E - Manual - 18x72 TRC - 20122010 PDF

INSTALLATION, OPERATION
& MAINTENANCE MANUAL

18”x 72” STANDARD DUTY TRIPLE ROLL CRUSHER
PROJECT ID #20122010

TRIPLE ROLL CRUSHER
S/N: 20122010
TABLE OF CONTENTS
SECTION PAGE
SAFETY PRECAUTIONS (VERSION A, REV. 03)

OVERVIEW.................................................................................................................................................................. 1
INTRODUCTION
INTRODUCTION ......................................................................................................................................................... 1
SHIPPING AND HANDLING

SHIPPING ..................................................................................................................................................................... 2
RECEIVING ................................................................................................................................................................ 2
UNLOADING AND HANDLING ............................................................................................................................... 2
STORAGE .................................................................................................................................................................... 2
FOUNDATIONS (VERSION A, REV. 03)

OVERVIEW.................................................................................................................................................................. 1
FOOTING ..................................................................................................................................................................... 1
STEEL SUPPORT STRUCTURES .............................................................................................................................. 1
CONCRETE SUPPORT STRUCTURES ..................................................................................................................... 2
STRUCTURAL DESIGN PARAMETERS .................................................................................................................. 2
DESIGN FACTOR CHART ......................................................................................................................................... 3
INSTALLATION
OVERVIEW.................................................................................................................................................................. 3
PLACEMENT ............................................................................................................................................................... 3
BASE FRAME .............................................................................................................................................................. 3
CRUSHER DRIVES ..................................................................................................................................................... 4
A. Rubber Tire Drive Design ............................................................................................................................... 4
B. V-Belt ‘Interstage’ Drive Design ................................................................................................................... 4
MOTOR ........................................................................................................................................................................ 5
ELECTRICAL CONNECTIONS ................................................................................................................................. 5
V-BELT DRIVE ........................................................................................................................................................... 5
DRIVE GUARD ........................................................................................................................................................... 5
CRUSHER ROLL TEMPLATES ................................................................................................................................. 5
MATERIAL HANDLING EQUIPMENT .................................................................................................................... 5
OPERATIONS
OVERVIEW.................................................................................................................................................................. 7
SAFETY PRACTICES ................................................................................................................................................. 7
START-UP AND SHUT-DOWN ................................................................................................................................. 7
INITIAL START-UP PROCEDURE
A. Preliminary Lubrication .................................................................................................................................. 7
B. Test Run .......................................................................................................................................................... 7
C. Break-in Period ............................................................................................................................................... 8
TRIPLE ROLL CRUSHER
S/N: 20122010
OPERATIONS (CONTINUED)
FEATURES AND ADJUSTMENTS
A. Hopper .............................................................................................................................................................. 8
B. Drives ............................................................................................................................................................... 8
C. Crusher Rolls .................................................................................................................................................... 8
1) Roll Shell Design ........................................................................................................................................ 8
2) Segmented Roll Design ................................................................................................................................ 8
D. Renewable Crushing Plate Tips ....................................................................................................................... 9
E. Torsion Bar ....................................................................................................................................................... 9
F. Deflecting Plates ............................................................................................................................................... 9
G. Bearings ............................................................................................................................................................ 9
H. Lubrication ....................................................................................................................................................... 9
I. Product Adjustment System .............................................................................................................................. 9
1) Primary Stage Adjustment ........................................................................................................................ 10
2) Secondary Stage Adjustment ..................................................................................................................... 10
J. Toggle Assemblies.......................................................................................................................................... 11
OPTIONAL EQUIPMENT
A. Automatic Lubrication System...................................................................................................................... 11
B. Bearing Temperature Probes ......................................................................................................................... 11
C. Zero Speed Switch ........................................................................................................................................ 12
MAINTENANCE
OVERVIEW................................................................................................................................................................ 13
LUBRICATION .......................................................................................................................................................... 13
BOLTS AND KEYS ................................................................................................................................................... 13
HOPPER LINERS....................................................................................................................................................... 13
CRUSHER ROLLS
A. Rebuilding ..................................................................................................................................................... 14
B. Replacement .................................................................................................................................................. 14
1) Segmented Roll Design.......................................................................................................................... 14
2) Roll Shell Design ................................................................................................................................... 15
C. Bolt Torque Requirements ............................................................................................................................ 16
1) Segmented Roll Design – Segment Bolts .............................................................................................. 16
2) Roll Shell Design – Flanged Shaft Bolts ............................................................................................... 16
TOGGLE ASSEMBLY ............................................................................................................................................... 17
A. Removal ........................................................................................................................................................ 17
ROLL ASSEMBLY WITH SEGMENTED ROLL DRAWING .............................................................................. 17942
ROLL ASSEMBLY WITH ROLL SHELL DRAWING .......................................................................................... 17297
ROLL ASSEMBLY WITH ROLL SHELL AND FLANGE SHAFT DESIGN DRAWING .................................... 18100
MOTOR (VERSION A, REV. 03)

OVERVIEW.................................................................................................................................................................. 1
APPLICATION ............................................................................................................................................................. 1
MAINTENANCE.......................................................................................................................................................... 2
STORAGE .................................................................................................................................................................... 2
TRIPLE ROLL CRUSHER
S/N: 20122010
V-BELT DRIVES (VERSION A, REV. 02)

OVERVIEW.................................................................................................................................................................. 1
INSTALLATION .......................................................................................................................................................... 2
ALIGNMENT ............................................................................................................................................................... 2
A. Shaft Alignment .............................................................................................................................................. 2
B. Sheave Alignment ........................................................................................................................................... 2
TENSIONING ............................................................................................................................................................... 3
BELT TIGHTENER (ONLY IF FURNISHED) ........................................................................................................... 4
MAINTENANCE.......................................................................................................................................................... 5
MANUFACTURER'S LITERATURE
A. T.B. WOOD'S VBD-IM – P 1688 (July 07)
CRUSHER ROLL SHAFT BEARINGS (VERSION B, REV. 00)

OVERVIEW.................................................................................................................................................................. 1
SAFETY PRACTICES ................................................................................................................................................ 1
DESIGN ....................................................................................................................................................................... 1
REPLACEMENT
A. Disassembly Procedure ................................................................................................................................... 2
B. Assembly Procedure ....................................................................................................................................... 3
RADIAL INTERNAL CLEARANCE TABLE AND EXAMPLE ............................................................................... 5
A. SKF - 640-810 Assembly and Lubrication Instructions (10-2005)
LOCKING ASSEMBLY (VERSION A, REV. 01)

OVERVIEW.................................................................................................................................................................. 1
INSTALLATION .......................................................................................................................................................... 2
A. B-LOC CORP. – Installation & Removal B400
WELDING (VERSION A, REV. 01)

OVERVIEW.................................................................................................................................................................. 1
MAINTENANCE SCHEDULE .................................................................................................................................... 1
WELDING PREPARATION ........................................................................................................................................ 2
BASE MATERIALS ..................................................................................................................................................... 2
WELDING MATERIAL ............................................................................................................................................... 2
CHILLED IRON ........................................................................................................................................................... 3
MCALLOY STEEL ...................................................................................................................................................... 4
MCL 400 ...................................................................................................................................................................... 5
11% - 14% MANGANESE STEEL .............................................................................................................................. 6
8637FB STEEL ............................................................................................................................................................. 7
HARDOX 400 ............................................................................................................................................................... 8
TRIPLE ROLL CRUSHER
S/N: 20122010
LUBRICATION (VERSION A, REV. 07)

OVERVIEW.................................................................................................................................................................. 1
NOTICE ........................................................................................................................................................................ 2
LUBRICANT QUANTITIES TABLE.......................................................................................................................... 3
LUBRICANT CROSS REFERENCE CHART-A ........................................................................................................ 4
LUBRICANT CROSS REFERENCE CHART-B ....................................................................................................... 5
LUBRICATION CHART – TRIPLE ROLL CRUSHER (VERSION A, REV. 00 ...................................................... 1
AUTOMATIC LUBRICATION SYSTEM

A. LINCOLN 422365 SECTION M50-PAGE 14A, UV Divider Valves
B. LINCOLN 2.1A-30002-C03, Owner Manual Quiklub Pump Model 203
ELECTRICAL
PROGRAMMING INSTRUCTIONS ................................................................... Turck Speed Switch MK21_070326
A. TURCK – MK21-122EXO-Ri_C9-C10
B. TURCK – NII0-M18-Y1X-H1141, Catalog Page
SPARE PARTS LISTS

SPARE PARTS LIST .................................................................................................................................................... 1
FIELD SERVICE CHARGES (VERSION A, REV. 1/1/12 MPS&APS DIVISIONS)

OVERVIEW.................................................................................................................................................................. 1
RATES .......................................................................................................................................................................... 1
EXPENSES ................................................................................................................................................................... 1
TAGS (VERSION B, REV. 07)

OVERVIEW.................................................................................................................................................................. 1
SAFETY/INFORMATIONAL TAG DESCRIPTIONS ............................................................................................... 2
MATERIAL SAFETY DATA SHEETS (VERSION A, REV. 03)

OVERVIEW.................................................................................................................................................................. 1
DRAWINGS (VERSION A, REV. 02)

OVERVIEW ................................................................................................................................................................. 1
PARTS LIST AND ASSEMBLY DRAWING, SN 20122010 .................................... P34E22 CF (SHEET 1, 2, & 3)
BASE FRAME ASSEMBLY DRAWING ..........................................................................................................99E19
PRIMARY ROLL ASSEMBLY DRAWING .................................................................................................... 172B33
STATIONARY ROLL ASSEMBLY DRAWING ............................................................................................ 172B34
MOVABLE ROLL ASSEMBLY DRAWING .................................................................................................. 172B35
CRUSHING PLATE ASSEMBLY ................................................................................................................... 173B03
TOGGLE ASSEMBLY ..................................................................................................................................... 152B31
LUBRICATION ASSEMBLY DRAWING ..................................................................................................... 200D26
HYDRAULIC ASSEMBLY DRAWING ......................................................................................................... 188A20
SAFETY PRECAUTIONS
VERSION A, REV. 03
SAFETY PRECAUTIONS
OVERVIEW
READ THIS MANUAL IN ITS ENTIRETY. DO NOT install, operate, or service this equipment (or any
portion thereof) without fully understanding the information contained herein. Further, DO NOT operate this
equipment in any manner other than that for which it has been designed or approved. A copy of this manual
must be provided to the operator of this equipment and must be kept with the equipment at all times.
The safety instructions presented throughout this manual do not supercede any other directives or practices
associated with this equipment or its operation. Rather, they are to be used in addition to any other applicable
guidelines set forth by governing bodies (ANSI, ISO, OSHA, MSHA, etc.), plant administrators, signs, tags, or
placards, etc. (Refer to the TAGS section of this manual for information regarding safety and instructional tags
provided with the equipment.) In the event of conflicting information, always use the guidelines providing the
highest degree of protection/safety.
The safety instructions used throughout this manual and on the equipment contain a “signal word” (CAUTION,
WARNING or DANGER) that indicates the seriousness of the hazard as described below.
DANGER indicates an imminently hazardous situation which, if not avoided, will

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

could result in death or serious injury.
CAUTION indicates a potentially hazardous situation which, if not avoided, may

result in minor or moderate injury.
CAUTION (used without the safety alert symbol) indicates a potentially

hazardous situation which, if not avoided, may result in property damage.
SAFETY PRECAUTIONS 1
SAFETY PRECAUTIONS
VERSION A, REV. 03
The safety instructions listed below are general guidelines. Additional safety instructions are listed throughout
this manual as required. All safety instructions must be followed at all times to insure personal safety and to
prevent equipment damage.
Verify that all personnel are clear of any/all moving or rotating parts (or parts
that are subject to movement or rotation) before installing, operating or servicing
this equipment or any portion thereof.
Verify that all guards and safety devices are in place, secured and functional
before operating this equipment or any portion thereof. (DO NOT circumvent or
disable any safety devices.)
Lockout/Tagout all controls and secure all applicable components to prevent

unexpected movement before performing any maintenance, repairs, or
adjustments on this equipment or any portion thereof.
Lockout/Tagout power at the source before accessing any electrical panels or

devices on this equipment, or before performing any maintenance or repairs to the
power line(s) feeding this equipment.
Wear appropriate personal protective equipment at all times.
Obey all safety tags and signs and replace any that are illegible or missing.
If any questions arise concerning the safe operation of this equipment, or if clarification of any information is
required, cease operation and contact McLANAHAN CORPORATION immediately.
SAFETY PRECAUTIONS 2
TRIPLE ROLL CRUSHER
VERSION A, REV. 01
20122010
INTRODUCTION
This manual covers information regarding shipping and handling, foundation design, installation,
operations, and maintenance of your McLanahan product. This manual also includes supplemental
information on components, which have been furnished by the component manufacturer. The
component information has been furnished only as a courtesy and is the representation of the component
manufacturer, not McLANAHAN CORPORATION.
NOTICE: Before installing or operating your McLanahan equipment, read this manual carefully
and completely. McLANAHAN CORPORATION cannot be held responsible for any problems
encountered unless the information presented in this manual is thoroughly read and understood
completely and that all instructions are carefully followed.
The product brochure located at the end of this manual section provides an overview of Triple Roll
crushers. Actual design features and specifications are subject to change, therefore certain information
contained therein may not be current. Use this product brochure only to familiarize yourself with the
general overall design and features of the machine.
All parts for your McLanahan machine are carefully inspected and approved for quality assurance and
fit. Also, typically each unit is completely assembled and factory operated under power prior to
shipment. Certain parts may be match marked or stamped where necessary to facilitate onsite assembly.
The size and/or serial number of the machine are stamped on an identification plate. Additionally, a steel
plate with the serial number stenciled on it is welded to the frame. When ordering parts or requesting
information concerning this equipment, please identify the unit by SIZE and SERIAL NUMBER.
The instructions and recommendations contained herein are based on previous experience. The
information is not all-inclusive and cannot cover every application or circumstance that may develop.
Additionally, if information presented in this manual varies from the manufacturer’s information for a
given component, always be sure to use that information, which yields the better protection.
(EXAMPLE: If a motor is furnished by a source other than McLanahan Corporation, discard the motor
information found in this manual and replace it with motor information furnished by the manufacturer.)
If questions arise concerning your machine, or if additional information is required, contact

McLANAHAN CORPORATION, Hollidaysburg, Pennsylvania.
NOTE: All drawings referenced in this manual are located within the DRAWINGS section unless
otherwise specified, and are the most current at the time when this manual was produced. The
McLANAHAN CORPORATION does reserve the right to change, or replace any drawing without
notice.
1
TRIPLE ROLL CRUSHER
VERSION A, REV. 01
20122010
SHIPPING AND HANDLING

SHIPPING
Triple Roll crushers generally ship completely assembled except for the flywheel pulleys, which are
shipped as separate units. Smaller detached parts for the crusher are also shipped in a separate box or
crate. The “PARTS LIST AND ASSEMBLY” drawing(s) (see DRAWINGS section) shows the
location of the various components and provides additional information as required for the proper
assembly of this crusher unit.
RECEIVING
Upon receipt of this order/shipment, unpack and inspect all equipment plus parts, which may have been
packed separately, for any missing or damaged items. Check packing slips carefully against the actual
shipment to verify that all parts were received and note any discrepancies on the bill of lading or packing
slip.
Notify McLANAHAN CORPORATION immediately upon discovery of any damaged or missing

part, or other discrepancy with this order/shipment. This is necessary in order to validate a claim.
UNLOADING AND HANDLING

McLanahan machines are typically large and very heavy. Although they appear to be extremely rigid,
improper handling during the unloading and installation process can damage them. Use adequately sized
lifting devices to lift the equipment as evenly as possible to ensure that parts are not dropped or
damaged during the unloading and installation procedures.
CAUTION: DO NOT wrap chains or cables around motors, bearings, reducers, or other portions of
the crusher machine, which could be damaged or scarred by such action.
STORAGE
If your McLanahan Triple Roll crusher is to be placed in storage or allowed to set idle for an extended
period of time, observe the following guidelines:
Apply a coating of anti-rust protectant to the following components:
a. Roll Shafts
b. Flywheel Bore(s)
NOTE: Remove this protective coating and thoroughly clean the components prior to placing the
machine in operation.
Rotate the roll shafts approximately two revolutions per week to maintain a film of lubricant on the
bearing surfaces.
2
FOUNDATIONS
VERSION A, REV. 03
FOUNDATIONS
OVERVIEW
This equipment, and any associated motors or drives must be mounted on a solid, level, and substantial
foundation. The foundation must be designed to withstand any vibration associated with the equipment’s
operation, including vibration from peripheral and/or adjacent equipment. Refer to the following pages for
foundation design information.
FOOTING
Many factors must be considered when designing footing for a support structure. These include the weight of
the support structure, the equipment's factored loading, plus any additional loads produced by auxiliary
equipment such as conveyors or screens. Refer to the STRUCTURAL DESIGN PARAMETERS and the
DESIGN FACTOR CHART for additional information. Design the footing area using a conservative
allowable soil bearing pressure (not to exceed one ton per square foot for most soils). If the substratum is a
granular material, such as sand or gravel, take into account any potential compacting or settling caused by
vibration of the operating equipment.
STEEL SUPPORT STRUCTURES
Design steel support structures in accordance with Allowable Stress Design (ASD) specifications of the
American Institute of Steel Construction (AISC). Select member sizes by ASD procedures using the factored
loads listed in the DESIGN FACTOR CHART, and use heavy cross bracing to transmit horizontal forces from
the equipment to the foundations. If openings are required for auxiliary equipment in one or more bays, use a
rigid frame design with connections able to withstand the full moment capacity of the connected elements. If
possible, these connections should be welded or connected with A490 bolts designed and installed to produce a
slip critical connection. Orient the column webs in the direction of the largest horizontal force and incorporate
the necessary horizontal bracing to prevent racking at the top of the structure.
NOTE: Intermediate horizontal bracing is recommended for structures higher than eight feet.
FOUNDATIONS 1
FOUNDATIONS
VERSION A, REV. 03
CONCRETE SUPPORT STRUCTURES

Due to their large mass and stiffness, concrete support structures are effective in damping shock and vibration
forces, and typically perform better than steel support structures. Follow the ACI Building Code Requirements
for Reinforced Concrete when designing and/or constructing a concrete support structure. Select support
structure members using the factored loads listed in the DESIGN FACTOR CHART and make the structure's
weight equal to or greater than the weight of the supported equipment. Position reinforcements close together in
the top surface and vertical walls of the structure to minimize cracking. Use concrete with a compressive
strength of at least 4,000 PSI at twenty-eight days, and employ an air entrainment mixture to obtain an air
entrained content of 5% to 7%. Properly embed anchor bolts of sufficient size to resist the factored gravity loads
while acting vertically upward.
NOTE: Use a pipe with an inside diameter of at least one inch larger than that of the anchor bolt at each bolt
location to help compensate for any irregularity in the layout.
Secure each foundation bolt (located on top of the bottom flange of the base frame) using two hex nuts. Then
secure the bottom of each foundation bolt using a heavy plate washer and one hex nut, cotter pinned to the bolt.
STRUCTURAL DESIGN PARAMETERS
The load factors listed in the DESIGN FACTOR CHART serve as a minimum guideline when designing
foundations (support structures and/or footings) for McLanahan equipment. Multiply these factors by the weight
of the equipment when fully loaded. Additionally, design the foundation with sufficient stiffness to minimize
the deflection and amplitude of any impact forces.
FOUNDATIONS 2
FOUNDATIONS
VERSION A, REV. 03
DESIGN FACTOR CHART
Severe Lateral
Low Frequency Horizontal Factors Vertical
EQUIPMENT and Vertical
Vibration
Impact Forces Lateral (1) Transverse (2) Factors
Drag Feeder X
Feeder-Breaker X
Heavy Duty Double Roll Crusher X
Rockmaster Crusher X
0.3 0.15 3.5
Shale King Crusher X
Super Black Diamond Crusher X
Super Quadroll Crusher X
Super Triple Roll Crusher X
DDC-Sizer X
Black Diamond Crusher X
Cobra Crusher X
Mini-Mac Hammermill X
Quadroll Crusher (Std./Med. Duty) X
Rotary Breaker X 0.2 0.15 3
Rotary Screen X
Rotary Scrubber X
Shalemaster Crusher X
Triple Roll Crusher (Std./Med. Duty) X
Two-Stage Sample Crusher X
Mixer/Pug Mill X
Mudmaster Log Washer X
Particle Bonding Machine X
Sand Classifier X
Sand Classifying Tank / Metering Bin X 0.1 0.1 2
Sand/Manure Separator X
Sand Separator X
Screw Conveyor / Manure Auger X
Screw Washer X
Vibrating Screen/Sizer Severe Vibrational Forces 0.3 3
(1)Lateral direction is perpendicular to the rotating axis of the roll shaft, screw shaft, or drum.
(2)Transverse direction is parallel to the rotating axis of the roll shaft, screw shaft, or drum.
FOUNDATIONS 3
TRIPLE ROLL CRUSHER
VERSION A, REV. 01
20122010
INSTALLATION
OVERVIEW
This section discusses procedures required to properly assemble this crusher. To assure correct
operation, adhere to these guidelines, regardless of whether the components described are provided by
McLanahan Corporation or by others. Use the “PARTS LIST AND ASSEMBLY” drawing(s) in
conjunction with these procedures for instruction clarification. Also refer to this same drawing(s) for
pertinent information regarding dimensions, bolt torque requirements, etc.
NOTE: Thoroughly clean all anti-rust protectant from any coated components prior to installation.
PLACEMENT
When designing your layout, provide sufficient clearance for removal of all parts. Also include a crane
of adequate size (or at least provisions for such a crane) directly above the crusher to facilitate handling
of parts.
BASE FRAME
Carefully lower your crusher onto a properly prepared foundation (see FOUNDATIONS section) and
level the unit by inserting steel shims between the base frame and the foundation at each applicable
mounting bolt hole location.
Once the unit is properly leveled, secure the machine in place. To affix the machine to a structural steel
foundation, weld the shims or wedges to the foundation and draw the mounting bolts down firmly.
When using a concrete foundation, weld the shims to the bottom of the base frame and draw the
foundation bolts down firmly. (The appropriate number of foundation bolts, the diameter of these bolts,
and each bolt location is shown on the “PARTS LIST AND ASSEMBLY” drawing.) Fill the space
between the foundation and the bottom of the base frame with a quality, non-shrinking grout.
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TRIPLE ROLL CRUSHER
VERSION A, REV. 01
20122010
CRUSHER DRIVES
Triple Roll crushers are available with one of two drive arrangements. The first drive arrangement
consists of a single V-belt flywheel on one shaft with power being transmitted to the other roll by means
of rubber tires. The second available drive arrangement is a V-belt ‘Interstage’ Drive which links the
primary roll to the secondary roll, by means of a V-belt arrangement.
A. Rubber Tire Drive

The flywheel and the roll shaft are match-marked to insure that the flywheel is mounted on the
proper shaft. The flywheel is to be mounted according to the earlier mentioned procedure.
In addition, securely mount both rubber tires onto their respective roll shafts then mount each tire
guard. The tire guard provided serves to protect the operator from injury, but also the tires from any
wet material that would cause a great reduction in the drive performance, therefore, it is imperative
that this guard remain in place
For the recommended tire pressure, see the identification tags listed under the tire guard door or
consult the information stamped in the tire’s side-wall. For specific questions regarding the
installation or operation of the rubber tire ‘interstage’ drive system contact the Engineering
Department of McLANAHAN CORPORATION.
Reduced tire pressure can cause heat to build up in the tires and may result in
CAUTION premature failure.
B. V-Belt ‘Interstage’ Drive

The flywheel and the roll shaft are match-marked to insure that the flywheel is mounted on the
proper shaft. Mount the flywheel according to the procedure outlined at the beginning of this
CRUSHER DRIVE subsection.
Clean the roll shafts thoroughly with a solvent to remove the anti-rust protectant that was used in
shipping. Verify that the shafts are absolutely clean and free of any rough spots.
Mount the interstage drive guard (less its cover) and securely bolt it in place.
For V-belt ‘interstage’ drive installation instructions refer to both the V-BELT DRIVES and V-
BELT ‘INTERSTAGE’ DRIVE sections.
A belt take-up is provided to tension the V-belt ‘interstage’ drive. When adjusting the crusher
movable roll setting, it will be necessary to re-tension the ‘interstage’ drive belts since the center
distance will change as the crusher roll setting changes.
Attach each ‘interstage’ drive guard cover and securely bolt it in place.
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TRIPLE ROLL CRUSHER
VERSION A, REV. 01
20122010
MOTOR
Mount the motor on the motor base frame and securely bolt it into place.
ELECTRICAL CONNECTIONS
Connect the motor in accordance with the motor specifications listed by the motor manufacturer and the
nameplate information listed on the motor.
NOTE: An electrician who is familiar with, and complies with the national electrical code and all other
applicable local codes and regulations which govern such practices as wiring protection, grounding,
disconnects, and other necessary current protection, must perform all machine wiring.
V-BELT DRIVE
Install the motor sheave and bushing on the motor shaft. Refer to the V-BELT DRIVES section for
complete details on the overall V-belt drive installation.
DRIVE GUARD
Position the drive guard and securely bolt it into place.
CRUSHER ROLL TEMPLATES

Tooth templates are provided with the crusher. Use these templates as gauges for rebuilding the rolls
when it becomes necessary to do so. (Refer to the MAINTENANCE and WELDING sections for
detailed instructions regarding replacement and rebuilding of the crusher rolls.)
MATERIAL HANDLING EQUIPMENT

The efficiency and effectiveness of your crusher is greatly effected by how the material is fed into, and
carried away from the machine. Although McLanahan Corporation does not typically supply feed and
discharge chutes and subsequent material handling apparatus, the importance of these components
warrants their discussion in this manual.
- Place some type of mechanical feeding device ahead of the crusher to maintain a uniform and
continuous feed. A properly regulated feed supply can save labor, reduce power consumption,
and increase the life expectancy of the machine.
- Proper chute design depends largely on the size and speed of the crusher, the roll design, and the
size and type of feed material. Design the feed chute such that the material enters the hopper in
the same direction as the roll rotation and is spread evenly across the roll. Consider feed
characteristics such as percentage of fines, moisture content, size, etc. These attributes factor into
possible build up on the sides of the chute, and/or bridging across the feed hopper. Such
conditions could limit or prevent further material from reaching the crusher roll. As a general
rule, set the feed chute width equal to the length of the crushing roll and set the slope at an angle
not less than the material’s angle of repose. Also, limit the size of the feed material in
accordance with the crusher’s size.
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TRIPLE ROLL CRUSHER
VERSION A, REV. 01
20122010
- Design the discharge chutes and/or the subsequent handling equipment to adequately convey the
product away from the crusher. If the material is not removed at a sufficient rate, it may build up
underneath the crusher to such a degree that it could cause the crusher to jam and stall.
Look at the individual characteristics for each installation when designing chutes and material handling
equipment.
6
OPERATIONS SECTION
OPERATIONS
OVERVIEW
Triple Roll crushers essentially function as a Single Roll crusher and a Double Roll crusher working in
unison. The primary stage (Single Roll) is effective in handling larger feed, while the secondary stage
(Double Roll) produces the desired size product. This configuration yields a uniform product with
minimum fines.
SAFETY PRACTICES
Prior to each start-up of your crusher, thoroughly check to insure that all personnel are free of any rotating
and/or moving parts. This includes the toggle assemblies, which are not ‘moving’ during normal operation,
but open very rapidly and without warning when non-crushable material is encountered.
START-UP AND SHUT-DOWN
Always start the crusher with the hopper empty. Introduce feed material only after the crusher is operating
at full speed and run the machine until empty (or as empty as possible) prior to shutting down.
INITIAL START-UP PROCEDURE
A. Preliminary Lubrication
Lubricate all applicable components prior to the test run. The “LUBRICATION” tab section contains
the pertinent information. Supplementary sources of lubrication information may also be provided in
various locations throughout this manual, or with the equipment (manufacturer's literature, lubrication
plate, printed tag, etc.). If any disagreement is encountered between multiple sources of information, the
more conservative instructions always prevail. (Note: If the motors are furnished by a source other than
McLanahan Corporation, replace the motor information found in this manual with that furnished by the
supplier.)
B. Test Run
Manually rotate the crusher rolls and verify that there are no obstructions and that the rolls turn freely.
Then, operate the crusher for one hour under power without feed material. During this time, check all
bearings for excessive heating (see the “BEARINGS” tab section). Never operate a bearing if it
becomes so hot that you cannot hold your hand on it. This will likely destroy the bearing and could also
cause distortion or failure of the shaft.
7
OPERATIONS SECTION
C. Break-in Period
The first 60 days of operation are a critical period for the crusher. Consequently, inspect the machine
frequently during this break-in period. During these inspections, check all bolts for tightness. Once the
bolts are properly seated, they need not be checked as frequently. Also, check all automatically
lubricated points (if an automatic lubrication system is supplied with the machine) to insure a proper
feed rate of lubricant is provided. Make any required adjustments at this time.
FEATURES AND ADJUSTMENTS
A. Hopper
The hopper is equipped with abrasion resistant, renewable steel side liners. The hopper top flange has
bolt holes for attachment of a feed chute furnished by others. Grease lubricated hopper seals may be
utilized to minimize leakage of dust between the hopper and the roll shafts.
B. Drives
Triple Roll crushers are equipped with one "main" drive and one "inter-stage" drive. The "main" drive
consists of a motor, sheave, V-belt arrangement, and flywheel. The flywheel is located on the stationary
secondary stage roll. The "inter-stage" drive links the movable secondary roll to the stationary
secondary roll with a chain, V-belt, or rubber tire configuration. The primary roll is driven by a gear and
pinion arrangement. The pinion is located on the stationary secondary roll opposite the flywheel, and
drives the gear located on the primary roll shaft.
C. Crusher Rolls
The crushing rolls are available in roll shell and segmented roll configurations. Following, is a brief
description of the various roll designs:
1. Roll Shell Design
With a roll shell design, a solid roll shell comprised of high carbon steel is pressed and keyed to
the roll shaft.
2. Segmented Roll Design
With a segmented roll design, two end hubs (and possibly a center hub) are pressed onto a roll
shaft. High strength segment bolts attach roll segments to the hubs. A recessed pocket for each
bolt protects the bolt heads from wear. Although all hubs provide support for the roll, only the
two end hubs transmit the crushing force from the roll shaft to the roll segments.
The following factors dictate the roll material and tooth configuration chosen for a given application:
product size, product hardness and abrasive characteristics, and rebuilding and/or replacement
requirements. If your crushing requirements change, contact McLanahan Corporation to determine
whether the existing crusher characteristics are suitable.
8
OPERATIONS SECTION
D. Renewable Crushing Plate Tips
Chilled iron or high carbon steel tips are attached to the wear side of the crushing plate by high tensile
bolts and lock nuts. The backside of each tip is zinc formed to a jig, ensuring conformity to the mating
surface. These abrasion resistant tips are designed for long wear life and maximum interchangeability.
E. Torsion Bar
A torsion bar and linkage system is located behind the movable secondary roll to insure parallel roll
alignment and uniform product sizing.
F. Deflecting Plates
Deflecting plates are incorporated between the primary and secondary stages of the crusher. These
plates properly direct the material to the secondary stage, thus minimizing spillage.
G. Bearings
This crusher is equipped with self-aligning, spherical roller bearings. The roll shaft bearings are adapter
mounted and are equipped with taconite seals. These seals are grease purged to improve the quality of
the seal and increase the life of the bearing. Detailed information on these bearings is provided in the
tab section titled "BEARINGS".
H. Lubrication
Crushers typically come equipped with the grease lines banked to a centralized area on one or both sides
of the machine. Any lubrication points not located at this bank will be tagged. An optional automatic
lubrication system (see "OPTIONAL EQUIPMENT" further in this tab section) is also available. For
detailed information on lubrication, refer to the tab section titled "LUBRICATION".
I. Product Adjustment System
The crusher setting, which is defined as the distance (space/gap) between the two crusher roll
bodies, dictates the size of the crushed product produced by the crusher. (NOTE: If teeth are
incorporated in the roll design, they are not included in the measurement when determining the
crusher setting.) In order to produce different sizes of crushed product, it is necessary to change the
crusher setting.
9
OPERATIONS SECTION
1. Primary Stage Adjustment

On the primary stage, the clearance between the crushing plate and the primary roll is
controlled by the hold-back bolt and the crushing load is absorbed by the compression
springs. Both springs must have equal compression on either side of the crusher to maintain
parallel movement of the crushing plate. The compression springs should be adjusted to the
point where they maintain the crusher setting during the normal crushing operation and will
allow the crusher to open to pass the uncrushable material that may enter the unit. When
making adjustments to the compression springs, it is recommended that you adjust them no
more than ½” at a time and then operate the crusher with the springs in that position in order
to make sure that you have not over-compressed the springs so they will not react when
uncrushable material enter the unit.
ON ALL CRUSHER INSTALLATIONS, THE CRUSHING PLATE MUST BE SET AS
CLOSE AS POSSIBLE TO THE PRIMARY ROLL in order to produce a satisfactory
product and achieve maximum capacity. This reduces the load on the secondary rolls to
increase capacity and improve roll wear life.
2. Secondary Stage Adjustment
The setting of the secondary crushing rolls is altered by adjusting the two setscrews, the
center bolt, and the shim pack at the top of the toggle frame. The setting is maintained by the
shims and the bolt at the center of the toggle frame while the setscrews are used to move the
toggle assembly. Since the toggle assembly is a tramp protection device for the crusher,
never adjust or work around the toggle while the crusher is running since the toggle could
break open and injure those working with it.
To reduce the product size, the movable roll must move towards the stationary roll and the
toggle assembly must move downward. To move the toggle assembly down, first remove the
toggle guard. Next, loosen the center bolt and the lock nuts on the two setscrews. Turn the
setscrews clockwise, causing the toggle assembly to move down and the movable roll to
move towards the stationary roll. A gage on the tye bar at the side of the crusher is set to
show the gap between the bodies of the two rolls. Use this gage as a reference to determine
how far the toggle assembly must be moved. After the roll setting has been achieved, insert
shims between the toggle frame and the shims already in place. After the space has been
filled with shims, loosen the setscrews and tighten the center bolt to compress the shim pack.
Turn the crusher over by hand to insure that the rolls do not interfere. If there is no
interference, tighten the lock nuts on the setscrews and re-install the toggle guard.
10
OPERATIONS SECTION
To increase the product size, the movable roll must be moved away from the stationary roll
and the toggle assembly must move upward. Remove the toggle guard and loosen the center
bolt and the lock nuts on the setscrews. Next, turn the setscrews clockwise to move the
toggle assembly down far enough to loosen the shim pack. Remove some shims to allow the
toggle assembly to move upward, back off the setscrews, and tighten the center bolt. This
will draw the toggle assembly upward. Repeat this procedure until the desired roll setting is
achieved. Use the gage on the tye bar as a reference to determine how far the toggle
assembly must be moved. When the desired roll setting has been achieved, insert shims into
the space between the toggle frame and the shims already in place. When the space is filled,
loosen the setscrews before tightening the center bolt to compress the shim pack. Turn the
crusher over by hand to be sure that there is no interference. If the rolls turn freely, tighten
the setscrews, the setscrew lock nuts, and the center bolt. Re-install the toggle guard.
J. Toggle Assemblies
Toggle assemblies provide automatic tramp protection on the secondary stage. When non-crushable
material is encountered, the toggles immediately open to allow the material to pass without damaging
the machine. Once this material has cleared the crusher, the compression springs force the toggles back
closed. Refer to the “MAINTENANCE” tab section for adjustment procedures and additional
information on the toggle assemblies.
Stay clear of the toggle assemblies and any associated movable members during
! WARNING operation and maintenance. The toggles open very rapidly upon encountering non-
crushable material. They also close very forcefully when the non-crushable
material clears the machine (whether on its own accord or manually assisted).
OPTIONAL EQUIPMENT
A. Automatic Lubrication System
With the automatic lubrication system, the timer-controlled lubricator pumps appropriately proportioned
grease quantities from the reservoir to each lubrication point. (Maintain an adequate supply of grease in
the lubricator reservoir at all times.) A warning signal activates if the grease flow to any point is
disrupted. If this option is supplied, detailed information will be found in the “LUBRICATION” and
“LUBRICATION SYSTEM” tab sections.
B. Bearing Temperature Probes
When selected as an option, pre-calibrated temperature probes independently monitor each bearing
temperature. Typically, the probes are wired to activate a visual or audible alarm system when the
bearing temperature exceeds the upper limit. (Others typically furnish the alarm system.) If your
machine is equipped with this option, refer to the "ELECTRICAL" tab section for wiring details.
11
OPERATIONS SECTION
C. Zero Speed Switch
Optional zero speed switches detect faults in the drive system (i.e. as when a belt breaks, etc.). Wire the
switch(es) to shut the machine down upon detection of a zero speed condition.
12
MAINTENANCE SECTION
MAINTENANCE
OVERVIEW
A proper maintenance program is essential in receiving the best results and longevity from this crushing
equipment. Establish a practical inspection schedule and maintenance procedure then follow them
faithfully. Experience will dictate any need for change to either the schedule or procedure.
As with all new equipment, some readjustment may be required during the initial "break-in" period (see
section titled OPERATIONS). Therefore, provide for frequent inspections during this time. After the
system has been run in, adjust inspection frequencies as experience dictates.
After performing any maintenance on the machine, verify proper bolt tightness on any effected bolts
(see the “PARTS LIST AND ASSEMBLY” drawing) and follow the “initial start-up procedure” found
in the OPERATIONS section.
The following maintenance instructions are intended to be self-supporting. They may however, be more
clear when used in conjunction with the “PARTS LIST AND ASSEMBLY” drawing(s) (see the
DRAWINGS section) and any or all other drawings contained in this manual. The sequence and
procedures in this manual are written according to methods employed by McLANAHAN
CORPORATION, and are not necessarily exclusive instructions.
LUBRICATION
Lubrication is vital to any maintenance program. The detailed information required for this topic
warrants covering it explicitly in a separate section (see the LUBRICATION section).
BOLTS AND KEYS

Inspect the segment bolts through the small, removable access covers on each side of the roll. Check the
bolt tightness at least monthly. (Refer to the MAINTAINENCE section for proper bolt torque settings.)
Check all other bolts and keys periodically for proper tightness. (See “PARTS LIST AND
ASSEMBLY” drawing for bolt torque requirements.) Operating conditions and crusher age influence
the frequency of this check.
HOPPER LINERS
The hopper consists of two steel side plates and two end plates used to direct the feed material into the
crusher. The two side plates are equipped with renewable, abrasion resistant steel liners. These liners are
fastened in place using countersunk head machine bolts, which extend through the hopper wall, and are
secured by lock nuts. As the hopper liners wear, they can be easily replaced.
13
MAINTENANCE SECTION
CRUSHER ROLLS
The crushing rolls are available in either a roll shell configuration or a segmented roll configuration.
With the roll shell configuration, the roll shaft assembly is comprised of two flanged shafts and a solid
roll shell. For a segmented roll design, the roll shaft assembly consists of a roll shaft, two end hubs, a
center hub, the roll segments, and the segment bolts. Drawings detailing the two roll configurations may
be found at the end of this section.
As the rolls become excessively worn, it will be required to rebuild or replace them, as the situation
warrants. The following paragraphs, in conjunction with the drawings at the end of this section, will
provide information to facilitate the rebuilding or replacement of the rolls.
A. Rebuilding
If the rolls are to be rebuilt, use the templates that were made prior to placing the crusher in service
(as advised in the INSTALLATION section), as gauges. For the actual rebuilding procedure, refer
to the WELDING section.
B. Replacement
1. Segmented Roll Design - Stationary and/or Movable Roll
a. Remove appropriate roll covers. (It may be necessary to remove the hopper.)
b. Position the roll shaft assembly such that the segment to be removed is located at the top.
c. Block the roll shaft assembly to prevent any movement.
d. Remove the segment bolts from the segment being replaced.
e. Disengage the hook-on portion of the segment from the roll hub.
f. Lift the segment from the assembly.
14
MAINTENANCE SECTION
2. Roll Shell Design - Stationary Roll and/or Movable Roll
a. Remove appropriate roll covers (It may be necessary to remove hopper).
b. Block the roll shaft assembly.
c. Loosen bearing foundation bolts.
d. Remove tie bars.
e. Unbolt hopper seal housings.
f. Unbolt flanged shafts from roll.
g. Slide bearing housing away from roll.
h. Remove roll shell from crusher.
15
MAINTENANCE SECTION
C. Bolt Torque Requirements
1. Segmented Roll Design - Segment Bolts
Segment bolts are fine thread, grade 5 bolts with a matching grip nut. In order to insure
proper seating of the roll segments, it is essential that the correct torque setting be
maintained. It should also be noted that a hardened washer must be used under the bolt head
for this application. Check bolt tightness monthly.
BOLT DIAMETER TORQUE

1" 647 Ft. Lbs.
2. Roll Shell Design - Flanged Shaft Bolts
Flanged shaft bolts are coarse thread, grade 5 bolts that thread into the roll shell. It is critical
that the proper torque setting be maintained. A small, removable access cover is located on
each side of the roll to facilitate this procedure. These access covers allow the operator to
check the tightness of the segment bolts without having to remove the roll covers. Check
bolt tightness monthly.
BOLT DIAMETER TORQUE

7/8" 353 Ft. Lbs.
16
MAINTENANCE SECTION
TOGGLE ASSEMBLY
The toggle assembly on a Triple Roll crusher is comprised of a single torsion shaft attached to both
movable bearing housings by way of connecting bars. The torsion shaft is then attached to a spring
loaded mechanical toggle device. A compression spring attached to the toggle provides the necessary
force to return the movable roll to its original position, should it open to pass uncrushable material.
(These components are illustrated in the 'TOGGLE ASSEMBLY' drawings found at the end of the
OPERATIONS section.)
If it becomes necessary to remove the toggle assembly for any reason, follow the below procedure.
Upon reassembly, all parts must be thoroughly cleaned and all joints must be lubricated.
A. Removal
1. Lock out all electrical controls to the crusher.
2. Remove the toggle guard.
3. Release the spring compression and remove the spring by unthreading the spring rod nuts on the
top of the spring.
4. All toggle components may be disassembled by removing the retaining pins at all connections.
All compression must be released from the compression springs before performing
! WARNING any maintenance, or personal injury may result.
17
MOTOR
VERSION A, REV. 03
MOTOR
OVERVIEW
The following instructions and manufacturer’s literature provide guidelines for proper motor installation and
maintenance. Although the literature may not be from the actual manufacturer of the motor used on this
machine, the information presented is applicable. Thoroughly read and understand all information regarding the
motor. In the event of conflicting information, always use the guidelines providing the highest degree of
protection/safety.
APPLICATION
Use only appropriate motors for a given application. Using motors in applications not suited to their design can
significantly reduce their life expectancy and/or may pose a safety hazard. Follow these fundamental guidelines:
Choose the proper horsepower rating for the load requirements.
Choose a motor with a NEMA design suited for the application.
o EXAMPLE: Do not use a standard NEMA design B motor when requiring high starting torque.
The prolonged starting time will shorten the life expectancy of the motor and/or trip the overload
devices.
Choose a motor with an appropriate duty cycle for the application.
o EXAMPLE: Do not use a motor with a “continuous” duty cycle in applications requiring
frequent starting, unless a clutch type arrangement is incorporated in the design. Provide
adequate time between start-ups to dissipate heat generated by the current surge. In addition, do
not “plug-stop” a motor unless the motor is specifically designed to withstand the tremendous
current/heat associated with this process.
SAFETY PRACTICES
The following guidelines are considered minimum for the safe operation of this equipment. No guidelines or
any amount of safety equipment, however, can guarantee safety. An alert, safety-conscious operator, properly
trained on the equipment and familiar with the location and function of all safety devices, is the key to safe
operation of any machine. Refer to the SAFETY PRECAUTIONS section of this manual before installing,
operating or maintaining this equipment.
 Wear appropriate personal protective equipment at all times.
 Obey all safety tags and signs and replace any that are illegible or missing.
 Obey all facility safety rules and operational regulations.
 Verify that all guards and safety devices are in place and that all personnel are clear of any/all parts
prone to movement or rotation.
 Lockout/Tagout all controls before performing any maintenance or repairs.
MOTOR 1
MOTOR
VERSION A, REV. 03
MAINTENANCE
An appropriate maintenance program is vital to achieve the expected life from a motor. Following, are some
general guidelines to abide by:
Keep the motor cooling fins, fans, and air passages clean to facilitate proper heat dissipation.
Keep the area around the motor clean and free from any obstructions that may prohibit adequate air
circulation.
Keep the motor properly lubricated.
NOTE: Do not over-grease a motor. Surplus grease that is forced out of a motor bearing housing can
destroy the insulation of the motor windings. Before lubricating a motor, remove the drain plug to
provide an exit for any excess grease, and wipe all fittings with a clean rag to prevent forcing any
contaminants into the unit. After lubricating the motor, run it for approximately one hour, before
reinstalling the drain plug.
Keep the motor windings free from moisture.
NOTE: Maintaining the temperature of the windings at 5°C to 10°C above the ambient temperature
helps prevent condensation. Two common methods of achieving this are by using an electric space
heater in the motor end bells and/or applying a low D.C. voltage to one phase of the motor windings
whenever the motor is at rest.

Vibration analysis can also help extend the useful life of a motor by facilitating early detection of such items as
bearing wear, mechanical looseness, defective belts, and imbalance.
STORAGE
When storing a motor or allowing it to set idle for an extended period of time, observe the following guidelines:
Keep the motor clean and dry, and raise or remove any brushes to prevent corrosion.
Periodically turn the shaft to prevent lubricants from hardening.
Periodically test the insulation resistance for deterioration (which may be a result from moisture
absorption or other factors).
MOTOR 2
V-BELT DRIVE
VERSION A, REV. 02
V-BELT DRIVE
OVERVIEW
V-belt drives, when properly applied, will provide years of reliable performance. Following, is a concise
guideline for the installation and maintenance of a V-belt drive mechanism. The information presented
is general in nature, and is to be used as a supplement to the manufacturer's literature found at the end of
this section. In the event of conflicting information, always use the guidelines providing the highest
degree of protection/safety.
SAFETY PRACTICES
The following guidelines are considered minimum for the safe operation of this equipment. No
guidelines or any amount of safety equipment, however, can guarantee safety. An alert, safety-conscious
operator, properly trained on the equipment and familiar with the location and function of all safety
devices, is the key to safe operation of any machine. Refer to the SAFETY PRECAUTIONS section
of this manual before installing, operating or maintaining this equipment.
 Verify that all guards and safety devices are in place and that all personnel are clear of any/all
parts prone to movement or rotation.
V-BELT DRIVE 1
V-BELT DRIVE
VERSION A, REV. 02
INSTALLATION
Lockout/Tagout all controls and secure all applicable components to

prevent unexpected movement before performing any maintenance,
repairs, or adjustments on this equipment or any portion thereof.
NEVER pry or roll belts into the sheave grooves. This action is not only
unsafe, but may seriously damage the belts as well.
Move the sheaves close enough together to allow the belts to be installed without the use of force. Work
each belt around the sheave by hand until the top and bottom span have approximately the same sag.
Once all belts are in place, apply tension by increasing the center distance between the sheaves. Since
3V, 5V, and 8V belts have a higher horsepower rating than conventional V-belts, fewer belts are
required for a given application. However, since the total required drive tension essentially remains
constant, fewer belts means greater individual belt tensions. Consequently, the feel of the 3V, 5V, or 8V
belt will be unlike that of a conventional belt… it may feel tight, yet be under-tensioned. To insure
proper tensioning, follow the procedure listed on the following page.
ALIGNMENT
A. Shaft Alignment
Check shaft alignment by measuring the distance between the drive shaft and the driven shaft at
three or more locations. All measurements will be equal if the shafts are parallel.
B. Sheave Alignment
Align the sheaves using the “four-point method” with a piece of string or straight edge. The sheaves
will be in alignment when the straight edge (or piece of string pulled tight to create a straight line)
touches the near and far edges on the face of both sheaves. If the sheaves are both grooved centrally
but are not equal in width, they should be aligned using the centerline rather than the face.
V-BELT DRIVE 2
V-BELT DRIVE
VERSION A, REV. 02
TENSIONING

With the drive stopped, measure the Span Length (T) as shown in the “BELT TENSIONING” drawing
below. Using this measurement, calculate the Deflection Height (H) as 1/64 of the Span Length (T). For
example, a 32" Span Length would require a deflection of 32/64" or 1/2".
Refer to the appropriate table in the manufacturer's literature to determine the minimum, maximum, and
initial recommended deflection force (lbs). Adjust the drive tension until the recommended deflection
force produces the calculated deflection height.
NOTE: When new V-belts are installed on a drive, always check the tension frequently and re-adjust as
necessary during the first 24 hours of operation.
BELT TENSIONING
SPAN LENGTH (T)
DEFLECTION FORCE
H = T/64
V-BELT DRIVE 3
V-BELT DRIVE
VERSION A, REV. 02
BELT TIGHTENER (ONLY IF FURNISHED)

McLanahan machines equipped with a movable roll are typically furnished with a belt tightener. This
mechanism will automatically tighten the V-belts that are coupled to the movable roll. Use the following
procedure in conjunction with the “HINGED MOTOR BASE” drawing below to set up the belt
tightener.
1. Set the motor at the height (H) as shown on the “PARTS LIST AND ASSEMBLY” drawing(s)
which can be found in the DRAWINGS section of this manual. This height is adjusted by
sliding the motor base. Tighten the stationary motor base bolts once the proper location is found.
2. Set the spring compression according to the value found on the belt tightener tag. This is
accomplished by adjusting the compression spring nuts. To obtain the actual spring setting,
simply measure the distance between the top and bottom compression spring washers.
HINGED MOTOR BASE
(Ref.) #17301
1. STATIONARY MOTOR BASE 6. BOTTOM COMPRESSION SPRING WASHER

2. MOVABLE MOTOR BASE 7. COMPRESSION SPRING NUTS
3. COMPRESSION SPRING 8. HINGE PIN
4. SPRING ROD 9. SPRING PIN
5. TOP COMPRESSION SPRING WASHER 10. ELECTRIC MOTOR
V-BELT DRIVE 4
V-BELT DRIVE
VERSION A, REV. 02
MAINTENANCE
 Keep belts free of dirt and oil (use only soap and water to remove oil and grease from V-belts).
 Store spare belts in a cool dry location.
 Maintain proper belt tension.
NEVER mix new and used belts on a drive.
NEVER use a belt dressing on V-belts.
V-BELT DRIVE 5
A L T R A I N D U S T R I A L M O T I O N
Installation & Maintenance of

V-Belt Drives
®
Quality Products and the

Support to Back Them Up – Wood’s
V-Belt sheaves of close grain, high-tensile cast iron are machined

to provide safe, vibration-free operation at speeds up to 6500 FPM.
Made to order sheaves of ductile iron material can be provided for
speeds up to 10,000 FPM. V-Belt drives are only the beginning of
what Wood’s can do.
Wood’s offers a complete line of high capacity synchronous drives. The

RPP-Plus system offers a higher horsepower capacity drive at the cost of
the competitions standard rated product. Wood’s also offers the aramid
fiber QT Powerchain drive in 8M and 14M pitch. The QT drive is capable
of high horsepower capacity in a smaller package. Both QT and RPP
sprockets offer metric/inch drilling for applications which require a totally
metric drive system.
Wood’s has many different ways of offering variable speed for customer
applications. The most basic way is through the use of one of our many
belted variable speed systems. Wood’s also offers many different options
in the line of electronic inverters and electronic speed controls. One of the
most unique ways of varying speed, however, is our HSV/HSVA hydro-
static systems. The HSV system is ideal for harsh, dirty, or explosive proof
environments.
Wood’s Elastomeric coupling line offers something for every

application. Wood’s Jaw couplings offer a full compliment of spider
materials and bore option. Our Sure-Flex line offers the 4-way flexing
action, and many different flange and sleeve options to meet your
needs. The Dura-Flex coupling is designed and patented with
improvements over other similar type coupling that provide for the
maximum possible service life.
Wood’s line of Steel couplings offers both gear and disc coupling
options. Wood’s Form-Flex disc couplings offer zero-backlash and
eliminate the need for lubrication. Our gear couplings are available in
all the standard, spacer, and special options common to the industry.
In both disc and gear lines we welcome the challenge of the “special”
coupling.
®
Contents
3
4
6
®
V-Drive Inspection and

Maintenance Procedures
1
®
2
®
3
®
Belt Selection
4
®
Classical Minimum*
Belt Section Pitch Diameter
Narrow Minimum
Belt Section Sheave Diameter
5
®
6
®
Safety Tips
7
®
Drive Installation
8
®
Tapered Size & Thread Ft.-Lbs.

Bushing of Cap Screw To Apply With
Torque Wrench
9
®
10
®
For Installation (Subtract) For take-up (Add)

Belt
Length 3VX 5VX 8VX
& 3V & 5V & 8V All
3V Banded 5V Banded 8V Banded Cross Sections
For Installation (Subtract) For take-up (Add)

Belt
Length AX BX BX CX CX DX DX
Designation & & & BP & & CP & & DP All
AP BP Banded CP Banded DP Banded Cross Sections
11
®
Tensioning V-Belt Drives
12
®
13
®
Small Sheave Drive Ratio

Belt Speed 4.0 &
Section Dia. 1.0 1.5 2.0
Range over
Arc Factor Arc Factor

D—d Contact D—d Contact
C Degree Ac K C Degree Ac K
14
®
Narrow Narrow Cog Classical Classical Cog

Factors
3V 4V 8V 3VX 5VX AP BP CP DP EP AX BX CX DX
15
®
16
®
NARROW BAND CLASSICAL BAND CLASSICAL COG BAND
Ts CROSS SECTION
Per
Strand
(lbs.) 5V 8V BP CP
3V DP BX CX DX
5V1700 5V1800 8V1700 8V1800 BP144 Over CP144 Over All All All
& under & over & under & over & under BP144 & under CP144 Sizes Sizes Sizes
17
®
Trouble Shooting V-Belts
18
®
19
®
20
®
21
®
SURE-GRIP® SHEAVE FEATURES
Wood’s sheaves are constructed of fine grain, high tensile cast iron, and have been carefully engineered
to assure maximum performance over a long life span. Behind each sheave is one of the most extensive
engineering design and testing programs in the industry.
DESIGN INTEGRITY MACHINING

TB Wood’s Incorporated has been a leading TB Wood’s Incorporated has numerous
supplier of cast iron pulleys, v-belt sheaves, machining facilities throughout North America.
synchronous belt sprockets and Sure-Grip Each is equipped with modern CNC equipment
mounting bushings since the inception of these and capable of doing high precision machining.
products. We are committed to the continual Statistical process controls are in place in each
improvement of our standard products and location, and each has been ISO-9000 certified.
special or MTO products through design, mate-
rials and quality enhancements. For example, SPECIFICATIONS
new product designs are typically computer TB Wood’s products are manufactured to conform
generated and then verified using finite element to or exceed recognized industry standard
analysis before CAD drawings are made. This specifications. The following is a listing of some of
enables Wood’s to quickly and accurately quote these specs.
on any special needs, and to relay the tool paths
for new designs quickly from engineering to the ANSI/RMA IP-20 Classical V-Belt Sheaves
shop floor. ANSI/RMA IP-22 Narrow V-Belt Sheaves
FOUNDRY PROCESSES ANSI/RMA IP-24 Synchronous Sprockets
TB Wood’s Incorporated has a modern state-of-
the-art foundry in Chambersburg, PA where cast MPTA QD-1 QD Bushing Guideline
iron and ductile iron castings are produced. This
captive foundry operation not only gives Wood’s MPTA SPB Pulley Balance
the control needed to obtain standard high quality MPTA SAS V-Belt Sheave Arm Stress
castings as they are required, but also enables
them to produce any special requirements in a MPTA SF Pulley Surface Finish
minimal amount of time.
Altra Industrial Motion
Altra Industrial Motion
Warner Electric TB Wood’s Boston Gear Altra Industrial Motion -

Electromagnetic Clutches V-Belt Drives, Synchronous Drives, Enclosed and Open Gearing, Asia Pacific and Africa
and Brakes - USA Flexible Couplings, Variable Electrical and Mechanical
China 852 2615 9313
Frequency AC Drives P.T. Components
South Beloit, IL
Charlotte, NC Taiwan 886 2 2577 8156
815-389-3771 Chambersburg, PA
717-264-7161 704-688-7300 Singapore 65 6487 4464
For application assistance: For customer service:
1-800-825-9050 1-800-825-6544
For assistance: Thailand 66 2 322 5527
1-888-829-6637
Electromagnetic Clutches Press #5 – Customer Service For application assistance: Australia 612 9894 0133
and Brakes - Europe Press #7 – Mechanical Applications 1-800-816-5608
St Barthelemy d’Anjou, France Press #8 – Electronic Applications S. Africa 27 11 918 4270
+33 (0)2 41 21 24 24 Huco Dynatork
For sales office: Wichita Clutch and Precision Couplings
+33 (0)2 41 21 24 76 Industrial Clutch and Air Motors
Pneumatic and Oil Immersed Hertford, England
Precision Electric Coils and Electro- Clutches and Brakes - USA +44 (0) 1992 501900
magnetic Clutches and
Brakes - USA Wichita Falls, TX U.S.
Columbia City, IN 940-723-3400 800-825-6544
260-244-6183 Pneumatic Clutches Ameridrives Couplings
and Brakes - Europe
Inertia Dynamics Gear Couplings, Mill Spindles,
Bedford, England Universal Joints
Spring Set Brakes; Power On and Wrap +44 (0)1234 350311
Spring Clutch/Brakes Erie, PA
Torrington, CT Twiflex Limited 814-480-5000
860-482-4444 Caliper Brakes and Thrusters Bibby Transmissions
Matrix International Twickenham, England Disc, Gear, Grid Couplings,
+44 (0) 20 8894 1161 Overload Clutches
Electromagnetic Clutches
and Brakes, Pressure Operated Dewsbury, England
Clutches and Brakes Formsprag Clutch +44 (0) 1924 460801
Brechin, Scotland Overrunning Clutches
and Holdbacks Nuttall Gear and
+44 (0) 1356 602000
Warren, MI Delroyd Worm Gear
U.S.
815-389-3771 586-758-5000 Worm Gear and
Helical Speed Reducers
For application assistance:
Warner Linear 1-800-927-3262 Niagara Falls, NY
Linear Actuators and
716-298-4100
Guideways - USA Marland Clutch
Roller Ramp and Sprag Type Saftek Friction
Belvidere, IL Overrunning Clutches
815-547-1106 Non-asbestos Brake and Clutch
and Backstops Materials
For application assistance: Burr Ridge, IL
1-800-825-9050 Telford, England
630-455-1752 +44 (0) 1952 581122
Stieber Clutch
Overrunning Clutches
and Holdbacks
Heidelberg, Germany
+49 (0)6221 30 47 0
TB Wood’s Incorporated
440 North Fifth Avenue • Chambersburg, PA 17201
Tel: 888-TBWOODS • 717-264-7161
Fax: 717-264-6420
www.tbwoods.com
VBD-IM P-1688-TBW 07/07 Printed in USA

CRUSHER ROLL SHAFT BEARINGS
VERSION B , REV. 00

OVERVIEW
This manual section contains information that has been assembled to provide for proper bearing
maintenance and repair. Included are written instructions as well as manufacturer's literature. The
manufacturer's literature was selected based solely on content and ease of understanding. Consequently,
this literature may or may not be from the actual manufacturer of the bearings on this particular
machine. Regardless of the bearing manufacturer, the information contained in this section must be
thoroughly read and understood prior to working on any bearings on this machine. In the event of
conflicting information, always use the guidelines providing the highest degree of protection/safety.
SAFETY PRACTICES
DESIGN
The roll shaft bearings on McLanahan Double Roll Crushers (including Quadroll Crushers and the
bottom stage of Triple Roll Crushers) are spherical roller bearings mounted in steel housings and of a
one-piece design. The position of the bearing on the driven end of the roll shaft is held, while the
bearing on the opposite end is free to move with the expansion or contraction of the shaft. The stationary
bearing housing is bolted to the base frame, and a steel stop is welded to the under side of the frame to
prevent the bolts from turning when being loosened or tightened. (It is essential that the bearing bolt is
seated against the frame and not hung up on this steel stop when installed.) The tie bar holds down the
movable bearing housing. (For more information, see the “PARTS LIST AND ASSEMBLY” drawing
for the roll shaft in the DRAWINGS section.)
Roll shaft bearings are equipped with bearing covers containing labyrinth type grease seals, which allow
grease to dissipate out of the bearing. Additionally, since the seals are also force lubricated, foreign particles
are blocked from entering back into the bearing (see the “ROLL SHAFT ASSEMBLY” drawing located in
the DRAWINGS section of this manual).
CRUSHER ROLL SHAFT BEARINGS | 1

VERSION B , REV. 00
BEARING REPLACEMENT
Roll shaft bearings are shipped completely assembled on the roll shaft, thus eliminating the need for in-field
mounting. If the bearings need to be replaced, however, refer to the disassembly and assembly procedures
on the following pages. These instructions are intended to be self-supporting. They may, however, be
clearer to the reader when used in conjunction with the “ROLL SHAFT ASSEMBLY” drawing located in
the DRAWINGS section of this manual. The sequence and procedures in this manual are written according
to the methods that McLANAHAN CORPORATION employs, and are not necessarily exclusive
instructions.
A. Disassembly Procedure

1. Remove any Crusher components required to gain access to the bearing housing.
2. Block the roll shaft to prevent any movement during maintenance.
3. Unbolt the outer bearing cover and slide it off of the shaft.
4. Prior to removing the bearing from the shaft, measure and record the distance from the end of the
shaft to the outside edge of the adapter.
5. Free the bearing from the adapter by following either the conventional method or the hydraulic
assistance method (if the adapter is equipped with a hydraulic fitting).
a. Conventional Method
1) Release the locking tab from the adapter nut and loosen the nut using a hammer and drift.
Once the nut is loose, back it away from the bearing at least 1/8".
2) Drive the adapter toward the Crusher by striking the adapter nut with a hammer. This will
free the adapter from the inner race. To facilitate this process, use a piece of pipe with an I.D.
slightly larger than the O.D. of the shaft, and with an end cap made of steel plate. Simply slide
the pipe over the shaft until it is in contact with the adapter, and hammer against the end cap of
the pipe.
b. Hydraulic Assistance Method

1) Unbolt the inner bearing cover and slide it against the Crusher side frame.
2) Release the locking tab from the adapter nut and loosen the nut using a hammer and drift.
Once the nut is loose, back it away from the bearing at least 1/8", but DO NOT remove it
completely. This nut will function as a stop when disengaging the bearing.
3) Release the bearing from the adapter using either a grease gun rated at 10,000 PSI or a porta
power pump to pressurize the unit. The oil injected between the mating surfaces will essentially
eliminate any friction, and the induced pressure will force the bearing off the tapered seat.
6. Once the bearing is free, remove the adapter nut and slide the bearing off of the adapter.
7. Remove the adapter from the shaft.

VERSION B , REV. 00
B. Assembly Procedure

1. Clean the bearing housing, shaft, seals, and end cover (if furnished) thoroughly. If necessary, file
or polish any rough edges.
2. With the bearing resting on a flat surface, measure the unmounted internal clearance of the new
bearing by inserting progressively larger feeler blades between the most vertical unloaded roller and
the outer race. The feeler blade must be slid, not rolled, through the full length of the roller. Record
the largest blade that will slide through.
3. Carefully tap the new bearing into the bearing housing using a soft hammer. Position the bearing
in the housing as follows:
a) The free (or expansion) bearing should be centered in the housing.
b) The held bearing must be offset toward the crusher by half the thickness of the stabilizing
ring. One method of positioning the held bearing is to insert the stabilizing ring and install the
end covers. Then, remove the covers and the stabilizing ring, and measure the distance from the
bearing to the edge of the bearing housing. This measurement should be recorded for later use.
4. Slide the inner bearing cover onto the shaft. (This cover should slide freely into position once the
labyrinth seal rings are started on the shaft.)
5. Coat the shaft with a light coating of micronized or powdered (not flaked) graphite, or light oil.
6. Locate the adapter on the shaft at the position recorded in step 4 of the disassembly procedure
above. (If this exact position is not known, locate the adapter as close as possible to the proper
position. The exact position will be located in step 10 of this assembly procedure.) Once the adapter
is correctly positioned, locate the bearing and bearing housing on the adapter, making sure that the
taper of the bearing's bore matches the taper of the adapter.
7. Locate the lock washer next to the bearing and locate the inner prong of the lock washer in the
slot of the adapter sleeve.
8. Thread the adapter nut onto the adapter until it is hand tight.
9. Bolt the bearing housing to the crusher frame.
10. Verify that the adapter is still in its proper position. If the adapters exact position was not known
earlier at step 6 of this procedure, then determined it now by the following this procedure:
Using the distance measured in step 3.b of this assembly procedure, locate the adapter such that the
bearing is the proper distance from the edge of the bearing housing.
From the chart found on the following page, determine the correct reduction in internal clearance.
When the bearing is tightened, it has a tendency to move axially along the shaft as it rides up the
taper of the adapter. Therefore, considering that the bearing will move approximately 0.016" for
each 0.001" of reduction in the internal clearance, calculate the distance that the bearing must be
moved away from the crusher to compensate for this action. For example, if the desired reduction in
internal clearance is determined to be 0.002", the bearing and adapter must be moved away from the
crusher by a distance of (0.002)(0.016 / 0.001) = 0.032".

VERSION B , REV. 00
11. Once the bearing and adapter are properly located, thread the setscrews into the tapped holes of
the adapter nut. Tighten each setscrew uniformly and sequentially until the proper internal clearance
(see chart and example on following page) is achieved. This clearance is measured by inserting
progressively larger feeler blades between the most vertical unloaded roller and the outer race. The
feeler blade must be slid, not rolled, through the full length of the roller.
12. After the proper internal clearance is achieved, verify that the bearing has maintained its proper
position in the housing (see step 3 of this assembly procedure). If the bearing position is not correct,
it will be necessary to loosen the adapter nut and reposition the bearing and adapter.
13. Once the proper internal clearance and bearing position are achieved, loosen the setscrews and
back them part way out of the nut. Turn the nut until it is tight against the lock washer and re-check
the bearing clearance. If the bearing clearance is still correct, verify that a slot in the lock nut aligns
with a lock washer tang and bend the tang over into the slot. (If a slot does not line up, tighten the
nut slightly by driving it with a spanner wrench and a hammer until it does line up. NEVER loosen
the adapter nut to align the slot with a washer tang.) When finished, remove the setscrews from the
adapter nut.
14. Pack the bearing full of grease (see the LUBRICATION section for proper grease selection) and
work the grease thoroughly into the rollers. (If working on the held bearing, insert the stabilizing
ring prior to greasing.)
15. Bolt all end covers to the bearing housing. Once all bolts are tightened, refer to the “Test Run”
procedure under the OPERATIONS section. Remove roll shaft stop block(s) prior to test run.

VERSION B , REV. 00
RADIAL INTERNAL CLEARANCE TABLE
SHAFT REDUCTION IN RADIAL

DIAMETER INTERNAL CLEARANCE
OVER INCLUDING MINIMUM MAXIMUM

EXAMPLE:
1-1/4" 1-3/4" 0.0010" 0.0012"
1-3/4" 21/4" 0.0012" 0.0015" Determine the required final internal clearance for a
3-7/16" diameter shaft when the unmounted internal
2-1/4" 2-3/4" 0.0015" 0.0020" clearance was measured to be 0.004" in step 2 of the
2-3/4" 3-1/2" 0.0018" 0.0025" Assembly Procedure.
3-1/2" 4-1/4" 0.0020" 0.0028"
A. Reduction in radial internal clearance from the
4-1/4" 5" 0.0025" 0.0035"
accompanying table is a minimum of 0.0018" and a
5" 5-1/2" 0.0030" 0.0040" maximum of 0.0025".
5-1/2" 6-1/2" 0.0030" 0.0045"
6-1/2" 7-1/4" 0.0035" 0.0050" B. Acceptable final radial internal clearance range
is:
7-1/4" 8" 0.0040" 0.0055"
8" 9" 0.0045" 0.0060"
Maximum = 0.0040" - 0.0018" = 0.0022"
9" 10-1/2" 0.0045" 0.0065"
10-1/2" 11" 0.0050" 0.0075"
Minimum = 0.0040" - 0.0025" = 0.0015"
11" 12-1/2" 0.0060" 0.0085"
12-1/2" 14" 0.0065" 0.0090"
14" 15-3/4" 0.0080" 0.0105"

Split Pillow Block Housing Assembly Instructions
for SAF and SAFS housings
WARNING: Read these instructions before felt seal and the lip of the contact seal. Fill induction heater may be used to heat the
starting work. Failure to follow these instruc- the TER seal cavity with grease. If the end of bearing, but only long enough to enlarge the
tions could result in injury or damage such as the shaft does not have a lead-in bevel, bearing bore for mounting, and in no case
catastrophic premature bearing failure. Be smooth the bore of the felt seal with a flat for more than four hours. A hot plate may be
careful with heavy weight and tools and instrument to aid in starting the felt over the used to heat the oil bath. In no case should
other devices, and with high pressure oil end of the shaft. Carefully slide the seal car- the bearing be heated with an open flame.
when using the hydraulic assist method. Be tridge assembly on the shaft to approximate Mount the bearing on the shaft firmly against
familiar with the MSDS or other safety assembly position. NOTE: Make sure the the shaft shoulder. Quickly follow through
instructions for any grease or oil used and lobes of the rubber extrusion on the outside with Steps ii and iii to prevent the bearing
keep them nearby. diameter of the taconite seal are not located drawing away from its proper position
at the split of the housing; to ensure this against the shaft shoulder.
Step 1: Check shaft tolerance. See chart F.
ii. Mount lockwasher over threads on shaft
occurs, the grease fitting should be at 12 or
Step 2: Install inboard seal. with inner prong of lockwasher toward the
6 o’clock. For seal misalignment capabilities,
face of the bearing and locate it in the slot in
see chart G.
PosiTrac (LOR) and PosiTrac Plus seal the shaft.
Slide the seal onto Step 3: Mount bearing on shaft.
the shaft. The resist- Note: Other mounting methods exist. Please iii. Apply the locknut with the chamfered face
ance should only consult SKF for alternative instructions or toward the bearing. Tighten with a spanner
require slight hand reference www.skf.com/mount. wrench and hammer until the bearing is
pressure to over- firmly seated against the shaft shoulder.
come. The O-ring Cylindrical Bore Mounting Bend one of the lockwasher tangs into a slot
can be lubricated with grease or oil to ease in the nut. It may be necessary to further
assembly. Locate the seal to match the
LOCKWASHER
tighten the nut in order to engage the lock-
labyrinths in the housing. The old style LER washer tang. A very slight movement of the
LOCKNUT
OUTBOARD
TRIPLE RING
nut will align a slot with the tang.

SEAL
labyrinth seal still used for small shaft diame-

INBOARD
TRIPLE RING
ters is installed in the same manner. The pic-

SEAL
BEARING (SELF-ALIGNING
ture shows the PosiTrac Plus seal, which Adapter Mounting for Spherical Roller
STABILIZING BALL OR ROLLER BEARING)
RING
requires greasing the seal lip at assembly. See i. To press small bearings onto the shaft, fit Bearing, and Self Aligning Ball Bearing.
PosiTrac Plus Assembly Instructions for more a clean pipe over the shaft and rest it on the Note: Do not remove preservative from bear-
information (Publication 655-810), which is inner ring. Before pressure is applied to the ing as it will mix with any petroleum grease
included with the B-10724 contact element. bearing, apply a coat of light oil or micronized or oil. The bore surface only should be wiped
graphite to the shaft and bearing bore. Be
SKF’s next generation M5 style SAF housings
clean.
sure bearing is square on the shaft and then
have the external labyrinth painted for i. Screw off the nut and remove the lock-
apply pressure using a hammer or arbor
improved corrosion resistance. Removal of ing washer.
press. To mount larger bearings that are not
this paint is not recommended.
easily pressed onto a shaft, heat the bearing
to a maximum temperature of (250°F). The
Taconite (TER) seal bearing may be heated in clean oil or in a
Coat the shaft with 10% – 15% emulsion of soluble oil for 30
oil. Smear grease in minutes to 1 hour depending on bearing size.
the bore of the seal Be sure to place supports under the bearing
cartridge, filling the to isolate it from the bottom of the container
cavity between to prevent overheating the bearing.
seals, and lubricat- Alternately, a temperature controlled oven or
ing the bore of the
ii. Wipe the preservative from the surfaces vi. Place the bearing on the sleeve. Screw ix. Unscrew the nut, place the locking washer
of the sleeve and apply light oil to the sleeves the nut with its chamfered face toward the in position, and tighten the nut firmly again.
outside diameter surface for easier bearing bearing, but do not mount the lockwasher. Make sure that the bearing is not driven up
mounting and dismounting. Do not push the inner ring up the taper of the sleeve any further.
the sleeve.
x. Lock the nut by bending one of the lock-

iii. Open up the sleeve by inserting a screw- ing washer tabs down (using a hammer and
driver in the slot; then position the adapter vii. Turn the nut sufficiently to ensure that a drift) into one of the slots in the nut. Do not
sleeve on the shaft, thread outward as indi- the shaft makes proper contact (self-locking) bend it to the bottom of the slot.
cated, to approximate location with respect to with the sleeve, continuing to drive the bear-
the required bearing centerline. ing up the sleeve.
xi. Check that the shaft or outer ring can be

rotated easily by hand.
viii a. For Spherical Roller Bearing Only

iv. Wipe the preservative from the bore of
Check the mounted internal clearance until
the bearing and then oil the surface lightly.
the required bearing internal clearance has
Use a thin mineral oil.
been achieved. See Chart C.
Step 4: Install outboard seal

(same as step 2).
Step 5: Lower half housing (base).

viii b. For Self-Aligning Ball Bearings Set lower halves of housings on base and
v. For Spherical Roller Bearing Only
Only lightly oil the bearing seats. SKF’s M5 style
Measure the unmounted internal radial
Then with a hammer, SAF housings have painted baseplanes.
clearance in the bearing by inserting pro-
drive the spanner Removal of this paint is not required prior to
gressively larger feeler blades the full length
wrench until the lock- installation.
of the roller between the most vertical
nut has been turned
unloaded roller and the outer sphere. See If grease is used as a lubricant, it should be
to the specified turn-
Chart B. applied before the upper half is secured.
ing angle indicated in
Smear grease between the rolling elements of
chart D.
the bearing and work in until 100% full. The
lower half of the housing should be packed
viii c. For CARB®
1/3 to 1/2 full. See chart E. For M5 style SAF
Consult SKF for the
housings, there is a cast line in the housing
axial Drive-up
base which can be used as a grease fill line (fill
method
to the bottom of the line). See fig. 1.
or refer to www.skf.com/mount.
Place the shaft with bearings into lower half
of the housing, carefully guiding seals into
the seal grooves. Be certain that the bear-
ings’ outer rings sit squarely in the pillow toroidal roller bearing (CARB®) units. In cases forced out and also between the housing
block bearing seats. when only one locating ring is used, move the bore and bearing outside diameter. This can
shaft axially so that the stabilizing ring can be pinch an outer ring or make a “free” bearing
Bolt the “held” housing securely in place (see
inserted between the bearing outer ring and actually “held”. The two dowel pins will align
step 6). The “free” bearing housing will be
housing shoulder on the locknut side of bear- the upper half of the housing to its mating
located and bolted to its mounting surface
ing, where practical. For bearings that will be base.
after properly positioning the bearing in the
free to float in the housing, generally center
“free” housing to ensure correct float. Note: If
the bearings in the housing seat.
NOTE: Caps and bases of pillow blocks are not
shimming is required, shims must cover the interchangeable. Each cap and base must be
full mounting surface of the pillow block. NOTE: There must be only one “held” bearing assembled with its original mating part. All
per shaft. One bearing should be “free” to SKF SAF and SAFS split pillow block housings
Fill with grease to bottom
of this cast line permit shaft expansion. Some pillow blocks are match marked with serialized identification
require two stabilizing rings, which must be on the cap and base to assist in assembling of
inserted to obtain a “held” assembly with the mating parts.
Lockwashers and cap bolts are then applied
bearing centered in the housing. Stabilizing
and tightened to complete the assembly to
rings enclosed in standard housings are
the proper tightening torque for the specific
intended for Spherical Roller Bearings or
cap bolts. See charts A1 and A2, and fig. 2.
CARB®. A different stabilizing ring is required
for Self Aligning Ball Bearings (purchased
separately). The rubber plug and plastic fitting in the cap
holes of M5 style SAF housings should be
Step 7: Upper half housing (cap). removed and discarded. Replace with appro-
The bearing seat in the upper half of the priate metallic plugs/fittings that are supplied
with each SKF M5 style SAF housing.
Fig. 1: Grease fill line
housing (cap) should be thoroughly cleaned,
Step 6: Stabilizing rings. lightly oiled and placed over the bearing. With
A stabilizing ring should be used if a spherical oil lubrication, use a sealing compound such
roller or self-aligning ball bearing is to be as Permatex 2 or equivalent at the split sur-
“Held” or “Fixed” (i.e. locating the shaft). The faces; apply sparingly. Wipe a thin film near
stabilizing ring should also be used for all the outer edges. Excessive amounts will be
Chart A1 - Tightening Torque for SAF “A” style and SAFS “N” style cap bolts Chart A2 - Tightening torque
for SAF M5 cap bolts. (see fig 2)
(see fig 2)
SAF (Cast Iron) SAFS (Cast Steel) Torque SAF FSAF SAF FSAF Cap bolt Torque
(ft-lbs) M5 M5 M5 M5 (no.) size ft-lbs
509 510 70 507 (2) 3/8-16 30

308 309 310 511 513 515 609 610 611 215 218 515 518 509 (2) 7/16-14 45
311 312 515 110 510 (2) 7/16-14 45
511 (2) 1/2-13 60
216 217 218 313 314 315 516 517 518 613 615 216 217 220 516 517 520 220 213 513 (2) 1/2-13 60
222 522
215 515 515 (2) 1/2-13 60
024 026 220 222 230 316 317 318 520 522 530 616 617 618 226 526
216 216 516 516 (2) 5/8-11 110
232 234 236 324 326 328 532 534 536 624 626 628 380
217 217 517 517 (2) 5/8-11 110
330 630
218 218 518 518 (2) 5/8-11 110
044 048 238 240 332 334 538 540 632 634 228 230 532 528 530 532 600
220 220 520 520 (2) 3/4-10 150
056 340 640 870
*222 *522 (2) 3/4-10 150
028 030 032 224 226 228 320 322 338 524 526 528 620 622 638 234 534 *224 *524 (2)1-8 295
034 052 244 544 900
*226 *526 (2)1-8 295
238 538 1280 *228 *528 (2)1-8 295
240 540 1820
236 244 536 544 2380
*4 BOLT BASE ONLY
Fig. 2 - Identification of Cap Bolt Grade
8.8
SKF 'A' STYLE SAF (IRON) SKF 'M5' STYLE SAF (IRON)
SKF SAFS (STEEL) ISO R898 CLASS 8.8
SAE J429 GRADE 8 CAP BOLTS ARE PAINTED BLUE
CAP BOLTS ARE BLACK IN COLOR (USE CHART A2 VALUES)
(USE CHART A1 VALUES)
Chart B - Unmounted radial internal clearance of SKF tapered Chart C - Recommended clearance reduction values for SKF
bore spherical roller bearings tapered bore spherical roller bearings
Bore Dia. Normal C3 C4 Bore Reduction in Radial Bore Reduction in Radial

d (mm) (in.) (in.) (in.) Diameter Internal Clearance Diameter Internal Clearance
d(mm) (in.) d(mm) (in.)
Over Incl. Min. Max. Min. Max. Min. Max.
Over Incl. Min. Max.(1) Over Incl. Min. Max.*
24 30 0.0012 0.0016 0.0016 0.0022 0.0022 0.0030
24 30 0.0006 0.0008 315 355 0.0060 0.0085
30 40 0.0014 0.0020 0.0020 0.0026 0.0026 0.0033
30 40 0.0008 0.0010 355 400 0.0065 0.0090
40 50 0.0018 0.0024 0.0024 0.0031 0.0031 0.0039
40 50 0.0010 0.0012 400 450 0.0080 0.0105
50 65 0.0022 0.0030 0.0030 0.0037 0.0037 0.0047
50 65 0.0012 0.0015 450 500 0.0085 0.0110
65 80 0.0028 0.0037 0,0037 0.0047 0.0047 0.0059
65 80 0.0015 0.0020 500 560 0.0095 0.0125
80 100 0.0031 0.0043 0.0043 0.0055 0.0055 0.0071
80 100 0.0018 0.0025 560 630 0.0100 0.0135
100 120 0.0039 0.0053 0.0053 0.0067 0.0067 0.0087
100 120 0.0020 0.0028 630 710 0.0120 0.0155
120 140 0.0047 0.0063 0.0063 0.0079 0.0079 0.0102
120 140 0.0025 0.0035 710 800 0.0135 0.0175
140 160 0.0051 0.0071 0.0071 0.0091 0.0091 0.0118
140 160 0.0030 0.0040 800 900 0.0145 0.0195
160 180 0.0055 0.0079 0.0079 0.0102 0.0102 0.0134
160 180 0.0030 0.0045 900 1000 0.0160 0.0215
180 200 0.0063 0.0087 0.0087 0.0114 0.0114 0.0146
180 200 0.0035 0.0050 1000 1120 0.0175 0.0235
200 225 0.0071 0.0098 0.0098 0.0126 0.0126 0.0161
200 225 0.0040 0.0055 1120 1250 0.0190 0.0255
225 250 0.0079 0.0106 0.0106 0.0138 0.0138 0.0177
225 250 0.0045 0.0060
250 280 0.0087 0.0118 0.0118 0.0154 0.0154 0.0193
250 280 0.0045 0.0065
280 315 0.0094 0.0130 0.0130 0.0169 0.0169 0.0213
280 315 0.0050 0.0075
315 355 0.0106 0.0142 0.0142 0.0185 0.0185 0.0232
355 400 0.0118 0.0157 0.0157 0.0205 0.0205 0.0256 *Caution: Do not use the maximum reduction of radial internal clearance when the initial unmounted radial
400 450 0.0130 0.0173 0.0173 0.0224 0.0224 0.0283 internal clearance is in the lower half of the tolerance range or where large temperature differentials between
450 500 0.0146 0.0193 0.0193 0.0248 0.0248 0.0311

the bearing rings can occur in operation (see chart B).
500 560 0.0161 0.0213 0.0213 0.0268 0.0268 0.0343

560 630 0.0181 0.0236 0.0236 0.0299 0.0299 0.0386
Chart D - Angular drive-up for self-aligning ball bearings
630 710 0.0201 0.0264 0.0264 0.0335 0.0335 0.0429
710 800 0.0224 0.0295 0.0295 0.0378 0.0378 0.0480 Bearing Bore Inch Nut Turning Bearing Bore Inch Nut Turning
800 900 0.0252 0.0331 0.0331 0.0421 0.0421 0.0539 Designation d Designation Angle a Designation d Designation Angle a
900 1000 0.0280 0.0366 0.0366 0.0469 0.0469 0.0598 (mm) (degrees) (mm) (degrees)
1000 1120 0.0303 0.0406 0.0406 0.0512 0.0512 0.0657 1205 K 25 N 05 100 2205 K 25 N 05 100
1120 1250 0.0327 0.0441 0.0441 0.0559 0.0559 0.0720 1206 K 30 N 06 55 2206 K 30 N 06 55
1207 K 35 N 07 75 2207 K 35 N 07 75
1208 K 40 N 08 75 2208 K 40 N 08 75
1209 K 45 N 09 80 2209 K 45 N 09 80
Chart E - Initial grease charge for SAF 1210 K 50 N 10 80 2210 K 50 N 10 80
pillow block assemblies 1211 K 55 N 11 100 2211 K 55 N 11 80
1212 K 60 N 12 100 2212 K 60 N 12 100
1213 K 65 N 13 100 2213 K 65 N 13 100
(see also step 5 for more information)
1214 K 70 N 14 100 2214 K 70 N 14 110

Initial Charge 1215 K 75 AN 15 75 2215 K 75 AN 15 75
SAF SAF SAF SAF SAF (oz) (lbs) 1216 K 80 AN 16 75 2216 K 80 AN 16 75
507 2.5 1217 K 85 AN 17 100 2217 K 85 AN 17 90
509 3.0 1218 K 90 AN 18 100 2218 K 90 AN 18 90
510 4.0 1219 K 95 AN 19 100 2219 K 95 AN 19 90
308 4.5 1220 K 100 AN 20 100 2220 K 100 AN 20 90
309 609 5.0 1221 K 105 AN 21 115 2221 K 105 AN 21 110
511 5.0 1222 K 110 AN 22 115 2222 K 110 AN 22 110
310 610 6.5 1224 K 120 AN 24 115
513 7.5
311 611 8.0
312
515 9.0
10.0 Chart F - Dia. tol. for adapter & cylindrical Chart G - SKF seal misalignment
216 313 516 613 13.0 bore mounted shaft extensions capabilities
217 517 13.0
314 14.0 Allowable
218 315 518 615 14.0 Nominal Dia. Dia. Tolerance Limits Designation Description misalignment
316 616 16.0 Inches Inches (deg.) 1)
317 617 20.0
220 520 024 21.0 Over Including S-1 S-2 & S-3 LER Labyrinth seal (SAF 507-513) 0.3
318 618 22.0 0.000 0.000 B-9784 Contact seal (SAF 507-513) 0.1 2)
1 2
222 522 026 28.0 –0.003 –0.003
224 320 524 620 028 40.0 0.000 0.000 LOR PosiTrac labyrinth seal 0.3
226 322 526 622 030 31⁄4 2 4
–0.004 –0.003
032 31⁄4 LOR + B 10724-xx PosiTrac Plus seal 0.3
0.000 0.000
228 528 034 31⁄4 4 6
–0.005 –0.003 TER Taconite seal w/contact seal 0.1 2)
230 324 530 624 33⁄4 0.000 0.000
232 326 532 626 036 41⁄4 6 10 TER-xx V Taconite seal w/ V-ring 0.5
038 41⁄4 –0.006 –0.004
0.000 0.000
234 328 534 628 040 51⁄4 10 15
–0.006 –0.005
1)
Values are approximate to cover a family of parts. For specific sizes,
236 330 536 630 6
consult SKF application engineering
238 332 538 632 044 71⁄4 0.000 0.000
15
2)
Optimum contact seal performance is obtained when shaft misalign-
240 334 540 634 048 81⁄2 –0.006 –0.006 ment and run-out are kept to a minimum
244 338 544 638 052 111⁄2

340 640 056 151⁄2
Note: S1 refers to the shaft tolerance for an adapter mounted bearing.
S2 and S3 refer to the shaft tolerance under the seal for a cylindrical
mounted bearing, not the bearing seat diameter
® SKF is a registered trademark of SKF USA Inc.
The contents of this publication are the copyright of the publisher and may not be reproduced (even extracts) unless prior written permission is granted.
Every care has been taken to ensure the accuracy of the information contained in this publication but no liability can be accepted for any loss or damage whether direct, indirect or consequential arising out of use of the
information contained herein.
© 2003 SKF USA Inc. Publication 640-810 (?M/?? 10/2005) Version 10/2005 Printed in U.S.A.
LOCKING ASSEMBLY
VERSION A , REV. 01
LOCKING ASSEMBLY
OVERVIEW
The following instructions and manufacturer’s literature provide guidelines for proper locking assembly
installation and maintenance. Although the literature may not be from the actual manufacturer of the
locking assembly used on this machine, the information presented is applicable. Thoroughly read and
understand all information regarding locking assemblies. In the event of conflicting information,
always use the guidelines providing the highest degree of protection/safety.
The basic function of a locking assembly is to secure a rotating component to a shaft. Many installations
may also include one or more keys as an added precaution against slippage. The locking assembly holds
the rotating component and any keys in place, and aids in the installation and removal of the rotating
component from the shaft.
SAFETY PRACTICES
LOCKING ASSEMBLY | 1
LOCKING ASSEMBLY
VERSION A , REV. 01
INSTALLATION

Before installing a rotating component, thoroughly clean the shaft O.D. and the bore I.D. Apply an anti-
seize compound, such as In-Sted-O-Lead or molybdenum-disulfide based grease to the shaft O.D. (only
in the area where the bore I.D. will contact the shaft). Prevent any anti-seize compound from contacting
the locking assembly, the counter-bore of the rotating component, or the shaft in the location of the
locking assembly. All anti-seize compound must be removed from these locking assembly mating
surfaces before installing the locking assembly. When using a key between the shaft and rotating
component, be sure there is adequate vertical and horizontal clearance to insure a slide fit. This will
allow the component to be more easily removed in the future.
When applying the anti-seize compound, do not to get any on the locking
assembly or its mating surface. These surfaces must be free from all
contaminants.
Refer to the “PARTS LIST AND ASSEMBLY” drawing(s), located in the DRAWINGS section of this
manual, for specific torque requirements for the locking assemblies used on this machine.
LOCKING ASSEMBLY | 2
INSTALLATION AND REMOVAL INSTRUCTIONS FOR INSTALLATION OF B-LOC LOCKING
B-LOC™ LOCKING ASSEMBLY SERIES B400 ASSEMBLIES OVER SHAFT KEYWAYS
Thank you for purchasing a B-LOC™ Keyless Frictional Locking Device. The Locking Assembly should be positioned so that slits in Locking Assembly
B-LOC™ keyless connectors provide a high capacity, zero-backlash collars that contact the shaft are located approximately opposite the keyway.
shaft/hub or coupling connection by means of a mechanical interference In addition, a locking screw should be centered directly over the keyway.
fit. Please follow these INSTALLATION AND REMOVAL INSTRUCTIONS
carefully to ensure proper performance of this B-LOC™ unit. When tightening locking screws, it is important to follow the installation
procedure outlined above, which specifies equal 1/4 turns of each locking
screw. Failure to follow these instructions could result in excessive tightening
EWARNING E of the screw over the keyway, possibly causing permanent deformation of the
Locking Assembly collars. Even after 1/4 turns can no longer be achieved, it
When installing or removing B-LOC™ products, always adhere to the following is important to continue to use equal turning angles for every screw until the
safety standards: specified tightening torque is reached.
1. Be sure that all power switches are locked out before installing or removing
B-LOC™ products. REMOVAL
2. Eye protection is required when installing or removing B-LOC™ products.
Please wear safety glasses and protective clothing.
INSTALLATION
(Refer to Figure 1)
B-LOC™ Locking Assemblies are supplied lightly oiled and ready for installation.
The frictional torque capacity of these devices is based on a coefficient of friction
of 0.12 for lightly oiled screw, taper, shaft and bore contact areas.
Therefore, it is important not to use Molybdenum Disulfide (e.g., Molykote,

Never-Seeze or similar lubricants) in any Locking Assembly installation.
1. Make sure that locking screw, taper, shaft and bore contact areas are
clean and lightly oiled.
Figure 2
(Refer to Figure 2)
Prior to initiating the following removal procedure, check to ensure that

no torque or thrust loads are acting on the Locking Assembly, shaft or
any mounted components.
1. Loosen locking screws in several stages by using approx. 1/4 turns, following
either a clockwise or counterclockwise sequence.
NOTE: B-LOC™ Series B400 Locking Assemblies feature self-releasing tapers,

meaning collars should release during Step 1. However, if for some reason
the thrust collars jam, a light tap on three (3) equally spaced heads of loosened
locking screws will positively release the connection.
2. Hub and Locking Assembly are normally removed together. Removal of

Figure 1 Cadmium plated screws Locking Assembly only from deep counterbores is accomplished by inserting
pull-off screws (not provided) into threads located under cadmium plated
locking screws. These threads are NOT to be used for high pulling forces,
as thrust collar is only partially threaded.
2. Insert Locking Assembly into hub counterbore prior to shaft installation.
LOCKING SCREW SIZES AND SPECIFIED
TIGHTENING TORQUE MA - B400 LOCKING ASSEMBLIES
3. After confirming correct hub position, hand-tighten three (3) or four (4) equally
spaced locking screws until initial contact with shaft and hub bore is established. MA S K dB
Metric Series Inch Series
ft-lb mm
4. Use torque wrench and set it approximately 5% higher than specified tightening
torque MA. Tighten locking screws in either a clockwise or counterclockwise 20 x 47 to 40 x 65 3/4 to 1-1/2 11 M 6 5 M 8
sequence (it is not necessary to tighten in a diametrically opposite pattern), using 42 x 75 to 65 x 95 1-5/8 to 2-9/16 26 M 8 6 M 10
only 1/4 (i.e., 90°) turns for several passes until 1/4 turns can no longer be achieved. 70 x 110 to 95 x 135 2-5/8 to 3-3/4 51 M 10 8 M 12
100 x 145 to 160 x 210 3-7/8 to 6 91 M 12 10 M 14
5. Continue to apply overtorque for 1 to 2 more passes. This is required to compensate 170 x 225 to 200 x 260 6-7/16 to 8 138 M 14 12 M 16
for a system-related relaxation of locking screws since tightening of a given screw 220 x 285 to 260 x 325 214 M 16 14 M 20
will always relax adjacent screws. Without overtorquing, an infinite number of 280 x 355 to 300 x 375 293 M 18 14 M 22
passes would be needed to reach specified tightening torque. 320 x 405 to 340 x 425 420 M 20 17 M 24
360 x 455 to 420 x 515 565 M 22 17 M 27
6. Reset torque wrench to specified torque (MA) and check all locking screws. No 440 x 545 to 1000 x 1110 725 M 24 19 M 30
screw should turn at this point, otherwise repeat Step 5 for 1 or 2 more passes. It
MA = Tightening Torque
is not necessary to re-check tightening torque after equipment has been in operation.
S = Screw Size
K = Hex Key Size
NOTE: In applications subject to extreme corrosion, the slits in all collars can be
SDS = Square Drive Size
sealed with a suitable caulking compound or equivalent.
dB = pull-off thread, located only under cadmium plated screws of front thrust collar
B-LOC Corporation 26 Gilbert Street Monroe, NY 10950 For technical assistance, please call 1-800-865-7756
WELDING
VERSION A , REV. 01
WELDING
OVERVIEW
The following welding instructions will assist with the building-up and hard-facing of crusher rolls.
Refer to the “PARTS LIST AND ASSEMBLY” drawing(s) to obtain the metallurgy that was used in
this particular application.
NOTE: The roll chemistry may have been changed from the original metallurgy due to a change in
application or to enhance performance. If there is any uncertainty as to the roll chemistry, contact the
Parts Department at McLANAHAN CORPORATION.
Welding of castings sometimes produces unpredictable results. There is no guarantee that any specific
weld overlay will perform better than any other because applications and welding conditions vary so
widely. The following recommendations are a result of extensive field and shop testing, and indicate the
procedures that have been the most effective.
SAFETY PRACTICES
MAINTENANCE SCHEDULE
 Rebuild the crusher teeth before the base metal wears.
 If the base metal is worn, use a welding rod designed for buildup of the base metal. Do not use
normal hard facing rods for more than 1/4" surface hard facing buildup.
NOTE: The best results are obtained when the hard facing is worn down just to the surface of the
base metal without any of the base metal being worn.
DO NOT allow wear to extend into the base metal of the casting.
WELDING | 1
WELDING
VERSION A , REV. 01
WELDING PREPARATION
Before performing any welding, clean all surfaces and remove any grease, oil, or surface dirt and scale.
Remove any existing weld hard-facing if it contains excessive surface cracks or if the weld surface is
work hardened. Grind or scarf any deep cracks and fill them with weld them before performing any
hard-facing.
NOTE: Normal, small cross checking cracks do not require repair. If there is any uncertainty as to
whether or not a crack requires repair, contact the Engineering Department at McLANAHAN
CORPORATION.

BASE MATERIALS
The following is a list of materials that are covered in this section of the manual:
1. CHILLED IRON
2. McALLOY STEEL
3. McL 400
4. 11% to 14% MANGANESE STEEL
5. 8637FB STEEL
6. HARDOX 400
WELDING MATERIAL
In many instances, a high quality rod with extended life is more cost effective than a lesser quality rod
with a shorter life. The information in this section pertaining to welding rod material is accurate at the
time of printing, but is subject to change due to the rapidly changing design and performance
characteristics of welding materials. Consequently, contact a local welding supplier to review the
application and roll metallurgy before welding.
WELDING | 2
WELDING
VERSION A , REV. 01
CHILLED IRON
CHEMISTRY: MATERIAL PERCENT

C 2.9 - 3.2
SI 1.5 - 1.7
MN 1.0 Maximum
P 1.0 Maximum
S .25 Maximum
CR Less than 0.10
NI Less than 0.10
HARDNESS: 500 BHN
PREHEAT: Preheat when temperature is below 50o F to a maximum of 150o F.
APPLICATION: When welding a large area, use a “skipping” pattern to help eliminate the
build-up of heat in a concentrated area. (Skipping refers to the welding in
one area then moving to another location.) Use a maximum of 1/4" build-
up. If more than 1/4" is needed, contact the welding supplier to
recommend a specific build-up rod.
Keep heat to a minimum in the part being welded or cracks could result.
WELDING | 3
WELDING
VERSION A , REV. 01
MCALLOY STEEL

C 0.48 - 0.52
SI 0.30 - 0.40
MN 0.60 - 0.90
MO 0.30 - 0.50
CR 0.20 Maximum
NI 0.28 - 0.32
HARDNESS: PLUS 250 BHN
PREHEAT: MINIMUM 475o F.
WELDING | 4
WELDING
VERSION A , REV. 01
MCL 400

C 0.20 - 0.29
SI 0.20 - 0.40
MN 0.80 - 01.20
MO 0.25 - 0.50
P .015 Maximum
S .015 Maximum
CR 1.25 - 2.00
NI 3.25 - 4.00
HARDNESS: PLUS 400 BHN
PREHEAT: 400o F (Maintain body of roll to 200o F to allow for a slow cooling.)
WELDING | 5
WELDING
VERSION A , REV. 01
11% - 14% MANGANESE STEEL

C 1.22
SI 0.33
MN 13.08
CR 0.09
AL 0.05
HARDNESS: 475 BHN (After work hardening)
PREHEAT: Preheat when temperature is below 50o F to a maximum of 150o F.
WELDING | 6
WELDING
VERSION A , REV. 01
8637FB STEEL
CHEMISTRY: MATERIAL PERCENTAGE

C 0.35 - 0.40
CR 0.40 - 0.60
MN 0.75 - 1.00
MO 0.15 - 0.25
NI 0.40 - 0.70
P 0.035 Maximum
S 0.040 Maximum
SI 0.15 - 0.30
HARDNESS: 363 - 415 BHN
PREHEAT: 250o F
Bore is Induction Hardened to 514 BHN, therefore DO NOT preheat above

250oF. Preheating above 250oF may reduce the induction hardness.
WELDING | 7
WELDING
VERSION A , REV. 01
HARDOX 400

C 0.20 Maximum
SI 0.10 - 0.70
MN 1.70 Maximum
P 0.025 Maximum
S 0.010 Maximum
CR 0.80 Maximum
MO 0.80 Maximum
NI 1.00 Maximum
B 0.005 Maximum
HARDNESS: 360-440 BHN
PREHEAT: Preheat when welding on Hardox 400 steel over 1 ½” thick as follows:
1 5/8” – 2 ½” 170 F
2 ½” – 4” 220 F
4” – 5 1/8” 350 F
Maximum Interpass Temperature: 300 F -350 F
WELDING | 8
LUBRICATION
VERSION A., REV. 07
LUBRICATION
OVERVIEW
Lubrication is vital to equipment operation. Many component failures are directly traceable to factors such as
contaminated lubricant, improper lubricant, and/or improper lubricant quantity. Follow these fundamental steps
to help prevent certain component failures:
Seal all grease and oil storage containers to prevent dust, grit, and moisture contamination.
Thoroughly clean all grease and oil lines before installation.
Wipe all fittings with a clean rag before lubricating to prevent forcing any contaminants into the
component.
Establish a regular lubrication schedule and follow it faithfully.
NOTE: If utilizing an automatic lubrication system, provide sufficient safeguards to prevent any loss of
lubricant to the machine. Incorporate warning devices (horns, bells, blinking lights, etc.) to signal a loss of
lubricant flow, or have the machine shut down during a lubrication failure. Additionally, always include a
regular visual inspection of the equipment, regardless of the number of mechanical safeguards present.
Refer to the following charts to assist in obtaining the proper lubricant and for developing appropriate
lubrication schedules for this particular piece of equipment. The listed lubricants are typical products only and
are not exclusive recommendations. Additionally, the enclosed lubrication schedule is for reference purposes
only and is to be used as a ‘minimum’ guideline when developing the schedule for a specific machine. Include
additional procedures and/or shorten inspection frequencies, as warranted by this machine’s specific operating
conditions.
Verify that all personnel are clear of any/all moving or rotating parts (or parts
that are subject to movement or rotation) before installing, operating or servicing
this equipment or any portion thereof.

LUBRICATION 1
LUBRICATION
VERSION A., REV. 07
SAFETY PRACTICES
The following guidelines are considered minimum for the safe operation of this equipment. No guidelines or
any amount of safety equipment, however, can guarantee safety. An alert, safety-conscious operator, properly
trained on the equipment and familiar with the location and function of all safety devices, is the key to safe
operation of any machine. Refer to the SAFETY PRECAUTIONS section of this manual before installing,
operating or maintaining this equipment.
 Verify that all guards and safety devices are in place and that all personnel are clear of any/all parts
prone to movement or rotation.
NOTICE
Consult your local lubricant supplier for any special conditions such as extreme ambient temperatures.
Certain components (motor, reducer, coupling, hydraulics, etc.) may have additional lubrication
information presented throughout this manual. Refer to each component’s section for more detailed
information regarding lubrication. In the event of conflicting information, always use the guidelines
providing the highest degree of protection/safety.
LUBRICATION 2
LUBRICATION
VERSION A., REV. 07
BEARING/SEAL LUBRICANT QUANTITIES

(CUBIC INCHES OF LUBRICANT REQUIRED TO PURGE BEARINGS/SEALS
AT EACH 8 HOUR LUBRICATION INTERVAL) 1
SHAFT ROLLER BRG. BRASS BRG. JOURNAL BRG. 3

DIAMETER 2 LUB. QTY. LUB. QTY. /SEAL LUB. QTY.
1-1/4” 0.49 0.03
2-3/16” 0.86 0.90 0.06
2-7/16” 0.96 1.12 0.06
2-7/8” 1.13 1.56 0.07
2-15/16” 1.15 1.63 0.07
3-7/16” 1.35 2.23 0.09
3-3/4” 1.47 2.65 0.09
3-15/16” 1.55 2.92 0.10
4-3/16” 1.64 3.31 0.10
4-7/16” 1.74 3.71 0.11
4-7/8” 1.92 4.48 0.12
4-15/16” 1.94 4.60 0.12
5-7/16” 2.14 5.58 0.14
5-15/16” 2.33 6.65 0.15
6” 2.36 6.79 0.15
6-7/16” 2.53 7.82 0.16
6-1/2” 2.55 7.97 0.16
LUBRICATION 3
LUBRICATION
VERSION A., REV. 07
7” 2.75 9.24 0.17
8” 3.14 12.07 0.20
8-15/16” 3.51 13.49 0.22
9” 3.54 13.58 0.22
9-3/8” 3.68 14.15 0.23
9-7/16” 3.71 14.24 0.23
10-7/16” 4.10 15.75 0.26
11” 4.32 16.60 0.27
280mm 4.33 16.64 0.27
12” 4.71 18.10 0.30
12-7/16” 4.89 18.76 0.31
320mm 4.95 19.01 0.31
13” 5.11 19.61 0.32
13-7/16” 5.28 20.27 0.33
14” 5.50 21.12 0.35
15” 5.89 0.37
450mm 6.96 0.44
1 The volume (cu. in.) per stroke of your grease gun must be known to appropriately lubricate bearings/seals. (If this information is not known, it can be determined
by pumping grease into a small container of known volume and counting the number of strokes required to fill the container.)
Over-greasing can cause excessive bearing temperatures, premature lubricant breakdown,

and bearing failure. Always be sure not to over grease.
2 If the shaft diameter is unknown and cannot be easily measured, refer to the “PARTS LIST AND ASSEMBLY” drawing.
3 For purposes of this chart, journal bearings are defined as sleeve bearings where the rotating member does not make complete revolutions. (Ex.; Toggle pins,
thehinge shafts, torsion shafts, etc.)
LUBRICATION 4
LUBRICATION
VERSION A., REV. 07
LUBRICANT CROSS-REFERENCE (CHART-A)

NOTE: LISTED PRODUCTS AND SPECIFICATIONS ARE TYPICAL BUT ARE NOT NECESSARILY EXCLUSIVE.
LUBRICANT REF. NO. 1** 2 3* 4 5 6

ENCLOSED HYDRAULIC HYDRAULIC
GREASE GREASE OPEN GEAR
DESCRIPTION SPUR GEAR SYSTEM SYSTEM
LUBRICANT LUBRICANT LUBRICANT
LUBRICANT FLUID FLUID
BP AW BP AW
BP ENERGREASE ENERGREASE ENERGOL GR-
N/A HYDRAULIC HYDRAULIC
LUBRICANTS LS-EP #1 LS-EP #2 XP ISO 220
32 46
HULLITH HULLITH HULBEST CENTAK CENTRAULIC CENTRAULIC
CENTURY LUBRICANTS CO.
EP-1 EP-2 220 11 W AW 32 AW 46
GEAR OPEN GEAR HYDRAULIC HYDRAULIC
DURA-LITH DURA-LITH
CHEVERON COMPOUND LUBRICANT OIL AW MV OIL
EP-1 EP-2
P ISO 220 MS ISO 30 AW 46
CITGO PREM. CITGO PREM. CITGO EP CITGO A/W CITGO A/W
CITGO LITHIUM LITHIUM COMPOUNDS N/A HYDRAULIC HYDRAULIC
GREASE #1 GREASE #2 220 32 46
EP 5 GEAR
CASTROL PYROPLEX PYROPLEX DUAL RANGE PARADENE
LUBRICANT N/A
HEAVY DUTY BLUE #1 BLUE #2 HV 32 AW 46
ISO 220
UNIREX LIDOK SPARTON UNIVIS NUTO
ESSO GEARGARD
EP-1 EP-2 EP-220 N 32 H 46
SPARTAN UNIVIS NUTO
EXXON N/A N/A N/A
EP-220 N 32 H 46
MOBILUX MOBILUX MOBILGEAR MOBILTAC MOBIL MOBIL
MOBIL
EP-1 EP-2 630 375 NC D.T.E. 13 M D.T.E. 25
GADUS S2 GADUS S2
OMALA S2 CARDIUM TELLUS S2 M TELLUS S2 M
SHELL OIL V220 V220
220 FLUID EP OIL 32 OIL 46
EP-1 EP-2
MUTIFAK MUTIFAK MEROPA RANDO OIL RANDO OIL
TEXACO CRATER 0
EP-1 EP-2 LUBE 220 HD 32 HD 46
EX. DUTY NL
UNOBA UNOBA GEARSHIELD UNAX UNAX
UNOCAL GEARLUBE
EP-1 EP-2 HVY AW 32 AW 46
SEP
ISO GRADE 220 32 46
AGMA GRADE “AGMA 250.04” SEP
NLGI GRADE 1 2 0
VISCOSITY SUS @ 100 F 500-1000 500-1000 918-1122 136-165 193-235
(SAYBOLT)
“ASTM D-445” SUS @ 210 F 100
VISCOSITY cSt @ 40 F 198-242 29-35 41-51
(KINEMATIC)
“ASTM D-88” cSt @ 100 C
VISCOSITY INDEX “ASTM D2270” 95 95 95
MAX. POUR POINT “ASTM D-97” 0 F, -18 C 32 F, 0 C 10 F, -12 C 10 F, -12 C
DENSION HF-0, HF-2 PUMP TEST PASS PASS
RUST TEST “ASTM D-1743” PASS PASS
CORROSION TEST “ASTM D-4048” PASS PASS
TIMKEN OK LOAD “ASTM D-2509” 45 LB, 20.4 KG 45 LB, 20.4 KG 60 LB, 27.2 KG 45 LB, 20.4 KG
FZG TEST….MIN. STAGES PASSED 12
DROPPING POINT “ASTM D-566” 360 F 365 F
FLASH POINT “ASTM D-92” 410 F 500 F 400 F 400 F
* FOR WET CONDITIONS, USE AN EMULSIFYING GEAR OIL TO SUSPEND WATER CONTAMINANTS (MODIFIED ASTM D-1401).
** WHEN UTILIZING AN AUTOMATIC GREASE LUBRICATION SYSTEM BELOW THE AMBIENT TEMPERATURE OF 20° F (-6° C) USE EP000 LUBRICANTS.
LUBRICATION 5
LUBRICATION
VERSION A., REV. 07
LUBRICANT CROSS-REFERENCE (CHART-B)

NOTE: LISTED PRODUCTS AND SPECIFICATIONS ARE TYPICAL BUT ARE NOT NECESSARILY EXCLUSIVE.
LUBRICANT REF. NO. 7 8 9 10 11 12
GEAR GEAR GEAR GEAR HYDRAULIC
AIR LINE
DESCRIPTION REDUCER REDUCER REDUCER REDUCER SYSTEM
LUBRICANT
LUBRICANT LUBRICANT LUBRICANT LUBRICANT FLUID
ENERGEAR
BP TURBINOL T TURBINOL T TURBINOL T TURBINOL T AW
HYPO-U
LUBRICANTS ISO 32 ISO 68 ISO 150 ISO 320 68
85W-140
MULTI-PURP.
NFO CENTRAULIC CRNTRAULIC AW
CENTURY LUBRICANTS CO. GEARLUBE
10W/NR R&O 68 AW 150 68
85W-140
RPM UNIV.
TURBINE OIL TURBINE OIL TURBINE OIL MACHINE OIL AW
CHEVERON GEARLUBE
CST 32 OC 68 OC 150 R&O 280 68
85W-140
CITGO CITGO PREM. CITGO CITGO
PACEMAKER AW
CITGO PACEMAKER GEAR OIL PACEMAKER PACEMAKER
320 68
32 85W-140 68 150
ALL PURP.
GASTROL PARADENE PARADENE PARADENE PARADENE AW
GEARLUBE
HEAVY DUTY R&O 32 R&O 68 AW 150 R&O 320 68
85W-140
TERESSO GEAR OIL TERESSO TERESSTIC TERESSTIC NUTO
ESSO
32 GX 85W-140 68 150 320 H 68
TERESSTIC TERESSTIC TERESSTIC TERESSTIC NUTO
EXXON N/A
32 68 150 320 H 68
D.T.E. MOBILUBE D.T.E. HEAVY D.T.E. EXTRA D.T.E. MOBIL
MOBIL
OIL LIGHT HD+ 85W-140 MED. HEAVY OIL AA DTE 26
SPIRAX
TELLUS TELLUS
SHELL OIL TURBO 32 HD GO TURBO 320
OIL 68 OIL 150
85W-140
MULTIGEAR
REGAL OIL REGAL OIL REGAL OIL REGAL OIL
TEXACO LUBE EP
R&O 32 R&O 68 R&O 150 R&O 320
85W-140
MP
UNAX UNAX UNAX TURBINE OIL
UNOCAL GEARLUBE
RX 32 AW 68 AW 150 320
LS 85W-140
ISO GRADE 32 68 150 320 68
AGMA GRADE “AGMA 250.04” 2EP 4EP 6EP
NLGI GRADE
VISCOSITY SUS @ 100 F 136-165 284-347 626-765 1790 356
(SAYBOLT)
“ASTM D-445” SUS @ 210 F 115 55
VISCOSITY CST @ 40 F 29-35 61-75 135-165 320 68
(KINEMATIC)
“ASTM D-88” CST @ 100 C 24-41 23.1 8.5
VISCOSITY INDEX “ASTM D2270” 95 95 95 95 90 95
MAX. POUR POINT “ASTM D-97” 0 F, -18 C 0 F, -18 C
DENSION HF-0, HF-2 PUMP TEST PASS PASS PASS PASS PASS
RUST TEST “ASTM D-1743” PASS
CORROSION TEST “ASTM D-4048”
TIMKEN OK LOAD “ASTM D-2509” 60 LB, 27.2 KG
FZG TEST….MIN. STAGES PASSED
DROPPING POINT “ASTM D-566”
FLASH POINT “ASTM D-92” 385 F 360 F 430 F 500 F 495 F 400 F
LUBRICATION 6
TRIPLE ROLL CRUSHER
LUBRICATION CHART
VERSION A, REV. 00
LUBRICATION CHART – TRIPLE ROLL CRUSHER
LUBRICATION CHART FOR TRIPLE ROLL CRUSHERS
LUBRICANT NO.
(See Lub. Cross-Ref. Sheet) LUBRICATION LUBRICATION LUBRICATION MAINTENANCE MAINTENANCE
MACHINE COMPONENT METHOD FREQUENCY QUANTITY PROCEDURE FREQUENCY
< 32°F > 32°F
(0°C) (0°C)
REFER TO
ROLL SHAFT ROLLER *HAND ‘LUBRICANT
1 2 LUBRICATED
*8 HOURS
QUANTITIES’
BEARINGS
CHART
REFER TO
CRUSHING PLATE HINGED *HAND ‘LUBRICANT
1 2 *8 HOURS
SHAFT BEARINGS LUBRICATED QUANTITIES’
CHART
REFER TO
*HAND ‘LUBRICANT
TORSION SHAFT 1 2
LUBRICATED
*8 HOURS
QUANTITIES’
CHART
*HAND
TOGGLE MECHANISM 1 2 LUBRICATED
*8 HOURS 0.10 CU. IN.
REFER TO
AUX. BEARING SEALS *HAND ‘LUBRICANT
1 2 *8 HOURS
(IF FURNISHED) LUBRICATED QUANTITIES’
CHART
REFER TO
HOPPER SEALS *HAND ‘LUBRICANT
1 2 LUBRICATED
*8 HOURS
QUANTITIES’
(IF FURNISHED)
CHART
TURNBUCKLE *HAND
1 2 LUBRICATED
200 HOURS 0.10 CU. IN.
(IF FURNISHED)
HYDRAULIC CYLINDER INSPECT PRIOR MAINTAIN OIL

5 6 HAND FILLED
TO USE LEVEL
(IF FURNISHED)
ENCLOSED SPUR GEARS CONTIUOUS OIL MAINTAIN OIL

3 3 BATH
8 HOURS INSPECT
LEVEL
CHANGE OIL 2000 HOURS
(IF FURNISHED)
NOTE: Certain components (motor, reducer, coupling, hydraulics, etc.) may have additional lubrication
information presented throughout this manual. Refer to each component’s section for more detailed
information regarding lubrication. In the event of conflicting information, always use the guidelines
providing the highest degree of protection/safety.
LUBRICATION CHART – TRIPLE ROLL CRUSHER | 1

UV DIVIDER VALVES
SERIES "B"
A PENTAIR COMPANY
SPECIFICATIONS:
Max. Operating Seal Lube Lube Indicator Mounting Screw Tie Rod
Pressure Material Inlet Outlets Ports Torque Nut Torque
3500 PSI Nitrile 1/4-18 NPSF 1/8-27 NPSF 1/8-27 NPSF 80-100 in.-lbs. 80-100 in.-lbs.
These divider valves are a component must be plugged. Use 68645 pipe plug.
part of a single line, progressive An 882000 By-Pass Block can be
lubrication system and can be used for used on any position on the base plate,
dispensing oil or grease. UV valves as long as there are at least three other
and baseplate segments are supplied working divider valves on the
with nitrile seals, however fluorocarbon baseplate. The bypass block allows
elastomer (Viton) seals are available. the addition or deletion of lubrication
Refer to the Modular Lube Planning points without disturbing existing piping.
Manual for system design information Both baseplate outlets under the
and an in-depth explaination of bypass block must be plugged.
operation. An in-line filter should be The valve blocks and bypass blocks
installed between the pump and divider are fastened to a baseplate mounted on
valves. Check valves should be the machine to be lubricated. The
installed at the inlets of all bearing baseplate contains the divider valve's
points. Refer to Service Manual Section inlet and outlet connections, interrelated
M50 Page 1 for check valve information. passageways, and built-in check
Valve blocks containing metering valves. All piping of lubricant to and
pistons discharge a predetermined from the divider valves is connected to
amount of lubricant with each cycle. the baseplate.
Description: Valve blocks will have either single or The baseplate consists of one inlet
UV Divider Valves are comprised of twin outlets and may be crossported block, three to eight intermediate blocks,
three to eight valve blocks fastened to a using Model 87944, 87945 or 87946 one end block, and a set of three tie
segmented base plate with O-ring seals Crossport Plate. Whenever a single rods and nuts. O-ring seals are
between the valve blocks and the outlet divider valve or crossport plate is installed into the intermediate and end
baseplate and the baseplate segments. used, the unused baseplate outlet(s) blocks. The valve block capacity of
UV VALVE BLOCKS
Divider Cycle indicator pin (right)
Single (1 outlet) Twin (2 outlet)
Valve Single Twin
Discharge/Outlet Discharge/Outlet
Stamping Single Twin
UV-5 882051 882052 - - .010 CU. IN. .005 CU. IN.

UV-10 882101 882102 - - .020 CU. IN. .010 CU. IN.
UV-15 882151 882152 - - .030 CU. IN. .015 CU. IN.
UV-20 882201 882202 882203 882204 .040 CU. IN. .020 CU. IN.
UV-25 882251 882252 882253 882254 .050 CU. IN. .025 CU. IN.
UV-30 882301 882302 882303 882304 .060 CU. IN. .030 CU. IN.
UV-35 882351 882352 882353 882354 .070 CU. IN. .035 CU. IN.
UV-40 882401 882402 882403 882404 .080 CU. IN. .040 CU. IN.
UV BASEPLATES **ALTERNATE THREAD CONFIGURATION

Inlet Intermediate End T ie
Outlets
B lock** B lo c k s * * B locks Rod Kit* Model No. Blocks Thread Size
2 to 6 87918 [3] 87919 87920 250290

2 to 8 87918 [4] 87919 87920 250291 87950 Intermediate 7/16 - 20 SAE
2 to 10 87918 [5] 87919 87920 250292 89951 Intermediate 1/8 - 28 BSPP
2 to 12 87918 [6] 87919 87920 250293 87952 Inlet 7/16 - 20 SAE
2 to 14 87918 [7] 87919 87920 250294 87953 Inlet 1/4 - 19 BSPP
2 to 16 87918 [8] 87919 87920 250295
* Kit consists of 3 rods and 3 nuts
One Lincoln Way

St. Louis, Missouri 63120-1578
Copyright 1999
Printed in U.S.A.
Section -M50
A PENTAIR COMPANY
(314) 679-4200
Page -14A
APRIL-99 FORM 422365
Page - 1
each baseplate is dependent upon the by disassembling the valve, reversing Operation:
number of intermediate blocks in the the piston in the valve bore, and The inlet passageway is connected to
baseplate assembly. There must be a reassembling by installing the indicator all piston chambers at all times with only
minimum of three working divider valves assembly on the left side of the valve. one piston free to move at any one time.
on each valve and baseplate assembly. With all pistons at the far right, lubricant
from the inlet flows against the right end
Cycle Indicator Pin Option: Assembly Instructions: of piston 1 (see illustration 1).
Optional cycle indicator pins provide 1. Screw three tie rods into inlet block Lubricant flow shifts piston 1 from
positive indication of system operation. until they bottom out in hole. right to left dispensing piston 1 output
The indicator pin is an extension of the 2. Check each intermediate block to through connecting passages to outlet 1.
piston in the valve block and will cycle in insure there are 9 O-rings securely Piston 1 shift directs flow against the
and out as the piston moves. installed in one face of each right side of piston 2 (see illustration 2).
Divider valves with cycle indicator intermediate block. Lubricant flow shifts piston 2 from
pins are supplied by the factory with the 3. Slide intermediate blocks onto the tie right to left dispensing piston 2 output
indicator assemblies on the right hand rods until the last intermediate block through valve ports of piston 1 and
side of the valve. If a left hand valve is is in place. Face of intermediate through outlet 2. Piston 2 shift directs
required, the valves may be converted block containing O-rings must be lubricant flow against the right side of
installed facing the inlet block end of piston 3 (See illustration 3).
the assembly. Lubricant flow shifts piston 3 from
4. Check end block to insure that there right to left dispensing piston 3 output
are 9 O-rings securely installed in through valve ports of piston 2 and
one face of the end block. through outlet 3. Piston 3 shift directs
5. Slide the end block, with O-ring face lubricant flow through connecting
adjacent to the last intermediate passage to the left side of piston 1 (See
block, over the tie rods. illustration 4).
6. Lay the baseplate assembly on a flat Lubricant flow against the left side of
surface. Install the three 1/4-28 lock piston begins the second half-cycle
nuts at the end block end of the which shifts pistons from left to right
250286 dispensing lubricant through outlets 4, 5
assembly. Torque the nuts to 80-100
Optional Mounting Bracket in. lbs. and 6 of the divider valve.
installation.
INLET INLET
OUTLET OUTLET OUTLET OUTLET

4 1 4 1

2 5 2 5

3 6 3 6
ILLUSTRATION 1 ILLUSTRATION 3
INLET INLET

4 1 4 1

2 5 2 5

3 6 3 6
ILLUSTRATION 2 ILLUSTRATION 4
Page - 2
7 2
3
4
4
1 5
SECTION A-A
6
CYCLE INDICATOR ASS'Y.
DIVIDER VALVE ASSEMBLY (Only divider valves which have cycle
indicator pins installed)
1
SECTION B-B
B B
BY-PASS BLOCK ASS'Y
882000
SERVICE PARTS
ITEM PK G. PA R T
D ESC R IPTION
N O. QUA N . N O.
1 O-R i ng (N i tri l e) 20 250309

1A O-R i ng (Vi ton) 20 250310
2 Al ternate Outl et Pl ug Assembl y (N i tri l e) 1 250377
2A Al ternate Outl et Pl ug Assembl y (Vi ton) 1 250371
3 Socket H d. C ap Screw (1/4-28 X 1 1/4") 1 250333
4 O-R i ng (N i tri l e) 10 250318
4A O-R i ng (Vi ton) 10 250319
5 End Por t Pl ug Ass’y. (N i tri l e) 1 250378
BASE PLATE ASSEMBLY 5A
6
End Por t Pl ug Ass’y. (Vi ton)
C ycl e Indi cator Ass’y. (N i tri l e)
1
1
250208
250379
6A C ycl e Indi cator Ass’y. (Vi ton) 1 250207
7 O-R i ng (N i tri l e) 10 250372
7A O-R i ng (Vi ton) 10 250373
Page - 3
DIMENSIONS ACCESSORIES
4x ø9/32" Mounting Holes
CROSS PORTING PLATES
2 1/4"
3" 1 1/8"
13/16" 1/4-18
1 3/4" NPTF
9/64"
5/8" 1/2"
Max.
D es c r i p t i o n Mo d el Nu m b er
1/2"
1 13/64" Cross Por t Right 87944
Cross Por t Left 87945
Cross Por t Both 87946
59/64"
TYP 9/16"
1 1/8"
A B
DISC 1/8-27 NPTF
1/8-27 NPTF
Lube Outlet
ATMOSPHERIC INDICATORS
1/2" Max.
Model No Pressure Repl. Disk* Color
87934 1450 PSI P/N 69813-10 Yellow

87935 1750 PSI P/N 69813-12 Red
Ou t let s A B 87936 3250 PSI P/N 250312 Purple
87937 3700 PSI P/N 250313 Yellow/Natural
2 to 6 3.58 4.56 *Packaged in quantities of 10
9/16"
2 to 8 4.50 5.48 1 5/8" 1/8-27 NPTF
2 to 10 5.42 6.40 DISK
2 to 12 6.34 7.33
2 to 14 7.27 8.25
2 to 16 8.19 9.17
PIN INDICATORS
TYPICAL ACCESSORY INSTALLATION Model No Pressure Repl. Disk* Color
87930 1450 PSI P/N 69813-10 Yellow

87931 1750 PSI P/N 69813-12 Red
INDICATOR
87932 2650 PSI P/N 250311 Pink
87933 3250 PSI P/N 250312 Purple
*Packaged in quantities of 10
1/2" 2 1/4"
BY-PASS 1/8-27 NPTF
BLOCK
RESET INDICATORS
Model No Pressure Inlet
Crossport Plate
87938 500 PSI 1/8-27 NPTF
87939 1000 PSI 1/8-27 NPTF
87940 1500 PSI 1/8-27 NPTF
87941 2000 PSI 1/8-27 NPTF
87942 3000 PSI 1/8-27 NPTF
RETAIN THIS INFORMATION FOR FUTURE REFERENCE

When ordering replacement parts, list: Part Number, Description, Model Number, and Series Letter.
LINCOLN provides a Distributor Network that stocks equipment and replacement parts.
Page - 4
Owner Manual
Technical Description / User Manual
2.1A-30002-C03
QUICKLUB®
Pump Model 203 with power supply for 110-240 VAC
without and with printed circuit board V10-V13
10011327
Suject to modifications
810-55233-1
LINCOLN GmbH & Co. KG • Postfach 1263 • D-69183 Walldorf • Tel +49 (6227) 33-0 • Fax +49 (6227) 33-259
Owner Manual
2.1A-30002-C03
Fields of Applications of the QUICKLUB Progressive Central Lubrication Pumps
Industry - Machines Pump Type
Pump: QUICKLUB 203 mit integriertem Netzteil

2) 2) 3) 1)
Behälter: 2 l -2XN ,2XNFL , 2YN , 2XNBO ,
3)
2YNBO
1) 3)
4 l -4XNBO , 4YNBO
1) 3)
8 l - 8XNBO , 8YNBO
1)
Filling from the top or bottom
2)
Filling only from the bottom
3)
Filling only from the top
Low Level Control: (option) for all reservoir sizes available,

on request (except for flat-type reservoir)
Control: without control unit

4)
with control unit V10 to V13
4)
See the respective model designation on the pump nameplate e.g. P203-2XN-1K6-AC-1A1.01- V10
Further information can be found in the following manuals:

Technical Description Progressive Metering Devices for Grease and Oil, model SSV, SSV M and SSV D
Installation Instructions
Parts Catalogue
Parts Catalogue Pump 103 and 203
All rights reserved.

Any duplication of this Owner Manual, in its entirety or in part,
by whatever means is prohibited without the prior consent in
writing of Lincoln GmbH & CO. KG.
Subject to modifications without prior notification.
© 2003 by
LINCOLN GmbH & Co. KG
Postfach 1263 Phone: +49 (6227) 33-0
D-69183 Walldorf Fax: +49 (6227) 33-259
Page 2 of 40
Owner Manual
2.1A-30002-C03
Table of Content
Page Page
Fields of Application ....................................................... 2 Printed Circuit Boards V10-V13 (V20-V23).................... 18

Fields of Application ......................................................... 18
Introduction ..................................................................... 4 Installation position of the printed circuit board (p.c.b.) .... 18
Explanation of Symbols Used ............................................ 4 Start Up ............................................................................ 19
user´s Responsibility ......................................................... 4 Mode of Operation ........................................................... 19
Environmental Protection .................................................. 4 Pause time ................................................................. 19
Service .............................................................................. 4 Operating time ............................................................. 20
Time storage .............................................................. 20
Safety Instructions .......................................................... 5 Time Setting ..................................................................... 20
Appropriate Use ................................................................ 5 Factory Setting ........................................................... 20
Misuse ............................................................................... 5 Setting Pause time ..................................................... 21
Gereral Safety Instructions ................................................ 5 Setting Operating time ................................................ 21
Regulations for Prevention of Accidents ............................ 5 Functional Check and Fault Indication ............................. 22
Installation ......................................................................... 5 Operational Test / To Trigger
Operation, Repair and Maintenance .................................. 6 an Additional Lubrication Cycle .................................. 22
Disposal ............................................................................. 6 Signal Output .............................................................. 22
Exclusion of Liability .......................................................... 6 To Remedy to a Fault ...................................................... 22
Pump Types ..................................................................... 7 Maintenance ................................................................... 23

Pump Filling ...................................................................... 23
Identification Code – Pump Models 203 ........................ 8 Repair .............................................................................. 24
Pump .......................................................................... 24
Description ....................................................................... 9 Replace pump element ............................................... 24
Electric connections for pump 203 .................................... 9 Printed Circuit Boards ................................................ 24
The QUICKLUB 203 central lubrication pump ................. 10 Tests ................................................................................ 25
Low Level Control ...................................................... 10 Operational Test / To Trigger
an Additional Lubrication Cycle .................................. 25
Mode of operation ......................................................... 11 To Check the pressure relief valve ............................. 25
Pump Elements with fixed Lubrication output .................. 11 Functional Check of the p.c.b. .................................... 25
Check valve ............................................................... 12
Arrangement of the pump elements ........................... 12 Troubleshooting ............................................................. 26
Pump Elements with adjustable Lubrication output ......... 12
Setting of adjustable pump elements ......................... 13 Technical Data ................................................................ 27
Retrofit adjustment of max. lubricant output................ 13 Electrical Data .................................................................. 28
Pressure relief valve ........................................................ 14 Possible Connecting and Control Types .......................... 29
without grease return ................................................. 14 Connection Diagram ........................................................ 30
with grease return ...................................................... 14 without p.c.b. .............................................................. 30
Return Line Connection ................................................... 15 V10-V13 ..................................................................... 30
Low Level Control (optional) Terminals of the p.c.b. ..................................................... 31
- for grease ................................................................ 16 Attaching Boreholes of the 2l-, 4l- and 8l- pump .............. 31
Reservoir filled ........................................................... 16 Dimensions ...................................................................... 32
Reservoir empty ......................................................... 16
Magnetic switch ......................................................... 16 Lubricants ....................................................................... 37
Float magnetic switch ................................................ 17
- for Oil ....................................................................... 17 Declaration of the Manufacturer ................................... 39
Contact protection measures ........................................... 17
Keep this user information always at hand

at the place of work of the pump!
Page 3 of 40
Owner Manual
2.1A-30002-C03
Introduction
Explanation of Symbols Used

The following description standards are used in this manual: Furthermore, you will find the following text symbols in this
Safety Instructions manual:
Structure of safety instructions: Listing of applicable partial statements
Pictogram - Subpoint of applicable partial statements
Signal word 1. Determination of the number or sequence of contents
Danger text Procedural instruction
- Danger note
- How to avoid danger
User's Responsibility
The following pictograms are used in this manual and are To ensure the safe operation of the unit, the user is responsi-
combined with the corresponding signal words: ble for the following:
1. The pump / system shall be operated only for the in-
tended use (see next chapter "Safety Instructions") and
its design shall neither be modified nor transformed.
2. The pump / system shall be operated only if it is in a
proper functioning condition and if it is operated in accor-
dance with the maintenance requirements.
1013A94 4273a00 6001a02 3. The operating personnel must be familiar with this Owner
- ATTENTION - ATTENTION - NOTE Manual and the safety instructions mentioned within and
observe these carefully.
- CAUTION - CAUTION - IMPORTANT
The correct installation and connection of tubes and hoses, if
- WARNING - WARNING not specified by Lincoln GmbH & Co. KG, is the user's re-
The signal words give the seriousness of danger if the follow- sponsibility. Lincoln GmbH & Co. KG will gladly assist you
ing text will be not observed: with any questions pertaining to the installation.
ATTENTION refers to faults or damages on

Environmental Protection
machines.
CAUTION refers to bad damages and possi- Waste (e.g. used oil, detergents, lubricants) must be dis-
ble injuries. posed of in accordance with relevant environmental regula-
WARNING refers to possible dangerous inju- tions.
ries.
NOTE refers to improvements in handling Service
of systems.
IMPORTANT refers to considerable disadvan- The personnel responsible for the handling of the pump /
tages in handling of systems. system must be suitably qualified. If required, Lincoln GmbH
& Co. KG offers you full service in the form of advice, on-site
Example: installation assistance, training, etc. We will be pleased to
inform you about our possibilities to support you purposefully.
ATTENTION! In the event of inquiries pertaining to maintenance, repairs
and spare parts, we require model specific data to enable us
When making use of other than the origi-
to clearly identify the components of your pump / system.
nal spare parts, serious damage may
Therefore, always indicate the part, model and series number
affect your device.
of your pump / system.
Therefore, for the operation of your device
always use original spare parts made by
1013A94
Lincoln GmbH & Co. KG.
Page 4 of 40
Owner Manual
2.1A-30002-C03
Safety Instructions
Appropriate Use Regulations for Prevention of Accidents

Use the 203 pump only for dispensing lubricants in cen- To prevent accidents, observe all city, state and federal
tralized lubrication systems. The pump is designed for in- safety regulation of the country in which the product will be
termittent operation. used.
Avoid operating by using
Misuse not allowed spare parts.
Any use of the 203 Pump that is not expressly mentioned in not allowed or polluted lubricants.
this Owner Manual will be regarded as misuse.
If the 203 pumpis used or operated in a different manner other Installation
than specified, any claim for warranty or liability will be null and
void. Any safety equipment already fitted to the vehicle or the
NOTE machine:
If personal injury or material damage - should not be modified or made ineffective.

occurs as a result of inappropriate opera- - should only be removed for the purpose of fitting the
tion, e.g. if the safety instructions are system.
ignored or resulting from an incorrect - must be replaced afterwards.
6001a02 installation of the 203 pump, no claims or
legal actions may be taken against Keep QUICKLUB centralized lubrication systems away
Lincoln GmbH & Co. KG. from sources of heat. Adhere to the operating temperature.
Use only original Lincoln spare parts (see Parts Catalog) or
General Safety Instructions parts approved by Lincoln.
Adhere to:
- are designed state-of-the-art.
- the installation instructions of the vehicle or machine
- can be assembled for safe operation. manufacturer as regards all drilling and welding proce-
- must be filled regularly without air inclusions with clean dures.
lubricant recommended by the manufacturer. - the specified minimum distances between the bore holes
Incorrect use may result in bearing damage caused by and the upper/lower rim of the frame or between two
poor or over-lubrication. bore holes.
Each outlet needed must be equipped with an appropriate
check valve.
Page 5 of 40
Owner Manual
2.1A-30002-C03
Safety Instructions, continuation
Operation, Repair and Maintenance
CAUTION! CAUTION!
110-240 V! Electrical tension!
The pump 203 may only be installed by In the case of pumps which are filled
qualified personnel. The connection from the reservoir cover, switch off
(N/L/PE) of the supply voltage must be the power supply before filling in the
made according to VDE 0100 and VDE lubricant.
4273a00
4273a00 0160. Install a protective and lock out
device for isolating and disconnecting the ATTENTION!
pump 203. Before beginning the instal- Risk of bursting if the reservoir is
lation work, disconnect the electrical overfilled!
supply.
When filling the reservoir by means of
WARNING! filling pumps with a large delivery
volume do not exceed the max. filling
110-240 V! 1013A94 mark.
Failure to observe the safety instructions,
e. g. touching electrically charged parts Lincoln-QUICKLUB central lubrication pumps
when the pump is opened, or improper - only be operated with a fitted pressure relief valve.
handling of the pump 203 may cause
4273a00 serious injury or death. If the values - must be refilled regularly without air inclusions with clean
specified in the Technical Data are ex- lubricant recommended by the manufacturer.
ceeded, the device may overheat. It may - operate automatically. However, a regular check (ap-
damage the pump 203 and thus impair the proximately every 2 days) should be made to ensure that
electric safety. lubricant is being dispensed from all lubricant points.
Repairs should only be performed by authorized personnel
CAUTION!
who are familiar with the instructions.
It is not allowed to use the pump in poten-
Defective printed circuit boards should be suitably packed tially explosive fields.
and returned to the factory (see page 36, paragraph
„Printed Circuit Boards“).
6001a02
Disposal Dispose of used or contaminated lubricants as well as of parts

that were in touch with lubricant according to the legal regula-
tions pertaining to environmental protection. Make sure to
observe the safety data sheets of the lubricants used.
Exclusion of Liability The manufacturer of the 203 pump will not accept any liability
for damages
caused by insufficient lubricant and irregular refilling of
pump.
caused by the use of contaminated lubricants.
due to the use of greases which are not or are only condi-
tionally pumpable in centralized lubrication systems (see
page 50ff).
chemical or biological changes of the used lubricant.
caused by an environmentally inadequate disposal of used
or contaminated lubricants or parts that were in touch with
lubricants.

caused by unauthorized modification of system compo-

nents.
caused by the use of unapproved parts.
Page 6 of 40
Owner Manual
2.1A-30002-C03
Pump Types
1173a95
Fig. 1 The different types of pump 203
Pumps 203 Control unit models 203

The 203 pumps differ from each other only in the design and The following control units can be used for the 203 pumps:
reservoir size as well as in the type of the electric connection (refer to the respective Technical Description)
(different plugs with or without electric cable). a) external control units
PSG 01
Reservoir sizes PSG 02 (Industry)
2 l transparent plastic reservoir b) integrated control units
4 l transparent plastic reservoir with adjustable pause and operating times
1)
8 l transparent plastic reservoir V10 -V13
with adjustable pause and operating times
1)
Electric connection V10 -V13 for alternate current 120, 230 VAC
with metering device monitoring (microprocessor control),
For the industrial applications, the pumps are only 1)
M 00 - M 23
equipped with plugs
c) integrated control unit (trailers)
All other data such as: with fixed time of availability (6 hours) and adjustable
1)
motor voltage operating time, H
version of the control unit 1)
Refer to the designation on the pump nameplate.
remote control for triggering an additional lubrication Example: P203 -2XNBO - 1 K6 - 24 - 2A1.10 - V10 or M10
cycle (2A1) Also refer to the designation code on page 8.
design and number of pump elements
design and number of safety valves
filling type
use of return line connections
low - level control (option)
- can be learnt from the pump type designation code.
- V10-V13: only as contact floating
Page 7 of 40
Owner Manual
2.1A-30002-C03
Identification Code – AC-Pump Models 203
without and with printed circuit board V10-V13, V20-V23
Examples of model designations
P203 - 2 X N - 1 K6 - AC - 1A 1. 10 - V10
NOTE P203 - 4 X L BO - 1 KR - AC - 2A 1. 01 - V12
Any pumps combinations other the P203 - 2 X N - 2 K5 - AC - 1A 1. 10
above standard pumps can be com-
P203 - 8 X L BO - 1 K6 - AC - 2A 6. 15
posed and ordered in accordance with
the valid model identification code. P203 - 4 Y L BO - 1 K7 - AC - 1A 1. 10 - V20
6001a02
P203 - 2 X L - 1 K6 - AC - 1A 6. 16 - V10
2)
P203, P 203 UL
Basic pump model for grease or oil
with 1-3 outlets and 12 VDC or 24 VDC motor
Reservoir design
2 = 2 l transparent plastic reservoir
X = Reservoire for grease

Y = Reservoire for oil
N = Standard design
L = Low-level control 4)
without designation = Standard reservoire (2 Litre)

BO = Filling from top
FL = Flat-type reservoire (only with 2 l reservoir, without low level
control and not for oil)
Pump elements
1-3 = Number of the use elements
K 5 = Piston diameter = 5 mm
KR = Pump element, adjustable, Piston diameter = 7 mm
B 7 = Piston diameter = 7 mm (output of K5)
S 7 = Piston diameter = 7 mm (food industry)
Supply voltage
AC = 110-240 VAC ±10%
(50-60 Hz ±5% mit 24 VDC direct current motor)
Number of electric connecting possibilities

1A = 1 connection for power supply (only cube type plug)
1)
left down
2A = connection for power supply (only cube type plug)
1) 1)
left down , low-level control (cube type plug) right down
2A = connection for power supply (only cube type plug)
1)
left down , illuminated push button + low-level control (quarter-turn
type plug)
Type of connection
1)
1 = Cube type plug
3)
7 = Quarter turn type plug, 7-/ 6-core (V10-V13, V20-V23)
Connection outside of the pump

1)
01 = with socket-outlet, without cable , without control p.c.b.
3)
16 = Quarter turn type plug with 10 m cable, 7-/ 6-wire , V10-V13,
V20-V23, connection vor low-level control and illuminated pushbutton
Control p.c.b. 12V / 24 V

V10-V13 = with adjustable pause and operating time
2)
V20-V23 = with adjustable pause and operating time
1)
Cube type plug according to DIN 43650, design A
2)
UL-proved, applies only to the North American market
3)
Quarter turn type plug according to DIN 72585-1
Page 8 of 40

Owner Manual
Description: Electric connections for pump 203

for example P203-2XN-1K6-24-... . ..-V10 oder M10
Printed circuit boards
Connecting plug, on the left Connecting plug, on the right
V10-V13, V20-V23, H
possible connections Power supply Illuminated push button External Lamp
Trigger additional
Activity/display Operating time Low level control
lubrication
Pump
without p. c. b. VDC 1A1.01/1A1.10 ----- ----- 2A1.01/2A1.10
without p. c. b. VAC 1A1.01 ----- ----- 2A1.01
with p. c. b. V...
1A1.01/1A1.10 2A1.01/2A1.10 2A1.01/2A1.10 2A1.01/2A1.10
for grease, VDC
with p. c. b. V...
1A1.01 -----1) -----1) 2A1.01
for grease, VAC
with p. c. b. V...
1A1.01/1A1.10 2A1.01/2A1.10 2A1.01/2A1.10 2A1.01/2A1.10
for oil, VDC
with p. c. b. V... separate plug on
1A1.01 -----1) -----1)
for oil, VAC lid of reservoir
with p. c. b. H
1A1.10 -----1) -----1) -----
for grease, VDC
Printed circuit boards Connecting plug,
Connecting plug, on the left
M00-M23 on the right
possible connections Power supply Illuminated push button Piston detector
Trigger additional Fault/low-level control/

Activity/display Operating time
lubrication readiness for service
Pump
with p. c. b. M08-M23 for
2A4/9.13 2A4/9.13 2A4/9.13 2A4/9.13 1 or 2 piston detector(s)
grease or oil, VDC
1)
- 1A1.01- cube-type plug, left without cable - 3A4.13- Quarter-turn type plug, 5-wires possible on the control p.c.b. only
- 1A1.10- cube-type plug, left with cable
2.1A-30002-C03
- 2A1.01- cube-type, right without cable - 3A9.13- Quarter-turn type plug, wire-to-wire, - 1A8.00-PG- cable gland without cable
- 2A1.10- cube-type, right with cable 5-wires - 1A8.XX-PG- cable gland with cable (option,OEM)
Page 9 of 40
Owner Manual
2.1A-30002-C03
Description, continuation
The QUICKLUB 203 central lubrication

pump
is a compact multiline pump consisting of the following
components:
- Housing with integrated motor
- Reservoir with stirring paddle
- Printed circuit board
- Pump element
- Pressure relief valve
- Filling nipple
- Electrical connection parts
can drive up to 3 pump elements
operates according to lubrication cycles (pause and oper-
ating times)
can be equipped with a low-level control (only with contact
floating)
can supply up to 300 lubrication points depending on the
00002618b line lengths
Fig. 2 Pump components is designed for the automatic lubrication of the connected
1- Reservoir 5- Plug 2A1 lubrication points
2- Pump element (V10-V13 : low level control) is designed for the delivery of greases up to NLGI 2 at
3- Safety valve 6- Filling nipple, pump
4- Filling nipple, system 7- Printed circuit board
temperatures from - 25° C to 70° C or of mineral oils of at
Emergency lubrication 8- Plug 1A1 least 40 mm²/s (cST)
possible 9- Return line connection can be used at low temperatures down to - 40° C.
During the operating time the pump dispenses lubricant to the
connected lubrication points via one or several metering de-
vices.
Low level control (optional)

The pump model 203 can be equipped with a low-level
control.
The following versions are available:
- Low-level control in conjunction with integrated printed
1)
circuit boards V10-V13
- Low-level control for pumps without printed circuit
board.
If the container is empty the contact floating (cube plug Fig.
4, pos. 5) can be used, in order to cause a flashing of a
control lamp (see page 16, paragraph „Reservoir empty“).
1)
The designation indicates the version of the printed circuit
board. It is part of the pump type designation code mentioned on
the nameplate of each pump.
Example: P203-2XN-1K6-24-1A1.10-V10
1006a93
Fig. 3 QUICKLUB central lubrication pump, 2 l reservoir
Page 10 of 40
Owner Manual
2.1A-30002-C03
Mode of Operation
Pump Elements with fixed Lubrication

output
The electric motor drives the eccentric (fig. 5 and 6, pos. 1).
During the operating time:
- piston 2 sucks in lubricant from the reservoir, see fig. 5.
- piston 2 dispenses the lubricant to the connected lubri-
cation points via the metering device, see fig. 6.
The following designs are available:

- Piston diameter, K5 ............................................ 5 mm
- Lubricant output............................... approx. 2 cm³/min
20002068 - Piston diameter K6 (standard) ............................ 6 mm
Fig. 4 Pump element - Lubricant output............................ approx. 2.8 cm³/min
1- Piston 2- Return spring - Piston diameter, C7, K7...................................... 7 mm
3- Check valve
- Lubricant output .............................. approx. 4 cm³/min
1003a95
Fig. 5 Pump element sucks in lubricant
1004a95
Fig. 6 Pump element dispenses lubricant

1- Eccentric 2- Piston 3- Spring 4- Check valve
Page 11 of 40
Owner Manual
2.1A-30002-C03
Mode of Operation, continuation
Check valve
The check valve
- closes the pressure line during suction stroke.
- prevents the lubricant from flowing back to the housing or
reservoir.
1 - Reservoir with stirring paddle

2 - Pump
3 - Check valve, spring-loaded
4 - Pressure relief valve
R - Return line
1164b95
p - Pressure line
Fig. 7 Hydraulic diagram of the pump
Arrangement of the pump elements
If several pump elements are to be installed, the installation

arrangement shown in Fig. 8 must be adhered to.
If there is only one pump element , it can be installed in any
position. Standard position is no. 3.
If there are two elements, install one in position 3 and the
other in position 1.
1163a95
Fig. 8 Arrangement of the pump elements
Pump Elements with adjustable Lubricant output

The mode of operation (suction and supply phase) is the
same as that of the pump elements with an invariable lu-
bricant output.
The lubricant outputs are adjustable from 0.04 to
3 3
0.18m /stroke, or 0.7 to 3cm /min.
The pump elements are factory-adjusted to the maximum
lubricant output; the adjusting dimensions “S” should be
29 ± 0.1 mm.
4158a99
Fig. 9 Adjustable pumpelement
Page 12 of 40
Owner Manual
2.1A-30002-C03
4159a98
Fig. 10 Sectional view: adjustable element

1- adjusting spindle SW 16 3- pump element body 6- control piston
(SW ~ with over flats) 4- gasket 7- delivery piston
2- counternut SW 24 5- pump cylinder S- setting dimension
Setting of adjustable pump elements

Unscrew the coupling nut for fixing the safety valve.
Loosen counter nut (pos.21)) while holding in position pump
element body (pos.3) by means of a second wrench.
Change the position of the adjusting spindle (pos.1) by
means of a wrench, see supply diagram (fig. 11).
The dimension “S” (fig. 10) for the desired lubricant output
can be ascertained by using the supply diagram (fig. 11).
Retrofit adjustment of max. lubricant output
NOTE
In order to ensure that the lubricant output

setting will be as exact as possible, first
6001a02
the actual dimensions “S” of the max.
lubricant output must be ascertained as
follows. The measured difference from
4179a99 the nominal value 29 must be considered
Fig. 11 Supply diagram for all other settings values (e.g. ± 0.1).
1)
A- Lubricant output cm3/min Unscrew the adjusting spindle (pos.1 ) from the pump
B- Lubricant output cm3/stroke element body (pos.3) until “S” is approx. 30 mm.
S- Setting dimension
Screw counter nut (Pos.2) onto stop collar of the adjusting
spindle (pos.1).
Screw adjusting spindle (pos.1) with counter nut (pos.2)
into pump element body (pos.3) until stop.
1)
All indications of positions refer to fig. 10.
Page 13 of 40
Owner Manual
2.1A-30002-C03
Retrofit adjustment of max. lubricant output, continuation

Before the pump element can be adjusted to a small lu- NOTE
bricant output, the dimension “S” for max lubrcant output
must be ascertained, and the difference from the nominal „S“ beträgt bei maximaler Einstellung
value 29 must be tranferred to any desired settings be- 29±0,1 mm.
tween 25.5 ... 28,.5.
6001a02
Dimension “S” must be adjusted to the desired value in
accordance with the delivery diagramm (see page 13, fig.
11).
Pressure relief valve without grease return
IMPORTANT
Each pump element must be secured with
a pressure limiting valve.
The pressure relief valve is not contained
6001a02 in the scope of supply of the pump 203.
Therefore it is to be ordered separately
(see Spare Parts Catalog).
The pressure relief valve
- limits the pressure build-up in the system.
- opens, if the specific overpressure is reached.
- is to be selected according to the requirements to the
lubrication plant (see different opening pressures; 200,
270, 350 bar).
10022618a
If lubricant is leaking at the pressure relief valve, this indi-
Fig. 12 Pressure relief valve cates that the system is malfunctioning.
Despite existing fault monitoring devices a regular visual
and function control must be carried out on the lubrication
system.
NOTE
The duration of the delay depends on the type and length of the lines, the type of lubricant, the ambient
temperature and other influences.
6001a02
Pressure relief valve with grease return (optional)

If the system is blocked, grease will leak from the pressure
relief valve. This grease quantity is returned to the reser-
voir.
00002626a
Fig. 13 Pressure relief valve with grease return
Page 14 of 40
Owner Manual
2.1A-30002-C03
Pressure relief valve, continuation

In the case of a blockage in the system, the grease pushes
out the red pin at the pressure relief valve, thus indicating
that there is a fault.
00002629a
Fig. 14 Fault indication in the case of a blockage
Return Line Connection

The lubricant quantities which cannot be dispensed by the
metering device must be returned to the pump via the re-
turn line connection (Abb. 15).
10032618
Fig. 15 Return line connection

Page 15 of 40
Owner Manual
2.1A-30002-C03
Low-level control (optional)

for grease
Reservoir filled
The stirring paddle rotates clockwise during the operating
time.
Due to the rotating motion of the stirring paddle in the
lubricant the pivoting guiding plate with the round solenoid
(pos.11)) is pressed backwards. The solenoid moves to-
ward the center of rotation of the stirring paddle. The elec-
tromagnetic switch (pos.21)) cannot be activated.
Control cam item (pos.31)) guides the round solenoid with
the pivoting guiding plate automatically outwards, in the
direction of the reservoir wall. After the lubricant has left the
control cam, it flows against the guiding plate, thus dis-
placing the solenoid again onto the center of rotation of the
stirring paddle.
1)
00002444
Fig. 16 Switching parts of the low-level control

1- Guiding plate with round 2- Electromagnetic switch (at Reservoir empty
solenoid stirring paddle)
3- Control cam During the rotating motion of the stirring paddle there is no
backpressure from the lubricant. The guiding plate with the
round solenoid no longer moves towards the center of ro-
1)
NOTE tation of the stirring paddle. After control cam (pos. 3 ), has
The above mentioned switching parts been overtravelled, the solenoid remains in the outer posi-
must not be used with fluid grease. In this tion and overruns electromagnetic switch (pos. 2). The
case, use a float magnetic switch, see solenoid activates the electromagnetic switch contact-free,
6001a02 below low-level control for oil. thus triggering a low-level signal.
The flashing frequency in the case of printed circuit boards
236-13891-1 or 236-13891-2 and in the case of pumps
NOTE without control units depends on the motor speed.
The flashing signal starts only after the 1)
solenoid has activated the electromag-
netic switch 6 times contact-free.
6001a02
Magnetic switch
The electromagnetic switch is activated contact-free and
with-out wear by the magnetic field of the solenoid fitted to
the float.
NOTE
The life of the float magnetic / magnetic
circuit breaker strongly depends on the
conditions under which it is loaded. Since
6001a02 the data relative to the maximum switch-
ing capacity refer to strictly resistive
loads, which cannot be always guaran-
4237a03
teed in practice, it is necessary to take the
Fig. 17 Connection diagram corresponding contact protection meas-
ures in the case of deviating loads.
Technical Data
Maximum switching capacity ........................ max. 60VA

Maximum switching voltage .......................... max. 230 V
Current switched ....................................................... 3 A
Page 16 of 40
Owner Manual
2.1A-30002-C03
Low Level Control (optional), continuation

Float magnetic switch
for oil Technical Data
Maximum switching capacity ........................ max. 60VA
Maximum switching voltage .......................... max. 230 V
Current switched ....................................................... 3 A
1202a99
Fig. 18 Connection diagram
Contact protection measures
1201a95
Fig. 19 Contact protection measures

1- Electromagnetic switch
2- RC element
3- Diode
4- Load
Page 17 of 40
Owner Manual
2.1A-30002-C03
Printed Circuit Boards V10-V131) (V20-V23)
1)
V10-V13 are names for the respective execution of the printed circuit board. It is part of the pump type designation on the identification
plate at each pump.
Fields of Application
Pump Voltage [V] Control unit Setting ranges Part-no. Applications
P1: 4 to 60 minutes
integrated P2: 1 to 15 hours
203 12/24 2) 4) 236-13891-1
V10 to V13 A1: 8 to 120 seconds
A2: 2 to 30 minutes
A- Operating time ranges 2)

1A1-Version Pump without connection for the illuminated pushbutton
B- Time of availability 3)
2A1-Version Pump with connection for the illuminated pushbutton
P- Pause time range 4)
2A4-Version Pump with microprocessor control
Ü- Monitoring time
NOTE
The applications of the progressive systems are various. There is therefore a control unit available for each
individual application.
6001a02
Installation position of the printed circuit boards (p.c.b.)

The control p.c.b. and the power supply p.c.b. are
integrated in the pump housing.
4238a99 1- control p.c.b.

2- power supply p.c.b.
Fig. 20 Printed circuit board integrated in the housing
Page 18 of 40
Owner Manual
2.1A-30002-C03
Printed Circuit Boards V10-V13 (V20-V23), continuation
Start up
With switching on of the machine contact (external contact on)
the p.c.b. and thus also the pump is ready for use.
Mode of Operation
The p.c.b. controls automatically the expiration of woring
hours and pause times of the Central Lubrication System
203, in dependence of the machine operation hours tB (see
fig. 22).
The expiration of working hours and pause times is started
and stopped via the machine contact.
20002443b
Fig. 21 p.c.b. 236-13891-1
A lubrication cycle consists of one pause time and one

operating time. Once the pause time has elapsed, the op-
erating time starts to run. This lubrication cycle is repeated
permanently after the machine has been put into operation.
During the operating time the pump element delivers the
lubricant to the lubrication points via progressive metering
devices.
tB - Working hours
tP - Various pause times
T- Lubrication cycle
T1 - Stored pause times
1059a95 T2 - Operating times
Fig. 22 Time sequence diagram
Pause time determines the frequency of the lubrication cycles within a

working cycle.
is started and stopped via the machine contact.
is adjustable.
When the machine contact or the driving switch is switched off,
the pause times which have already elapsed are stored and
added up (fig. 22) until the time which has been set on the blue
rotary switch (see page 22, fig. 25) is reached.
The pause time setting may be different for each application. It
must be adjusted in accordance with the respective lubrication
cycles (see page 22, paragraph „Setting pause time“).
Page 19 of 40
Owner Manual
2.1A-30002-C03

Operating time depends on the system´s lubricant requirement.
is finished when the machine contact is switched off.
is adjustable and is to be adapted to the necessary lubri-
cant need (see page 23, paragraph „Setting operating
time“).
When the machine contact is switched off, the operating times
which have already elapsed are stored and added up until the
time which has been set on the red rotary swtich (page 23, fig.
37) is reached. After this, the lubrication cycle starts again.
Time storage When switching off the operating voltage, the times already
expired are saved for an unlimited duration.
When the power supply is switched on again the printed circuit
board continues to operate from the point where it had been
interrupted.
Time Setting
To set the pause or operating time, remove the cover on
the pump housing.
IMPORTANT
After having set the pause time or operating

time, screw the cover on the pump house
again.
6001a02
NOTE
To reset a jumper (see page 21, fig. 24)

remove the p.c.b..
00002617a
Fig. 23 The cover to access hte printed circuit board has been
removed
Factory Setting
Pause time
V10-11: jumper position ................................ 1-15 hours
1)
rotary switch position (blue) 6 ............. 6 hours
V12-13: jumper position ............................ 4-60 minutes
1)
rotary switch position (blue) 6 ....... 24 minutes
Operating time
V10+12: jumper position ............................ 2-30 minutes
1)
rotary switch position (red) 3 ......... 6 minutes
V11+13: jumper position ......................... 8-120 seconds
1)
rotary switch position (red) 3 ....... 24 seconds
1)
20002452a see following page, fig. 25
Fig. 24 Preselection of the time ranges, jumper position
Page 20 of 40
Owner Manual
2.1A-30002-C03
Time Setting, continuation

Setting Pause time
The pause time can be set to 15 different settings by
means of the blue rotary switch.
Depending on the position of the jumper (see page 21, fig.
24, left hand) the necessary time intervall is adjustable
(4-60 minutes or 1-15 hours).
NOTE
During switching position 0 a failure report
at the light emitting diode takes place on the
right LED, (see also page 23, fig. 27, pos.
6001a02 3).
NOTE
20002451b To reset a jumper remove the p.c.b..
Fig. 25 Rotary switch for pause time
switch position 1 2 3 4 5 6 7 8 9 A B C D E F
minutes 4 8 12 16 20 24 28 32 36 40 44 48 52 56 60
hours 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Setting Operating time

The operating time can be set to 15 different settings by
mans of the red rotary switch.
Depending on the position of the jumper (see page 21, fig.
24, right hand) the necessary time intervall is adjustable
(8-120 seconds or 2-30 minutes).
NOTE
During switching position 0 a failure report
at the light emitting diode takes place on the
right LED, (see page 23, paragraph „Signal
6001a02 output“).
NOTE
20002453b
To resetz a jumper remove the p.c.b..
Fig. 26 Rotary switch for operating time
switch position 1 2 3 4 5 6 7 8 9 A B C D E F
minutes 8 16 24 32 40 48 56 64 72 80 88 96 104 112 120

hours 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30
Page 21 of 40
Owner Manual
2.1A-30002-C03
Functional Check and Fault Indication

Operational Test / To Trigger an Additional Lubrication
Cycle
To check the pump operation it is possible to perform an
operational test:
- Switch on the power supply (machine contact). To check
whether power is applied to the printed circuit board,
observe whether the LED (see fig. 27, pos. 1) is lit.
- Afterwards the pump is ready for operation.
- Press button (pos. 5 or externally if possible at the
switchgear cabinet) until the LED (pos. 3) is lit.
Diode 3 is lit: Motor starts
Diode 3 is not lit: Pump disturbed
The pause time runs when releasing an additional lubrica-
tion cycle shortened. The lubrication procedure takes as
20002457a long as the adjusted operating time.
Fig. 27 LED of the p.c.b.
1- LED left hand: power supply NOTE
2- Rotary switch (blue): pause time
3- LED right hand: indication of operation Additional lubrication cycles are at any time
4- Rotary switch (red): operating time possible over the manipulation of the
5- Pushbutton for additional lubrication pushbutton (pos. 5).
6001a02
Signal Output
The signal output takes place with the right LED (pos. 3) and is implemented as follows:
4 times flashing signal 3 times flashing signal
1) 1)
System Rotary switch (Pos. 2 oder 4) System Rotary switch (Pos. 5)
1) 1)
LED, right hand (Pos. 3) LED, right hand (Pos. 3)
Fault Rotary switch on switching posi- Fault Short-circuit at the pushbutton or

tion 0 at the the connection to the ex-
ternal illuminated push button
Signal output 4 times flashing signal, motor runs
along in flash frequency Signal output 3 times flashing signal, motor runs
along in flash frequency
Change to the factory set-
ting afterwards ignoring the 1)
signal
To Remedy to a Fault
IMPORTANT In the case of a fault, check whether the central lubrication

pump and the connected system are malfunctioning.
It must be checked, i.e. an additional lubri-
Eliminate the cause of the fault (see page 27, chapter
cation cycle must be triggered.
„Troubleshooting“).
6001a02
Page 22 of 40
Owner Manual
2.1A-30002-C03
Maintenance, Repair and Tests
Maintenance
The maintenance is essentially limited to refilling the res- NOTE
ervoir with clean lubricant in good time. However, check
regularly whether the lubricant is really dispensed to all the Whenever work is done on the centralized
lubrication points. lubrication system, particular attention
Also check the main lines and lubricant feed lines for 6001a02
should be paid to absolute cleanliness.
damage and replace them, if necessary. Dirt in the system will cause problems.
For cleaning the system use benzine or petroleum. Do not
use tri-, perchloroethylene or similar solvents.
Also do not use polar organic solvents such as alcohol,
methylacohol, acetone or similar
Pump Filling
2 l, 4 l, 8 l - reservoirs
Fill the reservoir up to the ”Max.” mark via the filling nipple, if
any, or via the upper filling opening.
It is possible to use greases up to penetration class NLGI 2 or
mineral oils of at least 40 mm²/s (cST).
IMPORTANT
The grease or oil must be free from im-

purities and must not be liable to change
6001a02
its consistency in the course of time.
CAUTION!
If the pump is filled via the upper filling

opening, switch off the power supply
before starting filling.
1011a93
4273a00
Fig. 28 Fill pump reservoir
CAUTION!
Risk of bursting if the reservoir is

overfilled.
When filling the reservoir by means of

1013A94
pumps with a large delivery volume do
not exceed the max. filling mark.
NOTE
If the reservoir has been completely

emptied, the pump may require until 10
6001a02
minutes before it operates with its full
output.
Page 23 of 40
Owner Manual
2.1A-30002-C03
Maintenance, Repair and Tests, continuation
Repair
Pump Use only original Lincoln spare parts for repair on the
pumps.
The pump should be returned to the factory for warranty
work or major repairs.
Replace pump element
Remove the pressure relief valve from the pump element.
Unscrew the pump element.
IMPORTANT
Take care that the piston, the pull-back
spring and the washer are not left lying in
the grease, otherwise the reservoir must be
6001a02
disassembled in order to remove these
pieces.
IMPORTANT
Do not leave the piston, spring and washer
in the housing because they may block the
motor.
NOTE
Pump element with adjustable lubricant
output is set to the same output as the old
pump element.
Install a new pump element and a new sealing ring.
5026a96
Fig. 29 Pumpenelement austauschen
Printed Circuit Boards Note all jumper positions of the defective p.c.b. (comp.
page 21, fig. 24).
Defective printed circuit boards should be suitably packed
and returned to the factory.
With substitution of a p.c.b. the type V10 is always
delivered.
Configure at the new p.c.b. the noted jumper positions of
the old p.c.b.
Page 24 of 40
Owner Manual
2.1A-30002-C03
Maintenance, Repair and Tests, continuation
Tests
Operational Test / To Trigger an Additional Lubrication To check the pump operation it is possible to perform an
Cycle additional test. Refer to the Technical Description of the
respective printed circuit board (see page 23, paragraph
„Operational Test / To Trigger an Additional Lubrication
Cycle“).
To Check the pressure relief valve

1st option
Connect the pressure gauge (0-600 bar; 0-8708 psi) to the
pressure relief valve (Fig. 30).
Trigger an additional lubrication cycle.
2nd option
Connect the manual pump of the pressure and checking
set 604-36879-1 to the safety valve and check the opening
pressure by means of the manual pump.
The safety valve should open at a pressure of 200, 270 or
350 bar depending on its design.
IMPORTANT
Do not connect the pressure gauge di-

rectly to the pump element. High pressure
6001a02
may exceed the above mentioned range,
causing the motor to stall. The motor is
designed in such a way that it can stall for
about 30 minutes without being damaged.
1- Hose line, min.length 1m

2- T-piece
3- Pressure gauge
1005a93
4- Relief cock
Fig. 30 To check the pressure relief valve
Functinal Check of the p.c.b. NOTE
See page 23, paragraph „Functional Check

and Fault Indication“.
6001a02
Page 25 of 40
Owner Manual
2.1A-30002-C03
Troubleshooting
NOTE
The pump operation can be checked from the outside by observing whether the stirring paddle is rotating (e.g.
by triggering an additional lubrication).
Additionally disturbances of the pump are recognizable from the p.c.b. (see page 29ff, chapter “Funktional
6001a02
Check and Fault Inidcation”).
Fault: The pump motor does not run
Cause: Remedy:
Power supply interrupted Check the power supply and fuses.
If necessary rectify the fault and/or replace the fuses.
Check the line leading from the fuses to the pump plug.
Electric motor defective Check the power supply to the motor. If necessary, replace
the motor.
p.c.b. defective Check the function of the p.c.b. (see page 23, paragraph
“Operational Test / To Trigger an additional Lubrication
Cycle”).
If necessary replace the p.c.b..
Fault: The pump does not deliver the lubricant
Cause : Remedy:
Reservoir empty Fill up the reservoir with clean grease or oil. Allow pump to
run (trigger an additional lube cycle, see page 23) until the
lubricant issues from all the lubrication points.
NOTE
If a lubricant low-level is available, the low level is indicated by the flashing light of the signal lamp in the case
of pumps without printed circuit board. The flashing frequency depends on the speed of the motor.
NOTE
6001a02 Depending on the ambient temperature and/or sort of lubricant it may take 10 minutes of operation before the
pump elements reach their full lubricant output.
Air bubbles in the lubricant Trigger an additional lubrication cycle (see page 23).
Loosen the outlet fitting or the main line at the pressure re-
lief valve. The lubricant must issue without air bubbles.
NOTE
When push-in type fittings are used, the high-pressure plastic hose which is under pressure cannet be easily
disconnected from the pressure relief valve. For this purpose, loosen the pressure relief valve. For this
purpose, filling nipple on the pressure relief valve in order to relieve the high-pressure hose.
6001a02
Unsuitable lubricant has been used Renew the lubricant. See the Lubricant List (see page 37ff).
Suction hole of the pump element clogged Remove the pump element. Check the suction hole for
foreign particles. If there are any, remove them.
Pump piston worn Replace the pump element.
Check valve in the pump element defective or clogged. Replace the pump element.
Page 26 of 40
Owner Manual
2.1A-30002-C03
Technical Data
PUMP TORSION TORQUES

1)
Admissible operating temperature .............. -40° C to 70° C Install pump .................................................................. 18 Nm
Number of outlets ...................................................... 1, 2 or 3 Electric motor on housing ............................................ 12 Nm
Reservoir capacity .................................................. 2 l, 4 l, 8 l Pump element in housing ............................................ 25 Nm
Refilling ............... via hydraulic lubrication fitting or from top Closure plug in housing ............................................... 12 Nm
Lubricant .................................. greases up to NLGI grade 2 Return line connector in housing ........................ 10 to 12 Nm
& .................. mineral oils of at least 40 mm²/s (cST) at 40° C
Class of protection ................. IP6K 9K acc. to DIN 40050 T9
............................................ UL Typ 4X only indoor, 12 and 13 WEIGHTS
The weights below include the following ‘‘individual weights”:
1)
NOTE - Pump kit with one pump element, safety valve, grease
The pump is designed for the above filling (0.75 kg, 1.5 kg)
mentioned temperature range. The lu- - Packing (cardboard box)
bricants used must still be pumpable at - Attaching parts
the temperatures mentioned above. In - Operating Instructions
6001a02
case of doubt, consult the lubricant
manufacturer. 2 l reservoir, standard design (0.75 kg)
- Pump 203 without connection cable ............................5.4 kg
MOTOR - Pump 203, version 1A1.10 ..........................................6.5 kg
- Pump 203, version 2A1.10 ..........................................7.1 kg
Speed .......................................................... approx. 17 U/min
4 l reservoir, standard design (1.5 kg)
Pump element with fixed lubricant output
- Pump 203 without connection cable ........................... 8.3 kg
Piston diameter, K5......................................................... 5 mm - Pump 203, version 1A1.10 ......................................... 9.3 kg
- Lubricant output ...................................... approx. 2 cm³/min - Pump 203, version 2A1.10 ......................................... 9.9 kg
Piston diameter, (Standard) K6....................................... 6 mm
- Lubricant output ................................... approx. 2.8 cm³/min
Piston diameter, K7, C7 .................................................. 7 mm 8 l reservoir, standard design (1.5 kg)
- Lubricant output ...................................... approx. 4 cm³/min - Pump 203 without connection cable ........................... 8.6 kg
max. operating pressure . ........................................... 350 bar - Pump 203, version 1A1.10 ..........................................9.6 kg
Connection thread ........................................................ G ¼“ - Pump 203, version 2A1.10 ........................................10.2 kg
- suitable for tube DIA ................................................... 6 mm
2)
suitable for chisel paste; contact the manufacturer of the lubrication In the case of pump versions deviating from those mentioned,
system. add the weights of the following components to the mentioned
weights:
- per pump element ..................................................... +0.2 kg
Pump element with adjustable lubricant output - per pressure relief valve ........................................... +0.1 kg
KR ..................................................... 0.04 to 0.18 cm³/stroke - 10 m monitoring cable, 5-wire
...................................................................... 0.7 to 3 cm³/min (microprocessor) 2A4.13 ......................................... +1.1 kg
Connection thread ........................................................ G ¼“ - 10 m monitoring cable, 4-wire
- suitable for tube DIA ................................................... 6 mm (microprocessor) 2A4.12 ......................................... +0.4 kg
- suitable for tube DIA ................................................... 8 mm - Connection cable with piston detector ...................... +0.1 kg
3)
- Reservoir version ”Filling from top” (only 2 l) ....... +0.15 kg
- 2 l flat-type reservoir ................................................. +0.5 kg
IMPORTANT
The lubricant output listed refers to
3)
grease of NLGI grade 2 measured at NOTE
20°C, backpressure 100 bar, nominal
voltage 12/24 V. Any differing pressures The 4l and 8l reservoirs have the standard
6001a02 design ”filling from top”.
or temperatures result in different lubri-
cant outputs. Any system design must be
6001a02
based on the above values compete.
PRESSURE RELIEF VALVE

SVETVT-350-G 1/4A-D6 .................................... 624-28894-1
SVETVT-350-G 1/4A-D8 .................................... 624-28774-1
Page 27 of 40
Owner Manual
2.1A-30002-C03
Technical Data, continuation
Electrical Data
PUMP Motor
DC gear motor (interference-suppressed)
Input
- Operating voltage .................................................... 24 VDC
Input voltage ................. 110-240 VAC ±10% ; 50/60 Hz ±5% - Max. current input ........................................................... 3 A
Input current ........................................... 200 mA at 230 VAC - Speed ........................................................ approx.17 U/min
Starting current impact ................................................... < 3 A
Fuse ..................................................... T 1,25 A/250 V intern
PRINTED CIRCUIT BOARD
NOTE Rated voltage ............................................................ 24 VDC
Operating voltage ..................................................... 9 to 30 V
If internal fuse has to be replaced, use only
Residual rippple in relation
the original type.
- With the operating voltage ............... ±5% acc. to DIN 41755
6001a02 Output motor ...................... transistor 7A / short-circuit proof
Reverse voltage protection ...... The operating voltage inputs
Output .......................... are protected against polarity reversal
Temperature range ....................................... -25 °C to 70 °C
Output voltage, internal ..................................... 24 VDC ±1% - Output fault / readiness for service
............................................ transistor 3A / short-circuit proof
Protection and monitoring Class of protection:
Current limiting ................ resistant to sustained short circuit Printed circuit board installed in housing ............... IP 6 K 9 K
Overload-proof ............................................................... yes
Idling-proof ..................................................................... yes In order to protect the printed circuit board against condensa-
Mains buffering time ............................... > 15 ms at 230 VAC tion, it has been covered with a protective varnish.
All the printed circuit boards comply with the EMC (Electro-
Safety VDE 085 / 11.93 / EN 60950 / IEC 950, EN 60204 magnetic compatibility) guidelines for road vehicles acc. to DIN
40839 T1, 3 and 4.
Output ................................ safety extra-low voltage (SELV)
Class of protection .................................................... class 1 Emitted interference ....................... acc. to EN 55011 / 03.91
Degree of protection ....... IP6K9K (installed in pump housing) and ................................................... acc. to EN 50081-1 / 01
Discharge current .......... < 0,25 mA (47-63 Hz and UON max.)
Noise immunity .......................... acc. to prEN 50085-2 / 1994
EMC
Radio interference suppression Time Setting
......................................... VDE 0875 T 11, EN 55011 class A - Pause time
Emitted interference ................................. acc. to EN 50081/2 either ................................................ 4, 8, 12, ... 60 minutes
Noise immunity ........................................ acc. to EN 50082/2 or ........................................................... 1, 2, 3, … 15 hours
NOTE - Operation time is switched off via the piston detector
- Monitoring time
The emitted interference meets the re- either .................................................................... 5 minutes
quirements for the industrial sector, if used or ........................................................................ 30 minutes
in the residential sector this may possibly - Monitored lubrication cycles
6001a02
lead to interference. either ........................................................................ 1 cycle
or ............................................................................. 2 cycles
- Factory setting
Operating Mode Pause time ................................................................ 6 hours
Operating time ...................................................... 6 minutes
IMPORTANT
Monitoring time ...................................................... 5 minutes
Suitable for interval operation only, not Monitored lubrication cycles ..................................... 1 cycle
for permanent operation!
6001a02
Operating voltage > 120 VAC:

- max. operating time ............................................ 30 minutes
- min. pause time .................................................... 4 minutes
Operating voltage < 120 VAC:
- max. operating time .............................................. 8 minutes

- min. pause time .................................................. 16 minutes
Page 28 of 40

Owner Manual
Possible Connecting and Control Types of the Pumps P 203, P 223 and P 233 outside the housing
Pumpe 203 without and with control p.c.b. V10-V13, H, M08-M23, DC/AC
Printed circuit boards
Connecting sockets with/without cable Plugs
X
Low level V10-

without H AC
Designation Type Design 3-core 5-core 6-core ADR 4 wire 7 wire 4 wire control V13 M08-
left 4 wire
left left left left left right M23
1A 1 01 X left x x
1A 1 10 x left x x x
1A 1 01 x left Oil x x
1A 1 10 x left Oil x x
1A 1 11 x x left x x
2A 1 01 x left, right x x
2A 1 01 x left, right Grease x x
2A 1 10 x left, right x x
2A 1 10 x left, right Grease x x
1A 5 14 x x x x x
1A 5 14 x x Oil x x
1A 5 17 x x x x x
1A 6 16 x x x
1A 6 16 x x Grease x x
2A 6 15 x x x x
2A 6 15 x x x Grease x
2A 6 16 x x x Grease x x
1A 1 01 x left x x x
1A 1 01 x left Oil x x x
2A 1 01 x left, right Grease x x x
2A 6 15 x x left x Grease x x x
3A 6 15 x x x x x x
2.1A-30002-C03
Page 29 of 40
Owner Manual
2.1A-30002-C03
Connection Diagram
(Consider the safety instructions, page 5!) NOTE
Consider the connetion diagrams and
contact protection measures for connecting
the low level control (see page 17).
without p.c.b. 6001a02
4235b99
Fig. 31 Connection diagram QUICKLUB 203 without p.c.b, connection by means of a square type plug DIN 43650-A
V10-V13
4236b99
Fig. 32 Connection diagram QUICKLUB 203 with p.c.b. V10-V13, connection by means of a square type plug DIN 43650-A
Page 30 of 40
Owner Manual
2.1A-30002-C03
Terminals of the p.c.b.
control lamp
additional lubrication
level control
- low level control
+ low level control
+ motor
- motor
machine contact
battery voltage
earth
20002443c
Fig. 33 Terminals of the p.c.b.
Attaching Boreholes of the 2 l-, 4 l- and 8 l- pump
1171b03
Fig. 34 Attaching Boreholes of the 2 l-, 4 l- und 8 l- pump
NOTE
Thighten pump models wih 2 l - flat, 4 L -

and 8 L reservoir with three fastening
screws (see pt. R 9,5).
6001a02
Page 31 of 40
Owner Manual
2.1A-30002-C03
Dimensions - 2 l reservoir
1166a95
Fig. 35 Dimensions - 2 l reservoir
Page 32 of 40
Owner Manual
2.1A-30002-C03
Dimensions - 2 l reservoir with filling from top

1167a95
Fig. 36 Dimensions - 2 l reservoir with filling from top
Page 33 of 40
Owner Manual
2.1A-30002-C03
Dimensions - 2 l flat-type reservoir

1168a95
Fig. 37 Dimensions - 2 l flat-type reservoir
Page 34 of 40
Owner Manual
2.1A-30002-C03
1169a95
Page 35 of 40
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2.1A-30002-C03
1170a95
Page 36 of 40
Owner Manual
2.1A-30002-C03
Lubricants
The lubricants tested did not cause any damage due to in-
IMPORTANT
compatibility on the material used by us. The composition of
Absolute cleaniness is essential when the lubricants, their behavior during the transport and their
handling Lubricants. Impurities will remain compatibility with other material are not known to us.
suspended in the lubricant and cannot
6001a02 settle. This will result in damage to the IMPORTANT
lubrication system and thus to the bea-
ring. The manufacturer of the centralized
The pump QUICK LUB 203 can dispense commercial greases lubrication system can accept no liability
up to NLGI grade 2 or mineral oils of at least 40 mm/s (cST) at for:
6001a02 - damages due to the use of greases that
40 ° C.
are not or only conditionally transportable
Lubricant recipes may change. In case of doubts, send your in centralized lubrication systems.
request for more information to the manufacturer of the cen- - damages on parts of the centralized
tralized lubrication system. This refers in particular to lubrication system caused by chemical or
lubricants with more than 3% graphite portion. These are only biological changes of the lubricant used.
conditionally in lubrication plants promotable. - damages due to the incompatibility with
The lubricants released by us have not been tested with regard other materials.
to their long-term behavior.
The liability is only limited to transportable
lubricants in central lubrication systems.
Lubricating greases for QUICKLUB systems

Manufacturer Designation Base soap min. delivery temperature
AGIP F1 Grease 24 Ca
ARAL Graisse multi-usages ZS 1/2 Ca/Li -20° C
AUTOL Top 2000 Ca -10° C
AUTOL Top 8000 W Ca -20° C
BP Graisse lubrifiante Ca
BP C1 Graisse lubrifiante Ca -20° C
CASTROL CLS - Grease Li/Ca -20° C
ESSO Cazar K2 Ca
ESSO Graisse haute pression Ca
FIAT LUBRIFICANTI Comar 2 Li -25° C
FINA CERAN LT Ca -20° C
FINA CERAN WR2 Ca
FUCHS FN 745 Ca -25° C
FUCHS Renocal FN3 Ca -20° C

FUCHS Renolit HLT 2 Li -25° C
KLÜBER Centoplex 2EP Li
MOBIL Mobilgrease 28 Li -30° C
MOLYKOTE TTF 52 anorg thickener -30° C
OPTIMOL Longtime PD 2 Li -20° C
OPTIMOL OLIT CLS Li/Ca -15° C
SHELL Retinax C Ca
WESTFALEN Gresalit ZSA 2 Li -15° C
ZELLER & GMELIN ZG 450 Li
ZELLER & GMELIN ZG 736 Li

Use Lubricants with solid matter additives only after having consulted the manufacture system!
Page 37 of 40
Owner Manual
2.1A-30002-C03
Lubricants, continuation
Bio-degradable greases
Manufacturer Designation Base soap min. delivery temperature
ARAL BAB EP 2 Li/Ca
AUTOL Top Bio 2000 Ca -25° C
AVIA Biogrease 1 Li up to 0 ° C
DEA Dolon E 2 Li -15° C
FUCHS Plantogel S2 Li/Ca
KLÜBER Klüberbio M32-82 Ca -20° C
Use Lubricants with solid matter additives only after having consulted the manufacture system!
Note:
Page 38 of 40
Owner Manual
2.1A-30002-C03
Manufacturer´s Declaration
D GB F I
Herstellererklärung Declaration by the Déclaration du fabricant Dichiarazione del
im Sinne der EG-Richtlinie manufacturer as defined by conformément à la directive costruttore ai sensi della
Maschinen 98/37/EG, machinery directive 98/37/EEC 98/37/CEE, annexe II B direttiva 98/37/CEE in
Anhang II B Annex II B materia di macchinari,
Appendice II B
Hiermit erklären wir, dass die Herewith we declare that the Par la présente, nous Si dichiara che il prodotto da
Bauart von supplied model of déclarons que le produit ci- noi fornito
dessous
Product: Pump 203 for 110-240 VAC with and without control p.c.b.
in der von uns gelieferten is intended to be incorporated dans l’exécution dans laquelle è destinato all' installazione
Ausführung zum Einbau in eine into machinery covered by this nous le livrons, est destiné à su di un macchinario e che la sua
Maschine bestimmt ist und dass directive and must not be put into être installé sur une machine, messa in funzione non sarà
ihre Inbetriebnahme solange service until the machinery into et que sa mise en service est autorizzata fino a quando non
untersagt ist, bis festgestellt which it is to be incorporated has interdite tant qu’il n’aura pas sarà stata accertata la
wurde, dass die Maschine, die in been declared in conformity with été constaté que la machine conformità del macchinario,
das o.g. Produkt eingebaut the provisions of the above sur laquelle il sera installé est sul quale esso dovrà essere
werden soll, den Bestimmungen mentioned directive – including conforme aux dispositions de installato, in relazione alle
der oben genannten Richtlinie – all modifications of this directive la directive ci-dessus, y disposizioni della direttiva
einschließlich deren zum Zeit- valid at the time of the compris les modifications qui 98/37/CEE – comprese tutte
punkt der Erklärung geltenden declaration. y auront été apportées et qui la rettifiche di questa direttiva
Änderungen – entspricht. seront valides à la date de la al momento della
déclaration. dichiarazione.
Angewendete harmonisierte Applied harmonized standards Normes harmonisées, Norme armonizzate applicate
Normen, insbesondere in particular notamment in particolare
Standards: EN 292-1; EN 292-2; EN 809
17.07.2002 Z. Paluncic
(Datum / Unterschrift) (date / signature) (date / signature) (data/firma)
GR E P NL DK
∆ηλωση του κατασκευασ Declaración del fabricante Declaração do Fabricante Verklaring van de fabrikant Fabrikantens erklaring
του συµφ. µε τις προδιαγρ conforme con la Directiva segundo directiva CE inzake de richtlijn betreffende i henold til EF-lovgivning om
αφες: CE sobre máquinas 98/37/CEE, Anexo II B machines, maskiner 98/37/EØF
98/37/ΕΟΚ, παρ. ΙΙ Β 98/37/CEE, Anexo II B (98/37/EEG, bijlage II B) bilag II b
∆ια του παροντος σας γνω− Por la presente, declaramos Em anexo declaramos que o hiermede verklaren wij, dat de Hermed erklares, at
στοποιουµε, οτι το προιον que el modelo suministrado modelo fornecido
Product: Pump 203 for 110-240 VAC with and without control p.c.b.
προοριζεται για τοποθετηση es destinado a ser deverá ser incorporado na ertoe bestemd is, ingebouwd er bestemt til inkorpoering i en
εντος µηχανηµατος, και οτι incorporado en una máquina maquinaria coberta por esta te worden in een machine en maskine og at igangsætningen
δεν επιτρεπεται να τεθει σε y que su puesta en servicio directiva e não poderá ser dat een inwerkstelling forbydes indtil der er
λειτουργια µεχρις οτου está prohibida antes de que colocado em serviço até a verboden is, voordat konstateret, at maskinen, som
διαπιστωθει, οτι το µηχανηµα la máquina en la que vaya a maquinaria na qual é para vastgesteld is, dat de skal inkorporeres i denne
εντος του οποιου προκειται ser incorporado haya sido ser incorporado for machine, waarin deze maskine, er bragt i
declarada conforme a las declarada em conformidade machine wordt ingebouwd, in overensstemmelse med alle
να τοποθετηθει ανταποκρινετ
disposiciones de la Directiva com as provisões da overeenstemming met de relevante bestemmelser, samt
αι στις προαναφεροµενες
en su redacción 98/37/CEE directiva acima mencionada bepalingen van de richtlijn ændringer gældende på
ισχυουσες προ − – incluso las modificaciones / incluindo todas as 98/37/EEG – ingesloten de tot deklarationstidspunktet.
διαγραφες (συµπεριλαµβανο− de la misma vigentes a la modificações desta directiva dit tijdstip geldende
µενων των αλλαγων που ισχυ hora de la declarción. válida desde a emissão veranderingen van deze
−ουν και που εγιναν στο χρον desta declaração. richtlijn - verklaard is.
ι−κο αυτο διαστηµα).
Προσθετα προς εφαρµογην Normas armonizadas Normas harmonizadas Gebruikte geharmoniseerde Harmoniserede standarder, der
χρησιµοποιηθησες εναρµον utilizadas, particularmente utilizadas, em particular normen,namelijk blev anvendt,i særdeleshed
ισµενες προδιαγραφες
Standards: EN 292-1; EN 292-2; EN 809

17.07.2002 Z. Paluncic
(ηµεροµηνια / υπογραφη) (fecha / firma) (Data / assinatura) (Datum/ handtekening) (dato/underskrift)
Page 39 of 40
Owner Manual
2.1A-30002-C03
America: Europe/Africa: Asia/Pacific:

Lincoln Industrial Lincoln GmbH & Co. KG Lincoln Industrial Corporation
One Lincoln Way Heinrich-Hertz Straße 2-8 51 Changi Business Park Central 2
St. Louis, MO 63120-1578 69190 Walldorf # 09-06 The Signature
USA Tel: (+49) 6227 33-0 Singapore 486066 © Copyright 2002
Phone: (+1) 314 679 4200 Fax: (+49) 6227 33-259 Phone: (+65) 6588-0188 Printed in Germany
Fax: (+1) 800 424 5359 Fax: (+65) 6588-3438 Web site:
Email: sales@lincolnindustrial.com.sg www.lincolnindustrial.com
Page 40 of 40
Programming Instructions for Turck Speed Switch MK21-122Ex0-RI
Display
Switching Status of Relay

Pulse Indicator
Power
S1 Key
S2 Key
Display Parameters:
Id - User Specified ID Number. No affect to operation.
Tb - Time Base (Set Tb=1 Pulses per Second)

(Set Tb=60 Pulses per Minute)
nt - Number of Targets per Revolution
Actual Speed Displayed and Threshold Values are a Scaling Factor of Tb and nt.
The Threshold Values are programmed in the same units as the Displayed Values.
Actual Speed Units: Set Tb=60

nt=Number of Targets
Values are displayed and programmed as Revolutions-per-Minute (RPM)
Example: Time Base (Tb=60)

Number of Targets (nt=8)
Shaft RPM = 175
Displayed Actual Speed Operating ~ 175.0
F-0 - Zero Speed Detection

If the rotation speed drops below this set value, the display will show 0000.
It must be set lower that all other set points.
Relay Switch Terminals 10,11,12
Uof - Switch OFF Threshold Underspeed (Critical Switch Point)

Uon - Switch ON Threshold Underspeed (Startup Switch Point)
(Always Set Uon > Uof)
Example: 175 RPM Operating

To set for 25% Underspeed Detection
175*0.75=130 RPM Critical Switch Point
Uof=130.0 Critical Switch Point
Uon=135.0 Startup Switch Point
Oon - Switch ON Threshold Overspeed (On Switch Point)

Oof - Switch OFF Threshold Overspeed (Critical Overspeed Switch Point)
(Always Set Oof > Oon)
Example: 175 RPM Operating

To set for 25% Overspeed Detection
175*1.25=218 RPM Switch OFF Point
Oon=175.0 Switch ON Point
Oof=218.0 Switch OFF Point
Analog Output Terminals 9+, 13-
Iout – Output Current Range, Set at either 0-20mA or 4-20mA
F-IL – Adjustment of minimum frequency for an output current of 0 or 4mA.

Use to adjust dead band of low RPM readings.
F-IH – Adjustment of maximum frequency for an output current of 20mA.

Use to set maximum range of 4-20mA signal.
Always set this 20% greater than maximum engineered speed of unit.
tc – Filter Reaction Time in seconds for “smoothing” the current signal.

This should be set at a minimum of 5 seconds.
Sensor Monitoring
I-Br - Value of current output in case of a wire break on sensor wiring.

Standard is to set this to 0 for underspeed monitoring.
I-Sh- Value of current output in case of a short-circuit on sensor wiring.

Standard is to set this to 0 for underspeed monitoring.
ICM – Input Circuit Monitoring.
Off – disabled
Br – Wire Break Monitoring
Sh – Short Circuit Monitoring
Both (BrSh) – Wire Break and Short Circuit Monitoring
Startup Time Delay

Sud – Startup Time Delay (seconds)
Range (0-1000secs)
During the Startup Time Delay the Underspeed Output Relay is energized. Terminals 7 & 8 control
the Startup Time Delay. The Startup Time Delay is triggered by a normally open with momentary
contact between terminals 7 & 8 during constant power. The Startup Time Delay is also triggered
when power for the speed monitor is applied with the terminals 7 & 8 jumpered.
Soft – Software Version Number (for troubleshooting purposes)
Programming Sequence
(Programming of the Turck Speed Switch Unit requires a mechanical lead pencil or similar device to
activate the S1 and S2 Keys.)
S1 – Programming Key (Adjuster Key)

S2 – Programming Key (Selector Key)
To Start Programming:
Depress the S2 Key to enter the parameters.

Press the S2 Key to display each parameter until the parameter to be changed is displayed.
To exit the Programming, press the S2 Key until the speed is displayed. (Displayed after Soft.)
To Change a Parameter’s Value:
While the parameter to be changed is displayed, depress the S1 key for three seconds to enter the
parameter.
The first value position to the left will be flashing when the parameter is entered.
Press the S1 key to increase the value by one (Scroll Past 9 to go to 0).
To change to another position press the S2 Key.
Before exiting the parameter, the decimal value can be moved by the S1 Key, when flashing.
(This value can be set to 103, for larger values, by pressing the S1 Key and scrolling the decimal position
from the right position to the left position. It can be removed in the same sequence.)
Press the S2 Key to exit the parameter after changing the decimal.
TURCK
Rotational Speed Monitors
The MK21-122Ex0-RI is a rotational speed monitor with intrinsically safe input circuits.
It is designed to monitor pulse sequences from rotating shafts, gears or turbines in
hazardous locations using NAMUR sensors. A display located on the front cover
indicates the actual speed.
The device operates on the digital pulse principle to provide optimum response times
for applications with relatively low speeds (up to 1 kHz). High-speed monitoring is
based on a time window
The analog output provides a 0/4-20 mA current signal that is proportional to the rate of
rotational speed. The beginning and end of the measuring range (window) are
independently adjustable. The current-output response time to a change in rotational
speed is set by means of a filter time constant.
The setpoint relay also operates within a window and includes a combination of
underspeed and overspeed monitoring. For both switching thresholds, a switch-on and
switch-off value can be set (switching hysteresis). A yellow LED indicates the switching
status of the output relay.
A start-up time delay of 0-1000 s can be set during which the output relay remains
energized. This function serves to inhibit underspeed indications during system start-up.
The start-up time delay is triggered by the closing of a set of contacts across terminals 7
and 8, or by powering the device with terminals 7 and 8 linked.
The NAMUR input is monitored for wire-break and short-circuit. In case of an input
circuit fault, the relay de-energizes and the yellow input pulse LED changes to red.
Two scaling parameters can be selected. The time base parameter enables computation
in units other than Hz. The second parameter is used when there is more than one
MK21-122Ex0-RI input pulse per revolution.
Example: Suppose it is desired for the display to read in pulses per minute rather than
Hz, and that there are two pulses per revolution. In this case, the scaling parameter
adjustments would be as follows:
- Parameter 1 (time base) = 60
- Parameter 2 (number of pulses/revolution) = 2
Connection Diagram
C9 TURCK Inc. 3000 Campus Drive Minneapolis, MN 55441 Application Support: 1-800-TURCK-IS Fax: (763) 553-0708 www.turck.com
Overspeed/Underspeed Monitor with Display
Intrinsically Safe Relay and Analog Current Outputs
MK21-122Ex0-RI
Type MK21-122Ex0-RI
ID Number M7543053
Power Supply
Supply voltage 20-250 VAC, 20-125 VDC
Power consumption £5 W
Galvanic isolation between hazardous and
non-hazardous circuits,
test voltage 2.5 kVrms
Rotational Speed
Rotational Speed Monitoring overspeed/underspeed
Measuring range 0.06-600,000/min. (1 mHz-10 kHz)
Monitors
- Input Frequency £1.2 million/min. (20 kHz)
Minimum pulse duration 0.02 ms
Minimum pause duration 0.02 ms
Start-up time delay 0-1000 s (adjustable)
Input Circuit
Nominal operating characteristics (per DIN 19234)
- Voltage 8.2 V
- Current 8.2 mA
- Switching threshold 1.55 mA
- Switching hysteresis 0.2 mA
- Wire-break threshold £0.1 mA
- Short-circuit threshold ³6 mA
Intrinsic Safety Parameters See page K11
Output Circuits one SPDT relay,

one current output
Relay output
- Contact Material AgCdO + 3m Au
- Switching voltage per output £250 V
- Switching current per output £2 A
- Maximum load per output £500 VA/60 W
Analog output
- Current source 0/4-20 mA
- Load £500 W
- Filter time constant 0-60 s in 80 ms increments
LED Indications
Power “ON” green
Relay status indication yellow
Input pulses/fault yellow/red
Display LCD display (4-digit)
Housing Style Diagram D (page A17)
TURCK Inc. 3000 Campus Drive Minneapolis, MN 55441 Application Support: 1-800-TURCK-IS Fax: (763) 553-0708 www.turck.com C10
TURCK
Inductive Sensors - Barrels
M Barrel Barrel, Metal with Quick Disconnect

Partial Threading
2-Wire DC, Requires Remote Amplifier eurofast â
5-30 VDC
Variable Resistance Output, NAMUR (EN 50227) NRTL/C
Sensor Selection
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Part Number Connection
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Bi 2-M12-Y1X-H1141 · 2 12 1 A 1 5000 · £1 M4010200 eurofast
Bi 5-M18-Y1X-H1141 · 5 18 3 A 1 1000 · £2 M4015200
Bi10-M30-Y1X-H1141 · 10 30 5 A 1 500 · £5 M4020200 Mating Cordsets
RK 4.21T-2 (2 meter)
Ni 5-M12-Y1X-H1141 5 12 2 A 1 2000 · £1 M4010300
For other styles see
Ni10-M18-Y1X-H1141 10 18 4 A 1 500 · £2 M4015300
Section H or consult
Ni15-M30-Y1X-H1141 15 30 6 A 1 200 · £5 M4020300
“Cordsets” catalog.
* Factory Mutual approval applies only when used with Factory Mutual approved switching amplifiers.
Material Accessories
Connector: Chrome Plated Brass Accessories and mounting devices can be found in Section J.
Barrel: Chrome Plated Brass Remote Amplifier required. Consult TURCK multimodul or Automation
Sensing Face: PA 12-GF30 Plastic Controls catalog.
C183 TURCK Inc. 3000 Campus Drive Minneapolis, MN 55441 Application Support: 1-800-544-PROX Fax: (763) 553-0708 www.turck.com
Specifications Wiring Diagram
Differential Travel (Hysteresis) . . . . . . . . 1-10% (5% typical) A NAMUR Output
Nominal Voltage. . . . . . . . . . . . . . . 8.2 VDC (EN 50227)
Resistance Change from
Nonactivated to Activated Condition . . . . 1.0 kW to >8.0 kW
Resulting Current Change . . . . . . . . . . ³2.2 mA to £1.0 mA
Recommended Switching Point for
Remote Amplifier . . . . . . . . . . . . . . 1.55 mA
Power-On Effect . . . . . . . . . . . . . . . Realized in Amplifier
Reverse Polarity Protection . . . . . . . . . Incorporated
Wire-Break Protection . . . . . . . . . . . . Realized in Amplifier
Barrels
Transient Protection . . . . . . . . . . . . . Realized in Amplifier
Operating Temperature . . . . . . . . . . . -25°C to +70°C (-13°F to +158°F)
Enclosure . . . . . . . . . . . . . . . . . . Meets NEMA 1,3,4,13 and IEC IP 67
Shock . . . . . . . . . . . . . . . . . . . . 30 g, 11 ms
Vibration . . . . . . . . . . . . . . . . . . 55 Hz, 1 mm Amplitude in all 3 Planes
Repeatability. . . . . . . . . . . . . . . . . £2% of Rated Operating Distance
LED On . . . . . . . . . . . . . . . . . . . Output Energized
Dimensions
1 2
3 4
5 6
TURCK Inc. 3000 Campus Drive Minneapolis, MN 55441 Application Support: 1-800-544-PROX Fax: (763) 553-0708 www.turck.com C184
Spare Parts List
18" x 72" Standard Duty Triple Roll Crusher
Qty Part Description Price Each Lead-Time

Number
Start-up
Qty Part Description Price Each Lead-Time
Number
1 2-909-57100 Spherical Roller Bearing (Primary Stage)
1 3-921-30504 Tapered Bearing Adapter
1 2-921-32004 Stabilizing Ring
2 2-909-57900 Spherical Roller Bearing (Secondary Stage)
2 3-218-85062 Spacer Ring Seal
4 2-986-57900 Seal
2 2-969-08904 Retaining Ring
4 2-909-15700 Radial Ball Bearing (Idler Pulleys)
8 2-939-93144 V-Belt, Double, CC144
3 2-939-14027 V-Belt, 4R5V2360
2 2-944-58032 Proximity Sensor
2 2-944-53087 Speed Switch
2 2-944-96145 Cordset
2 Year Spares
Primary Stage Components
2 2-909-57100 Spherical Roller Bearing
3 3-061-19801 Segment, McL400, 18x72, Tooth 8669
3 3-059-12802 Cr. Pl. Tip, MCL400, 18x24
1 3-315-16002 Hold Back Bolt Assemby
2 3-318-85031 Spring Rod
2 2-990-18906 Compression Spring
Secondary Stage Components
2 3-063-19800 Roll Shell, McL400, 18x72, Tooth 10171
4 2-909-57900 Spherical Roller Bearing (Secondary Stage)
7 3-218-85062 Spacer Ring Seal
14 2-986-57900 Seal
7 2-969-08904 Retaining Ring
1 3-315-85035 Spring Rod
1 2-990-18001 Compression Spring, 5" OD, 15" Free Height
Capital Spares
1 3-318-17031 Primary Stage Roll Shaft/Segment/Bearing Assembly
1 3-318-17032 Stationary Roll Shaft/Shell/Bearing Assembly
1 3-318-17033 Movable Roll Shaft/Shell/Bearing Assembly
FIELD SERVICE CHARGES
MINERAL & AGGREGATE DIVISIONS
VERSION A, REV. 1/1/12
FIELD SERVICE CHARGES

Mineral & Aggregate Divisions
OVERVIEW
Field service is provided by factory-trained personnel, and is available to operators of McLanahan
equipment. Field service personnel can be scheduled to assist in installation, inspection, maintenance,
major overhauls, or engineering. The parts and work performed by the service personnel carry a full
warranty. This warranty, however, does not necessarily cover the complete machine. Rather, it is limited
to only those components or sections upon which the maintenance is performed.
Engineering service personnel can also provide instruction to the user's operating, maintenance, and
engineering personnel upon request.
Field service assistance may be arranged by contacting the company’s Field Service Department. Rates
cover the total time spent working and traveling between the factory and the customer's facility, as
defined in the table below. A minimum of 8 hours will be invoiced for any day that service personnel are
retained at the site but work is not available.
RATES
SUBJECT TO CHANGE SATURDAYS

WITHOUT NOTICE WEEKDAYS HOLIDAYS TRAVEL
& SUNDAYS
HOURLY RATE HOURLY RATE HOURLY RATE HOURLY RATE HOURLY RATE
LOCATION SERVICE FIRST 8 HRS. AFTER 8 HRS. ALL HOURS ALL HOURS ALL HOURS
CONTINENTAL MAINTENANCE
PERSONNEL
$100.00 $150.00 $150.00 $200.00 $100.00
UNITED STATES,
CANADA, & ENGINEERING
PUERTO RICO PERSONNEL
$130.00 $195.00 $195.00 $260.00 $130.00
OUTSIDE CONT. MAINTENANCE

PERSONNEL
$120.00 $180.00 $180.00 $240.00 $120.00
UNITED STATES,
CANADA, &
ENGINEERING
PUERTO RICO
PERSONNEL
$160.00 $240.00 $240.00 $320.00 $160.00
PROCESS ENGINEERING CONSULTING RATES: WEEKDAYS, WEEKENDS AND TRAVEL DAYS ..............$1200.00/DAY
HOLIDAYS .................................................................................$2000.00/DAY
EXPENSES
The customer will be charged for all actual travel and living expenses incurred during the time that
service personnel work at the site or travel to or from the site. Expenses include, but are not limited to
food, lodging, and transportation. Mileage for non-rental vehicles is charged at $0.50 per mile for
automobiles, $0.50 per mile for pick-up trucks, and $1.25 per mile for a specially equipped field service
truck. Rental vehicles and fuel will be invoiced at cost. The higher rates apply only if the corresponding
vehicle is specifically required for the job.
FIELD SERVICE CHARGES 1

TAGS
VERSION B, REV. 07
TAGS
OVERVIEW
This section contains information regarding operational and personal safety tags that may be used on
this equipment. Each tag used on the machine conveys a message that is significant to proper operation
and/or personal safety, and must be adhered to at all times. If any tag becomes damaged, lost, or is
missing from its designated location, cease operation of the machine and replace the tag immediately.
A duplicate tag may be obtained free of charge by contacting McLANAHAN CORPORATION.
Each personal and product safety tag has been designed according to the ANSI Z535.4 standard. These
tags contain a “signal word” (CAUTION, WARNING or DANGER) that indicates the seriousness of the
hazard as described below.
DANGER indicates an imminently hazardous situation which, if not

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

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

avoided, may result in minor or moderate injury.
CAUTION (used without the safety alert symbol) indicates a potentially

hazardous situation which, if not avoided, may result in property damage.
The following page contains a table of the safety and informational tags that are currently available from
McLANAHAN CORPORATION. Many of the tags included in this table do not relate to this
particular piece of equipment. A list of the tags used on this equipment, as well as the actual location of
each tags, can be found on the “INSTRUCTION AND SAFETY DECAL LOCATION” drawing located
in the DRAWINGS section of this manual.
NOTICE: MCLANAHAN CORPORATION RESERVES THE RIGHT TO ALTER TAGS AND TO ADD OR DELETE TAGS
WITHOUT NOTICE.
TAGS 1
TAGS
VERSION B, REV. 07
SAFETY/INFORMATIONAL TAG DESCRIPTIONS

TAG # TAG DESCRIPTION TAG # TAG DESCRIPTION
T-1 WARNING - SAFETY INTERLOCK SWITCHES MUST BE WIRED INTO MOTOR… T-51 FRENCH T-18
T-2 SUPERCEDED BY T-3 SERIES TAG T-52 FRENCH T-22
T-3a WARNING - STAY CLEAR - V-BELT DRIVE T-53 FRENCH T-17
T-3b WARNING - STAY CLEAR - CHAIN AND SPROCKET T-54 FRENCH T-20 (OLD STYLE)
T-3c WARNING - STAY CLEAR - SCREW/MIXER SHAFT T-55 FRENCH T-5 (OLD STYLE)
T-3d WARNING - STAY CLEAR - ROTATING SHAFT/COUPLING T-56 FRENCH T-3 (OLD STYLE)
T-3e WARNING - STAY CLEAR - ROTARY PINCH POINT T-57 FRENCH - FIELD WELD GUSSET TO I-BEAM, 4-PLACES
T-3f WARNING - STAY CLEAR - TOGGLE/LINKAGE T-58 FRENCH - FIELD WELD GUSSET TO I-BEAM
T-3g WARNING - STAY CLEAR - TWO ROLL CRUSHER T-59 DISENGAGE CYLINDER FROM TORSION ARM BAR BEFORE OPERATING
T-3h WARNING - STAY CLEAR - ONE ROLL CRUSHER T-60 CAUTION - THIS EQUIPMENT MUST BE PROPERLY ALIGNED
T-3i WARNING - STAY CLEAR - ROTATING HAMMERS T-61 SUPERCEDED BY T-3 SERIES TAG
T-3j WARNING - STAY CLEAR - MOVING DRAG CHAIN/BELT T-62 FEED END
T-3k WARNING - STAY CLEAR - GEAR/PINION PINCH POINT T-63 DISCHARGE END
T-4 SUPERCEDED BY T-3 SERIES TAG T-64 1
T-5 CAUTION - TO AVOID TWISTING FRAME: DO NOT PULL DOWN TO FOUNDATION T-65 2
T-6 WARNING - TOP COVERS MUST BE INSTALLED BEFORE OPERATING T-66 3
T-7 CRUSHER SETTING CYLINDER OPERATING INSTRUCTIONS T-67 4
T-8 TWO-STAGE CRUSHER ROLL ADJUSTMENT NOTICE FOR MAX. EFFICIENCY T-68 5
T-9 ROLL ADUSTMENT INDICATOR T-69 6
T-10 CONTROL HANDLE POSITION NOTICE T-70 7
T-11 CAUTION - CYLINDER MUST BE DISENGAGED FROM CRUSHING PLATE… T-71 8
T-12 OPERATING POSITION/NEUTRAL POSTIONS TAGS T-72 9
T-13 WARNING - DO NOT ADJUST WHILE EQUIPMENT IS ENERGIZED T-73 0
T-14 REMOVE PIPE PLUG FROM BEARING HOUSING - INSERT OIL RESERVOIR T-74
T-15 GREASE LUBRICATED BEARING INSTRUCTIONS (50-70%) T-75 NOTICE - RECOMMENDED INITIAL COMPRESSED HEIGHT OF SPRING IS____
T-16 MAINTAIN OIL AT CENTERLINE OF OIL LEVEL GAGE T-76 CAUTION - TRAVEL SPEED NOT TO EXCEED 10 MPH WHEN ASSEMBLED
T-17 LUBRICATION FITTING T-77 HUB LOCKING ASSEMBLY - REFER TO OPERATORS MANUAL FOR TORQUES
T-18 OIL LEVEL T-78 VIBRATOR INFORMATION - COUNTER-ROTATING ARROWS
T-19 CAUTION - LIFT HERE T-79 ROTATION ARROW (CW) (3" X 3")
T-20 SUPERCEDED BY T-3 SERIES TAG T-80 ROTATION ARROW (CCW) (3" X 3")
T-21 DRIVE THIS KEY FIRST T-81 McLANAHAN CORPORATION - BLUE W/WHITE LETTERS (4" X 12")
T-22 WHEN INSTALLING MACHINE THESE POINTS MUST BE LEVEL T-82 McLANAHAN CORPORATION - WHITE W/BLUE LETTERS (4" X 12")
T-23 REMOVE PLUG AND CONNECT AIR SUPPLY (90-100 PSI REQ'D) T-83 McLANAHAN/MOGENSEN - WHITE W/BLACK LETTERS (2" X 36")
T-24 REMOVE PLUG AND ATTACH OILER WHICH WAS SHIPPED SEPARATELY T-84 McLANAHAN/MOGENSEN - WHITE W/BLACK LETTERS (1 3/4" X 21")
T-25 A T-85 WEDGE INSTALLATION INSTRUCTIONS – CHAMFER ON UNDERSIDE
T-26 B T-86 STROKE METER – OPERATING INSTRUCTIONS HAVE BEEN SUPPLIED
T-27 C T-87 DANGER - HIGH CURRENT
T-28 D T-88 RED SCREEN CLOTH TAG
T-29 E T-89 YELLOW SCREEN CLOTH TAG
T-30 F T-90 GREEN SCREEN CLOTH TAG
T-31 TIRE PRESS. 50 PSI T-91 BLUE SCREEN CLOTH TAG
T-32 TIRE PRESS. 45 PSI T-92 WARNING –READ INSTRUCTIONS - FEEDER BREAKER MOVEMENT
T-33 TIRE PRESS. 40 PSI T-93 DISENGAGE COUPLING BEFORE TRAMMING
T-34 TIRE PRESS. 32 PSI T-94 DISENGAGE PUMP COUPLING BEFORE OPERATING CONVEYOR
T-35 TIRE PRESS. __ PSI T-95 FILL COUPLING WITH ____ OZ. OF ___FLUID OR EQUIVALENT
T-36 BLANK T-96 EMERGENCY SHUT-OFF
T-37 THIS BOLT TO BE USED FOR ADJUSTMENT ONLY T-97 THIS HOUSING CONTAINS A STABILIZING RING THAT MAY NOT BE REQ’D.
T-38 115 VOLTS T-98 McLANAHAN/WILLIAMS - WHITE W/BLUE LETTERS - LARGE
T-39 ROTATION ARROW (CCW) (7/8" X 5") T-99 CAUTION - PROCESSING EQUIPMENT/LUBRICATE REDUCER SPLINES
T-40 ROTATION ARROW (CW) (7/8" X 5") T-100 WARNING - ELECTRONIC EQUIPMENT STORAGE INSTRUCTIONS
T-41 ROTATION ARROW (CCW) (1/4" X 1 1/2") T-101 TORQUE HUBS SET IN FREE-WHEEL MODE FOR SHIPPING
T-42 ROTATION ARROW (CW) (1/4" X 1 1/2") T-102 CAUTION - DO NOT START POWER UNIT WITH SUCTION VALVE CLOSED
T-43 INSTALL HOPPER BOLT BEFORE INSTALLING SIDE LINER T-103 McLANAHAN CORPORATION - WHITE W/BLUE LETTERS ( 7 1/2" X 24 1/2")
T-44 THIS SEAL KIT CONTAINS EPOXY CEMENT WHICH EXPIRES AFTER ______ T-104 SLING HERE
T-45 DRILL 3/4" HOLE THRU FIBRE BEARING USING TOP WATER INLET AS GUIDE T-105 McLANAHAN CORPORATION - BLUE W/WHITE LETTERS (7 1/2" X 24 1/2")
T-46 SPARE O-RING FOR DRIVE BELT. DO NOT REMOVE T-106 McLANAHAN CORPORATION - WHITE W/BLUE LETTERS (12 1/8" X 37")
T-47 ____ AMP FUSE. DO NOT EXCEED T-107 McLANAHAN CORPORATION - BLUE W/WHITE LETTERS (12 1/8" X 37")
T-48 WARNING - PROCESS EQUIPMENT - STAY CLEAR WHILE IN OPERATION T-108 10
T-49 INSTALL BOTTOM SECTION OF GEAR CASE BEFORE LOCATING GEAR T-109 11
T-50 FRENCH T-19 (OLD STYLE) T-110 PORT "A"
TAGS 2
TAGS
VERSION B, REV. 07
SAFETY/INFORMATIONAL TAG DESCRIPTIONS (CON'T)

TAG # TAG DESCRIPTION TAG # TAG DESCRIPTION
T-171 McLANAHAN CORPORATION - BLUE W/WHITE LETTERS (2" X 6")
T-111 PORT "B" T-172 McLANAHAN CORPORATION - BLUE W/WHITE LETTERS (1 1/2" X 4 1/2")
T-112 CHARGE PRESSURE T-173 CAUTION THE BEARINGS ON THIS ASSEMBLY HAVE BEEN DRAWN UP ON …
T-113 McLANAHAN CORPORATION - WHITE W/GREEN LETTERS (4" X 12") T-174 WARNING – DO NOT HAMMER. CERAMIC LINING INSIDE
T-114 PATENT #5,720,393 OTHER PATENTS PENDING T-175 WARNING – CRUSH HAZARD. RAISED DOOR COULD FALL CAUSING ….
T-115 McLANAHAN CORPORATION - WHITE W/GREEN LETTERS (7 1/2" X 24 1/2") T-176 ISO – CE Mark
T-116 FLUID COUPLING FILL ANGLE ____ DEGREES FROM VERTICAL OR ____ FL. OZ T-177 ISO – PROTECTIVE EARTH GROUND
T-117 RIGHT SIDE T-178 ISO – READ OPERATOR’S MANUAL
T-118 LEFT SIDE T-179 ISO – EYE PROTECTION REQUIRED
T-119 CAUTION - BREAKER ROLL ROTATES DURING TRAMMING IF COUPLING NOT … T-180 ISO – EAR PROTECTION REQUIRED
T-120 OIL HEATER T-181 ISO – LOCKOUT/TAGOUT
T-121 TEMPERATURE SWITCH T-182 ISO – LIFT POINT
T-122 FLUSHING VALVE T-183 ISO – STAY CLEAR
T-123 SYSTEM PRESSURE SWITCH T-184 ISO – DO NOT OPERATE WITH GUARD REMOVED
T-124 OIL LEVEL SWITCH T-185 ISO – NO OPEN FLAME
T-125 RETURN FILTER T-186 ISO – GENERAL DANGER
T-126 CHARGE FILTER T-187 ISO – HAZARDOUS VOLTAGE
T-127 CHARGE PRESSURE SWITCH T-188 ISO – AUTOMATIC STARTUP
T-128 CASE DRAIN FILTER T-189 ISO – HAND ENTANGLEMENT
T-129 McLANAHAN CORPORATION - RECOMMENDED OILS AND LUBRICANTS T-190 ISO – CUTTING OF FINGERS OR HAND / AUGER
T-130 CHECK CHAIN FOR PROPER TENSION - 30 TOOTH SPROCKET T-191 ISO – CUTTING OF FINGERS OR HAND / ROTATING SHAFT
T-131 CHECK CHAIN FOR PROPER TENSION - 36 TOOTH SPROCKET T-192 ISO – ENTANGLEMENT / ROTATING SHAFT
T-132 SUPERCEDED BY T-160 T-193 ISO – FLAMMABLE MATERIAL
T-133 BELT TILT – FEED CONVEYOR / BELT SPEED – DISCHARGE BELT
T-134 CAUTION - NOISE HAZARD. HEARING PROTECTION MAY BE REQUIRED
T-135 CAUTION - HEARING PROTECTION MAY BE REQUIRED - SMALL
T-136 SEE IOM MANUAL FOR WIRING DIAGRAM AND INSTALLATION INSTRUCTIONS
T-137 LPT GROUP, INC. (7" X 40")
T-139 HSS SAMPLING SYSTEMS (3 1/2" X 5")
T-140 DANGER - STAY CLEAR. THIS MACHINE MAY START AUTOMATICALLY
T-141 HSS SAMPLING SYSTEMS (5" X 7")
T-142 HSS SAMPLING SYSTEMS (8" X 11")
T-145 NOTE - THE GLAND ON THIS PUMP REQUIRES ADJUSTMENT
T-146 THE IMPELLER CLEARANCE HAS BEEN CORRECTLY SET ON THIS PUMP
T-147 CLEARANCE BETWEEN THE IMPELLER AND SUCTION LINER IS CRITICAL…
T-148 WARNING - POLYURETHANE PRODUCT. FIRE AND TOXIC FUME HAZARD
T-149 THE WOOD PACKING MAT'L. IN THIS SHIPMENT IS NOT CONIFEROUS WOOD
T-150 NO WELD OR BURN (ENGLISH & SPANISH) - (2" X 4")
T-151 VD-6 - (4" X 9 1/2")
T-152 VD-9 - (4" X 9 1/2")
T-153 VD-12 - (4" X 10 1/2")
T-154 VD-15 - (4" X 10 1/2")
T-155 VD-18 - (4" X 10 1/2")
T-156 VD-21 - (4" X 10 1/2")
T-157 WARNING - READ & UNDERSTAND OPERATORS MANUAL BEFORE USING…
T-158 SAND MANGAGER CLASSIFYING TANK - WHITE W/BLUE LETTERS (24 X 36)
T-159 WARNING - DO NOT OPEN WHILE MACHINE IS OPERATING
T-160 DANGER - SHOCK, ARC FLASH AND EXPLOSION HAZARD
T-161 LPT - (4" X 6")
T-162 LPT - (6" X 9")
T-163 LPT - (12" X 18")
T-164 LPT - (24" X 36")
T-165 McLANAHAN - WHITE W/GREEN W/PHONE NO. AND WEB SITE (4" X 12")
T-166 WARNING - RUBBER PRODUCT. FIRE AND TOXIC FUME HAZARD.
T-167 CAUTION – BALL TRAY MAY PLUG. DO NOT USE WITH SCREENS OVER 3/8”
T-168 DANGER – FLYING DEBRIS. STAY CLEAR DURING OPERATION.
T-169 CAUTION – VERIFY DIRECTION OF MOTOR ROTATION BEFORE OPERATING
T-170 LPT - (2 1/2" X 4 1/2")
TAGS 3
MATERIAL SAFETY DATA SHEETS
VERSION A, REV. 03
MATERIAL SAFETY DATA SHEETS
OVERVIEW
This equipment is considered an Article within the Occupational Safety and Health Administration (OSHA)
hazard Communication Regulation 1910.1200 and is exempt from the requirements of 1910.1200 including
Material Safety Data Sheets. However, this equipment has been produced using a variety of raw materials and
purchased components that may become hazardous, or emit hazardous chemicals, if they are exposed to certain
fluids or chemicals, heat, or other adverse conditions. In accordance with OSHA regulations, McLANAHAN
CORPORATION will supply Material Safety Data Sheets, at the user’s request, for any material used to
manufacture this equipment.
Always consult the raw material or purchased component Material Safety Data Sheets (MSDS) before using,
working with, or altering any part of this equipment, to be assured of its safety and health risks. To request a
specific MSDS, please contact the Safety Director at McLANAHAN CORPORATION.
MATERIAL SAFETY DATA SHEETS 1

DRAWINGS
VERSION A, REV. 02
DRAWINGS
OVERVIEW
The drawings in this manual provide information such as parts identification and nomenclature, and
specific safety and technical data to aid in the proper installation, operation and maintenance of this
equipment. Although the drawings are current at the time of this printing, McLANAHAN
CORPORATION reserves the right to revise any drawing without notice.
If any drawings become damaged or misplaced, contact the Engineering Department at McLANAHAN
CORPORATION to obtain a replacement copy. (Refer to the Table of Contents for a complete list of
drawings.)
DRAWINGS 1
8 7 6 5 4 3 2 1
H H
137 11/16"
66 1/4" 61 1/4"
56 15/16"
G G
7 11/16"
11 3/4"
7 5/16"
F F
4 1/2"
CENTERLINE OF
107 1/16"
PRIMARY ROLL SHAFT
3"
1
71 72 73
7 1/2"
64
9 3/4" 9 3/4" 9 3/4" 9 3/4" 9 3/4" 9 3/4"
65
7 1/2"
66
7 1/2"
4 3/4" 5 1/4" 5 1/4" 4 3/4"
68
E 53 E
54 69
29 1/4"
55
56
57
58
1
39 1/4" 39 1/4"
49 3/16" 58"
31" 31 1/4"
D 16" D
4 1/8" 20 1/2"
37" 37" 14 15 16 17 18
3 1/2" 3 1/2"
FEED OPENING
22
47 46 45
GROOVED FOR 12-5V BELTS,

CENTRALLY LOCATED
1/2"
13
19 7/16"
5
11"
62
20
55 13/16"
51 50 49 61
C C
60 9
40 1/4"
8
Ø50"
7
29 11/16"
25 3/8"
28 27 26 25 24
16"
16"
10"
32 31 30 11
9"
1-1/8" HOLE 17-3/4" MIN
38 1/8" 38 1/8" 21"
FOR 1" BOLTS 22-1/4" MAX
DISCHARGE OPENING
4-PLACES
24" 51 1/4" DISCHARGE OPENING 3 1/2"

41 1/4" 41 1/4"
12 3/4" 60" 6"
8 3/8" 12"
43 1/8" 43 1/8"
B FACE FACE B
78 3/4" 26 3/4"
70 7/16" 67 1/4"
105 1/2"
SEE SHEET #1 OF 3 FOR ASSEMBLY DETAILS

SEE SHEET #2 OF 3 FOR FOUNDATION PLANS
SEE SHEET #3 OF 3 FOR SAFETY TAGS
INFORMATION CONTAINED IN
THE LOADED WEIGHT OF THIS MACHINE IS 26,200 THIS DOCUMENT IS A TRADE
THIS DRAWING, INCLUDING THE SECRET AND ANY USE OF THE
INFORMATION HEREON, IS NOT LBS. WHEN DESIGNING THE SUPPORTING INFORMATION, EXCEPT BY ITS
INTENDED RECEIVER, IS
TO BE USED FOR ERECTION STRUCTURE, A FACTOR OF SAFETY SHOULD BE STRICTLY PROHIBITED AND
PURPOSES UNLESS CERTIFIED MISAPPROPRIATION OF THE
A APPLIED TO THE MACHINE LOADED WEIGHT PER INFORMATION SHALL MAKE
A
BY THE McLANAHAN THE NONINTENDED RECEIVER
CORPORATION. THE DRAWING, THE FOLLOWING CHART: LIABLE FOR ANY AND ALL
DAMAGES SUFFERED AS A DESCRIPTION AUTHOR CREATION DATE
DESIGN AND DETAIL IS THE RESULT BY THE McLANAHAN
PROPERTY OF McLANAHAN CORPORATION.
PARTS LIST AND ASSEMBLY FOR 18" X 72" JMcConnell 4/20/2012
UNLESS OTHERWISE
CORPORATION AND SHALL NOT STANDARD DUTY TRIPLE ROLL CRUSHER, CHECKED BY CHECKED DATE
SPECIFIED, TOLERANCES ON
BE MODIFIED, COPIED OR USED
VERTICAL LOADS HORIZONTAL LOADS DIMENSIONS ARE: S/N: 20122010
DIRECTLY OR INDIRECTLY FOR DECIMAL ±0.010 MACHINE MACHINE SIZE
ANY OTHER PURPOSE WITHOUT LATERAL TRANSVERSE FRACTIONAL ±1/64
FABRICATION ±1/8 STRC 18" X 72"
THE WRITTEN APPROVAL OF CAST SURFACES ±1/16
ADDED QTY 2 OF SPEED SENSOR BRACKET P/N: DRAWING NUMBER
THE McLANAHAN SURFACE FINISH √125
3.0 0.20 0.15
1 3-360-85047, ITEM #77, AND ADDED V-BELT 7/2/2012 JJM CORPORATION. ALL RIGHTS OF UNLESS OTHERWISE NOTED,
DESIGN AND INVENTION ARE PERPENDICULAR TO THE PARALLEL TO THE ALL WELDS ARE TO BE SCALE WEIGHT PART NUMBER REV.
ARRANGEMENT VIEW TO SHEET #2 OF 3 CONTINUOUS. FILLET WELDS
RESERVED. ROTATING AXIS OF THE ROTATING AXIS OF ARE TO BE 9/16 OF MINIMUM
REV DESCRIPTION DATE BY ROLL OR DRUM THE ROLL OR DRUM PLATE THICKNESS. TRC1872002 REF: P30E32 SHEET 1 OF 3
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
12 1/2" 60" 6"
25 1/2" 34 1/2"
H H
59 TOOTH GEAR,
PRIMARY STAGE
CENTERLINE OF
CENTERLINE OF MOVABLE ROLL
STATIONARY ROLL ASSEMBLY
ASSEMBLY
41 1/4"
IDLER ASSEMNBLY #1
G G
MOVABLE
ROLL
76 1/4" DISCHARGE OPEING

CENTERLINE
OF CRUSHER
STATIOANRY ROLL
IDLER ASSEMNBLY #2
F 51 1/4" DISCHARGE OPENING 1 INTERSTAGE V-BELT ARRANGEMENT F
41 1/4"
55 5/8"
55 5/8"
1 1/8" HOLE
FOR 1" BOLT
4-PLACES
71 11/16"
61 7/8"
67 7/8"
E E
5/8" HOLE
FOR 1/2" BOLT
8"
4-PLACES
10"
13 1/4" 12 1/4"
24"
D D
3/4" HOLE
FOR 5/8" BOLT
4-PLACES
77 11/16" 22"
SECTION B-B
SCALE 1 / 8
C C
B B

B B INTENDED RECEIVER, IS
A
UNLESS OTHERWISE
THE WRITTEN APPROVAL OF CAST SURFACES ±1/16 DRAWING NUMBER
3.0 0.20 0.15
CORPORATION. ALL RIGHTS OF UNLESS OTHERWISE NOTED,
CONTINUOUS. FILLET WELDS
ROLL OR DRUM THE ROLL OR DRUM PLATE THICKNESS. TRC1872002 REF: P30E32 SHEET 2 OF 3
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
H H
T-77SP
G G
T-17SP
T-3fSP
F F
T-157SP T-140SP T-134SP T-48SP T-13SP T-8SP T-8SP T-13SP T-48SP T-134SP T-140SP T-157SP
T-17SP
E E
T-9SP
ON TYE BAR
D D
T-19SP T-17SP
T-19SP
C C
T-3fSP
BOTH SIDES
B B
T-5SP
AT FOUNDATION HOLES

A
UNLESS OTHERWISE
THE WRITTEN APPROVAL OF CAST SURFACES ±1/16 DRAWING NUMBER
3.0 0.20 0.15
CORPORATION. ALL RIGHTS OF UNLESS OTHERWISE NOTED,
CONTINUOUS. FILLET WELDS
ROLL OR DRUM THE ROLL OR DRUM PLATE THICKNESS. TRC1872002 REF: P30E32 SHEET 3 OF 3
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
D D
45
101 1/2"
52 51 50
43
C 59 C
54
108"
21 22 23 24 25 27 28 29 30 98 3/4"
8
B B
19 18 17 16
45 46 47 48
64 65 66
62 61 60 59
35 34 33 32
57 56 55 54
55 3/4"
11 10 9 43
14 13 12 37
6 5 4 3
38 39 40 41
Ø1-1/8" HOLE 1
4-PLACES
41 1/4" 41 1/4"
6" 60" 12 1/2" 43 1/8" 43 1/8"
A 26 3/4" 21" 59 7/16" 109 7/8" A
107 3/16" INFORMATION CONTAINED IN

THIS DOCUMENT IS A TRADE
SECRET AND ANY USE OF THE
INFORMATION, EXCEPT BY ITS
STRICTLY PROHIBITED AND
MISAPPROPRIATION OF THE
INFORMATION SHALL MAKE THE
NONINTENDED RECEIVER LIABLE
FOR ANY AND ALL DAMAGES
SUFFERED AS A RESULT BY THE
McLANAHAN CORPORATION. DESCRIPTION AUTHOR CREATION DATE
UNLESS OTHERWISE SPECIFIED, JMcConnell 4/30/2012

TOLERANCES ON DIMENSIONS CHECKED BY CHECKED DATE
ARE:
MACHINING
DECIMAL ±0.010 BASE FRAME ASSEMBLY FOR 18" X 72" MACHINE MACHINE SIZE
FRACTION ±1/64
PROFILE/SAW ±1/16 STANDARD DUTY TRIPLE ROLL CRUSHER TRC 18" X 72"
FABRICATION ±1/8
DRAWING NUMBER
CAST SURFACES ±1/16
SURFACE FINISH √125
UNLESS OTHERWISE NOTED, ALL SCALE WEIGHT PART NUMBER REV.

WELDS ARE TO BE CONTINUOUS.
FILLET WELDS ARE TO BE 9/16 3-318-18004
OF MINIMUM PLATE THICKNESS. REF: 96E48 SHEET 1 OF 1
8 7 6 5 4 3 2 1
4 3 2 1
9
11
12
D 13 D
15
6 14
3 4
7
10
2
C C
5
EXPLODED VIEW
SCALE 1 / 20
75"
74" INSIDE OF FRAME
36" 36"
DIRECTION OF ROTATION
13 12 11
15 14 A
FREE 5 HELD
9 BEARING BEARING
1 6
6
B B
7
10
8 8
2
7 2
6
12 3/4" END OF 1/2" END OF
SHAFT TO FACE SHAFT TO FACE
OF ADAPTER OF ADAPTER A 4
4
14 13/16" 91 1/4" 3 3/4"
109 13/16"
SECTION A-A SECRET AND ANY USE OF THE
SCALE 1 / 8 INFORMATION, EXCEPT BY ITS
A NONINTENDED RECEIVER LIABLE A

ARE:
MACHINING
DECIMAL ±0.010 PRIMARY ROLL SHAFT ASSEMBLY, 18" 72" MACHINE MACHINE SIZE
FRACTION ±1/64
PROFILE/SAW ±1/16 STANDARD DUTY TRIPLE ROLL CRUSHER STRC 18" X 72"
FABRICATION ±1/8
DRAWING NUMBER

OF MINIMUM PLATE THICKNESS. REF: SHEET 1 OF 1
4 3 2 1
4 3 2 1
5
10
3
D D
16
15
8 15
14
7
13 6
12 13 11
7 7 6 11 7
7
12
11 12
15
15 15
6 16 15
16
1
16 16
C C
EXPLODED VIEW
17 SCALE 1 / 16
3
14 2
14
14 14
10 10
8 8
DETAIL B 9
9 DETAIL C
HELD BEARING
SCALE 1 / 4 FREE BEARING
SCALE 1 / 4
77 1/4"
76 1/4" INSIDE OF FRAME DIRECTION OF ROTATION

17
HELD 17
FREE
A
BEARING BEARING
3
B 2 B
B C
14 5/16" END OF 20 5/8" END OF

SHAFT TO FACE SHAFT TO FACE
5 4 A
OF ADAPTER OF ADAPTER
1 6 1
16 1/2" 95" BEARING CENTERS 23"
134 1/2"
SECTION A-A MISAPPROPRIATION OF THE
SCALE 1 / 8 INFORMATION SHALL MAKE THE

ARE:
MACHINING STATIONARY ROLL SHAFT ASSEMBLY,

DECIMAL ±0.010 MACHINE MACHINE SIZE
FRACTION ±1/64
PROFILE/SAW ±1/16 18" X 72"
SECONDARY STAGE, 18" X 72" STANDARD STRC
FABRICATION ±1/8 DUTY TRIPLE ROLL CRUSHER DRAWING NUMBER

4 3 2 1
4 3 2 1
4
5
11 3
10 1
18
D D
14 9
9
13
12
6
12 6 14
8 6 12 8
16 16
16 13 17 16
15 17
16
17 17
9
2
3
C C
19 EXPLODED VIEW
SCALE 1 / 16
15
15
9 8 15 2
11 13
8
10
DETAIL B 9
11 10
FREE BEARING
SCALE 1 / 4 DETAIL C
HELD BEARING
SCALE 1 / 4
77 1/4"
76 1/4" INSIDE OF FRAME DIRECTION OF ROATATION

18 19 A
FREE HELD
BEARING BEARING
B 2 B
3
C
3/8" END OF 20 13/16" END OF

SHAFT TO FACE 5 4 SHAFT TO FACE
OF ADAPTER OF ADAPTER
1 A 1
6
3 9/16" 95" BEARING CENTERS 23"
121 9/16"
SECTION A-A SUFFERED AS A RESULT BY THE
SCALE 1 / 8 UNLESS OTHERWISE SPECIFIED, JMcConnell 4/13/2012

ARE:
MACHINING MOVABLE ROLL SHAFT ASSEMBLY,

DECIMAL ±0.010 MACHINE MACHINE SIZE
FRACTION ±1/64
PROFILE/SAW ±1/16 18" X 72"
SECONDARY STAGE, 18" X 72" STANDARD STRC
FABRICATION ±1/8 DUTY TRIPLE ROLL CRUSHER DRAWING NUMBER

4 3 2 1
4 3 2 1
D D
C C
81 1/2"
45 9/16" 10 9 8
6 2
7
6
4 5 1
B 3 12 13 11 B
29 9/16"
18
19 20 21 22
14 17
22 21 20 19 15 23
16
26 25 24
72"

ARE:
MACHINING
DECIMAL ±0.010 CRUSHING PLATE ASSEMBLY FOR 18" X 72" MACHINE MACHINE SIZE
FRACTION ±1/64
PROFILE/SAW ±1/16 STANDARD DUTY TRIPLE ROLL CRUSHER STRC 18" X 72"
FABRICATION ±1/8
DRAWING NUMBER

OF MINIMUM PLATE THICKNESS. REF: 166B21 SHEET 1 OF 1
4 3 2 1

E - Manual - 18x72 TRC - 20122010 PDF

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E - Manual - 18x72 TRC - 20122010 PDF

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INSTALLATION, OPERATION

& MAINTENANCE MANUAL

SAFETY PRECAUTIONS (VERSION A, REV. 03)

SHIPPING AND HANDLING

FOUNDATIONS (VERSION A, REV. 03)

MOTOR (VERSION A, REV. 03)

V-BELT DRIVES (VERSION A, REV. 02)

CRUSHER ROLL SHAFT BEARINGS (VERSION B, REV. 00)

LOCKING ASSEMBLY (VERSION A, REV. 01)

WELDING (VERSION A, REV. 01)

LUBRICATION (VERSION A, REV. 07)

AUTOMATIC LUBRICATION SYSTEM

SPARE PARTS LISTS

FIELD SERVICE CHARGES (VERSION A, REV. 1/1/12 MPS&APS DIVISIONS)

TAGS (VERSION B, REV. 07)

MATERIAL SAFETY DATA SHEETS (VERSION A, REV. 03)

DRAWINGS (VERSION A, REV. 02)

DANGER indicates an imminently hazardous situation which, if not avoided, will

WARNING indicates a potentially hazardous situation which, if not avoided,

CAUTION indicates a potentially hazardous situation which, if not avoided, may

CAUTION (used without the safety alert symbol) indicates a potentially

Lockout/Tagout all controls and secure all applicable components to prevent

Lockout/Tagout power at the source before accessing any electrical panels or

Wear appropriate personal protective equipment at all times.

If questions arise concerning your machine, or if additional information is required, contact

SHIPPING AND HANDLING

Notify McLANAHAN CORPORATION immediately upon discovery of any damaged or missing

UNLOADING AND HANDLING

Apply a coating of anti-rust protectant to the following components:

CONCRETE SUPPORT STRUCTURES

DESIGN FACTOR CHART

A. Rubber Tire Drive

B. V-Belt ‘Interstage’ Drive

CRUSHER ROLL TEMPLATES

MATERIAL HANDLING EQUIPMENT

START-UP AND SHUT-DOWN

INITIAL START-UP PROCEDURE

FEATURES AND ADJUSTMENTS

1. Roll Shell Design

2. Segmented Roll Design

D. Renewable Crushing Plate Tips

I. Product Adjustment System

1. Primary Stage Adjustment

A. Automatic Lubrication System

B. Bearing Temperature Probes

C. Zero Speed Switch

BOLTS AND KEYS

1. Segmented Roll Design - Stationary and/or Movable Roll

c. Block the roll shaft assembly to prevent any movement.

d. Remove the segment bolts from the segment being replaced.

f. Lift the segment from the assembly.

2. Roll Shell Design - Stationary Roll and/or Movable Roll

a. Remove appropriate roll covers (It may be necessary to remove hopper).

b. Block the roll shaft assembly.

c. Loosen bearing foundation bolts.

d. Remove tie bars.

e. Unbolt hopper seal housings.

f. Unbolt flanged shafts from roll.

g. Slide bearing housing away from roll.

h. Remove roll shell from crusher.

C. Bolt Torque Requirements

1. Segmented Roll Design - Segment Bolts

BOLT DIAMETER TORQUE