4). Unbolt the two bolts
holding the bracket to the side of the hydraulic assembly.
Disengage the linkage from the cylinder rod toggle end as the
position sensor assembly is lifted off the hydraulic cylinder.
B
A
A B
Figure 8–3. Flywheel Removal

A. Lift Chain B. Hub Wedges (4)
6. Slide the flywheel hub back off the eccentric shaft and
lower flywheel to the ground with the hoist.
7. Remove the wedges from the hub splits on the flywheel. Figure 8–4. Disconnect Sensor Linkage
8. Remove the shaft key from the eccentric shaft and inspect A. Step 1: Remove bracket mounting bolts
for damage or wear. Replace the key if worn, mis-shaped or B. Step 2: Disconnect linkage at this point
otherwise damaged. Inspect the keyway on the shaft for 2. Attach a hoist and sling of sufficient capacity (Fig. 8-5)
damage, and reshape with a cutting wheel if edges are worn around the cylinder body of the adjusting assembly to hold
rounded or mis-shaped. the assembly from dropping during the following removal
9. Repeat the flywheel removal sequence in steps 3 through steps. Failure to support the assembly could result in the
8 for the remaining flywheel. hydraulic adjust cylinder falling down prior to removal.
8
C
Figure 8–5. Hydraulic Adjusting Assembly Lift Sling

A. Lift Strap B. Relief Manifold
C. Hydraulic Cylinder
04/09 8–5
4. Move the adjust switch to RETRACT and maintain

! WARNING switch in position. Retract the swing jaw fully.
The hydraulic assembly and swing jaw will move 5. Remove the jam nuts, the upper spring washer and the
during the following steps. To prevent serious spring from all four spring tension assemblies on the
personal injury, be sure no personnel are on, hydraulic adjust assembly (Fig. 8-5).
inside or under the crusher before restoring
power and activating the hydraulic functions. 6. Remove the lower spring washer from all four tension
spring pockets (Fig. 8-5) and allow the tension pins to swing
3. Restore power to the hydraulic control panel. Move the down out of the adjuster assembly.
function switch to CRUSH. Start the hydraulic pump.
7. Extend jaw until lockout pins can be inserted to support
swing jaw (Fig. 8-6).
E F
C D
8 A B
Figure 8–6. Tension Spring Removal

A. Swing Jaw Toggle Seat B. Tension Pin (4) C. Rod Side Toggle End D. Lower Spring Washer (4)
E. Tension Spring (4) F. Upper Spring Washer (4) G. Lower Jam Nut (4) H. Upper Jam Nut (4)
I. Hydraulic Cylinder J. Fixed Toggle Seat K. 2550 Frame L. Swing Jaw Assembly
8–6 04/09
C B
Figure 8–7. Install Swing Jaw Locking Pins

A. Step 1 : Extend Hydraulic Adjust Cylinder B. Step 2: Install Lock-Out Pin on each side of jaw.
8. Retract the hydraulic cylinder fully (Fig 8-7) using the

RETRACT switch. The toggle wear bar should now
disengage from the swing jaw toggle seat. Caution: The
hydraulic adjust assembly will now be supported only by the
lift strap.
Figure 8–8. Hydraulic Adjust Cylinder Retract

9. Depressurize the hydraulic adjust assembly as detailed in
Chapter 6. Lockout power to hydraulic power unit.
04/09 8–7
! WARNING
F a i l u r e t o L o c k o u t / Ta g o u t p o w e r a n d
depressurize the hydraulic adjust assembly
before attempting to remove hydraulic hoses or
remove the adjuster assembly could result in B B
serious personal injury or death.
10. Disconnect the hydraulic hoses (3) at the relief manifold
on top of the hydraulic adjusting assembly noting the position
of the lines (Fig. 8-8).
A A
C
B
Figure 8–10. Grease Line Removal
A. Swing Jaw Grease Line B. Main Frame Grease Line
Fitting (2) Fitting (2)
2. Attach chains to the lower swing jaw lugs and attach the
chains to a frame mounted come-along puller (Fig. 8-11)
A
Figure 8–9. Hydraulic Line Disconnection

A. Hydraulic Adjusting Cylinder B. Hydraulic Pressure Lines (2)
C. Hydraulic Relief Line
11. Maneuver the hydraulic adjusting assembly so the toggle

wear bar slides out of the fixed toggle seat bolted to the frame
(J, Fig. 8-5). Tilt the back of the hydraulic adjust assembly
(the end removed from frame toggle seat) up and carefully lift
the assembly up out of the 2550 frame.
Pull-Alo
ng
NOTE:
If your 2550 application has sufficient room beneath the Figure 8–11. Positioning Swing Jaw
crusher to extract the hydraulic assembly from below, it
8 may be possible to lower the assembly and remove it
from under the crusher. Refer to Hydraulic Adjustment
3. Remove the locking pins from both sides of the swing
jaw. Use the come-along to slowly move the swing jaw back
Assembly Service in this chapter for additional to the neutral position. Remove the come-along and chains.
detailed service and installation/removal instructions. 4. Attach a suitable lifting device and cables or chains to the
two lifting lugs at the top of the swing jaw (swing jaw
Swing Jaw Removal assembly with die weighs approximately 4700 Kg (10,300
1. Remove the grease lines at the swing jaw and main frame Lbs)).
bearing fittings (Fig. 8-10).
! WARNING
Keep all personnel clear of the work area while
removing the swing jaw with a hoist. Do not
allow personnel to work on or in the crusher until
the swing jaw assembly has been completely
removed from the crusher and secured in a work
area.
8–8 04/09
5. While maintaining slight pressure on the lift mechanism,

remove the six capscrews holding each bearing mounting
flange to the crusher mainframe (Fig. 8-12).
A
C
Figure 8–12. Flange Mounting Bolt Removal

A. Flange Mounting Bolt (12) B. Locknut and Washer (12)
C. Mounting Flange
6. Using the hoist, lift the swing jaw assembly straight up Figure 8–13. Swing Jaw Removal
until the bearing mounting flanges clear the crusher frame 7. Lift the swing jaw assembly straight up out of the frame
(Fig. 8-13). Move the swing jaw assembly slightly forward and place on suitable supports with the wear surface facing
toward the stationary die until it is hanging straight down. down (Fig. 8-14).
Figure 8–14. Swing Jaw Support
04/09 8–9
Eccentric Shaft Bearing Removal 4. Attach a grease gun to the fitting and pump grease into the
shaft until grease begins to flow between the bearing inner
Main Frame Bearing Removal race and the shaft.
1. Remove the main frame bearing spacer and seals from the 5. Fabricate a bearing removal tool using 4 Grade 8 threaded
eccentric shaft (A, Fig. 8-15). rods, a metal plate and a hydraulic jack or portable power unit
(Fig. 8-17). Thread the 4 rods into the face of the main
2. Remove the 8 hex head capscrews (C, Fig. 8-15) and bearing flange spacing the rods evenly around the
washers holding the main frame bearing retainer to the main circumference of the flange. Suspend the plate from a hoist
frame bearing housing (B, Fig. 8-15). Remove the bearing and install the rods through the plate, securing with nuts on
retainer from the shaft. the rods.
B E
Figure 8–15. Bearing Spacer and Retainer Removal B C

A. Bearing Space( B. Main Frame Bearing Retainer
C. Hex Head Capscrew (8)
3. Remove the threaded plug from the first journal step on

the eccentric shaft and install a grease fitting into the threaded
A
hole in the shaft (Fig. 8-16).
8 Figure 8–17. Main Frame Bearing Removal
A. Hydraulic Jack B. Reinforced Metal Plate
C. Threaded Rod (4) D. Bearing Housing
E. Bearing
! WARNING
Always wear safety glasses or a safety shield
during bearing removal procedures. Parts may
break and be ejected with tremendous force
when removing bearings. To prevent serious
personal injury, remain a safe distance from the
bearings and the removal tools while force is
bring applied.
Figure 8–16. Grease Fitting Location
8–10 04/09
6. Install the portable power tool or hydraulic jack between

the end of the eccentric shaft and the metal plate (Fig. 8-17).
Apply enough force to hold the jacking unit in position. Step
back a safe distance from the bearing and puller and slowly
apply hydraulic pressure to the bearing and bearing housing.
As the hydraulic shaft extends, verify that the bearing has
unseated and is moving off the shaft. If the force of removing
the bearing shows signs of bending the metal plate, it may be
necessary to use a thicker plate, or weld reinforcing straps in
a V-pattern across the face of the plate.
7. If the hydraulic jacking device does not have sufficient
cylinder travel to remove the bearing in one stroke, it may be
necessary to relocate the metal plate inward and repeat the
jacking process until the bearing assembly can be removed
completely from the shaft journal. When the bearing
assembly reaches the first step on the shaft, attach a lift
harness to the bearing housing and remove the assembly from
the shaft.
8. Lower the bearing assembly onto blocking with the open
end of the bearing housing facing down (Fig. 8-18).
! CAUTION
When tipping the bearing housing onto its face,
be aware that the bearing assembly could slide
out of the housing if the bearing is worn/
damaged or a loose fit in the housing bore.
8
Figure 8–18. Bearing Removal From Housing
9. If the bearing will be reused, make certain that a soft
surface is provided beneath the bearing where it will drop out
of the housing to prevent bearing damage. Heat the bearing
housing with a torch (Fig. 8-18), moving around the housing
to heat the area beneath the mounting flange uniformly until
the bearing drops out.
10. Repeat steps 1 through 9 to remove the second main frame
bearing/housing from the eccentric shaft.
04/09 8–11
Eccentric Shaft Removal from Housing 1. Remove the outer seal (H, Fig. 8-19), the bearing spacer
(G) the inner seal (F) and the inner seal housing (E) from both
Removing the eccentric shaft from the swing jaw is necessary
sides of the eccentric shaft.
to gain access to the swing jaw bearings. Remove the shaft
and bearings as a unit as follows. 2. Remove the capscrews and washers (A, Fig. 8-19)
holding the bearing retainers (E, Fig 8-15) to both sides of the
swing jaw. Remove both bearing retainers.
D
E
F G
H
C
B A
Figure 8–19. Eccentric Shaft Seal and Bearing Retainer Removal

A. Capscrew and Washer (8) B. Eccentric Shaft C. Swing Jaw D. Swing Jaw Bearing.
E. inner Seal Housing F. Inner Seal (290 mm) G. Spacer H. Outer Seal (250 mm)
3. Thread two lift eyes into the flywheel (expansion) end of

8 the eccentric shaft and attach a chain puller to the eyes (Fig.
8-20).
4. Have two hoists and chains of sufficient capacity to
support the shaft assembly at both the center and the end
ready for use. Install a blocking device between the swing jaw
housing and a solid object to prevent the swing jaw from
shifting during the pulling operation (Fig. 8-20)
Figure 8–20. Shaft Pulling Arrangement
8–12 04/09
5. Attach one lift hoist and chain to the pulling end of the
shaft (Fig. 8-21). IMPORTANT:
It is necessary to immediately begin the pulling
operation when the swing jaw housing has been heated
to the correct temperature. A delay in beginning the pull
of the swing jaw assembly could allow heat to begin to
transfer to the bearing assemblies.
8. Slowly pull the eccentric shaft and swing jaw bearing
assemblies out of the swing housing until both the thrust and
expansion side bearings have unseated from their bores in the
housing and the approximate center of the shaft is exposed.
Attach the second lift chain at the center of the eccentric shaft
(Fig. 8-23).
Figure 8–21. Shaft Lift Hoist Arrangement

6. Heat the swing jaw housing around the circumference of
both swing jaw bearings to approximately 71oC (160oF) to
77oC (170oF). Move around the complete circumference of
the housing with an acetylene torch directly above the swing
jaw bearings (Fig. 8-22). Use a heat gun to check the swing
jaw housing temperature.
Figure 8–23. Center Lift Chain Location

9. When both bearings are unseated, make certain the thrust
(sheave) side bearing that remains in the housing is
suspended so it is floating in the housing and is not touching
the swing jaw housing at the circumference or face of the
bearing.
10. Reheat the expansion side bearing housing to
8
approximately 71oC (160oF) to 77oC (170oF). Immediately
align the thrust side bearing in the expansion side bore and
use the puller to withdraw the eccentric shaft assembly from
Figure 8–22. Swing Jaw Housing Heating Areas the swing jaw housing.
7. Apply a small amount of lift tension to the lift chain (Fig.
8-21) to remove swing jaw weight from the swing jaw bore. NOTE:
It may be necessary to reposition the center lift chain
and/or use support blocking as needed to maintain even
support of the shaft during removal.
11. When completely removed from the housing, lower the
eccentric shaft onto blocking or fixtures of sufficient capacity
to support the assembly.
04/09 8–13
12. Carefully inspect both swing jaw bearings for the Swing Jaw Bearing Removal
following signs of wear or damage:
1. Remove the threaded plug from the second journal step on
• Obvious wear such as worn through plating or both ends of the eccentric shaft (Fig 8-24). Install grease
discoloration of rollers and races fittings in threaded holes.
• Excessive bearing clearance
Maximum radial clearance mounted: 0.279 mm (0.011”) A
Maximum radial clearance not-mounted: 0.330 mm (0.013”)
• Corrosion B
• Spalling or pitting E
• Out-of-round races
13. If the bearings appear worn or damaged or other problems
are suspected, replace the bearings. Remove the bearings C
from the shaft as described in the following paragraph of this D
chapter.
14. If the shaft and bearings will be stored for a prolonged
period: Coat the bearings and all shaft surfaces with heavy Figure 8–24. Bearing Grease Fitting Location
oil. Wrap both bearings and the shaft in waterproof paper. A. Grease Channel B. Threaded Plug
Store the entire assembly in a clean dry place until needed for C. Bearing D. Swing Jaw Housing
re-installation. E. Eccentric Shaft
2. Install eyebolts on one end of the eccentric shaft and stand

the shaft on one end supported by cables or slings inserted in
the eyebolts (Fig. 8-25).
3. Install wood blocking around the base of the shaft to the
level of the first journal step to prevent the bearing from
dropping to the ground when released.
Figure 8–25. Swing Jaw Bearing Removal

A. Lift Eyes B. Swing Jaw Bearings
C. Eccentric Shaft D. Wood Block
8–14 04/09
4. Apply grease to the grease fitting on the lower bearing 4. Using a feeler gauge, check the clearance between the top
until grease is visible around the complete circumference of roller and the outer race on each bearing before installation.
the shaft/inner race junction. Clearance must be within 0.226 to 0.330 mm (0.009 to 0.013
in.).
! CAUTION NOTE: Repeat steps 5 through 11 for both ends of
The bearing assembly may drop down suddenly shaft. Heat and install bearings one at a time.
during the following removal steps. Never place 5. Heat the bearing inner race to between 93° and 104°C
any part of the body (hands, feet etc.) between (200 to 220 degrees °F) using an induction heater. If an
the lower bearing race and the blocking. Failure induction heater is not available an oil heater may be used. If
to comply could lead to serious personal injury. an oil heater is used, slowly bring the oil up to the required
5. Apply light blows to the top side of the inner bearing race temperature to ensure even heating. Do not allow oil
with a wooden block and a hammer to move the bearing down temperature to exceed 107°C (225°F).
the shaft. 6. Suspend the bearing in a cable or place it in a basket so
6. If the bearing will not come free from the journal using that it does not contact the bottom of the oil bath. Direct heat
the grease pressure and hammer method, it may be necessary may permanently damage the bearing.
to apply some heat to the inner race.
7. Prior to applying any heat, coat all surfaces of the bearing IMPORTANT:
with heavy grease. The following steps must be performed quickly to
prevent the bearing from cooling and seizing before it is
8. Carefully heat the inner bearing race with a rosebud type
fully installed on the shaft. Review the installation steps
heating torch or a welding torch. Continuously move around
before removing the bearing from the heater.
the race and apply more grease if needed during heating. The
bearing and inner spacer should drop down onto the blocking
when heated sufficiently. ! WARNING
The bearing will be extremely hot when removed
IMPORTANT: from the bearing heater or oil. Make certain all
personnel involved in the installation have heat
Do not apply heat to any ungreased surface. Do Not use
resistant clothing before beginning installation.
a cutting torch to apply heat.
Failure to wear heat (and oil resistant) garments
9. Lift the eccentric shaft free of the bearing and reverse could cause severe burns.
shaft to remove the remaining bearing.
7. Remove the bearing from the heater and carefully slide
onto shaft using a sling or hook to lift the bearing (Fig. 8-26).
! CAUTION Make certain that the bearing seats fully against the shaft step.
Allow removed bearing to cool before handling if
8
heated during the removal process.
Eccentric Shaft Bearing Installation
Swing Jaw Bearing Installation

1. Place the new or refurbished eccentric shaft on suitable
supports that will prevent the shaft from shifting during
component installation.
2. Be sure that all machined surfaces of the shaft are
completely free of grease and dirt. Remove any nicks, burrs
or scratches with a grinder or emery cloth.
3. Using a micrometer, measure the diameter of the shaft
journals on which the swing jaw bearings will be installed.
The diameter of each shaft journal must be between 240 mm
and 240.1 mm (9.452 to 9.453 in.).
04/09 8–15
11. Using a feeler gauge, check the clearance between the

inner race of the bearing and the step on the shaft (Fig. 8-28).
There should be no clearance at this point.
Figure 8–26. Swing Jaw Bearing Installation Figure 8–28. Race to Shaft Step Clearance Check
8. Assemble a blocking device (Fig. 8-27) using a metal bar 12. Repeat the installation process for the remaining swing
threaded into the end of the eccentric shaft and two 2x4s. jaw bearing.
Tighten the blocking until the 2x4s are tight against the
13. When both bearings have completely cooled remove the
bearing inner race.
bearing stop apparatus and prepare the swing jaw housing for
eccentric shaft installation.
Figure 8–27. Blocking Swing Jaw Bearings

9. Allow the bearing to cool with blocking in place.
Approximately 30 to 60 minutes will be required, depending
on bearing temperature. Remove the blocking after the
bearing has cooled.
10. Using a feeler gauge, check the clearance between the top
roller and the outer race on each bearing. Clearance must be
within 0.127 to 0.279 mm (0.005 to 0.011 in.).
8–16 04/09
Eccentric Shaft Installation in Swing Jaw

The installation of the eccentric shaft into the swing jaw
housing will require an overhead hoist with two lift chains of A
sufficient capacity and a chain puller arrangement similar to
what was used to pull the eccentric shaft from the housing.
1. Remove any dirt or grease from the machined surfaces of
the swing jaw bore. Check all machined surfaces for nicks,
burrs or scratches. Remove with emery paper or a stone if
present.
2. Using a micrometer, check the inside diameter of the bore
B
on both sides of the swing jaw (Fig. 8-29). Make two
measurements 90 degrees apart in each location. Verify that
all measurem ents are between 39.994 and 39.999
centimeters. (15.746 to 15.748 in.).
Figure 8–30. Bearing Stop Fixture

A. Bearing Stop Fixture Plate B. Mounting Capscrew (4 places)
IMPORTANT:
Be sure that both bearings have fully cooled before
continuing with the following steps:
4. Attach a double lifting chain to the center balance point of
the shaft assembly (Fig. 8-31). Thread lift eye bolts into both
Figure 8–29. Checking Swing Jaw Bore I.D. ends of the eccentric shaft.
3. Install bearing stop fixture plate pn #1041654 on the

swing jaw expansion side housing with four (4) capscrews.
The fixture plate will act as the bearing stop as the eccentric
shaft assembly is pulled into the housing and provide 5.97
mm (0.235 in.) clearance when the stop fixture plate is
8
removed and replaced with the bearing retainer plate.
Figure 8–31. Center Lift Chain

5. Horizontally suspend the shaft assembly using an
appropriate lifting device. Align the leading end of the shaft
with the opening of the swing jaw bore. Refer to Chapter 2 for
shaft assembly weights.
04/09 8–17
6. Coat the swing jaw bearings with clean oil.
! CAUTION
Do not overheat swing jaw bores in the following
step. Overheating can expand the length of the
bore which can lead to bearing seating problems
as the unit cools. A temperature measuring
device must be used in the following sequence.
7. Heat both swing jaw housing bores to 71oC to 76oC
(160oF to 170oF) using a rosebud torch (Fig 8-32). Keep torch
head 3 feet from end of each bore to prevent hotspots and
move the torch around the inner circumference of the bore to
allow heat to penetrate gradually. Use a heat gun to check Figure 8–33. Checking Bearing Alignment
temperature periodically. 10. Guide the first bearing through the bore until the end of
the eccentric shaft emerges on the far side (bearing stop plate
side) of the housing.
11. Block up the end of the shaft that is outside the swing jaw
housing and remove the double lift chain from the center of
the eccentric shaft. Attach one chain to the lift eyes at each
end of the shaft. Attach the pulling device (Fig. 8-21) to the
lift eyes in the eccentric shaft.
12. Support the shaft at both ends with the lift chains and
remove the blocking from the shaft. Immediately begin to
draw the shaft assembly through the bore using the puller.
Monitor both bearings to make certain they are square in the
housing as the pulling operation begins (Fig. 8-34). Continue
to pull the shaft, until the first bearing bottoms on the bearing
retainer plate (Fig. 8-30). Remove the pulling device.
Figure 8–32. Heating Housing Bores
! CAUTION
8 In the following steps personnel will be working
with and around heated components. Proper
heat resistant safety gear should be worn to
prevent burns if inadvertent contact is made with
heated components.
8. When both bores are properly heated, align the first
bearing outer race with the swing jaw bore opening (Fig 8-
31). Coat the swing jaw bearing bores with clean oil.
9. Check alignment with a T-Square at four locations, 90
degrees apart (Fig. 8-32) as the bearing face first enters the
swing jaw housing bore. Adjust the shaft if necessary to
square up housing. Figure 8–34. Second Bearing Alignment
13. Move to the other side of the housing (without bearing
stop plate). Rotate or rock the eccentric shaft back and forth
several times to help center the bearings.
8–18 04/09
14. Insert two (2) brass shims 180 degrees apart on the 17. Remove the bearing stop fixture from expansion side of
bearing. Matched shims in the range from 0.381 mm to 0.508 swing jaw. Replace bearing stop fixture with retainer plate.
mm (.015” to .020”) should be used. Use the largest set of Install retainer plate (A, Fig. 8-36) on the swing jaw housing
shims that the bearing will accept. The shims should be with eight (8) capscrews and washers. Use a medium thread
inserted at the 3 o’clock and 9 o’clock position between the locker (Loctite #242) on the retainer bolts and torque to 330
thrust side bearing rollers and the outer race (Fig. 8-35). Nm (246 Ft. lbs). Repeat the retainer plate installation on the
Rotate the eccentric shaft several turns to allow all rollers to opposite side of the swing jaw housing.
run over the shims. This helps work the outer race towards the
18. Install pipe plug in the threaded grease hole (Fig. 8-16).
end of the swing jaw bore. Leave the shims in place for 30
minutes as the assembly cools and then remove.
A D
Figure 8–36. Seal and Retainer Installation

A. Bearing Retainer Plate B. Bearing Spacer
C. Outer Seal (250 mm) D. Bearing Retainer Capscrew (8)
19. Install the 290 mm seal on the inner step of the bearing
spacer and the 250 mm seal on the outer step of the spacer 8
Figure 8–35. Shim Location and Installation (Fig. 8-36). Completely pack the area above the seals on the
15. When the entire assembly has cooled to room spacer with NLGI #2 grease. Use a putty knife to make
temperature, check the following: certain the gap above the seal is completely full of grease.
• Check alignment of the outer bearing race with the inner 20. Slide the spacer/seal assembly onto the shaft making
race. If the radial clearance is not correct it will be certain the larger (290 mm) seal faces in against the bearing.
necessary to realign the races. (Refer to Swing Jaw Repeat the seal and retainer installation on the opposite side
Bearing Race Alignment). of the shaft.
• Use a feeler gauge to check the radial bearing clearance.

Clearance should be in the range from 0.10 to 0.27 mm
(0.004” to 0.011” ).
16. If clearances are within tolerance, continue to assemble
the swing jaw.
04/09 8–19
Swing Jaw Bearing Race Alignment 5. If the bearing races are now aligned, move back to the
other side of the swing jaw housing and check that the upper
If the swing jaw bearings have less than minimum radial
bearing race has not pulled away from the bearing retainer
clearance when the unit has cooled (Step 15), it will be
plate more than the required 5.97 mm (.040”) clearance. If the
necessary to reduce preload effect to prevent premature
bearing to retainer plate clearance is correct, remove the
bearing wear or overheating. The position of the outer races
retainer plate and check the bearing radial clearance.
can be manipulated by realigning the swing jaw housing in
relation to the outer bearing race as follows: 6. If the upper bearing race does not have the required 5.97
mm (.040”) clearance with the retainer plate or radial
1. Install four (4) threaded rods (equally spaced around the
clearance is incorrect, it will be necessary to move the
circumference) into the face of the swing jaw housing using
hydraulic/ fixture plate assembly to the thrust side and pull
the threaded holes that are used for mounting the bearing
the expansion side outer race out to re-align.
retainer plate. The rods must be long enough to reach past the
end of the eccentric shaft by several feet.
2. Secure a fixture plate (or a metal plate with four holes
NOTE:
drilled for the threaded rods) to the end of the rods by It is not necessary to remove the bearing retainer plate
installing nuts and washers on the threaded rods. Install a to pull the upper housing into alignment. Remove four
hydraulic jack or portable power unit between the end of the bolts from around the circumference of the plate to allow
eccentric shaft and the steel plate (Fig. 8-37). the threaded puller rods to be installed.
3. Apply hydraulic pressure and pull the swing jaw housing
Main Frame Bearing Installation
and upper bearing race back into alignment. Release
hydraulic pressure and remove the jack (Fig. 8-37). 1. Heat the main frame bearing mounting bore to 4oC (40oF)
greater than the current ambient temperature..
! CAUTION
Expansion In the following steps personnel will be working
Side around and with heated components. Proper
heat resistant safety gear should be worn to
prevent burns if inadvertent contact is made with
heated components.
2. Place the heated main frame bearing housing face up on a
work surface (Fig. 8-38). Oil the heated bore of the housing.
3. Lower the main frame bearing down into the housing. Use
a soft faced mallet on the outer race if necessary to fully seat
8 the bearing in the housing bore. When bearing is fully seated
at the bottom of the bore, install a bearing stop (C, Fig. 8-38)
to prevent the bearing from moving as the housing cools.
Figure 8–37. Bearing Race Alignment

4. Rock the shaft back and forth several times to center the
inner races in the bearings. Check both the bearing race
alignment and the radial clearance again.
8–20 04/09
B
A
Figure 8–38. Seating Main Frame Bearing In Housing

A. Main Frame Bearing Housing B. Main Frame Bearing
C. Bearing Stop A
NOTE: Figure 8–39. Main Frame Bearing Assembly

Before attempting to install the main frame bearing Installation
assemblyon the eccentric shaft, check the shaft A. Main Frame Bearing Housing B. Eccentric Shaft
condition. Make certain all high spots are polished off C. Bearing Strap Tool
with an emery cloth, and check that all machined 6. Oil the eccentric shaft at the bearing race mounting point
grooves or keyways in the shaft do not have high edges before beginning to mount the bearing.
or burrs. Use a stone or file to remove any
imperfections. 7. Lift the bearing assembly up into position with a hoist
(Fig. 8-39) and quickly (before assembly cools) slide it back
4. Heat the bearing and housing assembly to 120oC to 138oC on the shaft until it is fitting flush against the bearing spacer
(250oF to 280oF). DO NOT exceed 149oC (300oF).
5. Install a bearing strap tool with handles around the
(B, Fig. 8-36) installed previously. 8
8. Install bearing blocks and a face bar at the end of the
machined portion of the bearing housing (Fig. 8-39). This eccentric shaft to hold the inner bearing race in place on the
will provide lift points and non-heated handles to aid in shaft until it cools (Fig. 8-40). Repeat steps 1 through 8 to
alignment of the heated bearing assembly. install the main bearing assembly on the other side of the
eccentric shaft.
04/09 8–21
! WARNING
D
B The complete 2550 swing jaw assembly without
flywheels weighs approximately 4662 Kg (10,279
Lb.). Always use suitable rigging and hoisting
equipment to stabilize and lift heavy objects. Lifting
heavy components with inadequate hoisting
apparatus can damage machinery and may result in
serious personal injury or death. Refer to Chapter 2
for actual weight of components. Never attempt to
lift the jaw assembly by slinging around the bearing
A housings or the flywheel shafts. Lift only at the lift
eyes built into the upper casting as shown in Figure
8-42. Failure to lift the swing jaw at the correct
C
points could result in damage to the jaw assembly
or crusher frame.
Figure 8–40. Blocking Main Frame Bearing
A. Inner Bearing Race B. Wood Blocking 3. Using a suitable lifting device, carefully lift the swing jaw
C. Face Bar D. Grease Plug at the two lift eyes cast into the top of the bearing housing
9. If the eccentric shaft grease plugs (D, Fig. 8-40) were not (Fig. 8-42) and suspend it over the crusher frame opening. Be
fitted in the grease channels previously, install them at this sure that the swing jaw die faces toward the stationary jaw
time. die. Position the swing jaw assembly over the center of the
frame with the bearing assemblies forward of the frame
mounting saddles.
Installing Swing Jaw In Main Frame
When the main frame bearing assemblies have cooled
completely and the bearing blocking assemblies are removed,
install the swing jaw in the 2550 frame as follows:
Install the swing jaw as described in the following procedure.
Refer to figures as indicated.
1. Using an appropriate cleaning solvent, completely
remove any rust preventative coating, grease, paint
overspray, dirt, corrosion etc. from the unpainted machined
surfaces of the swing jaw mounting saddles (Fig. 8-41).
8
Figure 8–42. Lifting the Swing Jaw Assembly

Figure 8–41. Swing Jaw Frame Mounting Saddles
2. After removing any contamination or rust preventative

coating, verify that there are no nicks, burrs, scratches or
damage on the machined surfaces of the frame.
8–22 04/09
4. Slowly lower the swing jaw into the center of the crusher.
When the swing jaw is approximately 1/2 depth in the frame,
C
maneuver the swing jaw directly over the frame mounting
saddles. Make certain the main bearing assembly mounting
flanges are aligned outside the frame.
A
C B
Figure 8–44. Bearing Mounting Flange Hardware

A. Mounting Bolt (12) B. Flat Washer (24)
C. Hex Nut (12)
8. Using a torque multiplier tool (Fig. 8-45), torque each

mounting bolt to a final torque of 2745 Nm (2043 Ft. lb.).
Work in a cross pattern alternating from one side to the other
on the crusher until all fasteners hold the final torque value.
NOTE:
Failure to properly torque mounting bolts could result in
loosening of the bearing mounting to frame connection
which will cause damage to machine parts.
Figure 8–43. Positioning Swing Jaw in Frame
5. As the jaw assembly begins to seat on the frame, slide two
mounting bolts through the bearing flange mounting holes
and into the frame on each side of the unit to help align the
unit with the crusher frame. It may be necessary to align the
flange holes using a hardened drift while maintaining some
tension on the lift hooks before bolts can be fully inserted.
6. When the swing jaw unit is completely seated on the
8
frame mounting saddles, and at least three mounting bolts can
be installed with no interference on each side of the unit, the
tension can be released from the lift hooks. Remove the
lifting lugs and lift chains at this time.
7. Install all six mounting bolts on each side of the frame
with a washer on the head of the bolt (Fig. 8-44). Coat the
threads of mounting bolts with high strength thread locker
(Loctite #271). Install a washer and the hex nut on all
mounting bolts and hand tighten.
Figure 8–45. Torquing Mounting Flange Bolts
9. Install the grease lube lines at both the swing jaw and
main frame bearings (Fig 8-10) when the swing jaw is
completely mounted.
10. Reinstall the hydraulic adjusting assembly as detailed in
the Hydraulic Adjustment Assembly Service in this chapter.
04/09 8–23
Flywheel Installation 3. Align the flywheel with the shaft keyway and install a
new key (Fig. 8-47).
Sheave Flywheel Installation
1. Install a lift sling or chain and a hoist of sufficient
capacity to the sheave (grooved) flywheel (flywheels weigh
approximately 833 Kg (1833 Lb.)). With the flywheel
supported and standing on end, drive wedges into the hub
splits at both the front and back of the hub (Fig. 8-46).
Figure 8–47. Key Installation

B
Figure 8–48. Flywheel Weight Position (Sheave
Flywheel)
B 4. When the flywheel is correctly aligned, install the

flywheel retainer on the end of the eccentric shaft. Coat the
retainer bolts with medium thread locker (Loctite #242) and
torque to 571 Nm (425 Ft. Lb.) in an alternating pattern.
5. Remove the hub wedges from the front and rear of each
hub split. Install the four flywheel retaining capscrews down
through the hub. Coat the threads with medium thread locker
Figure 8–46. Installing Flywheel Wedges (Loctite #242) and install the flatwashers and locknuts
A. Lift Chain B. Hub Wedge (4) torquing in a cross pattern to 571 Nm (425 Ft. Lb.).
C. Rotation Arrow
Pulley Flywheel Installation
! WARNING Install the pulley flywheel using the same sequence as step 1
Always use suitable rigging and hoisting through 5 for the sheave flywheel installation. Complete the
8 equipment to stabilize and lift heavy objects. installation by removing the hub wedges and installing the
flywheel retaining capscrews. Use medium thread locker
Lifting heavy components with inadequate
hoisting apparatus can damage machinery and (Loctite #242) and install the flatwashers and locknuts
may result in serious personal injury or death. torquing in a cross pattern to 571 Nm (425 Ft. Lb.).
2. Make certain the flywheel weight is facing in (towards the

crusher). Lift the flywheel up and align with the end of the
eccentric shaft. Slide the flywheel back onto the eccentric
shaft until it contacts the spacer.
NOTE:
If the flywheel is difficult to slide on the last portion of the
shaft, it may be possible to pull it down with the end cap.
After the drive key is installed in the keyway, finish
seating it on the shaft by drawing down the end cap
fasteners.
8–24 04/09
HYDRAULIC ADJUSTING ASSEMBLY

SERVICE A
The hydraulic adjusting assembly removal method will be

dictated by clearances beneath the 2550 crusher. If your
application has sufficient clearance to lower the unit and pull
it out from beneath the back of the crusher, this method is C
suggested. If clearances are not available to lower the
hydraulic unit, it is also possible to extend the swing jaw fully
and tilt the hydraulic unit slightly as it is lifted out of the
crushing chamber from the top. If your application has a
discharge conveyor with forward/reverse operation and the
capacity and width to hold the hydraulic adjuster, it may also
be possible to remove and replace the assembly using the
conveyor.
B
Hydraulic Adjustment Assembly Removal
1. Lockout/tagout power to the crusher drive motor and to Figure 8–50. Hydraulic Adjusting Assembly Lift Sling
the crusher hydraulic system before beginning any service A. Lift Strap B. Relief Manifold
work. C. Hydraulic Cylinder
2. Disconnect Position Sensor bracket and linkage to

prevent damage during handling (Fig. 8-49). Unbolt the two ! WARNING
bolts holding the bracket to the side of the hydraulic
The hydraulic assembly and swing jaw will move
assembly. Disengage the linkage from the cylinder rod toggle
during the following steps. To prevent serious
end as the position sensor assembly is lifted off the hydraulic
personal injury, be sure no personnel are on,
cylinder.
inside or under the crusher before restoring
power and activating the hydraulic functions.
4. Restore power to the hydraulic control panel. Move the
function switch to CRUSH. Start the hydraulic pump.
5. Move the adjust switch to RETRACT and maintain
switch in position. Retract the swing jaw fully.
B
A 6. Remove the jam nuts, the upper spring washer and the
spring from all four spring tension assemblies on the
hydraulic adjust assembly (Fig. 8-51). 8
7. Remove the lower spring washer from all four tension
spring pockets (Fig. 8-51) and allow the tension pins to swing
down out of the adjuster assembly.
8. Extend jaw until lockout pins can be inserted to support
Figure 8–49. Disconnect Sensor Linkage swing jaw (Fig. 8-52).
A. Step 1: Remove bracket mounting bolts
B. Step 2: Disconnect linkage at this point
3. Attach a hoist and sling of sufficient capacity (Fig. 8-49)

around the cylinder body of the adjusting assembly to hold
the assembly from dropping during the following removal
steps. Failure to support the assembly could result in the
hydraulic adjust cylinder falling down prior to removal.
04/09 8–25
F
E
D
C
A B
Figure 8–51. Tension Spring Removal

8 A. Swing Jaw Toggle Seat B. Tension Pin (4)) C. Rod Side Toggle End D. Lower Spring Washer (4)
E. Tension Spring (4) F. Upper Spring Washer (4) G. Lower Jam Nut (4) H. Upper Jam Nut (4)
I. Hydraulic Cylinder J. Fixed Toggle Seat K. 2550 Frame L. Swing Jaw Assembly
8–26 04/09
C B
Figure 8–52. Install Swing Jaw Locking Pins

A. Step 1 : Extend Hydraulic Adjust Cylinder B. Step 2: Install Lock-Out Pin on each side of jaw.
9. Retract the hydraulic cylinder fully (Fig 8-53) using the

RETRACT switch. The toggle wear bar should now
disengage from the swing jaw toggle seat. CAUTION: The
hydraulic adjust assembly will now be supported only by the
lift strap.
Figure 8–53. Hydraulic Adjust Cylinder Retract
04/09 8–27
10. Depressurize the hydraulic adjust assembly as detailed in

Chapter 6. Lockout power to hydraulic power unit.
! WARNING
F a i l u r e t o L o c k o u t / Ta g o u t p o w e r a n d
depressurize the hydraulic adjust assembly
before attempting to remove hydraulic hoses or
remove the adjuster assembly could result in
serious personal injury or death.
11. Disconnect the hydraulic hoses (3) at the relief manifold Pull-Alo
ng
on top of the hydraulic adjusting assembly noting the position
of the lines (Fig. 8-54). Disconnect the electrical connector at
the position sensor. Figure 8–55. Positioning Swing Jaw
C
B
Figure 8–54. Hydraulic Line Disconnection

A. Hydraulic Adjusting Cylinder B. Hydraulic Pressure Lines (2)
C. Hydraulic Relief Line
12. Attach a chain and come-along puller or hoist to the

bottom swing jaw eyes (Fig. 8-55). Pull the swing jaw fully
forward until it contacts the stationary die to provide
additional room for the hydraulic adjuster assembly removal.
13. Maneuver the hydraulic adjusting assembly so the toggle
wear bar slides out of the fixed toggle seat bolted to the frame
8 (J, Fig. 8-51). Tilt the back of the hydraulic adjust assembly
(the end removed from frame toggle seat) up and carefully lift
the assembly up out of the 2550 frame.
NOTE:
If your 2550 application has sufficient room beneath the
crusher to extract the hydraulic assembly from below, it
may be possible to lower the assembly and remove it
from under the crusher. Refer to Hydraulic Adjustment
Assembly Service in this chapter for additional
detailed service and installation/removal instructions.
8–28 04/09
Hydraulic Adjuster Component Replacement Toggle End Replacement

The hydraulic adjuster assembly (Fig. 8-57) can be Both the stationary toggle end attached to the hydraulic
disassembled to replace the toggle wear bars, the toggle ends cylinder body, and the cylinder rod toggle end attached to the
and the hydraulic relief manifold. Telsmith supplies o-rings cylinder rod can be removed from the hydraulic assembly to
as spare parts that will allow you to replace internal seals on allow the hydraulic cylinder assembly to be serviced. Note
the cylinder assembly. If internal cylinder repairs to the ram that the cylinder rod toggle end is a shrink fit and must be
or seals are required, Telsmith suggests that these type of removed using heat.
repairs be carried out by a qualified hydraulic repair facility.
! CAUTION
Toggle Wear Bar Replacement
Personnel will be working with and around
1. Toggle wear bars (and possibly the matching toggle seat heated components in the following removal
and end) are worn to replacement depth when only 12.7 mm s t e ps . P r o p e r h e a t r e s i s ta n t s a f e t y g e a r
(1/2”) of clearance remains between the face of the toggle end including gauntlets and an apron should be
and the leading edge of the toggle seat (Fig. 8-56). worn to prevent burns if inadvertent contact is
2. Remove the four hex head capscrews, flatwashers and made with heated components.
locknuts holding each wear bar in the toggle end (Fig. 8-56).
3. Slide the wear bar out of the toggle end and inspect for 1. Remove the six socket head capscrews (K, Fig. 8-56)
major wear or damage. Wear bars that are bent, cracked or from the face of the cylinder rod toggle end (J, Fig. 8-56).
missing pieces should be replaced. Wear bars that have worn
in length to allow less than the 12.7 mm (1/2”) of clearance
(Fig. 8-56) must be replaced with a new bar. NOTE:
4. Install a new wear bar in the toggle end (Fig 8-56) after Cylinder rod toggle end capscrews were assembled
inspecting the condition of the toggle seat. Toggle seats that with high strength threadlocker. It may be necessary to
are extremely worn or dished out should be replaced as a use heat when removing the six (6) socket head
matched set with a new toggle wear bar. capscrews in Step 1.
5. Align the holes in the new wear bar with the matching 2. If a portable hydraulic power unit is available attach it to
holes in the toggle end and install the four retaining the hydraulic inputs on the hydraulic manifold (H, Fig. 8-56).
capscrews from the bottom up. Install the flat washers and Fully extend the cylinder with hydraulic pressure and install
locknuts and torque to 218 Nm (162 Ft. lbs). hardwood blocks or bar stock between the stationary toggle
end (D, Fig 8-56) and the cylinder rod toggle end (J, Fig. 8-
56) on both sides of the cylinder assembly.
3. Heat the cylinder rod toggle end at the round cylinder seat
portion of the casting with a torch. When the toggle end
reaches 121oC (250oF) quickly use the hydraulic pressure
8
device to retract the piston rod from the toggle end before
heat transfers to the cylinder rod (Fig. 8-57).
04/09 8–29
J
G
I
D
B E
A
C
Inspection (Wear) Dimension
B
12.7 mm (1/2 in.) >
8 Toggle Wear Bar New Dimension

38.1 mm (11/2 in.)
J
Figure 8–56. Toggle Cylinder Components

A. Socket Head Capscrew (6) B. Toggle Wear Bar (2) C. Hex Head Capscrew (4) D. Stationary Toggle End
E. Socket Head Capscrew (4) F. Dowel Pin (2) G. Hydraulic Cylinder H. Hydraulic Relief Assembly
I. Hex Head Cap Screws (4) J. Cylinder Rod Toggle End K. Socket Head Capscrew (6) L. Swing Jaw Toggle Seat
4. If hydraulic pressure is not available, it will be necessary

to manually remove the toggle end. Remove the wear bar (B,
Fig. 8-56) from the stationary toggle end, and bolt two chains
of sufficient capacity to support the hydraulic adjuster
assembly to the stationary toggle end (hydraulic adjuster
assembly weighs approximately 816 Kg (1800 Lb.). Lift the
hydraulic adjuster assembly up with a suitable hoist or crane
and suspend approximately a foot off the ground by the lift
chains (Fig. 8-57).
8–30 04/09
! WARNING ! CAUTION
Always use suitable rigging and hoisting Installation personnel will be working with and
equipment to stabilize and lift heavy objects. around heated components in the following
Lifting heavy components with inadequate installation steps. Proper heat resistant safety
hoisting apparatus can damage machinery and gear including gauntlets and an apron should be
may result in personal injury or death. Make worn to prevent burns if inadvertent contact is
certain all service personnel keep feet and hands made with heated components.
away from the area beneath the cylinder rod
6. Heat the new or replacement cylinder rod toggle end to
toggle end while heating and removal is in
121oC (250oF). Square the toggle end on the cylinder rod
progress. The toggle end could separate from
making certain the mounting holes in the toggle end are
the cylinder rod and drop at any time.
aligned with the threaded mounting holes on the end of the
5. Heat the cylinder rod toggle end at the round cylinder seat cylinder rod. Press the toggle end down onto the cylinder rod
portion of the casting (A, Fig. 8-57) with a torch to until it is fully seated.
approximately 121oC (250oF). If the cylinder rod toggle end
does not drop down off the cylinder rod using heat only, use
a soft faced mallet to help drive the toggle end down off the
NOTE:
cylinder rod. Remove the lift chains and hoist after returning If the toggle end is difficult to press down fully onto the
the hydraulic cylinder to a suitable work stand or bench. cylinder rod, use the mounting capscrews in step 7 to
I
draw the toggle end down onto the rod.
7. Coat the four capscrews (K, Fig. 8-56) with high strength
thread locker (Loctite #271) and install with flatwashers to
fasten the toggle end to the cylinder. Torque fasteners to 1007
Nm (749 Ft. Lb.) in a cross pattern.
8. Allow the toggle end to cool completely on the cylinder
shaft before installing further components.
9. Install a new wear bar in the cylinder rod end following
the instructions in Toggle Wear Bar Replacement.
Stationary End Replacement

B
B 1. Remove the six socket head capscrews and washers (A,
Fig. 8-56) holding the stationary toggle end (D, Fig. 8-56) to
the end of the hydraulic cylinder. Support the toggle end to
prevent it from dropping (stationary toggle end weighs 52 Kg 8
(114 lbs)). Remove the four socket head cap screws and
washers securing the toggle end to the sides of the hydraulic
cylinder and remove the toggle end from the dowels on the
end of the hydraulic cylinder.
A
Figure 8–57. Cylinder Rod Toggle End Removal NOTE:

A. Apply heat at this point. Cylinder rod toggle end capscrews were assembled
B. Install blocking between toggle ends if using the hydraulic with high strength threadlocker. It may be necessary to
pressure removal method. use heat when removing the ten (10) socket head
capscrews in Step 1.
2. If the dowels (F, Fig. 8-56) on the end of the hydraulic
cylinder are damaged or worn, remove them with locking
pliers. New dowels are a shrink fit and must be chilled to
-40oC (-40oF) before driving into cylinder holes.
04/09 8–31
3. Check the stationary toggle end for signs of dishing or Hydraulic Adjustment Assembly
extreme wear in the wear bar seat. If the seat is worn out of Replacement
square , it is recommended that the wear bar and toggle seat
be replaced as a set. 1. If you will be installing the hydraulic adjustment
assembly from the top of the crusher, pull the swing jaw fully
4. Slide a new or replacement toggle end onto the mounting forward with chains and a frame mounted come-along puller
dowels on the face of the hydraulic cylinder. Hold the toggle and secure in place (Fig. 8-55). Attach a lift harness and hoist
in place with a lift sling and hoist and install the four of sufficient capacity around the hydraulic cylinder and lower
capscrews and washers into the sides of the lift cylinder. Coat the hydraulic adjustment assembly down until it is positioned
the threads with high strength thread locker (Loctite #271) between the swing jaw toggle seat and the fixed toggle seat
and torque the capscrews to 1007 Nm (749 Ft.lbs). on the frame.
5. Remove the lift apparatus and install the six socket head 2. If you are installing the hydraulic assembly from below
capscrews (A, 8-57) through the face of the stationary end. the crusher, move the assembly into place with a rolling
Coat the threads with high strength thread locker (Loctite machine cart or the discharge conveyor (Fig. 8-58). Install a
#271) and torque the capscrews to 1007 Nm (749 Ft.lbs). lift strap of sufficient capacity to lift the complete assembly,
6. Install a new wear bar in the stationary end following the around the hydraulic cylinder (Fig. 8-58).
instructions in Toggle Wear Bar Replacement.
Figure 8–58. Positioning Assembly Under Crusher

3. Pull the swing jaw fully forward with chains and a frame
mounted come-along puller (Fig. 8-55) to provide more
installation space. Lift the Hydraulic Adjuster Assembly up
with a hoist or crane of sufficient capacity and align the wear
bars between the fixed toggle seat and the swing jaw toggle
seat (Fig. 8-59).
8–32 04/09
A
A
B C
Figure 8–59. Aligning Wear Bar With Jaw Toggle Seat

A. Spring Pocket (4) B. Swing Jaw Toggle Seat
C. Wear Bar
4. Slowly move the swing jaw back into the chamber using
the come-along. Tilt the hydraulic adjuster assembly as Figure 8–61. Spring Installation
necessary to line up the wear bars with the toggle seats on the
frame and swing jaw. 8. Install the upper spring washer and lower jam nut on each
spring (Fig. 8-62). Remove the chains and come-along puller
5. When both wear bars (C, Fig 8-59) are located in the from the swing jaw.
toggle seats, align all four spring pockets (A, Fig. 8-59) with
the tension pin brackets on the toggle seats (B, Fig. 8-59).
6. Slide the toggle end (C, Fig. 8-60) of toggle tension pin up
into the slot in the bottom of the spring pockets. Swing the
tension pins up into the spring pockets and secure with the
lower spring washer (B, Fig, 8-60).
Figure 8–62. Upper Spring Washer and Lower Jam

Nut Installation
9. Compress each spring with the lower jam nut until the
B
compressed dimension (face to face) is 120 mm (43/4”) as
shown in Figure 8-63. Install the upper jam nuts when all four
spring dimensions are identical. Remove the lift harness from
the adjuster hydraulic cylinder.
C
Figure 8–60. Securing Tension Pins

A. Tension Pin (4) B. Lower Spring Washer (4)
C. Toggle End
7. Install the springs in all four spring pockets (Fig. 8-61).
04/09 8–33
120 mm (4.75 in)
Figure 8–63. Spring Compression Dimension

10. Install the three hydraulic lines to the hydraulic manifold
on the adjuster assembly hydraulic cylinder (Fig. 8-54).
Install the position sensor assembly and linkage (Fig. 8-49).
11. Apply power to the crusher and check the hydraulic
adjuster assembly and swing jaw for correct operation. Cycle
the cylinder five (5) complete times to remove any air from
the circuit before starting crusher.
8–34 04/09
Telsmith 2550 Jaw Crusher Appendix A - Torque Tables
SAE GRADES
Fastener Information SAE J429 Grade 2 SAE J429 Grade 5
Size Thread Threads Major Dia. Tensile Torque Torque Torque Torque
Type Per Inch (in) Stress Dry Lubricated Dry Lubricated
(n) Area in-lb/ft-lb in-lb/ft-lb in-lb/ft-lb in-lb/ft-lb
(in2) (Nm) (Nm) (Nm) (Nm)
1/4 UNC 20 0.2500 0.0318 66 (7.4) 49 (5.5) 100 (11.2) 76 (8.5)

UNF 28 0.2500 0.0364 75 (8.4) 56 (6.3) 120 (13.5) 87 (9.8)
5/16 UNC 18 0.3125 0.0524 11 (14.9) 8 (10.8) 17 (23.0) 13 (17.6)

UNF 24 0.3125 0.0581 13 (17.6) 9 (12.2) 19 (25.7) 14 (18.9)
3/8 UNC 16 0.3750 0.0775 20 (27.1) 15 (20) 31 (42.0) 23 (31.1)

UNF 24 0.3750 0.0878 23 (31.1) 17 (23) 35 (47.4) 26 (35.2)
7/16 UNC 14 0.4375 0.1063 32 (42.3) 24 (32.5) 49 (66.4) 37 (50.1)

UNF 20 0.4375 0.1187 36 (48.8) 27 (36.6) 55 (74.5) 41 (55.5)
1/2 UNC 13 0.5000 0.1419 49 (66.4) 37 (50.1) 75 (101) 57 (77.2)

UNF 20 0.5000 0.1600 55 (74.5) 41 (55.5) 85 (115) 64 (86.7)
9/16 UNC 12 0.5625 0.1819 70 (94.9) 53 (71.8) 110 (149) 82 (111)

UNF 18 0.5625 0.2030 78 (106) 59 (79.9) 120 (162) 91 (123)
5/8 UNC 11 0.6250 0.2260 97 (131) 73 (98.9) 150 (203) 110 (149)
UNF 18 0.6250 0.2560 110 (149) 83 (112) 170 (230) 130 (176)
3/4 UNC 10 0.7500 0.3345 170 (230) 130 (176) 270 (366) 200 (271
UNF 16 0.7500 0.3730 190 (258) 140 (188) 300 (407) 220 (298)
7/8 UNC 9 0.8750 0.4617 170 (230) 120 (163) 430 (583) 320 (434)
UNF 14 0.8750 0.5095 180 (244) 140 (190) 470 (630) 360 (488)
1 UNC 8 1.0000 0.6057 250 (339) 190 (258) 640 (868) 480 (651)
UNF 12 1.0000 0.6630 270 (366) 210 (285) 710 (963) 530 (719)
1 1/8 UNC 7 1.1250 0.7633 350 (474) 270 (366) 800 (1085) 600 (813)
UNF 12 1.1250 0.8557 400 (542) 300 (407) 890 (1207) 670 (908)
1 1/4 UNC
UNF
7
12
1.2500
1.2500
0.9691
1.0729
500 (677)
550 (746)
380 (515)
420 (569)
1,100 (1491)
1,200 (1627)
840 (1139)
930 (1260) 7F
1 3/8 UNC 6 1.3750 1.1549 660 (895) 490 (664) 1,500 (2033) 1,100 (1491)
UNF 12 1.3750 1.3147 740 (1003) 560 (760) 1,700 (2304) 1,300 (1762)
1 1/2 UNC 6 1.5000 1.4053 870 (1179) 650 (881) 2,000 (2711) 1,500 (2033)
UNF 12 1.5000 1.5810 980 (1328) 730 (989) 2,200 (2982) 1,600 (2169)
ASTM A307 Grade A ASTM A449
1 3/4 UNC 5 1.7500 1.8995 1,400 (1898) 1,000 (1355) 2,300 (3118) 1,700 (2304)
1 3/4 UN 12 1.7500 2.1873 1,600 (2169) 1,200 (1627) 2,600 (3525) 2,000 (2711)
2 UNC 4 1/2 2.0000 2.4982 2,100 (2847) 1,500 (2033) 3,400 (4609) 2,600 (3525)
2 UN 12 2.0000 2.8917 2,400 (3254) 1,800 (2440) 4,000 (5423) 3,000 (4067)
2 1/4 UNC 4 1/2 2.2500 3.2477 3,000 (4067) 2,300 (3118) 5,000 (6779) 3,800 (5152)
2 1/2 UNC 4 2.5000 3.9988 4,100 (5559) 3,100 (4203) 6,900 (9355) 5,200 (7050)
2 3/4 UNC 4 2.7500 4.9340 5,600 (7592) 4,200 (5694) 9,400 (12745 7,000 (9491)
3 UNC 4 3.0000 5.9674 7,400 (10033) 5,600 (7592) 12,000 (16270) 9,200 (12473)
Torque Coefficients Dry: 0.20

Lubricated: 0.15
04/09 A–1
Torque Tables
Alloy Socket Head Cap

Fastener Information SAE J429 Grade 8
Screws ASTM A574
Size Thread Threads Major Dia. Tensile Torque Torque Torque Torque
Type Per Inch (in) Stress Dry Lubricated Dry Lubricated
(n) Area ft-lb ft-lb ft-lb ft-lb
(in2) (Nm) (Nm) (Nm) (Nm)
1/4 UNC 20 0.2500 0.0318 12 (16.2) 9 (12.2) 14 (18.9) 10 (13.5)

UNF 28 0.2500 0.0364 14 (18.9) 10 (13.5) 16 (21.6) 12 (16.2)
5/16 UNC 18 0.3125 0.0524 25 (33.8) 18 (24.4) 29 (39.3) 22 (29.8)

UNF 24 0.3125 0.0581 27 (36.6) 20 (27.1) 32 (43.3) 24 (32.5)
3/8 UNC 16 0.3750 0.0775 44 (59.6) 33 (44.7) 51 (69.1) 38 (51.5)

UNF 24 0.3750 0.0878 49 (66.4) 37 (50.1) 58 (78.6) 43 (58.3)
7/16 UNC 14 0.4375 0.1063 70 (94.9) 52 (71.8) 82 (111) 61 (82.7)

UNF 20 0.4375 0.1187 78 (106) 59 (79.9) 91 (123) 68 (92.1)
1/2 UNC 13 0.5000 0.1419 110 (149) 80 (109) 120 (162) 93 (126)
UNF 20 0.5000 0.1600 120 (163) 90 (122) 140 (188) 110 (149)
9/16 UNC 12 0.5625 0.1819 150 (203) 120 (162) --- ---
UNF 18 0.5625 0.2030 170 (230) 130 (176) --- ---
5/8 UNC 11 0.6250 0.2260 210 (285) 160 (217) 240 (325) 180 (244)
UNF 18 0.6250 0.2560 240 (325) 180 (244) 270 (366) 200 (271)
3/4 UNC 10 0.7500 0.3345 380 (515) 280 (379) 420 (569) 320 (434)
UNF 16 0.7500 0.3730 420 (569) 320 (433) 470 (637) 350 (474)
7/8 UNC 9 0.8750 0.4617 610 (827) 460 (624) 680 (922) 510 (691)
UNF 14 0.8750 0.5095 670 (908) 500 (677) 750 (1017) 560 (759)
1 UNC 8 1.0000 0.6057 910 (1234) 680 (922) 1,000 (1350) 770 (1044)
UNF 12 1.0000 0.6630 1,000 (1356) 750 (1017) 1,100 (1491) 840 (1139)
1 1/8 UNC 7 1.1250 0.7633 1,300 (1762) 970 (1315) 1,400 (1898) 1,100 (1491)
7F UNF 12 1.1250 0.8557 1,400 (1898) 1,100 (1491) 1,600 (2169) 1,200 (1627)
1 1/4 UNC 7 1.2500 0.9691 1,800 (2440) 1,400 (1898) 2,000 (2711) 1,500 (2003)
UNF 12 1.2500 1.0729 2,000 (2711) 1,500 (2003) 2,300 (3118) 1,700 (2305)
1 3/8 UNC 6 1.3750 1.1549 2,400 (3254) 1,800 (2440) 2,700 (3660) 2,000 (2711)
UNF 12 1.3750 1.3147 2,700 (3660) 2,000 (2711) 3,000 (4068) 2,300 (3118)
1 1/2 UNC 6 1.5000 1.4053 3,200 (4338) 2,400 (3254) 3,600 (4881) 2,700 (3660)
UNF 12 1.5000 1.5810 3,600 (4881) 2,700 (3660) 4,000 (5423) 3,000 (4068)
ASTM A354 Grade BD
1 3/4 UNC 5 1.7500 1.8995 5,000 (6779) 3,700 (5017) 5,600 (7592) 4,200 (5694)
1 3/4 UN 12 1.7500 2.1873 5,700 (7728) 4,300 (5830) 6,400 (8677) 4,800 (6508)
2 UNC 4 1/2 2.0000 2.4982 7,500 (10169) 5,600 (7593) 8,400 (11389) 6,300 (8541)
2 UN 12 2.0000 2.8917 8,700 (11796) 6,500 (8813) 10,000 (13588) 7,300 (9897)
2 1/4 UNC 4 1/2 2.2500 3.2477 11,000 (14914) 8,200 (11118) 12,000 (16270) 9,300 (12609)
2 1/2 UNC 4 2.5000 3.9988 15,000 (20338) 11,000 (14914) 17,000 (23049) 13,000 (17626)
2 3/4 UNC 4 2.7500 4.9340 18,000 (24405) 13,000 (17626) 23,000 (31184) 17,000 (23049)
3 UNC 4 3.0000 5.9674 24,000 (32540) 18,000 (24405) 30,000 (40676) 23,000 (31184)
Torque Coefficients Dry: 0.20

Lubricated: 0.15
A–2 04/09
Operation and Maintenance Appendix B - Conversion Tables
Appendix B - Conversion Tables
Telsmith Model 2550 Jaw Crusher – Appendix B
LINEAR MEASURE SQUARE MEASURE
To Convert Info Multiply by To Convert Info Multiply by

Inches Centimeters 2.54 Sq. Inches Sq. Centimeters 6.452
Feet Meters 0.3048 Sq. Miles Sq. Kilometers 2.59
Centimeters Inches 0.3937 Sq. Centimeters Sq. Inches 0.15499
Millimeters Inches 0.0394 Sq. Meters Sq. Inches 1549.9
Meters lnches 39.37 Sq. Meters Sq. Feet 10.763
Meters Feet 3.2808
CUBIC MEASURE WEIGHT
To Convert Info Multiply by To Convert Info Multiply by

Kilograms Pounds 2.2046
Cu. Inches Cu. Centimeters 16.387
Pounds Kilograms 0.4536
Cu. Feet Cu. Meters 0.0283
Pounds/Sq. Kilograms/Sq. 0.0703
Cu. Centimeters Cu. Inches 0.06102
Inch Centimeter
Cu. Meters Cu. inches 610233779.0
Pounds/Sq. Kilograms/Sq. 4.8824
Cu. Meters Cu. Feet 35.314
Foot Meter
DEGREES FAHRENHEIT TO DEGREES CENTIGRADE
F C F C F C F C F C
-30 -34.44 +20 -6.67 +55 +12.78 +90 +32.22 +225 +107.22
-28 -33.33 21 -6.11 56 13.33 91 32.78 230 110.00
-26 -32.22 22 -5.56 57 13.89 92 33.33 235 112.78
-24 -31.11 23 -5.00 58 14.44 93 33.89 240 115.56
-22 -30.00 24 -4.44 59 15.00 94 34.44 245 118.33
-20 -28.89 25 -3.89 60 15.56 95 35.00 250 121.11
-18 -27.78 26 -3.33 61 16.11 96 35.56 255 123.89
-16 -26.67 27 -2.78 62 16.67 97 36.11 260 126.67
-14 -25.56 28 -2.22 63 17.22 98 36.67 265 129.44
-12 -24.44 29 -1.67 64 17.78 99 37.22 270 132.22
-10 -23.33 30 -1.11 65 18.33 100 37.78 275 135.00
-8 -22.22 31 -0.56 66 18.89 105 40.55 280 137.78
-6 -21.11 32 0.00 67 19.44 110 43.33 285 140.55
-4 -20.00 33 +0.56 68 20.00 115 46.11 290 143.33
-2
0
-18.89
-17.78
34
35
1.11
1.67
69
70
20.56
21.11
120
125
48.89
51.67
295
300
146.11
148.89 7F
+1 -17.22 36 2.22 71 21.67 130 54.44 305 151.67
2 -16.67 37 2.78 72 22.22 135 57.22 310 154.44
3 -16.11 38 3.33 73 22.78 140 60.00 315 157.22
4 -15.56 39 3.89 74 23.33 145 62.78 320 160.00
5 -15.00 40 4.44 75 23.89 150 65.56 325 162.78
6 -14.44 41 5.00 76 24.44 155 68.33 330 165.56
7 -13.89 42 5.56 77 25.00 160 71.11 335 168.33
8 -13.33 43 6.11 78 25.56 165 73.89 340 171.11
9 -12.78 44 6.67 79 26.11 170 76.67 345 173.89
10 -12.22 45 7.22 80 26.67 175 79.44 350 176.67
11 -11.67 46 7.78 81 27.22 180 82.22 355 179.44
12 -11.11 47 8.33 82 27.78 185 85.00 360 182.22
13 -10.56 48 8.89 83 28.33 190 87.78 365 185.00
14 -10.00 49 9.44 84 28.89 195 90.55 370 187.78
15 -9.44 50 10.00 85 29.44 200 93.33 375 190.55
16 -8.89 51 10.56 86 30.00 205 96.11 380 193.33
17 -8.33 52 11.11 87 30.56 210 98.89 385 196.11
18 -7.78 53 11.67 88 31.11 215 101.67 390 198.89
19 -7.22 54 12.22 89 31.67 220 104.44 395 201.67
04/09 B–1
Appendix B - Conversion Tables Operation and Maintenance
NOTES
7F
B–2 04/09
Telsmith 2550 Jaw CrusherAppendix C- Torque Tables
ISO GRADES
Fastener Information ISO S98 HHCS Grade 8.8 ISO S98 HHCS Grade 10.9
Size Pitch Major Dia. Tensile Torque Torque Torque Torque

(mm) (imm) Stress Area Dry Lubricated Dry Lubricated
(mm2) Nm Nm Nm Nm
(ft-lb) (ft-lb) (ft-lb) (ft-lb)
M6 1.00 6.00 20.12 11 (8) 8 (6) 15 (11) 11 (8)
M10 1.50 10.00 57.99 50 (36) 38 (28) 72 (54) 54 (40)
M12 1.75 12.00 84.27 68 (65) 66 (49) 126 (94) 94 (72)
M16 2.00 16.00 156.67 218 (162) 164 (122) 312 (232) 234 (174)
M20 2.50 20.00 244.79 441 (326) 330 (246) 610 (454) 457 (340)
M24 3.00 24.00 352.50 761 (567) 571 (425) 1,053 (784) 790 (588)
M30 3.50 30.00 560.59 1,514 (1,126) 1,135 (845) 2,094 (1,588) 1,570 (1,166)
M36 4.00 36.00 816.72 2,646 (1,969) 1,985 (1,477) 3,661 (2,724) 2,745 (2,043)
M42 4.50 42.00 1120.91 4, 237 (3,153) 3,178 (2,364) 5,881 (4,361) 4,396 (3,271)
M48 5.00 48.00 1473.15 6,364 (4,736) 4,773 (3,551) 8,804 (6,550) 6,603 (4,913)
7F
04/09 C–1
Torque Tables
7F
C–2 04/09

Jaw Crusher 2550-C50Fin09 PDF

Загружено:

Сведения о документе

Оригинальное название

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

Jaw Crusher 2550-C50Fin09 PDF

Загружено:

Авторское право:

Доступные форматы

2550 (C50) Jaw Crusher

Operation and Maintenance

ISSUE DATE: 04/09 TP527

2. Before removing spilled materials.

3. Before clearing jams or working inside the machinery.

4. If any unusual noises or sudden changes in operation are noticed.

HOW TO CONTACT TELSMITH INC.

REQUESTING SERVICE ASSISTANCE

INSTALLATION & ASSEMBLY DRAWINGS FAX:

Installation and assembly drawings (blueprints) are provided

FEATURES, DIMENSIONS and SPECIFICATIONS . . . . . . . . . . . . . . . 2

CRUSHER INSTALLATION and ASSEMBLY . . . . . . . . . . . . . . . . . . 3

CRUSHER OPERATION and ADJUSTMENTS . . . . . . . . . . . . . . . . . 4

CRUSHER LUBRICATION and MAINTENANCE SCHEDULE . . . . . . . . . 5

WEAR LINER and CHEEK PLATE REPLACEMENT . . . . . . . . . . . . . . 7

REPAIR and OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

GENERAL SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

PRECAUTIONARY STATEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

QUARRY SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

EQUIPMENT INSTALLATION SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

1 Operator Vantage Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

MAINTENANCE AND REPAIR SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

HOISTING AND HANDLING SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

TRANSPORTATION SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

MAINTENANCE INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

SAFETY LABELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18

GENERAL SAFETY Hazard Statements 1

1 There are many maintenance procedures contained LOCKOUT/TAGOUT

Use a high impact type grout which contains a non-

Figure 1–1. Sample Precautionary Statements

1 How Is Lockout/Tagout Performed? In situations in which lockout or tagout devices must be

When Can Lockout/Tagout Devices Be

Lockout/Tagout Devices • Your company’s lockout/tagout program may be 1

Observe Personal Safety Precautions

Be Aware of Your Surroundings

Electrical Installation Safety

Welding, Cutting or Grinding on Machinery

Clearing Jammed Material Disposal of Excess Fuels, Lubricants and 1

1 HOISTING AND HANDLING SAFETY Forming Wire Rope Eyes

• Be sure wire ropes are inspected regularly following the

! CAUTION MAINTENANCE INSPECTIONS

Fiber or Synthetic Slings

1 SAFETY LABELS It should be mentioned here that the ANSI Z535.4-2002

Figure 1–3. Safety Label

A. “SAFETY ALERT SYMBOL” 1

B. “SIGNAL WORD in PANEL”

MAJOR FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

MOUNTING ARRANGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

EXTERNAL DIMENSIONS DRAWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

DESCRIPTION The Model 2550’s hydraulic relief feature automatically

Figure 2–1. 2550 Cutaway

MAJOR FEATURES OPTIONS

EXTERNAL DIMENSIONS DRAWING

Figure 2–2. 2550 Dimension in Millimeters (Inches)

Crusher, Assembled and Complete 15,875 35,000 2

Swing Jaw Assembly

Flywheel Sheave 757 1668

Flywheel Pulley 833 1836

Swing Jaw Die 1332 2930

Stationary Jaw Die 1332 2930

Swing Jaw Guard Plate 126 277

Cheek Plate, Upper 80 177

Cheek Plate, Lower 53 116