Trio Engineered Products, Inc.

• 12823 Schabarum Avenue • Irwindale, CA 91706 USA • Telephone 626-851-3966 • Fax 626-851-9526

OPERATOR INSTRUCTION MANUAL

Model TC-Series
Cone Crushers

Operation Instruction Manual- rev1

Copyright © 2012 Trio Engineered Products, Inc. All rights reserved.
All editorial content, information, software, photos, video, graphics, music, HTML, sounds or other
material (collectively, "Content") contained within are protected by U.S. copyright and international
treaties and may not be copied without the express permission of Trio Engineered Products, Inc., which
reserves all rights. All Content is copyrighted as a collective work under the U.S. copyright laws, and Trio
Engineered Products, Inc. owns a copyright in the selection, coordination, arrangement and enhancement
of such Content.
Re-use of any of our Content for any purpose other than stated commercial use is strictly prohibited. You
may not modify, publish, transmit, participate in the transfer or sale, create derivative works, or in any way
exploit, any of the Content, in whole or in part. You may not upload, post, reproduce or distribute content
protected by copyright, or other proprietary right, without obtaining permission of the copyright owner.
 Operator Instruction Manual

To the Owner & Operator

We have tried to provide information that gives our customers a clear understanding of equipment
construction, function, capabilities and requirements. This information is based on the knowledge and
experience of qualified people at our company and in our field organization. Proper use of this information
provides users of our equipment with high efficiency, maximum service life and low maintenance costs.
That is why we strongly recommend that anyone using our equipment be familiar with this manual.
Information presented here should not be considered authoritative in every situation. Users will as a matter
of course encounter problems and circumstances that raise questions not anticipated here. Such questions
should be directed to their distributor or the manufacturer.
Anyone who uses this equipment for any purpose other than that for which it was intended assumes sole
responsibility for dangers encountered and injuries sustained as a result of such misuse.

DANGER
Federal, state and local safety regulations aim to protect both people and property from
accident, injury and harmful exposure. When complied with, such regulations are often
effective. Hazards to personnel and property are further reduced when this equipment is
used in accordance with all operation and maintenance instructions. Generally:

(1) Read and heed all danger, warning, caution, and notice decals. Know what guards and protective
devices are included and see that each is installed and in operational condition. Additional guards and
protective devices may be required and must be installed by the user (owner) before operating.
(2) Never attempt to maintain, lubricate or adjust this equipment while it is running. Lock out and tag
out all energy sources before doing maintenance, cleaning, adjusting or repairing this equipment. Make it
impossible for anyone to start this machine while others are working on it or in it.
(3) Wear personal protective equipment such as hard hats, ear plugs, safety glasses and safety shoes
when operating this equipment. Do not wear loose clothing or long hair.
(4) Think safety and act safely. Stay alert at all times. Eliminate or neutralize potential hazards as soon
as you spot them. Never allow anyone to engage in horseplay when near this equipment.

DANGER
Failure to take these precautions will result in death or severe personal injury.

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Operator Instruction Manual

The following warning applies to equipment supplied with lead-acid batteries:

WARNING
Battery posts, terminals and related accessories contain lead and lead compounds,
chemicals known to the State of California to cause cancer and reproductive harm.
Wash hands after handling.

The following warning applies to equipment supplied with diesel powered engines:

WARNING
Diesel engine exhaust and some of its constituents are known to the State of California to
cause cancer, birth defects, and other reproductive harm.

127,&(

Product Registration:
All equipment must be registered within 14 days of start-up to receive warranty coverage.
Registration information will only be accepted from the end-users of the equipment, however dealers can
register the equipment for the end-user provided the information registered is the end-user’s information.
In addition to this registration, all cone crushers, vertical shaft impact crushers, and all screens using
urethane media must have an application data sheet on file and approved by Trio.
After completion of the registration and application data sheet, if required, all submitted information will
be reviewed and a confirmation email sent to the email address provided to Trio.
Warranty will be fully enforced upon confirmation of payment and receipt of the above information.
Register online at: http://www.trioproducts.com/register/form
or call Trio at +1 626 851 3966.

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 Operator Instruction Manual

Warranty Terms & Conditions

Seller warrants all new equipment manufactured or imported by Trio Engineered Products, Inc. (Trio) against defects
in material or workmanship attributed to the original machine manufacturing. No other warranties are expressed or
implied.
Warranty claims must be made through the dealer or agent responsible for the original equipment sale, as the
equipment will have been registered with them at the time of sale from Trio. Claims must be made within twelve (12)
months or 2,000 working hours, whichever occurs first, from the date of readiness for operation, but not more than
fifteen (15) months from the date of shipment from Trio. All parts claimed to be defective shall be returned to Trio,
freight prepaid, for inspection to determine that the said part or parts are defective.
If it is determined that the fault lies with Trio, Trio will ship a replacement part or parts at no cost, but freight charges
will be paid by customer. If it is determined that the fault does not lie with Trio, a replacement part or parts will be
shipped, freight collect, to the customer with the receipt of a purchase order from the dealer or agent. Trio will not be
responsible for freight costs associated with warranty claims.
When petitioning for a warranty item, the serial number of the equipment must be referenced. The serial number must
be clearly identifiable on the Trio nameplate on the equipment. This warranty is void if:
The serial number plate and/or other markings identifying the machine as Trio have been altered or removed.
The machine was not sold under the Trio brand name or another brand name approved by Trio.
Parts have been used other than those supplied by Trio.
Trio makes no warranty with respect to damages or defects in any product caused by improper installation, operation,
maintenance, and storage or caused by negligence or accident. In addition, any product repaired or altered in any way
as reasonably determined by Trio, that affects the performance or purpose for which the equipment was originally
manufactured, will not be covered under this warranty.
Under this warranty, the buyer will not be entitled to any labor charges involving the repair of the equipment involving
warranty items, unless authorized by Trio in writing.
Warranties of merchantability or of fitness for any particular purpose or arising from the course of dealing or usage of
trade are specifically excluded. Any affirmation of fact, description of goods, or sample or model referred to in this
agreement or elsewhere, whether or not the same relate to production or capability of the goods to perform, are not the
basis of this agreement, unless specifically made a party of the agreement in writing.
Under no circumstances will Trio be responsible for consequential or punitive damages of any nature, whether based
on contract or tort, including but not limited to lost profits, loss of production, delays or other expenses. Under no
circumstances shall the liability of Trio exceed the purchase price of the equipment furnished.
The laws of the state of California shall govern the warranty. The parties agree that exclusive jurisdiction for any claim
for breach of this warranty shall rest in the Los Angeles County Superior Court in the State of California.

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Table of Contents

Copyright © 2012 Trio Engineered Products, Inc. All rights reserved. . . . . cover back page
To the Owner & Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a
Warranty Terms & Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . c

Section 1 - Introduction
About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 1
Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 1
Safety Alert Symbol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 1

Section 2 - Safety
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 1
Symbols and Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 1
Hazard Classification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 1
Safety Signs and Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 2
Safety Sign Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 2
Personal Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 3
Management Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 3
Operator Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 3
Work Area Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 4
Equipment & Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 4
Training and Knowledge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 4
What is Lockout & Tagout? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 5
When is Lockout & Tagout required? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 5
Who must apply a lock & tag? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 5
When can a lock and tag be removed? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 5
Who can remove a lock and tag? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 5

Section 3 - General Information

Cone Crusher Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 1
Serial Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 1
Countershaft Rotation Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 1
Cone Crusher Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 2
Cone External Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 2
Cone Internal Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 3
Cone Lubrication System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 4
Cone Crusher Gradation, Capacity & General Specification Charts . . . . . . . . . . . . . . . . .3 - 5
TC Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 6
Cone Crusher Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 8
Cone Crusher Weight & Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 8

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Section 4 - Set-Up & Installation

Crusher Receiving and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 1
Crusher Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 1
Level the Crusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 1
Lifting the Crusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 1
Positioning the Crusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 1
Crusher Frame Grouting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 2
Grouting to a Concrete Foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 2
Mounting Crusher on a Steel Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 3
Mounting Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 3
Crusher Auxiliary Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 4
Hydraulic Power Unit Description & Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 4
Lubrication System Unit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 5
Lubrication System Unit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 5
Countershaft Box Pressure Line Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 6
Lubrication System Unit Settings & Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 7
Test Safeties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 9
Return Oil Temperature Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 9
Return Oil Flow Switch (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 9
Lube Pressure Safety Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 10

Section 5 - Inspection & Lubrication

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 1
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 1
Inspection Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 1
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 2
General Lubrication Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 2
Lubricating Oil and Hydraulic Oil Quantities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 2
Lubricant Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 2
Lubrication Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 4
Lubricating System Oil Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 5
Cone Crusher Daily Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 6

Section 6 - Start-Up & Operation

Start-Up & Operation Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 1
Initial Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 4

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Section 7 - Adjustments & Troubleshooting

Cone Crusher Crushing Chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 1
Crusher Setting Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 1
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 2
CRUSHER OVERHEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 2
CRUSHER THROWING OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 2
LOW OUTPUT (TONNAGE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 3
CRUSHER STALLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 3
ADJUSTMENT RING TILTED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 3
COUNTER SHAFT IS SEIZED OR BROKEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 4
BOWL STALLED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 4
LOOSE BOWL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 4
LOOSE SOCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 4
LOOSE BOWL LINER OR MANTLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 5
GEAR AND PINION TOOTH WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 5
EXCESSIVE VIBRATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 6
WEAR ON HEAD OR BOWL SEATING SURFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 6
GEAR AND PINION NOISY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 6
MAIN SHAFT BROKEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 6
DUST AND DIRT GETTING INTO LUBE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 7
HEAD SPIN HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 7

Appendix A - Torque Specs

Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A - 1
Standard Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A - 1
Metric Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A - 1
Standard Bolt Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A - 2
Metric Bolt Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A - 3

Appendix B - V-Belt Drive Information

General Belt Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
General Belt Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Belt Drive Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Maintaining V-Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4
Tension-Deflection Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4
Belt Type Cross-Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6
Belt Idlers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6
Inside Idler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6
Backside Idler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6
Kiss Idler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6

CRSH-OI-0004ENG (NOV-2012) iii Model TC-Series Cone Crushers

Operator Instruction Manual
Table of Contents

Appendix C - Crushing Terminology

Glossary of Terms & Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Backlash: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Bridging: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Capacity: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Cavity: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Choke Feed: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Closed Circuit Crushing: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Closed Side Setting (CSS): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Crushing Chamber: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Discharge Opening: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Drive: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Drive Guard: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
Feed: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
Feed Opening: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
Feed Opening (Closed Side): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
Feed Opening (Open Side): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
Fines: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
Finished Product: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
Friable: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
Gradation: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
Grizzly: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
Liners: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
Minimum Discharge Setting: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
Open Circuit Crushing: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
Oversize: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
Parallel Zone: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
Plugging: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
Product Size: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
Reduction Ratio: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
Scalping: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
Top Size: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
Tramp Material: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
Yield: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3

CRSH-OI-0004ENG (NOV-2012) iv Model TC-Series Cone Crushers


Section 1 - Introduction
About This Manual
This book is an operation instruction manual for
the owner or operator of the equipment described
within.
We strongly recommend that anyone working with
this equipment become familiar with the manual,
whether or not you have experience with similar
equipment.
This manual will help you understand how to
install your equipment, prepare it for operation,
and perform normal operation and general
maintenance tasks.
General maintenance tasks and utilization of
special tools refer to
"Cone Standard Job Procedures"
Intended Use
The Cone Crusher described within is designed to
crush rock, recycle concrete, and also a wide range
of other products and materials. Use of
this machinery in any other way is
prohibited and contrary to its intended use.
Safety Alert Symbol
The safety alert symbol (Figure 1 - 1) is used to
alert you to potential personal injury hazards.
Obey all safety messages that follow this
symbol to avoid possible injury or death.
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CRSH-OI-0004ENG (NOV-2012) 1-1
Operator Instruction Manual
About This Manual
DANGER
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This manual contains information
necessary for proper and safe
operation. Carefully read this
manual before attempting to
operate. Failure to read and heed
instructions preceded by a safety-
alert symbol (Figure 1 - 2) can
cause death or severe personal
injury as well as equipment and
environmental damage.
Experience has shown it is to your advantage to
keep a copy of this manual where operators can
consult it as needed and to have a copy on file in
your office, so that shift leaders or supervisors can
conveniently refer to it. Additional copies can be
ordered through your distributor.
This equipment is precisely engineered, highly
functional, and heavy-duty designed to provide
years of excellent service performing to customer
specifications. We are proud to manufacture this
equipment for your use and profit. We also take
pride in the quality of our service and replacement
parts.
Only your Parts Catalog, identified with your
machine’s serial number, is an authoritative source
of part numbers and part descriptions for your
equipment.
Ongoing improvement of product design may in
the future result in changes to some parts. Use part
numbers, model numbers and serial numbers from
your Parts Catalog to communicate with your
distributor.
Model TC-Series Cone Crushers
Operator Instruction Manual
About This Manual

This Page Intentionally Left Blank

CRSH-OI-0004ENG (NOV-2012) 1-2 Model TC-Series Cone Crushers


Section 2 - Safety
Introduction
The Cone Crusher is designed to crush rock,
recycle concrete, and also a wide range of other
products and materials. Use of this machinery in
any other way is prohibited and contrary to its
intended use.
When our equipment is used for purposes other
than those for which it was designed, user assumes
sole responsibility for any injuries or damage that
may result from said misuse. We emphatically
recommend that this equipment be operated only
by personnel who are trained in its use.
We make no guarantee, either expressly or by
implication, that this equipment meets all local or
federal safety regulations. It is the responsibility of
those individuals who own and/or operate this
equipment to verify that all safety regulations are
complied with before starting either this unit or
any associated equipment.
Symbols and Standards
Important symbols and hazard classification
standards relating to safe equipment operation are
used throughout this manual. Make sure you read,
understand and follow all DANGER, WARNING
and CAUTION decals on equipment.
CRSH-OI-0004ENG (NOV-2012)
Operator Instruction Manual
Introduction
Hazard Classification
A multi-tier hazard classification system is used to
communicate potential personal injury hazards.
The following signal words used with the safety
alert symbol indicate a specific level of severity of
the potential hazard (Figure 2 - 1). Signal words
used without the safety alert symbol relate to
property damage and protection only. All are used
as attention-getting devices throughout this
manual as well as on decals and labels fixed to the
machinery to assist in potential hazard recognition
and prevention.
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2-1 Model TC-Series Cone Crushers
Operator Instruction Manual
Symbols and Standards

Safety Signs and Icons

Beneath all safety regulations lies a set of 5HDGPDQXDO
common-sense rules. Everyone who works with or
near heavy equipment must be aware of those
rules. To foster and maintain such an awareness in 6DIHW\DOHUWV\PERO
our customers, safety signs are fixed on our
equipment.
Icons on our safety signs remind both workers and
supervisors of common hazards and procedures /RFNRXWSRZHUEHIRUHVHUYLFLQJ
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that, in the course of a busy day, they might
otherwise forget. The language of the icons is
simple and direct (Figure 2 - 2). :HDUKHDULQJSURWHFWLRQZKHQ\RX¶UH
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Safety Sign Maintenance
Replace any missing or damaged safety signs. :HDUH\HSURWHFWLRQZKHQ\RX¶UH
Keep operator safety in mind at all times. Use mild QHDUWKLVHTXLSPHQW
soap and water to clean safety signs. Do not use
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CRSH-OI-0004ENG (NOV-2012) 2-2 Model TC-Series Cone Crushers


Personal Safety
This equipment is designed with the safety of all
personnel in mind. Never attempt to change,
modify, eliminate or bypass any of the safety
devices installed at the factory. Guards, covers and
shields installed around moving parts at the factory
are meant to prevent accidental injury to operators
and other personnel. Do not remove them.
DANGER
Sometimes, at a customer’s
request, equipment is shipped
without certain features such as a
drive sheave. In such cases it is the
customer’s responsibility to guard
the machine properly.
We recommend the following basic safety
practices:
Management Responsibilities
• Make sure that everyone working on or near
this equipment is familiar with safety
precautions. Have a supervisor at the job site
responsible for job safety.
• Give crew members specific safety
responsibilities and instruct them to report any
unsafe conditions to their supervisor
Operator Responsibilities
• Read all danger, warning, caution and notice
signs.
• Always lock out and tag out involved energy
sources before performing maintenance or
adjustments on this equipment. Make it
impossible for anyone to start this machine
while others work on it or in it.
• Never remove any guard, cover or shield when
this equipment is in motion.
CRSH-OI-0004ENG (NOV-2012)
Operator Instruction Manual
Personal Safety
• Replace guards, covers and shields when the
task for which you removed them is finished.
• Block parts as necessary to prevent their
sudden movement while people are working
on the machine.
• Never attempt to clear away jammed feed
material, discharge material or other stoppage
while the machine is running. Stop the
equipment, lock out and tag out before
touching this machine with your tools or your
hands.
• Wear proper personal protective equipment,
including eye protection, hard hat and safety
shoes, whenever you’re near this machine
while it is running.
• Dress appropriately in every way. Never wear
loose clothes, long hair, coat tails, jewelry,
pockets full of tools or any other item that
could get caught in moving parts.
• Know where your fellow workers are. Always
look around and inside this machine before
starting it. Make sure nobody is in the way of
moving parts or working on the machine.
• Lift with your legs, not with your back. Keep
the weight close to your body. If the load is
more than 40 lbs., get someone to help you.
• Never engage in horseplay when near this
machine, or any other.
• Report any defective machinery or equipment
and unsafe conditions or activity to your boss
immediately.
• Don’t limit safety practices to the few rules
listed here. Think safety and act safely at all
times.
• Most of all, know your equipment. Understand
the machinery, the conditions under which it
operates and what it is capable of doing.
2-3 Model TC-Series Cone Crushers
Operator Instruction Manual
Personal Safety
Work Area Safety
• Keep the work area as neat and clean as
practical.
• Keep all product safety signs clean, clear and
current.
• Make sure all electrical equipment is properly
grounded. Wet spots near electrical current are
especially dangerous.
• Store hazardous materials in restricted access
areas and mark them clearly. Federal
regulations require special labeling of certain
materials.
• Never start an engine in an enclosed space
without properly venting the exhaust.
• Do not smoke or allow smoking near fuels and
solvents. Never strike a spark or use an open
flame near fuels and solvents.
• Store flammable fuels, solvents and gases in
secure, well ventilated areas. Never allow
fumes to accumulate in the storage area. Use
nonflammable solvents for cleaning parts and
equipment whenever possible.
• Know where fire extinguishers and other fire-
suppression equipment are located. Learn how
to use them effectively.
• Be alert and wary around any pressurized
system, hydraulic or pneumatic. High-pressure
oils and gases are very dangerous.
CRSH-OI-0004ENG (NOV-2012)
Equipment & Tools
• Clean tools that are properly labeled and stored
are safer tools. Keep your tools in good order.
• Keep drive belts and sheaves in good
condition. Frayed belts or cracked sheaves are
not only dangerous, they cost you downtime.
• Always use mechanical assistance to lift heavy
loads. Never overload a hoist, crane, jack or
other lifting device. Check lifting tackle
regularly; replace it at the first sign of stretch,
fraying or other wear.
• Keep your equipment clean, free of dirt and
grease, so that loose, cracked or broken parts
are more easily spotted. Replace defective
parts as soon as they are discovered.
Training and Knowledge
Proper training and equipment knowledge is
essential to the safe operation of this machine.
Carefully read the entire manual before attempting
to operate. Keep this manual for future reference.
WARNING
Do not operate this equipment until
you have been trained in its
operation or maintenance. This
equipment may only be operated or
maintained by trained personnel,
who have demonstrated their
ability to do so safely.
2-4 Model TC-Series Cone Crushers
 Operator Instruction Manual
What is Lockout & Tagout?

What is Lockout & Tagout? When can a lock and tag be removed?

Lockout & Tagout is a procedure that’s designed
to prevent the unexpected or accidental startup of
equipment and to alert all workers whenever it is
unsafe to operate any piece of equipment. When
used as intended, Lockout & Tagout also protects
personnel from energy stored in devices such as
springs, accumulators, batteries, hydraulic
systems, etc.
When is Lockout & Tagout required?
• Any time anyone is maintaining, repairing,
lubricating, or, for whatever reason, working
on the equipment.
• When the equipment is broken or, for whatever
reason, unfit or unsafe to operate.
• While clearing blocked or jammed
mechanisms.
• Whenever the equipment is left unattended.
After performing these six steps:
1) All safety guards are back in place.
2) All work is complete and tools are put away.
3) All workers are notified that a lock is being
removed.
4) All workers are positioned safely for startup.
5) Controls are positioned for safe startup.
6) The machine is ready for safe operation.
Who can remove a lock and tag?
• Only the person who applied a lock and tag is
permitted to remove them.
Lockout & Tagout rules laid out here are generic.
To get instructions for your particular workplace,
consult your employer’s lockout/tagout procedure.

Who must apply a lock & tag?

• Any person working on the equipment.
• Foreman or other person responsible for the
work being done.
• If several people are working on a machine at
the same time, each person must apply his or
her own lock and tag.

CRSH-OI-0004ENG (NOV-2012) 2-5 Model TC-Series Cone Crushers

Operator Instruction Manual
What is Lockout & Tagout?

This Page Intentionally Left Blank

CRSH-OI-0004ENG (NOV-2012) 2-6 Model TC-Series Cone Crushers

 Operator Instruction Manual
Cone Crusher Description

Section 3 - General Information Serial Numbers

Crushers are assigned a serial number which is
Cone Crusher Description stamped on a plate on the machine.
The Cone Crusher is a high-capacity compression- Other components on the crusher may have
type crusher that fractures material along its separate serial numbers or identifying numbers.
natural fault lines.
Always give the model and serial number or
Product size is controlled by adjusting the distance identifying number of your crusher when ordering
between the bowl liner and mantle. The bowl liner parts or requesting information. If parts are
and mantle are commonly referred to as liners and required for the other certain components, you
make up the crushing chamber of the cone. These should supply that serial number or identifying
liners are replaceable and come in several different number as well as the crusher numbers.
profiles depending upon the type of material to be
crushed and customer preference.
Countershaft Rotation Direction
The crusher utilizes a hydraulic cylinder system
The TC-Series cone crushers are driven by a
which provides protection for the crusher as well
countershaft fitted with a belt drive sheave. The
as a simple method for release and clearing should
direction of rotation is counter clockwise as
an uncrushable object enter the crushing chamber.
viewed from the drive end of the countershaft. See
The Cone Crusher may be mounted or installed in (Figure 3 - 2).
static stationary, modular skid, as well as portable
wheel or mobile track plant applications. No
matter which type application the Cone Crusher is
used in, it must be level to operate properly.

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CRSH-OI-0004ENG (NOV-2012) 3-1 Model TC-Series Cone Crushers

Operator Instruction Manual
Cone Crusher Components

Cone Crusher Components To be certain your machine has the proper

Be familiar with the crusher’s components.
Each model/size cone crusher consists of similar
components, however certain models/sizes may
not have all the same components as other models/
sizes.
components, check to ensure it was equipped as
ordered.
Cone External Components
See (Figure 3 - 3) for a side view of a typical cone
crusher’s external components.

5
6
4

3 7 8
9

10

11

1 - Crusher Main Frame 8 - Drive Motor

2 - Clamping Cylinders 9 - Electrical Controls & Power Unit
3 - Bowl Adjusting Gearbox & Motor (See separate Hydraulic Supplement Manual)
4 - Upper Frame Assembly 10- Crusher Lubrication System Unit
5 - Feed Hopper (See separate illustration for details)
6 - Adjustment Gear 11- Lubrication Oil Lines
7 - Countershaft Drive Sheave

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CRSH-OI-0004ENG (NOV-2012) 3-2 Model TC-Series Cone Crushers

 Operator Instruction Manual
Cone Crusher Components

Cone Internal Components

See (Figure 3 - 4) for a cutaway view of a typical
cone crusher’s internal components.

12
13
14 15
11

16
10
17
9
18
8
19
7
20
6 21 22
23
5

4
3
24
2
1
25
26
1 - Crusher Main Frame 14- Torch Ring
2 - Outer Eccentric Bushing 15- Locking Cylinder
3 - Inner Eccentric Bushing 16- Lock Ring
4 - Frame Arm Guard 17- Seat with Liner
5 - Main Shaft 18- Socket Liner
6 - Cone Head 19- Socket
7 - Mantle 20- Eccentric with Gear
8 - Bowl Liner 21- Countershaft Box Guard
9 - Bowl 22- Countershaft Box
10- Adjustment Ring 23- Countershaft Flinger & Seal Assembly
11- Adjustment Gear 24- Countershaft
12- Feed Hopper 25- Bushings
13- Main Shaft Nut 26- Countershaft Pinion Gear

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CRSH-OI-0004ENG (NOV-2012) 3-3 Model TC-Series Cone Crushers

Operator Instruction Manual
Cone Crusher Components

Cone Lubrication System Components

See (Figure 3 - 5) for views of a typical cone
crusher’s lubrication system components.

13 14 15 16 17 18 19

12 2
A 11
Oil Cooler & Fan 10 3
Removed for Clarity 9
of End View 8
4
7 6 5
21 12 16 22 23
20

28

27

26

25 24
A
1 - Oil Reservoir 11- Ball Valves 21- Temperature Switch
2 - Oil Level/Temp. Gauge 12- Temperature Gauges 22- Oil Cooler Motor & Fan
3 - Pump 13- Flow Switch 23- Oil Cooler
4 - Motor Pump Coupling 14- Pressure Switch 24- Gate Valve & Gasket
5 - Coupling Guard 15- Pressure Gauge 25- Oil Filter/Strainer
6 - Pump Drive Motor 16- Adjustable Bypass Valve 26- Electric Junction Box
7 - Heater 17- Breather/Fill Cap 27- Return Oil Filter Basket
8 - Heater Housing 18- Filter 28- Electric Junction Box
9 - Temperature Gauge 19- Pressure Gauge
10- Temperature Switch 20- Temperature Switch

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CRSH-OI-0004ENG (NOV-2012) 3-4 Model TC-Series Cone Crushers

 Operator Instruction Manual
Cone Crusher Gradation, Capacity & General Specification Charts

Cone Crusher Gradation, Capacity &

General Specification Charts
The following pages show charts for each model/
size cone crusher. These charts are general in
nature and should serve to give the operator an idea
for the crusher’s capabilities.

CRSH-OI-0004ENG (NOV-2012) 3-5 Model TC-Series Cone Crushers

 Operator Instruction Manual
Cone Crusher Gradation, Capacity & General Specification Charts

TC Series
C
A

Product Range

MODEL A B C

mm mm mm

TC36 1,321 2,700 1,304

TC51 1,765 3,185 1,517

TC66 2,261 3,960 2,045

TC84X 2,490 4,650 1,375

Typical Physical Properties

MAX INSTALLATION MAX MAINTENANCE ROTATING

MODEL MACHINE WEIGHT RECOMMENDED POWER
WEIGHT PART WEIGHT SPEED
kg lbs kg lbs kg lbs kw hp rpm

TC36 12,000 26,455 5,000 11,023 <2,700 <5,952 75-90 100-125 585

TC51 22,500 49,604 9,200 20,283 <5,000 <11,023 160-200 200-250 625

TC66 43,500 95,901 19,000 41,888 <10,000 <22,046 225-250 300-350 550

TC84X 78,000 171,960 36,500 80,469 <17,000 <37,479 400-450 500-600 480-530

Capacity Chart (TPH)

CSS
MODEL CAVITY
6mm 10mm 13mm 16mm 19mm 25mm 32mm 38mm 51mm 64mm
TC36 Standard - 45-60 55-75 70-90 80-105 110-135 125-155 145-190 - -
Short Head 45-65 65-85 80-110 90-125 115-150 - - - - -
TC51 Standard - - 100-135 110-160 135-200 155-265 175-315 230-350 310-420 -
Short Head 70-100 90-130 115-190 140-230 175-260 200-300 - - - -
TC66 Standard - - - 160-210 175-240 250-340 290-410 320-495 380-570 480-770
Short Head 120-165 150-230 190-290 220-330 250-370 300-405 - - - -
1,200-
Standard - - - - 360-480 480-680 600-860 720-940 900-1,300
TC84X 1,500
Short Head 215-315 300-415 360-500 410-580 450-630 520-700 - - - -

Note: Indicated capacity is neither minimum or maximum values. Actual capacity will depend on eccentric speed, chamber selection, and feed parameters. For best
results, operating the cone crusher with a full crusher chamber is recommended. However, all TC series crushers accept reasonable variations in feed rates.

CRSH-OI-0004ENG (NOV-2012) 3-6 Model TC-Series Cone Crushers

 Operator Instruction Manual
Cone Crusher Gradation, Capacity & General Specification Charts

TC Series

Typical Physical Properties

DISCHARGING
POWER OF
OPENING
MODEL CAVITY STANDARD HEAD SHORT HEAD ELECTRIC
ADJUSTMENT
MOTOR
RANGE
Minimum Minimum
Close feed Open feed Close feed Open feed Standard Short
discharging discharging
opening opening opening opening Head Head kW
opening opening
(mm) (mm) (mm) (mm) (mm) (mm)
(mm) (mm)

EC 25 160 178 - - - 25-38 -

C 13 138 158 6 61 76 13-38 6-19

TC36 75/90
M - - - 3 48 60 - 3-16

F 9 85 105 3 33 40 9-22 3-13

EC 25 255 281 16 106 128 25-50 16-25

C 19 225 251 10 84 105 19-50 10-20

TC51 160/200
M 16 200 221 6 72 90 16-38 6-16

F 13 108 135 3 50 60 13-30 3-16

EC 38 320 330 16 106 115 38-64 16-25

C 25 215 241 10 95 106 25-50 10-25

TC66 250
M 22 195 213 6 55 72 22-38 6-19

F 16 170 188 5 35 55 16-38 5-13

EC 38 399 427 16 152 203 38-64 16-25

C 32 331 367 13 127 178 32-64 13-25

TC84X 400
M 25 308 343 10 92 134 25-60 10-25

F 19 259 293 6 50 99 19-45 6-25

Note: E = Extra Coarse; C = Coarse; M = Medium; F = Fine

Details may vary due to product updates and/or customisation. Data for marketing use only. Please contact us for a solution designed to meet your unique needs.

CRSH-OI-0004ENG (NOV-2012) 3-7 Model TC-Series Cone Crushers

Operator Instruction Manual
Cone Crusher Specifications

Cone Crusher Specifications Cone Crusher Weight & Dimensions

Specifications for the cone crusher are found in the Weights and dimensions for the cone crusher are
serial specific parts manual. found in the serial specific parts manual.

CRSH-OI-0004ENG (NOV-2012) 3-8 Model TC-Series Cone Crushers

 Operator Instruction Manual
Crusher Receiving and Inspection

Section 4 - Set-Up & Installation Lifting the Crusher

To lift the crusher, use machinery, lifting slings,
Crusher Receiving and Inspection and equipment of sufficient size to safely handle
the load. When hooking lifting slings to the
When the crusher is delivered, thoroughly check
crusher, always attach to the crusher frame. Never
for damage that might have occurred during
lift complete crusher by attaching to upper frame
transport. Do not set up the unit until the
assembly or feed hopper. If only upper frame
inspection is complete.
assembly is to be removed from crusher for
Note any damage on the shipper’s bill of lading maintenance or component replacement, fasten
and have the deliverer sign your description of any lifting slings and equipment to lifting lugs
problem(s). Keep a copy of the marked-up bill of provided on top of assembly. See (Figure 4 - 1)
lading for your files. Take photos if possible. File
a claim with the carrier within 30 days of receipt of
the equipment. Lifting Lugs(Holes)
Check loose parts, small parts boxes, and tools
against the packing list to ensure all items shipped
are present.

Crusher Installation
To operate correctly, the crusher must be installed
on a firm, level foundation. Make sure the
foundation and supporting structures are strong
enough to support the dynamic load of the
operating crusher and related equipment with
material moving through it. Lifting Lugs(Holes)

)LJXUH7\SLFDO&RQH&UXVKHU/LIWLQJ/XJV(Holes)
Level the Crusher
Wherever the crusher is installed, it must be Positioning the Crusher
mounted level. For stationary units, the supporting
Allow enough room around the crusher for
structure must be level when completed. For skid-
conveyors, loaders, and maintenance equipment
mounted, mobile, or portable plant units, the frame
and personnel. Allow enough clearance below
must be leveled. Use leveling jacks or suitable
crusher for discharge material conveyor and also
blocking as needed to bring the unit to a level
clearance above and around the unit for access to
position.
maintain, repair or replace components on the
crusher.

CRSH-OI-0004ENG (NOV-2012) 4-1 Model TC-Series Cone Crushers

Operator Instruction Manual
Crusher Frame Grouting
Crusher Frame Grouting
To install the crusher on a concrete foundation or to
grout a steel structure to a concrete slab, proceed as
follows:
Grouting to a Concrete Foundation
1) When using epoxy or concrete grout, place the
crusher on hardwood blocks positioned beneath
each of the four (4) corners of the frame
assembly. Wood is used because grout shrinks
when it sets, and the wood will shrink with the
grout. See (Figure 4 - 2)
2) The blocks should be able to support the
crusher approximately 1" to 1-1/2" (25 to
38mm) for epoxy grout and 2" to 2-1/2" (50 to
64mm) above the top of the concrete foundation
to allow for the proper thickness of concrete
grout.
3) The surface of the foundation, where the
grouting will be poured, should be left rough
and be carefully cleaned before grouting.
4) When using concrete grout, this surface should
be thoroughly saturated with water and kept
wet to prevent any rapid absorption of water
from the grout mix. However, remove any
excess water from the top of the foundation
just prior to pouring the concrete grout. Use a
concrete grout mixture which contains a non-
shrink additive to minimize the shrinkage.
5) Mix and pour the epoxy grout following the
instructions in the carton, paying particular
attention to the temperature requirements.
CRSH-OI-0004ENG (NOV-2012)
WARNING
Always make sure the lifting
equipment is of sufficient capacity
to lift the required weights.
6) Using an overhead crane or other lifting
device that is capable of lifting the total
weight of the crusher, attach suitable steel
cable slings to the four (4) ribs near the lower
corners of the main frame flange.
WARNING
The steel cables should be held
apart by heavy-duty spreaders to
prevent any shifting of the cables.
7) Lower the crusher in position on the
foundation on top of the hardwood blocks.
8) Level the crusher by inserting steel shims
between the underside of the main frame
flange on top of the wood blocks.
9) Construct a form around the inside and outside of
the main frame flange to contain the epoxy or
concrete during pouring. Use 1” x 4” (25 x
102mm) wood strips for the forms. Locate and
fasten the 1" x 4" (25 x 102mm) wood strips, 1/2"
(13mm) from the outside of the main frame
flange. On the inside, place the forms against the
side of the foundation and the underside of the
main frame flange. All forms must be thoroughly
waxed with several coats of ordinary paste wax.
This will prevent the wood strips from sticking to
the grout. All joints and seams must be sealed
with tubes of silicone caulk to prevent leakage of
the grout during pouring.
4-2 Model TC-Series Cone Crushers
 Operator Instruction Manual
Crusher Frame Grouting

10) To prevent air entrapment under the crusher,

pour the grout from one place at a time, 4 5
allowing the grout to cover an area of 3
approximately 2 feet (.6 meters) on either side
of the pouring spot. Then move to a position
where the previous pour flow has stopped and
pour again. Continue this procedure until
grouting is completed.

127,&( 2
1
Do not pour the grout into more
1 - Concrete Foundation
than one area at a time.
2 - Wood Forms
3 - Foundation Bolt
11) Epoxy or concrete grout should harden
4 - Outline of Crusher
sufficiently in 2 or 3 days to permit operation.
5 - Epoxy Grout - As it appears after
After the grouting has hardened, tighten the
forms removed.
crusher firmly to the foundation.
)LJXUH7\SLFDO&RQH&UXVKHU)UDPH*URXWLQJ

Mounting Crusher on a Steel Structure

When crusher is to be mounted directly onto a steel
structure, it is only necessary to level, shim and
firmly tighten the crusher to the structure.

Mounting Drive Motor

When mounting crusher drive motor, be sure it is
mounted on a similar mounting isolation platform
as the crusher. This will insure the drive motor
will not allow the drive belts to be slack under
load.

CRSH-OI-0004ENG (NOV-2012) 4-3 Model TC-Series Cone Crushers

Operator Instruction Manual
Crusher Auxiliary Equipment

Crusher Auxiliary Equipment

The crusher utilizes a system to provide hydraulic
power and controls (see separate Hydraulic
Supplement Manual) as well as a separate unit
which supplies lubricating oil to the crusher.
Make sure these units’ oil lines are properly
connected and tightened as well as the electrical
drive motor(s) are properly connected and run in
the correct direction.

Hydraulic Power Unit Description &

Installation
The full description and installation instructions Hydraulic Power
for this unit are found in the separate Hydraulic and Controls Unit
Supplement Manual provided with the crusher.
Generally, this unit should be placed as close to the
crusher as possible and clear of possible rock
impacts from the crusher. It also should be placed )LJXUH7\SLFDO+\GUDXOLF3RZHUDQG&RQWUROV8QLW
so the operator can view the crusher when standing
at the controls. Standard connecting hoses lengths
are around 6M (20 feet). See (Figure 4 - 3)

CRSH-OI-0004ENG (NOV-2012) 4-4 Model TC-Series Cone Crushers


Lubrication System Unit Description
The lubrication system consists of an oil reservoir,
pump and motor, pump relief valve, filter, filter
relief valve, oil cooler, lube pressure switch,
immersion heater and high temperature switch.
Sensors are used at various locations in the circuit
to monitor the oil temperature. Pressure gauges
are used at various locations to monitor oil
pressure as it flows through the entire circuit.
See (Figure 4 - 4)
Lubrication System
Unit
)LJXUH7\SLFDO/XEULFDWLRQ6\VWHP8QLW
CRSH-OI-0004ENG (NOV-2012)
Operator Instruction Manual
Crusher Auxiliary Equipment
Lubrication System Unit Installation
The lubrication system must be mounted below the
crusher’s drain line to prevent oil from being able
to back up into the crusher and cause oil leaks or
other problems.
The drain/return oil line must have a minimum
pitch of 25mm (1 inch) for every 300mm (12
inches) of run to provide proper oil drainage from
crusher. See (Figure 4 - 5)
The drain/return oil line should be less than 5M
(16 feet). The bottom of the lube unit should be
greater than 1800mm (71 inches) to the crusher
mounting surface. See (Figure 4 - 5)
1
4
2&3
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4-5 Model TC-Series Cone Crushers
Operator Instruction Manual
Crusher Auxiliary Equipment

Countershaft Box Pressure Line Connection

The lubrication system pressure lines must run to
the bottom center of the crusher as well as to the
top of the countershaft box housing to assure
proper lubrication oil circulation.
See (Figure 4 - 6)

4 3 2
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CRSH-OI-0004ENG (NOV-2012) 4-6 Model TC-Series Cone Crushers

 Operator Instruction Manual
Crusher Auxiliary Equipment

Lubrication System Unit Settings & 6) Set cooling fan switch (if adjustable). Normal
Adjustment setting is 100°F (37.8°C) to 110°F (43°C).
See (Figure 4 - 8)
The lubrication system unit must be adjusted after
it is located and installed at the crusher site. The
following steps outline these settings and
adjustments:

1) Make sure proper amount and grade of oil are

in tank.

2) Open tank gate valve.

3) Check pump for proper rotation.

4) Check cooling fan for proper rotation (air

blows through the cooling fins).
)LJXUH&RROLQJ)DQ6ZLWFK
5) Set heater switch (if adjustable). Normal
setting is at 80°F (27°C). See (Figure 4 - 7)
7) Remove cover on bottom of return oil
temperature switch and set it to 130°F (55°C).
See (Figure 4 - 9)

)LJXUH+HDWHU6ZLWFK

)LJXUH5HWXUQ2LO7HPSHUDWXUH6ZLWFK

CRSH-OI-0004ENG (NOV-2012) 4-7 Model TC-Series Cone Crushers

Operator Instruction Manual
Crusher Auxiliary Equipment

8) Check to make sure ball valves are turned to

allow oil to run through cooler. Table 4 - 1 Cone Crusher Lubrication System
See (Figure 4 - 10) Pressure Setting

MODEL PRESSURE
TC36 36,
TC51 36,
TC66 36,
&RQWDFW7ULR(QJLQHHUHG
TC84
3URGXFWV
$GG36,IRUHYHU\IWRIHOHYDWLRQ\RX
KDYHEHWZHHQWKHOXEHOLQHDWWKHVNLGDQG
WKHFRXQWHUVKDIWER[RQFUXVKHU

)LJXUH/XEULFDWLRQ6\VWHP&RROHU/LQH%DOO
9DOYHV

9) Start lube system pump and allow the oil to

circulate until it has reached 60°F (16°C).
Adjust to correct pressure. See (Table 4 - 1)

127,&(
Once the cone has started and the oil heats
up, the pressure will need to be fine tuned.
The recommended pressure should be
maintained when cone temperature is
around 98°F (37°C) which means the
pressure may be slightly higher until cone
reaches that temperature.

CRSH-OI-0004ENG (NOV-2012) 4-8 Model TC-Series Cone Crushers

 Operator Instruction Manual
Test Safeties

Test Safeties

Return Oil Temperature Switch

1) Start the cone when oil has reached 80°F

(27°C). The countershaft should rotate
counterclockwise.

2) Turn adjustment knob on return oil

temperature switch down below ambient
temperature. Cone should shut off after 15
seconds indicating the safety circuit is wired
correctly and functioning properly.

Return Oil Flow Switch (If Equipped)

1) Start the cone when oil has reached 80°F

(27°C). The countershaft should rotate
counterclockwise.

2) With a screwdriver, gently push the flap inside

the return line towards the flow of oil until
you hear the contacts actuate.
)LJXUH5HWXUQ2LO)ORZ6ZLWFK
See (Figure 4 - 11) Cone should shut down
indicating it is wired correctly and functioning
properly.

CRSH-OI-0004ENG (NOV-2012) 4-9 Model TC-Series Cone Crushers

Operator Instruction Manual
Test Safeties

Lube Pressure Safety Switch
1) Start the cone. It may be necessary to wait a
while if a soft start is set for a limited amount
of starts.
2) Remove cover of the pressure safety switch.
See (Figure 4 - 12)
3) Loosen jam nut on adjustment at the top of
switch.
4) Test the switch by turning the adjustment until
the lever on the inside travels to the top, thus
actuating the contacts. The cone should stop.
5) Re-adjust the switch so the contacts actuate
when the cone is at 60 - 70% of the normal
operating pressure.
(Example - A cone calculated as needing
12 PSI at the gauge on the skid to operate
should be set to shut down when the
pressure is 7 - 8 PSI)

127,&(
The cone pressure is measured at the gauge
nearest to the cone. At no time should the
oil pressure at the countershaft be less
than 5 PSI.
)LJXUH/XEH3UHVVXUH6DIHW\6ZLWFK

CRSH-OI-0004ENG (NOV-2012) 4 - 10 Model TC-Series Cone Crushers


Section 5 - Inspection & Lubrication
General
To insure efficient operation, the crusher should be
inspected, lubricated, and have necessary
maintenance adjustments and repairs made at
regular intervals.
Inspection
Performing a daily inspection is a good way to
keep your crusher performing safely and
efficiently. Utilizing the Daily Inspection Form at
the end of this section as a guide will help you
establish a maintenance routine, provide a
maintenance record, and help monitor the
condition of the equipment.
CRSH-OI-0004ENG (NOV-2012)
Operator Instruction Manual
General
Inspection Procedures
The following are major steps in a daily inspection
of your crusher:
1) Lockout & Tagout all power to crusher before
any lubrication or maintenance is performed.
DANGER
Failure to Lockout & Tagout will
result in death or severe personal
injury.
2) Look the complete crusher over carefully.
When sure that everything is in good order
and safe, the crusher should be ready to
operate.
3) Remove the lock and tag.
4) Clear the area and prepare to start the crusher.
5-1 Model TC-Series Cone Crushers
Operator Instruction Manual
Lubrication

Lubrication Lubricating Oil and Hydraulic Oil Quantities

The table below shows the approximate quantities
General Lubrication Information of the respective lubricating and hydraulic units
The greatest single factor governing the life and for each model crusher.
efficiency of any piece of machinery, where
friction is encountered, is proper lubrication. Table 5 - 1 Lubricating Oil and Hydraulic Oil
Lubrication is critical to the Trio cone crusher. Quantities
The lubrication system provides oil to the crusher
components, protecting them from friction and Lubricating Oil Hydraulic Oil
Cone Qty. Qty.
heat. Not only does the lube oil prevent metal-to- Model
metal contact between internal components, it also Liters Gallons Liters Gallons
acts as a coolant by carrying heat to the reservoir TC36    
where it radiates out from the machine.
TC51    
Cleanliness in the handling of lubricants, fittings,
TC66    
grease guns, and the openings and plugs of
housings is of vital importance. Foreign TC84    
substances contaminate lubricant. Be sure all
fittings and openings are thoroughly cleaned Lubricant Specifications
before starting to inject lubricant. In using a grease Refer to (Table 5 - 2) as a guide for the proper
gun make sure the nozzle makes proper contact lubricants used on the crusher. If you do not have
with the cleaned fittings or openings and that the access to the brands shown, see your lubricant
nozzle has not been allowed to touch uncleaned distributor for an equivalent.
surfaces.
The table lists at what ambient temperature range
Never mix diffenent brands or types of lubricant to use a particular recommended lubricant
within the crusher. Always drain and flush out old specification. Contact Trio if questions arise
lubricant before changing to a different brand as concerning what specific lubricant should be used
chemical breakdown can occur in lubricant for your particular operating environment.
mixtures.

CRSH-OI-0004ENG (NOV-2012) 5-2 Model TC-Series Cone Crushers

 Operator Instruction Manual
Lubrication

Table 5 - 2 Cone Crusher Lubricant Specifications

Ambient
Recommended Recommended
Lubricant Type Temperature Specification
Standard Lubricant Synthetic Lubricant
°C (°F)

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CRSH-OI-0004ENG (NOV-2012) 5-3 Model TC-Series Cone Crushers

Operator Instruction Manual
Lubrication

Lubrication Intervals
The cone crusher should use the specified
lubricants shown in (Table 5 - 2). See (Table 5 - 3)
for recommended lube intervals.

Table 5 - 3 Cone Crusher Lubrication Intervals

Location Crusher Lubrication System Oil
1 Lubricant Lubrication System EP Gear Oil
Interval Change every 2000 hours, if dirty
Location Hydraulic Power Unit, Tramp Release Cylinders and Locking Cylinders
2 Lubricant Hydraulic System Oil
Interval Change every 2000 hours, if dirty
Location Clevis Pins
Lubricant Grease
3
Interval 200 hours
Method Manual
Location Bowl and Head Surfaces that contact the backing material (Not on seating surfaces)
Lubricant Lubrication System EP Gear Oil
4
Interval Every liner change
Method Manual, brush
Location Bowl, Clamping Ring and Adjustment Ring Threads, (Unclamp bowl before greasing)
5 Lubricant Grease
Interval 40 hours; Every liner change
Method Manual, brush
Location Head and Locking Nut Threads
Lubricant Grease
6
Interval Every liner change
Method Manual, brush
Location Main Frame and Adjustment Ring Seating Surfaces
Lubricant Grease
7
Interval During Assembly
Method Manual, brush
Location Countershaft Box Inner Flange
Lubricant Grease
8
Interval During Assembly
Method Manual, brush
Location Socket Sealing Ring Chambers
Lubricant Grease
9
Interval Every liner change
Method Manual, hand pack
Location Bowl Adjusting Ring Gear Teeth and Pinion Teeth (On Hydraulic Drive Motor)
Lubricant Grease
10
Interval 200 hours
Method Manual, brush
Location Hydraulic Adjustment Mechanism Driver Ring Supports
Lubricant Silicone Spray
11
Interval 200 hours
Method Spray can
Location Main Frame Pins
Lubricant Grease
12
Interval Every Liner Change
Method Manual, brush

CRSH-OI-0004ENG (NOV-2012) 5-4 Model TC-Series Cone Crushers

 Operator Instruction Manual
Lubricating System Oil Analysis

Lubricating System Oil Analysis

The following table shows oil contamination limits
to assist in determining whether the oil should be
changed or not. Lubrication system oil analysis is
also beneficial in that it can indicate to you if some
internal crusher components may be failing.
To have accurate analysis, it is recommended to
have a sample of the fresh oil you are using
analyzed to establish a baseline for that oil.

Table 5 - 4 Cone Lubricating System Contamination Limits

Acceptable High
Contaminant
Parts Per Million - PPM Parts Per Million - PPM

Copper (CU) %HORZ330 $ERYH330

Aluminum (Al) %HORZ330 $ERYH330

Iron (Fe) %HORZ330 $ERYH330

*Silica (Si) %HORZ330 $ERYH330

Chromium (Cr) %HORZ330 $ERYH330

Lead (Pb) %HORZ330 $ERYH330

Contamination Level
%HORZ $ERYH
(Total Solids)

Water %HORZ $ERYH

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CRSH-OI-0004ENG (NOV-2012) 5-5 Model TC-Series Cone Crushers

Operator Instruction Manual
Cone Crusher Daily Log

Cone Crusher Daily Log

OPERATOR’S INITIALS:

DATE (MO/DAY/YR) :

TIME :

AMBIENT TEMP (ºF) :

Normal Values *
NO-LOAD CRUSHING
CLOSED SIDE SETTING (INS.) - 4 LOCATIONS

CHECKED FOR FREE PRODUCT DISCHARGE (YES/NO)

HEAD SPIN (RPM @ NO LOAD) 15 MAX

COAST DOWN TIME (SECONDS) >= 35 SECONDS

POWER DRAW (AMPS) AVERAGE CRUSHING

LOOSE BOLTS OR UNUSUAL NOISES (YES/NO)

LOOK / LISTEN / COMMENT

FEED / CHOKE FED (YES/NO)

FEED / EVEN DISTRIBUTION (YES/NO)

ANY Adjustment RING BOUNCE
0 - 5 SCALE WHERE: 0 = NONE AND 5 = CONTINUOUS
AIR BREATHER OBSTRUCTED (YES/NO)
OIL LEVEL (INCHES FROM BOTTOM OF SIGHT
POWER UNIT
HYDRAULIC

GAGE)
ANY OIL LEAKS (YES/NO)

OVER LOAD CYLINDER PRESSURE (PSI) 1900-2050 PSI

THREAD LOCKING CYLINDER PRESSURE (PSI) 2600-2800 PSI

AIR BREATHER OBSTRUCTED (YES/NO)

LUBE OIL LEVEL (INCHES FROM BOTTOM OF
SIGHT CAGE)
ANY OIL LEAKS (YES/NO)
LUBRICATION SYSTEM

CRUSHER INLET OIL TEMP >16 °C (60ºF)

CRUSHER OUTLET OIL TEMP <60°C (140ºF)

∆T = OUTLET OIL TEMP - INLET OIL TEMP

<= 3°C (5ºF)
OIL PRESSURE kPa (PSI) AT PUMP

CRUSHER OIL PRESSURE kPa (PSI)

BY-PASSING (% OF BY-PASS PIPE AREA)

OTHER OBSERVATIONS/COMMENTS :-

CRSH-OI-0004ENG (NOV-2012) 5-6 Model TC-Series Cone Crushers


Section 6 - Start-Up & Operation
Start-Up & Operation Information
The cone crusher is generally used as a component
of an overall plant system. Specific equipment
start-up procedures will depend on the particular
plant and the material flow as well as the type of
controls used. Always refer to hydraulic power
unit supplement manual and controls schematics
and information received with your particular
equipment for start-up and operation.
The following steps should be used as a general
guide to operation of the cone crusher:
1) Check the surrounding area to ensure no
personnel are in a dangerous position prior to
start-up.
WARNING
Always sound horn or other warning
device to warn others that you are about to
start up the equipment.
2) If the crusher is part of a plant system, make
sure it is started in proper sequence with other
components.
CLEARING THE CRUSHING CAVITY
SHOULD THE CRUSHER STOP UNDER LOAD ,NO ATTEMPT SHOULE BE MADE TO START THE CRUSHER
AGAIN UNTIL THE ENTIRE CRUSHING CAVITY HAS BEEN CLEARED.ATTEMPTING TO START THE
CRUSHER WITH THE CAVITY FULL OF MATERIAL MAY RESULT IN SERIOUS DAMAGE TO THE CRUSHER
AND CRUSHER MOTOR OR ENGINE.
CRSH-OI-0004ENG (NOV-2012)
Operator Instruction Manual
Start-Up & Operation Information
3) Start up all other components on the plant in
the proper sequence prescribed for your
particular plant system. If no prescribed
sequence is available, start with the last piece
of equipment to discharge material and work
back toward the initial feed point until all
components are operating empty.
4) Make sure crusher is running at the proper
RPM for the material being crushed. See
RPM charts elsewhere in this manual.
5) Note the head spin RPM and direction. When
material is introduced, the cone head should
reverse its spin rotation.
6) Set the closed side setting (CSS) - A reduction
ratio of 6:1 for standard head and 4:1 for fine
head machines is recommended. 80% or more
of the feed material should fall within the ratio
unless ring bounce is detected. If ring bounce
is detected, it may be necessary to open the
CSS or reduce the feed size.
7) Begin material flow to the plant. Keep safety
in mind.
8) Record any observation about plant operating
conditions in the plant log book.
6-1 Model TC-Series Cone Crushers
Some of the reasons a crusher stops under load are as follows:
• Crusher drive motor or engine stopped because of power failure or lack of fuel.
• Too much feed entering the crushing cavity causing the crusher to stall.
• Discharge conveyor stopped (allowing discharging material to back up and plug the crusher
from underneath).
• The gyrating crushing action of the head causes the material caught between the mantle and
bowl liner on the CLOSED SIDE to tip and raise the adjustment ring a small amount and stall the
crusher.
• ON OCCASION AN OVERSIZE PIECE OF "TRAMP IRON" CAN BECOME CAUGHT, OR
WEDGED BETWEEN THE CRUSHING MEMBERS AND CAUSE THE CRUSHER TO STALL

UNDER NO CIRCUMSTANCES ENTER THE CRUSHING CAVITY WHEN A PIECE OF

TRAMP IRON IS WEDGED BETWEEN THE BOWL LINER AND MANTLE.
To clear the crusher of plugged material, or to remove tramp iron wedged between the bowl
liner and mantle, ALWAYS USE THE HYDRAULIC CLEARING SYSTEM! Proceed as follows:

1. Stop the feed to the crusher.

2. Shut the power OFF to the crusher
motor or engine as quickly as possible.
LOCKOUTAND TAG THE MACHINERY.
3. Warn or inform personnel of what is
occurring.
4. Check the oil level in the sight gauge on
the side of theHydraulic Power Unit.
5. Be sure there is proper clearance above
and aroundthe crusher.
6. Check that the Hydraulic Power Unit is
ON.

7. Turn the CRUSHER CAVITY selector switch on the operator control cabinet to CLEAR. The six
(6) CLAMPING/CLEARING cylinder rods will EXTEND TO RAISE the adjustment ring to its
MAXIMUM HEIGHT of 5" (125 mm) OFF its seating surface on the main frame. In most cases, this
will allow the plugged material to fall through and clear the crushing cavity. If the cavity DOES NOT
CLEAR after the ring has been fully raised, insert the three (3) SAFETY BLOCKS provided with the
cavity clearing system, between the bottom of three (3) equally spaced clamping/clearing cylinders
and on top of the cylinder mounting ribs on the main frame flange (See Figure 10 - 7).

ONE OF THE MOST DANGEROUS OPERATIONS AROUND A CRUSHER IS THE REMOVAL

OF TRAMP IRON THAT HAS JAMMED IN THE CRUSHING CHAMBER. EXTREMELY SEVERE
INJURIES CAN OCCUR BY TRYING TO REMOVE TRAMP IRON.

ALWAYS USE THE HYDRAULIC CAVITY CLEARING SYSTEM TO REMOVE TRAMP

MATERIAL. DO NOT SIMPLY TRY TO LOOSEN THE TRAMP WITH A PRY BAR! SEVERE
PERSONAL INJURY COULD RESULT!

CRSH-OI-0004ENG (NOV-2012) 6 -2 Model TC-Series Cone Crushers

8. When the safety blocks have been properly installed, LOWER the adjustment ring so
that the clamping/clearing cylinders rest on top of the SAFETY BLOCKS!
9. Turn the CRUSHER CAVITY selector switch on the operator control cabinet to OFF.
10. With the adjustment ring in the raised position and the safety blocks properly installed,
jog the crusher by applying short spurts of power to the crusher drive motor or engine to clear
the crushing cavity.

DO NOT PLACE FEET OR HANDS ON THE CLAMPING/CLEARING CYLINDERS,

ACCUMULATORS, IN THE SPACE BETWEEN THE ADJUSTMENT RING AND MAIN
FRAME; OR ANY PART OF YOUR BODYBETWEEN THE CYLINDERS AND THE MAIN
FRAME LOWER FLANGE!

ALWAYS USE THE "SAFETY BLOCKS" WHEN THE ADJUSTMENT RING IS IN THE
RAISED POSITION AND MATERIAL IS BEING REMOVED FROM THE CRUSHING
CHAMBER! THESE SAFETY BLOCKS ARE USED TO PROTECT HANDS, ARMS,
EQUIPMENT, ETC. FROM BEING CAUGHT BETWEEN THE CRUSHING MEMBERS, IN
THE EVENT OF A HYDRAULIC FAILURE.

11. MAKE SURE THE ADJUSTMENT RING IS IN ITS RAISED POSITION AND THE
SAFETY BLOCKS ARE IN POSITION between the bottom of three (3) equally spaced
clamping/clearing cylinders and on top of the cylinder mounting ribs on the main frame
flange. Then stand on top of the adjustment ring and use a long pipe, wooden pole or a pry
bar to dislodge the compacted material in the crushing chamber until it falls out. BE
CAREFUL! (See Figure 10 - 7)

UNDER NO CIRCUMSTANCES SHOULD THE CRUSHER BE STARTED AND

CRUSHING RESUMED WITH THE ADJUSTMENT RING IN THE RAISED POSITION.
SERIOUS PERSONAL INJURY AND SEVERE DAMAGE TO THE CRUSHER COULD
RESULT!

12. Jog the crusher a few times as described in Step 10 and check for free head movement
in the crusher. DO NOT STAND ON OR NEAR CRUSHER DURING THE JOGGING
PROCEDURE.
13. If the head is still not free, repeat Steps 10 through 12, several times or as long as
material continues to discharge from the crushing cavity.
14. After the crushing cavity has been cleared, turn the CRUSHER CAVITY selector
switch on the operator control cabinet to CLEAR to "raise" the adjustment ring. THEN
REMOVE THE THREE (3) SAFETY BLOCKS.
15. Turn the CRUSHER CAVITY selector switch to CRUSH. The adjustment ring will now
LOWER and return to its seating surface on the main frame SEAT LINER. The adjustment
ring may lower with a SLIGHT TILT. This is normal!
16. Resume normal crushing.

CRSH-OI-0004ENG (NOV-2012) 6-3 Model TC-Series Cone Crushers

Operator Instruction Manual
Start-Up & Operation Information
Initial Break-In
A break-in period of operation is required at the
crusher initial start-up or after installation of new
bushings.
Initial Start-Up
OK Not OK
Crusher run no load for 2 hours minimum.
Crusher running no load at ____________RPM.
Power draw running no load at _________Amps.
Crusher lube oil temperature running no load.
_______________(Do not exceed 140°F. / 60°C.)
Crusher no load balance is good.
Crusher run at 50% rated power for at least 2 hours.
Power draw running at 50% is _________Amps.
Crusher lube oil temperature running at 50%.
_______________(Do not exceed 140°F. / 60°C.)
Crusher 50% power balance is good.
Figure 6 - 1 Cone Crusher Break-In
CRSH-OI-0004ENG (NOV-2012) 6-4
Use the following taken from the Delivery/
Commissioning Form as a guide and checklist:
OK Not OK
Crusher run at 75% rated power for at least 4 hours.
Power draw running at 75% is _________Amps.
Crusher lube oil temperature running at 75%.
_______________(Do not exceed 140°F. / 60°C.)
Crusher 75% power balance is good.
After 8 Hours Initial Operation
Power draw running at 100% is _________Amps.
Crusher lube oil temperature running at 100%.
_______________(Do not exceed 140°F. / 60°C.)
Crusher 100% power balance is good.
Model TC-Series Cone Crushers
 Operator Instruction Manual
Cone Crusher Crushing Chamber

Section 7 - Adjustments & Crusher Setting Adjustment

Troubleshooting
Cone Crusher Crushing Chamber
The cone crusher’s crushing chamber consists of
the opening between the bowl liner and the cone
head mantle. See (Figure 7 - 1)
1 making the setting larger.
The size of the crushed product required
determines the crusher setting. Also, as equipment
is used, the crushing chamber wear parts must be
adjusted to keep the machinery operating
efficiently and properly.
The setting is changed by either lowering or
raising the bowl in the adjustment ring. By turning
the bowl assembly clockwise, it lowers the bowl
making the setting smaller. By turning the bowl
assembly counter-clockwise, it raises the bowl

2
6

5
3

4
1 - Bowl
2 - Bowl Liner
3 - Crusher Setting (Closed Side)
4 - Parallel Zone
5 - Mantle
6 - Cone Head

Figure 7 - 1 Cone Crusher Crushing Chamber

CRSH-OI-0004ENG (NOV-2012) 7-1 Model TC-Series Cone Crushers

Operator Instruction Manual
Troubleshooting
Troubleshooting
CRUSHER OVERHEATING
PROBABLE CAUSES
Pump worn - not delivering enough oil.
Insufficient running clearances between main
shaft and inner eccentric bushing or eccentric
and outer bushing.
Oil not draining properly.
Improper crusher liners for application.
Hot or unusually hard feed causes crusher to
generate more heat.
Insufficient oil supply.
V-belts tensioned too tight.
Crusher pulling too much power.
Crusher set too tight.
Lubrication hole in the main shaft plugged with
dirt.
CRUSHER THROWING OIL
PROBABLE CAUSES
High head spin.
Socket liner is worn.
Slabby feed trapped under feed plate and
cocking head.
Excessive countershaft speed (RPM)
Crusher not vented properly.
Oil passages in socket liner are plugged,
preventing proper oil drainage.
Oil not draining properly.
CRSH-OI-0004ENG (NOV-2012)
COMMENTS/CORRECTIVE ACTIONS
Check for proper oil flow (GPM) in drain line, If required
change Pump.
Replace inner eccentric bushing or outer bushing.
Check pitch in drain line from crusher to oil tank (Minimum
pitch 1” per 12”) [25mm per 305mm].
Clean air breather on main frame countershaft box housing.
Check all drain holes and lines from the crusher for plugging.
Too much crushing in lower portion of crushing cavity causing
excessive power draw.
Make sure water or air cooler is functioning effectively - keep
cooler clean!
Check for the proper oil level in tank.
Oil bypassing crusher. Check main relief valve for leakage,
due to wear, chips or stuck spring.
Re-tension V-belts.
Improper feed conditions often involved. Excessive amount of
fines in feed, or crusher set too tight for application.
Large amount of tramp material in the feed causing overloads.
Do not set crusher setting below recommended minimum
discharge setting.
Vertical hole in main shaft and interconnecting horizontal holes
in shaft must be cleaned using high pressure air.
COMMENTS/CORRECTIVE ACTIONS
See corrective actions for high head spin problem.
Renew the parts.
Reduce feed size.
Check for correct countershaft speed (RPM).
Clean breather on main frame countershaft box housing.
Dismantle and clean all socket liner oil drain holes and
grooves.
Check all drain holes and drain lines from the crusher for
plugging.
7-2 Model TC-Series Cone Crushers

LOW OUTPUT (TONNAGE)
PROBABLE CAUSES
Low operating speed (RPM).
Too much moisture in the feed, slowing the
movement of the feed in the crushing cavity.
Extremely slabby feed causing bridging at the
feed opening, at the top of the liners.
Large pieces of debris in the feed (wood, tree
roots, re-bar, etc.) slowing feed movement in
crushing cavity.
Too large of a feed top size.
Large amount of clay in the feed.
Incorrect feed distribution, segregated feed
causes fines to be fed in one side of the
crushing cavity.
Too many fines in feed.
Mantle or bowl liner “cupping” at the bottom.
CRUSHER STALLING
PROBABLE CAUSES
V-belts too loose.
Electrical problems with drive motor.
Build-up under crusher.
Countershaft speed too low.
Feed level too high in crushing activity causing
excessive power draw.
Incorrect feed opening (too small) in crushing
cavity. Most crushing being done at top of feed
opening which increases power draw.
Closed-in outer bushing and/or inner eccentric
bushing, thereby reducing running clearances.
Electrical problems with the drive motor.
Oil pressure too low.
ADJUSTMENT RING TILTED
PROBABLE CAUSES
Uneven wear on main frame seat liners and/or
adjustment ring seat.
Continuous overload or improper liners causing
adjustment ring to “pound” on main frame seat
liners and adjustment ring
seat.
CRSH-OI-0004ENG (NOV-2012)
Operator Instruction Manual
Troubleshooting
COMMENTS/CORRECTIVE ACTIONS
Check for correct countershaft speed (RPM).
Moisture should be less than 5%.
Reduce feed size.
Feed to crusher should be free of this type of material.
Reduce feed size.
Remove clay or sticky material from the feed.
Correct the feed arrangement.
Incorrect or inadequate screening.
Torch cut the lip at the bottom of either liners to eliminate
restriction.
COMMENTS/CORRECTIVE ACTIONS
Re-tension V-belts.
Check power draw of crusher running empty and compare to
power draw of motor running free (without belts). If both
readings are close, have electrician check motor.
Check foundation for ample discharge of crusher material.
Check for correct countershaft speed (RPM).
Reduce amount of feed to crusher.
Check for correct selection of liners.
Crusher must be disassembled to inspect condition of the
bushings.
Have the electrician check the motor.
Check for correct oil flow and viscosity. Check relief valve to
make sure it is not bypassing at the operating temperature.
COMMENTS/CORRECTIVE ACTIONS
Improper feed distribution in crushing cavity. Replace seat
liners, and correctly feed crusher.
Re-check for correct mantle and bowl liner combination,
and/or reduce feed to crusher. Replace seat liners. Increase
the setting.
7-3 Model TC-Series Cone Crushers
Operator Instruction Manual
Troubleshooting
COUNTER SHAFT IS SEIZED OR BROKEN
PROBABLE CAUSES
V-Belts tensioned too tight.
No lubrication or not enough lubrication to
countershaft bearings.
Bent countershaft. Usually shows up as
excessive vibration to end of countershaft or
“wobble” to crusher sheave.
Broken gear or pinion tooth.
Incorrect backlash and/or root clearance
between gear and pinion.
BOWL STALLED
PROBABLE CAUSES
Accumulation of dirt or rust between threads of
adjustment ring, locking collar and bowl
because of:
· Hot incoming feed (slag)
· Poor thread lubrication
· Worn adjustment cap seal
· Operating too long at one setting
· Galled bowl, locking collar and/or
adjustment ring threads
· Broken threads
Insufficient oil pressure (PSI) to hydraulic motor
mounted on adjustment ring.
LOOSE BOWL
PROBABLE CAUSES
Worn adjustment ring, locking collar and
bowl threads.
Operating with hydraulic locking collar
cylinders pressure being too low!
Too small of a crusher setting.
Operating with leaking hydraulic locking
cylinders.
Check that the hose between power unit and
locking cylinders is properly connected.
LOOSE SOCKET
PROBABLE CAUSES
Loss of interference fit between the socket
and the mainframe. Socket bolts and dowels
sheared.
CRSH-OI-0004ENG (NOV-2012)
COMMENTS/CORRECTIVE ACTIONS
Re-tension V-Belts and check sheave alignment.
Check the pipe/hose supplying oil to the ct. shaft box
Replace countershaft.
Replace gear or pinion.
Check for correct backlash and root clearance.
COMMENTS/CORRECTIVE ACTIONS
Try the following steps in order:
1.Pour penetrating oil into threads.
2.Turn the BOWL ADJUSTMENT selector switch on the
operator control cabinet to the OFF position and run material
through crusher.
3.Run short pieces of lumber through crusher (4”x4” or 4”x6”)
[102x102 or 102x152mm].
4.Throw small pieces of “SOFT” steel through crusher.
See Power Unit troubleshooting guide to resolve the issue.
COMMENTS/CORRECTIVE ACTIONS
Re-machine 45º surface of threads to provide uniform pitch if
threads are not worn too badly. If threads are severely worn,
contact Trio for proper procedures for correcting the wear
areas.
Pressurize the hydraulic locking collar cylinders to the proper
pressure.
Open crusher setting until bowl stops bouncing.
Replace locking cylinder assembly or assemblies.
When power unit is operating, hose between power unit and
locking collar cylinders should feel somewhat “stiff”.
COMMENTS/CORRECTIVE ACTIONS
Restore the fit to the original value. If needed, rebuild the
socket turn and machine oversize to match with the enlarged
mainframe bore.
7-4 Model TC-Series Cone Crushers

LOOSE BOWL LINER OR MANTLE
PROBABLE CAUSES
Mantle - locking nut does not self-tighten.
Mantle - crusher countershaft rotating in
wrong direction.
Locking nut bottoming on head.
Mantle or head seating surfaces worn or not
machined correctly.
Insufficient backing clearance behind mantle
and head.
Mantle out-of-round.
Mantle not centered on head, or mantle not
tight on head during initial installation.
Mantle - operating crusher without feed for
too long of a time.
Mantle too thin.
Old backing not completely removed before
installing new mantle.
Bowl liner - broken “scallops” at top of liner.
Bowl liner too thin.
Too much tramp iron or sticky material going
through the crusher.
Bowl liner or bowl seating surfaces worn or
not machined correctly.
Old backing not completely removed before
installing new bowl liner.
GEAR AND PINION TOOTH WEAR
PROBABLE CAUSES
Excessively dirty oil.
Tooth wear profile too low.
Tooth wear profile too high.
Crusher overloaded.
Tooth wear profile on the ends of the teeth.
CRSH-OI-0004ENG (NOV-2012)
Operator Instruction Manual
Troubleshooting
COMMENTS/CORRECTIVE ACTIONS
Check for backing material poured too high and left in
contact with underside of locking nut.
Self-tightening feature of mantle will not work if countershaft
is rotating in wrong direction; correct direction is COUNTER
CLOCKWISE.
Insufficient clearance between bottom of locking nut and top
of head. Minimum clearance should be approximately 3/8”
(10mm).
Restore seating surfaces to factory dimensions.
Backing clearance should be at least 1/4” to 3/8” (6 to
10mm).
Maximum out-of-round condition should be 1/4" (6mm).
Check with feeler gauge at bottom of mantle. Clearance
should be no more than 0.005” (0.127mm).
Maximum idle time should be 30 minutes.
Wear not to exceed 2/3 of mantle thickness.
Remove all old backing to permit the new mantle to seat
correctly on the head.
Badly worn bowl liner; thin section flexing.
Wear not to exceed 2/3 of bowl liner thickness.
Too much tramp iron or sticky material will cause adjustment
ring to jump or bounce excessively.
Restore seating surfaces to factory dimensions.
Remove all old backing to permit the new bowl liner to seat
correctly in the bowl.
COMMENTS/CORRECTIVE ACTIONS
Replace oil and clean oil tank.
Worn thrust bearing plates. Raise eccentric assembly by
shimming under eccentric thrust bearing plate.
Lower eccentric assembly by removing shims beneath the
eccentric thrust bearing plate.
Usually shows up as bouncing adjustment ring. Reduce feed
to crusher and/or increase the setting.
Excessive wear on inner eccentric bushing and/or outer
eccentric bushing.
7-5 Model TC-Series Cone Crushers
Operator Instruction Manual
Troubleshooting
EXCESSIVE VIBRATIONS
PROBABLE CAUSES
Weight change due to worn crusher parts.
Excessive head spin.
Gear and pinion tooth root interference.
Bent countershaft.
Crusher sheave badly out of balance.
If crusher is mounted on a portable plant,
cribbing or soil conditions may be
inadequate.
Inadequate foundation and/or soil bearing
capacity.
Loose mantle.
Countershaft speed (RPM) too high.
WEAR ON HEAD OR BOWL SEATING SURFACE
PROBABLE CAUSES
Crusher operating with loose mantle or bowl
liner.
Crusher operating with excessively worn
mantle or bowl liner.
Wearing completely through mantle or bowl
liner and crushing on head or bowl.
Cracked mantle or bowl liner.
GEAR AND PINION NOISY
PROBABLE CAUSES
Incorrect backlash and/or root clearance.
Operating crusher with new gear and worn
pinion or worn gear and new pinion.
MAIN SHAFT BROKEN
PROBABLE CAUSES
Frequent tramp iron passing through
crusher.
Crusher continually overloaded.
CRSH-OI-0004ENG (NOV-2012)
COMMENTS/CORRECTIVE ACTIONS
Excessively worn mantle, replace mantle.
Head moving with eccentric due to seized inner bushing.
Improper gear mesh, gear bottoming on pinion. Raise
eccentric assembly by shimming.
Replace countershaft.
Remove dirt build-up on rim of sheave.
Check cribbing or soil conditions.
Check foundation or soil conditions.
Remove mantle and re-install properly.
Check for correct countershaft speed (RPM).
COMMENTS/CORRECTIVE ACTIONS
Make sure crushing members are seated properly when
assembling, and that the locking nut is tightened securely
against the torch ring and mantle BEFORE operation.
Thin section of crushing member flexes, accelerating wear
on head or bowl seating surfaces.
Thin section of crushing member flexes, accelerating wear
on head or bowl seating surfaces.
Crushing member flexes, accelerating wear on head or bowl
seating surfaces.
COMMENTS/CORRECTIVE ACTIONS
Recheck backlash and/or root clearance
It is recommended that both the gear and pinion be replaced
at the same time
COMMENTS/CORRECTIVE ACTIONS
Install metal detection device.
Usually shows up as bouncing adjustment ring. Reduce feed
to crusher and/or increase the setting.
7-6 Model TC-Series Cone Crushers

DUST AND DIRT GETTING INTO LUBE SYSTEM
PROBABLE CAUSES
Oil filter housing cover not properly closed.
Lube System tank cover not properly closed.
No air breather on the main frame
countershaft box housing.
Air breather on main frame countershaft box
housing not functioning properly.
Crusher sheave swirling dust into the air
breather.
Dust and dirt falling into crusher when
crusher has been dismantled for servicing or
maintenance.
Floating ring and/or head wipers are
damaged or worn.
No seal (gasket) or bad seal between oil tank
and oil tank cover.
Floating ring is not supplied with proper
amount of grease.
HEAD SPIN HIGH
PROBABLE CAUSES
Head wipers damaged.
Ball of head contacting the inside portion of
socket liner thereby offering less resistance
to spinning.
Scored or burned inner eccentric bushing.
Wrong lube oil.
CRSH-OI-0004ENG (NOV-2012)
Operator Instruction Manual
Troubleshooting
COMMENTS/CORRECTIVE ACTIONS
Properly close Lube System oil filter housing cover.
Properly close Lube System tank cover.
Install breather on the main frame countershaft box housing.
Replace air breather. To check, place a piece of paper over
the breather piping, with the crusher running; the paper
should move in and out.
Using hose, relocate air breather away from crusher sheave.
Cover socket and eccentric area with canvas tarpaulin or
polyethylene (plastic) sheeting when servicing crusher.
Renew damaged or worn parts.
Replace tank seal.
Supply proper amounts of grease.
COMMENTS/CORRECTIVE ACTIONS
Renew damaged parts.
Scrape the socket liner spherical bearing surface so that the
ball of the head makes contact on the outer surface of the
socket liner.
Replace the bushing or polish out the scores, gouges or
burn marks.
Check and replace with the correct oil.
7-7 Model TC-Series Cone Crushers
Operator Instruction Manual
Troubleshooting

This Page Intentionally Left Blank

CRSH-OI-0004ENG (NOV-2012) 7-8 Model TC-Series Cone Crushers


Appendix A - Torque Specs
Torque Charts
The following pages contain charts for use as
guides when tightening bolts and nuts. These
specifications should be followed unless specific
torques are given elsewhere in this manual.
Standard Bolt Torque
Table A - 1 is a list of recommended torque values
for standard bolts. Use this torque chart to avoid
overstressing standard nuts and bolts used on
equipment. These specifications should be
followed unless specific torques are given. Trio
uses various bolts Grades 2, 5, and 8. The
CRSH-OI-0004ENG (NOV-2012)
Operator Instruction Manual
Torque Charts
maximum torque values are based on 75% of the
specified minimum proof strength of the bolt steel
in order to provide a safety factor. The term "lube"
applies to cadmium plating and/or application of
thread lubricants. Hardened washers should
always be used, regardless of whether standard
nuts or lock nuts are employed.
Metric Bolt Torque
Table A - 2 is a list of torque values recommended
for metric bolts. The maximum torque values are
based on 75% of the specified minimum proof
strength. The term "lube" includes the application
of thread lubricants, cadmium plating and the use
of hardened washers regardless of whether
standard or lock nuts are used.
A-1 Model TC-Series Cone Crushers
Operator Instruction Manual
Torque Charts

Standard Bolt Torque Chart

S.A.E Grade 2 S.A.E Grade 5 S.A.E Grade 8
dia. pitch Dry Lube Dry Lube Dry Lube
(in.) (thd/in.) (ft-lbs) N-M (ft-lbs) N-M (ft-lbs) N-M (ft-lbs) N-M (ft-lbs) N-M (ft-lbs) N-M
1/4 20 5 7 4 5 8 11 6 8 12 16 9 12
1/4 28 6 8 5 7 10 14 7 9 14 19 11 15
5/16 18 11 15 9 12 17 23 13 18 25 34 19 26
5/16 24 12 16 10 14 19 26 15 20 27 37 21 28
3/8 16 20 27 15 20 31 42 24 33 44 60 34 46
3/8 24 23 31 17 23 35 47 27 37 49 66 38 52
7/16 14 32 43 25 34 49 66 38 52 70 95 54 73
7/16 20 36 49 27 37 55 75 42 57 78 106 60 81
1/2 13 49 66 38 52 75 102 58 79 106 144 82 111
1/2 20 55 75 42 57 85 115 65 88 120 163 92 125
9/16 12 70 95 54 73 109 148 84 114 154 209 118 160
9/16 18 79 107 60 81 121 164 93 126 171 232 132 179
5/8 11 97 132 75 102 150 203 115 156 212 287 163 221
5/8 18 110 149 85 115 170 231 131 178 240 325 185 251
3/4 10 157 213 121 164 266 361 205 278 376 510 289 392
3/4 16 180 244 133 180 297 403 229 311 420 570 323 438
7/8 9 210 285 160 217 430 583 330 447 606 822 466 632
7/8 14 230 312 177 240 473 641 364 494 668 906 514 697
1 8 320 434 240 325 644 873 495 671 909 1233 699 948
1 14 340 461 255 346 704 955 542 735 995 1349 765 1037
1-1/8 7 350 475 270 366 794 1077 611 829 1288 1747 990 1342
1-1/8 12 395 536 305 414 891 1208 685 929 1445 1959 1111 1507
1-1/4 7 495 671 380 515 1120 1519 862 1169 1817 2464 1398 1896
1-1/4 12 550 746 425 576 1241 1683 954 1294 2012 2728 1548 2099
1-3/8 6 655 888 500 678 1469 1992 1130 1532 2382 3230 1832 2484
1-3/8 12 745 1010 570 773 1673 2269 1287 1745 2712 3677 2086 2829
1-1/2 6 865 1173 665 902 1949 2643 1500 2034 3161 4286 2432 3298
1-1/2 12 975 1322 750 1017 2194 2975 1687 2288 3557 4823 2736 3710
1-3/4 5 1370 1857 1055 1430 2286 3100 1758 2384 4988 6764 3837 5203
2 4.5 2060 2793 1585 2149 3438 4662 2644 3585 7500 10170 5769 7823
2-1/4 4.5 3015 4088 2320 3146 5027 6817 3867 5244 10969 14874 8438 11442
2-1/2 4 4125 5593 3170 4298 6875 9323 5288 7171 15000 20340 11538 15646
2-3/4 4 5590 7579 4300 5830 9321 12639 7170 9723 17794 24129 13688 18561
3 4 7385 10013 5680 7701 12313 16696 9472 12844 23507 31875 18082 24519
Table A - 1: Torque Values for Standard Hardware

CRSH-OI-0004ENG (NOV-2012) A-2 Model TC-Series Cone Crushers

 Operator Instruction Manual
Torque Charts

Metric Bolt Torque Chart

Property Class = 8.8 Property Class = 10.9 Property Class = 12.9
dia pitch Dry Lube Dry Lube Dry Lube
(mm) (mm) (ft-lbs) N-M (ft-lbs) N-M (ft-lbs) N-M (ft-lbs) N-M (ft-lbs) N-M (ft-lbs) N-M
6 6.9 9.3 5.2 7 9.7 13.2 7.3 9.9 11.6 15.7 8.7 11.8
8 17.7 23.9 13.3 18 24.9 33.8 18.7 25.4 29.8 40.4 22.4 30.4
10 1.5 30 41 24 32 44 60 34 46 52 71 40 54
10 1.25 32 43 24 33 46 63 36 49 55 74 42 57
12 1.75 53 72 41 55 77 105 60 81 91 123 70 95
12 1.25 58 78 44 60 85 115 65 88 99 134 76 103
14 2 85 115 65 88 124 168 95 129 145 196 111 151
14 1.5 91 124 70 95 134 181 103 139 156 212 120 163
16 2 131 178 101 137 192 260 148 200 225 305 173 234
16 1.5 140 190 108 146 204 277 157 213 240 325 184 250
18 2.50 181 246 139 189 265 359 204 276 311 421 239 324
18 1.5 204 276 156 212 297 403 229 310 349 473 268 364
20 2.5 256 347 197 267 374 507 288 390 439 595 338 458
20 1.5 284 385 218 296 415 563 319 433 487 660 375 508
22 2.5 349 473 268 364 510 692 392 532 599 812 460 624
22 1.5 383 519 294 399 560 759 431 584 657 891 505 685
24 3 443 600 340 461 647 877 497 674 759 1029 583 791
24 2 482 654 371 503 705 956 543 736 828 1122 637 863
27 3 648 879 499 676 949 1286 729 989 1112 1508 856 1160
27 2 700 949 538 730 1023 1387 787 1067 1200 1627 923 1252
30 985 1335 741 1004 1389 1883 1044 1416 1665 2257 1252 1697
36 1716 2326 1290 1749 2419 3280 1819 2466 2900 3931 2180 2956
42 2753 3732 2070 2806 3882 5263 2919 3957 4652 6307 3498 4742
48 4156 5634 3124 4236 5860 7944 4406 5973 7023 9521 5280 7159
56 6662 9032 5009 6791 9393 12735 7063 9575 11259 15264 8465 11477
64 9954 13496 7484 10147 14035 19028 10553 14307 16822 22807 12648 17148
72 14410 19536 10835 14689 20319 27547 15277 20712 24353 33016 18310 24824
Table A - 2: Torque Values for Metric Hardware

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Operator Instruction Manual
Torque Charts

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CRSH-OI-0004ENG (NOV-2012) A-4 Model TC-Series Cone Crushers

 Operator Instruction Manual
General Belt Care

Appendix B - V-Belt Drive 5) Do not overtighten belts. Overtightening

Information shortens the useful life of belts and sheaves.
This can also cause premature bearing
failures. Ideal belt tension is the lowest at
General Belt Care which belts won’t slip under peak loads.
V-belts achieve more service life if kept clean and
dry. Rock dust and rust from metals are abrasive. 6) Periodically inspect v-belt drives for wear on
Oils and acids deteriorate belt material. Dust and belts or sheaves. See (Figure B - 1) and
moisture on belts can cause slippage. Dust buildup (Figure B - 2) Replace worn sheaves.
in sheaves can cause harmful vibration.
Belt dressing compounds are available and are Worn Worn Belt
sometimes used for various reasons. While they Sheave or Sheave Normal
may be used, belt dressing may actually shorten
belt life. Clean, well cared for belts are the best
way to care for belt problems. Daily cleaning of
belts and sheaves by blowing them off with
compressed air can increase their useful life.
Store un-used belts in a cool and dry environment
with no direct sunlight. Store on shelves or in
original containers. Do not allow belts to be bent
to diameters smaller that what is recommended for
the belt cross section.
Figure B - 1 Typical Belt & Sheave Wear
General Belt Recommendations

1) Keep belts and sheaves clean.

2) Avoid belt or sheave rubbing. Don’t let belts

or sheaves rub against a guard (or anything
else) while they are running.

3) Drive belts with motors mounted on

adjustable bases. This allows convenient and
proper installation of belts without prying on
belts.

4) Keep belts properly tightened. Most belt

stretch occurs in the first 30-40 hous of
operation. Check belt tension frequently Figure B - 2 Sheave Gauge Shows Wear
during this period.

CRSH-OI-0004ENG (NOV-2012) B-1 Model TC-Series Cone Crushers

Operator Instruction Manual
Belt Drive Troubleshooting
7) Keep belts straight. Don’t allow v-belts to run
out of alignment. To run properly, sheaves
must be parallel and grooves must be in line.
See (Figure B - 3)
Figure B - 3 Sheave Alignment
CRSH-OI-0004ENG (NOV-2012)
8) If a drive uses multiple belts, use only
matched belts. A matched set of belts lasts
longer and loading is evenly divided among
all the belts. Belts from different
manufacturers should not be mixed in a set
because material differences could reduce belt
life. Always replace belts in full sets.
9) Don’t overload belts. If the drive has 10
sheave grooves, use 10 belts. Using less than
the designed number puts stress on the
remaining ones. This can cause premature
failure.
Belt Drive Troubleshooting
Good maintenance practices should help you
experience minimal trouble with belts and
sheaves, however there may be times when
troubles are experienced. The following table can
be used as a troubleshooting tool.
B-2 Model TC-Series Cone Crushers

Table B - 1 Belt Drive Troubleshooting
Trouble Cause
Belt Slip (sidewalls glazed) Insufficient tension
Overloaded drive
Drive squeals Arc of contact too short
Heavy starting load
Broken cord caused by prying
Overloaded drive
Impulse loads
Misalignment
Belts roll over
Worn sheave grooves
Flat idler sheave
Excessive vibration
New belts installed with old
Sheave grooves worn unevenly
Mismatched belts
Improper groove angle
Shafts not parallel
Shock loads
Heavy starting load
Belt breaks
Belt pried over sheaves
Foreign object in drive
Sheave grooves worn
Sheave diameter too small
Mismatched belts
Drive overloaded
Belt wears prematurely
Belt slips
Sheaves misaligned
Oil present
Excessive heat present
CRSH-OI-0004ENG (NOV-2012) B-3
Operator Instruction Manual
Belt Drive Troubleshooting
Correction
Replace belts; increase tension
Find cause and correct
Increase distance between hubs
Increase tension
Replace belt correctly
Redesign drive
Apply proper tension
Realign drive
Replace sheave
Align and reposition
Check drive design, mounting
Consider banded belts
Replace belts with matched set
Replace sheaves
Align drive
Apply proper tension
Apply proper tension
Use compensator starting
Replace belt correctly
Determine source of object,
design guard to correct problem
Replace sheaves
Redesign drive
Replace with matched set
Redesign drive
Increase tension
Align sheaves
Eliminate oil
Ventilate drive
Model TC-Series Cone Crushers
Operator Instruction Manual
Maintaining V-Belt Tension

Maintaining V-Belt Tension
V-belt tension must be maintained to provide
proper drive effectiveness. The following method
of tensioning v-belts has been established as an
acceptable and preferred method.
Tension-Deflection Method
1) Place a straightedge across the top of both
sheaves. See (Figure B - 4)
2) Measure the span length.
3) Using a spring scale at right angle to belt at
1/2 of span length, apply a force to the scale
on one of the belts enough to deflect the belt
1/64 inch per each inch of span length.
Example:
For a 100 inch span, the deflection would be
100/64, or approximately 1-1/2 inches.
4) Compare the force measurement to the
recommended ranges shown in (Table B - 2)
below for the appropriate belt cross section
type shown in.
5) Tighten or loosen belt to bring it into the
recommended range.
6) When installing new belts, tighten them to
“Initial Installation” tension. This tension will
drop during the run-in period.

1 4
2

9 5
8
6
1 - Straightedge 5 - Motor Drive Sheave
2 - Span Length 6 - V-belt
3 - 1/2 Span 7 - Spring Scale
4 - Deflection Measurement - 1/64 Inch for each 8 - Force Measurement
Inch of Span Length
9 - Driven Sheave

Figure B - 4 Tension-Deflection Diagram

CRSH-OI-0004ENG (NOV-2012) B-4 Model TC-Series Cone Crushers

 Operator Instruction Manual
Maintaining V-Belt Tension

Table B - 2 Belt Deflection Forces

Recommended Belt Deflection Force (Pounds)

V-Belt Smallest Sheave Initial Retensioning

Cross Diameter Range Installation
Section (Inches) Maximum Minimum

- 3.0 3.6 3.1 2.4

3.1 - 4.0 4.2 3.6 2.8
A 4.1 - 5.0 5.2 4.6 3.5
5.1 - 6.1 5.3 4.1

- 4.6 7.3 6.4 4.9

4.7 - 5.6 8.7 7.5 5.8
B 5.7 - 7.0 9.3 8.1 6.2
7.1 - 10.0 8.8 6.8

- 7.0 12.5 10.7 8.2

7.1 - 9.0 15.0 13.0 10.0
C 9.1 - 12.0 18.0 16.3 12.5
12.1 - 19.5 16.9 13.0

12.0 - 13.0 25.5* 22.1 17.0

D 13.1 - 15.5 30.0* 26.0* 20.0
15.6 - 22.0 32.0* 28.0* 21.5

18.0 - 22.0 45.0* 39.0* 30.0*

E 22.1 - 52.5* 45.5* 35.0*

- 3.0 5.1 4.4 3.4

3.1 - 4.0 5.5 4.8 3.7
AX 4.1 - 5.0 6.0 5.2 4.0
5.1 - 6.7 5.9 4.5

- 4.6 10.0 8.7 6.7

4.7 - 5.6 11.0 9.5 7.3
BX 5.7 - 7.0 11.5 9.9 7.6
7.1 - 12.0 10.1 7.8

- 7.0 18.0 15.6 12.0

7.1 - 9.0 19.5 16.9 13.0
CX 9.1 - 12.0 20.0 17.6 13.5
12.1 - 21.0 18.2 14.0

2.65 - 3.35 4.6 4.0 3.1

3.65 - 4.50 5.5 4.8 3.7
3V 4.75 - 6.0 6.4 5.6 4.3
6.5 - 10.6 7.3 6.4 4.9

7.1 - 10.3 16.5 14.3 11.0

5V 10.9 - 11.8 19.5 16.9 13.0
12.5 - 16.0 21.0 18.2 14.0

12.5 - 16.0 39.0* 33.8* 26.0*

8V 17.0 - 20.0 45.0* 39.0* 30.0*
21.2 - 24.4 51.0* 44.2* 34.0*

2.2 - 2.5 4.8 4.2 3.2

2.65 - 4.75 5.7 4.9 3.8
3VX 5.0 - 6.5 7.2 6.2 4.8
6.9 - 8.7 7.5 5.8

- 5.5 15.0 13.0 10.0

5.9 - 8.0 19.0 16.9 13.0
5VX 8.5 - 10.9 21.0 18.2 14.0
11.8 - 22.0 19.5 15.0

* Note: For banded belts, multiply the force in table by

the number of belts in the band.

CRSH-OI-0004ENG (NOV-2012) B-5 Model TC-Series Cone Crushers

Operator Instruction Manual
Belt Type Cross-Sections
Belt Type Cross-Sections
Figure B - 5 Belt Type Cross-Sections
Belt Idlers
A properly designed v-belt drive does not require
and idler to deliver full horsepower if proper belt
tension can be maintained. Idlers should be
avoided if possible because it puts additional
bending stress points on the belt. Due to drive
design parameters, idlers are sometimes used. The
following are general descriptions of the types of
idlers that may be used.
Inside Idler
A v-grooved idler located on the inside of the belts
on the slack side of drive would be recommended
over a backside idler. The idler should be located
near the large sheave to minimize reduction of the
arc of contact on the small sheave. The diameter
should be equal to or larger than that of the small
sheave.
Figure B - 6 Inside Idler
CRSH-OI-0004ENG (NOV-2012)
Backside Idler
A backside idler increases the arc of contact on
both sheaves. However, it forces a backward bend
in the v-belt that can contribute to premature
failure. The idler puts additional stress on the
bottom portion of the belt which will result in
bottom cracking. If a backside idler must be used,
the diameter should be at least 1 - 1/2 times the
diameter of the small sheave. It should also be
located as close as possible to the small sheave.
Figure B - 7 Backside Idler
Kiss Idler
A kiss idler differs from the backside idler because
the kiss idler does not penetrate the belt span and
create a backward bend on the belt. A kiss idler
does not contribute to premature belt failure. Use
of a kiss idler can help control belt vibration and
whip on drives subject to shock and pulsating
loads. If a kiss idler is used, the diameter should
be at least 1 - 1/2 times the diameter of the small
sheave.
Figure B - 8 Kiss Idler
B-6 Model TC-Series Cone Crushers
 Operator Instruction Manual
Glossary of Terms & Definitions

Appendix C - Crushing Terminology Closed Circuit Crushing:

The type of operation where uniformity of product
Glossary of Terms & Definitions size is important and the product is screened as it
is being discharged and the material that does not
The following list contains terms and definitions
pass through the screen is returned to the crusher.
commonly used throughout this manual as well as
in the rock-processing industry.
Closed Side Setting (CSS):
Backlash: The distance between the bottom of the crushing
members as measured at the point where the two
Total clearance between pinion teeth and gear
crushing members are at their closest relationship
teeth at pitch line.
during their gyrating cycle. This closed side
setting regulates product size.
Bridging:
Material wedged or covering the feed opening of Crushing Chamber:
the crusher and preventing entry of additional
The area of the crusher where crushing takes place.
material.
Discharge Opening:
Capacity:
The distance between the bottom of the crushing
The output of the crusher computed in tons per
members measured at the point where they are at
hour.
their farthest relationship during their gyrating
cycle. This opening permits rapid discharge of the
Cavity:
crushed material.
The internal contour formed by the two crushing
members. (Bowl liner and mantle). Drive:
Any device used to transmit rotating force from the
Choke Feed:
electric motor or diesel engine to the crusher
A condition when the feed material completely countershaft, v-belt or flexible coupling.
fills the crushing chamber.

CRSH-OI-0004ENG (NOV-2012) C-1 Model TC-Series Cone Crushers

Operator Instruction Manual
Glossary of Terms & Definitions

Drive Guard: Finished Product:

Safety enclosure for the drive with small opening The resultant material after it has been processed.
(opposite countershaft with cover) for tachometer.
Friable:
Feed:
Material that fractures easily.
The raw material which is to be crushed.
Gradation:
Feed Opening:
The range of sizes contained in a sample of rock.
The opening of the crusher where the material enters
the crushing chamber. Grizzly:
A heavy duty screening surface consisting of a series of
Feed Opening (Closed Side):
spaced bars, rails, or pipe members which may be
The smallest distance between the top of the crushing stationary or vibrating.
members as measured when the two crushing
members are at their closest relationship during Liners:
their gyrating cycle.
The bowl liner and mantle are the crushing
members and are commonly referred to as liners.
Feed Opening (Open Side):
The largest distance between the top of the Minimum Discharge Setting:
crushing members measured when the two
The smallest safe distance between the bottom of the
crushing members are at their farthest relationship
crushing members as measured when the two crushing
during their gyrating cycle. The feed opening
members are at their closest relationship during the
(open side) determines the maximum size of feed.
gyrating cycle.
Fines:
Open Circuit Crushing:
Material having particle size smaller than a
The type of operation where uniformity of product
specified screen opening. Fines are equal to or
size is not considered to be of prime importance and
smaller than closed side setting.
the feed is run through the crusher only once.

CRSH-OI-0004ENG (NOV-2012) C-2 Model TC-Series Cone Crushers

 Operator Instruction Manual
Glossary of Terms & Definitions

Oversize: Reduction Ratio:

Material that will not pass through a specified screen Relationship of the top size of the feed material to the
opening. top size of the desired crushed product.

Parallel Zone: Scalping:

With the liners in their closest relationship during the
gyrating cycle, the lower portion of both the bowl liner
and mantle, for some distance, will be parallel to each
other. This area is known as the parallel zone.
Plugging:
Excessive fine material causes crusher to stall.
Product Size:
The size of screened material after it has been
crushed.
Removing from crusher feed most of the
undersize material.
Top Size:
The largest particle size in the feed or product.
Tramp Material:
Material in the crusher feed that contains wood, clay,
pieces of rubber belting, iron or steel, difficult (hard) to
crush material or oversize material, causing the crusher
to stall.

Yield:
Product at the desired size or sizes

CRSH-OI-0004ENG (NOV-2012) C-3 Model TC-Series Cone Crushers

Operator Instruction Manual
Glossary of Terms & Definitions

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CRSH-OI-0004ENG (NOV-2012) C-4 Model TC-Series Cone Crushers