Kue Ken Jaw Crusher Manual Table of Contents — Rev. 1 (Section 4 Safety [ Section 2 Kue-Ken Jaw Crusher General Information & Output Rates ] Section 3 Installation | [section 4 Field Assembly instructions | | Section 5: [Size of Feed | {Section 6 | Methods of Crushing and Feeding | | ‘Section 7 | Crusher Adjustments | | Section 8 Feed Chutes & Spring Adjustments | [Section 9 safety Release Mechanism | Section 10___| Crankcase Seals & Ventilation / Bearings / Limit Bar / Cheek Piates | Section 41 Lubrication | ‘section 42) Drives/ Horsepower Required/RPM's/Sheave information | Section 13 Starting a New Crusher Section 14 Pressure Switches Section 15. Instructions for Removing Eccentric Shaft end Bearings in Kue-Ken Jaw Crushers | Section 16 Instructions for Removal of Toggles and Pittman ‘section 17 [Kue-ken Jaw Crushers, Recommended Maintenance Schedule Section 18 Installation of Diaphragm, Kue-Ken Jaw Crushers Models 22-35 Section 19 instalation of Diaphragm, Kue-ken Jaw Crushers Models 55-95 Section 20 instalation of Digphragm, Kue-Ken Jaw Crushers Models 104-126X Section 24 Procedure for instaling Toggle Seat Backing Plates Section 22 Trouble Shooting Common Kue-Ken Jaw Problems Section 23 For Technical Assistance or Parts for your Crusher Please Contact: Metso Minerals, 262.717.2500 or Metso.com Table OF ContentsSafety Information ‘SAFETY OF THE CRUSHER OPERATOR AND MAINTENANCE PERSONNEL IS OF PRIME IMPORTANCE TO EVERYONE! This first section of the KUE-KEN Jaw Crusher Manua| is to stress the basic safety practices necessary for the safe operation and maintenance of the KUE-KEN Jaw Crusher. The information contained in this manual does not replace or supercede any existing safety codes, insurance requirements, company safety rules or Federal, State or local regulations. nor is it Intended that this manual replace common sense! Crusher Operators, Plant Supervisors and Plant Safety Engineers are urged to be avare of all potential hazards that exist in the work environment and reach 2 mutual understanding as to what constitutes safe crusher operating conditions and practices. er Safe ices: Dress properly for the job. Know what safety clothes and gear must be worn on the job and wear them at all times. Be cautious with medications, Many mecications cause drowsiness or other side effects, Use extreme caution when operating the crusher. IF you are under any medication, consult your dactor prior to beginning work. Alcohol and Drugs have no place on the job, If you are under the influence of either alcohol or drugs, stay off the job - Pease! Know and understand the Crusher, It is mandatory that the Crusher Operator knows and understands the crusher thoroughly. Including the locations and functions of all the controls, gauges, indicators, alarms, and proper maintenance procedures and service periods to prevent crusher breakdowns. Check the crusher before start-uo, Walk around the crusher and inspect for loose, worn or damaged parts or faulty safety devices. Inspect all crive belts and pulleys for wear. Make sure that the hydraulic, air and lubrication systems, their rescective valves, drains and fittings are secure, Report or fix any defects or problems immediately. Follow the crusher start-up instructions, Be sure that the gauges, controls and alarms are working properly. Check for bearing or other unusual noises or sudden rises in cil temperature or low all pressure. Shut down immediately if problems are detected and report them at once. ‘Stop the Crusher safelv, The crusher must be at a complete stop with power off and locked out, with the controls tagged before any clearing, repairs, adjustments, servicing or attempts to clear the crusher chamber of jams are made. Prevent fires, Never weld or use a cutting torch near exposed fuels, lubricants or any Flammable material. Always extinguish smoking materials properly. Know where the nearest fire extinguisher is located. Keen the work area clean, Make certain that the job-site is free of all potential safety hazards. inspect it daily and make sure that all guards, rails and platforms or wakways are secure and free of spillage and/or obstructions. Keep tools stored in their proper place aS Well as spare parts, Section 4 - Safety Information* Expect the unexpected. Emergencies can and will hapoen! Be on the alert at all times and know the exact location of first-aid equipment, emergency phone numbers and fire- fighting equipment. Safe Maintenance Practices * Always lockout the electrical power and tag the control switches, This rust be done prior to starting any work on the crusher. This warning cannot be repeated too often! Electrical power is hazardous. Be certain that all equipment is properly grounded to prevent electrical shock hazards. Prevent any power cable from contacting water in puddles or drainage ditches, Do not run over power cables or lay them in traffic routes. Bridge power cables over traffic areas and inspect them regularly for wear or damage. Correct all electrical problems at once! * Pressure systems are dangerous, Before you start to work on any hydraullc or air line, bleed off the pressure first! Always assume that a line is under pressure and lock out and tag the power source and controls before starting work © Hydraulic fluids or air released under hich pressure can penetrate and/or burn the skin, or damage the eves causing serious injury, blindness and even death, If you get pressured hydraulic fluld or air under the skin or into your eyes, get medical treatment at oncet * Avoid exposure to hydraulic Fluids to the skin or eves, Mineral-based hydraulic oil is considered hazardous! Hydraulic fluid splashed in the eyes or open wounds must be thoroughly washed out. If imtation persists, get medical assistance at once! Hydraulic fluid dissolves the skin's natural oils so, frequent or prolonged exposure can cause severe skin irritations. Be sure to wear protective gear and wesh-up thoroughly after handling flulds. * Always dispose of toxic materials properly, Fuels; used lubricating or hydraulic oils and other hazardous wastes must be handled in strict accordance with all Federal State and/or Local regulations, * Construct safety quards to meet all current requlations, Refer to the MSHA “Guide to Equipment Guarding at Metal and Non-Metal Mines’ booklet for design and manufacturing instructions, + Tramp iron jams are particularly dangerous, It is impossible to know how tightly tramp iron or other uncrushable materials are ladged in the crushing chamber Be aware that It can elect itsef at anytime without prior notice at high velocity causing severe bodily harm or even death. Section 4 ~ Safety information‘Standard Jaw Crushers (Crushing Ratos for Mocols 22-108 TR Jassfeso| ors [ren aos [tem] ron [rao [aoe [rw | aco | sm | eo ou fea] art ior eet [ase ant| sm | eas | re [ ex | yee | 20 | ‘ear Thon To ere oie Sheet Tose Short Tons were Tone ‘her Tose wer Toss ‘Soe Foss Shot Too hort Tone = Shon Tone [ss] ert Tout Teme were To Short Tone GF] wore Ton ff Bien tom gH vere Tom General Spacifcations: Crushing ‘ates given ere neither minimum nor manirum. Rates described ae for = continuous feed of wall sre6ec sizes and are basec on ersting average clean, hard, cry cuertz or similar matvial having a bulk deny of approximately 100 los. per cubic foot (1600 kg. per cubic meter). For optimum performance. product aleacy at Closed Sized Seting size shouldbe emaved from ‘he leod and the maemum material input ste should not exceed 80-85% of the crushers gape. Minimum setings shown are ot neceesarly applicable to al installations. Some ofthe fastere whioh may afect espacty and roduc analyes clude food gradation, ‘moisture content. Frabilly ane method of feecing, For assistance In properiy application, please consult the factory. ‘Section 2 - Jaw Crusner General information Output Ratesse}ey andyng oeuLosU! jesdU9D saYsrUD Mer - Z uoHIES, Fr 62 SOpoW 10; Sore B4ysHID sioysnig mer iia O18Installation Bulld a concrete foundation to sult the ground, bearing in mind that foundations in soft ground should have a “spread footing” or wide extension all around to distribute the weight of the crusher and foundation over sufficient area to prevent settling or sinking. Be sure that the crusher shaft is level by using an accurate machinist sairit level on the Face of edge of the flywheel. It is not so important that the crusher be leveled so exactly lengthways, you can use the base line of the frame as a guide. ‘The general form, height, etc., of the foundation must be made to conform to your requirements, but in no event should concrete come up to the bottom sheet of the frame, as space underneath is reguired for air cooling, draining oll and the pull back rod and springs. When a conveyor belt passes under the crusher lenathways, the foundations will be substantially in the form of 2 walls. If structural steel Is used for foundations, the same general instructions will apply. if such foundations are relatively tal, be sure and make provisions for the ampie diagonal or “sway braces” that will be necessary to prevent lateral movement. Section § - InstallationField Assembly Instructions Kue-Ken crushers are sometimes shipped with the Pulley (illustrated part #74) removed from the Eccentric Shaft illustrated part #75) and the Oil Pump (lllustrated part #49) also removed fram the frame. ting te tot arts list dre located in Section 23 of this manuial, The hub of the Pulley has a Seal (iustrated part #47} at each ‘end, These Seals must not be damaged while replacing the Pulley. Therefore, ciean and thoroughly inspect the Eccentric Shaft removing all burrs, etc, As the Seals have to slide over the keyseat in the end of the Eccentric Shaft, it is necessary to avoid any chance of the sharp edges of the keyseat cutting and ruining the Seals. Therefore, cut and fit a plece of wood tightly into the keyseat. Make the wood slightly thicker than the depth of the keyseat so that the wood projects slightly above the Eccentric Shaft. Then trim and smooth the projecting part of the wood so that it follows the contour of the Eccentric Shaft. (Sandpaper on a wood block makes a good tool for the finishing ‘operation,) Now that the Keyseat hes been filled with wood, clean and oll the Eccentric Shaft; taking care to also clean and oil the inside of the hub. Hoist the Pulley and place it on the Eccentric Shaft, with the Safety Shoe (lustrated part #84) outward, Take extreme care when the Outer Se: (Wlustrated part #47) Is Just about to engage the extreme end of the Eccentric Shaft, If necessary, use @ smooth wood strip to secure easy entrance, Once the seal has Fully engaged the Eccentric Shaft, remove the wood from the keyseat. Next install the Safety Driving Arm (lliustrated part #80) on the Eccentric Shaft so that there is at least 1/16” end play between the Bearing Housing (ustrated part #45) and the end of the hub of the Pulley. To-engage the Leaf Spring (ilustrated #82) with the Safety Shoe Illustrated part #84) insert the Spring Compression Screw (llustrated part #83) in the Safety Driving Arm (lilustrated part #80). Tighten this screw to bend the Leaf Soring sufficiently to nass behind the Safety Shoe. Rotate the Pulley to the desired point & remove the Spring Compression Screw completely, The Leaf Spring will thus engage the Safety Shoe, Fil the hub of the Pulley at the Flywheel Oil Pug (llustrated part #98) with the correct oi. Fil nub until the oil shows over the Eccentric Shaft - do not overfil. Very Important: Never run the crusher unless the Spring Compression Screw has been completely removed from the Safety Driving Arm. ‘To fit the Oil Pump assembly in place. First, remove the temporary covers bolted aver the opening in the frame. Enter the end of the pump shaft in the pump case or frame, taking care that the driving hub on the end of the pump shaft properly enters the mating part that is part of the crusher shaft. Parts must enter voluntarily, and without force, Use the gaskets furnished, tightening ail bolts evenly and reasonably tight. Be sure that the suction ipe connections are tight, otherwise ‘the ump will suck air Instead of oil. The arrangement of oll piping on cifferent sizes of crushers may be slightly different from the drawing (40743), out the same instructions will apply. ‘Lastly, connect the pressure switch as shown on drawing #40745, Its required that the Pressure Switch (liustrated Part #59) and Pressure Gauge (lilustrated part #69) be connected to the pressure side of the Oil Pump, Do not mount the pressure switch or gauge on the crusher, Section 4 ~ Field Assembly InstructionsThe Crusher Feed Before operating the crusher, the basic laws of crushing must be considered and followed The machine is designed to receive up to a certain size of rock and crush it with the least expense of bower and maintenance. We call your attention to the folowina: The largest pieces entering the crusher must be able to enter the crushing zone. Generally speaking, the largest pieces should not be larger than 80% of the size of the feed opening, Example: if the feed opening is defined as 10” X 36”, the actual feed opening is 10” (the 36” dimension is the width of the crushing chamber), With a 10° feed opening the largest size rock that should be fed to it would be 8", If the feed contains pieces too large to enter, then install reject bars to reject such pieces, The large pieces can then be broken with hammers, etc. Do not permit them to obstruct the mauth of the crusher where it is difficult to break them, * It is equally important to remove all “Fines” from the crusher feed. By “fines” we mean all material that is already as small as the crusher output material will be. If fines are put in the crusher, capacity wil be reduced, power and maintenance will be much higher and, in some: cases, destructive stresses will be placed an the Toggle mechanism. It is oarticularly bad with damp or mucky material, and also with some of the softer rocks that have a tendency to “pack” Therefore, install a vibrating grizaly Feeder or scalper 2head of the jaw, The spaces between bars should be 54” to 1” more than the closed setting of the crusher jaws. For example, with the jaws set at a closed side setting of 2 ‘4", the grizzly bars would be spaced at 3 %" to 3%", Material passing through this grizzly is usually arranged to rejoin the material that hes gone through the crusher, ‘*Disregarcing “fines*, it is equally important that the size of feed to the crusher is not too small. An extremely small feed permits the material to instantly Fall down to the bottorn of the crushing zone, causing congestion, an extremely bad condition. If the size of the crusher feed) ‘opening is very much larger than the size of Feed, please consult us, as it might be possible to furnish special extra thick jaw plates or a “boister” to correct this matter. Remember the finer you wish to crush, the more important it becomes to properly prepare and “size” the feed, Section 5 ~ Size of FeedMethods of Crushing and Feeding Kue-Ken crusher usually operate as “primary” crushers and for this work it Is customary to use a plain Jaw plate with elther a straight face or a combination curve and straight face. Corrugated Jaws are rarely used, and only on special order. We endeavor to furnish the most desirable type of iaw plates in order to give the most economical crushing. When certain size of crusher are to be used for gravel crushing, special reduction Jaw plates ere suoplled, Single Pass Crushing: Kue-Ken crushers are suitable for single pass or open circuit operation. By single pass we mean that the material passes once only through the machine. If the resulting product is not fine enough for your purpose, then it should be screened to remove all that is of the desired size, and the remaining “oversize” crushed again in a secondary machine of a suitable type. There is always a practical limit of “reduction” or crushing that can be done in a single pass, and any attempt to exceed this mit will undoubtedly cause trouble, For most jaw crusher applications this limit, in the extreme is 8.1, however For most applications a limit of 7:1 or 6:1 should be considered. Closed Circuit Crushing: In this system, the crusher discharges onto a screen with openings of the desired size of finished product. The “oversize” that Is not yet small enough to go through the screen is returned to the crusher, together with the new incoming feed or raw material. Closed circuit crushing should not be attempted until we have had full details of the problem submitted to us at which time we will make recommendations, Obviously, when crushing in this closed circuit system, 100% of the product must be or screen size or smaller, in order to escape from the circutt. This system of “closed circuit” crushing in jaw crusher reauires consultation with the factory. oth ding Kue-Ken Jaw Crushers: As a general rule and orovided the material nas been properly “sized”, and is free from “fines” as previously explained these crushers should be “choke- fed” with a solid and continuous stream of material, keeping the crushing zone between the jaws full at all times. This will give more capacity and more finely crushed product for a given Jaw “setting’, as rock will crush rock as they descend through the machine. This will enaole you to get a finer and more evenly crushed product than you would get if the crusher were sparsely fed at a finer setting, Always feed material evenly across the full wicth of crusher. Never feed continuously at one side only Feed Chutes: A sloping feed chute, leading to the crusher, should have a grade of not less than 45 degrees, which is 12" in 12°, This chute must enter the crusher squarely without any horizontal anale. if the chute feeds rock to the crusher at an angle, it will cause large rock to ao to one side of the jaw, and all small rock will go to the other side, The crusher mechanism will then be loaded unevenly causing costly damage to the machine. In some operations where minimum production of fines is desired, “sparse” feeding and a mechanical feeder delivering a reduced but even flow is desirable, Even with “choke feeding’ a mechanical feeder is sometimes desirable, reducing labor costs and insuring maximum capacity, Such feeders are usually arranged to draw the sized and clean material from a storage bin. If such a feeder is used it should have a readily adjustable speed or weight control. Some of the soft, non-metallic minerals are not sultable for choke feeding, especialy if a great reduction Is attempted in a single pass, as ‘they have a tendency to “pack" in the crushing chamber. Section 6 - Methods of Crushing and FeedingJaw (Diel Plates: Jaw plates must be of the correct design to suit your work. We will be glad to discuss with you any questions you may have concerning them. To change Jaw Plates, first remove the Keeper Plate(s) and Bolts. Referencing drawing #4074R3 (in section #23) shows how these hold the Jaw Plates in place by clamping them downwardin the toe of the Jews. Tip the Jaw plate away from the Jaw with a bar. Insert a U-bolt with 2 threaded end nuts ‘through the lifter holes, which will be Found cast through the upper lugs at the back of the plate. Use a chain block and carefully lift the plate out of the machine. Remember these Jaw Plates are extremely heavy and made of manganese steel, Great care should be taken to avoid accidents. Before installation of the new Jaw Plates be sure to clean out rocks and grit that may be in the groove (or toe) at the bottom of the Jaw so that the new Jaw Plates will fit properly. Replace the Keeper Plates and Bolts, greasing the threads well with an anti-selze product to prevent rusting and aid in future removal, Tighten firmly, hammering on piates then tighten again, Run the crusher under load, and re+tighten Until the new plates are properly becded down onto the Jaws. The backs Of all Jaw Plates and Faces of the Stationary and Swing Jaws are machined flat. See that one end of ‘the Keeper Plates rests firmly on the Jaw Plate, mid stee!-Full width shims may be necessary to insure complete contact between the Keeper Plate and Jaw Die. Jaw Setting Measurements: We find that some operators have different methods of measuring the “Jaw setting’, Please note that when we refer to say a 3” jaw setting, we mean that 3” is the distance between the nearest opposite points on the 2 Jaw plates, measured when the Jaws are in ‘the closest position of their stroke, The place of measurement is usually at or near the bottom of the Jaw plates. When taking this measurement, use a short piece of board of the correct thickness and at least 6” or 8” wide. Insert this board between the jaw piates using it as 2 gauge and thus avoiding errors, At this 5° Jaw setting, if the crusher pulley is revolved 180 degrees (or half a Fevolution) the distance between the same points on the Jaw plates will be considerable more depending on the length of stroke built into your machine, but usually somewhere between 1%" and 1", Do not measure “jaw setting’ in the open position of the jews, as it is wrong. Full instruction on how to make the actual changes in jaw setting wil be found in Section 7, Permissible Jaw Setting: Just how close together the jaws may be set depends on many different factors, and there is no definite fixed rule. Naturaly, a clean, dry, free splitting rock will permit a finer (closer) jaw setting than a wet, Gamo or sticky rock that does not shatter and fall Freely through the crushing zone. Usually the best al-around jaw setting is found by trial, always taking care that packing or congestion does not take place under any circumstances. Excessive power demands by the motor, pulsating driving belts and any other evidence of “packing” or “tiling” of the crushed rock must mest with your immediate attention. Instead oF trying to get a finely crushed product by setting the jaws more closely, try and set them as open as possible, and depend on rapid choke feeding to make rock crush rock to maximum Fineness, Whenever the jaws are being set more closely then before make sure that the safety device in the pulley is in perfect working order. ‘While there are many variable factors entering into each crushing problem, please remember this ‘one basic fact - that you will get more capacity, a better and finer crushed prociuct, with less power and wear and tear, if you wil follow the aforementioned simple instructions. Section 6 - Methods of Crushing and FeedingCrusher Adjustments Altering Size of Crushed Product: First refer to the illustrated Part Drawing (#4074R3] where we show several views of the crusher. You will note that the Stationary Jaw illustrated part #3) rests upon and hinges around the curved seat an the upper part of the frame. To control the size of crushed product (or Jaw Setting) the Spacer Shims (llustrated part #35) are inserted through slotted holes in the sides of the frame. There they are traoped between the Rocking Seat (lilustrated part #55) in the Stationary Jaw, and the flat seat on the lower part of the frame strongback. The Upper Holding Bolts (llustrated part #36) end the Lower Holding Bolts (Illustrated part #57) hold the Stationary Jaw firmly against the upper & lower frame strongbacks. Note that the upper bolts have only 4 nut while the lower bolts have 2 nuts, one on each side of the lug on the frame. When crushing, the cuter nuts on both upper and lower holding bolts are tightened firmly against thelr respective lugs, and the inner nuts on the lower bolts are run away from the lugs as snown in Figure #1, Positively, you must not attempt to run the crusher with the inner nuts against the lugs as the full pressure of the crusher would then come on the lugs and break them off. When you want to change the setting of the jaws, proceed 2s follows: 4. Remove the Shim Keeper Bolt(s) (lilustrated Part #56) that are through the projecting ends of the shims, 2. Slack away the nuts on Upper Holding Bolts about “1/8” away from the lugs as shown in Figure 2 on drawing #4074R3, 3. Run out the inner nuts on the Lower Holding Bolts until they touch the lugs. Then slack away the ‘outer nuts on the lower bolts about %", 4, Tighten up the inner nuts so that the bolts then act as screw jacks and thus cause the Jaw to swing inward relieving pressure on the shims. When doing this monitor the nuts on the upper boits and siack them away a littie at a time, and only es much as needed. The idea |s to avoid letting the stationary jaw fall off the curved seat on the upper frame, which could happen if you do not follow instructions. See figure #2 on drawing #4074R3 5, Now remove shims if you want to open the Jaw setting, or Install another shim if you want to lose the setting. See that the holes for the Shim Keeper Balts line up, and replace the bolts in same fashion. 6, Then pull back the stationary Jaw against the shims by slacking away on the inner nuts and tightening all outer nuts evenly. Run the inner nuts to the extreme inner end of the threads near the jaw. Tighten the outer nuts firmly, then check the jaw setting by measuring with a plece of board as explained in Section 6. ‘Then run the crusher under load. After a few minutes, you wil find you can probably tighten the outer nuts a little more, as some dust and grit usually gets down between the spacer shims, and is reduced to powder in a few minutes. Check the nuts occasionally to prevent Jaw movement, keeping them tight, but not excessively so. We provide spacer shims of different thickness that if used in different combinations will give you a complete range of adjustment. Section 7 - Crusher AdjustmentsFeed Chutes & Spring Adjustments Feed Hooper or Chutes The chute or trough bringing rock to the crusher must not be fastened to the sloping Keeper Plate that holds the Stationary Jaw plate in place. This plate changes its position slightly whenever the Stationary Jaw is adjusted to deliver a different size of product. Allow about 1/8" to '4’ clearance at this point. if necessary fasten your feed chute to the crusher frame at the side of the feed opening, using the holes provided in the frame for that purpose. Be sure to allow enough working roam at the front end of the crusher so that @ person can work comfortably when making adjustments on the Stationary Jaw’s holding boits. Arrange a strong guard or baffle plate above the Swing Jaw at the Hinge pin to prevent large rocks from bouncing down the feed chute and over the Swing Jaw. A quickly removable guard should be fitted over the Pulley and belts to give quick access to the Safety Driving Arm in the center of the Pulley. Allow ample neight above the crusher, sufficient to permit removal and replacement of Jaw Plates and Swing Jaw. Always provide a substantial steel beam and trolley above the crusher. The Hinge Pin and Eccentric Shaft are withdrawn sideways through the frame so leave sufficient room at the side Of the crusher to do this, Provide ample flood lighting so that the machine is properly liluminated at all times. Machinery located in dark places never gets proper attention and Is usually dirty and frequently dangerous to the operator. If necessary to set the crusher outdoors protect it with a light roof. It will run cooler, save wear and power and the belts wil give good service. Belts will not stay on a wet puley so be sure to make the roof wide enough to keep the rain away from the pulley. For outdoor cold weather installations see Section #41 for special instructions regerding pipe connections from the crusher to the pressure switch. Soring Adjustments: The spring adjustments on Kue-Ken crusher are very important. Each Toggle Soring (lllustrated #44) eitner Individual or as part of a set - depends on size of crusher- are set at ‘the factory and do not have any field adiustment. They serve to lift the weight of the two Toggles and the Pittman and are calculated to properly lift these parts at normal crusher speeds, At the sare time they help avoid excessive pressures and strains on the Eccentric Shaft. Excessively nigh crusher soeeds may cause hammering and pounding of these perts, which must be avoided. The Pull Back Spring(s) (Ilustrated #25) must be carefully regulated. If too loose the Toggles will hammer in their seats. If too tight harmful pressure wil result and extra power will be needed at the moment of starting. Refer to Section 2 for the original length of the pull back spring when the crusher was assembled. This length should be considered the starting point whenever a repair is completed that requires the removal and replacement of these Pull Back Rods. When measuring the spring you should first set the jaws so that they are in the fully “open* Position, or in other words, when thay are at the end of the opening stroke, and just ready to begin their crushing stroke, Then measure the overall lencth of the spring itself. Measure the spring only, remembering that one end enters a short distance in the spring seat of the frame, Do not include Section § - Feed Chutes & Spring Adjustmentthe Washer (llustrated part #24) in your measurement. When this measurement is correct the other or “closeci” measurement will eutomatically be correct. Measurements should be reasonably accurate, within 1/16” or so. Check them occasionally as wear on the Pull Back Pin illustrated Part #27), Pull Back Rod Bushing ililustrated Part #28), seating area or Washer may require the spring to be tightened a little. The Pull Back Pin Bushing (\Ilustrated #28) is of the self-lubricating type and does not require attention. However, check the locking screws an the Pull Back Rod Pin (\llustrated part #27) and see that they are tight. Correct Method of Tightening the Pull Back Rod Soring(s) IF the crusher in question has been repaired or undergone any changes the abave dimensional checking method to set the Pull Back Rod Spring |s) tension may be inadequate. Therefore the following method should be used. 1. With the crusher stopped, tighten the Pull Back Rod Bolt Nut sufficiently to hold the entire Pull Back Rod assembly in piace. 2. Start crusher allowing it to run idle with ne material in the crushing chamber, if at start up, severe knocking 's heard or it is noticed that the Pull Back Rod Assembly Is excessively loose, stop machine immediately and tighten the nut 2-3 turns. Continue until machine can be started without severe knocking or excessive looseness in the Pull Back Rod Assembly. 3, With the crusher running, and hearing the ‘knocking’ inside the crankcase, tihten the Pull Back Rod Boit Nut unt! the ‘knocking’ quiets and stops. 4. Once the ‘knocking’ stops tighten the nut the following amount noted by machine type & size: Machine sizes 20-426 (Inclusive] and 170; tighten 2 compiete turns of the Pull Back Rod Nut, Machine sizes larger than 126 and al machines desionated as "Portables": tiahten 41-4 complete tums of the Pull Back Rod Nut. Once complete (and with the machine running empty) visually check the Pull Back Rod Spring(s) to insure that the Sorina{s) are not being completely depressed to the point where the colls are contacting each other while the crusher is operating. If the Soring|s) are collapsing to the point where the coils are contacting each other during the crushing cycle, the Spring(s) are warn out and must be replaced, Do not under any circumstances allow the Spring{s) to wear to the point where they are no longer adequate to keep the proper pre-load in the Toggle system, as severe damage can result, Section 8 - Feed Chutes & Spring AdjustmentFlywheel Safety Release Mechanism Safety Device - Leaf Soring Type: Refer to Drawing #407483 for ilustrations, names of parts and general assembly. The Pulley (lllustrated part #74) runs freely on the Eccentric Shaft (llustrated Part #75). The hub oF the Pulley has 2 seal (Iiustrated Part #47) at each end forming an oil bath filed at the Fiywheel Oil Plug (llustrated Part #98). The Safety Driving Arm (lilustrated Part #80) is keyed to the shaft by means of 2 Safety Arm Key (llustrated Part #87), The Safety Arm Clamp bolt (\lustrated Part #86) in the Safety Driving Arm must be kept tight. A Safety Shoe (llustrated Part #84) having a wide groove on the inside is Fastened to the Pulley by 2 stud bolts. Safety Shoe Spacer Washers Illustrated Part #85) are plecec between the Safety Shoe and the Pulley to determine the height oF the Safety Shoe in relation to the Safety Driving Arm Spring(s), which mate to It. One, two or three normally straight Leaf Sprina{s) (llustrated Part #82) are firmly clamped to the inside of the Safety Driving Arm Driving Arm by the Leaf Spring Clemp Illustrated #84) and suitable bolts. These bolts must be kept tight. When the outer end of the Leaf Spring is bent inwardly and engaged into the groove on the inside of the Safety Shoe, the power from the Pulley is transmitted through the Sefety Driving Arm into the shaft with all the parts then revolving as a single unit. The end of the Leaf Spring and the groove in the Safety Shoe are made so that the Leaf Soring can come out of the Safety Shoe in case of excessive load, tramp iron, etc. In that event the Leaf Spring instantly snaps back to its normally flat condition coming to rest against the inside of the Safety Driving Arm with the now free end of the Leaf Spring outside of the Safety Shoe, When the spring is in this “free” or “disengaged” condition no power is delivered to the shaft, although the pulley continues to revolve, IF the Pressure Switch (Illustrated Part #59) has been properly connected, the crusher motor will also be stopped as soon as the lubricating oll pressure drops to less than 5 PSI, usually within a few seconds after the Leaf Spring has disengaged. Caution: {as the Pulley continues to rotate after the Leaf Spring is disengaged from the Safety Shoe. Do not ‘open the belt guard inspection door until the Pulley comes to a complete stop. To restore the device to running position, insert the Spring Compression Screw (Illustrated Part #83) in the threaded hole in the end of the Safety Driving Arm as shown in drawing #4074R3. Tighten Just enough to bend the Leaf Spring sufficiently to pass the back of the Safety Shoe Rotate the Pulley by hand untli the Safety Shoe and Leaf Springs) are In the correct location, and then remove the Spring Compression Screw completely. Never run the crusher with this screw in the arm! After removing the cause of the overload the crusher is again ready for service, Always wipe dry the end of the Leaf Spring where it contacts the Safety Shoe - do not use or allow oll or grease in this Junction. Adjustments: The load carrying ability is determined by: 4. The strength of the Leaf Spring{s) is determined at the factory for all normal operating conditions. We suggest consulting us before making any change. 2. The number of Safety Shoe Spacer Washers determines the height of the Safety Shoe, and its load cerrying ability. Removing the Safety Shoe Spacer Washers will cause the Leaf Springs) to be more curved. Therefore engaging more firmly in the Safety Shoe and requiring more force Section 9 - Flywheel Safety Release Mechanism(overload) to release them. The assembly then becomes less sensitive and will carry additional load. Adding additional Safety Shoe Spacer Washers will give the opposite effect, To get maximum protection always try to use all the Safety Shoe Spacer Washers, keen all boits tight and do not exceed the correct speed for the machine size, Keep the nub of the Pulley almost full of the correct oil at ali tmes Check the ail level according to the maintenance scheciule noted in Section 17 by removing the Flywheel Oil Plug and rotating the Pulley to a suitable angle to permit oll to show at the hole. Do not fill the hu of Pulley completely! Use the same oll es used in the crankcase and Hinge Pin cavities Note: Do not run any crusher in regular service unless this. Fiywheel Safety Release Mechanism has been correctly adjusted as explained above. Contact the Factory if necessary for further Information, Section 9 - Flywheel Safety Release MechanismCrankcase Seals & Ventilation / Bearings / Limit Bar / Cheek Plates Crankcase Seals; A Seal (illustrated Part #47) is provided at the point where the Eccentric Shaft passes through the frame, It does not require any maintenance It must be handled very carefully if the Eccentric Shaft and Bearing assembly Is dismantled at any time, See Sections 4 & 15 for additional information, A specially designed diaphragm Illustrated Part #21) is provided between the lower part of the Swing Jew and that portion of the frame forming the crankcase. Both inner and outer edges of this clahragm are clamped in place by frames (illustrated #'s 22 & 23) with suitable cap screws, These cap screws are accessible only from inside the crankcase after removing the Pittrmen (illustrated Pert #94) the Rear Toggle (llustrated Part #96) and the Front Toggle (illustrated Part #95), The Diaghraam can be inspected daily from outside the crusher through large holes in the sides of the crusher frame and also from underneath, No attention is required except prevention of damage by physical means such as rocks, etc, IF rocks are permitted to counce from the feed chute over the top oF the Swing Jaw they might fall down between the back of the Swing Jaw and the frame plate above the Diaphragm. Care must be taken to avoid this. Diaphragms on crushers’ 16" or less in width of jaw plate have molded diaphragms of different design held in place with clamps. Crankcase Ventilation: On the Crankcase Cover Plate you will find a Crankcase Breather (\lustrated Part #53), This is to permit any pressure within the crankcase generated by the rise in temperature to equalize with the outer atmosphere, This breather should be cleaned regularly. On some models It is located on the side of the crusher. Frame Beerings: These are of the self-aicning roller type, no regular maintenance is required. The Bearing at the pump side is clamped in the frame. The Bearing in the pulley side has a provision to permit sliding if necessary because of the Eccentric Shaft increasing in iength when wermed, Both bearings are automaticaly lubricated by oll mist generated by the mechanism In the crankcase. Be aware that the wrong kind of oil or oil that has become acidic will damage these bearings When the crusher is not being used or is in storage turn the shaft slightly by hand or pawer every week or ten days, This wil alter the position of the rollers in the bearings and reciuce the possiblity of focal corrosion If the oll is acidic, Limit Bar: in Figure #1 of drawing #40743 you will note 2 Limit Bar (llustrated Part #16) located at the bottom of the frame and slightly Forward of the arm to whieh the Pull Back Rod (llustrated Part #26) is attached. This limit bar is very important and it should never be removed. tt is located so that there Is about 1/8” space between it and the Swing Jaw when the Swing Jaw is in the “closed” crushing position, The purpose of this limit bar is to prevent the Swing Jaw from swinging forward and possioly tearing out the Diaphragm. Allowing the Toggles, Pittman, etc. to drop inside the crankcase, causing serious damage. This may occur if the Pull Beck Rod (\lustrated Part #26) should break or is otherwise loosed or removed for repair or replacement. Cheek plates: By remaving the bolts, these are easily lifted out. in some sizes of crushers, cheek plates are withdrawn upwards at the rear of the hinge pin. in others the cheek piates are taken out ‘through the mouth of the crusher. Section 10 ~ Crankcase Seals & Ventilation / Bearings / Limit Bar / Cheek Plates,Lubrication Lubrication system: For the Hinge Pin (Illustrated Part #13) a flooded bath oF oil is provided, Witn this bath at the oroper level both Hinge Pin Bushings (llustrated Part #14) and the Hinge Shaft Thrust Washers (lliustrated Part #30) are kept lubricated at all times. The Hinge Shaft Flexible Seals {lilustrated Part #31) are provided to prevent the escape of oll at the Hinge Shaft Thrust Wasners and at the end of the Hinge Pin itself. All seals noted are frictioniess. Maintenance is only required if the seals are physically damaged. Keep al clamps moderately tight For the Toggles & Pittman mechanism In the crankcase a comolete, closed circulating oil system is provided. This system Is comprised of an Ol Pump illlustrated Part #49), an Oil Filter (llustrated Part 463), a Pressure Control Valve (illustrated Part #64), an Oil Manifold (illustrated Part #73), a Pressure Switch (illustrated #59) and a Pressure Gauge (|llustrated #60), This system is shown on crawing #407483, Be sure anc keen ali the fittings on the suction side of the Oil Pump tight. If there are any leaks the Oil Pump will draw air instead oF oil. The Oil Pump is a positive type pump that is driven directly from the end of the Eccentric Shaft via a coupling. The Oil Pump is easily taken off for inspection by first removing the pipe connections ‘then the four capscrews in the flange then pulling straight out. The Oll Pump has a mechanical seal and does not require packing. f it is necessary to prime the pump use the Priming Piug (llustrated Pert #62) above the oumno. The Oil Filter should be replaced during the first week of operation and then replaced an a monthiy basis thereafter. ‘The Pressure Control Valve is provided for the sole purpose of keeping enouah ail pressure in the pressure side of the ail pining at all times. This, to keep the contacts within the Pressure Switch closed, thereby allowing the crusher to run. The Pressure Control Valve Is a spring-loaded type vaive ‘that can be adjusted by screwing the project screw in or out, Screw it in to raise pressure anc out to reduce pressure, The Pressure Control Valve is made with a bleed hole in the seat to drain off ‘residual pressure and thus make the Pressure Switch act promptly. Always make the final adjustment when the machine is hot, as the oil will then be thinner. Set the Pressure Control Valve to keep 10 psi or slightly more on the gauge under hot conditions. Remember: when starting up a cold machine the pressure may temporarily run up to 40 - 50 psi but will dron to the actual valve setting when the oll warms up. Note: that while you must not have less than 10 psi at ail times, do Not set the valve unduly high as this simply meens the pump is Wearing out faster, more power Is. being used but no more oll is being delivered. ‘The oll flows thru the Pressure Contro| Valve to the Oil Manifold (illustrated #73) above the Eccentric Shaft, The Pressure Switch is provided to automatically shut down the crusher motor iF for any reason there is not sufficient ail pressure in the olling systern. Therefore it wll shut down the motor if the Safety Driving Arm “kicks Out” as the crusher shaft and Oli Pump then stop revolving causing a drop in oil pressure, It wil also shut down the motor for a defective Oil Pump or broken suction or pressure pipes or if the ail level in the crankcase is too low to flaw into the oll line, It will Go all these things for you but only if it is properly installed and maintained in good order. ‘Attach the Pressure Switch as shown on drawing #4074R3; preferably on a post or wall and close to the motor starting switch, Set switch in a vertical position and if the location is exposed enciose it in Section 11 ~ Lubricationa small box or cover for additional protection. When the crusher is first started loosen the final tube connection below the switch and “bleed” out the air in the tube so that the tube is filed solid with oll, Have your electrician wire up the terminals on the Pressure Switch in a circuit suitable to the type of motor starting eauloment you have. The contacts in this switch are set at S psi so that with the pressure control valve set to give 10 psi the switch will operate correctly. Remember that when you start your crusher motor you will have to hold the motor starter switch in long enough to build up the required 5 psi in the Pressure Switch otherwise the crusher motor will stop again. For gasoline engine driven crushers connact the Pressure Switch to “ground” the ignition circuit. For Glesel engine driven crushers connect the switch as recommended by the builders of the engine. Never run the crusher without this protection. Insect and clean at least once a month -if crusher will be exposed to cold weather outdoor temperatures replace the Flexible Tube (lilustrated Part #57) with a much larger pipe; say ¥2" and make same short as possible to avoid sluggish action of cold thick oil in a small tube lprication Service Recommendations: ‘* Drain the crankcase oll and replace the oil filter once each 500 hours of operation or every 3 months, whichever occurs first. ‘© Check the oil level in the hinge pin reservoir daily by removing Hinge Shaft Filing Plug \lllustrated Part #15) in the hinge pin casting. Maintain level to cover the shaft at all times by adding new oll IF necessary. Ol level should be %4" to 4" 2bove the hinge shaft ~ na more. * Check the oll in the Pulley hub once a week. Keep almost full. See section 4 for additional information, ‘+ Check the oll level in the crankcase daily and maintain the level so that oll is up to the ton of the two O1l Level Plugs (illustrated Part #64) or if the machine is equipped with 2 sight glass ‘that the sight glass is indicating ‘Full, Maintain this level by adding fresh oll if necessary at the Crankcase Filler Plug (illustrated Part #65). Always check level when crusher is not running, Excessively high ol level is as bad as too low level. Oil Level should never be allowed to come up to the bottom of the Toggles in their lowest position. if the Toggles are allowed to ‘slap’ into the oll during a crushing stroke they may be damagec. Recommended Lubricating Oils: Section “11 - Lubrication19.0 Nene “s a ‘Seybot Unersal Seconds @ 100 ea 5 700 1000 Amoco oma ower s> | pera eoree 70 | Pome earch a0 ie err nt i's | Pama nt 130 | Peon Nt 04 220 even WM cetrconsene oo fear congain cM cee Consens 20 > tae ep conpaind ee | ep conaaind i | EP conseunt 220 5 exon snemerat | seamersso | spouneezae 3 cat wa | eetabteone wo 180 ap stone vo 220 Moot oon ceertas | wooiceeraa9 | mats onacoo Teaco voonee vero 0 epost Note" For large temperature variations use Synthesized Hydrocarbon Fluids euch ae Mobil SHC 630 Section 11 ~ LubricationDrives/Horsepower Required/RPM's/Sheave Information for Kue-Ken Jaw Crushers Drives for Kue-Ken Crushers: When standing facing the feed end of a standard! RICHT-HAND Kue-Ken crusher, the driving pulley is at your left hand. Then when you stand facing the Pulley, the Pulley must revolve counter-clockwise (top of pulley travels from right to left). The diameter of the Pulley and the direction of rotation cannot be altered without major changes in design, IF rotated in the opposite directions, the oll pump and lubrication system wil not work. Causing severe damage In a short amount of time. The speed of tne Pulley must also be within the recommenced limits. The standerd and best method of driving these crushers is with a V-Flat drive, For this, the face of the crusher pulley is made perfectiy flat, while the face of the motor pulley is made with grooves to suit the size and number of V belts that we recommend, Due to the easy starting of Kue-Ken crushers, ordinary induction motors may be belted cirect to the crusher. There is no need to use the more expensive slip ring (wound rotor motors) with Kue- Ken Jaw Crushers, When gasoline or diesel engines are used, they should be furnished with a suitable clutch so that the engine can be started easily, The best location for the electric motor or internal combustion engine is usuelly at the rear of the crusher. Motor or engine must be mounted on a sliding base to permit mounting the belts without damage and also to allow adjustment of belt tension Remember that if you use gasoline or diesel engines, they should be about 25 % stronger than the recommended electric motor to take care of unavoidable momentary “peak” loads that occur during crushing, Also, gasoline and diesel engines must be large enough to compensate for altitude losses (roughly 3% for each 1000-Ft. above sea level), Section 12 ~ Drives/Horsepower Required/2PM's/Sheave Information, for Kue Ken Jaw Crushers