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 Clearing a Stalled Jaw Crushers

32 EN Clearing a Stalled Jaw Crusher

EN 32-1
Clearing a Stalled Jaw Crushers

Stalled Jaw Crusher

nnWARNING
Refer to Safety Notices Section for relevant
warning and procedure

LOCKOUT
MACHINE

FALLING
HAZARD

Safety
1. In the situation where an oversize or tramp piece
of material causes the crusher to stall, and the
toggle plate does not fail, it is possible that very
high pressure will be sustained on the moving
swing jaw, dependent on which position the
stall occurred in the crushing cycle.
2. This pressure may result in the object to be
ejected in a random direction under high force
and therefore will need to be released under
controlled conditions to enable safe removal of
the material that has created the stall condition.

32-2
 Clearing a Stalled Jaw Crushers

nnWARNING
CUTTING THROUGH THE TOGGLE
PLATE WILL CAUSE THE RELEASE
OF STORED ENERGY IN THE
MOVING JAW WHICH MAY SWING
VIOLENTLY BACK TOWARDS THE
PERSON PERFORMING THE CUTTING
OPERATION.
BEFORE ANY ATTEMPT TO CARRY
OUT THE PROCEDURES TO CLEAR
THE STALLED CONDITION OF THE
CRUSHER THE MACHINE MUST BE
ISOLATED FROM ALL SOURCES OF
SUPPLY AND THE SAFETY GRID AT
THE MOUTH OF THE CRUSHER MUST
BE SECURELY FASTENED IN PLACE.
SUITABLE PERSONAL PROTECTION
EQUIPMENT MUST BE WORN.

nnCAUTION
The following procedure or any other
procedure developed to remove tramp
metal, or any other material that results
in the stalling of the crusher should
be incorporated into a permit to work
procedure and a risk assessment under-
taken to reflect all local factors. This
procedure should be maintained under
the control of the component person
appointed by the management.

3. The procedure should cover all factors of safety

including notification to the manager, isolation
of systems and locking out procedure, methods
of removal, safe positions for persons and
any other precautions as may be deemed
necessary.

EN 32-3
Clearing a Stalled Jaw Crushers

Procedure to release a stalled jaw crusher

1. Observe all safety warnings.
2. Isolate machine from all energy sources.
3. Ensure the safety grid is over the mouth of the
crusher. (Note that this may not be sufficient to
withstand the force of an ejected object under all
conditions, and all persons must be kept clear in
case it is pushed backwards.

4. If the crusher is equipped with hydraulic drive,

attempt to start the machine in reverse.

5. If the crusher is equipped with a hydraulic

wedge adjust system, attempt to release the
pressure on the jaw by opening the jaw using
the machine controls.
6. If none of the above operations are applicable,
or successful, then the toggle plate must be cut.
7. Before the cutting operation is commenced
adequate and appropriate provision MUST
be made to support the weight of the stored
energy in order to prevent the violent swinging
movement of the jaw.
8. The toggle plate should heated across the
centre line, between the holes, using a long-
handled large gas torch, such that the operator
can stand in a protected position, preferably to
the side of the plant.
9. Heat the material to a dull red, starting at the
mid point, and working outwards either side in
turn. Ideally, the toggle plate should be heated
until it yields. The yielding of the toggle plate
will reduce or eliminate the pressure on the
trapped object.
10. If the plate does not yield, then it is
recommended that small cuts are made in
either side of the toggle plate with an acetylene
cutting torch approximately 50mm (2in) from
each side and the heating procedure repeated
until yielding occurs.
11. After the pressure is released due to the toggle
plate yielding, the toggle plate should be cut in
two and removed.

For advice, contact your local dealer or technical

support.
03

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 Servicing Electrical System

50 EN Servicing Electrical System

EN 50-1
Servicing Electrical System

General
1. The plant electrical equipment is a self
contained 24V DC system operated via
automotive batteries which are recharged when
the engine is running.
2. Depending upon the model of plant and the
equipment fitted, various types of control,
monitoring, sequencing, electrical safeguards
and fault detection devices are built into the
system including a multi station emergency stop
circuit.
3. Any work on the plant electrical system shall
only be undertaken by a qualified electrician,
familiar with this type of system.
4. Circuit protection fuses or circuit breakers fitted
depend upon the plant model. The replacement
of a protection device after failure must not
exceed the rating of the original otherwise
damage to components may occur and any
warranty invalidated. A repeat of the failure
must be investigated and the problem rectified
by a competent person.
5. Always keep the electrical cabinets and control
boxes closed during the crushing operation to
prevent the ingress of dust and damp.
6. At regular intervals check the tightness of the
electrical components on the plant and look for
any damage to the electrical wiring.
7. Battery electrolyte level MUST be checked
every 50 Hours and replenished if necessary.

nnDANGER
Emergency stop equipment and all other
safety systems, including the audible
warning siren, must be operative at all
times whilst the plant is running or being
manoeuvred.
The safety devices must be checked as
fully operational at each daily start and
must not have been tampered with or
disabled in any way.

16
8. Refer to emergency stop section.

50-2
 Servicing Electrical System

Battery Replacement
Safe Handling of Automotive Batteries
9. The plant contains 2 automotive type batteries
which are replacable.
10. Battery Posts, terminals and related
accessories contain lead and lead compounds.
11. Handle batteries carefully and keep them level
as they contain sulphuric acid, an electrolyte
which can cause severe burns and produce
explosive gases.
12. Avoid contact with the skin, eyes or clothing.
13. Wash hands thoroughly after handling.

EN 50-3
Servicing Electrical System

Automotive Battery Replacement

14. Batteries should only be replaced by a
competent person.

15. Stop the plant and remove the ignition key. 15

16. Set the battery disconnect switch to ‘0’ and

lockout.
16 0
1
17. Two batteries are used for the plant electrical
system, located near or within the engine
powerpack.
18. Remove fasteners and guard, cover or floor
panel to gain access to the batteries.

nnWARNING
Refer to Safety Notices Section for relevant
warning and procedure

LOCKOUT
PLANT

19. On some plants it is necessary for a suitable FALLING

working platform to be used. HAZARD

20. The plant has a negative [-] chassis

connection.
21. Disconnect the cable at the negative [-] battery
terminal first.
22. Disconnect the positive [+] plant feed cable at
the battery terminal.
23. Disconnect the battery linking cable.

50-4
 Servicing Electrical System

24. Release the batteries from the securing clamps

and remove batteries.
25. Replacement batteries must be of the same
type and capacity as the original ones fitted.

26. Contact your local Powerscreen® dealer or

Powerscreen® technical support department for
advice if in doubt. 03

Battery Recycling
27. Do not dispose of any old batteries with normal
waste that may to go to landfill.
27

28. All batteries shall be disposed of correctly to be 28

recycled at an approved treatment facility.

EN 50-5
Servicing Electrical System

50-6
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