Manual C145 Jaw

NORDBERG C SERIES JAW CRUSHERS
INSTRUCTION MANUAL
140588-EN
NORDBERG C SERIES JAW CRUSHERS CHAPTER 0
This manual is valid for the Nordberg C Series Jaw Crushers manufactured by Metso Minerals. These
crushers are high capacity jaw crushers, intented to be used in primary crushing applications.
Because of the continuous development of the products, the manufacturer reserves a right to alter the
technical specifications written in this manual, without any advance information.
This is the first edition published in April 2003 in Tampere, Finland .
Metso Minerals (Tampere) Oy

P.O. Box 306
FIN-33101 Tampere
Finland
Tel. +358 (0)20 484 142

Fax +358 (0)20 484 143
EN 140588-0_I NORDBERG C SERIES JAW CRUSHERS 0-1

CHAPTER 0 - NORDBERG C SERIES JAW CRUSHERS
This Page Left Intentionally Blank.
0-2 NORDBERG C SERIES JAW CRUSHERS 140588-0_I EN

Nordberg C Series Jaw Crushers
Table of Contents
NORDBERG C SERIES JAW CRUSHERS
PREFACE
1.1 FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.2 SAFETY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
SAFETY
2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.1.1 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.2 Warning signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.2.1 Warning sign codes and texts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
GENERAL CRUSHER INFORMATION
3.1 CRUSHER TERMINOLOGY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.2 CRUSHER COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.3 SPARE PARTS BOOK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.4 ORDERING PARTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.5 ESTIMATING CRUSHER CAPACITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.6 ESTIMATING CRUSHER PRODUCT GRADATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.7 CRUSHER SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.8 CRUSHER SETTING LIMITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3.9 OPTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3.9.1 Intermediate Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3.9.2 Protection Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3.9.3 Conveyor Belt Protector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3.9.4 Hydraulic Setting Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
3.9.5 Automatic Lubrication Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
OPERATING INSTRUCTIONS
4.1 PREPARATIONS BEFORE STARTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.2 STARTING THE CRUSHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.3 STOPPING THE CRUSHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.4 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.4.1 Oversized Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.4.2 Tramp Iron/Uncrushables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.4.3 Packing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Table of Contents
4.5 RE-STARTING A CRUSHER STALLED UNDER LOAD . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.6 CRUSHER SETTING ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.6.1 Mechanical Wedge Setting Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.6.2 HYDRAULIC WEDGE SETTING ADJUSTMENT (OPTIONAL) . . . . . . . . . . . . . . . . . . . 4-6
4.6.3 HYDRAULIC CONTROL SYSTEM SETTING ADJUSTMENT (OPTIONAL) . . . . . . . . . 4-8
4.7 TOGGLE PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.8 SPACER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
4.9 TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
MAINTENANCE
5.1 SPACER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.1.1 Spacer Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.1.2 Spacer Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.2 TOGGLE PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.2.1 Replacing the Toggle Plate And Toggle Seats (with wedge setting adjustment) . . . . . . 5-4
5.2.2 Replacing the Toggle Plate And Toggle Seats with Hydraulic Control System . . . . . . . 5-6
5.3 LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
5.3.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
5.3.2 Grease Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
5.3.3 Eccentric Shaft Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5.3.4 Eccentric Shaft Bearing Temperatures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5.3.5 Jack-shaft Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5.3.6 Jack-shaft Bearing Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5.3.7 Thrust Bearing And Cap Nut Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5.3.8 Electric Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5.3.9 Toggle Seats And Toggle Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5.3.10Setting Adjustment Wedges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
5.4 INSTRUCTIONS FOR LIFTING A JAW CRUSHER WHEN REPLACING CRUSHER
SUPPORT BRACKET DAMPERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
5.5 HYDRAULIC SETTING ADJUSTMENT POWER UNIT (OPTIONAL). . . . . . . . . . . . . . . . 5-16
5.5.1 Checking oil level and temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
5.5.2 Changing oil and filter (Figure 5.8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
5.5.3 Oil recommendation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
5.5.4 Bleeding the hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
5.6 PERIODICAL MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
5.6.1 Daily maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
5.6.2 Weekly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
5.6.3 Monthly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
5.6.4 Twice a Year. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
5.6.5 Regularly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
Table of Contents
5.7 MAINTENANCE INTERVALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
5.8 OTHER BOLT TORQUE VALUES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
REPLACEMENT OF WEAR PARTS
6.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.2 JAW SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.3 JAW WORK HARDENING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.4 CHEEK PLATE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.4.1 Cheek Plate Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.4.2 Cheek Plate Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.5 CHANGING OR ROTATING THE JAWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6.5.1 One Piece Jaws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.5.2 C105 One Piece Jaws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
6.5.3 TWO-PIECE JAW REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
6.6 PITMAN EYE PROTECTION PLATE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
6.7 FEED HOPPER LINER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
6.8 TOGGLE PLATE SEAT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
APPENDIX
NORDBERG C-SERIES JAW CRUSHER'S JAW-LIFTING TOOL . . . . . . . . . 1-1

SAFETY, OPERATING AND MAINTENANCE INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . 1-1
1. Purpose of the jaw-lifting tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
2. Storage of the jaw-lifting tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
3. Safe use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
4. Commissioning and operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
5. Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
6. The jaw-lifting tool verification before first use and in service . . . . . . . . . . . . . . . . . . . . 1-1
7. Handling the load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
8. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
9. Operating instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
APPENDIX
NORDBERG C-SERIES JAW CRUSHER'S CHEEK PLATE LIFTING TOOL . 1-1

SAFETY, OPERATING AND MAINTENANCE INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . 1-1
1. Purpose of the cheek plate lifting tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
2. Storage of the cheek plate lifting tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
3. Safe use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Table of Contents
4. Commissioning and operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
5. Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
6. The cheek plate lifting tool verification before first use and in service . . . . . . . . . . . . . . 1-2
7. Handling the load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
8. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
9. Operating instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
PREFACE CHAPTER 1
1.1 FOREWORD 1.2 SAFETY
This instruction manual provides guidance for first BASIC RULES REGARDING SAFETY IN AND
time operators of the crusher as well as technical AROUND A CRUSHING PLANT ARE
procedures as a reference for the experienced OUTLINED IN THE SECTION ENTITLED
crusher operator. Read, study, and keep it for future "SAFETY."
reference.
OPERATOR SAFETY AND THE SAFETY OF

The instructions given are for the operation and OTHERS DEPEND UPON REASONABLE
basic maintenance procedures only, as this CARE AND JUDGEMENT IN THE OPERATION
instruction book is not a repair manual. Should OF THIS CRUSHER. A CAREFUL OPERATOR
maintenance procedures not covered in this manual IS GOOD INSURANCE AGAINST AN
be required, contact Metso Minerals. ACCIDENT.
Illustrations and instructions guide the operator MOST ACCIDENTS, NO MATTER WHERE
through correct procedures for checking, operating THEY OCCUR, ARE CAUSED BY FAILURE TO
and maintaining the crusher and its accessories. OBSERVE AND FOLLOW SIMPLE
FUNDAMENTAL RULES OR PRECAUTIONS.
FOR THIS REASON RECOGNIZING HAZARDS
Operating techniques outlined in this manual are AND TAKING STEPS TO AVOID THEM CAN
basic. Operating skills and additional techniques PREVENT MOST ACCIDENTS.
will develop through experience as the operator
gains knowledge of the crusher and its capabilities.
REGARDLESS OF THE CARE USED IN THE
DESIGN AND CONSTRUCTION OF THIS
Continuing improvement and advancement of TYPE OF EQUIPMENT, THERE ARE
product design may result in changes to your new CONDITIONS THAT CANNOT BE
machine that may not be included in this COMPLETELY SAFEGUARDED AGAINST
publication. As required, each publication is WITHOUT INTERFERING WITH
reviewed and revised to update and include REASONABLE ACCESSIBILITY AND
appropriate changes in the later editions. EFFICIENT OPERATION. WARNINGS ARE
INCLUDED IN THIS INSTRUCTION MANUAL
TO HIGHLIGHT THESE CONDITIONS.
The descriptions and specifications in this manual
were in effect at the time this manual was approved
for printing. Metso Minerals reserves the right to
discontinue models at any time and to change
specifications and designs, without notice and
without incurring obligation.
Whenever a question arises concerning your

crusher, or this publication, please consult your
Metso Minerals representative for the latest
available information.
EN 140588-1_I NORDBERG C SERIES INSTRUCTION MANUAL 1-1

CHAPTER 1 - PREFACE
1-2 NORDBERG C-SERIES INSTRUCTION MANUAL 140588-1_I EN

SAFETY CHAPTER 2
2.1 GENERAL
The instructions of the safety guide, these safety
instructions and other manuals and safety labels for
the equipment must be read, understood and used
by each person who works with this equipment.
WARNING!
DANGER
In addition to these unit-specific safety
instructions, the operators of this
equipment must also read the safety
guide with instructions for general
operational safety.
WARNING
The following symbol is used in this manual and on
the machine to call attention to instructions, which
will help prevent machine related injuries.
CAUTION
When you see this symbol on your machine or in
this manual, be alert to the potential for personal
injury.
Sign Description
Immediate hazards or unsafe practices
DANGER that will result in severe personal injury
or death.
Hazards or unsafe practices that could
WARNING
result in severe personal injury or death
Hazards or unsafe practices that could
CAUTION result in minor personal injury or
equipment damage
Kuva 2.2 Danger, warning, caution signs and

their meaning
Kuva 2.1 Alert Symbol
This manual uses the alert symbol, with words such

as DANGER, WARNING or CAUTION, to alert
you and other Crushing Plant personnel of actions
or conditions that pose a potential safety hazard,
with an attending risk of personal injury (including
death) or property damage. The machine also
displays safety signs, labels and tags at appropriate
points to show safety risks that may exist.

CHAPTER 2 - SAFETY
2.1.1 General safety instructions of the Owner and Operator to determine the
necessity and adequacy of protective
1. Ignoring the safety instructions or the
devices and warnings, to provide them, and
warning signs increases the risk of the
to ensure that they are used and followed!
severe injury or death.
11. The noise level is dangerously high near the
2. Nordberg C series jaw crushers has been
crusher. All personnel working near the
designed for safe operation when used by
crusher must wear hearing protection. The
professional staff in the operating situations
noise level is typically about 102-110 dB
included in this instruction manual. All
next to the crusher during crushing.
other service and repair procedures must be
performed by specially trained personnel or 12. Before performing any maintenance or
authorized Metso service staff. repair work, make sure that the crusher is
stopped and locked out.
3. Never operate the crusher without proper
covers and safety devices. 13. The surfaces of the crusher may become hot
during crushing. Hot surfaces can cause
4. Before starting the crusher make sure that no
severe burn injuries. Make sure that the
one is near the crusher.
surfaces have cooled before performing any
5. It is prohibited to stay in the danger area maintenance work.
during the crushing process. The crushing
14. Before changing any wear parts of the
material may be thrown into a few meters
crusher, read chapter 6: Replacement of
distance from the crusher. Always use
wear parts and appendixes A and B
helmet and safety glasses.
carefully.
6. Do not look into the jaw cavity during
15. Before lifting any wear parts, check the
crushing. Material may be thrown from the
weight of the component and ensure that
crusher during crushing and cause injuries.
lifting equipment being used is adequate to
Always use a helmet and safety glasses.
lift the weight. In addition, familiarize
7. Because the crusher is installed on rubber yourself with all the special tools provided
dampers, it moves during crushing. This with the crusher specifically for replacing
movement causes a crushing danger. Never the wear parts.
put your hands or feet between the moving
16. Read the instructions regarding the lifting
parts and the structure of the crusher during
tools and replacing wear parts carefully
crushing. The movement may be as much as
before replacing any wear parts. Make sure
± 10mm.
that the parts are adequately supported
8. Clearing a jammed cavity is extremely before lifting. Never go under a hanging
dangerous. Do not attempt to clear the cavity part. The lifting tools delivered with the
until the crusher has stopped completely. crusher are designed to be used only with
9. The crusher does not stop immediately after original Metso Minerals wear parts.
the motor has been turned off. Make sure 17. The spring of the mechanical setting
that the crusher has stopped completely adjustment may accumulate significant
before opening any covers, performing any amount of energy. Follow the instructions
maintenance, or adjusting the crusher. strictly and be extremely accurate when
10. The crushing plant and auxiliary equipment adjusting the spring. Never release the
such as chutes, transfer stations, screens, protective plate.
etc. can create dust and, if not contained, the 18. The pressure accumulator of the hydraulical
dust can escape into the air. Metso Minerals setting adjustment may be charged only by a
highly recommends that dust protective professional. If the pressure accumulator is
devices such as an appropriate respirator be charged incorrectly, it may explode. Do not
worn by anyone exposed to airborne dust to charge the accumulator yourself. Release the
prevent its inhalation. It is the responsibility pressure from the hydraulic system
2-2 NORDBERG C SERIES INSTRUCTION MANUAL 140588-2_I EN

CHAPTER 2 - SAFETY
according to instructions before any 2.2 WARNING SIGNS

maintenance to the system.
The warning signs attached to the equipment must
19. Keep the warning signs clean. Replace always be kept readable and clean. Damaged or
illegible and damaged signs before starting loose signs must be replaced at once before starting
the crusher. Make sure that the warning the crusher. Make sure that the warning signs are
signs are not hidden from sight when not covered during installation. If a part of the
installing the crusher. If a part with a crusher attached a warning sign are replaced,
warning sign is replaced, make sure that the always make sure that the warning signs needed are
new part also has the required warning included in a new part.
signs.
Figure 2.3 The locations of the warning signs
The number and exact locations of the warning

signs may vary according to options (for example,
guards). IMPORTANT!
The warning signs 1, 2, 3, and 4 are located on both Safety labels 1, 2, 3 and 4 are not
sides of the crusher. attached on crushers installed in
Lokotracks or Nordwheelers.
The warning signs 3 are delivered only if the
crusher delivery includes the drive guards.
The warning sign 5 is delivered only with crushers
that have a mechanical setting adjustment.
The warning signs 6, 7, and 10 are delivered only
with crushers that have a hydraulical setting
adjustment.

CHAPTER 2 - SAFETY
1
2
3 4
5 6
7 8
10
Figure 2.4 Warning signs

CHAPTER 2 - SAFETY
2.2.1 Warning sign codes and texts before adjusting or servicing.

Do NOT remove this protection plate.
1. MM0229994
WARNING 6. MM0230002
Read and understand instruction manual WARNING
before using or maintaining this machine. Servicing while pressurized can cause
Failure to follow operating instructions may severe injury.
result in death or serious injury. Lock out source and relieve pressure before
servicing.
DANGER 7. MM0230006
Lung disease hazard.
CAUTION
Dust protection required. Hot surface.
Contact with skin may cause burns.
WARNING
Do not touch.
Risk of eye injury.
Use of eye protection required. 8. MM0230004
CAUTION
CAUTION Hot surface.
Risk of head injury. Contact with skin may cause burns.
Use of a helmet required. Do not touch.
9. MM0230001
CAUTION WARNING
Hazardous noise level. Read and understand instruction manual
Use of ear protection required. before changing toggle plate.
2. MM0229995 Use only genuine toggle plate of Metso
DANGER Minerals.
Moving parts can crush and cut. 10. MM0230447
Do not insert tools in the crusher cavity WARNING
when the motor is running. Pressurized device.
Only authorized personnel should service
WARNING this dev ice.
Material can fall out. See instruction manual for safety
do not stand in the vicinity of the crusher information.
when the motor is running.
3. MM0229997
WARNING
Exposed moving parts can cause severe
injury.
Do not open drive guard before machine is
completely stopped.
4. MM0229996
WARNING
Exposed moving parts can cause severe
injury.
Do NOT operate this machine without
proper guards.
5. MM0229998
DANGER
Spring in compression.
Read and understand instruction manual

CHAPTER 2 - SAFETY

GENERAL CRUSHER INFORMATION CHAPTER 3
3.1 CRUSHER TERMINOLOGY
Throughout this instruction manual, technical terms

are used to describe the crusher, its components and
its operation. These terms are defined herein with
the intent of avoiding any confusion or
misunderstanding.
Callout Description Callout Description

1 Feed opening depth 5 Stroke
2 Moving jaw 6 Nip angle
3 Stationary jaw 7 Feed opening width
4 Closed side setting (c.s.s)
Figure 3.1 Jaw crusher terminology
distribution or based on an average top (maximum)

size.
Feed: The raw material to be crushed, such as the
rock type (limestone, basalt, granite, etc.) or
man-made materials such as concrete and asphalt. Capacity: The output of the crusher in tons per
The feed size is typically denoted in terms of a size
hour.
distribution or based on an average top (maximum)
size. Feed Opening: The opening where the feed
material is fed into the crusher. The feed opening
Product size: The size of the material after it has has two dimensions: a width and a depth. The feed
been crushed. Similarly to the feed size, the product opening depth is a critical dimension because it
size is typically denoted in terms of a size
dictates the maximum feed size a given jaw crusher
model can accept.

CHAPTER 3 - GENERAL CRUSHER INFORMATION
Maximum Recommended Feed Size: As a Stroke: The difference between the maximum and
general guideline, the maximum average minimum distances at the bottom of the fixed and
recommended feed size should be about 80% of the moving jaws during one revolution of the eccentric
feed opening depth. Such measures will ensure that shaft.
any bridging events resulting from oversized feed
are kept to a minimum. A rock hammer is
recommended for applications where the maximum
feed size is regularly close to the feed opening
depth.
Maximum
Rec. Feed
Feed Opening
Size
mm inch mm inch
C80 800 X 510 20 X 32 408 16
C95 930 X 600 24 X 37 480 19
C100 1000 X 760 30 X 40 608 24
C105 1060 X 700 28 X 42 560 22
C110 1100 X 850 34 X 44 680 27
C115 1150 X 800 32 X 45 610 24
C3054 1380 X 760 30 X 54 608 24
C125 1250 X 950 37 X 49 760 30
C140 1400 X 1070 42 X 55 856 34
C145 1400 X 1100 43 X 55 880 35
C160 1600 X 1200 47 X 63 960 38
C200 2000 X 1500 59 X 79 1200 47
Table 3-1 Maximum recommended feed sizes
Nip Angle: The angle between the fixed and

moving jaws. The nip angle is often referred to as
the "bite" angle as well.
Jaws: The members that perform the crushing are
commonly referred to as jaws. The jaws consist of a
stationary and moving jaw, and depending on the
model each one of these may consist of either 1 or 2
pieces. Different jaw profiles are available for
different applications.
Discharge Setting: The shortest distance between
the bottom of the fixed and moving jaws as
measured at the point where the jaws are at their
closest relationship during their work cycle (i.e. the
closed side setting, or c.s.s.). The method in which
the setting is measured varies depending on the jaw
profile. These differences are explained in detail in
the CRUSHER SETTING section.

3.2 CRUSHER COMPONENTS

1 Front frame 12 Moving jaw, lower
2 Upper wedge 13 Frame bolt
3 Filling wedge 14 Fixed wedge
4 Jaw bolt 15 Pitman eye protection plate
5 Disc spring package 16 Flywheel
6 Cheek plate, upper 17 Eccentric shaft
7 Fixed jaw, upper 18 Pitman bearing
8 Moving jaw, upper 19 Pitman
9 Center wedges 20 Frame connecting rods
10 Cheek plate, lower 21 Side plate
11 Fixed jaw, lower 22 Toggle seat
Figure 3.2 Jaw crusher main components


1 Rear frame 8 Tension rod
2 Adjustment wedges 9 Toggle plate
3 Spacer 10 Piston rod
4 Toggle seat holder 11 Piston
5 Toggle seat 12 Pressure relief valve
6 Locking nuts with thrust bearing 13 Pressure accumulator
7 Tension spring 14 Tension cylinder
15 Cylinder cover
Figure 3.3 Jaw crusher rear frame components

3.3 SPARE PARTS BOOK 3.5 ESTIMATING CRUSHER CAPACITY

The capacity of the crusher depends on factors such
as the type of feed (material type, size distribution,
A Spare Parts Book containing various assembly
fracture characteristics, moisture content, etc.), type
drawings pertaining to your crusher will be sent
of operation (feed availability, feed arrangement)
immediately after the crusher has been shipped.
and discharge setting. To obtain an estimate of the
This book illustrates each and every part used in the
capacity, refer to the following capacity table.
assembly of the machine and is to be used when
These capacities are based on results obtained in
ordering spare or replacement parts.
actual practice with hard granite that has a bulk
density of 1.6 t/m3 (100 lb/ft3), and are where the
feed has been properly graded so that bridging does
3.4 ORDERING PARTS not take place.
To obtain more accurate capacity estimates specific
Metso Minerals endeavors to carry an ample supply to your actual crushing application, contact your
of parts in stock to provide prompt and efficient local Metso Minerals sales representative to request
service on all orders for repairs and replacements. a computer simulation of your circuit's operating
condition
To avoid delay and the possibility of incorrect parts
being furnished, the following information should
be given:
1. Crusher size.
2. The serial number of the crusher which is
stamped on the crusher nameplate. The
serial number is also on the cover of the
spare parts books.
3. Complete name and part code number as
shown in the Spare Parts Book.
4. Exact quantity of each part ordered.
5. Complete shipping instructions.
If your crusher Spare Parts Books have been lost,

destroyed or misplaced, an additional set can be
ordered.
For proper operation, only genuine factory parts
should be installed. These are guaranteed as to
accuracy, workmanship and material. Using pirate
parts may put your safety and that of your crusher
at risk. Make sure you completely understand your
crusher's Warranty conditions at all times.

c.s.s. C80 C95 C100 C105 C110 C115 C125 C140 C145 C160 C200 C3054
Mtph Mtph Mtph Mtph Mtph Mtph Mtph Mtph Mtph Mtph Mtph Mtph
mm in Stph Stph Stph Stph Stph Stph Stph Stph Stph Stph Stph Stph
40 65
1-5/8" 70
50 80
2" 90
60 95 120
2-3/8" 105 135
70 115 140 150 155 190 175 240
2-3/4" 125 155 165 170 210 190 265
80 130 160 170 175 210 195 270
3-1/8" 145 175 190 195 235 220 295
90 150 180 190 200 235 220 295
3-1/2" 165 200 210 220 260 240 325
100 165 200 215 220 255 245 290 325
4" 180 220 235 245 285 270 320 355
125 210 250 265 280 310 305 250 385 400 390
5" 230 275 290 305 345 335 385 425 440 430
150 250 300 315 335 370 360 410 455 470 520 460
6" 275 330 350 370 405 400 455 500 520 575 510
175 290 350 370 390 425 425 470 520 540 595 760 530
7" 320 385 405 430 470 465 520 575 595 655 840 585
200 420 445 480 530 590 610 675 855 600
8" 465 490 530 585 650 670 740 940 660
225 590 655 680 750 945
9" 650 725 750 825 1045
250 650 725 750 825 1040
10" 720 800 825 910 1145
275 820 900 1130
11" 900 995 1250
Table 3-2 Nominal jaw crusher capacities

3.6 ESTIMATING CRUSHER PRODUCT These product gradations are based on results
GRADATION obtained in actual practice with hard granite.
To obtain more accurate product gradation
estimates, contact your local Metso Minerals sales
The crusher's product gradation depends on the
representative to request a computer simulation of
same factors that affect capacity. The following
your circuit's operating conditions.
figure gives an indication of the product gradation
as a function of the closed side setting (c.s.s.).
1" 2" 4" 8" 16"

100
90
css 40 50 70 100 130 160 200 250 300

80
70
Percentage passing, weight %
60
50
40
30
20
10
0
1 10 100 1000
Product size
Figure 3.4 Crusher product gradation

3.7 CRUSHER SETTING The Crusher setting is measured in three different

ways, first referring to the tooth groove (bottom) or
crown (top) of the stationary jaw and then to the
The Crusher setting is the most important Crusher tooth groove (bottom) or crown (top) of the
parameter since it determines the Crusher's capacity movable jaw. Thus, the setting is always measured
as well as the top size of the Crusher product. It is from the Stationary (bottom or top) to the Movable
therefore indispensable for everyone to understand jaw (bottom or top). The three alternatives are
how the Crusher setting is measured. shown in Table 3-3.
The measurement type depends on the profile as
The discharge setting is the shortest distance well as on the Crusher model. This information is
between the bottoms of the fixed and moving jaws also found in the Crusher Spare Parts Book.
during their work cycle. This distance is referred to
as the closed side setting (c.s.s.), and it is a
calculated distance as the Crusher setting is Measurement
Reading Sequence (Jaws)
typically measured when the Crusher is at rest. The Type
largest distance between the bottoms of the fixed Stationary to Movable
and moving jaws is referred to as the open side 1 Bottom to Top
setting (o.s.s.), and it is typically a distance that is 2 Top to Top
directly measured when the Crusher is at rest. 3 Top to Bottom
Table 3-3 Measurement types
Figure 3.5 Crusher setting measurement

For example, the setting of the C125, equipped with

Quarry jaws, is measured from Top to Top (Type 2).
However, with Standard jaws, the setting is Example
measured from Bottom to Top (Type 1). Crusher: C140
Stroke: 42 mm (15/8” ) (Table 3-4)
Jaw Profile: Quarry (top to top)
IMPORTANT! O.S.S.: 230 mm (9")
The Crusher setting must always be C.S.S.: 230 – 42 = 188 mm (9" – 1 5/8" = 7 3/8")
measured in a straight line at the bottom of
the crushing cavity. Measure the setting
always from the least worn area.
It is easiest to measure the setting when the Crusher

is at rest with a device such as a block of wood of
known dimensions (several blocks should be
available if more than one setting is typically used).
The distance measured this way is larger than the
closed side setting (c.s.s.) because the pitman
always stops at its lowest point. This value is close
(±2mm/±0.08") to the open side setting (o.s.s.). As
previously mentioned, the closed side setting is
calculated by deducting the stroke from the open
side setting (Table 3-4).
Model Stroke
mm Inch
C80 24 1
C95 32 1¼
C100 32 1¼
C105 32 1¼
C110 36 13/8
C115 37 1½
C3054 32 1¼
C125 39 1½
C140 42 15/8
C145 36 13/8
C160 39 1½
C200 50 2
Table 3-4 Dimension (stroke) to be deducted

from the open side setting (o.s.s.) to calculate
the closed side setting (c.s.s.).
Dimension (stroke) to be deducted from the open
side setting (o.s.s.) to calculate the closed side
setting (c.s.s.).

Figure 3.6 Measuring the setting
NOTE: The C.S.S does not have to be calculated if The minimum allowed setting (c.s.s. or o.s.s.) is the
the user knows the Crusher setting limits in terms minimum setting at which the Crusher can be used
of the O.S.S. The C.S.S. is typically calculated when the Crusher is operated according to Metso
because Crusher capacity is always denoted in Minerals' recommendations. The minimum allowed
terms of the C.S.S. only. setting is very important as it takes into account the
design and operation limits of the Crusher. Not
respecting these recommendations can lead to a
3.8 CRUSHER SETTING LIMITS poor utilization of the jaws (high scrap rate) as well
as a shortened Crusher life.
The minimum allowed setting varies depending on
All C-Series Crusher models have a maximum whether the application is a normal rock application
possible setting as well as a minimum allowed (Normal), or a recycling application (Special),
setting, and it is very important that the user when materials such as concrete, asphalt and bricks
understands why these are important to keep these are being crushed. Note that the minimum allowed
in mind at all times. setting does not depend on the jaw profile (it is
The maximum possible setting is simply the always the same for a specific Crusher model). See
maximum setting that the Crusher is physically able Table 3-5.
to accommodate. Typically, such setting is
indicated with new jaws, and the setting actually
depends on the jaw profile as well as on whether a
spacer is being used or not. This information is
always found in the Crusher Spare Parts Book.

CSS OSS
Crusher Hard rock Soft Rock Hard rock Soft Rock
model Stroke
(>150 Mpa) (<150 MPa) Recycling (>150 Mpa) (<150 MPa) Recycling
mm
(> 22 000 psi) (<22 000 psi) (> 22 000 psi) (<22 000 psi)
mm mm mm mm mm mm
C80 40 30 20 24 64 54 44
C95 60 45 25 32 92 77 57
C100 70 60 45 32 102 92 77
C105 70 50 25 32 102 82 57
C110 70 60 45 36 106 96 81
C115 70 60 45 37 107 97 82
C3054 70 60 45 32 102 92 77
C125 100 N.A N.A 39 139 N.A N.A
C140 130 N.A N.A 42 172 N.A N.A
C145 125 N.A N.A 36 161 N.A N.A
C160 150 N.A N.A 39 189 N.A N.A
C200 175 N.A N.A 50 225 N.A N.A
CSS OSS
Crusher Hard rock Soft Rock Stroke Hard rock Soft Rock
model (>150 Mpa) (<150 MPa) Recycling in (>150 Mpa) (<150 MPa) Recycling
(> 22 000 psi) (<22 000 psi) (> 22 000 psi) (<22 000 psi)
in in in in in in
C80 1 5/8 1 2/8 7/8 1 2 5/8 2 2/8 1 6/8
C95 2 4/8 1 7/8 1 1 2/8 3 6/8 3 1/8 2 3/8
C100 2 7/8 2 4/8 1 7/8 1 2/8 4 1/8 3 6/8 3 1/8
C105 2 7/8 2 1 1 2/8 4 1/8 3 3/8 2 3/8
C110 2 7/8 2 4/8 1 7/8 1 4/8 4 3/8 3 7/8 3 2/8
C115 2 6/8 2 3/8 1 6/8 1 4/8 4 2/8 3 7/8 3 2/8
C3054 2 7/8 2 4/8 1 7/8 1 2/8 4 1/8 3 6/8 3 1/8
C125 4 1/8 N.A N.A 1 5/8 5 5/8 N.A N.A
C140 5 2/8 N.A N.A 1 6/8 7 N.A N.A
C145 5 1/8 N.A N.A 1 4/8 6 5/8 N.A N.A
C160 6 1/8 N.A N.A 1 5/8 7 6/8 N.A N.A
C200 7 1/8 N.A N.A 2 9 1/8 N.A N.A
Table 3-5 Minimum allowed settings for hard rock, soft rock and recycling applications.

To increase the length of the crushing zone (and

thus increase the life of the jaw dies) when the feed
WARNING! material is consistently smaller than the crusher's
The minimum allowed setting of a input capacity.
Crusher must be respected at all times The intermediate plate is not available for all
unless otherwise indicated by Metso models. Moreover, multiple plate thicknesses are
Minerals. Not respecting these available with certain models. Before ordering
recommendations can lead to a poor intermediate plate consult Metso Minerals if it fits
utilization of the jaws (high scrap rate) to your application.
as well as to a shortened Crusher life.
Moreover, operating the Crusher at
settings smaller than allowed will void
the Crusher's warranty.
3.9.2 Protection Plates
WARNING! Protection plates are designed for additional

The maximum size of tramp iron protection of the crusher's front frame and pitman.
(rebars, excavator teeth, etc.) must be They are recommended when using small settings
smaller than the Crusher closed side (always greater than or equal than the minimum
setting (c.s.s.). recommended setting) and/or when the rock to be
crushed is very hard (very low crushability). Of
course, these can be used at any time for added
protection.
3.9 OPTIONS
NOTE: The front frame protection plate is not
used when an intermediate plate is used.
Following options can be installed on Crusher after Protection plates are not available options with all
start-up. C-Series crusher models.
3.9.1 Intermediate Plate IMPORTANT!

When using protection plates, different
bottom retaining wedges must be used.
Fitting an intermediate (backing) plate behind the
fixed jaw reduces the nip angle of the crusher. The
intermediate plate reduces the feed opening and the
NOTE: Excessive replacement of the protection
setting range by approximately the same amount as
plates indicated a feed problem. Contact Metso
its thickness. However the intermediate plate
Minerals if such is the case with your Crusher.
does not, under normal circumstances, allow the
user to use a smaller setting than the minimum
recommended setting.
If available with the specific C-Series jaw crusher

model, an intermediate plate may be used for the
following reasons:
To improve the nip angle (by decreasing the nip
angle) when crushing slippery material (material
that is difficult to bite).


1 Front frame protection plate 2 Pitman protection plate
Figure 3.7 Protection plates
3.9.3 Conveyor Belt Protector
Conveyor belt protector prolongs lifetime of

conveyor belt under Crusher. Angle of the protector
can be adjusted.
Especially in recycling applications, rebars can
damage the belt.

3.9.5 Automatic Lubrication Unit
The lubrication system automatically lubricates the

four (4) eccentric shaft bearings in accordance with
the recommendations provided by the factory.
Refer to Chapter 5.3 and Installation Manual
Chapter 6.5.
Callout Description
1 Protector plate
2 Support holder
3 Eye screw
4 Split pin
5 Washer
6 Washer
7 Hex screw
8 Hex nut
9 Joint pin
Figure 3.8 Conveyor belt protector
3.9.4 Hydraulic Setting Adjustment
A Crusher equipped with mechanical setting

adjustment can be retrofitted with the hydraulic
setting adjustment.
Refer to Chapter 4.6.2.

OPERATING INSTRUCTIONS CHAPTER 4
4.1 PREPARATIONS BEFORE STARTING This is a brief outline of the control logic sequence
that is required to start the Crusher. Other measures
may be taken in accordance with local conditions.
Good inspection habits will do much to insure years
of successful operation of the Crusher. Do not rely
on memory alone to regulate required periodic
maintenance, keep an accurate written record.
Regularly performing pre-start and maintenance
inspections will pay off in the way of eliminating
costly down time and prolonging the life of the
Crusher. Before starting the Crusher, perform the
following operations:
1. Make a final inspection of the Crusher to be

certain that no tools or mechanical
obstructions are on the Crusher, that all
joints and fasteners are properly tightened,
that no leaks are apparent and that there is
no other reason why the Crusher should not
be started.
2. Ensure that the Crusher cavity is empty.
Figure 4.1 Starting and stopping sequence
3. Ensure also that there are no persons in the
area whose safety may be endangered. Walk
around the Crusher and ensure that there is
nobody on, by or below the Crusher. Warn 4.3 STOPPING THE CRUSHER
everybody in the vicinity before starting.
To stop the Crusher, proceed as follows:

4.2 STARTING THE CRUSHER
1. Stop the feeder.
An electric motor or diesel engine drives the 2. Wait until the Crusher cavity is empty.
Crusher. Starting the Crusher merely amounts to 3. Stop the electric motor or diesel engine.
starting the motor or engine according to the
manufacturers' instructions. Do not introduce any 4. Stop the discharge conveyor.
feed to the Crusher during starting. To start the
Crusher, proceed as follows:
IMPORTANT!
After stopping the Crusher motor or diesel
1. Start the discharge conveyor.
engine, the Crusher will coast down for
2. Start the electric motor or diesel engine. If a about five minutes
slip ring motor is used, wait until its starting
resistor reaches the operating stage. If a
pounding or thumping sound is heard, refer
to the TROUBLESHOOTING section of
this chapter (page 11).
3. Start the feeder.

CHAPTER 4 - OPERATING INSTRUCTIONS
4.4 OPERATION
WARNING!
Feed the material to the Crusher evenly in Lift or turn the rocks in the cavity only
accordance with the feed arrangement when the Crusher is stopped. Do not try
recommendations. Note that the Crusher operates to clear the blocked crushing cavity
most efficiently when the crushing cavity is when the Crusher is running. Be always
two-thirds (2/3) full. An ultrasonic level sensor very careful when clearing the cavity.
may be integrated into the Crusher control in order Never use a crowbar to turn oversized
to optimize the feed level of the Crusher. feed.
WARNING!
Never use explosives to clear a blocked
crushing cavity. Make sure no
explosives enter the Crusher
The oversized rock can be lifted out of the cavity

with a "clamp" and crane or it can be turned to a
better position.
When the Crusher is running a hydraulic hammer
can be used for breaking the oversized or blocked
feed.
4.4.2 Tramp Iron/Uncrushables
Uncrushable ("tramp iron") material larger than the

Crusher's c.s.s., such as excavator teeth, should be
Figure 4.2 Recommended filling ratio prevented from entering the Crusher by installing a
magnetic separator. Uncrushable material larger
than the c.s.s will cause the toggle plate to buckle,
and will impose unnecessary stresses on the
Refer to the WEAR PARTS section for operating
Crusher.
instructions pertaining to wear parts.
If tramp iron enters and stays in the Crusher, stop
the feeder and Crusher immediately. Empty the
4.4.1 Oversized Feed cavity and remove the tramp iron. If necessary
increase the Crusher setting to remove the tramp
iron.
Avoid trying to crush oversized feed (feed too large
for the cavity). Having to reposition rock wastes
time, reduces capacity and imposes unnecessary WARNING!
loads on the Crusher. Therefore attention must be
Always inspect the toggle plate, tension
paid to the size of feed. A stationary grizzly is a
rod and spring (or hydraulic cylinder)
suitable alternative for limiting oversized feed. A
for possible damage.
hydraulic hammer can be used for breaking
oversized material and is recommended if such
problems are foreseen.

4.4.3 Packing 4.5 RE-STARTING A CRUSHER STALLED

UNDER LOAD
The Crusher should never be operated when the

feed is packing in the crushing cavity (i.e. when the A stalled Crusher MUST be treated as possibly
feed packs in such a way that it cannot be reduced being jammed and therefore a potential hazard.
in size), as this results in a drastic reduction of the Clear the plant area of all personnel. Notify the
Crusher lifetime. manager or his deputy of a stalled Crusher situation
immediately.
WARNING!
Never operate the Crusher when the WARNING!
feed is packing in the cavity. This will Any inspection of the crushing cavity
result in a drastic reduction of the must be carried out from underneath the
Crusher lifetime. Crusher, not from above. Tramp iron
could be ejected from the crushing
cavity. Serious personal injury can
When packing occurs, the: result.
1. Crusher speed slows down. Find out why the Crusher stalled. If, after careful
2. Engine speed slows down. examination, there appears to be no electrical or
mechanical reason why the Crusher has stalled, it
3. Load of the Crusher rises. would indicate that the Crusher is jammed by the
4. The Crusher is overloaded. ingress of foreign matter and is in a hazardous state.
If a Crusher stalls under load any stored energy
within a mechanism due to tramp material can be
Packing can occur due to the following reasons: reduced to insignificant level by ensuring that the
jaws are moved to the open position. After that start
the Crusher. If the Crusher won't start, repeat this
1. There is too much fines in the feed material. procedure. When the jaws are fully open, don't start
2. The maximum feed size relative to the feed the Crusher anymore. In this case stones and tramp
opening is very small (less than 50 % of the metal must be removed from the Crusher manually.
feed opening width).
3. The material is very brittle and readily
WARNING!
breaks into fines (material characteristics).
4. Wet feed material. Always note the position of the gib
keys to determine if the crusher is "at
5. Incorrect jaws. rest" or if there is potential energy
remaining in the flywheels.
To prevent packing, all possible causes must be

addressed. If, however, the causes cannot be
eliminated, the material level in the Crusher cavity
must be lowered and/or the Crusher setting must be
increased.

4.6 CRUSHER SETTING ADJUSTMENT

The setting adjustment of C Series Jaw Crushers is WARNING!
done either by means of moving two wedges
against or away from each other or optionally with Turning the cap nuts should be made
a hydraulic control system. with the ratchet provided with the
Crusher. NO HYDRAULIC OR
4.6.1 Mechanical Wedge Setting PNEUMATIC WRENCH MAY BE
Adjustment USED
The movement of the wedges changes the effective
thickness "s" of the wedge pair, which in turn
increases or decreases the Crusher setting, WARNING!
respectively. The wedges are self-restraining and
The setting adjustment may be done mechanically their surfaces must not be lubricated. It
by turning cap nut(s) manually, or alternatively may overload the adjusting mechanism.
hydraulically (option) through the use of an
electrical control panel. For instructions concerning
the hydraulic setting adjustment (option), refer to To change the setting, the locking nuts of the
chapter 4.6.2. tension rod must be loosened, and then the cap nuts
must be turned clockwise or counterclockwise to
The main components of the device are the increase or decrease the Crusher setting,
adjusting wedges, cap nut(s) (2) and locking pipe(s) respectively. A single complete rotation of one cap
(3). Changing the setting requires the use of the nut has a net effect on the Crusher setting as
ratchet delivered with the Crusher (special tool) to indicated in Table 4-1. Turning both cup nuts one
turn the cap nuts. complete rotation in the same relative direction will
thus change the Crusher setting by twice as what is
indicated in Table 4-1.
Change in Setting
Model
mm (in)
C80 2.3 (0.09)
4
C95 2.2 (0.09)
C100 2.3 (0.09)
C105 4.0 (0.16)
C110 2.0 (0.08)
C115 2.3 (0.09)
C3054 2.3 (0.09)
C125 1.7 (0.07)
C140 2.3 (0.09)
C145 2.5 (0.10)
Callout Description
C160 2.2 (0.09)
1 Adjusting wedges
C200 3.2 (0.12)
2 Cap nut
3 Locking pipe Table 4-1 Average change in setting per cap nut
rotation
4 Rubber bellow
Figure 4.3 Mechanical setting adjustment

To calculate how many rotations the cap nuts must
be turned to change the Crusher setting, simply

divide the desired setting change amount by the 8. Start the Crusher and listen if the toggle
appropriate value in Table 4-1 and the quantity of plate knocks. If it knocks, contact Metso
cap nuts. Minerals.
Required Rotations = (Desired Setting 9. Start crushing.
Change)/(Crusher Change in Setting)
Round the result to the nearest higher number.
WARNING!
Example:
Always tighten and loosen the spring
To change the setting of a C125 by 10 mm from the side. Never remove the
(3/8"), turn the cap nuts as follows: protection plate
10 mm / 1.7 mm / rotation = 5.88 => 6 total
rotations => 3 rotations per cap nut
3/8" / 0.07" / rotation = 5.35 => 6 total rotations
=> 3 rotations per cap nut
4.6.1.1 Decreasing the Crusher Setting
The Crusher setting can only be adjusted while the

crusher is at rest.
1. Stop crushing, then stop the Crusher.

2. Determine how much the setting must be Figure 4.4 Mechanical wedge setting adjustment
decreased and calculate how many rotations
the cap nuts must be turned.
3. Loosen the locking nuts of the tension Tension Spring Length
Model
spring (Figure 4.4). Be careful not to drop L mm (in.)
the toggle plate as the spring gets loose. C80 310 (12 ¼")
4. Remove the locking pin from the locking C95 385 (15 ¼”)
pipe and push the pipe towards the Crusher. C100 370 (14 ½")
C105 365 (14 ¼")
5. Turn the cap nuts COUNTERCLOCKWISE.
Make sure that both wedges are adjusted C110 365 (14 ¼")
equally so that their position in relation to C115 365 (14 ¼")
the Crusher remains the same. If you have to C3054 440 (17 1/3")
change the setting remarkably, turn the cap
C125 425 (16 ¾")
nuts for a while and loosen the spring
locking nuts again if necessary. There are C140 540 (21 ¼")
washers fastened to the rear end of the C145 540 (21 ¼")
adjusting wedges. When decreasing the C160 540 (21 ¼")
setting, push the wedges only until these C200 540 (21 ¼")
washers are against the guide plates.
6. Lock the pipes with the pin. Table 4-2 Tension Spring Operating Length
7. Adjust the spring length according to

Table 4-2 (see Figure 4.4).

4.6.1.2 Increasing the Crusher Setting 4.6.2 HYDRAULIC WEDGE SETTING

ADJUSTMENT (OPTIONAL)
The Crusher setting can only be adjusted while the

crusher is at rest. IMPORTANT!
The hydraulic setting adjustment system
1. Stop crushing, then stop the Crusher. in the Lokotrack is different from the
system shown here. See details in the
2. Determine how much the setting must be Lokotrack manual.
increased and calculate how many rotations
the cap nuts must be turned.
3. Loosen the locking nuts of the tension Hydraulic wedge setting adjustment enables remote
spring (Figure 4.4). setting adjustments that are much quicker and
simpler as setting adjustments are made remotely
4. Remove the locking pin from the locking by operating a control panel.
pipe and push the pipe towards the Crusher.
5. Turn the cap nuts CLOCKWISE. Make sure
that both wedges are adjusted equally so that
their position in relation to the Crusher
remains the same. Be careful not to drop the
toggle plate as the spring gets loose.
6. Lock the pipes with the pin.
7. Adjust the spring length according to
Table 4-2 (Figure 4.4).
8. Start the Crusher and listen if the toggle
plate knocks. If it knocks, contact Metso
Minerals.
9. Start crushing.
Figure 4.5 Hydraulic wedge setting adjustment
WARNING!
Always tighten and loosen the spring The system is powered with an independent
from the side. Never remove the hydraulic unit, or it can be connected to a large
protection plate hydraulic system, as in the Lokotrack. The
hydraulic oil pressure forces the wedges either
towards or apart from each other, therefore
decreasing or increasing the setting, respectively.
Setting can be adjusted while the Crusher is at rest

or idling. If adjustment of setting is done during
crushing lifetime of crusher components is shorter.
For detailed information, refer to the Installation
Manual, Chp. 4.7 Installing the Hydraulic Unit.

4.6.2.1 Oil heater
The hydraulic setting adjustment power unit is

equipped with a hydraulic oil heater. The heater’s
thermostat is set to switch the heater on when the
oil temperature is below 35°C (95°F). The heater
can be switched on/off from the control panel (7,
Figure 4.6).
Use the heater for about 30 minutes before setting

adjustment when the oil temperature is below 0°C
(32°F).
4.6.2.2 Decreasing the setting
Turn the setting adjustment switch 6 (located in the

control panel) to the "decrease" position. Observe
the wedge movement. Time relay in control panel Callout Description
will stop the adjusting after 6 sec. To adjust the 1 Main switch
setting more you have to turn the switch back to 2 ON
"neutral" position and again to "decrease" position.
3 Running
4 ON
IMPORTANT! 5 Hydraulic pump
6 Setting (1 Decrease, 2 Increase)
Do not let the jaws hit each other.
7 Oil heating
Figure 4.6 Setting adjustment control panel

Adjust the setting in several stages. Check the
setting between adjustments, see the minimum 4.6.2.3 Increasing the setting
setting in chapter General Crusher Information.
After adjustment, check the pressure value in the
tension cylinder. Turn the setting adjustment switch 6 (located in the
control panel) to the "increase" position. Observe
the wedge movement. Setting adjustment may stop
if the pressure in the tension cylinder decreases. To
adjust the setting more you have to turn the switch
back to "neutral" position and again to "increase"
position.
When the setting is increased, the pressure in the
adjusting cylinder will rise automatically and the
wedges will stop for a moment.
tension cylinder.

4.6.3 HYDRAULIC CONTROL SYSTEM

SETTING ADJUSTMENT (OPTIONAL)
IMPORTANT!
The hydraulic control system works as a
Hydraulic control system setting adjustment is used safety device only in the adjustment range
in basically the same way as the hydraulic wedge of the cylinders. If the uncrashable object
setting adjustment.
is larger than the maximum setting, the
The system is powered with an independent toggle plate collapses through elastic
hydraulic unit, or it can be connected to a large buckling. (See chapter 4.7)
hydraulic system, as in the Lokotrack. The
hydraulic oil pressure moves the cylinder, which
increases or decreases the setting. 4.6.3.1 Oil heater
Setting can be adjusted while the Crusher is at rest The hydraulic setting adjustment power unit is
or idling. If adjustment of setting is done during equipped with a hydraulic oil heater. The heater’s
crushing lifetime of crusher components is shorter. thermostat is set to switch the heater on when the
oil temperature is below 35°C (95°F). The heater
can be switched on/off from the control panel (7,
Figure 4.6). Use the heater for about 30 minutes
before setting adjustment when the oil temperature
is below 0°C (32°F).
4.6.3.2 Decreasing the setting

control panel) to the "decrease" position. Time
relay in control panel will stop the adjusting after 6
sec. To adjust the setting more you have to turn the
switch back to "neutral" position and again to
"decrease" position.
IMPORTANT!
Figure 4.7 Hydraulic control system Do not let the jaws hit each other.
The hydraulic control system also functions as a
safety device. If there are any uncrushable objects
in the jaw cavity, the pressure in the cylinders rises. Adjust the setting in several stages. Check the
When the pressure rises over a pre-set value, the setting between adjustments, see the minimum
pressure relief valves open and let the piston move setting in chapter General Crusher Information.
backwards. The crusher setting opens and the After adjustment, check the pressure value in the
uncrushable material can exit the jaw cavity. tension cylinder.
In a Lokotrack, after the uncrushable material has 4.6.3.3 Increasing the setting
left the cavity, the setting returns to where it was.
control panel) to the "increase" position. Observe
the wedge movement.
tension cylinder.

4.7 TOGGLE PLATE

WARNING!
For spontaneous overloading or uncrushable Do not lubricate the toggle seats, toggle
objects that are larger than the Crusher setting, such plate or toggle plate ends. This area of
as excavator bucket teeth, the Crusher is equipped the crusher is designed to operate
with a toggle plate that serves as a safety device. In without lubrication.
the event of overloading, the toggle plate collapses
through elastic buckling, frequently preventing
damage to more costly parts. WARNING!
Always use original Metso Minerals
IMPORTANT! toggle plates. Toggle plate design and
manufacturing is more complicated than
Note that the toggle plate is designed to most people think. Using a toggle plate
buckle when overload events occur in the that is not manufactured by Metso
lower half of the crushing cavity. The Minerals will put the Crusher at risk and
toggle plate will not buckle if the crusher will void the Crusher's warranty.
is overloaded due to oversized feed or an
inadequate feed arrangement. Thus, in
these cases, certain crusher components Check the condition of the seats and protection
such as the eccentric shaft, flywheels, rubber regularly during weekly maintenance. They
bearings and bearing housings will be must be kept clear of dust and dirt. If dust has
unnecessarily loaded. entered the seat surfaces, flush with running water.
If there is no water available, compressed air may
be used. It is important that dust doesn't enter these
IMPORTANT! areas and contaminate seat surfaces.
Although the toggle plate is designed to
protect the more expensive Crusher
components, certain overload events are Toggle plate and seat installation and removal
described in Maintenance chapter.
often so violent in nature that it is possible
for other components such as the tension
spring, tension rod and tension spring
bracket to fail when the toggle plate
buckles
IMPORTANT!
Toggle plate is not protecting crusher
components of fatigue damages when
crusher is continuously overloaded with
smaller setting than allowed by Metso
Minerals’
The function of the toggle seats is based upon a

rolling concept against the roll-shaped surfaces
with different radii against each other. Therefore
the toggle seats should be kept dry and must not be
lubricated.

4.8 SPACER minimum allowed settings (see the Crusher Setting

section).
Qualitatively, the use of the spacer reduces both the
A spacer may be placed between the lower
Crusher's minimum and maximum setting. Refer to
adjusting wedge and the toggle seat holder (not
the Crusher parts book for details concerning the
applicable to all models and models with the
effect of the spacer on the Crusher setting range for
hydraulic control system). The use of the spacer
a specific jaw profile.
makes it possible to use two different Crusher
setting ranges, but its use does not permit that the Spacer installation and removal instructions can be
Crusher is used with settings smaller than the found in Maintenance chapter.
Callout Description
1 Spacer
Figure 4-8 Spacer

4.9 TROUBLESHOOTING
PROBLEM CAUSE REMEDY

Toggle plate falls out of Feed material is too large. Feed the Crusher with proper size material. Make sure
seat. the feed hopper's rear wall is properly designed.
Tension spring too loose. Tighten the tension spring.
Material fed directly onto Material must be fed into the crushing chamber
the upper pitman cover. without hitting the upper pitman cover. Make sure the
feed hopper's rear wall is properly designed.
Tension cylinder Check the pressure.
hydraulic pressure too
low.
Toggle plate seating Tension spring too loose. Tighten the tension spring.
surfaces wear
prematurely.
Toggle plate breaks Feed material is too small. Feed the Crusher with proper size material.
(buckles).
Tramp iron or other Empty the crushing chamber to remove tramp iron or
uncrushable material other uncrushable material.
caught near the bottom of
the crushing chamber.
Toggle plate not installed When installing the toggle plate, inspect the toggle
correctly. seats for good condition and smooth, even surfaces.
Feed hopper has Feed material is being RESTRICT FEED! Feed to keep the chamber 2/3 full
loosening or breaking crushed too high in the with proper size material for greatest efficiency.
bolts. chamber.
Bolt fastener not applied to Apply bolt fastener.
the feed hopper bolts.
Jaw bolts loosening or Incorrect jaws installed. Use Metso Minerals jaws.
breaking.
Jaws installed Re-install the jaws.
incorrectly.
Insufficient capacity. Feed too large. Check for proper feed size.
Wrong direction of flywheel Make sure the flywheels turn in the correct direction.
rotation.
Incorrect speed. Check for proper speed.
Discharge setting too Increase the discharge setting.
small.
Jaws worn excessively. Replace the jaws.
Loose jaws. Tighten the jaw bolts.
Wrong jaw profile. Consult your Metso Minerals representative.
Stalled Crusher. Large rock or tramp iron Remove stuck material. DO NOT USE EXPLOSIVES
jammed in the crushing TO CLEAR A STALLED CRUSHER!
chamber.
Discharge setting is too Each Crusher has a minimum recommended setting.
small. DO NOT use a smaller setting unless authorized by
Metso Minerals.
Power failure. Check all fuses in the motor electrical control panel.

PROBLEM CAUSE REMEDY

Motor failure. Check the motor.
Damaged and/or loose Check the condition of the V-belts.
V-belts.
Excessive vibration. Wrong speed. Operate the Crusher at the recommended speed.
Flywheels loose. Tighten the flywheels properly. Weld the bolts together
with plates to prevent them from coming loose.
Flywheel aligned with the Remount the flywheel with the appropriate keyway
wrong keyway (gibkey) (gibkey).
during assembly.
Counterweights Consult your Metso Minerals representative.
incorrectly installed.
Bearings too hot. Bearings damaged. Consult your Metso Minerals representative.
Too much or insufficient Use correct quantity of grease for each bearing. Seat
grease. a schedule for greasing of the bearings.
Incorrect crusher speed. Check the Crusher's speed.
Crusher operating at a Each Crusher has a minimum recommended setting.
smaller setting than DO NOT use a smaller setting unless authorized by
recommended. Metso Minerals.
Crusher not level. Check or re-level the Crusher.
Feeding the Crusher with Feed the Crusher with proper size material.
very fine material.
Crusher speed varies. Damaged and/or loose Check the condition of the V-belts.
V-belts.
Inadequate plant voltage Check the plant's voltage level.
level.
A "knocking" is heard Tension spring too loose. Tighten the tension spring.
while operating.
Toggle plate improperly Check the toggle plate and seats for wear.
seated.
Loose jaws. Tighten the jaw bolts.
Jaws hitting each other. Check the Crusher's discharge setting.
Tension cylinder Check the pressure.
hydraulic pressure too
low.
Movement of the jaws. Loose jaws. Tighten the jaw bolts.
Inadequate clearance. Check that the clearance between the upper and
lower jaws is between 5-8 mm (3/16-5/16").
Centralizing lug worn Repair the lug.
out.
Adjusting wedges don´t Wedge surfaces worn. Drop a couple of small stones to cavity to decrease
move friction between wedges.
Hydraulic control The seals are leaking. Check the possible oil leaks. Contact your Metso
system: The setting Minerals representative.
opens by itself. There is
no uncrushable material
in the cavity.
Feed material is too small. Feed the crusher with proper size material.

MAINTENANCE CHAPTER 5
5.1 SPACER 5.1.1 Spacer Installation
A spacer is only used in crushers with wedge
setting adjustment.
1. Open the crusher’s setting to maximum
A spacer may be placed between the lower
adjusting wedge and toggle seat holder
(Figure 5.1). Use of the spacer makes it possible to
use two different crusher setting ranges. Never use
a setting smaller than the minimum allowed setting
even using the spacer.
After installing or removing the spacer the crusher
setting must be adjusted (also when using hydraulic
setting adjustment).
Before you operate the machine make sure that
there is no clearance between the upper and lower
wedge. When using the spacer make sure there is
no clearance between the spacer and adjusting
wedges.
IMPORTANT!
After installing or removing the spacer the
Crusher setting and the spring tension
must be adjusted. 2. a. Hydraulic setting:
In the valve unit, release the hydraulic pressure
from the return cylinder by turning the knob of
the shut-off valve (1) counter-clockwise. You
can check the pressure level from the pressure
gauge (2).
Figure 5.1 Spacer makes it possible to use two

different crusher setting ranges

CHAPTER 5 - MAINTENANCE
2b. Mechanical setting:

Loosen the tension spring in order to be able to 5. Insert the spacer between the front wedge
move the pitman. and toggle seat holder by inserting the
spacer through the side plate hole.
3. Use a come-along in order to retract the
pitman. Attach on shackle to the bottom of
the front frame and another shackle to the
WARNING!
back of the pitman. Use these shackles to
support the ends or hooks of the Always tighten and loosen the spring
come-along. Make sure that both ends (or from the side. Never remove the
hooks) are properly secured. protection plate
4. Inch the come-along until the lower

adjustment wedge touches the washers (or
the jaws contact each other).
6. Release the pitman and remove the
IMPORTANT! come-along and shackles.
Be careful not to drop the toggle plate. 7. a. Hydraulic setting:

Pressurize the return cylinder by turning the
knob of the shut-off valve clockwise in the

valve unit (check the pressure level from the

pressure gauge).
7 b. Mechanical setting:
Fasten the locking nuts of the tension spring.
Adjust the tension spring length.
IMPORTANT!
After installing or removing the spacer the
Crusher setting and the spring tension
must be adjusted
5.1.2 Spacer Removal

1. When removing the spacer pull the setting
adjustment wedges as far out as possible.
Secure the wedges so that they do not slide
down when spacer is being removed.
3. Loosen the tension rod spring to make it

possible to move the pitman.
2. Make sure that the toggle plate does not fall

down.

4. Pull the pitman forward with a winch. 5.2 TOGGLE PLATE

Remove the flange from the end of the
spacer. Then pull the spacer out. 5.2.1 Replacing the Toggle Plate And
Toggle Seats (with wedge setting
adjustment)
If the toggle plate has to be replaced, it is
recommended that the following steps be followed:
1. Open the crusher's setting to maximum.
2. Remove all necessary covers.

3. Attach and tighten lifting hooks (3, fig
below) to the toggle plate on both sides.
4. Attach the chain of a come-along to the
toggle plate lifting tool (3, fig below) and
upper end for example to the eyebolt of the
pitman (4, fig below).
5. Tension the come-along so that the toggle

plate does not drop.

6. Support the lower setting adjustment wedge 7 b. Mechanical setting:

to its position by using a proper sling. Make
Remove the locking nuts of the tension spring
sure that the sling is properly tensioned. (fig below).
WARNING!
Always tighten and loosen the spring
from the side. Never remove the
protection plate
7. a. Hydraulic setting:
In the valve unit, release the hydraulic pressure
from the return cylinder by turning the knob of
the shut-off valve (1, fig below) 8. a. Hydraulic setting:
counterclockwise. You can check the pressure
Unfasten the return cylinder from the pitman.
level from the pressure gauge (2, fig below).
8 b. Mechanical setting:
Unfasten the tension rod from the pitman.
9. Use the come-along in order to retract the
pitman. Attach one shackle to the bottom of
the front frame and another shackle to the
back of the pitman. Use these shacles to
support the ends or hooks of the
come-along. Make sure that both ends (or
hooks) are properly secured (fig below).
10. Inch the come-along until the toggle plate is

loose.
11. Lower the toggle plate on to the discharge
conveyor belt and take it out.
12. Check the condition of the toggle seats and
other related components.

13. Replace the toggle seats if they are

damaged.
Tension Spring Length L
14. Install the new toggle plate and release the Model
mm inch
pitman.
C80 310 12 ¼
15. Remove lower adjusting wedge support. C95 385 15 ¼
16. a. Hydraulic setting: C100 370 14 ½
Attach the return cylinder to the pitman and C105 365 14 ¼
pressurize the hydraulic return cylinder C110 365 14 ¼
16 b. Mechanical setting: C115 365 14 ¼
C3054 440 17 1/3
Attach the tension rod to the pitman and fasten
the locking nuts of the tension spring. C125 425 16 ¾
Adjust the tension spring length according to C140 540 21 ¼
Table 5.1 C145 540 21 ¼
17. Remove the toggle plate lifting tool. C160 540 21 ¼
C200 540 21 ¼
Table 5.1 Tension spring operating length
5.2.2 Replacing the Toggle Plate And

Toggle Seats with Hydraulic Control
System
If the toggle plate has to be replaced, it is

recommended that the following steps be followed:
1. Open the crusher's setting to maximum.
2. Remove all necessary covers.
3. Attach and tighten lifting hooks (3, fig
below) to the toggle plate on both sides.
4. Attach the chain of a come-along to the
toggle plate lifting tool (3, fig below) and
upper end for example to the eyebolt of the
pitman (4, fig below).
5. Tension the come-along so that the toggle
Callout Description
plate does not drop.
1 Lifting tool 6. Ensure that the pistons cannot move.
2 Chain block 7. In the valve unit, release the hydraulic
3 Protection rubber pressure from the return cylinder by turning
4 Chain block the knob of the shut-off valve (1, fig below)
counterclockwise. You can check the
Figure 5.2 pressure level from the pressure gauge (2,
fig below).
8. Unfasten the tension cylinder from the
pitman.

9. Use the come-along in order to retract the • Appropriate for cold temperatures
pitman. Attach one shackle to the bottom of (-30ºC/-22ºF) and hot temperatures
the front frame and another shackle to the (continuous operating temperatures of
back of the pitman. Use these shackles to +100ºC/212ºF).
support the ends or hooks of the
• Good resistance to water
come-along. Make sure that both ends (or
hooks) are properly secured (fig below). • The grease must not oxidize easily and it must
10. Inch the come-along until the toggle plate is contain EP-additives.
loose.
11. Lower the toggle plate on to the discharge Some of the recommended lithium based grease
conveyor belt and take it out. brands are as follows. Other grease brands with
12. Check the condition of the toggle seats and similar characteristics may be used as well.
other related components.
13. Replace the toggle seats if they are Brand Type
damaged.
CASTROL APS 2
14. Install the new toggle plate and release the BP Energrease LS-EP 2
pitman.
ESSO Beacon EP 2
15. Release the pistons. GULF Gulfcrown Grease EP 2
16. Attach the return cylinder to the pitman and MOBIL Mobilux EP 2
pressurize the hydraulic return cylinder SHELL Alvania Grease EP 2
17. Remove the toggle plate lifting tool. SKF LG EP 2
Table 5.2 Recommended grease brands
5.3 LUBRICATION
WARNING!
5.3.1 GENERAL Do not use grease types containing
The appropriate lubrication of your crusher is of molybdenum or calcium as their solid
outmost important. To ensure that your crusher is components cause additional wear in the
bearings and thus decrease bearing
appropriately lubricated at all times, follow the
instructions provided in this chapter diligently. lifetime.
5.3.2 Grease Specifications WARNING!

C Series crushers are not designed to
operate at temperatures lower than
For lubrication points, lithium-based multi-purpose -30ºC/-22ºF. Should operating
grease with the following characteristics is temperatures be lower than -30ºC/-22ºF,
required: contact Metso Minerals.
• NLGI-class of 2 Metso Minerals does not recommend that different

• Minimum viscosity of the base oil must be 160 brands of grease are mixed. When in doubt, please
mm2/s (cSt) in +40ºC/104ºF with a minimum contact Metso Minerals.
viscosity-index 80.

5.3.3 Eccentric Shaft Bearings through four grease fittings. Refer to Figure 5.3 and
Figure 5.4.
Lubrication of the jaw crusher spherical roller

bearings is accomplished by using a manual type
grease gun or an automatic lubricating system
Figure 5.3 Lubrication of jaw crusher spherical roller bearings with grease gun


1 Pump unit 2 Distributor unit
Figure 5.4 Lubrication of jaw crusher spherical roller bearings using automatic lubricating system
During operation there is always a very slight and frequency of bearing grease requirements. The
working of the grease out through the pitman and amount of grease required and the length of time
frame bearings and adjacent labyrinth seals. between greasings will vary in accordance with
Movement of the grease out of the bearing and the operating conditions.
adhering of grease outside the seal, protects the Before greasing the bearings, thoroughly clean the
bearing and seal from foreign particles. By area around each grease fitting before removing the
observation of this grease working action, the
cover from the fitting. If the grease gun method of
operator will soon be able to estimate the amount

lubrication is used, add the grease immediately

after shut down while the bearings are still warm.
Refer to the Lubrication Schedule in Table 5.3.
Manual Lubrication Automatic Lubrication
Normal Conditions Very Dusty Conditions All Conditions
Model (every 80 hours) (every 40 hours) (continous)
Grease Amount/Nipple Grease Amount/ Nipple Grease Amount g/h
grams (oz.) grams (oz.) (oz./h)
C80 60 (2.1) 30 (1.1) 1.1 - 1.8 (.04 - .06)
C95 125 (4.4) 63 (2.2) 2.0 - 3.4 (.07 - .11)
C100 175 (6.1) 88 (3.1) 2.9 - 4.8 (.1 - .17)
C105 125 (4.4) 63 (2.2) 2.0 - 3.4 (.07 - .11)
C110 175 (6.1) 88 (3.1) 2.9 - 4.8 (.1 - .17)
C115 175 (6.1) 88 (3.1) 2.9 - 4.8 (.1 - .17)
C3054 175 6.1) 88 (3.1) 2.9 - 4.8 (.1-.17)
C125 250 (8.8) 125 (4.4) 3.9 - 6.5 (.14 - .23)
C140 300 (10.5) 150 (5.3) 4.7 - 7.8 (.16 - .27)
C145 300 (10.5) 150 (5.3) 4.7 - 7.8 (.16 - .27)
C160 400 (14) 200 (7) 5.9 - 9.8 (.2 - .34)
C200 500 (17.5) 250 (8.8) 7.7 - 12.9 (.27 - .45)
Table 5.3 Lubrication schedule of eccentric shaft bearings
WARNING! WARNING!
Avoid using too much grease as C Series crushers are not designed to
excessive grease will cause overheating operate at temperatures lower than
and shorten the bearing life. -30ºC/-22ºF. Should operating
temperatures be lower than -30ºC/-22ºF,
contact Metso Minerals.
5.3.4 Eccentric Shaft Bearing
Temperatures
WARNING!
Bearing temperature should be checked frequently
and greasing accomplished immediately if an If temperature sensors are not installed
unusual temperature rise is noted. During on the crusher, temperature reading
operation, bearings will feel warm to the touch but must be done when the crusher is at rest.
it should always be possible to touch them for a few
seconds without discomfort to the hand. Normal
bearing operating temperature is 40-70°C
(104-158°F). Should operating temperature reach
75°C (167°F) or in very warm conditions 90°C
(194°F) a check should be made to determine the
cause. A check should also be made, if one bearing
is over 10-15°C (18-27°F) warmer than the other
bearings.

5.3.5 Jack-shaft Bearings lubrication is used, add the grease immediately

after shut down while the bearings are still warm.
When applicable, the jack-shaft bearings must be
Refer to the Lubrication Schedule in Table 5.4.
lubricated manually with a grease gun. Before
greasing the bearings, thoroughly clean the area
around each grease fitting before removing the
cover from the fitting. If the grease gun method of
Figure 5.5 Jack-shaft bearings lubrication
Normal Very Dusty

Conditions Conditions
Normal Very Dusty (every 80 (every 40
Conditions Conditions hours) hours)
(every 80 (every 40 Model
hours) hours) Grease
Model Grease
Amount/
Grease Amount/Nipple
Grease Nipple
Amount/ grams (oz.)
Amount/Nipple grams (oz.)
Nipple
grams (oz.) C125 70 (2.5) 35 (1.2)
grams (oz.)
C80 40 (1.4) 20 (0.7) C140 70 (2.5) 35 (1.2)
C95 40 (1.4) 20 (0.7) C145 70 (2.5) 35 (1.2)
C105 40 (1.4) 20 (0.7) C160 80 (2.8) 40 (1.4)
C110 70 (2.5) 35 (1.2) C200 80 (2.8) 40 (1.4)
C115 55 (2) 28 (1) Table 5.4 Lubrication schedule of jack-shaft
C3054 55 (2) 28 (1) bearings

WARNING! Thrust Bearings Cap Nut(s)

Avoid using too much grease as Model Grease Grease Amount/
excessive grease will cause overheating Amount/Nipple Nipple
grams (oz.) grams (oz.)
and shorten the bearing life.
C80 n/a 20 (0.7)
C95 20 (0.7) 20 (0.7)
5.3.6 Jack-shaft Bearing Temperatures C105 20 (0.7) 20 (0.7)
C110 20 (0.7) 20 (0.7)
C115 20 (0,7) 20 (0,7)
Bearing temperature should be checked frequently
C3054 20 (0.7) 20 (0.7)
and greasing accomplished immediately if an
unusual temperature rise is noted. During C125 20 (0.7) 20 (0.7)
operation, bearings will feel warm to the touch but C140 20 (0.7) 20 (0.7)
it should always be possible to touch them for a few C145 20 (0.7) 20 (0.7)
seconds without discomfort to the hand. Normal C160 20 (0.7) 20 (0.7)
bearing operating temperature is 40-70°C C200 20 (0.7) 20 (0.7)
(104-158°F). Should operating temperature reach
75°C (167°F) or in very warm conditions 90°C Table 5.5 Lubrication schedule of thrust
(194°F) a check should be made to determine the bearings
cause.
5.3.8 Electric Drive Motor

WARNING!
If temperature sensors are not installed
on the crusher, temperature reading For instructions, refer to the motor documentation
must be done when the crusher is at rest. that has been provided with the crusher.
5.3.7 Thrust Bearing And Cap Nut Bearings 5.3.9 Toggle Seats And Toggle Plate
This only applies to crushers equipped with WARNING!

mechanical setting adjustment. The turning cap
nut(s) and the thrust bearing must be manually Do not lubricate the toggle seats, toggle
plate or toggle plate ends. This area of
lubricated in accordance with the following
Lubrication Schedule (Table 5.5). the crusher is designed to operate
without lubrication

Figure 5.6 Do not lubricate the toggle seats, toggle plate or toggle plate ends

5.3.10 Setting Adjustment Wedges 5.4 INSTRUCTIONS FOR LIFTING A JAW

CRUSHER WHEN REPLACING CRUSHER
SUPPORT BRACKET DAMPERS
CAUTION!
Do not lubricate the setting adjustment Two crusher lifting brackets (if applicable) are used
wedges. This area of the crusher is to lift a jaw crusher when replacing crusher support
designed to operate without lubrication. bracket dampers.
Water or dust suppression spray mists
must be kept away from this area of the The crusher is lifted one side at a time. For location
Crusher. of the crusher lifting bracket in relationship to the
crusher, refer to Figure 5.7.
1. Loosen and remove stop block bolts and
rubber dampers.
2. Fasten the lifting brackets with bolts to
crusher support bracket.
NOTE: Make sure that the lifting bracket bolts are
properly tightened before attempting to lift the
crusher.
3. Once the lifting brackets are secured to the
crusher brackets, place a hydraulic jack
(cylinder) under each lifting bracket.
NOTE: Make sure that the jacks that were selected
are capable of lifting the crusher weight.
4. Once desired height is achieved to remove
worn dampers, block the crusher with timber
or steel blocks.
NOTE: Do not attempt to remove the worn
dampers before the crusher is properly blocked.
5. Remove worn dampers and replace with
new.
6. Remove the blocks.
7. Simultaneously lower the crusher on the
dampers.
8. Remove the jacks and crusher lifting
brackets.
9. Repeat the procedure on the opposite side.

3
1

1 Lifting bracket 3 Washer
Hydraulic cylinder (not a part of the
2 Bolt 4
delivery)
Figure 5.7

5.5 HYDRAULIC SETTING ADJUSTMENT Hydraulic setting adjustment system relief valve
POWER UNIT (OPTIONAL) pressure settings and pressure accumulator filling
pressures are shown in Table 5.8.
The hydraulic setting adjustment is powered with

an independent hydraulic power unit, or it can be 5.5.1 Checking oil level and temperature
integrated to an extensive hydraulic system, as in
the Lokotrack.
Hydraulic power unit produces oil flow to the Hydraulic oil level can be checked from sight glass
adjusting cylinders and keeps the correct pressure (3) on the tank's front panel. Oil level is correct
level in the tension cylinder. when the oil level is visible in the sight glass.
Hydraulic setting adjustment system has a dump The glass also houses a thermometer showing the
valve, which automatically releases the tension temperature of the oil in the tank.
cylinder pressure when the crusher is stopped. This
helps adjustment wedges to move smoother.
5.5.2 Changing oil and filter (Figure 5.8)
This function is tightly limited to take place only
when the crusher is completely stopped. After the
power of the crusher motor is switched off, time Change oil and the filter in the hydraulic unit for
relay prevents valve to open until preset time the first time after 100 operating hours. After that
(Table 5.6). This prevents pressure release while the oil and the filter must be changed at 1000 hour
the crusher is coasting down. The pressure release intervals or at least twice a year.
while crusher is rotating will cause the drop of the
toggle plate. • Stop the crusher and wait until it is completely
stopped.
• Turn off and lock out power from main switch
Model Time relay setting (min) (located in the control panel).
C80 2
• Remove cover of the hydraulic power unit.
C95 2
C100 2 • Blow off the dust on the unit using pressurized
air.
C105 2
C110 2 • In the valve unit, release the hydraulic pressure
C115 2 from the tension cylinder by turning the knob
of the shutoff valve (1) counterclockwise. You
C3054 2
can check the pressure level from the pressure
C125 3 gauge (2). Remember to shut the pressure
C140 3 gauge valve after checking.
C145 3
• Drain oil by removing the drain plug (5).
C160 4
C200 7 • Loosen the filter cover (4) screws.
• Pull the cover out carefully. Observe the filter
Table 5.6
assembly when it is dismantled for the first
time.
WARNING! • Pull the filter cartridge out. If possible, clean
the filter base groove. Protect the filter housing
Only authorized personnel can adjust from contamination when changing filter
relief valves and refill the accumulator.
cartridges.
• Install a new cartridge.

• Check the seal surfaces and renew seal if 5.5.3 Oil recommendation
necessary.
• Replace the cover carefully, so that the Oil amount in the hydraulic unit is:
cartridge settles into the correct position.
– 40 litres (10½ gal) in all crushers other
• Fill the oil tank with new oil. Oil amount is: than C200
– 40 litres (10½ gal) in all crushers other – 125 litres (33 gal) in C200
than C200
Use only high quality hydraulic oil with good
– 125 litres (33 gal) in C200 resistance to corrosion, water, air and foam. The oil
• Tighten the pressure relief knob (1). must not oxidize easily. The minimum viscosity
index is 100.
• Turn the main switch on and check the
pressure level of the tension cylinder from Suitable brands are listed in Table 5.7.
pressure gauge (2). Correct pressure values are
Ambient Ambient
shown in Table 5.8. Remember to shut the
temperature temperature
pressure gauge valve after checking. -30...+25°C -10...+60°C
• Check the oil level. (-22...+77°F) (+14...+140°F)
BP Bartran HV 32 Bartran HV 46
ESSO Univis N 32 Univis N 46
SHELL Tellus oil T 32 Tellus oil TX 46
Tebo hydraulic lift Tebo hydraulic lift
TEBOIL
32 46
MOBIL DTE 24 DTE 25
CASTROL Rando HD 32 Rando HD 46
Table 5.7 Suitable oil brands
Figure 5.8 Hydraulic power unit

Tension cylinder Tension cylinder Pressure

Pressure relief
Model lower limit bar upper limit bar accumulator filling
valve bar (PSI)
(PSI) (PSI) pressure bar (PSI)
C80 80 (1160) 100 (1450) 70 (1015) 120 (1740)
C95 100 (1450) 115 (1670) 80 (1160) 125 (1815)
C100 135 (1960) 155 (2250) 100 (1450) 170 (2465)
C105 135 (1960) 155 (2250) 100 (1450) 170 (2465)
C110 135 (1960) 155 (2250) 100 (1450) 170 (2465)
C115 135 (1960) 155 (2250) 100 (1450) 170 (2465)
C3054 135 (1960) 155 (2250) 100 (1450) 170 (2465)
C125 80 (1160) 100 (1450) 70 (1015) 120 (1740)
C140 135 (1960) 155 (2250) 100 (1450) 170 (2465)
C145 135 (1960) 155 (2250) 100 (1450) 170 (2465)
C160 90 (1305) 105 (1520) 75 (1090) 125 (1815)
C200 100 (1450) 120 (1740) 85 (1230) 145 (2100)
Table 5.8 Tension cylinder and accumulator pressures
Tension cylinder Tension cylinder Pressure

Pressure relief
Model lower limit bar upper limit bar accumulator filling
valve bar (PSI)
(PSI) (PSI) pressure bar (PSI)
C95 100 (1450) 150 (2175) 80 (1160) 170 (2465)
Table 5.9 Tension cylinder and accumulator pressures for crushers with hydraulic control system
5.5.4 Bleeding the hydraulic system WARNING!

Oil can splash.
Air in the hydraulic system can be bled with the Use eye protection and safety gloves.
following procedures. When installing the adjusting
cylinders, tension cylinder and pipes/hoses must be
properly filled with hydraulic oil. Observe oil level
CAUTION!
during bleeding and add oil if necessary.
Read the oil supplier’s safety
Recover all hydraulic oil coming out from the
instructions before handling hydraulic
system during bleeding. Waste it properly.
oil. Beware of hot oil!
WARNING!
Air in the tension cylinder may cause
the toggle plate fall down.

Bleeding the tension cylinder when the cylinder 6. Ask an assistant to turn the hydraulic power
is removed for maintenance or is new: unit on and observe the oil coming out from
the system. Recover the oil to a container
1. Place the tension cylinder and the pressure
and waste it properly.
accumulator beside the crusher. Turn hose
couplings upwards and the piston rod end of 7. Wait until the oil has no air bubbles in it and
the cylinder higher than the other end. tighten the screw immediately.
2. Push the piston rod fully in.
3. Fill the cylinder, accumulator and hoses
with new hydraulic oil. Prevent
contamination.
4. Connect the hoses and disconnect the C-line
from the hydraulic power unit (refer to the
Installation Manual, fig. 4-11 and 4-12).
Plug the C-line hose by the power unit.
Prevent contamination.
5. Install the accumulator and the tension
cylinder’s cap end to the rear frame.
6. Ask an assistant to unplug the C-line hose
and pull the piston rod of the tension
cylinder out enough to install it to pitman.
Use a come-along if needed. The oil coming
out from the C-line hose must be recovered
and wasted properly. The hose must be
connected to the power unit immediately Figure 5.9 Pressure accumulator vent screw
after the rod is out enough.
7. Install the rod end of the tension cylinder.
Bleeding the adjusting cylinders:
1. Stop the crusher and wait until it is
Bleeding the tension cylinder when the cylinder completely stopped.
has not been removed.
2. Adjust the setting to maximum.
3. Slightly loosen the hoses at the inner ends of
completely stopped.
the adjusting cylinders. Recover the oil to a
2. Turn off the hydraulic unit power from the container and waste it properly.
main switch (located in the control panel).
4. Turn the setting adjustment switch to the
3. Make sure that the toggle plate does not "decrease" position. Observe the oil coming
drop (See chapter 5.2.1). from the hose. Tighten the hoses when the
4. In the valve unit, release the hydraulic oil has no air bubbles in it.
pressure from the return cylinder by turning 5. Slightly loosen the hoses at the outer ends of
the knob of the shutoff valve (Figure 5.8: 1) the adjusting cylinders. Recover the oil to a
counterclockwise. You can check the container and waste it properly.
pressure level from the pressure gauge
(Figure 5.8: 2). Remember to shut the
"decrease" position. Observe the oil coming
pressure gauge valve after checking.
from the hose. Tighten the hoses when the
5. Loosen the vent screw (Figure 5.9: 1) of the oil has no air bubbles in it. Do not let the
pressure accumulator carefully using a jaws hit each other!
10mm wrench. Do not turn the screw for
more than 8 revolutions.

Bleeding the hydraulic control system cylinders:

completely stopped.
2. Decrease the setting if it is increased.
3. Loosen the bleeding screws (Figure 5.10: 1).
"increase" position. Observe the oil coming
from the hose. Tighten the screw when the
oil has no air bubbles in it. Recover the oil to
a container and waste it properly.
Figure 5.10 Hydraulic control system vent

screws

5.6 PERIODICAL MAINTENANCE 4. Check that the protection rubber of the

toggle plate (C) is in good condition and in
5.6.1 Daily maintenance place.
5. Check the tightness of tightening rod nuts
• BEFORE STARTING (D). The washers must be in the level
with the disc spring housing 0-0,5mm
See Figure 5.11 for reference. (0-0.02").
1. Check the tension of the V-belts. See chapter 6. Clean all safety signs and ensure that they
3.8.2 Installation Manual. are legible.
2. Check the tightness of the jaw bolt nuts (A). 7. Hydraulic control system: Drive the setting
The washers must be in the level with the to the minimum and to the maximum to
disc spring housing 0-0,5mm (0-0.02") ensure the functioning of the lubrication.
3. Check the tightness of the cheek plate bolts 8. Hydraulic control system: Check for
(B), see the tightening torque in chapter 6.1. possible oil leaks.
Figure 5.11 C80, C95, C100, C110, C115, C125, C140, C145, C160, C200

Figure 5.12 C105
• DURING OPERATION 40 hours). See the required grease quantity in

Table 5.3.
Listen to the sound of the bearings and check their
temperature (max. 75°C/167°F). Check for the Lubricate the cap nut bearings of the setting
proper outflow of grease. adjustment device and check their rubber bellows
(mechanical setting adjustment), see
Check the tension and operation of the return rod,
Chapter 5.3.7 .
see chapter 4.4 - 4.7 Installation Manual.
Check the wear on the cheek plates. Change if
necessary.
5.6.2 Weekly Maintenance Check the toggle plate for alignment, straightness
and cracks.
If an automatic lubrication device is not used, Check the toggle seats and their stopper plates.
lubricate the eccentric shaft bearings (Figure 5.13). Clean or replace if necessary.
Before lubrication, the grease nipples must be Check the tightness of the frame tie bolts.
cleaned. Under normal operating conditions add
grease every 80 operating hours. Under dusty Check the mounting and condition of the flywheel
condition the frequency must be doubled (to every and the tightness of the gib keys.

Check the rubber dampers under the crusher's Check for any wear on the seating surfaces between
mounting brackets. If any damper is damaged, it the side plates and cheek plates.
should be changed. Check the hydraulic control system seals for leaks.
Check the mounting of the crusher. Replace the seals, if necessary.
5.6.3 Monthly Maintenance
Check the tightness of the frame mounting bolts on 5.6.5 Regularly
the side plates. Change oil and the filter in the hydraulic unit first
5.6.4 Twice a Year time after 100 operating hours. After that the oil
and the filter must be changed at 1000 hours
Check the condition of the eccentric shaft bearings, intervals or at least twice a year.
using e.g. a hearing device.
Check for any wear on the seating surfaces of the
pitman as well as the front frame.
Figure 5.13 Lubricate eccentric shaft bearings weekly

5.7 MAINTENANCE INTERVALS

Every 6
ITEM Daily Weekly Monthly
months
Check V-belt tension. X
Check the tightness of jaw bolts. X
Check the tightness of cheek plate bolts. X
Check wear on the jaw plates X
Check the sound, temperature (max. 75°C/167°F) and grease flow
X
in the eccentric bearings.
Lubricate eccentric shaft bearings. X
Check wear on the cheek plates. X
Check toggle plate for alignment, straightness and cracks X
Check the toggle seats and their stopper plates. Clean or replace
X
as necessary.
Check the tightness of the mounting bolts of the labyrinth covers. X
Check the tightness of the frame tie rods X
Check the mounting and condition of the flywheel and the
X
tightness of the gib keys.
Check the rubber dampers under the crusher's mounting brackets,
X
and the mounting of the crusher.
Lubricate crusher drive jackshaft (optional). X
Check the tightness of the frame mounting bolts on the side
X
plates.
Check the bearings on the eccentric shaft. X
Check for any wear on the contact surfaces of the pitman and front
X
frame.
Check for any wear on the contact surfaces between the side
X
plates and cheek plates.
Mechanical wedge setting adjustment
Check tension and operation of tension rod spring. X
Lubricate the cap nuts of the setting adjustment device X
Check the rubber covers X
Lubricate thrust bearing. X
Hydraulic wedge setting adjustment
Check the pressure of the tension cylinder. X
Check operation and oil amount (add oil if necessary). X
Change oil and filter. X
Hydraulic control system
Drive the setting to the minimum and to the maximum to ensure
X
the functioning of the lubrication.
Check for possible oil leaks. X
Check the seals for leaks. Replace the seals, if necessary. X
Automatic lubricating device
Check operation and grease amount (add grease if necessary). X

5.8 OTHER BOLT TORQUE VALUES

All other bolts must be tightened according to the
table below. Correct pretightening is possible only
with clean , unlubricated screw threads that are not
surface treated. The table applies to bolts with
property class 8.8.
Torque
Bolt
Nm kpm ft lbs
M10 47 4.8 35
M12 81 8.3 60
M16 196 20 145
M20 382 39 285
M24 662 67 490
M30 1320 135 975
M36 2310 236 1705
M42 3700 378 2730
M48 5590 570 4125
M52 7180 733 5295
M56 8960 914 6610
M64 13460 1370 9930
M72 19350 1970 14275
M80 26850 2740 19805
M100 53340 5440 39280
Table 5.10


REPLACEMENT OF WEAR PARTS CHAPTER 6
6.1 GENERAL 6.3 JAW WORK HARDENING
Before performing any maintenance or repair work, Because the wear and work hardening does not
make sure that the crusher is stopped and locked occur evenly in the crushing cavity, it is
out. recommended that the following measures are
taken to maximize the useful life of the jaws:
Nordberg C-Series crusher jaws are made from
Manganese steel which work hardens. For different
materials and applications there are different jaw – When using 2-piece jaws, and to optimize
profiles to obtain the best possible capacity to jaw the wear profile, flip the upper and lower
cost ratio.
jaws after first 50 to 200 hours. Hardness
Before lifting any wear parts, check the weight of of the feed material will dictate when to
the component and ensure that lifting equipment rotate the jaws.
being used is adequate to lift the weight. In
– Flip the upper and lower jaws after every
addition, familiarize yourself with all the special
400 to 500 operating hours (200 hours if
tools provided with the crusher specifically for
the material is very hard) to properly work
replacing the wear parts.
harden the jaws.
DANGER!
WARNING!
Before entering into the crushing cavity,
remove any loose rocks from the feed The jaw lifting tools are designed by
Metso to lift Metso manufactured jaws.
hopper and the feeder.
Metso cannot be responsible for any
personal injury or property damage,
bodily harm, or equipment damage
6.2 JAW SELECTION resulting from attempting to lift other
There are several different jaws available for the manufacturer’s jaws.
Nordberg C-Series jaw crusher. For profile details These lifting tools are sized based on the
and application guidelines contact a Metso jaw being lifted. If a customer decides to
Minerals representative. purchase a one-piece jaw instead of a
The type of jaw must be selected according to the two-piece jaw, then a different lifting
feed material and desired end product. Because of tool must be purchased to make that lift.
Never attempt to lift a jaw with a lifting
many different applications and variables, one jaw
profile is capable of performing in many tool that is intended for a lighter jaw.
applications.
If you are experiencing problems with your existing
application or would like to improve the CAUTION!
application, contact your Metso Minerals Damage to the crusher side plates,
representative. When inquiring about the correct pitman and front casting will result if
jaw profile, the following information must be the cheek plates and jaws are allowed to
provided: wear through.
1. Feed size and gradation
2. Feed type and characteristics For more detailed information on lifting
3. End product gradation accessories, see appendices A and B.
4. Capacity required
5. Options; intermediate plate, spacer
6. Crusher setting

CHAPTER 6 - REPLACEMENT OF WEAR PARTS
6.4 CHEEK PLATE REPLACEMENT 3. When the lifting tool is engaged and locked
to the cheek plate, remove the lock nuts (5),
washers (4), and bolts (3).
The lower cheek plates will normally wear before
4. Lift the upper cheek plate (1) out from the
the upper cheek plates. When the lower cheek
crusher.
plates are replaced, a small shelf may form between
the upper and lower cheek plate. This shelf may 5. Follow the above procedure for removal of
slow down the material movement through the the lower cheek plates (2).
crusher.
WARNING!
6.4.1 Cheek Plate Removal
The cheek plate lifting tools are
designed by Metso to lift Metso
To remove the cheek plate, refer to Figure 6.2 and manufactured cheek plates. Metso
proceed as follows: cannot be responsible for any personal
injury or property damage, bodily harm,
1. Loosen the lock nuts approximately 12 mm or equipment damage resulting from
(1/2”) and pull the cheek plate away from attempting to lift other manufacturer’s
the side plate,so that the cam of the lifting cheek plates.
tool can be rotated into the locked position.
(Figure 6.1).
Figure 6.1
2. Lock the lifting tool.
WARNING!
Make sure that the hoist being used is
capable of lifting the cheek plate weight.


1 Cheek plate, upper 4 Washer
2 Cheek plate, lower 5 Locking nut
3 Bolt
Figure 6.2 Cheek plate removal

6.4.2 Cheek Plate Assembly

1 Cheek plate, upper 2 Cheek plate, lower
Figure 6.3 Cheek plate assembly

To assemble the cheek plates, refer to Figure 6.3 6.5 CHANGING OR ROTATING THE JAWS
and proceed as follows:
1. Insert and lock the cheek plate lifting tool
into the cheek plate. Refer to appendix B. DANGER!
2. Align the lower cheek plate with the bolt Never place yourself or other personnel
holes. in a position beneath or adjacent to a
jaw that is not properly secured against
unintended movement.
DANGER!
Make sure e.g. with a wooden block,
that the cheek plate does not fall onto DANGER!
you.
A working platform should be installed
into the crushing cavity before entering.
3. Insert bolts and washers and tighten the nuts
so that a 12 mm (1/2”) gap exists between
the cheek plate and the side plate. NOTE: Metso’s customers have different
4. Unlock and remove the lifting tool by preferences regarding material choice and
turning the lever. configuration of their work platforms. As a result
Metso does not sell working platforms for use with
5. Tighten the cheek plate bolts to torque
the C-Series jaw crushers.
specified in Table 6.1.
Regardless of the material or configuration of the
Follow the above procedure to install the upper
working platform, it must rest securely in the jaw
cheek plate (1).
cavity, must protect the personnel against fall
hazards, and must restrain the jaws to prevent
unintended movement.
Bolt
Torque
Size
Nm kpm ftlbs WARNING!
C80 M24 216 22 160
It is the customer’s responsibility to
C95 M24 216 22 160
provide a safe working environment for
C100 M30 437 44.5 325 his employees, including safe working
C105 M24 216 22 160 platforms.
C110 M36 760 77.5 560
C115 M24 216 22 160
C3054 M24 216 22 160
C125 M36 760 77.5 560
C140 M42 1216 124 900
C145 M42 1216 124 900
C160 M48 1834 187 1355
C200 M42 1216 124 900
Table 6.1 Cheek plate bolt torques.

6.5.1 One Piece Jaws – Remove the jaw. (Figure 6.4, b)

6.5.1.1 Removal – Place the jaw on wooden blocks.
(Figure 6.5)
To remove the jaw, refer to Figure 6.4, Figure 6.5,
and Figure 6.6 and proceed as follows: NOTE: If the jaw is being rotated, before
installation make sure that all the jaw seating
1. Stationary jaw removal
surfaces are clean.
DANGER!
– Insert a working platform into the

crushing cavity.
– Remove material build up from the jaw
lifting holes.
– Remove material build up between the
stationary jaw and cheek plates.
– Insert the jaw lifting tool into the lifting
holes of the jaw, and lock it in place. Refer
to Appendix A for additional information.
DANGER!
Properly retain the jaw from unintended
movement before releasing the locking
mechanism of the lifting tool.
– Make sure the lifting hoist is capable of
lifting the weight of the one piece jaw.
WARNING!
The lifting tool’s locking mechanism
must be engaged (cammed over into the
locking position and secured with the
butterfly screw) prior to attempting to
remove any jaw locking components.
Never attempt to lift a jaw without the
lifting tool’s locking mechanism fully
engaged and in the locked position.
– Remove the hex nuts (10) and the jaw disc

spring assembly (8).
– Remove the jaw bolts (6), tightening
wedge (4) and filling wedge (3).
– Exit the crushing cavity and remove the
working platform.

a b
Figure 6.4

WARNING!
– Remove the hex nuts (10) and jaw disc
spring assembly (8) (Figure 6.6).
wedge (5), and filling wedge (3).
Figure 6.5 – Exit the crusher cavity and remove the
working platform.
– Remove the jaw (2).
2.1 Movable Jaw Removal (all jaw crusher models
except C115) Figure 6.6 – Place the jaw on wooden blocks.
(Figure 6.5)
NOTE: If the jaw is being rotated, before
DANGER! reinstallation make sure that all the jaw seating
A working platform should be installed surfaces are clean.

crushing cavity.
lifting holes.
– Remove any loose material from between
the movable jaw and cheek plates.
to Appendix A for additional information..
DANGER!
– Make sure that the lifting hoist is capable
of lifting the weight of the one piece jaw.

c d
Figure 6.6

2.2 Movable Jaw Removal C115 (Figure 6.7)
to Appendix A for additional information..
DANGER!
DANGER!
A working platform should be installed movement before releasing the locking
into the crushing cavity before entering. mechanism of the lifting tool.
– Insert a working platform into the of lifting the weight of the one piece jaw.
crushing cavity.
lifting holes.


WARNING!
The lifting tool’s locking mechanism wedge (5), and filling wedge (3).
locking position and secured with the – Exit the crusher cavity and remove the
butterfly screw) prior to attempting to working platform.
lifting tool’s locking mechanism fully – Place the jaw on wooden blocks.
engaged and in the locked position. (Figure 6.5)
NOTE: If the pitman protection plate or the
tightening wedge are worn, replace them when
WARNING!
replacing the jaw.
Make sure that the pitman protection
plate (11) is securely attached to the
pitman so that it cannot fall.
Figure 6.7

6.5.1.2 Assembly
CAUTION!
Before installing new or partially worn jaws, make
DO NOT install jaws into the crusher if
sure that the jaw and crusher cavity (front frame
the jaw seating surfaces are not straight.
and pitman) seating surfaces are cleaned. The jaws
Warped or distorted jaws can cause
must have metal to metal contact on all seating
severe damage to the crusher seating
surfaces. (Figure 6.8).
surfaces. Contact your Metso Minerals
Check the condition of the protection plate (if representative for assistance.
equipped). Replace if necessary.
NOTE: If the ends of the jaws are bent in, or

IMPORTANT! distorted, excess material must be removed to
original shape by torching before the jaws can be
When rotating the jaws, it is a good
installed.
practice to check the seating surfaces of
the jaw for straightness. This is easily
accomplished with the use of a straight
edge.
The jaw can warp or deform if the jaw is
not properly tightened, or is allowed to
wear thin while crushing.
Figure 6.8 Checking the straightness of a jaw

Figure 6.9 Jaw seating surfaces
1. Stationary Jaw Installation (Figure 6.4)

– Clean all jaw seating surfaces (Figure 6.9). DANGER!
– Insert and lock the the jaw lifting tool to A working platform should be installed
the jaw according to appendix A. into the crushing cavity before entering.
– Install the jaw into the crushing cavity,
making sure that the jaw seating surface
makes full contact with the lower wedge. – Insert the working platform into the
crushing cavity.

2. Movable Jaw Installation (Figure 6.6)

WARNING!
Properly retain the jaw from unintended IMPORTANT!
This installation and removal procedure of
the jaws is also used on a C3054 jaw
– Install the filling wedge (3), tightening crusher with one exception. The C3054
wedge (4) and jaw bolts (6). does not use the filling wedges.
– Install the disc spring assembly (8). Make – Clean all jaw seating surfaces (Figure 6.9).
sure that the disc spring stack up is – Insert and lock the jaw lifting tool to the
according to Figure 6.17. jaw according to appendix A.
– Tighten the spring assembly per
– Install the jaw into the crushing cavity.
Chapter 5.6 , and lock with double hex Make sure that the jaw seating surface has
nuts (10). full contact with the lower wedge.
– Remove the jaw lifting tool.
DANGER!
– Remove the working platform.
IMPORTANT!
– Insert the working platform into the
Check the compression of the disc springs crushing cavity.
shortly after the re-start of the jaw crusher.
Retighten the disc springs if necessary. WARNING!
– Install the filling wedge (3), tightening
wedge (5) and jaw bolts (7).
– Install the disc spring assembly (8). Make
sure that the disc spring stack up is
according to Figure 6.17.
– Tighten the spring assembly per
Chapter 5.6 , and lock with double hex
nuts (10).
IMPORTANT!
Check the compression of the disc springs
Retighten the disc springs if necessary.

6.5.2 C105 One Piece Jaws
IMPORTANT!
To remove the C105 jaws, refer to Figure 6.10,
Prior to starting the crusher, the crusher
discharge setting must be adjusted. Figure 6.11and Figure 6.12 and proceed as follows:
1. Stationary Jaw Removal

DANGER!

crushing cavity.
lifting holes.
stationary jaw and cheek plates.
holes of the jaw and lock it in place. Refer
to Appendix A for more information..
DANGER!
of lifting the weight of the stationary jaw.
WARNING!
– Remove the hex nuts (2), disc spring
assembly (8), bushing (3), and tightening
rod (5).
– Drive the tightening wedges (4) with a
steel bar (Figure 6.11) toward the side
plates.

NOTE: The wedges can also be pulled toward the – Place the jaw on wooden blocks.
side plate by threading into the wedge with a (Figure 6.5)
threaded rod.
– Remove the working platform. installation make sure that all the jaw seating
surfaces are cleaned.
– Remove the jaw.

1 Fixed jaw 7 Nuts
2 Nuts 8 Spring package
3 Bushing 9 Jaw bolts
4 Wedge 10 Tightening wedge
5 Tightening rod 11 Moving jaw
6 Spring package
Figure 6.10 Changing of jaw plates C105

2. Movable Jaw Removal
DANGER!

crushing cavity.
lifting holes.
Figure 6.11
holes of the jaw and lock it in place. Refer
to Appendix A for additional information.
DANGER!
lifting the weight of the movable jaw.
WARNING!
Figure 6.12
– Remove the hex nuts (7) and jaw spring
assembly (8).
– Remove the jaw bolts (9), movable wedge
(10), and filling wedge.
working platform.
– Remove the jaw.
– Place the jaw on wooden blockings.
(Figure 6.5)
reinstallation make sure that all the jaw seating
surfaces are clean.

6.5.2.1 C105 Jaw Assembly

Before installing new or partially worn jaws, make DANGER!
and pitman) seating surfaces are cleaned. The jaws A working platform should be installed
must have metal to metal contact on all seating into the crushing cavity before entering.
surfaces.
Check the condition of the protection plate (if
equipped). Replace if necessary. – Insert the working platform into the
crushing cavity.
IMPORTANT!
When rotating the jaws, it is a good WARNING!
practice to check the seating surfaces of Properly retain the jaw from unintended
the jaw for straightness (Ref. Figure 6.4). movement before releasing the locking
This is easily accomplished with the use mechanism of the lifting tool.
of a straight edge. The jaw can warp or
deform if the jaw is not properly – Install the bushings (3) on the tightening
tightened, or allowed to wear thin while rod.
crushing. – Install and tighten the disc spring
assembly per Chapter 5.6 , and lock with
double hex nuts (2).
CAUTION! – Remove the jaw lifting tool.
DO NOT install jaws into the Crusher if – Remove the working platform.
surfaces. Contact your Metso Minerals IMPORTANT!
representative for assistance. Check the compression of the disc springs
NOTE: If the ends of the jaws are bent in or
distorted, before the jaws can be installed, excess
material must be removed to original shape by
torching.
1. Stationary Jaw Installation

– Clean all jaw seating surfaces (Figure 6.9).
– Install the tightening wedges (4) and
tightening rod (5) positioning the wedges
as close to the crusher side plate as
possible.
– Insert and lock the the jaw lifting tool to
the jaw according to appendix A.
makes full contact with the lower wedge.

2. Movable Jaw Installation (Figure 6.10)

– Clean all jaw seating surfaces (Figure 6.9).
– Insert and lock the jaw lifting tool to the
jaw according to appendix A.
DANGER!

crushing cavity.
WARNING!
– Install the filling wedge (10), movable
wedge and jaw bolts (9).
– Install disc spring assembly (8), making
sure the disc spring stack up is according
to Figure 6.17.
– Tighten the disc spring assembly per
nuts (7).
IMPORTANT!
IMPORTANT!
Prior to starting the crusher, the crusher
discharge setting must be adjusted.

6.5.3 TWO-PIECE JAW REMOVAL – Exit the crushing cavity and remove the
working platform.
To remove a two piece jaw, refer to Figure 6.13 and – Remove the upper jaw.
proceed as follows: – Place the jaw on wooden blocks.
(Figure 6.5)
1. Stationary Jaws
DANGER!
DANGER! A working platform should be installed
crushing cavity.
crushing cavity. NOTE: A smaller working platform might be
required, as it is fitted further into the crushing
– Remove material build up from the upper cavity when the lower two piece jaw is removed.
jaw lifting holes.
DANGER!
stationary upper jaw and cheek plates. Properly retain the jaw from unintended
– Insert the jaw lifting tool into the lifting mechanism of the lifting tool.
holes of the upper jaw and lock it in place.
Refer to Appendix A for more – Remove material build up from the lower
information.. stationary jaw lifting holes.
DANGER! – Remove material build up between the

stationary lower jaw and cheek plates.
movement before releasing the locking – Insert the jaw lifting tool into the lifting
mechanism of the lifting tool. holes of the lower jaw and lock it in place.
Refer to Appendix A for more information
lifting the weight of the two piece jaw. DANGER!
WARNING! Never place yourself or other personnel

in a position beneath or adjacent to a
The lifting tool’s locking mechanism jaw that is not properly secured against
must be engaged (cammed over into the unintended movement.
WARNING!
lifting tool’s locking mechanism fully The lifting tool’s locking mechanism
engaged and in the locked position. must be engaged (cammed over into the
– Remove the hex nuts (13) and jaw disc remove any jaw locking components.
spring assembly (11). Never attempt to lift a jaw without the
– Remove the jaw bolts (8), tightening engaged and in the locked position.

– Remove the disc spring assembly (11) – Remove the lower jaw.
from center jaw bolts (7)
– Place the jaw on wooden blockins.
– Remove the jaw bolts and center wedge. (Figure 6.5)
working platform.

1 Fixed jaw 7 Jaw bolt
3 Center wedge 8 Jaw bolt
4 Filling wedge 11 Spring package
6 Filling wedge 13 Hex nut
Figure 6.13 Removal of a fixed jaw

2. Movable Jaw removal (ref. Figure 6.14) – Insert the working platform into the
crushing cavity.
NOTE: Smaller working platform might be
DANGER! required, as it is fitted further into the crushing
A working platform should be installed cavity when the lower two piece jaw is removed.
into the crushing cavity before entering. – Remove material build up from the lower
movable jaw lifting holes.
crushing cavity. – Remove any loose material from between
the lower movable jaw and cheek plates.
– Remove material build up from the upper
movable jaw lifting holes. – Insert the jaw lifting tool into the lifting
– Remove any loose material from between to Appendix A for additional information.
the upper movable jaw and cheek plates.
– Remove the disc spring assembly from the
– Insert the jaw lifting tool into the lifting center movable jaw bolts (9).
to Appendix A for additional information. – Remove the jaw bolts and center wedge.
DANGER! work platform..
movement before releasing the locking DANGER!
mechanism of the lifting tool. Never place yourself or other personnel
in a position beneath or adjacent to a
jaw that is not properly secured against
WARNING! unintended movement.
– Remove the lower jaw.
butterfly screw) prior to attempting to – Place the jaw on wooden blocks.
remove any jaw locking components. (Figure 6.5)
lifting tool’s locking mechanism fully NOTE: If the jaw is being rotated, before
engaged and in the locked position. reinstallation make sure that all the jaw seating
surfaces are clean.
working platform.
– Place the jaw on wooden blocks.
(Figure 6.5)
reinstallation make sure that all the jaw seating
surfaces are clean.


2 Moving jaw 9 Jaw bolt
3 Center wedge 10 Jaw bolt
4 Filling wedge 11 Spring package
5 Tightening wedge 13 Hex nut
Figure 6.14

6.5.3.1 Two Piece Jaw Assembly
Before installing new or partially worn jaws, make

and pitman) seating surfaces are clean. The jaws
must have metal to metal contact on all seating
surfaces.
Check the condition of the protection plate (if
equipped). Replace if necessary.
IMPORTANT!
When rotating the jaws, it is a good
practice to check the seating surfaces of
the jaw for straightness (Ref. Figure 6.4).
This is easily accomplished with the use
of a straight edge. The jaw can warp or
deform if the jaw is not properly
tightened, or allowed to wear thin while
crushing.
CAUTION!
DO NOT install jaws into the Crusher if
surfaces. Contact your Metso Minerals
representative for assistance.
NOTE: If the ends of the jaws are bent in, or

distorted, before the jaws can be installed, excess
material must be removed to original shape by
torching.
To install a two piece jaw refer to Figure 6.15,
Figure 6.16, Figure 6.17, and Figure 6.18 and
proceed as follows:

Figure 6.15 Jaw seating surfaces
1. Two Piece Stationary Jaw Installation

(Figure 6.13) – Insert the working platform into the
– Clean all jaw seating surfaces crushing cavity.
(Figure 6.15).
the jaw according to appendix A. WARNING!
– Install the jaw into the crushing cavity, Properly retain the jaw from unintended
making sure that the jaw seating surface movement before releasing the locking
– Install the center wedge (3) and jaw bolts
(7).
DANGER! – Install the spring assembly (11) making
A working platform should be installed sure that the disc spring stack up is
into the crushing cavity before entering. according to Figure 6.18.

– Tighten the center jaw bolt nuts until most 2. Movable Two Piece Jaw Installation
of the clearance between all the wedge (Figure 6.14)
retention components is removed. The – Clean all jaw seating surfaces
center wedge should be positioned farthest (Figure 6.15).
away from the front casting on top of the
lower jaw. – Insert and lock the the jaw lifting tool to
– Clean all jaw seating surfaces of the
stationary upper jaw (Figure 6.15). – Install the lower movable jaw into the
crushing cavity, making sure that the jaw
– Insert and lock the the jaw lifting tool to seating surface makes full contact with the
the jaw according to appendix A. lower wedge.
makes full contact with the center wedge. DANGER!
DANGER!
crushing cavity.
– Install the center wedge (3) and jaw bolts
– Insert the working platform into the (9).
crushing cavity.
– Install the spring assembly (11) making
wedge (4) and jaw bolts (8). according to Figure 6.18.
– With center jaw bolt hex nuts, adjust the – Tighten the center jaw bolt nuts until most
gap between the lower and upper jaw. A
of the clearance between all the wedge
gap of 5 - 8 mm (.20” - .30”) must exist retention components is removed. The
between the two jaws. Refer to center wedge should be positioned farthest
Figure 6.16.
away from the pitman on top of the lower
– Tighten the disc spring assembly per jaw.
Chapter 5.6 , and lock with a double hex – Clean all jaw seating surfaces of the
nut (13).
movable upper jaw (Figure 6.15).
– Remove the jaw lifting tool. – Insert and lock the the jaw lifting tool to
– Remove the working platform. the jaw according to appendix A.
IMPORTANT! makes full contact with the center wedge.
Retighten the disc springs if necessary. DANGER!


crushing cavity.
WARNING!
wedge (5) and jaw bolts (10). Properly retain the jaw from unintended
– With center jaw bolt hex nuts, adjust the mechanism of the lifting tool.
gap of 5 - 8 mm (.20” - .31”) must exist
between the two jaws. Refer to
IMPORTANT!
Figure 6.16.
– Clean all jaw seating surfaces of the
stationary upper jaw (ref. Figure 6.15).
– Install the lower movable jaw into the IMPORTANT!
crushing cavity, making sure that the jaw Prior to starting the crusher, the crusher
seating surface makes full contact with the discharge setting must be adjusted.
lower wedge.
DANGER!

crushing cavity.
– Install the filling wedge, tightening wedge
and jaw bolts.
– With center jaw bolt hex nuts, adjust the
gap of 5 - 8 mm (.20” - .31”) must exist
between the two jaws. Refer to
Figure 6.16.
– Install the disc spring assembly making
according to Figure 6.18
– Tighten the filling wedge spring assembly
nut.

Figure 6.16
Figure 6.17

6.7 FEED HOPPER LINER REPLACEMENT
The jaw crusher feed hopper is lined with an

abrasion resistant plate. This liner should be
replaced, and not allowed to be worn through.
Abrasion of the material being crushed will dictate
the frequency of replacement.
6.8 TOGGLE PLATE SEAT REPLACEMENT
The toggle plate seats are hardened in the toggle

plate contact area. The hardness depth is
approximately 3 mm (.12”). If the seats are worn
more than 3 mm (.12”), they should be replaced.
Callout Description
1 Washer
2 Cup spring
3 Spring casing
4 Rubber plate
Figure 6.18 Assembly order
6.6 PITMAN EYE PROTECTION PLATE

REPLACEMENT
Pitman eye protection plate is designed to protect

the pitman from wear. The wear to the protection
plate is contributed by feed material impact if the
feed material enters the crushing cavity too fast. In
addition, the protection plate will show premature
wear, if it is allowed for the feed material to be
crushed to high in the cavity. To prevent the
protection plate from wearing through, periodic
replacement is necessary.

APPENDIX A
NORDBERG C-SERIES JAW CRUSHER'S
JAW-LIFTING TOOL
SAFETY, OPERATING AND MAINTENANCE
INSTRUCTIONS
4. Commissioning and operating
1. Purpose of the jaw-lifting tool conditions
The jaw-lifting tool that is provided with Nordberg The jaw-lifting tool is supplied fully assembled and
C Series jaw crushers is intended for the lifting of it is ready for immediate use.
genuine Metso Minerals Nordberg C Series wear The jaw-lifting tool can be used in the same
parts (jaws) only. The jaw-lifting tool is not
operating conditions as the jaw crusher.
designed nor tested for the lifting of other types of
jaws (including copies of the Nordberg C Series
jaws).
5. Technical data
2. Storage of the jaw-lifting tool The maximum lifting load is mentioned on the
When not in use the jaw-lifting tool should attached tag of the jaw-lifting tool. Table 1 shows
normally be kept on a properly designed rack. They available lifting tools.
should not be left lying on the ground where they
may be damaged.
Lifting Maximum lifting load
If it is likely that the jaw-lifting tool will be out of
tool (Working load limit, WLL)
use for some time they should be cleaned, dried and
protected from corrosion, e.g. lightly oiled. 582133 1500 kg (3307 lbs)
582151 2800 kg (6173 lbs)
3. Safe use 585042 5000 kg (11023 lbs)
Table 1
WARNING!
Before lifting any wear parts, check the
6. The jaw-lifting tool verification before
first use and in service
the lifting equipment being used is
adequate to lift the weight.
Read carefully all instructions concerning the Before first use
jaw-lifting tool and make sure that the tool is Before first use of the jaw-lifting tool it should be
inspected regularly. Prior to lifting, make sure that ensured that:
the jaw-lifting tool is locked and does not come out
of the lifting hole. The jaw-lifting tool is only a. the jaw-lifting tool is precisely as
meant for the lifting of genuine Metso Minerals ordered;
Nordberg C Series jaws. It is neither designed nor b. the manufacturer's certificate is to hand;
tested for unfastening used jaws that may not
readily come loose prior to lifting. c. the identification and working load limit
marking on the jaw-lifting tool
Do not overload the jaw-lifting tool. The maximum correspond to the information on the
lifting load is found on the tag of the jaw-lifting certificate;
tool (see Table 1). Stop the lifting procedure
immediately if the jaw is stuck to its location. d. full details of the jaw-lifting tool are
recorded.
Load the lifting tool evenly and carry out lifting and
displacement of the jaw carefully. Keep the lifting
zone free of people during lifting. Do not use the
jaw-lifting tool in a hurry.
EN N11450704_I JAW LIFTING TOOL -1

APPENDIX A
Before each use b. The hook to which the jaw-lifting tool is

attached should be directly above the
Before each use the jaw-lifting tool should be
centre of gravity.
inspected for obvious damage or deterioration (see
8 Maintenance / Inspection). If faults are found Method of connection
during this inspection, the procedure given in 8 The jaw-lifting tool is attached to the load and the
Maintenance should be followed. lifting machine by means of terminal fittings such
The jaw-lifting tool must be inspected visually as hooks and links. Chains should be without twists
before every lift and more precisely at least once a or knots. The lifting point should be seated well
year. See detailed instructions below. Inspections down in a hook and the hook should be free to
must be documented for own as well as authority incline in any direction so as to avoid bending. For
audits. the same reason, the master link should be free to
incline in any direction on the hook to which it is
A damaged jaw-lifting tool must be replaced or
fitted.
repaired immediately. Special attention should be
paid to the condition of the threads, welds and Straight leg
fasteners. In this case lower terminals are connected directly
The jaw-lifting tool should be clean enough to to the attachment points. Selection of hooks and
observe possible damages. attachment points should be such that the load is
carried in the seat of the hook and tip loading of the
Adequate lighting should be provided and the
hook is avoided.
jaw-lifting tool should be examined throughout its
length to detect any evidence of wear, distortion or In order to prevent dangerous swaying of the load
external damage. and to position it for loading, a tag line is
recommended.
When loads are accelerated or decelerated
7. Handling the load suddenly, high dynamic forces occur which
Preparation increase the stresses in the chain. Such situations,
which should be avoided, arise from snatch or
Attention should be given to any specific shock loading e.g. from not taking up the slack
instructions provided for the handling of the load. chain before starting to lift or by the impact of
Before starting the lift, it should be ensured that the arresting falling loads.
load is free to move and is not bolted down or
otherwise obstructed. Safety of lift
Mass of the load Hands and other parts of the body should be kept
away from the chain to prevent injury as the slack is
It is essential that the mass of the load to be lifted is taken up. When ready to lift, the slack should be
known. If the mass is not marked the information taken up until the chain is taut. The load should be
should be obtained from the consignment notes, raised slightly and a check made that it is secure
manuals, plans etc. If such information is not and assumes the position intended. This is
available the mass should be assessed by especially important with basket or other loose
calculation. hitches where friction retains the load.
Centre of gravity Landing the load
The position of the centre of gravity of the load The landing site should be prepared. It should be
should be established in relation to the possible ensured that the ground or floor is of adequate
points of attachment of the chain sling. To lift the strength to take the weight taking account of any
load without it tilting or toppling the following voids, ducts, pipes etc. which may be damaged or
conditions should be met: collapse. It should also be ensured that there is
a. For two leg chain slings the attachment adequate access to the site and that it is clear of any
points should be either side of and above unnecessary obstacles and people. It may be
the centre of gravity. necessary to provide timber bearers or similar
-2 JAW LIFTING TOOL N11450704_I EN

APPENDIX A
material to avoid trapping the chain sling or to

protect the floor or load or to ensure the stability of
the load when landed.
8. Maintenance
Inspection
During service, the jaw-lifting tool is subjected to
conditions which affect their safety. It is necessary
therefore to ensure, as far as is reasonably
practicable, that the chain sling should be safe for
continued use. Figure 1
If the tag or label identifying the chain sling and its
e. Cuts, nicks, gouges, cracks, excessive
working load limit becomes detached and the
corrosion, heat discoloration, bent or
necessary information is not marked on the master
distorted links or any other defects.
link itself, or by some other means, the jaw-lifting
tool should be withdrawn from service. f. Check the condition of the pin in
position 1 (see Figure 2) below. If the pin
The chain sling should be withdrawn from service
is worn by 10% (or more) of its original
and referred to a competent person for thorough
dimension (10 mm, 0.39"), it must be
examination if any of the following are observed:
replaced immediately.
a. The chain sling markings are illegible,
i.e. information on the chain sling
identification and/or the working load
limit.
b. Distortion of the upper or lower
terminals.
c. Chain stretch.
If the chain links are elongated or if there is
any lack of free articulation between the
links or noticeable difference in the leg
length of multi-leg chain slings, the chain
may have been stretched.
d. Wear by contact with other objects
usually occurs on the outside of the
straight portions of the links where it is
easily seen and measured. Wear between
adjoining links is hidden. The chain
should be slack and adjoining links
rotated to expose the inner end of each
link. Inter-link wear, as measured by
taking the diameter indicated ( d1) and
one at right angles, (d2) may be tolerated
until the mean of these diameters has
been reduced to 90 % of the nominal
diameter (dn) (see Figure 1) provided
d +d
1 2
> 0.9d n
Figure 2

APPENDIX A
Dimension L (4), measured between positions 2 If any chain link within the leg of a chain sling is
and 3, must not exceed 10% of the value given in required to be replaced then the whole of the chain
Table 2 below. If dimension L (4) exceeds 10% of within that leg should be renewed.
the original value, the jaw-lifting tool must be The repair of chain in a welded the jaw-lifting tool
should only be carried out by the manufacturer
Lifting using a resistance butt or flash butt welding
Check dimension L process.
tool
582133 382 +38 mm (15.04" +1.50") Components that are cracked, visibly distorted or
582151 +37 mm +1.47") twisted, severely corroded or have deposits which
367 (14.45"
cannot be removed should be discarded and
585042 395 +40 mm (15.55” +1.57”) replaced. Minor damage such as nicks and gouges
may be removed by careful grinding or filing. The
Table 2
surface should blend smoothly into the adjacent
g. Check the condition of the locking material without abrupt change of section. The
mechanism (5). complete removal of the damage should not reduce
h. Lubricate the mechanism (6) with spray the thickness of the section at that point to less than
vaseline oil and turning the lever. the manufacturers specified minimum dimensions
or by more than 10 % of nominal thickness of the
i. Check the surfaces of the centre pin (7) section.
and shoulder (8) visually.
In the case of the jaw-lifting tool on which repair
j. The locking bolt (9) must be able to lock work has involved welding, each repaired chain
the lever during lifting. If worn or sling should be proof tested following heat
damaged replace the jaw-lifting tool treatment using a force equivalent to twice the
immediately. working load limit and thoroughly examined before
Thorough examination it is returned to use. However, where repair is
carried out by inserting a mechanically assembled
A thorough examination should be carried out by a component, proof-testing is not required providing
competent person at intervals not exceeding twelve that the component has already been tested by the
months. This interval should be less where deemed manufacturer in accordance with the relevant
necessary in the light of service conditions. European standard.
Records of such examinations should be The accuracy of the tensile test equipment should
maintained. be of class 2 as given in EN 10002-2.
Chains slings should be thoroughly cleaned so as to
be free from oil, dirt and rust prior to examination.
Any cleaning method which does not damage the 9. Operating instructions
parent metal is acceptable. Methods to avoid are
those using acids, overheating, removal of metal or
movement of metal which may cover cracks or WARNING!
surface defects.
Adequate lighting should be provided and the chain weight of the component and ensure that
sling should be examined throughout its length to the lifting equipment being used is
detect any evidence of wear, distortion or external adequate to lift the weight.
damage.
a. Clean the lifting hole of jaw in order to
Repair insert the jaw-lifting tool in. Make sure
Any replacement component or part of the chain that there is not any material in the
sling should be in accordance with the appropriate jaw-lifting hole, as it may prevent
European Standard for that component or part. jaw-lifting tool's locking mechanism to
function properly.

APPENDIX A
b. Jaw-lifting holes can be kept clean by

covering them with polyurethane. The
polyurethane must withstand ambient
temperatures and must be melted away
with a torch prior to inserting the
jaw-lifting tool.
c. Turn the lever to the installation position
so that the hinged tip of centre pin and
the stationary part of the pin form a flush
shape (Ref. Figure 2). The lever must
remain locked in this position.
d. Insert both hooks into the lifting holes
and turn the levers 180 degrees in order
to lock the pins to the jaw. The levers
lock themselves to this position but as an
additional safety precaution the locking
mechanisms are secured by means of
screwing in butterfly screws.
e. Before beginning the hoist make sure
that jaw is loose.
f. Start the hoist slowly. If the jaw jams,
stop lifting and unfasten jaw.
g. Keep the hoisting zone free of people at
all times.
h. Never stand underneath a suspended
load.
Figure 3 Lifting tool usage:

A) Locked
B) Unlocked

APPENDIX A

APPENDIX B
NORDBERG C-SERIES JAW CRUSHER'S
CHEEK PLATE LIFTING TOOL
SAFETY, OPERATING AND MAINTENANCE Load the lifting tool evenly and carry out the lifting
INSTRUCTIONS and displacement of the cheek plate carefully. Keep
the lifting zone free of people during lifting. Do not
1. Purpose of the cheek plate lifting tool use the cheek plate lifting tool in a hurry.
The cheek plate lifting tool that is provided with
4. Commissioning and operating
Nordberg C Series jaw crushers is intended for the
conditions
lifting of genuine Metso Minerals Nordberg C
Series wear parts (cheek plates) only. The cheek The cheek plate lifting tool is supplied fully
plate lifting tool is not designed nor tested for the assembled and it is ready for immediate use.
lifting of other types of objects. The cheek plate lifting tool can be used in the same
2. Storage of the cheek plate lifting tool operating conditions as the jaw crusher.
When not in use the cheek plate lifting tool should
normally be stored carefully away from damaging
materials, such as dirt or sand. They should not be
left lying on the ground where they may be
damaged.
If it is likely that the cheek plate lifting tool will be
out of use for some time they should be cleaned,
dried and protected from corrosion, e.g. lightly
oiled.
3. Safe use
WARNING!
adequate to lift the weight.
Read all instructions concerning the cheek plate
lifting tool carefully and make sure that the tool is
inspected regularly. Prior to lifting, make sure that
the cheek plate lifting tool is locked and does not
come out of the lifting hole. The cheek plate lifting
tool is only meant for the lifting of genuine Metso
Minerals Nordberg C Series cheek plates. It is
neither designed nor tested for unfastening used
cheek plates that may not readily come loose prior
to lifting.
Do not overload the cheek plate lifting tool. The
maximum lifting load is found on the tag of the
cheek plate lifting tool (see Table 1). Stop the
lifting procedure immediately if the cheek plate is
stuck to its location.
EN N11456138_I CHEEK PLATE LIFTING TOOL -1

APPENDIX B
5. Technical data
The maximum lifting load is mentioned on the
attached tag of the cheek plate lifting tool. Table 1
shows available lifting tools and the corresponding
lifting hole sizes.
Maximum lifting load
Lifting tool Diameter of lifting hole
(Working load limit, WLL)
MM0209800 1000 kg (2204 lbs) 80 mm (3.1”)
MM0209814 500 kg (1102 lbs) 40 mm (1.6”)
Table 1
The cheek plate lifting tool should be clean enough
to observe possible damages.
6. The cheek plate lifting tool verification
before first use and in service Adequate lighting should be provided and the
cheek plate lifting tool should be examined
Before first use throughout its length to detect any evidence of
Before first use of the cheek plate lifting tool it wear, distortion, or external damage.
should be ensured that:
a. the cheek plate lifting tool is precisely as
7. Handling the load
ordered;
Preparation
b. the manufacturer's certificate is at hand;
Attention should be given to any specific
c. the identification and working load limit
instructions provided for the handling of the load.
marking on the cheek plate lifting tool
Before starting the lift, it should be ensured that the
correspond to the information on the
load is free to move and is not bolted down or
certificate;
otherwise obstructed.
d. full details of the cheek plate lifting tool
Mass of the load
are recorded.
It is essential that the mass of the load to be lifted is
known. If the mass is not marked, the information
Before each use should be obtained from the consignment notes,
Before each use the cheek plate lifting tool should manuals, plans, etc. If such information is not
be inspected for obvious damage or deterioration available, the mass should be assessed by
(see paragraph 8 Maintenance / Inspection). If calculation.
faults are found during this inspection, the Centre of gravity
procedure given in paragraph 8 Maintenance
The position of the centre of gravity of the load
should be followed.
should be established in relation to the possible
The cheek plate lifting tool must be inspected points of attachment of the chain sling. To lift the
visually before every lift and more precisely at least load without tilting or toppling it, the following
once a year. See detailed instructions below. conditions should be met:
Inspections must be documented for own as well as
a. For two leg chain slings the attachment
authority audits.
points should be on either side of and
A damaged cheek plate lifting tool must be above the centre of gravity.
replaced or repaired immediately. Special attention
b. The hook to which the cheek plate lifting
should be paid to the condition of the threads,
tool is attached should be directly above
welds, and fasteners.
the centre of gravity.
-2 CHEEK PLATE LIFTING TOOL N11456138_I EN

APPENDIX B
Method of connection protect the floor or load or to ensure the stability of

the load when landed.
The cheek plate lifting tool is attached to the load
and the lifting machine by means of terminal 8. Maintenance
fittings such as hooks and links. Chains should not
have any twists or knots. The lifting point should be Inspection
seated well in the hook and the hook should be free During service, the cheek plate lifting tool is
to incline in any direction to avoid bending. For the subjected to conditions which affect their safety. It
same reason, the master link should be free to is necessary therefore to ensure, as far as is
incline in any direction on the hook to which it is reasonably practicable, that the chain sling should
fitted. be safe for continued use.
Straight leg If the tag or label identifying the chain sling and its
In this case the lower terminals are connected working load limit becomes detached and the
directly to the attachment points. The hooks and necessary information is not marked on the master
attachment points should be selected so that the link itself, or by some other means, the cheek plate
load is carried in the seat of the hook and tip lifting tool should be withdrawn from service.
loading of the hook is avoided. The chain sling should be withdrawn from service
In order to prevent dangerous swaying of the load and referred to a competent person for thorough
and to position it for loading, a tag line is examination if any of the following are observed:
recommended. a. The chain sling markings (information
When loads are accelerated or decelerated on the chain sling identification and/or
suddenly, high dynamic forces occur that increase the working load limit) are illegible.
the stresses in the chain. Such situations, which b. Distortion of the upper or lower
should be avoided, arise from snatch or shock terminals.
loading, e.g. from not taking up the slack chain
before starting to lift or by the impact of stopping c. Chain stretch.
falling loads. If the chain links are elongated or if there is
any lack of free articulation between the
links or noticeable difference in the leg
Safety of lift length of multi-leg chain slings, the chain
Hands and other parts of the body should be kept may have been stretched.
away from the chain to prevent injury as the slack is d. Wear by contact with other objects
taken up. When ready to lift, the slack should be usually occurs on the outside of the
taken up until the chain is taut. The load should be straight portions of the links where it is
raised slightly and a check made that it is secure easily seen and measured. Wear between
and assumes the position intended. This is adjoining links is hidden. The chain
especially important with basket or other loose should be slack and adjoining links
hitches where friction retains the load. rotated to expose the inner end of each
Landing the load link. Inter-link wear, as measured by
taking the diameter indicated (d1) and
The landing site should be prepared. It should be one at right angles, (d2) may be tolerated
ensured that the ground or floor is of adequate until the mean of these diameters has
strength to take the weight taking into account any been reduced to 90 % of the nominal
voids, ducts, pipes, etc. which may be damaged or diameter (dn) provided. (see Figure 1)
collapse. It should also be ensured that there is
adequate access to the site and that it is clear of any
unnecessary obstacles and people. It may be d +d
1 2
> 0.9d n
necessary to provide timber bearers or similar
material to avoid trapping the chain sling or to
2

APPENDIX B
e. Cuts, nicks, gouges, cracks, excessive

corrosion, heat discoloration, bent or
distorted links or any other defects.
f. Check the condition of the pin in
position 1 (see Figure 2). If the pin is
worn by 10% (or more) of its original
dimension (MM0209800 = 10 mm, 0.39";
MM0209814 = 8 mm, 0.31”), it must be
Figure 1
Figure 2
Dimension L (4), measured between positions 2 Lifting tool Min. length L Max. length L
and 3, must be within the values given in Table 2. If MM0209800 210 mm (8.3”) 250 mm (9.8”)
dimension L (4) is outside of the values given in the
MM0209814 182 mm (7.2”) 222 mm (8.7”)
table, the cheek plate lifting tool must be replaced
immediately. Table 2

APPENDIX B
g. Check the condition of the locking the thickness of the section at that point to less than
mechanism (8). the manufacturer’s specified minimum dimensions
or by more than 10 % of nominal thickness of the
h. Lubricate the mechanism (7) with spray
section.
vaseline oil and turning the lever.
If the repair work of the cheek plate lifting tool has
i. Check the surfaces of the centre pin (5)
involved welding, each repaired chain sling should
and shoulder (6) visually.
be proof-tested following heat treatment using a
j. The locking bolt must be able to lock the force equivalent to twice the working load limit,
lever during lifting. If worn or damaged and thoroughly examined before it is returned to
replace the cheek plate lifting tool use. However, where repair is carried out by
immediately. inserting a mechanically assembled component,
Thorough examination proof-testing is not required providing that the
component has already been tested by the
A thorough examination should be carried out by a manufacturer in accordance with the relevant
competent person at intervals not exceeding twelve European standard.
months. This interval should be less where deemed
necessary in the light of service conditions. The accuracy of the tensile test equipment should
be of class 2 as given in EN 10002-2.
Records of such examinations should be
maintained.
Chains slings should be thoroughly cleaned so as to 9. Operating instructions
be free from oil, dirt and rust prior to examination.
Any cleaning method which does not damage the
parent metal is acceptable. Methods to avoid are WARNING!
those using acids, overheating, removal of metal, or
movement of metal which may cover cracks or
surface defects.
Adequate lighting should be provided and the chain adequate to lift the weight.
sling should be examined throughout its length to
a. Clean the lifting hole of the cheek plate
detect any evidence of wear, distortion or external
in order to insert the cheek plate lifting
damage.
tool. Make sure that there is no material
Repair in the cheek plate lifting hole, as it may
Any replacement component or part of the chain prevent the cheek plate lifting tool's
sling should be in accordance with the appropriate locking mechanism from functioning
European Standard for that component or part. properly.
If any chain link within the leg of a chain sling has b. Cheek plate lifting holes can be kept
to be replaced then the whole of the chain within clean by covering them with
that leg should be renewed. polyurethane. The polyurethane must
withstand ambient temperatures and
Any chain repairs that require welding should only must be melted away with a torch prior
be carried out by the manufacturer using a to inserting the cheek plate lifting tool.
resistance butt or flash butt welding process.
c. Turn the lever to the installation position
Components that are cracked, visibly distorted or so that the hinged tip of the centre pin
twisted, severely corroded, or have deposits which and the stationary part of the pin form a
cannot be removed should be discarded and flush shape (Ref. Figure 2). The lever
replaced. Minor damage such as nicks and gouges must remain locked in this position.
may be removed by careful grinding or filing. The
surface should blend smoothly into the adjacent d. Insert the hook into the lifting hole and
material without abrupt change of section. The turn the lever 180 degrees in order to
complete removal of the damage should not reduce lock the pins to the jaw. The lever locks

APPENDIX B
to this position but as an additional

safety precaution the locking mechanism
is secured with a butterfly screw.
e. Before beginning the hoist make sure
that the cheek plate is loose.
f. Start the hoist slowly. If the cheek plate
jams, stop the lifting and unfasten the
cheek plate.
g. Keep the hoisting zone free of people at
all times.
h. Never stand underneath a suspended
load.

APPENDIX B

Manual C145 Jaw

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NORDBERG C SERIES JAW CRUSHERS

Metso Minerals (Tampere) Oy

Tel. +358 (0)20 484 142

EN 140588-0_I NORDBERG C SERIES JAW CRUSHERS 0-1

This Page Left Intentionally Blank.

0-2 NORDBERG C SERIES JAW CRUSHERS 140588-0_I EN

NORDBERG C SERIES JAW CRUSHERS

1.1 FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

GENERAL CRUSHER INFORMATION

3.1 CRUSHER TERMINOLOGY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

4.1 PREPARATIONS BEFORE STARTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

5.1 SPACER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

REPLACEMENT OF WEAR PARTS

6.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

NORDBERG C-SERIES JAW CRUSHER'S JAW-LIFTING TOOL . . . . . . . . . 1-1

NORDBERG C-SERIES JAW CRUSHER'S CHEEK PLATE LIFTING TOOL . 1-1

OPERATOR SAFETY AND THE SAFETY OF

Whenever a question arises concerning your

EN 140588-1_I NORDBERG C SERIES INSTRUCTION MANUAL 1-1

This Page Left Intentionally Blank.

1-2 NORDBERG C-SERIES INSTRUCTION MANUAL 140588-1_I EN

Kuva 2.2 Danger, warning, caution signs and

Kuva 2.1 Alert Symbol

This manual uses the alert symbol, with words such

EN 140588-2_I NORDBERG C SERIES INSTRUCTION MANUAL 2-1

2-2 NORDBERG C SERIES INSTRUCTION MANUAL 140588-2_I EN

according to instructions before any 2.2 WARNING SIGNS

Figure 2.3 The locations of the warning signs

The number and exact locations of the warning

EN 140588-2_I NORDBERG C SERIES INSTRUCTION MANUAL 2-3

Figure 2.4 Warning signs

2-4 NORDBERG C SERIES INSTRUCTION MANUAL 140588-2_I EN

2.2.1 Warning sign codes and texts before adjusting or servicing.

EN 140588-2_I NORDBERG C SERIES INSTRUCTION MANUAL 2-5

This Page Left Intentionally Blank.

2-6 NORDBERG C SERIES INSTRUCTION MANUAL 140588-2_I EN

Throughout this instruction manual, technical terms

Callout Description Callout Description

Figure 3.1 Jaw crusher terminology

distribution or based on an average top (maximum)

EN 140588-3_I NORDBERG C SERIES INSTRUCTION MANUAL 3-1

Table 3-1 Maximum recommended feed sizes

Nip Angle: The angle between the fixed and

3-2 NORDBERG C SERIES INSTRUCTION MANUAL 140588-3_I EN

3.2 CRUSHER COMPONENTS

Callout Description Callout Description

Figure 3.2 Jaw crusher main components

EN 140588-3_I NORDBERG C SERIES INSTRUCTION MANUAL 3-3

Callout Description Callout Description

Figure 3.3 Jaw crusher rear frame components

3-4 NORDBERG C SERIES INSTRUCTION MANUAL 140588-3_I EN

3.3 SPARE PARTS BOOK 3.5 ESTIMATING CRUSHER CAPACITY

If your crusher Spare Parts Books have been lost,

EN 140588-3_I NORDBERG C SERIES INSTRUCTION MANUAL 3-5

Table 3-2 Nominal jaw crusher capacities

3-6 NORDBERG C SERIES INSTRUCTION MANUAL 140588-3_I EN

1" 2" 4" 8" 16"

css 40 50 70 100 130 160 200 250 300