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TH
Models 38, 44, 52, 57 and 68 H/SBS
Cone Crushers
Wear Liner Replacement
TP401
SAFETY
Be sure to read and fully understand the precautions shown on the inside front cover of this manual before
operating or servicing your Telsmith product. Also refer to Chapter 1 for important safety information.
! WARNING
Failure to follow the safety precautions shown below may result
in serious personal injury or death!
Never attempt to work on quarry equipment while it is in operation. Always stop the machinery, lockout power
and tag controls:
1. Before performing any lubrication, maintenance, adjustment, or repairs.
2. Before removing spilled materials.
3. Before clearing jams or working inside the machinery.
4. If any unusual noises or sudden changes in operation are noticed.
Stay clear of feed and discharge areas and other places where falling rock is present. Keep away from loading
vehicles. Wear and use personal protective equipment in accordance with all applicable health and safety
regulations. Safety goggles, hard hat, ear plugs and steel-toed shoes are mandatory when working near
machinery. Wear and use additional personal protective equipment as required.
Stay clear of springs and other pinch points. Never reach in-between vibrating equipment and its support
structure. Keep a safe distance from all moving components.
Never attempt to enter the crushing chamber when tramp iron or other uncrushable objects are wedged inside.
These materials are under tremendous pressure and may be propelled upward through the feed opening at any
time. On crushers not equipped with hydraulic clearing, use a pole, hook, grappling device, or breaker bar to
safely dislodge uncrushable objects.
Do not make equipment modifications that will result in a safety hazard or create a dangerous situation. Never
remove or disable safety devices. Maintain all machinery in accordance with manufacturers instructions and
maintenance schedules.
Read the operators manual for the equipment that you operate. Be sure that you fully understand all phases of
operation for each machine. A careful and well-trained operator is the best insurance against an accident.
Refer to Chapter 1, Safety, for important quarry safety information. If your copy is missing, replacement
copies may be obtained from your local Telsmith Dealer or the Telsmith Parts Department.
All rotating power products are potentially dangerous and must be properly guarded. Placement of guards and
other safety equipment is the users responsibility. Such equipment must be installed wherever appropriate and
maintained as required.
It is the purchasers responsibility to ensure that quarry equipment is installed and used in a safe and lawful
manner. All machinery must be operated in compliance with applicable health and safety laws and general
standards of reasonable care.
Foreword
INTRODUCTION
For replacement parts information, please refer to the SBSSeries Cone Crusher Drawings. These drawings contains
exploded diagrams and parts lists to help you quickly identify
the major components used on your crusher.
Parts:
07/09 (Rev 1)
Foreword
SERVICE BULLETINS
Telsmith periodically issues service bulletins to inform
customers of the latest repair and maintenance procedures.
Service bulletins may have been included separately with this
manual. Always read and understand all service bulletins
before starting any maintenance or service work.
SAFETY
All quarry personnel operating or servicing the machine must
read and fully understand the information included in
Chapter 1, Safety of this manual.
ILLUSTRATIONS
This manual contains some illustrations in which guards,
access panels and other safety equipment have been removed
for instructional purposes or to provide greater clarity.
However, to prevent serious personal injury or death, always
be sure all such equipment is installed before operating the
product.
CONTACTS
TELSMITH PARTS DEPARTMENT CONTACTS
Name:
Phone (Office):
Phone (Cell):
FAX:
Name:
Phone (Office):
Phone (Cell):
FAX:
Name:
Phone (Office):
Phone (Cell):
FAX:
Name:
Phone (Office):
Phone (Cell):
FAX:
OTHER CONTACTS
Name:
Phone (Office):
Phone (Cell):
FAX:
Name:
Phone (Office):
Phone (Cell):
FAX:
07/09 (Rev 1)
Table of Contents
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents
12
07/09 (Rev 1)
Chapter 1
Chapter 1
Safety
Page
SAFETY OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
HAZARD AND ADVISORY STATEMENTS . . . . . . . . . . . . . . . . . . . . . . 1-2
LOCKOUT/TAGOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
7F
07/09 (Rev 1)
11
Safety
SAFETY OVERVIEW
It is the responsibility of the quarry management team to
develop a comprehensive safety awareness program, and to
ensure that all quarry workers and support personnel receive
appropriate safety training as required by federal, state and
local regulations.
! DANGER
! WARNING!!!
DANGER
Hazard
Statements
! CAUTION
DANGER !!!
Important
Note
Advisory
Statements
7F
Hazard Statements
The Caution, Warning and Danger statements are hazard
statements used to alert workers of unsafe practises and
potentially harmful or life-threatening situations. Each of
these statements is preceded by the Safety Alert Symbol.
Failure to follow the instructions contained in a Caution
statement may result in MINOR PERSONAL INJURY.
Failure to follow the instructions contained in a Warning
statement could result in SERIOUS PERSONAL
INJURY or DEATH.
Failure to follow the instructions contained in a Danger
statement will result in SEVERE PERSONAL INJURY
or DEATH.
Advisory Statements
The Note and Important statements are advisory statements
which relate to equipment operation, maintenance and
service procedures. They are used to draw attention to proper
procedures and practises.
12
LOCKOUT/TAGOUT
Who Must Use Lockout/Tagout?
Quarry owners, managers, and safety officers must be aware
of OSHAs lockout/tagout standard: CRF Section 29
1910.147, The Control of Hazardous Energy. This standard is
also recognized by MSHA.
All mechanics, maintenance personnel, operators, and
electricians must fully understand and comply with this
standard to ensure the safety of all employees.
What is Lockout/Tagout?
Lockout/tagout is a means to ensure that personnel who
install, operate, repair, maintain, service or otherwise disable
machines, equipment, or electrical energy systems are
protected from harm due to unexpected energizing, or the
release of stored energy by...
1. Lockout Placing a disconnect switch, circuit breaker,
valve, or other energy-isolating mechanism in the off or
safe position and securing it with a lock so the energyisolating mechanism cannot be activated.
07/09 (Rev 1)
Safety
7F
2.
3.
4.
! WARNING!!!
DANGER
Failure to perform lockout/tagout procedures can result
in serious personal injury or death!
Figure 12. Lockout/Tagout
07/09 (Rev 1)
13
Safety
Lockout/Tagout Devices
Lockout/tagout devices include:
1) locks
2) tags and labels
3) multiple lockout devices
A lock must be sufficiently durable, so it can withstand the
environmental conditions (heat, cold, moisture, etc.) around
it. A lock must also be strong enough so that it cannot be
easily removed or forced open.
A tag or label must be affixed to each lock to alert others that
service work is in progress. Each tag or label must have the
following characteristics:
7F
Lockout/Tagout Rules
Always lockout/tagout any machinery before performing
any adjustment, inspection, lubrication, maintenance or
repair procedures. Failure to observe this precaution may
result in serious personal injury or death.
14
GYRASPHERE SAFETY
Perform a complete walk around inspection before
starting the crusher. Be sure that no persons are on, inside
or under the crusher. Refer to the Operation and
Maintenance Manual for crusher daily start-up
procedures.
Be sure that all guards and other safety devices are
correctly installed and tightly secured before starting the
crusher. Stay clear of rotating or moving parts during
crusher operation.
Do not allow personnel to be on or near the crusher during
operation. Stay clear of feed and discharge areas to
prevent being injured or killed by flying or falling rock.
Rock projected upwards through the feed opening can
injure or kill. Do not look directly into the feed opening
while the crusher is operating. Use mirrors or closedcircuit cameras if close observation of the feed
arrangement is necessary for troubleshooting or
evaluation purposes.
Never attempt to clear jammed material from the crushing
chamber while the crusher is operating. Serious injury or
death could result if you are pulled into, or fall inside, the
crushing chamber.
07/09 (Rev 1)
Safety
15
7F
Safety
7F
16
07/09 (Rev 1)
Safety
07/09 (Rev 1)
17
7F
Safety
Guarding
Quarry management is responsible for the proper
installation and placement of guards to prevent personnel
from coming in contact with rotating or moving parts.
In addition to the guards supplied with the machinery,
additional guards and related safety equipment may be
required to comply with OSHA, MSHA and any
applicable local regulations. The proper fabrication,
installation and placement of these items is the users
responsibility.
7F
Electrical Hook-up
! WARNING!!!
DANGER
When installing any electrical equipment, be sure
t o c o m p l e t e l y f o l l o w t h e m a n u f a c t u r e r s
instructions. Failure to observe this precaution
could result in a dangerous electrical shock hazard.
Be sure that all electrical equipment is properly grounded.
Lay out the power lines, especially those for portable
plants, so that contact with standing water is minimized.
Do not place power lines in an area where they will be
driven over by transport vehicles or other quarry
equipment. If it is absolutely necessary to extend a power
line across a traffic area, protect the cable with properly
rated bridging.
Be sure that all auxiliary control panels or power supply
panels can be securely locked out. This type of panel is
mandatary.
Maintain adequate overhead clearance from power lines
or other obstructions, particularly when planning to use
stacking conveyors for stockpiles.
Be sure that electrical power supplies are located in an
area that will be safe from accidental contact during
crushing operations.
All Telsmith machinery is designed with electrical
components of the proper size and voltage. Any
modifications to these components or to the power supply
must be approved in writing by the Telsmith Engineering
Department.
Be sure that all connections are in accordance with the
National Electric Code and any applicable state or local
codes.
Customer Modifications
Do not modify quarry machinery in any way without prior
approval from the manufacturer. Such modifications may
include (but are not limited to) changing machine speed or
direction of rotation, drilling additional holes and welding
or bolting additional equipment to the machinery.
All customer modifications to Telsmith machinery must
be approved in writing in writing by the Telsmith
Engineering Department.
18
07/09 (Rev 1)
! WARNING!!!
DANGER
Always lockout/tagout power to machinery and
conveying equipment before performing any
maintenance or repairs. Warn all personnel that the
machinery is being serviced.
General Precautions
To help ensure safe machine operation, use only genuine
OEM replacement parts that are sold or approved by the
machines manufacturer. Use of non-OEM parts may
adversely affect machine operation and could result in an
a hazardous situation.
Always tighten all fasteners to the proper torque as
described in the repair procedures. When torque
specifications are not listed, use the values in the torque
chart at the back of this manual. Refer to Appendix A of
this manual.
Be sure all replacement fasteners are of the proper grade
and specifications. Replace any worn or damaged
fasteners.
Electrical Systems
Always read, understand and follow appropriate electrical
system troubleshooting, maintenance and repair
instructions in the machinery manufacturers manuals.
Allow only trained and licensed electricians to install,
troubleshoot and repair electrical equipment. All
procedures must be in compliance with the National
Electric Code and any applicable state or local
regulations.
When servicing an electrical system, work with the power
locked out and tagged. Always assume that an electrical
system is live until it has been locked out.
Always tag and lockout power before removing cables
with quick-disconnect plugs.
Repair any obviously worn or damaged wires and
connectors.
Inspect power cables and connections daily for signs of
wear, cracked insulation and worn or damaged
connectors. Repair or replace as required.
Do not store tools inside electrical cabinets.
Verify that all tools are grounded with a three wire plug or
double insulated. Be sure that all extension cords are
grounded with a three wire plug.
07/09 (Rev 1)
Safety
19
7F
Safety
Welding On Machinery
Be sure to provide adequate ventilation when welding
inside enclosed areas to prevent the buildup of hazardous
fumes. Special concern should be exercised when welding
chromium, manganese, cadmium, copper, cobalt, lead and
nickel, as these materials are considered to be potentially
carcinogenic.
Be sure to wear the proper welding shield, welding gloves
and clothing. Do not wear synthetic fabric clothing or
clothing which could be easily ignited by sparks.
7F
Hazardous Materials
Be aware potentially hazardous chemicals or materials.
Such items can be harmful if they are improperly used,
stored, mixed or transported, or if they are inhaled,
swallowed or allowed to contact the skin.
Consult your employers hazard communications plan for
instructions regarding the proper handling and use of
hazardous materials. Read and understand the labels
attached to the product containers. Always follow the
instructions carefully.
Consult the manufacturers material data sheet (MMD)
for potential hazards and appropriate medical procedures
should an accident occur.
Store hazardous materials only in approved containers. Be
sure containers are clearly labeled.
To avoid potential health hazards, persons in regular
contact with hydraulic oils must be aware of the
importance of thorough hygiene, and the proper methods
for handling mineral oils.
Mineral-based hydraulic oils act as solvents on the natural
oils of the skin. Frequent and prolonged skin contact can
cause dermatitis or severe irritation.
Always wear suitable protective clothing when handling
hydraulic oil.
Be sure protective clothing and proper wash-up facilities
are available to all personnel that may come in contact
with mineral-based hydraulic oils.
Always dispose of used rags or paper towels in the correct
and safe fashion.
110
07/09 (Rev 1)
Safety
Wire Rope
Wire rope requires careful use, handling and maintenance to
ensure long life and safe operation. Always observe the
following precautions.
Be sure to use the correct wire rope for the application.
Be sure that the wire rope is inspected regularly following
the manufacturers guidelines.
Avoid sudden loading in cold weather. Never use frozen
wire rope.
Use suitable padding to protect wire rope from sharp
corners or edges.
Chains
Chains require careful use, handling and maintenance to
ensure long life and safe operation.
Be sure that the correct size chain is being used for the
application.
Be sure that the chain is inspected regularly following the
manufacturers guidelines.
Avoid sudden or shock loading (DO NOT jerk load
upright).
07/09 (Rev 1)
111
7F
Safety
! CAUTION
DANGER !!!
Always follow proper rigging procedures as provided by the chain manufacturer. The angle of rigging
may decrease the rated lifting capacity.
7F
TRANSPORTING MACHINERY
Be sure that the machinery is properly secured so that it
cannot vibrate or move during transport. Remove any dirt,
stones or other loose material from the machinery.
Install shipping brackets, wood blocking or other shipping
materials as directed in the machinery manufacturers
manuals. Perform any shipment preparation procedures as
indicated in the manuals.
Plan your route carefully. Know the clearance height of
the machinery. Be aware of bridges, power lines and steep
or uneven grades. Be aware of any other conditions which
may present hazards or obstructions.
112
07/09 (Rev 1)
Chapter 2
Chapter 2
General Instructions
Page
7F
07/09
21
General Instructions
7F
HANDLING BEARINGS
Remove any loose dirt from the machinery before
exposing bearings. Handle bearings with clean, dry hands.
Use only clean lint-free rags. Use clean tools in clean
surroundings. Use clean solvents and flushing oils.
Install new bearings as removed from packaging without
washing. Do not remove bearings from packaging until
ready to use.
Soak used bearings in solvent. Then wash the bearings
and blow them dry with filtered, moisture-free
compressed air. Dip the bearings in oil immediately after
drying to prevent rust.
Cleaning solvent.
Flushing oil.
Refer to the Tools and Supplies Required heading at the
beginning of each chapter for additional items needed to
perform specific repair and overhaul procedures.
! WARNING!!!
DANGER
Always wear eye protection and face shield when
using compressed air.
To prevent bearing damage, do not spin the bearings by
hand or with compressed air after the bearing surfaces
have dried.
22
07/09 (Rev 1)
USING HEAT
When using an oil bath, avoid contact with hot oil.
General Instructions
! WARNING!!!
DANGER
Lockout/tagout power to the hydraulic control
console before performing any hydraulic system
maintenance or repairs.
! WARNING!!!
DANGER
Before disconnecting the power rotator hoses, be
certain that any trapped pressure is completely
relieved.
! WARNING!!!
DANGER
Up to 3000 PSI (206 bar) may remain trapped in the
power rotator circuit even when the hydraulic
pump is off and the pressure gauge indicates zero
(0) PSI. Before disconnecting the power rotator
hoses, be certain that pressure is completely
relieved. Refer to the following section of this
chapter for procedure.
! WARNING!!!
DANGER
07/09 (Rev 1)
23
7F
General Instructions
11. To verify that pressure has been relieved, check that both
power rotator hoses are relaxed and not stiff. A stiff hose
indicates that high pressure remains trapped in the circuit.
OFF
ON
CRUSH
CLEAR
MANUAL
EXTRACT
HIGH
SPEED
AUTO
START
CLOSE
STOP
OPEN
Crush/Clear
High Speed
Switch
! WARNING!!!
DANGER
38/44 Models
7F
(Pressure Sensor)
Pressure Adjustment
Screw
Locknut
Figure 22. Counterbalance Valve Details
07/09 (Rev 1)
Counterbalance
Valve A
General Instructions
Counterbalance
Valve A
7F
Counterbalance
Valve B
Counterbalance
Valve B
07/09 (Rev 1)
25
General Instructions
NOTES
7F
26
07/09 (Rev 1)
Chapter 3
Support Bowl and Concave Ring
CONTENTS
Page
GENERAL SHUTDOWN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
TOOLS AND SUPPLIES REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
EXPLODED VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Type A Support Bowl and Concave Ring Assembly . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Type B Support Bowl and Concave Ring Assembly . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Type C Support Bowl and Concave Ring Assembly . . . . . . . . . . . . . . . . . . . . . . . . 3-6
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
SUPPORT BOWL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Type A and B Bowl Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Type C Bowl Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
CONCAVE RING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Old Style TypeA and B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
New Style Type C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
CONCAVE RING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Old Style Type A and B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
New Style Type C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
SUPPORT BOWL PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
SUPPORT BOWL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
Old Style A and B Support Bowl. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
New Style C Support Bowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
RECEIVING HOPPER INSTALLATION (Old Style A and B) . . . . . . . . . . . . . . . . 3-36
DRIVE RING COVER INSTALLATION (New Style C). . . . . . . . . . . . . . . . . . . . . . . 3-38
MIXING AND POURING SMITHBOND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
07/09 (Rev 1)
31
Support Bowl
Concave Ring
32
07/09 (Rev 1)
5 pound hammer
Sledge hammer
Extension brackets (special tools - provided with crusher)
Eyebolts 3/4-10 UNC 2B (quantity = 3)
Crowbar
Hand grinder
Feeler gauge
Tape measure
Cold steel chisel
Cleaning solvent
Putty
Moly-based EP-2 grease (refer to Appendix D)
Smithbond backing compound (refer to Table 3-1)
Crush
Clear Extract
High Spd
Start
Manual Auto
Stop
Close
Open
07/09
33
C
A
B
D
E
F
G
Type A
W
K
X
J
N
L
M
Model 38 only
T
Q
X
O
U
R
34
B. Flatwasher
G. Support Bowl Driver
L. Filler Ring
Q. Nut
V. Ring Gear
D. Felt Seal
I. Support Bowl
N. Capscrew
S. Drive Ring
X. Wedge
07/09 (Rev 1)
Type B
D
F
G
V
H
W
I
Model 38 only
K
J
A
M
B
O
L
B
N
R
S
P
Q
T
U
07/09
B. Flatwasher
G. Flatwasher
L. Extension Bracket
Q. Nut
V. Tapered Key
E. Felt Seal
J. Smithbond Compound
O. Felt Seal
T. Locknut Ring
35
B
A
Type
B
TYPE
C
38 SBS
Non-Rimmed Wedge
44/52/57/68 SBS
Rimmed Wedge
E
F
K
L
M
36
C. Drive Ring
H. Felt Seal
M.Upper Frame
D. Keeper
I. Locknut
N. Felt Strip
E. Felt Seal
J. Felt Strip
07/09
DESCRIPTION
The concave ring is a replaceable casting that forms the upper
surface of the crushing chamber. It is made from manganese
steel, a wear-resistant alloy that work hardens during
crushing.
B
C
B. Locknut Ring
D. Upper Frame
On models 44, 52 and 57, one full rotation of the support bowl
changes the discharge setting approximately 1-1/2 inches. On
Model 68 only, a full rotation changes the discharge setting
approximately 2 inches.
B
C
07/09
B. Locknut Ring
D. Upper Frame
37
! WARNING
Always use suitable rigging and hoisting equipment
to stabilize and lift heavy objects. Lifting heavy
components with inadequate hoisting apparatus
can damage machinery and may result in serious
personal injury or death. Refer to Appendix C for
weights.
B. Flat Washer
D. Nut
B
C
3. Remove any loose dust and dirt from the area between the
support bowl and the inner receiving hopper (H, Fig. 3-2 &
D, Fig. 3-3).
4. Using an appropriate lifting device and cables, carefully
lift the inner receiving hopper straight up and remove it from
the support bowl (I, Fig. 3-2 & 3-3).
5. Install the extension brackets (C, Fig. 3-7 & C, Fig. 3-8)
on the drive ring. Secure with capscrews, flatwashers and
nuts.
38
B. Flat Washer
D. Nut
07/09
Cutaway
View
Moly-Based
EP-2
Figure 39. Buttress Thread Lubrication
6. Apply a generous amount of moly-based EP-2 grease at
each of the four grease fittings around the upper frame. See
Figure 3-9. Refer to Appendix D for grease specifications.
7. Be sure that power to the hydraulic power unit is lockedout, and that the hydraulic pressure gauge indicates zero (0)
PSI.
8. Disconnect the hydraulic locking cylinder hose at the
hydraulic power unit. Leave all other hoses connected. See
Figure 3-10.
Hydraulic Locking
Cylinder Hose
Function
Selector
Switch
39
3
B
B. Drive Ring
13. Depress and hold the OPEN button. Visually check that
the ring gear (C, Fig. 3-12) begins turning slowly
counterclockwise. On some crushers, there may be a brief
delay before the gear starts turning.
C. Ring Gear
D. Upper Frame
14. Depress and hold the OPEN button. Allow the support
bowl (A, Fig. 3-12) to become completely unthreaded from
th e u pp e r fr a m e ( D , F i g . 3 - 12 ) a nd lo c k n ut r i n g.
Approximately 7 to 10 revolutions will be required,
depending on the initial position of the support bowl.
15. Depress the STOP button after the support bowl becomes
completely unthreaded. Lockout/tagout power to the
hydraulic control console.
16. Type A support bowl assemblies only: Install 3/4 inch
eyebolts in the three lifting holes on the support bowl driver.
Secure the eyebolts with jamnuts.
17. Type B support bowl assemblies only: Install 3/4 inch
eyebolts in the three lifting holes on the top edge of the
support bowl (Fig. 3-13). Secure the eyebolts with jamnuts.
18. Using an appropriate lifting device and cables, carefully
lift the support bowl straight up and remove it from the upper
frame. See Figure 3-13.
19. Suspend the support bowl over a clean, flat work area.
07/09
IMPORTANT:
Do Not place timbers beneath the lower lip of the
concave ring. This area must remain unobstructed to
allow room for the concave ring removal.
21. Slowly lower the support bowl onto the timbers.
07/09
311
A
D
3
C
A
C
D
A
B. Support Bowl
D. Drive Keys (3)
! CAUTION
B. Drive Ring
312
7. Thread three 3/4 lift eyes fully into the upper rim of the
support bowl (A, Fig. 3-17) and attach a lift harness and hoist
of sufficient capacity to lift the bowl (bowls range in weight
from 2700 lbs (1225 Kg) on the 38SBS to 13,000 lbs (5,900
Kg on the 68 SBS). Make certain the external threads on
the support bowl are fully disengaged from the threads on
the lock ring. Lift the support bowl straight up out of the
drive ring until the drive keys (D, Fig. 3-16) clear the drive
key extensions (A, Fig. 3-16).
07/09
313
! CAUTION
The concave ring can release and drop at any
time after the mounting lugs are cut. To prevent
serious personal injury, be sure that all
personnel are clear of the area between the
concave ring lower lip and the ground.
3. Using a torch or air-arc, cut the concave ring mounting
lugs. The number of lugs will vary depending on crusher
model. Refer to Figure 3-19.
4. Using a sledge hammer, strike the top edge of the
concave ring until it breaks loose and drops from the support
bowl.
5. Units with standard concave ring lugs (Fig. 3-19): Using
a torch, remove the cut-off lug ends from the taper wedge
segments. Save the taper segments for later use.
6. Units with slotted concave ring lugs (Fig. 3-2 & 3-3):
Using a torch, remove the cut-off lug ends from the tapered
keys (W, Fig. 3-2). Save the keys and taper wedge segments
(X, Fig. 3-2) for later use.
! WARNING
Always use suitable rigging and hoisting equipment
to stabilize and lift heavy objects. Lifting heavy
components with inadequate hoisting apparatus
can damage machinery and may result in serious
personal injury or death. Refer to Appendix C for
weights.
7. Using an appropriate lifting device, move the support
bowl to a suitable work area where it can be thoroughly
cleaned and inspected.
8. If present, remove the filler rings (M, Fig. 3-3) from the
old concave ring. Save the filler rings for later use.
314
Note: Quantity of
lugs varies by
crusher model
07/09
3. Slowly lower the support bowl onto the timbers (Fig. 320) Make certain the support timbers are placed beneath the
lower ring of the support bowl only. If timbers protrude in and
reach under the concave ring, they will prevent the concave
ring from dropping during removal.
C
B
! CAUTION
Removing the tapered wedges that support the concave ring may require standing inside the support
bowl. Make certain your feet are not below the concave ring lower lip when driving out wedges. The
concave liner could drop suddenly as the tapered
wedges are driven out. Serious personal injury
could result if all personnel are not clear of the area
beneath the concave ring lower lip and the ground
as the liner is prepared for removal.
4. Torch or grind off the welds holding the tapered wedges
in place at the concave ring ears (B, Fig. 3-21). If possible, Do
Not cut through the wedges, as they will be reused when
mounting the new concave ring.
5. Use a sledge and driver bar to drive the tapered wedges
out from beneath the mounting ears. The concave ring should
drop down of its own weight as the final tapered wedge is
driven out.
07/09
B. Weld
C. Concave Ear
6. If the concave liner does not drop down after the wedges
are removed, it will be necessary to strike the top edge of the
liner and the ears with a sledge hammer to free the liner.
7. When the liner has dropped, use a torch to remove the
wedges (and keys if used) from the torched off mounting ear
segments. If wedges and keys are not damaged they can be
reused in the new liner installation.
315
! WARNING
! WARNING
When grinding, cutting or breaking up pieces of
old Smithbond filler it is mandatory to wear a
respirator that prevents inhalation of toxic
fumes. Failure to provide adequate ventilation
and filter toxic fumes could cause injury to
personnel working on the crusher.
9. Move the support bowl to a suitable stand or work area
where it can be cleaned and examined. Clean any remaining
Smithbond backing material from the bowl with a handheld
grinder. Use a grinder to remove any weld in the area where
the wedges were removed. Be careful not to nick or scratch
the machined seat of the support bowl while cleaning or
grinding on the bowl. Check that the mounting surfaces for
the concave support ears are clean and flat. Check that the
exterior threads on the bowl are undamaged. If support bowl
is reusable, remove the old grease from threads, as
contamination in the grease could cause problems during
reassembly.
10. Remove the filler rings from the old concave ring and
clean any Smithbond filler from the rings. Check the filler
rings (Fig. 3-22) for signs of damage, particularly at the lower
seating surface and at the mounting holes. If a filler ring is
bent, shows signs of chatter marks on the surface or has
damaged mounting holes or broken or bent mounting feet,
replace it.
316
B. Lift Hole
D. Mounting Feet (4)
07/09
Coat With
Heavy
Gear Oil
(ISO 150)
No Lube
No
A
No
Lu
be
Lu
be
B. Support Bowl
IMPORTANT:
DO NOT apply any lube to the concave ring.
4. Apply a thin coat of heavy gear oil to the complete surface
of each filler ring. (Lubricant is applied to help prevent
adhesion of filler compound.).
5. Lift each filler ring up into position on the concave ring
with a suitable lifting device. Position the filler ring locator
mounting hole (C, Fig. 3-22) over the mounting stub on the
concave ring and lower into position.
07/09
! WARNING
Always use suitable rigging and hoisting
equipment to stabilize and lift heavy objects.
Lifting heavy components with inadequate
hoisting apparatus can damage machinery and
may result in serious personal injury or death.
Support bowls range in weight from 2,600 lbs
(1179 Kg) on the Model 38 to 12,000 lbs (5443 Kg)
on the Model 68.
7. Slowly lower the support bowl onto the concave ring (Fig.
3-26. Align the support bowl so that the support bowl slots
align with the concave ring lugs. Lower the support bowl so
the slots pass down over the lugs.
317
A
B
318
07/09
38, 44 & 52
IMPORTANT:
Be certain that all wedge segments are driven as tight
as possible. Failure to fully tighten wedge segments
could allow the concave ring to loosen during crushing.
15. Re-check the concave ring position in the support bowl
when all wedges are tight. Check that the ring is still centered
in the bowl and has not shifted. If measurements are unequal
(Fig. 3-27), it will be necessary to drive the wedge segments
back out and re-center the ring in the bowl.
68 Only
Figure 330. Wedge Tightening Sequence per Model
16. Using a feeler gauge check that the machined seat of the
concave ring is TIGHT against the machined seat of the
support bowl. Move completely (360o) around the lower edge
of the support bowl checking the clearance (Fig. 3-31). There
should be no clearance at any point.
07/09
319
IMPORTANT:
Make certain the concave ring is properly installed as
described in the previous steps. Serious damage to the
support bowl will occur if the concave ring is loose or
cocked when the crusher is put into production.
17. If any clearance is detected in Step 16, check again that
the concave ring is centered in the support bowl, and that all
wedges are fully seated. If the concave ring is correctly
seated, any clearance may indicate that the support bowl has
wear on the machined seat. Any worn areas will need to be
sealed with putty before pouring the Smithbond sealant. This
will prevent any of the backing sealant from leaking out
through the worn areas.
! CAUTION
DO NOT weld the tapered wedges to the support
bowl. Concave ring lugs may break if tapered
wedges are welded to the support bowl.
18. For crusher models using a tapered wedge only (Fig. 332), tack weld the taper wedges to the concave ring lugs.
320
07/09
Medium
Fine
Concave
Medium
Concave
Medium
Coarse
Concave
Coarse
Concave
Extra
Coarse
Concave
38S
N/A
N/A
N/A
38FC
N/A
N/A
N/A
44S
N/A
N/A
N/A
44FC
N/A
N/A
N/A
52S
N/A
N/A
N/A
52FC
N/A
N/A
N/A
57S
N/A
N/A
15
N/A
10
57FC
18
16
15
12
14
N/A
68S
N/A
N/A
16
N/A
16
16
68FC
24
N/A
22
N/A
22
N/A
Crusher
Model
NOTE: Quantities shown are approximate. Actual quantities required may vary. Consult Telsmith if your
liner configuration is not shown above.
21. Mix each pail of Smithbond one-at-a-time as described in
the Mixing and Pouring Smithbond section of this chapter.
After mixing, pour the Smithbond mixture through the
support bowl slots as shown in Figure 3-34.
07/09
321
New Style C
A
B
D
E
322
07/09
IMPORTANT:
DO NOT apply any grease or gear oil to the concave
ring.
NO GREA
SE
NO GREA
S
NO
GR
EA
SE
07/09
323
A
B
C
6. Install 3/4 inch eyebolts into the three lifting holes on the
top edge of the support bowl. Secure the eyebolts with
jamnuts.
! WARNING
Always use suitable rigging and hoisting
equipment to stabilize and lift heavy objects.
Lifting heavy components with inadequate
hoisting apparatus can damage machinery and
may result in serious personal injury or death.
Support bowls range in weight from 2,600 lbs
(1179 Kg) on the Model 38 to 12,000 lbs (5443 Kg)
on the Model 68.
7. Slowly lower the support bowl onto the concave ring (Fig.
3-40). Align the support bowl so that the support bowl slots
align with the concave ring lugs. Lower the support bowl so
the slots pass down over the lugs. Lower the support bowl
until it is resting on the machined lip of the concave ring. DO
NOT rotate the support bowl, the support bowl cutout slots
must remain aligned with the ears on the concave ring.
324
07/09
IMPORTANT:
2
1
Non-Rim
Wedge
MODELS 38
Figure 344. Wedge Tightening Sequence Model 38
Figure 342. Centering The Concave Ring.
11. Using a hammer, alternately tap all taper wedge segments
into place until they are tight beneath the concave ring ears
and have bridged the slots in the support bowl.
07/09
325
IMPORTANT:
Make certain that all wedge segments are driven as
tight as possible. Failure to fully tighten wedge
segments could allow the concave ring to loosen during
crushing.
3
4
3
Rimmed
Wedge
2
14. Using a feeler gauge, check that the machined seat of the
concave ring is TIGHT against the machined seat of the
support bowl. Move completely (360o) around the lower edge
of the support bowl checking the clearance (Fig. 3-46). There
should be no clearance at any point.
MODELS 44 & 52
2
1
Rimmed
Wedge
3
MODEL 57
1
6
IMPORTANT:
Rimmed
Wedge
5
2
MODEL 68
Figure 345. Wedge Tightening Sequence per Model
326
07/09
16. Tack weld the taper wedges to the concave ring lugs (Fig.
3-47).
! CAUTION
DO NOT weld the tapered wedges to the support
bowl. Concave ring lugs may break, if tapered
wedges are welded to the support bowl.
17. Before mixing and pouring Smithbond epoxy backing
compound, determine the amount of Smithbond required for
your crusher model using Table 3-2. Make certain you have
an adequate amount of compound to complete the job.
#1
#2
#3
#4
#5
#6
#7
#8
#9
38SBS
N/A*
N/A*
N/A*
NA*
NA*
NA*
N/A*
N/A*
N/A*
44SBS
N/A
N/A
52SBS
N/A
57SBS
N/A
16
11
11
11
68SBS
N/A
18
18
18
16
16
16
16
NOTE: Quantities shown are approximate. Actual quantities required may vary. Consult Telsmith if your liner
configuration is not shown above.
*Model 38 SBS crushers use non-numbered liners. Use the 38S quantities in Table 3-1 when determining
quantities for the SBS.
18. Mix each pail of Smithbond one-at-a-time as described in
the Mixing and Pouring Smithbond section of this chapter.
After mixing, pour the Smithbond mixture through the
support bowl slots as shown in Figure 3-48.
07/09
327
3
A
B
D
E
328
07/09
07/09
329
3
A
B
Crusher Model
Seal Length in
feet/(cm)
Seal Thickness in
inches/(mm)
38
44
52
57
68
11.0
(335.3)
12.5
(381.0)
14.4
(438.9)
16.3
(496.8)
18.4
(560.8)
5/8
(16)
5/8
(16)
5/8
(16)
5/8
(16)
5/8
(16)
B
A
330
07/09
10. Coat the buttress threads of the locknut ring and the upper
frame with moly-based EP-2 grease (Fig. 3-54).
11. Coat the buttress threads of the support bowl with molybased EP-2 grease (Fig. 3.54).
12. Coat the smooth lower surface of the support bowl with
moly-based EP-2 grease.
13. Coat both felt seals with moly-based EP-2 grease.
IMPORTANT: Failure to apply grease as described in
the previous steps may result in thread damage and/or
excessive thread wear.
Crusher
Model
Seal Length
feet/(cm)
Seal Thickness
inches/(mm)
38
12.3
(374.9)
5/8
(16)
44
13.3
(405.3)
5/8
(16)
52
16.4
(499.8)
5/8
(16)
57
18.0
(548.6)
5/8
(16)
68
20.0
(609.6)
3/4
(16)
07/09
331
332
07/09
! WARNING
C
D
07/09
333
8. Slowly rotate the support bowl until the leading end of the
support bowl buttress thread is positioned about 6 inches
(15.2 cm) behind the start of the locknut ring buttress thread.
See Figure 3-55.
20. Depress and hold the CLOSE button. Verify that the
support bowl begins turning slowly clockwise.
21. Allow the support bowl to become threaded within the
bore of the locknut ring and the upper frame (Fig. 3-56). The
support bowl will move slowly downward as it rotates.
22. Type A support bowl assemblies only: Continue to
depress the CLOSE button until the keys on the drive ring
become fully engaged in the keyways of the support bowl
driver.
23. Type B support bowl assemblies only: Continue to
depress the CLOSE button until the support bowl drive keys
become fully engaged in the keyways of the drive ring.
24. Depress the STOP button. Lockout/tagout power to
the hydraulic control console. Refer to Chapter 1 for
complete lockout/tagout procedures.
25. Remove capscrews, flatwashers, nuts and extension
brackets.
26. Install the inner and outer receiving hoppers. Refer to the
Receiving Hopper Installation section of this chapter for
procedure.
.
B
B. Support Bowl
334
07/09
New Style C
1. Apply Moly-based EP#2 grease to the support bowl felt
seal as shown in Figure 3-57.
3
D
07/09
335
! WARNING
4. Clean the top surface of the drive ring and the mating
surface of the outer receiving hopper. Apply a bead of caulk
completely around the drive ring. See Figure 3-60.
336
07/09
07/09
337
07/09
! WARNING
Failure to observe the following safety
precautions may result in serious personal
injury or death.
B. Plastic Partition
D. Resin
F. Pail
07/09
339
Mixing Smithbond
1. Read and understand all safety precautions on the
Smithbond pail and hardener before proceeding with mixing.
2. Mix the resin using the stirring rod and a low speed
electric drill. Continue stirring the resin for about 5 minutes.
If any crust has formed on the top of the resin use a sharp tool
to break it up.
3. As stirring continues, add the entire contents of the
hardener can into the pail at a slow, continuous rate. Mix until
a uniform color is obtained. Be sure all settled material is
thoroughly mixed (Fig. 3-64).
4. Pour Smithbond IMMEDIATELY after mixing in
hardener. DO NOT allow Smithbond to stand. Hardening
begins quickly and the mixture will remain pourable for only
about 15 minutes.
! CAUTION
Smithbond may become hot when mixed,
especially if pouring occurs during high ambient
temperatures. To avoid burns, use gloves when
handling the Smithbond pail. Avoid contact with
the concave ring while pouring Smithbond.
5. Mix and pour additional batches of Smithbond as required
to completely fill the cavity.
340
07/09
Chapter 4
Mantle and Head
CONTENTS
Page
EXPLODED VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
SHUTDOWN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
TOOLS AND SUPPLIES REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
MANTLE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
MANTLE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
HEAD and SHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Mantle Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
HEAD and SHAFT INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
HEAD and SHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Mantle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Installation - Crushers Without Anti-Spin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Installation - Crushers With Anti-Spin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
07/09 (Rev 1)
41
Head
42
07/09 (Rev 1)
4
A
07/09 (Rev 1)
C. Mantle
D. Burn Ring
43
J
B
44
C. Mantle
D. Burn Ring
E. Shaft Nut
F. Spacer (FC Only)
07/09 (Rev 1)
Model 38
Models 44-68
I
H
B
G
4
Figure 43. Exploded View, Head and Shaft Components (Type C)
A. Main Shaft
B. Taper Head
07/09
C. Mantle
D. Burn Ring
E. Shaft Nut
F. Shaft Nut Cap
G. Washer
H. Hex Head Capscrew Gr5
45
DESCRIPTION
The mantle (C, Fig. 4-1, 4-2 & 4-3) is a replaceable coneshaped maganese steel casting that forms the lower surface of
the crushing chamber.
The mantle is secured by a shaft nut (E, Fig. 4-1, 4-2 & 4-3)
located on the upper threaded portion of the main shaft.
Before the nut is loosened for removal, a burning ring (D)
located between the mantle and the nut must be cut away with
a torch. A special wrench supplied with the special tools kit
is required to remove the nut. Nuts come in several styles. A
matching wrench is required for loosening and tightening
each style nut.
Smithbond, a special epoxy based backing compound, fills
the void area between the top surface of the taper head (B)
and the underside of the mantle (C).
46
07/09
SHUTDOWN PROCEDURE
Sledge hammer
Crowbar
Hand grinder
NLGI #2 grease
Lubricating oil
! WARNING
Always lockout/tagout power before performing
any maintenance, adjustments, lubrication or
repairs. Failure to lockout/tagout power may
result in serious personal injury or death!
1. Stop the material feed, operate the crusher until the
crushing chamber is completely empty. If necessary, use the
hydraulic clearing function to clear the crushing chamber.
IMPORTANT:
Be sure that power remains connected to the hydraulic
control console during the next step.
! WARNING
Pressures of up to 4000 PSI (276 bar) may remain
trapped in the power rotator circuit even when
the hydraulic pump is off and the pressure
gauge indicates zero PSI (0 bar). Relieve
pressure as described in Chapter 10 of your
Operator Manual before disconnecting the
power rotator hoses or servicing any hydraulic
components in the power rotator circuit.
07/09
47
MANTLE REMOVAL
1. Lockout/tagout power. Perform the Shutdown Procedure
described earlier in this chapter. Refer to Chapter 1 for
complete lockout/tagout instructions.
2. Remove chutes, conveyors or other feeding devices from
above the crusher.
3. Remove the complete upper frame assembly from the
crusher following the instructions in Chapter 3 of this
manual.
! CAUTION
To avoid heat damage when cutting the burn
ring, direct the cutting torch away from the taper
head and the shaft nut (Fig. 4-3).
11. Use a sledge hammer to loosen the shaft nut (Fig. 4-7 &
4-8). Drive the wrench COUNTERCLOCKWISE to loosen
the nut.
Figure 45. Burn Ring Removal
6. Use a torch to cut the welds holding the bolt locking plate
(I, Fig. 4-1) to the shaft nut cap (F, Fig. 4-1). Remove the
locking plate, the hex head cap screw (H) and the flat washer
(G) from the shaft nut cap.
48
07/09
13. Lifting of the worn mantle from the taper head is most
commonly done by welding lifting eyes to the mantle in three
places. Weld three pieces of mild steel stock that can be bent
to conform to the mantle surface into place using stainless
steel welding rod AWSE3091L-17 (Fig. 4-10). Cut lift holes
in the steel stock to mount lift eyes.
! WARNING
You must provide adequate ventilation when
removing parts backed with Smithbond with a
torch. Wear a properly rated respirator to
prevent inhalation of fumes when torch cutting,
grinding or chopping maganese and Smithbond.
07/09
49
! CAUTION
Welding lift eyes to the mantle maganese must
be done carefully with the correct equipment.
Welds have a tendency to pull out of the surface
of worn maganese if the lift eyes are not
correctly welded into place with maganese
compatible welding rod. Stainless steel rod
AWSE309L-17 is recommended.
14. Using a suitable lifting device of correct capacity, lift the
mantle a short distance off the taper head. Place blocking
around the circumference of the mantle to hold it in the lifted
position. Remove the lift device and cables from the lift eyes.
15. Install mantle U hooks at three points around the lower lip
of the mantle (Fig. 4-11). Transfer the lift device and cables
to the U hooks (Fig. 4-11).
16. Using a hammer, chisel and hand grinder, remove all old
Smithbond and any accumulated debris from the surface of
the taper head. Do not nick or scratch the machined seat at the
bottom of the taper head.
! WARNING
Provide adequate ventilation when removing
Smithbond debris. Wear a certified respirator to
prevent inhalation of fumes when torch cutting,
grinding or breaking up Smithbond or
components backed with Smithbond.
MANTLE INSTALLATION
1. Inspect the machined seat on the taper head and the new
mantle (Fig. 4-12). No paint, dirt, grease or rust should be
present on either machined surface. Remove any rough spots
or burrs with a grinder.
4
B
NOTE:
If U hooks are not available, it is possible to sling
through the mantle (running the slings through the shaft
mounting hole at the top) at several places. When
installing slings that run up the inside of the mantle, be
aware of pieces of Smithbond backing that could break
off and fall to the ground.
410
07/09
2. When both the taper head and the new mantle are clean
and dry, apply a coat of heavy gear oil (ISO 150) to the
unmachined upper surface of the taper head (Fig. 4-13). Do
Not apply any oil to the machined seat of the taper or any
portion of the new mantle.
NO LUBE ON SEAT
A. Mantle
C. Shaft
B. Burn Ring
! WARNING
Always use suitable rigging and hoisting when
lifting the mantle into place. Lifting heavy
components with inadequate or incorrectly
stabilized hoisting apparatus could damage
components or result in serious injury or death
to personnel.
3. Install U hooks at three points around the mantle (Fig.411). Install an appropriate lift device and cables and lower the
new mantle down into the crusher onto the taper head.
! CAUTION
Do Not weld lifting eyes to a new mantle. Welding
on the new maganese could damage the new
mantle if the lift eyes were to fail. Use only lift U
hooks or lift harnesses to install the new mantle
on the taper head.
4. Remove the lifting apparatus and the U-hooks from the
mantle.
5. Place a new burning ring around the threaded portion of
the main shaft (Fig. 4-14). Center it on the upper lip of the
mantle. If the new burn ring will not drop down into position,
it may be necessary to use a pry bar to center the top of the
mantle in relation to the main shaft (Fig. 4-15).
07/09
411
C
D
E
F
G
IMPORTANT:
Telsmith introduced a new style tapered shaft nut for all
sizes of H/SBS cone crushers in 2008. When replacing
your burn ring, it will be necessary to use the new style
nut, a new style cap and a new style shaft nut wrench
for the installation (Fig. 4-17).
7. Secure the shaft nut wrench (F, Fig. 4-17) to the shaft nut
(G), and hand thread the shaft nut onto the shaft until it is snug
against the burn ring (H).
8. Final tighten the shaft nut using a sledge hammer to strike
the shaft nut wrench (Fig. 4-18). Tighten the nut
CLOCKWISE until it stops turning. To prevent the mantle
from loosening during crushing, the shaft nut must be as tight
as possible against the burning ring.
412
07/09
IMPORTANT:
Carefully inspect the joint between the mantle and the
taper head. Seal any worn areas that create a gap with
putty to prevent Smithbond leakage during backing
installation. If any major clearance is detected, check
that the mantle is not cocked, or the shaft nut not fully
tightened.
Torque Specification
38
44
52
57
68
NOTE:
It is possible to use a new style shaft nut cap on an old
style shaft nut on models 44, 52 and 57 cone crushers.
To use the new style cap, grind off the locating lug (Fig.
4-20) until it is smooth with the surrounding surface.
07/09
413
A
A
12. The void between the mantle and the taper head will now
need to be filled with Smithbond epoxy-based backing
compound. Refer to Table 4-2 for the approximate amount of
Smithbond needed for your particular model crusher. Be sure
that an adequate supply of Smithbond is available before
beginning the pour.
Table 42. Smithbond Quantities - Mantle*
Crusher Model
Quantity
38S/FC
44S
44FC
52S/FC
57S
57FC
68S/FC
13. Form a clay funnel around each of the two pouring holes
near the top of the mantle (Fig. 4-21).
Figure 422. Pouring Smithbond
16. Mix another pail of Smithbond and pour into the opposite
funnel from the first pour. Continue pouring until the pail is
completely empty. Pouring should be alternated between the
two pouring holes.
414
07/09
17. Mix and pour additional pails of Smithbond until the level
just reaches the lower edge of the pour hole on the mantle
(Fig. 4-23). DO NOT fill the holes so that backing compound
backs up into the clay funnels. If this occurs, quickly remove
the clay funnels and allow backing compound to drain down
to the correct level.
23. Weld the shaft nut cap to the burning ring using stainless
steel weld rod E (R) 309L. Apply 2 welds in four places as
shown in Figure 4-24.
WEL
WELD
C
A
B
B. Mantle
D. Shaft
WELD
20. After the Smithbond has fully hardened, remove the clay
pouring funnels and any clay putty that was used at the mantle
joint. Grind off any excess Smithbond residue.
21. Tack weld the shaft nut locking plate to the shaft nut cap
(Fig. 4-24) using stainless steel weld rod E (R) 309L.
IMPORTANT:
If the shaft nut cap bolt locking plate is not welded to the
shaft nut cap, the bolt could loosen and cause damage
to the shaft nut cap or crusher. If you have further
questions on how or where to weld the shaft nut, shaft
nut cap or burning ring, contact Telsmith Service.
22. Weld the burning ring to the mantle using stainless steel
weld rod E (R) 309L. Apply 2 welds in four places as shown
in Figure 4-24.
07/09
415
NOTE:
Perform steps 5 and 6 ONLY if your crusher is equipped
with the anti-spin option (4-25). If your crusher is not
equipped with anti-spin, skip steps 5 and 6.
With Anti-Spin
Without Anti-Spin
Figure 425. Anti-Spin Option Check
5. At one of the crusher arms, measure the distance between
the top of the frame arm and the bottom of the taper head
skirt. (Fig. 4-26). Record this measurement for further use. It
will be checked again during reassembly procedures.
416
07/09
A
C
7. Remove the shaft nut cap bolt, washer and shaft nut
locking plate from the shaft nut (Fig. 4-24). It will be
necessary to use a cutting torch to remove the weld holding
shaft nut locking plate to the shaft nut cap.
! WARNING
Always use suitable rigging and hoisting
equipment to stabilize and lift heavy objects.
Lifting heavy components with inadequate
hoisting apparatus can damage machinery and
may result in serious personal injury or death.
8. Use a torch to cut the weld holding the shaft nut locking
plate (Fig. 4-24) to the shaft nut cap. Remove the locking
plate, the hex head cap screw and the flat washer from the
shaft nut cap.
07/09
417
B
C
D
B
E
C
IMPORTANT:
The upper bearing race (B, Fig. 4-29 & 4-30) may
temporarily stick to the inside of the taper head due to
oil adhesion. To prevent bearing damage, do not lift the
taper head more than 2 inches off the eccentric before
determining if the upper bearing race has detached
from the head.
11. Slowly lift the head and shaft assembly approximately
two inches off the eccentric. Stop and wait several minutes
while listening for the upper race to drop. A distinctive
clunk should be audible when the race drops down out of
the taper head.
418
07/09
! WARNING
Do Not reach or work under the taper head while
it is suspended. If the race remains stuck to the
underside of the taper head, use a sling to retain
it as described below. Serious personal injury or
death will result if the race loosens and falls on
personnel.
12. If there is a question whether the race has dropped, lift the
head and shaft assembly up several more inches and check
visually with a mirror to see if the race has dislodged. Do Not
under any circumstances place any portion of your body
under the shaft assembly while checking for the position of
the upper race.
Mantle Removal
Remove the mantle from the head and shaft assembly as
detailed in MANTLE REMOVAL in this chapter.
! CAUTION
Make certain the head and shaft assembly is
securely supported when removing the mantle
(Fig. 4-31). A sledgehammer will be required to
break the mantle free. The head and shaft
assembly must be securely blocked to prevent
the head and shaft assembly from moving while
the mantle is being broken loose.
! WARNING
NOTE:
Hitting the side of the mantle with a sledge hammer may
help loosen a stuck upper race.
13. If the race still has not dropped down, loop a sling around
the lower end of the main shaft to form a noose. Do Not reach
under the taper head while positioning the noose. Secure the
loose end of the sling to the eyebolt at the upper end of the
shaft.
14. Using the lift device, slowly lift the head and shaft
assembly completely from the crusher and place on suitable
work supports (Fig.4-31).
IMPORTANT:
The shaft assembly has a 16 RMS finish that can be
damaged if handled improperly. NEVER attempt to
remove nicks, scratches or burrs by working in a vertical
motion with sandpaper, emery cloth or a file. If attempts
are made to remove imperfections, use only a fine file
and work horizontally when attempting to repair the
surface. If the shaft will not be reused immediately, coat
it with grease or oil to prevent rust.
15. If the upper bearing race remains stuck in the head, again
rap on the mantle with a sledgehammer to loosen the race and
get it to fall into the noose wrapped around the head.
07/09
419
B
A
E
C
3. Check the taper head on both the inside and outside for
signs of cracks or other damage. Cracking on the taper head
will typically be visible on the flange (B, Fig. 4-32) or on the
inside of the taper at the main shaft junction. Check the inside
of the taper for signs of scoring that could indicate the upper
bearing has spun. If the taper head is cracked or badly scored,
it must be replaced.
4. Check the machined surface of the taper flange for
denting or gouging. Remove any surface imperfections with
a grinder.
5. Check the taper flange for dents or caved in areas that
could cause the flange to hang up on the eccentric assembly.
If it is not possible to bend the flange back into position or
into the correct shape, it will be necessary to replace the taper.
6. Inspect the upper bakelite seals (D, Fig. 4-33) for wear.
Replace the seals if worn or damaged.
420
7. Inspect the inner piston ring (F, Fig. 4-33) for cracks or
damage. File or sand any rough areas on the ring and clean
out the piston ring groove thoroughly. If the piston ring is
cracked or damaged, it must be replaced.
8. Inspect the upper thrust bearing components (A, B and C,
Fig. 4-33) for wear, scratches, score marks, cracks in the
cages, roller wear or damage, pitting in rollers or races, rust,
etc. Replace the bearing if any damage is present or wear is
evident.
07/09
IMPORTANT:
If the main shaft, taper head, bearing components or the
bronze sleeve in the eccentric were replaced with new
components after the inspection procedure, it will be
necessary to check head and shaft tolerances before
re-installing the head and shaft in the crusher. Refer to
the H or SBS service manual for the correct procedures
on measuring tolerances.
Mantle Installation
Install a new mantle on the taper head following the
instructions in MANTLE INSTALLATION in this chapter.
IMPORTANT:
Before installing the new mantle on the taper head,
make certain all old Smithbond and other debris has
been removed from the taper head. If it is necessary to
remove material using a grinder or hand chisels, be
careful not to nick or scratch the machined seat at the
bottom of the taper head.
C
B
! CAUTION
Failure to properly install and align bearing
components will result in bearing failure which
could damage other components on the crusher.
07/09
421
NOTE:
! WARNING
Always use suitable rigging and hoisting
equipment to stabilize and lift heavy objects.
Lifting heavy components with inadequate
hoisting apparatus can damage machinery and
may result in serious personal injury or death.
7. Attach a lift cable or chain to the eyebolt. Using a properly
rated lifting device, carefully suspend the head and shaft
assembly over the crusher.
8. Align the bottom of the main shaft with the bore of the
bronze sleeve in the eccentric (Fig. 4-35). Slowly lower the
head and shaft assembly into the crusher. DO NOT rotate the
assembly as it is being lowered into the sleeve.
C
B
4
D
B. Main Shaft
D. Bronze Sleeve
F.Thrust Bearing Upper Race
10. Remove the lifting apparatus from the eyebolt when the
taper and shaft assembly is fully seated.
11. Block the flywheel sheave so it cannot move. Attempt to
turn the taper head by hand. The assembly should turn freely
and smoothly in both directions.
422
07/09
! CAUTION
Failure to properly install and align bearing
components will result in bearing failure which
could damage other components on the crusher.
4. Place a long bar down through the bore of the eccentric.
Using the bar, shift the slider plate from side to side until the
rectangular center hole is aligned with the round center hole
of the adapter plate (Fig.4-37).
NOTE:
Crushers built after 3/09 have two threaded inspection
plugs on the anti-spin cover. These plugs should be
removed and used to help visually align anti-spin
components when installing the shaft drive tang into the
slider plate groove. Best results can be obtained by
shining a light in through the side hole (A, Fig. 4-39) and
viewing the tang and slider plate through the front
inspection hole (B).
07/09
423
! WARNING
Always use suitable rigging and hoisting
equipment to stabilize and lift heavy objects.
Lifting heavy components with inadequate
hoisting apparatus can damage machinery and
may result in serious personal injury or death.
10. Attach a lift cable or chain to the eyebolt. Using a properly
rated lifting device, carefully suspend the head and shaft
assembly over the crusher (Fig. 4-41).
C
A
ECCENTRIC
LOW POINT
B. Main Shaft
11. Align the bottom end of the main shaft with the bore of the
inner bronze sleeve. With the shaft suspended above the bore,
slowly rotate the head and shaft assembly until the drive tang
is precisely aligned with the drive tang groove on the slider
plate (Fig. 4-42).
4
A
B. Oil Duct
D. Countershaft
424
07/09
1
Turn
1/4
Turn
NOTE:
Figure 442. Aligning Drive Tang with Groove
A. Adapter Plate
C. Drive Tang
12. Slowly lower the head and shaft assembly into the
crusher. To ensure drive tang engagement, DO NOT rotate
the assembly as it is being lowered into the bronze sleeve.
13. Continue lowering the head and shaft assembly until the
underside of the taper head is seated on the top race of the
upper thrust bearing.
14. Remove the lifting chain from the eyebolt. Rock the head
slightly to check that the tang has seated in the tang groove.
15. Block the flywheel sheave so that the eccentric assembly
cannot turn.
16. Rotate the taper head slowly counter-clockwise by hand.
Verify that it turns freely for at least one full turn (Fig. 4-43).
07/09
425
IMPORTANT:
If the drive tang has not engaged the slider plate groove,
the measurement made in step 20 will be approximately
1
/2 to 1 inch (1.25 to 2.5 cm) longer than the earlier
measurement. If the measurement is too long, raise the
shaft and head assembly and install the assembly again
re-aligning the drive tang and the slider plate groove
(Fig. 4-39).
27. When the shaft nut cap is correctly installed, install the
shaft nut cpascrew locking plate and weld the plate, the burn
ring and the shaft nut cap as shown in Figure 4-45. A stainless
steel weld rod E (R) 309L is required when making these
welds.
WEL
WELD
C
A
B
! CAUTION
Never reach between the rotary seal ring and the
underside of the taper head to check clearance.
Serious personal injury will result if the rotary
seal ring is lowered onto hands or fingers.
23. Tang engagement can also be checked at the top of the
crusher. Lay a long straight edge or bar across the top of the
main frame (Fig. 4-44) parallel to the tang direction. Observe
the bar in relation to the taper head. The bar to head should
show a 3o gap on the eccentric low point side. If no gap is
present, this is an indication that the shaft tang has not
correctly seated in the slider groove.
WELD
B. Flat Washer
B. Straight Bar
26. Install the shaft nut cap, flatwasher and capscrew. Torque
the shaft nut capscrew to specification (Table 4-1).
426
07/09
Fastener Information
Size
Thread
Type
Threads
Per Inch
(n)
Major Dia.
(in)
(in2)
Torque
Dry
in-lb/ft-lb
(Nm)
Torque
Lubricated
in-lb/ft-lb
(Nm)
Torque
Dry
in-lb/ft-lb
(Nm)
Torque
Lubricated
in-lb/ft-lb
(Nm)
Tensile
Stress
Area
1/4
UNC
UNF
20
28
0.2500
0.2500
0.0318
0.0364
66 (7.4)
75 (8.4)
49 (5.5)
56 (6.3)
100 (11.2)
120 (13.5)
76 (8.5)
87 (9.8)
5/16
UNC
UNF
18
24
0.3125
0.3125
0.0524
0.0581
11 (14.9)
13 (17.6)
8 (10.8)
9 (12.2)
17 (23.0)
19 (25.7)
13 (17.6)
14 (18.9)
3/8
UNC
UNF
16
24
0.3750
0.3750
0.0775
0.0878
20 (27.1)
23 (31.1)
15 (20)
17 (23)
31 (42.0)
35 (47.4)
23 (31.1)
26 (35.2)
7/16
UNC
UNF
14
20
0.4375
0.4375
0.1063
0.1187
32 (42.3)
36 (48.8)
24 (32.5)
27 (36.6)
49 (66.4)
55 (74.5)
37 (50.1)
41 (55.5)
1/2
UNC
UNF
13
20
0.5000
0.5000
0.1419
0.1600
49 (66.4)
55 (74.5)
37 (50.1)
41 (55.5)
75 (101)
85 (115)
57 (77.2)
64 (86.7)
9/16
UNC
UNF
12
18
0.5625
0.5625
0.1819
0.2030
70 (94.9)
78 (106)
53 (71.8)
59 (79.9)
110 (149)
120 (162)
82 (111)
91 (123)
5/8
UNC
UNF
11
18
0.6250
0.6250
0.2260
0.2560
97 (131)
110 (149)
73 (98.9)
83 (112)
150 (203)
170 (230)
110 (149)
130 (176)
3/4
UNC
UNF
10
16
0.7500
0.7500
0.3345
0.3730
170 (230)
190 (258)
130 176)
140 (188)
270 (366)
300 (407)
200 (271)
220 (298)
7/8
UNC
UNF
9
14
0.8750
0.8750
0.4617
0.5095
170 (230)
180 (244)
120 (163)
140 (190)
430 (583)
470 (630)
320 (434)
360 (488)
UNC
UNF
8
12
1.0000
1.0000
0.6057
0.6630
250 (339)
270 (366)
190 (258)
210 (285)
640 (868)
710 (963)
480 (651)
530 (719)
1 1/8
UNC
UNF
7
12
1.1250
1.1250
0.7633
0.8557
350 (474)
400 (542)
270 (366)
300 (407)
800 (1085)
890 (1207)
600 (813)
670 (908)
1 1/4
UNC
UNF
7
12
1.2500
1.2500
0.9691
1.0729
500 (677)
550 (746)
380 (515)
420 (569)
1,100 (1491)
1,200 (1627)
840 (1139)
930 (1260)
1 3/8
UNC
UNF
6
12
1.3750
1.3750
1.1549
1.3147
660 (895)
740 (1003)
490 (664)
560 (760)
1,500 (2033)
1,700 (2304)
1,100 (1491)
1,300 (1762)
1 1/2
UNC
UNF
6
12
1.5000
1.5000
1.4053
1.5810
870 (1179)
980 (1328)
650 (881)
730 (989)
2,000 (2711)
2,200 (2982)
1,500 (2033)
1,600 (2169)
ASTM A449
1 3/4
1 3/4
UNC
UN
5
12
1.7500
1.7500
1.8995
2.1873
1,400 (1898)
1,600 (2169)
1,000 (1355)
1,200 (1627)
2,300 (3118)
2,600 (3525)
1,700 (2304)
2,000 (2711)
2
2
UNC
UN
4 1/2
12
2.0000
2.0000
2.4982
2.8917
2,100 (2847)
2,400 (3254)
1,500 (2033)
1,800 (2440)
3,400 (4609)
4,000 (5423)
2,600 (3525)
3,000 (4067)
2 1/4
2 1/2
2 3/4
3
UNC
UNC
UNC
UNC
4 1/2
4
4
4
2.2500
2.5000
2.7500
3.0000
3.2477
3.9988
4.9340
5.9674
3,000 (4067)
4,100 (5559)
5,600 (7592)
7,400 (10033)
2,300 (3118)
3,100 (4203)
4,200 (5694)
5,600 (7592)
5,000 (6779)
6,900 (9355)
9,400 (12745
12,000 (16270)
3,800 (5152)
5,200 (7050)
7,000 (9491)
9,200 (12473)
Torque Coefficients
07/09
Dry: 0.20
Lubricated: 0.15
A1
7F
Torque Tables
Fastener Information
Size
7F
Thread
Type
Threads
Per Inch
(n)
Major Dia.
(in)
(in2)
Torque
Dry
ft-lb
(Nm)
Torque
Lubricated
ft-lb
(Nm)
Torque
Dry
ft-lb
(Nm)
Torque
Lubricated
ft-lb
(Nm)
Tensile
Stress
Area
1/4
UNC
UNF
20
28
0.2500
0.2500
0.0318
0.0364
12 (16.2)
14 (18.9)
9 (12.2)
10 (13.5)
14 (18.9)
16 (21.6)
10 (13.5)
12 (16.2)
5/16
UNC
UNF
18
24
0.3125
0.3125
0.0524
0.0581
25 (33.8)
27 (36.6)
18 (24.4)
20 (27.1)
29 (39.3)
32 (43.3)
22 (29.8)
24 (32.5)
3/8
UNC
UNF
16
24
0.3750
0.3750
0.0775
0.0878
44 (59.6)
49 (66.4)
33 (44.7)
37 (50.1)
51 (69.1)
58 (78.6)
38 (51.5)
43 (58.3)
7/16
UNC
UNF
14
20
0.4375
0.4375
0.1063
0.1187
70 (94.9)
78 (106)
52 (71.8)
59 (79.9)
82 (111)
91 (123)
61 (82.7)
68 (92.1)
1/2
UNC
UNF
13
20
0.5000
0.5000
0.1419
0.1600
110 (149)
120 (163)
80 (109)
90 (122)
120 (162)
140 (188)
93 (126)
110 (149)
9/16
UNC
UNF
12
18
0.5625
0.5625
0.1819
0.2030
150 (203)
170 (230)
120 (162)
130 (176)
-----
-----
5/8
UNC
UNF
11
18
0.6250
0.6250
0.2260
0.2560
210 (285)
240 (325)
160 (217)
180 (244)
240 (325)
270 (366)
180 (244)
200 (271)
3/4
UNC
UNF
10
16
0.7500
0.7500
0.3345
0.3730
380 (515)
420 (569)
280 (379)
320 (433)
420 (569)
470 (637)
320 (434)
350 (474)
7/8
UNC
UNF
9
14
0.8750
0.8750
0.4617
0.5095
610 (827)
670 (908)
460 (624)
500 (677)
680 (922)
750 (1017)
510 (691)
560 (759)
UNC
UNF
8
12
1.0000
1.0000
0.6057
0.6630
910 (1234)
1,000 (1356)
680 (922)
750 (1017)
1,000 (1350)
1,100 (1491)
770 (1044)
840 (1139)
1 1/8
UNC
UNF
7
12
1.1250
1.1250
0.7633
0.8557
1,300 (1762)
1,400 (1898)
970 (1315)
1,100 (1491)
1,400 (1898)
1,600 (2169)
1,100 (1491)
1,200 (1627)
1 1/4
UNC
UNF
7
12
1.2500
1.2500
0.9691
1.0729
1,800 (2440)
2,000 (2711)
1,400 (1898)
1,500 (2003)
2,000 (2711)
2,300 (3118)
1,500 (2003)
1,700 (2305)
1 3/8
UNC
UNF
6
12
1.3750
1.3750
1.1549
1.3147
2,400 (3254)
2,700 (3660)
1,800 (2440)
2,000 (2711)
2,700 (3660)
3,000 (4068)
2,000 (2711)
2,300 (3118)
1 1/2
UNC
UNF
6
12
1.5000
1.5000
1.4053
1.5810
3,200 (4338)
3,600 (4881)
2,400 (3254)
2,700 (3660)
3,600 (4881)
4,000 (5423)
2,700 (3660)
3,000 (4068)
UNC
UN
5
12
1.7500
1.7500
1.8995
2.1873
5,000 (6779)
5,700 (7728)
3,700 (5017)
4,300 (5830)
5,600 (7592)
6,400 (8677)
4,200 (5694)
4,800 (6508)
2
2
UNC
UN
4 1/2
12
2.0000
2.0000
2.4982
2.8917
7,500 (10169)
8,700 (11796)
5,600 (7593)
6,500 (8813)
8,400 (11389)
10,000 (13588)
6,300 (8541)
7,300 (9897)
2 1/4
2 1/2
2 3/4
3
UNC
UNC
UNC
UNC
4 1/2
4
4
4
2.2500
2.5000
2.7500
3.0000
3.2477
3.9988
4.9340
5.9674
11,000 (14914)
15,000 (20338)
18,000 (24405)
24,000 (32540)
8,200 (11118)
11,000 (14914)
13,000 (17626)
18,000 (24405)
12,000 (16270)
17,000 (23049)
23,000 (31184)
30,000 (40676)
9,300 (12609)
13,000 (17626)
17,000 (23049)
23,000 (31184)
Torque Coefficients
A2
Dry: 0.20
Lubricated: 0.15
07/09
SQUARE MEASURE
To Convert
Info
Multiply by
To Convert
Info
Multiply by
Inches
Feet
Centimeters
Millimeters
Meters
Meters
Centimeters
Meters
Inches
Inches
lnches
Feet
2.54
0.3048
0.3937
0.0394
39.37
3.2808
Sq. Inches
Sq. Miles
Sq. Centimeters
Sq. Meters
Sq. Meters
Sq. Centimeters
Sq. Kilometers
Sq. Inches
Sq. Inches
Sq. Feet
6.452
2.59
0.15499
1549.9
10.763
CUBIC MEASURE
WEIGHT
To Convert
Info
Multiply by
To Convert
Info
Multiply by
Cu. Inches
Cu. Feet
Cu. Centimeters
Cu. Meters
Cu. Meters
Cu. Centimeters
Cu. Meters
Cu. Inches
Cu. inches
Cu. Feet
16.387
0.0283
0.06102
610233779.0
35.314
Kilograms
Pounds
Pounds/Sq.
Inch
Pounds/Sq.
Foot
Pounds
Kilograms
Kilograms/Sq.
Centimeter
Kilograms/Sq.
Meter
2.2046
0.4536
0.0703
4.8824
07/09
-30
-28
-26
-24
-22
-20
-18
-16
-14
-12
-10
-8
-6
-4
-2
0
+1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
-34.44
-33.33
-32.22
-31.11
-30.00
-28.89
-27.78
-26.67
-25.56
-24.44
-23.33
-22.22
-21.11
-20.00
-18.89
-17.78
-17.22
-16.67
-16.11
-15.56
-15.00
-14.44
-13.89
-13.33
-12.78
-12.22
-11.67
-11.11
-10.56
-10.00
-9.44
-8.89
-8.33
-7.78
-7.22
+20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
-6.67
-6.11
-5.56
-5.00
-4.44
-3.89
-3.33
-2.78
-2.22
-1.67
-1.11
-0.56
0.00
+0.56
1.11
1.67
2.22
2.78
3.33
3.89
4.44
5.00
5.56
6.11
6.67
7.22
7.78
8.33
8.89
9.44
10.00
10.56
11.11
11.67
12.22
F
+55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
C
+12.78
13.33
13.89
14.44
15.00
15.56
16.11
16.67
17.22
17.78
18.33
18.89
19.44
20.00
20.56
21.11
21.67
22.22
22.78
23.33
23.89
24.44
25.00
25.56
26.11
26.67
27.22
27.78
28.33
28.89
29.44
30.00
30.56
31.11
31.67
+90
91
92
93
94
95
96
97
98
99
100
105
110
115
120
125
130
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
+32.22
32.78
33.33
33.89
34.44
35.00
35.56
36.11
36.67
37.22
37.78
40.55
43.33
46.11
48.89
51.67
54.44
57.22
60.00
62.78
65.56
68.33
71.11
73.89
76.67
79.44
82.22
85.00
87.78
90.55
93.33
96.11
98.89
101.67
104.44
F
+225
230
235
240
245
250
255
260
265
270
275
280
285
290
295
300
305
310
315
320
325
330
335
340
345
350
355
360
365
370
375
380
385
390
395
C
+107.22
110.00
112.78
115.56
118.33
121.11
123.89
126.67
129.44
132.22
135.00
137.78
140.55
143.33
146.11
148.89
151.67
154.44
157.22
160.00
162.78
165.56
168.33
171.11
173.89
176.67
179.44
182.22
185.00
187.78
190.55
193.33
196.11
198.89
201.67
B1
7F
NOTES
7F
B2
07/09
Appendix C - Weights
Appendix C - Weights
26,912 (12207)
27, 275 (12371)
16,389 (7433)
16,026 (7269)
10, 885
(4937)
8440
(3828)
175
(79)
453
(205)
40
(18)
96
(44)
Eccentric
859
(390)
263
(119)
121
(55)
508
(230)
4070
(1846)
94
(43)
557
(253)
223
(101)
Locknut
1431
(649)
30
(14)
4360
(1977)
Concave ring
1300
(590)
44
(20)
07/09
38
7F
3083
(1398)
C1
Appendix C - Weights
1290
(585)
545
(247)
Mantle only
1022
(464)
44
(20)
7F
38
1,475
(669)
Countershaft
125
(57)
60
(27)
Flywheel sheave
162
(73)
200
(91)
54
(24)
35
(16)
780
(354)
326
(148)
509
(231)
1380
(626)
1880
(853)
600
(272)
520
(236)
Important: All weights shown are estimated and may vary by +/-5 percent.
When available, always refer to the bill-of-lading or packing list for actual weights.
C2
07/09
Appendix C - Weights
32,818 (14885)
33,178 (15049
20,436 (9269)
20,074 (9105)
12,744
(5780)
9010
(4087)
185
(84)
1041
(472)
40
(18)
130
(59)
Eccentric
1069
(485)
263
(119)
121
(55)
508
(230)
3320
(1506)
150
(68)
732
(332)
263
(119)
Locknut
1664
(755)
30
(14)
07/09
44
7F
4791
(2173)
1600 (726)
1700 (771)
110 (50)
C3
Appendix C - Weights
4380
(1986)
2280
(1034)
640
(290)
Mantle only
1325
(601)
44
(20)
7F
44
1,519
(689)
Countershaft
125
(57)
60
(27)
Flywheel sheave
320
(145)
234
(106)
54
(24)
35
(16)
385
(175)
960
(435)
1380
(626)
1880
(853)
600
(272)
520
(236)
Important: All weights shown are estimated and may vary by +/-5 percent.
When available, always refer to the bill-of-lading or packing list for actual
weights.
C4
07/09
Appendix C - Weights
50,053 (22074)
50,454(22886)
31,857(14,454)
31,465 (14,272)
16740
(7593)
13500
(6123)
350
(159)
1426
(647)
125
(57)
173
(78)
Eccentric
1550
(703)
486
(220)
173
(78)
570
(259)
4080
(1851)
202
(92)
875
(397)
229
(104)
Locknut
1663
(754)
30
(14)
8503
(3857)
176 (80)
132 (60)
(80)
07/09
52
7F
8405
(3812)
C5
Appendix C - Weights
7F
52
5196
(2357)
1258
(571)
Mantle only
1626
(738)
88
(40)
2310
(1048)
Countershaft
223
(101)
160
(73)
Flywheel sheave
540
(245)
200
(91)
54
(24)
35
(16)
355
(161)
1367
(620)
1880
(853)
2465
(1118)
1280
(581)
778
(353)
Important: All weights shown are estimated and may vary by +/-5 percent.
When available, always refer to the bill-of-lading or packing list for actual weights.
C6
07/09
Appendix C - Weights
70,078 (31989)
70, 523 (31787)
44,739 (20293)
44,294 (20091)
29102
(13200)
19708
(8940)
475
(215)
2342
(1062)
280
(127)
280
(127)
Eccentric
2800
(1270)
1040
(472)
283
(128)
734
(333)
9187
(4167)
210
(95)
1292
(586)
569
(258)
Locknut
5700
(2586)
7F
30
(14)
13,589
(6164)
Concave ring
4000
(1814)
07/09
57
330 (150)
C7
Appendix C - Weights
10,662
(4,836)
5883
(2668)
1713
(777)
Mantle only
2653
(1203)
7F
57
176
(80)
2,243
(1,018)
Countershaft
240
(109)
200
(91)
Flywheel sheave
750
(340)
234
(106)
78
(35)
35
(16)
1240
(562)
1725
(782)
569
(258)
2680
(1216)
1280
(581)
506
(230)
Important: All weights shown are estimated and may vary by +/-5 percent.
When available, always refer to the bill-of-lading or packing list for actual weights.
C8
07/09
Appendix C - Weights
106,643 (48372)
107,102 (48581)
65,783 (29838)
65,324 (29630)
40460
(18352)
29564
(13410)
750
(340)
748
(339)
265
(120)
345
(156)
Eccentric
4400
(1996)
3270
(1483)
296
(134)
755
(342)
11509
(5220)
225
(102)
1543
(700)
306
(139)
Locknut
4896
(2221)
7F
122
(55)
20,485
(9,292)
Concave ring
5120
(2322)
07/09
68
352 (160)
484 (220)
C9
Appendix C - Weights
15882
(7177)
7412
(3362)
2949
(1338)
Mantle only
3280
(1488)
7F
68
154
(70)
3,728
(1,691)
Countershaft
373
(169)
480
(218)
Flywheel sheave
870
(395)
234
(106)
78
(35)
35
(16)
2934
(1331)
647
(293)
647
(293)
2760
(1252)
3660
(1660)
1280
(581)
739
(335)
Important: All weights shown are estimated and may vary by +/-5 percent.
When available, always refer to the bill-of-lading or packing list for actual weights.
C10
07/09
Appendix D - Lubricants
Appendix D - Lubricants
Above 40 F
(4.5 C)
C-100
C-150
3 EP
4 EP
469 to 575
709 to 871
61 to 67
74 to 82
Viscosity Index
95 Min.
95 Min.
60 Min.
60 Min.
Yes
Yes
Yes
Yes
Anti-Foaming Agent
Yes
Yes
Pass
Pass
NOTE: Oil must not be corrosive to metals generally used in bearings, gears, shafts,
pumps and housings. Oil must have the least possible effect on rubber seals, synthetic
seals, packings and hoses. Refer to the Gyrasphere Operation & Maintenance Manual
for detailed crusher lubrication procedures and oil capacities.
7F
Hydraulic Oil Specifications
Viscosity ISO Grade
68
317
53 to 57
Viscosity Index
95 Min.
API Gravity
29 Min.
Pour Point, F
-10 to +10
Flash Point, F
400 to 425
Anti-Wear Agent
Yes
Anti-Foaming Agent
Yes
Yes
NOTE: Refer to the Gyrasphere Operation and Maintenance Manual for detailed
hydraulic system maintenance instructions and oil capacities.
07/09
D1
Appendix D - Lubricants
285
300
Dropping Point F
365
Pass
Pass
50
NOTE: The above grease must contain an extreme pressure (EP) agent that is not
harmful to bronze, brass or lead. For satisfactory lubrication, grease must be
absolutely free from any ingredients which could cause corrosion, and from gritty
material which could produce wear. Grease should also be uniform in texture,
consistency, structure, stability, flow characteristics and lubricating characteristics.
MOLY
EP-2
7F
265/295
Dropping Point F
510
Pass
Pass
D2
<3
<4
<5
1000
65
800
0.51 mm
Aluminum Complex
0 to 450 F
3.0
07/09
Pipe Sealant
Description
Loctite 592 PST Pipe Sealant, Medium
Strength, Slow Cure, Anti-Galling.
Part No. 59241.
Manufacturer
Loctite Corp
Manufacturer
Loctite Corp.
Loctite Corp.
7F
Spray Primer
(for use with Loctite 242 thread locking compound)
07/09
Description
Manufacturer
Loctite Corp.
E1
Anti-Seize Compound
Description
Manufacturer
Bostik Corp.
Silicone Sealant
Description
Manufacturer
Shellac
7F
E2
Description
Manufacturer
07/09
Type A Gear
Arrangement
Type B Gear
Arrangement
7F
Support Bowl Removal Clearances
Dimensions in inches (centimeters)
Crusher
Dimension B
Dimension C
Dimension A
Dimension B
Dimension C
Model 38
104 (264)
67 (170)
5 (13)
106 (269)
67 (170)
5 (13)
Model 44
N/A
N/A
N/A
104 (264)
67 (170)
5 (13)
Model 52
N/A
N/A
N/A
116 (295)
76 (193)
5 (13)
Model 57
133 (338)
87 (221)
5 (13)
125 (318)
83 (211)
5 (13)
Model 68
144 (366)
96 (244)
5 (13)
142 (361)
94 (239)
5 (13)
NOTE: Measurements shown above are typical. Actual measurements may vary, due to product changes, custom engineering
or fabrication variables. See the inset views above to determine gear arrangement.
07/09
F1
A
B
C
Type A Upper
Frame Assembly
Type B Gear
Arrangement
7F
Head and Shaft Removal Clearances
Dimensions in inches (centimeters)
Crusher
Dimension A
Dimension B
Dimension C
Dimension A
Dimension B
Dimension C
Model 38
136 (345)
130 (330)
5 (13)
136 (345)
130 (330)
5 (13)
Model 44
N/A
N/A
N/A
141 (358)
132 (335)
5 (13)
Model 52
N/A
N/A
N/A
161 (409)
151 (384)
5 (13)
Model 57
182 (462)
169 (429)
5 (13)
177 (450)
164 (417)
5 (13)
Model 68
203 (516)
188 (478)
5 (13)
201 (511)
186 (472)
5 (13)
NOTE: Measurements shown above are typical. Actual measurements may vary, due to product changes, custom
engineering or fabrication variables. See the inset views above to determine gear arrangement.
If crusher is NOT equipped with anti-spin, Dimensions A and B will be approximately 6 inches less than shown.
F2
07/09
7F
CONCAVE RING WEAR MEASUREMENT
1. Stop the crusher. Lockout/Tagout power to the crusher drive.
2. Raise the upper frame using the hydraulic clearing feature. Place hardwood blocks or safety spacers
between the upper and main frames. Refer to the crusher operators manual for instructions.
3. Lockout/Tagout Power to the hydraulic power unit.
4. At the bottom lip of the concave ring, measure dimension A.
5. Place a straight edge along the concave ring wear surface. Measure Dimension B.
6. Subtract Dimension B from Dimension A. This measurement should be 3/4 to 1 inch minimum.
7. If measurement is less than 1 inch, the concave ring should be replaced.
07/09
G1
7F
G2
07/09