Mandibulas KPI 2640 - 4450

OPERATION &
MAINTENANCE
CRUSHING & SCREENING
Vanguard Jaw Crusher
IB-1007 5/12
Record your Jaw Crusher serial number and order number in the space provided below. You will find
the serial number plate attached to the inside of the base on the rear side of the jaw crusher. Please
include these numbers when requesting service or ordering replacement parts.
JOB ORDER
MODEL S/N
MANUFACTURED BY KOLBERG-PIONEER, INC. YANKTON, SD, U.S.A.
JOB ORDER
MODEL S/N
MANUFACTURED BY KOLBERG-PIONEER, INC. YANKTON, SD, U.S.A.
Serial Number Plate

Location
Front
Rear
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its
constituents are known to the state of
California to cause cancer, birth defects, an
other reproductive harm.
Copyright KPI-JCI
2012
Vanguar
anguardd Series
Jaw Cr usher
Crusher
OPERATION &
OPERATION
MAINTENANCE
MANU AL
MANUAL
Models Covered:
2640 3165
2650 3352
3055 4450
3144
Printed in the USA
All rights reserved. No part of this manual may be reproduced

or transmitted in any form or by any means, electronic or
mechanical, including photocopying, recording or by any
information storage or retrieval system, without permission
from KPI-JCI.
This manual contains operating, lubrication and maintenance

information. Application of this information should maximize
the performance and life of your equipment and minimize
down time.
Safe and efficient operation requires that you and anyone

else who will be operating or maintaining this equipment read
and understand the safety, operation, maintenance and
troubleshooting information contained in the operator's
manual.
Continuing improvement and advancement of KPI-JCI products

may cause changes to your equipment which may not be
reflected in this publication.
KPI-JCI reserves the right to make changes or add

improvements to its products at any time, without incurring
any obligation to make such changes on previously
manufactured equipment.
Although care has been taken to assure the accuracy of this

publication, KPI-JCI does not assume any liability for loss,
damage or injury caused by errors or omissions.
0-3
Contents
Introductory Pages About This manual 0-4
Serial Number Plates 0-5
Buying Replacement Parts 0-6
Maintenance Techniques and Tools 0-7
Lubricants and Fluids 0-8
Storage 0-9
Introduction to the
Jaw Crusher Chapter 1
Orientation 1-1
Terminology 1-2
Safety Chapter 2
General Safety Guidelines 2-1
Safety Decals 2-7
Specifications Chapter 3 3-1
Application Chapter 4 4-1
Site Selection and Setup Chapter 5

Site Selection and Foundation 5-1
Lifting Crusher 5-2
Feed Arrangement 5-3
Flywheel Balance 5-4
Open Side Setting (OSS) - Auto Adjust 5-5
Open Side Setting (OSS) - Manual Adjust 5-7
Operation Chapter 6 6-1
Preoperation Checklist Chapter 7 7-1
Pressure Adjustment and

Synchronization Chapter 8 8-1
Maintenance Chapter 9
10 hours 9-3
50 hours 9-6
200 hours 9-7
Jaw Die Reversal/Replacement 9-8
Side Liners 9-11
Lubrication Chapter 10
10 hours 10-1
1000 hours 10-2
Troubleshooting Chapter 11 11-1
Welding Lifting Lugs to Jaw

Manganese Appendix A A-1
0-4
About This Manual

Purpose consecutively numbered Special Notations
The purpose of this manual paragraphs. Within this manual
is to help you get the best value Procedures, once procedures or situations that
from your equipment. This described in the text, are not require special attention are
manual can help you decide normally repeated. When it is indicated with the words,
what work must be done, even if necessary to refer to another Danger, Warning, Caution
you decide to have it done by a chapter, the reference will be and Important.
dealer service department or a given as chapter and section Danger, Warning and
repair shop. It also provides number. Cross references Caution are used to indicate
information and procedures for given without the word "chapter" procedures or situations where
routine maintenance and apply to sections and/or personal safety is involved.
servicing. paragraphs in the same Important is used to
chapter, "see section 8" means indicate special procedures or
Using the Manual in the same chapter. situations which, if not
The manual is divided into Even though this manual has observed, could result in
chapters. Each chapter is been prepared with extreme damage to the equipment or
divided into numbered care, Kolberg-Pioneer can not affect the operation of the
sections, which are headed in accept responsibility for errors machine.
bold type between horizontal in, or omissions from the
lines. Each section consists of information given.
0-5
Serial Number Plates

Modifications are a
continuing process in the
manufacture of this equipment.
Since replacement parts
manuals and lists are compiled
specifically for each unit, the
serial numbers are essential to
correctly identify the component
required.
Kolberg-Pioneer Serial Number Plate.
The serial number plate will
show the serial number, job
order number and model
number.
Jaw Crusher Serial Number

The serial number for the
jaw crusher is stamped on a
plate which is attached to the
inside of the base on the rear
side of the jaw crusher.
Jaw Crusher Serial Number Plate

0-6
Buying Replacement Parts

Authorized Dealer Parts Purchased Components component in your area, as in
Department Replacement parts for the case of engine parts.
An authorized dealer parts components purchased by KPI-
department is the best source JCI such as gear reducers, Serial Number
for parts, particularly parts which electric motors and engines are Since replacement parts
are unique to this equipment. If available through your manuals and lists are compiled
you do not know who the authorized dealer. However, specifically for each unit, the
authorized dealer is in your area some items like engine parts serial numbers are essential to
contact KPI-JCI. Dealerships are typically not stocked by the correctly identify the component
are located throughout the dealer or KPI-JCI. required.
United States and some parts If the situation warrants, it
of the world. may be necessary to contact
the authorized dealer for that
Typical motor drive assembly parts page.
Typical tail pulley assembly parts page.

0-7
Maintenance Techniques and Tools

Tools large containers, seal them and It is a good habit to replace
Although a minimal number take them to an authorized all damaged fasteners when
of tools are needed for disposal or recycling center. performing maintenance; never
operation and maintenance, a reuse a damaged fastener.
good selection of basic tools is Special locknuts with nylon
required. inserts can only be used once.
If they are removed, they lose
their locking ability and must be
replaced.
Rusted nuts and bolts should
be treated with a penetrating
fluid to ease removal and
prevent breakage. Badly rusted
fasteners may have to be
chiseled, sawed or torched off.
Flat washer and
lockwashers, when removed
from an assembly, should
Fasteners always be replaced exactly as
Typically, standard SAE removed.
Waste oil and fluids fasteners are used. Fasteners When replacing nuts and
Waste oil and fluids drained are nuts, bolts, studs and screws bolts be sure to use the correct
from the engine and hydraulic used to hold two or more parts grade. Never use a different
system during normal together. grade of bolt than the original
maintenance and repair can All threaded fasteners equipment.
present a disposal problem. should be clean and straight,
To avoid pouring them on with undamaged threads and
the ground or into the sewage undamaged corners on the hex
system, pour the used fluids into heads.
Grade 5 Grade 8 Grade 1 or 2 Grade 5 Grade 8
Grade marking standard SAE nuts. Grade marking standard SAE bolts.
0-8
Lubricants and Fluids

The lubricants shown below Jaw crusher pitman bearings -
are "factory fill" lubricants. Other grease lubricated system
lubricants may be used
provided they meet the
lubrication requirements
specified.
Jaw Crusher Pitman

Bearings
If the jaw crusher eccentric
Chevron Ultra-duty HD
shaft is a grease lubricated
system, the jaw crusher pitman
bearings are lubricated with
For low operating
temperatures (40 degrees NOTICE
Chevron Ultra-duty HD, a lithium Fahrenheit and below), Mobilith Chevron Ultra-Duty HD00 is
based semi-fluid grease SHC-007 can be used. compatible with Mobilith
specially formulated with a high Store all lubricants in a warm SHC-007; however, mixing
viscosity base oil, and an area for easier application. products may decrease
additive package that contains performance. For maximum
inhibitors and tackifiers. performance, thoroughly
clean the system before
adding a new lubricant.
Storage
When the jaw crusher will 4. Attach a tag to the jaw Extended Period Storage
not be used for a period of a few crusher indicating what (6 months or more)
months, use the following storage procedures have
procedure to minimize been done. If the machine will be stored for
corrosion and deterioration. a period of six months or more
5. Spray a rust preventative on follow the guidelines below.
1. Remove all dirt and debris screws, rods, etc.
from the jaw crusher. These guidelines should be
completed once every three
2. Lubricate all points as months.
specified in the lubrication
section of this manual. • Lubricate bearings
• Rotate the shaft two
3. Clean the outside of the jaw revolutions.
crusher and repaint areas
where needed.
1-1
Introduction to the Jaw Crusher

Jaw crusher orientation is References to the front and/
determined by standing at the or back will be as shown below.
front of the jaw crusher looking
toward the direction of travel
Material flow
Left Side Front View
Right Side Rear View

1-2 Introduction to the Jaw Crusher
The following is a brief

description of the jaw crusher’s
basic parts and their function.
Base
The base contains the crushing
chamber for the stationary jaw
and the moving jaw. Steel
saddles at the top of the base
support the eccentric shaft and
pitman assembly. The lower
rear section contains the
adjusting mechanism and
supports the tension rod
assembly. Abrasion resistant
steel wear plates, bolted to the
sides of the base, hold the
stationary jaw in place.
Eccentric Shaft
The eccentric shaft translates

circular motion into the crushing
actions of the moving jaw. The
shaft revolves on two roller
bearings mounted at the top of
the base. The center portion of
the shaft is eccentric and carries
the pitman on two inner roller
bearings.
Introduction to the Jaw Crusher 1-3
Pitman
The pitman carries the moving

jaw and moves in an oval path
from the rotation of the eccentric
shaft.
Flywheels
The flywheels store energy to

provide smooth operation when
surges of material enter the
crusher. The motor drives the
jaw with a v-belt drive to the
flywheel.
Moving Jaw
The moving jaw is located

opposite the stationary jaw and
moves toward the stationary jaw
and downward. This motion
causes the material being fed
into the chamber to be crushed.
Both jaw dies are reversible to

extend jaw life.
Stationary Jaw
The stationary jaw fits on the

inside front face of the base.
The moving jaw pushes material
against the stationary jaw to
crush material.
Side Liners
The side liners, which are made

of abrasion resistant steel, line
the sides of the base for wear
protection.
Introduction to the Jaw Crusher 1-5
Tension Rods
The tension rod assembly is a

threaded rod extending through
a spring. This assembly pulls
the pitman back against the
toggle plate holding it in place.
Toggle Plate
Toggle plate
The toggle plate positions the
lower end of the pitman.
Toggle seat
Toggle Plate and Toggle Seat
Adjusting Mechanism
The mechanism sets the

opening at the bottom of the
jaws. Adjustments are made
by moving the wedges with
hydraulic cylinders and properly
adjusting tension rods. Closed
side setting is adjustable to
control material size.
Grease Type System

The grease type system uses a
self-purging seal which allows
contaminants to be forced out
when fresh grease is added.
Eccentric Shaft
Side Liners
Pitman
Base
Stationary
Jaw
Adjusting
Mechanism
Moving Jaw
Toggle Plate
Tension Rods
2-1
Safety First!
This symbol is used to bring
attention to safety precautions
Warning decals have also
been placed on the equipment DANGER
and instructions. to provide instructions and to Imminently hazardous situation
identify specific hazards which, which, if not avoided, will result
if not heeded, could cause in death or hazardous injury.
bodily injury or death to you or
other persons.
KPI-JCI cannot anticipate WARNING
every possible circumstance A potentially hazardous
that might involve a potential situation which, if not avoided,
hazard. The warnings in this could result in death or serious
When you see this symbol, publication and on the injury.
be alert and pay attention to all equipment are therefore not all
instructions. inclusive.
If an operation is not
CAUTION
YOUR PERSONAL SAFETY A potentially hazardous situation
performed as specifically which, if not avoided, may result
IS INVOLVED recommended by KPI-JCI you in minor or moderate injury. It
must satisfy yourself that it is may also be used to alert against
Most accidents are caused safe for you and others. You
by failure to observe basic unsafe practices.
should also ensure that the
safety rules or precautions. An
accident can often be avoided
equipment will not be damaged
or made unsafe by the method NOTICE
by recognizing potentially of operation you choose. Specific practices that are
hazardous situations before an The following signal words critical to the operation or
accident occurs. may be used in this manual to maintenance of the equipment.
Improper operation is designate a degree or level of
dangerous and could result in hazard and are defined as
injury or death
Basic safety precautions
follows. CAUTION
are outlined in the “SAFETY Read and understand all
PRECAUTIONS” portion of this safety precautions and
manual and in the description warnings before operating
of operations where hazards this equipment
exist.
2-2 Safety First!
The safe operation and others and are not qualified to 5. Check and secure all
maintenance of the jaw crusher operate or service the jaw guards before operating.
is the responsibility of the owner/ crusher. Repair or replace any
employer and the operator/ Never modify the jaw damaged or missing
employee. crusher in any way. guards or guarding
The owner/employer must Unauthorized modifications can devices.
ensure that anyone who affect the function and/or safe
operates, maintains, services, operation and life of the jaw 6. Repair or replace any
transports or works around the crusher. damaged handrails,
conveyor is familiar with ladders or walkways.
operation, maintenance and General Safety
safety procedures and 7. Place all controls in neutral,
information outlined in this The following section stop engine, remove
manual. presents material on specific ignition key, follow lockout/
safety items. Although specific tagout procedure and wait
Owner/Employer's safety guidelines are given, for all motion to stop before
Responsibility each situation can have its own lubricating, adjusting or
peculiarities which can not servicing.
It is the owner/operator's always be covered by specific
responsibility to insure rules. 8. Clear area of people
everyone operating the before starting the
equipment is familiar with safe 1. Read and understand the conveyor.
operation and maintenance of Operation and Maintenance
the jaw crusher. Do not risk manual before operating, 9. Review safety practices
injury or death by ignoring safety servicing or working around annually.
practices or failing to instruct. this machine.
It is the owner's Assembly Safety
responsibility to give the 2. Have a first aid kit
operator or employee available and know how to 1. Assemble in an area with
instruction before allowing them use it. sufficient space to handle
to operate, service, transport the largest component and
or work around the jaw crusher. 3. Have a fire extinguisher access to all sides of the
This instruction should be available and know how to machine.
reviewed at least annually. use it.
2. Use only cranes, jacks and
Operator/Employee's 4. Wear necessary protective tools with sufficient
Responsibility gear, including but not capacity.
It is the operator's limited to:
responsibility to read, a. Hard hat 3. Do not allow spectators in
understand and follow all b. Protective shoes with the assembly area.
operation, service and safety slip resistant soles
information presented in this c. Eye protection
manual and on the conveyor. d. Protective gloves
Untrained operators and e. Hearing protection
maintenance personnel are a f. Respirator or filter
hazard to themselves and mask
Safety First! 2-3
Operating Safety 3. Always be aware of the counterbalance valve

location of other personnel before servicing or
1. Read and understand the and keep them away from maintaining system.
Operation and Maintenance hazard areas.
manual before operating, 8. Keep hands, feet, hair and
servicing or working around 4. Keep away from power clothing away from moving
this machine. lines when relocating or or rotating parts.
transporting the conveyor.
2. Keep hands, feet, hair and 9. Clear the area of
clothing away from moving bystanders when carrying
parts. Maintenance Safety out any maintenance or
adjusting.
3. Follow lockout/tagout 1. Read and understand the
procedure and wait for all Operation and Maintenance Hydraulic Safety
motion to stop before manual before lubricating,
lubricating, adjusting or servicing or working around 1. Always place all controls in
servicing. this machine. neutral before servicing
hydraulic system.
4. Clear the area of people 2. Support the machine with
before starting the jaw blocks when changing 2. Replace any worn, cut,
crusher. tires. abraded, flattened or
crimped hoses or steel
5. Place the jaw crusher so 3. Follow lockout/tagout lines.
that it is visible from the procedure and wait for all
operator's station. motion to stop before 3. Do not attempt any
lubricating, adjusting or makeshift repairs to the
6. Never operate the jaw servicing. hydraulic lines, fittings or
crusher if it has been hoses by using tape,
damaged. 4. Follow good shop clamps or cements.
practices.
7. Keep all hydraulic lines, The hydraulic system
fittings and couplers free 5. Make sure all guards are operates under extremely
from leaks before in place and properly high-pressure. Such
operating. secured when repairs will fail suddenly
maintenance work is and create a hazardous
8. Review safety practices completed. and unsafe condition.
annually.
6. Never wear poor fitting,
Operating Safety Area baggy or frayed clothing
when working around or
1. Keep away from receiving on any of the drive system
hopper and loading area. components.
2. Keep away from discharge 7. Relieve pressure from the

end. hydraulic circuit and at the
2-4 Safety First!
4. Wear proper hand and eye 5. Be sure that electrical power 6. If applicable, be sure the
protection when searching supplies are located in an king pin is locked and the
for a hydraulic leak. Use area that will be safe from break-away safety chain is
a piece of wood or accidental contact during attached to the tow vehicle
cardboard as a backstop crushing operations. before towing.
instead of hands to isolate
and identify a leak. 6. Be sure all connections are 7. The machine is not
in accordance with the grounded. Electrocution
5. If injured by a National Electric Code and can occur without direct
concentrated high- any applicable state or local contact. Stay away from
pressure stream of codes. overhead power lines.
hydraulic fluid, seek
medical attention Transport Safety
immediately. Serious Tire Safety
infection or toxic reaction 1. Make sure you are in
can develop from hydraulic compliance with all local 1. Failure to follow proper
fluid piercing the skin regulations regarding procedures when
surface. transporting equipment on mounting a tire on a wheel
public roads and or rim can produce an
Electrical Safety highways. explosion which may result
in serious injury or death.
1. Be sure that all electrical 2. Make sure that all the lights
equipment is properly and reflectors that are 2. Do not attempt to mount a
grounded. required by the tire unless you have the
local highway and proper equipment and
2. Lay out the power lines, transportation authorities experience to do the job.
particularly those for are in place, are clean and
portable plants, so that can be seen clearly by all 3. Have a qualified tire dealer
contact with standing water overtaking and oncoming or repair service perform
is minimized. traffic. required tire maintenance.
3. Do not place power lines in 3. Do not allow anyone to ride

an area where they will be on the jaw crusher during
driven over by transport transport.
vehicles or other quarry
equipment. If it is necessary 4. Do not exceed 55 mph
to extend a power line when transporting the
across a traffic area, protect machine. Reduce speed
the cable with properly rated on rough roads and
bridging. surfaces.
4. Be sure that all auxiliary 5. Install lighting bar when

control panels or power transporting.
supply panels can be
securely locked out.
Safety First! 2-5
Lockout Procedures every worker is in a safe place. energy as part of the operation
Lockout procedures are a This last step often involves of the machine. For example, a
principal means of controlling placing padlocks on equipment device might use electricity to
energy hazards. A lockout controls, which is the origin of power a pump, creating
procedure is a set of safe work the term “lockout”. For example, hydraulic pressure to operate
practices and rules that makes there might be five workers the device. The hydraulic
it impossible for a worker to involved in a maintenance pressure remains stored in the
come into contact with an procedure. Each of them might system even when the
uncontrolled energy source. have a color-coded lock. All five electricity is turned off. Gravity
The first step in designing locks could be placed on an and momentum can be stored
a lockout procedure is to electrical switch, preventing the in a stationary machine by
identify all sources of energy power from being turned back springs or counterweights. The
that affect the work. on until all workers have term zero energy state means
Second, before workers removed their locks. that all of these energy sources
have been controlled.
Lockout Policy
Every workplace where
workers could come into
contact with energy sources
should have written safe work
procedures that implement a
lockout policy.
In some cases job hazard
analyses will be required.
Training programs need to
be designed. Responsibility for
specific lockout procedures
must be assigned to individuals
by the employer.
enter the area to make Zero Energy State The exact procedures
adjustments or perform Achieving a zero energy involved in implementing a
maintenance, action must be state is often more complex lockout will depend on the
taken to neutralize, redirect or than the simple example given circumstances of the individual
stop the energy from above. Energy sources are not workplace. These general
performing its normal function. always obvious. Equipment is principles apply in every
The third step is to verify often initially powered by situation.
that a zero energy state has electricity. But this “main”
been achieved. This means energy source may be
that there is no energy available converted into other forms of
to cause a hazard.
CAUTION
The final step is to physically
prevent the accidental re-
energizing of the system until Failure to follow correct lockout/tagout procedures could
the work is completed and result in death or serious injury.
2-6 Safety First!
Anyone who will be operating and/or A sign-off sheet has been provided for your
maintaining the jaw crusher must read and clearly record keeping to show that all personnel who will
understand all safety, operating and maintenance be working with this equipment have read and
information presented in this manual. understand the information in this manual and
that they have been instructed in the operation of
Do not operate or allow anyone else to operate this equipment.
this equipment until this manual has been read
and clearly understood. This manual should be reviewed at least
annually.
The following personnel have reviewed and have been trained in the proper operation and maintenance
of the Vanguard jaw crusher.
Date of review and

training completion Trainee Signature Trainer Signature
2-7
Safety Decals
CAUTION The following illustrations are shown to help
identify decals when they require replacement.
Safety decals are provided for your Make sure machine surface is clean and free
personal safety. If they should become from grease and oil before applying new decal.
damaged, they must be replaced.
139083 254815
Black PIONEER logo
114933 213616
221578
Built in USA decal with
eagle and American
flag
265540
3055 only 220762
KPI-JCI logo -
rectangle
** 46-60146 - Rock Eater Dragon decal may be included in decal kit. This decal can be placed anywhere on either
side of jaw ba
2-8 Safety Decals
139083
114933 174848
24 hour parts &
service decal
254815
Black PIONEER
logo
265543
221578 3055 only
Built in USA decal with 220762
eagle and American KPI-JCI logo -
flag rectangle
139014
Located on inside jaw

base.
Safety Decals 2-9
! CAUTION
1. Read and understand manual before
operating. If you do not have a manual
WARNING
contact: Kolberg-Pioneer, Box 20,
Yankton, SD 57078.
2. Do no lubricate, adjust, clean, or service
equipment while in operation.
3. Disconnect, lock-out and tag-out power
before servicing.
4. Be sure all safety devices and shielding
are in place and functioning before
operating.
5. Be sure everyone is clear before starting
equipment.
6. Wear hard hat, safety goggles and
protective footwear while operating.
7. Breathing crystalline silica dust or other
contaminates can cause serious or fatal
respiratory diseases including silicosis.
Respirator may be required.
LOADING AREA
8. Noise hazard is possible. Hearing
protection may be required.
9. Keep away from overhead electrical while
operating or moving.
Keep Away
10. Review all safety instructions annually. P/N 139083
P/N 114933
P/N 139083
P/N 114933
! WARNING
Respiratory hazard.
Breathing crystalline silica dust
or other contaminates can
cause serious or fatal
respiratory diseases including
silicosis.
Wear approved respirator in
this area.
P/N 213616
P/N 213616
3-1
Specifications - 2640
95”
14”
50”
”
40
26”
51.5”
Jaw Opening (Gap): 26" (660 mm) Standard Toggle Plate Weights: 258 lbs
(117 kg)
Jaw Width: 40" (1,016 mm)
Top Adjusting Wedge Weight: 320 lbs.
Moving Jaw, Overall Depth: 53" (1,346 mm) (145 kg)
Stationary Jaw, Overall Depth: 49" (1,244 mm) Bottom Adjusting Wedge Weight: 250 lbs.
(113 kg)
Power Required (HP): 150 Electric,
190 Diesel Moving Jaw Die Weight: 2000 lbs.
(907.2 kg)
RPM: 280
Stationary Jaw Die Weight: 1764 lbs.
Eccentric Stroke: 1-1/4" (32 mm) (800.13 kg)
Weight: 29,500 lbs.(13,393 kg) A-dimension: 41.370 - 41.380
Base Weight: 8,900 lbs.(4,037 kg) Standard CSS (at factory):
Pitman Assembly Weight: 8,930 lbs. (4,051 kg)
Flywheel Weight (each): 2,650 lbs. (1,202 kg)
Peak to Peak Closed Side Setting - Approximate Capacity

Crusher Setting 2 1/2” 3” 3 1/2” 4” 5”
(Close of inches
Stroke) mm 64 76 89 102 127
* Tons per Hour 140 160 180 200 240
mt/h 128 145 164 182 218
3-2
Specif ica
Specifica tions - 2650
ications
104 1/2”
14”
50”
”
50
26”
61”
Jaw Opening (Gap): 26" (660 mm) Pitman Assembly Weight: 10,270 lbs.
(4658 kg)
Jaw Width: 50" (1270 mm) (less flywheels)
Moving Jaw, Overall Depth: 53" (1346 mm) Flywheel weights (each): 2,328 lbs.
(1056 kg)
Stationary Jaw, Overall Depth: 49" (1244 mm)
Standard Toggle Plate Weights: 540 lbs.
Power Required (HP): 150 Electric, (245 kg)
190 Diesel
Top Adjusting Wedge Weight: 307 lbs.
RPM: 285 (139 kg)
Eccentric Stroke: 1-1/4" (32 mm) Bottom Adjusting Wedge Weight: 246 lbs.
(112 kg)
Weight: 32,300 lbs.
(14,528 kg) Moving Jaw Die Weight: 2,437 lbs.
(1105 kg)
Base Weight: 10,370 lbs.
(4658 kg) Stationary Jaw Die Weight: 2,207 lbs.
(1001 kg)
A-dimension: 50.870 - 50.880

Crusher Setting 2 1/2” 3” 3 1/2” 4” 5”
(Close of inches
Stroke) mm 64 76 89 102 127
* Tons per Hour 165 188 211 235 282
mt/h 150 170 192 216 256
3-3
Specif ica
ications
108”
50” 63”
55”
30”
Jaw Opening (Gap): 30" (762 mm) Flat Flywheel Weight: 3,066 lbs.
(1391 kg)
Jaw Width: 55" (1397 mm)
Grooved Flywheel Weight: 2,657 lbs.
Moving Jaw, Overall Depth: 60.5" (1537 mm) (1205 kg)
Stationary Jaw, Overall Depth: 59.5" (1511.3 mm) Toggle Plate Weight: 732 lbs.
(332 kg)
190 Diesel Top Adjusting Wedge Weight: 583 lbs.
(264 kg)
RPM: 250
Bottom Adjusting Wedge Weight: 463 lbs.
Stroke: 1-1/2" (32 mm) (210 kg)
Weight: 50,000 lbs. (22,700 kg) Moving Jaw Die Weight: 3,450 lbs.
(1565 kg)
Base Weight: 15,350 lbs. (6963 kg)
Stationary Jaw Die Weight: 2,940 lbs.
Pitman Assembly Weight: 16,450 lbs. (7462 kg) (1334 kg)
(less flywheels)
A-dimension: 56.870 - 56.880

Crusher Setting
in.
3” 3 1/2” 4” 5” 6” 7”
(Close of
Stroke) mm 76 89 102 127 152 178
* Tons per Hour 265 300 334 402 471 528
mt/h 240 272 302 365 428 479
3-4
Specif ica
ications
94”
50” 63”
44”
31”
Jaw Opening (Gap): 31" (787 mm) Flat Flywheel weight: 2,882 lbs.
(1307 kg)
Moving Jaw, Overall Depth: 65" (1651 mm) (689 kg)
Stationary Jaw, Overall Depth: 62" (1575 mm) Standard Toggle Plate Weights: 560 lbs.
(254 kg)
(183 kg)
RPM: 260
Stroke: 1-1/2" (32 mm) (210 kg)
Weight: 43,500 lbs. Moving Jaw Die Weight: 2,540 lbs.

(19,746 kg) (1152 kg)
Base Weight: 14,300 lbs. Stationary Jaw Die Weight: 2,600 lbs.
(6486 kg) (1179 kg)
Pitman Assembly Weight: 12,600 lbs. A-dimension: 44.870 - 44.880

(5715 kg)
less flywheels

Crusher Setting
in.
3” 3 1/2” 4” 5” 6” 7”
(Close of
Stroke) mm 76 89 102 127 152 178
* Tons per Hour 212 240 267 320 373 426
mt/h 191 218 241 288 355 383
3-5
Specif ica
ications
115.65”
65”
31”
97”
(1232 kg)
Moving Jaw, Overall Depth: 60.5" (1536 mm) (1177 kg)
Stationary Jaw, Overall Depth: 56" (1422 mm) Toggle Plate Weight: 795 lbs.
(361 kg)
Power Required (HP): 200 Electric
(283 kg)
RPM: 243
Stroke: 1-1/2" (38 mm) (222 kg)
(2153 kg)
Base Weight: 22,080 lbs. (10,015 kg)
Stationary Jaw Die Weight: 4,413lbs.
Pitman Assembly Weight: 19,820 lbs. (8990 kg) (2002 kg)
less flywheels
A-dimension: 66.058 - 66.068

Crusher Setting
(Close of in. 3” 3 1/2” 4” 5” 6” 7” 8”
Stroke) mm 76 89 102 127 152 178 203
* Tons per Hour 265 305 372 459 530 611 692
mt/h 240 277 337 415 480 554 628
3-6
Specif ica
ications
112”
62 3/4”
52”
33”
90”
Jaw Opening (Gap): 33" (838 mm) Flat Flywheel Weight: 3830 lbs.
(1737 kg)
Stationary Jaw, Overall Depth: 69" (1753 mm) Toggle Plate Weight: 26” - 613 lbs. (278 kg)
28” - 852 lbs. (386 kg) 31” - 1,090 lbs. (494 kg)
(268 kg)
RPM: 225
Stroke: 1-1/2" (38 mm) (226 kg)
(2253 kg)
Base Weight: 22,420 lbs. (10,170 kg)
Pitman Assembly Weight: 23,200 lbs. (10,523 kg) (2393 kg)
less flywheels
A-dimension: 53.035 - 53.045

Crusher Setting
(Close of inches 3 1/2” 4” 5” 6” 7”
Stroke) mm 89 102 127 152 178
* Tons per Hour 218 360 416 484 553
mt/h 250 328 378 440 503
3-7
Specif ica
ications
116”
63”
50”
44”
133”
(1544 kg)
Stationary Jaw, Overall Depth: 94" (2388 mm) Toggle Plate Weight: 680 lbs.
(308 kg)
(268 kg)
RPM: 230
Stroke: 1-1/2" (38 mm) (226 kg)
Weight: 101,900 lbs.(46,262 kg) Moving Jaw Die Weight: 6,780 lbs.
(3075 kg)
Base Weight: 35,000 lbs.(15,876 kg)
Pitman Assembly Weight: 34,000 lbs (15,422 kg) (2994 kg)
less flywheels
A-dimension: 50.930 - 50.940

Crusher Setting
(Close of in. 4” 5” 6” 7” 8” 9”
Stroke) mm 102 127 152 178 203 228
* Tons per Hour 423 492 574 654 735 816
mt/h 386 448 521 595 668 740
4-1
Application
The Pioneer Vanguard jaw The space between the Feed size is limited to 80%
crusher can be used as a stationary and moving jaw is of the jaw gap. Product size is
primary or secondary crusher called the crushing chamber. controlled by adjusting the
for all types of aggregate The opening at the top of the closed side setting (CSS) at the
material including sand and crushing chamber has fixed bottom of the jaw crusher. This
gravel or shot rock, as well as dimensions, but the distance setting is adjusted using a
recycle. between the stationary jaw and hydraulic adjust wedge valve to
the moving jaw at the bottom of increase or decrease
In this type of crusher, a the crushing chamber can be discharge opening. The closed
moving jaw is attached to the varied. side setting (peak to peak) is
pitman, a large pendulum-like adjustable between 2 1/2”- 8”
casting, which is mounted at its The material is reduced in depending on jaw crusher
upper end with bearings on an size as it moves further down model. See specifications for
eccentric shaft fixed with into the crushing chamber and more information on the
another set of bearings to the is finally discharged directly approximate capacity of the
top of the crusher base. below the crusher onto the closed side setting.
undercrusher conveyor.
The material to be
processed is fed into a crusher
hopper directly above the
crushing chamber or a vibrating
grizzly feeder. The material is
reduced in size as it moves
further down into the crushing
chamber and is finally
discharged directly below the
crusher.
The rotating eccentric shaft

induces an oval motion; each
rotation of the shaft causes it to
move toward the stationary jaw
and downward. It is this motion
which causes the material fed
into the chamber to be crushed.
Oversized Material in Jaw Crushing Chamber

4-2 Application
The Jaw Crusher is On jaw crusher units without Feeding material over the
generally fed using an a vibrating feeder, or with a maximum feed size could
excavator, front end loader, or feeder more than fifteen feet, a drastically lower production,
similar equipment. Efficiency bucket loader can be used to damage equipment
and production is greatly feed material into the jaw components, and could cause
improved by pre-sizing and/or crusher. jamming and bridging.
prepping the material. Pre-
sizing includes eliminating Maximum feed size is 80% Do not overfeed the jaw
material larger than the of the jaw gap. Quarry and shot crusher. Overfeeding occurs
recommended top size (see rock material characteristics when the material in the
chart on page 4-2) as well as may allow a maximum feed size crushing chamber comes in
minimizing the amount of fines of 90% of the jaw gap (consult contact or backfeeds into the
in the feed material. For factory before feeding material feed mechanism. Backfeeding
example, when recycle larger than 80% of jaw gap). into the feed mechanism will
concrete is removed from See the table for maximum result in damage to the feeder.
roadway, care should be taken feed size according to jaw
to reduce the amount of model.
subgrade material that is
NOTICE
removed with the concrete.
This will result in more efficient
crusher operation as well as a Overloading may damage
cleaner product. the crusher. Do not exceed
recommended reduction
For Fast Trax Jaw Plants ratio.
with vibrating feeders, the
excavator is the preferred
Jaw Maximum Feed Size (80% of jaw gap)
method of loading the jaw 2640 21” (53 cm)
crusher for several reasons 2650 21” (53 cm)
including a more consistent 3055 24” (60 cm)
feed rate, convenient, 3144 24” (63.5 cm)
continuous prepping process 3165 24” (63.5 cm)
to identify oversize and 3352 27” (66 cm)
unwanted contamination in 4450 36” (89 cm)
recycle. This is more difficult
with a larger loader bucket due
mainly to visibility and the size
of the load being delivered to
the feeder hopper. With a
smaller bucket size on the
excavator, it is easier to direct
the feed to the solid pan section
of the feeder.
Application 4-3
The jaw crusher operates

Crushing chamber
most efficiently at a uniform (outlined in black)
feed rate according to its
capacity at a predetermined
closed side setting.
The crushing chamber is the

area from the bottom of the
wedge at the top of the jaw
crusher to the ends of the jaw
dies at the bottom. Refer to the
picture below for more
information.
Production rates will vary

depending on feed material
type, gradation of the feed and
feed methods, material
hardness and shape, the
amount of fines in the material
being processed, and the
closed side setting.
Choke Point The material can compact,
Rock is typically crushed in restricting progress down to the
stages as it progresses further The choke point of the next crushing zone, drastically
down into the crushing crushing cavity is a zone of reducing capacity. This is
chamber. minimum capacity. It is that known as the choke point.
point or zone in the chamber
Optimum reduction is where the volume of material Choking occurs when
typically 6:1 for hard rock and can approach a solid mass. enough fines are present in the
8:1 for soft rock and recycle. feed material or produced in the
Reference “Allowable Minimum Upon entering the crushing crushing process to eliminate
Closed Side Setting” table on chamber, the material is most of the voids in the choke
page 4-6 for more information. composed of large particles zone.
with numerous voids. As they
Reductions over 8:1 tend to are crushed, the particles Jaw crusher capacity is
choke the crusher by holding become smaller, as do the influenced by many factors
rock in the bottom of the voids. This process continues which are widely variable and
crushing chamber causing it to down through the cavity until the will directly affect production.
pack. Packing, or any voids are essentially Material hardness and shape,
condition causing a loss of nonexistent. the amount of fines in the
“voids”, can cause overload material being processed,
and may result in damage to material feed method and the
the crusher. crusher discharge setting are
all factors affecting production.
4-4 Application
The jaw crusher operates

the most efficiently at a uniform
feed rate according to its
capacity at a predetermined
setting. Prescreening material
will remove fines and increase
production capacities.
Presizing material will also

increase production capacities
and reduce maintenance cost.
Crushing oversized material

will cause damage to the jaw,
bearings, jaw base or the shaft
assembly.
Percentage Chart
The chart shown to the right Choke point

is particularly useful in
determining the percentages of
various sizes that will be
produced. It is also helpful in APPROXIMATE GRADATIONS AT PEAK TO PEAK CLOSED SIDE SETTINGS
determining necessary Test Test

3/4” 1” 1 1/4”1 1/2” 2” 2 1/2” 3” 3 1/2” 4” 5” 6” 7” 8”
Sieve Sieve
screening facilities for making Sizes 19 25.4 31.8 38.1 50.8 63.5 76.2 89.1 102 127 152 178 203 Sizes
size separations. (in.) mm mm mm mm mm mm mm mm mm mm mm mm mm (mm)
12 100 98 95 305
To determine the amount of a 10 100 97 95 90 254
particular size material 8 100 96 92 85 75 203
7 Values are percent passing 100 97 92 85 76 65 178
produced at a closed side 6 100 98 93 85 74 65 53 152
setting, find the closed side 5 100 97 95 85 73 62 52 40 127
4 100 96 90 85 70 56 45 38 28 102
setting at the top of the chart 3 100 93 85 75 65 50 38 32 27 23 76.2
2 1/2 100 95 85 73 62 52 38 31 24 22 17 63.5
and follow down the vertical line 2 100 96 85 70 55 47 39 28 24 20 17 13 50.8
to the size to be produced. The 1 1/2 100 93 85 67 49 39 33 27 21 18 15 13 10 38.1
1 1/4 96 85 73 55 39 31 27 23 17 15 13 10 8 31.8
figure in the horizontal line will 1 85 69 55 40 29 24 20 17 14 12 10 8 6 25.4
show the percent passing at 3/4 66 49 39 28 21 18 15 13 11 9 8 6 5 19
1/2 41 29 24 19 14 12 10 9 7 6 6 5 4 12.7
that setting. 3/8 28 21 18 14 11 9 8 7 5 5 5 4 3 9.53
1/4 18 14 12 10 7 7 6 5 4 4 4 3 2 6.35
#4 12 10 9 7 5 5 4 4 3 3 3 2 1 #4
Example: #8 6 6 5 5 4 4 3 3 2 2 2 1 0.5 #8
To determine the amount of 2”

the vertical line to 2” test sieve
material when the crusher is set
sizes. The horizontal line
at 3” closed side setting, find
shows 47% passing or 53%
3” at the top and follow down
retained.
Application 4-5
Calculating Closed Side Minimum Closed Side Setting* listed since it is a not a fixed
Setting (CSS) 2640 2 1/2” dimension. It will vary
2650 2 1/2” depending on crushing
Before the closed side 3055 3”
3144 3”
conditions, the compressive
setting (CSS) can be 3165 3” strength of the material being
calculated, the open side 3352 3 1/2” crushed and the material work
setting (OSS) must be 4450 4” index number.
*Rock compressive strength
measured. The OSS is the 30,000 psi or lower
measurement of the jaw dies If the compressive strength
from peak to peak when the Minimum Closed Side of the rock is 30,000 PSI or
jaw is at rest. Setting (CSS) lower the minimum closed side
setting is used (refer to the
Note: The pitman must be in The minimum closed side Minimum Closed Side Setting
its lowest position to measure setting may be greater than table on this page).
the OSS.
To calculate the CSS Minimum CSS Measurement - 30,000 PSI and Higher
subtract the crusher’s throw Rock Compressive
from the OSS. Jaw Multiplier Gap Minimum
Strength CSS
2640 30,000 .12 3.12
On 2640 and 2650 jaws the
35,000 .14 3.64
throw is 1.25”. On all other 26
40,000 .16 4.16
models the throw is 1.5”. 2650 45,000 .18 4.68
For example, the throw 50,000 .20 5.20
(stroke) on the 2640 is 1- 1/4” 3055 30,000 .12 3.60
and the OSS is 4”. The CSS is 35,000 .14 30 4.20
2 - 3/4”. 40,000 .16 4.80
45,000 .18 5.40
4” - 1-1/4” = 2-3/4” 50,000 .20 6.00
3144 30,000 .12 3.72
Open side 35,000 .14 4.34
setting 31
(peak to peak 40,000 .16 4.96
measurement 3165 45,000 .18 5.58
at rest)
50,000 .20 6.20
30,000 .12 3.96
NOTICE 3352
35,000
40,000
.14
.16 33
4.62
5.28
Never operate jaw crusher 45,000 .18 5.94
below minimum closed side 50,000 .20 6.60
setting.
30,000 .12 5.28
4450 35,000 .14 6.16
40,000 .16 44 7.04
45,000 .18 7.92
50,000 .20 8.80
4-6 Application
If the compressive strength of
60
the rock is 30,000 PSI or higher,
Average Compressive Strength

123456712345678901234
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50
use the table on page 4-5 to 1234567
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determine the minimum CSS. 1234567123456
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40
(X = 1000 PSI)
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NOTICE
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30
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Adjust the CSS when the 1234561234567123456123456712345678901234
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20
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compressive strength of the 1234561234567123456123456712345678901234
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10
material is higher than 30,000 1234561234567
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PSI. 1234561234567123456
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.05 x G .10 x G .15 x G .20 x G12345678901
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Example: 2640 Jaw 12345678901
Allowable Minimum Closed Side Setting 12345678901
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Gap: 26” (G=Gap opening in inches) Safe zone
PSI: 40,000 of operation
Minimum C.S.S.:
.16 x 26” = 4.16” C.S.S.
Filled-in-end Jaw Dies
KPI-JCI allows the use of a

filled-in-end jaw die on one side
only. The use of filled-in-end
jaw dies on both sides can
generate up to 5x more force
in the crushing chamber
compared to standard ribbed
jaw dies.
When using filled in or flat

jaw dies (dies with little or no
corrugation) an adjustment to
the CSS is required.
KPI-JCI requires the Filled-in-end Jaw Die

operator to make at least a 1”
adjustment in the minimum Using filled-in-end or flat
CSS as detailed on page 4-5. jaw dies without prior factory
This adjustment is in addition approval may void warranty.
to the adjustment made for the Consult factory before using
compressive strength. See these types of jaw dies.
page 4-5 for more information
on CSS adjustment.
Application 4-7
Worn Jaw Dies
Jaw die maintenance is

essential for consistent
production as well as for overall
jaw crusher performance.
Worn jaw dies require

higher pressure to crush rock
and when jaw teeth are worn to
75-80% of new jaw die tooth
depth, the material cannot flow
freely causing packing and
crusher overload.
New Jaw Die
Flip or replace jaw dies that
are worn 75-80% of new jaw die
tooth depth NOTICE
Jaw dies must be checked every ten hours for wear. Failure
If jaw dies have been worn to properly monitor and maintain jaw dies reduces
to a point where there are production, creates unnecessary stress on jaw crusher
pockets, flat spots, flat parallel components, and will void warranty.
zones, or fishhooking they
should be removed and
replaced.
See Maintenance - Wear

Items for procedure on
removing or replacing jaw dies.
Excessively Worn Jaw Die

5-1
Site Selection and Setup

Site Selection • Proper drainage. Proper Foundation
drainage is important to
allow for runoff of normal A properly constructed
When selecting a suitable site
rainfall. foundation that is level is critical
for operation, many factors
for proper operation of the jaw
need to be taken into
• Wind direction. You may crusher. Foundation drawings
consideration. Selecting a site
also want to consider are typically provided with the
without anticipating problems
prevailing wind direction crusher or can be obtained
could lead to unsatisfactory
and its effect on the operator from the factory.
operation and plant relocation
or loading personnel. Thick exterior grade 1/2”
could be required.
plywood shims, or factory
installed shims, should be
Some things to consider
installed between the crusher
when selecting a site:
• Ground stability. If the

ground is too soft or
unstable, proper leveling
and loading may be
impossible.
• Ample room. Leave plenty

of room around the screen
to facilitate access of
loading equipment,
assembly of screen
components and service
personnel.
Site Selection and Setup 5-2
base and the foundation.

These shims provide a means
of leveling and provide a
cushion between the crusher
frame and the foundation.
To ensure proper lubrication,
the eccentric shaft must be level
after installation is complete.
Level can be checked at the
machined surfaces or the
flywheels.
The base can be set at a
slight slope, 15 degrees
maximum, with the tension rod
end elevated. Lifting eyes
Platforms should be installed
to provide access for
maintenance. Local, state and
Jaw Base
federal guidelines should be
followed when installing these
platforms.
Lifting Crusher
Four lifting eyes have been

provided on the crusher base.
One at the upper corner of each
side plate.
CAUTION
Use only lifting equipment in
good condition with
sufficient capacity. Never
work under a suspended
load.
Lifting brackets provided on
the pitman are for lifting the
Lifting straps
pitman casting ONLY.
Lifting straps should be used Lifting Pitman from Base - Flywheels Removed for Clarity
to lift the pitman assembly with
the eccentric shaft and
flywheels. The entire crusher or
shaft assembly should never be
lifted using the lifting brackets
on the pitman.
5-3 Site Selection and Setup
CAUTION
Feed Arrangement Place the grizzly feeder or
scalping screen in a position to
It may be necessary to attach feed over the stationary jaw end The discharge opening of
a hopper or chutes to direct of the crusher. This method of the crusher must be
material flow to the crusher. feeding will direct the rock into guarded.
the crushing chamber and
NOTICE toward the moving jaw. To
reduce wear, material should
If a chute is used, it must be
When welding on or around sloped at least 45 degrees from
not be directed against the the horizontal to reduce
the crusher, make sure that
pitman barrel unless equipped plugging.
the ground lead does not arc
with a barrel protector wear
through the bearings.
plate. Drive
Consideration should be
Discharge Arrangement The jaw crusher uses a v-belt
given to the removal of feed
devices to allow for service, drive which is typically powered
Where possible, a shelf or by an electric motor or diesel
cleaning, and inspection of the
ledge should be constructed to engine. Use the following
crusher.
provide a bed of material for the procedure to install the v-belts
A properly installed feed
discharge material to hit. This if needed.
arrangement will provide an
ledge will absorb most of the
even distribution of material to
impact before it falls on the 1. Clean all grease, oil and
the jaw crusher opening.
conveyor or discharge device. foreign material from the
If the feed material contains
Material must not be allowed sheave grooves.
large amounts of fine material,
to buildup in the discharge
a grizzly feeder or screen
device. If material builds up to 2. Sheave alignment should
should be installed to remove
the lower part of the crusher, be checked prior to
this material prior to crushing.
excessive wear and damage to installing and tensioning
Removing fine material before
the crusher could occur. belts. Alignment can be
crushing will increase capacity
and reduce wear. checked using a straight
edge or by using a string or
cord.
Feeder
3. Complete electrical or
Jaw Conveyor
Screen diesel connections and
check the motor for proper
flywheel rotation.
CAUTION
Installation and
maintenance of electrical
devices must comply with
all applicable codes and
regulations.
Flywheel Balance The counterweight(s) on the

4. Place v-belts in sheave
flywheels must be positioned
grooves and tighten belts.
Flywheels are provided on as shown when the pitman is in
Never mix new and used v-
both sides of the crusher to the lowest position. Both
belts. Always use a
offset the vibration caused by flywheels must be installed in
matched set of v-belts to
the eccentric shaft. the balanced position for
provide best performance.
proper operation.
If the flywheels are not
WARNING properly balanced the crusher
will vibrate excessively causing
The flywheels can be
mounted on either side of the
The drive belts, motor damage and reducing crusher, but the counterweights
sheave, crusher sheave, production. MUST be in the balanced
and feed hopper must be
position for proper operation.
guarded.
5. Retighten v-belts after run-

in period.
Flywheel rotation
Counterweights
Flywheel
Pitman in lowest
position
Open Side Setting (OSS) Closed Side Setting (CSS)

Adjustment - Auto Adjust
Crusher Size Minimum Stroke Minimum
OSS (at rest) CSS *
The OSS is the peak to peak
2640 3 3/4” 1-1/4” 2-1/2”
measurement of the jaw
2650 3 3/4” 1-1/4” 2-1/2”
crusher when it is at rest. The
3144 4 1/2” 1-1/2” 3”
OSS measurement is used to
3055 4 1/2” 1-1/2” 3”
calculate the closed side setting
3163 4 1/2” 1-1/2” 3”
(CSS). If the OSS needs
adjustment, use the following 3352 5” 1-1/2” 3-1/2”
procedure: 4450 5 1/2” 1-1/2” 4”
* If compressive strength is greater than 30,000 PSI, or you are using a
filled-in-end jaw die, refer to page 4-5 and 4-6 for adjustment in minimum
1. Adjust the wedges all the CSS.
way out using the wedge
adjust hydraulic control
Spring compression
valve to synchronize the cylinder valve
Wedge adjust valve
system. Hold until cylinders
are fully retracted. This
resets the system and the
wedges will be aligned.
2. Adjust wedges in using the

wedge adjust hydraulic
control valve until desired
OSS is reached.
3. Shut down all power to the

jaw crusher. Follow all
lockout/tagout procedures.
4. Measure the peak to peak

OSS between the moving
and stationary jaw die as
described on page 4-5.
5. Calculate the CSS.
The CSS is calculated by

subtracting the crusher’s
stroke from the OSS
measurement.
Subtract 1-1/2” from the

OSS measurement. For
2640 and 2650 jaw OPEN SIDE SETTING
crushers, subtract 1-1/4”. Open Side Setting Measurement - Pitman is at rest and at lowest
position
NOTICE Centering the tension rods

inside the base of the spring
11. After all adjustments are
made, all personnel and
Never set the closed side plate maintains zero contact tools are clear of the
setting lower than the from tension rod to spring plate. machine, remove lockout/
minimum CSS. tagout.
6. Remove lockout/tagout. WARNING 12. Run the jaw empty to ensure

If the spring safety brackets that all adjustments have
7. Repeat steps 2-6 until have been removed, make been made correctly by both
desired CSS is reached. sure they are re-installed visual and audible
before operating the jaw. observation. Once this is
8. Use the spring Failure to do so could result achieved, begin crushing.
compression cylinder valve in serious injury or death.
to charge the system.
9. Check that 900 PSI relief

pressure is displayed on the
gauge.
In addition to this, listen for

toggle knock or look for
movement at the wedges. If
toggle knock or movement
is present, the relief
pressure in the auto adjust
circuit must be increased.
Spring safety
When the gauge pressure brackets
is 800 psi or below,
recharge the system. Refer
to page 8-2 to recharge the
system.
10. Make sure tension rods are

centered inside the spring
plate assembly.
If they are not centered,

follow the Synchronization
procedure on page 8-3 to
center.
Open Side Setting (OSS) Tension rod

Adjustment - Manual Adjust spring nuts
The OSS is the peak to peak

measurement of the jaw
crusher when it is at rest. The
OSS measurement is used to
calculate the closed side setting
(CSS). If the OSS needs
adjustment, use the following
procedure:
1. Shut down all power to the

jaw. Follow all lockout/
tagout procedures.
2. Loosen the tension rod

spring nuts with a 2-1/4”
wrench (2-5/8” wrench for Wedge adjust Wedge adjust
3352 jaws) until the spring valve valve
hangs freely on the tension
rods (this allows forward
travel of the wedges for
decreasing the CSS).
3. Remove lockout/tagout.
Restart the power source.
Make sure all personnel are
clear and in a safe area
before starting equipment.
4. Adjust wedges in or out

using the wedge adjust Closed Side Setting (CSS)
hydraulic control until the Crusher Size Minimum Stroke Minimum
desired OSS is reached. OSS (at rest) CSS *
2640 3 3/4” 1-1/4” 2-1/2”
Adjust both wedges equally 2650 3 3/4” 1-1/4” 2-1/2”
to keep the crusher load 3144 4 1/2” 1-1/2” 3”
centered on the jaw base. 3055 4 1/2” 1-1/2” 3”
3163 4 1/2” 1-1/2” 3”
5. Shut down all power to the 3352 5” 1-1/2” 3-1/2”
jaw crusher. Follow all 4450 5 1/2” 1-1/2” 4”
lockout/tagout procedures. * If compressive strength is greater than 30,000 PSI, or you are using a
filled-in-end jaw die, refer to page 4-5 and 4-6 for adjustment in minimum
CSS.
6. Measure the peak to peak

OSS between the moving
and stationary jaw die as
described on page 4-5.
7. Calculate the CSS
The CSS is calculated by

subracting the crusher’s
stroke from the OSS
measurement.
Subtract 1-1/2” from the OPEN SIDE SETTING

OSS measurement. For Open Side Setting Measurement - Pitman is at rest and at lowest
2540 and 2650 jaws deduct position
1-1/4”.
Pivot pin
NOTICE
Never set the closed side
setting lower than the
minimum CSS.
8. Repeat steps 3-7 until the

desired CSS is reached.
9. Make sure the tension rods

are centered inside the
spring plate assembly
(centering tension rods
slightly below center is best
to keep range of motion in Locking bolt
center).
Tip Spring Plate Assembly Up or Down To Center Tension Rods
To center the tension rods,

loosen the locking bolts.
This allows the spring plate
assembly to pivot up and
down for centering. Once
centered, tighten the locking
bolts.
Centering the tension rod inside

the base of the spring plate
maintains zero contact from
tension rod to spring plate. Tension Rod Centered Inside the Base of the Spring
10. Retighten the tension rod

spring nuts. Tension
rod spring nuts should be
tightened evenly and with
just enough tension to
eliminate toggle knock.
WARNING
If the spring safety brackets
have been removed, make
sure they are re-installed
before operating the jaw.
Failure to do so could result Spring safety
in serious injury or death. brackets
Begin with 1-1/2”

spring compression on each
tension rod (1-1/4” for 2640
and 2650 jaw crushers).
Tighten nuts in 1/4”
increments each time
thereafter until toggle knock
is eliminated. Spring
compression is measured
from a free standing length
(no compression) from
spring collar to spring collar.
Spri
ng C
Example: If free standing omp
ress
measurement is 13” then after ion
spring is compressed 1-1/4”,
measurement would be 11-3/
4”. Each spring should be 12. Run the jaw empty to
checked individually as spring insure that all adjustments
free standing length can vary. have been made correctly
by both visual and audible
11. After all adjustments are observation. Once this is
made, all personnel and achieved, crushing can
tools are clear of the begin .
machine, remove lockout/
tagout.
6-1
Operation
Use the following procedure Start the crushing operation in the order shown below:
to start the jaw crusher.
4. Feeder
Run the jaw crusher empty 2. Jaw 1. Conveyor
initially to insure everything is 3. Screen
operating properly and there are
no misaligned or binding parts.
Operate a new crusher empty
for 30 minutes to make sure all
components are functioning
properly. After this run-in period,
check bearing temperatures
and relubricate as required.
CAUTION
Before starting the jaw
Stop the crushing operation in the opposite order.
crusher, be sure all tools and
foreign objects have been
removed and everyone is for more than a second or If the crusher stops while
clear. two. When the clutch has crushing, and there is no
been fully engaged, the electrical or mechanical reason
1. Remove any shipping engine speed can for stoppage, reverse the
brackets or other material be increased. crusher if this option is available
used for transporting the on your unit, open the jaws, and
crusher. If the crusher becomes then restart the crusher. If this
blocked, it will be necessary to fails to start the crusher, it will be
2. Check the crushing stop jaw crusher operation, necessary to clear the crushing
chamber to make sure it is lockout power and remove the chamber manually.
empty. blockage.
3. Start the engine or electric

motor.
Oversized rock or material WARNING
should be lifted out or can be Never attempt to service or
broken to suitable sizes with a adjust this machine until all
If a diesel engine is hydraulic hammer. motion has stopped and
used, the jaw crusher may power has been
be started by using 3-4 short
engagements and NOTICE disconnected and locked
out.
disengagements of the Uncrushable material, such
clutch with the engine at idle. as tramp metal, must be
Under no circumstances prevented from entering the
should the clutch be slipped crushing chamber. Damage
to the crusher could result.
6-2 Operation
Although the toggle plate will

sometimes fail in the event of
an extreme overload, this may Crushing chamber 80%
full
not always occur and cannot be
counted on as a safety device.
The best assurance is to

prevent uncrushable items from
entering the jaw chamber.
Since most uncrushable items
are encountered while working
with recycle materials, such as
concrete, it is inevitable that this
will occasionally happen. In this
case, it may be beneficial for
the operator to use a lighter
duty, less durable toggle plate
in order to have a better chance
of the plate failing, thus sparing
the shaft and bearings.
NOTICE
The crusher should be fed
at a rate to keep the
crushing chamber no more
than 80% full.
Overfeeding the crusher will

result in damage to feeder
and crusher.
7-1
Preoperation Checklist
The preoperational check new site, or if it has been in condition. This check should
should be performed any time storage for an extended period. include, but not be limited to the
the equipment is moved to a Check each component to following items.
insure that it is in operational
PREOPERATIONAL CHECKS OK Adjust OPERATIONAL CHECKS OK Adjust
1.Sheet metal/appearance/paint. 1.Unit vibration.

2.Lubrication
a.Inner Pitman Bearings 2. Jaw crusher eccentric shaft
b.Outer Main Bearings RPM ________________
c.Type of grease__________
3. Crusher setting_______________
3.V-belts
4.Jaw Manganese 4. Bearings - record bearing temperatures as indicated
5.Tension Rod/Auto Adjustment below. Normal operating temperature is 30 above
Pressure ambient. If temperature is greater than 80 above
6.Safety guards in place. ambient contact factory.
7.General
a.Operator's manual on unit.
b.Decals in place and readable.
c.Safety guards in place 4 HOURS
Outer Main Bearing Outer Main Bearing

Initial Operation (float) (held - drive side)
The jaw crusher should initially be run empty Pitman Bearing
to insure everything is operating smoothly. While
the jaw is running, listen carefully for loose bolts, Pitman Bearing
screws, etc.
After the jaw crusher has operated for a few
minutes, disconnect and lockout power.
With jaw crusher stopped and power
disconnected and locked out, inspect for loose
bolts, screws, etc. and make any necessary
adjustments.
When this final inspection and adjustment 8 HOURS
has been completed, the jaw crusher should be
ready for service. (float) (held - drive side)
Pitman Bearing
Pitman Bearing
8-1
Pressure Adjustment and

Synchronization
Auto adjust allows the operator to change the
closed side setting (CSS) without adjusting the NOTICE
position of the tension rods, springs, and tension Release hydraulic pressure in
rod spring nuts. Tension rod adjustment is initially counterbalance valves prior to loosening
done at the factory; however, if major changes any hoses in the circuit. Follow the
have been made to the system, it must be “Instructions for Releasing Counterbalance
synchronized. Valve”.
There are two phases to synchronizing the

Flow divider
tension rod system. Phase one adjusts the
spring compression cylinder pressure to
compress the tension rod springs. Phase two
calibrates the system so that the cylinder stroke
is synchronized with the adjustment range of the
jaw and also to ensure that the tension rod is
centered in the spring plate hole.
It is important that tension rod and spring

adjustment are set at the correct initial position.
Spring adjustment is initially done at the factory.
Single counterbalance valve
This ensures that the spring and tension rod are
aligned with each other throughout the adjustment Auto Adjust Counterbalance Valve and Flow
range and the tension rod system is Divider Assembly
synchronized.
Dual counterbalance valve
If, for any reason, the tension rod nuts are

adjusted (for example,when changing springs on
tension rods) so that their location on the tension
rod is changed from the factory setting, the initial
location of the nuts on the tension rod should be
measured (refer to the table in step three of phase
two). Return the nuts to that location or follow
the initial setup procedure below. If the nuts are
not properly located, the tension rod system will
be out of synchronization.
The spring compression control valve system Dual Counterbalance Valve with Shuttle for Wedge
is protected from movement by a single Cylinders
counterbalance valve. The counterbalance valve
will hold the tension rod spring compression
cylinder in a fixed position during operation. The
wedge cylinders are held in position by dual
counterbalance valves.
Pressure Adjustment and Synchronization 8-2
Phase One - Setting Relief Pressure for 5. Loosen the jam nut on the auto adjust relief
Proper Spring Compression valve and turn screw clockwise to increase
pressure, counterclockwise to decrease
1. Use the jaw wedge adjust valve and cycle the pressure.
jaw wedge cylinders several times to
eliminate air in the lines. Note: Turning the screw on the auto adjust relief
valve 1/2 turn adjusts the pressure approximately
2. Set the wedge cylinders to approximately the 150 psi.
middle of their stroke. Be sure the spring is
seated inside the cup and the tension rod nut After adjustment is made, tighten the jam nut.
is loosely tightened against the spring.
6. Use the spring compression cylinder
3. Use the spring compression cylinder hydraulic valve to compress the springs.
hydraulic valve to compress the springs.
Check that the auto adjust relief pressure is 7. Repeat steps 4-6 until reading is 900 psi or
set at 900 psi. until there is no toggle knock or wedge
movement present.
Auto adjust Wedge adjust valve

relief valve
Relief Pressure Gauge - Located on Inside of Jaw

Base Spring compression
cylinder valve
Auto Adjust Relief Pressure Adjustment
Use the following procedure if the relief pressure

needs adjustment.
4. Use the wedge adjust hydraulic valve to move

the wedges in and out 1” to release the
tension in the cylinder.
NOTICE
Moving the wedges in and out after every
relief valve adjustment will give you an
accurate pressure reading in the spring
compression cylinder.
8-3 Pressure Adjustment and Synchronization
Phase Two - Synchronization
Once synchronized, you will not need to adjust

the tension rod nuts when making changes to the
closed side setting. Use the following procedure
if you need to synchronize the auto adjust system.
1. Lockout/tagout all power to the unit.
2. With the springs compressed and the wedge

cylinders in approximately the middle of their
stroke, measure distance “L” in the picture
below. 3144 Old Style
Measurement “L” is from the bottom of the

spring seat to the middle of the pin hole at
the end of the tension rod.
3144 New Style

L
4. Remove lockout/tagout. Use the wedge
adjust hydraulic valve to adjust the wedges in
3. Compare “L” measurement to chart below and and out approximately 1” which will relieve
calculate difference. the tension on the spring. Turn nuts on tension
rod in or out by the difference.
Jaw “L” (+/- 1/4”)
2640 34” 5. Compress springs again and check “L”
2650 34” measurement.
26” Toggle Plate 37”
3055 27” Toggle Plate 6. Repeat steps 1-5 until the correct
38”
3144* 29” Toggle Plate 36” measurement is reached according to the
(old style) 31” Toggle Plate (std.) table in step 3.
39.5”
29” Toggle Plate (std.) 38.5”
3144* This should position the tension rods so they are
30” Toggle Plate (std.) 40”
(new style) just below the center line of the spring plate mount
31” Toggle Plate 41.5”
hole.
28.5” Toggle Plate 40.5”
3352
31” Toggle Plate 43.5” Use the spring compression cylinder hydraulic
4450 28.5” Toggle Plate 45.5” valve to charge the spring compression cylinder
*Refer to the pictures in the next column to determine
daily or when pressure drops below 800 psi.
old and new style on 3144 jaw crusher.
9-1
Maintenance
CAUTION
The following section Failure to perform regular
contains instructions for maintenance may result in
maintaining the Vanguard jaw damage to the jaw crusher. Never attempt to service or
crusher Use the hour meter as a adjust this machine until all
Maintenance intervals guide to perform maintenance motion has stopped and
shown are for normal operating as recommended. power has been disconnected
conditions. If the jaw crusher is and locked out.
operated under severe or
adverse conditions
maintenance may need to be
performed more often.
9-2 Maintenance
1
5
3
8
11
10 2
7 9
Interval Ref. No. Component Notes

1 V-belt Drive Check for proper tension.
2 Jaw Bolts Check for proper tightness.
3 Side Liner Bolts Check for proper tightness
4 Stationary and Moving Jaw Check for wear
10 hours 5 Outer Main Bearings Add 16 oz. lubricant to each bearing
6 Pitman Bearings Add 32 oz. lubricant to pitman
7 Tension Rod and Spring Refer to page 9-3
Inner and Outer Flinger Collar Add lubricant until grease is seen
-
purging from collar
8 Side Liners Check for wear
50 hours
9 Toggle Plate and Seats Check for wear.
200
10 Flywheel and Bearing Bolts Check for tightness
hours
1000 11 Grease Lubrication Drain pitman and side bearings. Flush
hours and refill.
Maintenance 9-3
General Inspection 1. Make sure all guards are 4. Hydraulic fluid leaks. If
(10 hours) in place and functional. leaks are found or
Repair or replace any suspected and are not
A walk around inspection damaged or missing repaired right away, be
should be made on a daily guards or guarding sure to monitor the
basis. By taking a few minutes devices. hydraulic fluid level
each day to inspect the plant, closely.
potential problems can be 2. Repair or replace any
spotted and taken care of damaged handrails, 5. Clear away built up dirt
before they become serious. ladders, or walkways. and debris.
Generally, you should check 3. Check for loose nuts,

the following items: bolts, and set screws.
Tension Rod and Spring

(10 hours)
Tension rod springs should

be tightened just enough to
keep the toggle plate from
knocking.
For jaws with auto adjust, if

toggle knock or movement in
the wedges is present the relief
pressure in the auto adjust
circuit must be increased. See
Chapter 8 for information on
settingproper relief pressure.
For manual adjust jaws, normal

adjustment requires about 1-1/ Tension rod spring nuts
4" spring compression.
Additional compression may be
Tension Rods
required. See pages 5-7 to 5-
9 for information on proper
spring compression.
Make sure that the tension

rods are centered.
9-4 Maintenance
Moving and Stationary Jaw

Die Upper Wedge Bolts
(10 hours)
Check moving jaw bolts for

tightness. Access to bolt is
behind each jaw die.
Moving Jaw Die Upper

Stationary Jaw Die Upper
Wedge Bolts
Wedge Bolts
Side Liner Retaining Bolts

(10 hours)
Check side liner retaining

bolts for tightness.
Sideliner
retaining bolts

Maintenance 9-5
Stationary and Moving Jaw

Dies
(10 hours)
Check stationary and
moving jaw dies for wear. If
worn excessively, rotate or
replace. See page 9-8 for more
information.
The following guidelines can

be used when determining
whether or not the stationary or
moving jaw die should be
reversed or replaced.
• Any flat spots, pockets,

fishhooking or flat parallel Stationary and Moving Jaw
zones with less than 75-
80% of new jaw die tooth
depth at the flattest spot.
Use the table at the bottom

of this page for an
approximation of new jaw
die tooth depth. This table
is only for jaws equipped
with factory standard jaw
dies.
• Any spot where the

corrugation of the peaks Peak corrugation
elimination
have been eliminated.
NOTICE
Failure to properly maintain Tooth Depth - Standard Jaw Die*
Jaw 2640 2650 3055 3144 3165 3352 4450
jaw dies increases crushing Model
pressure resulting in Stationary 2 1/4”
damage to other jaw 2 1/4” 2 1/4” 2 1/4” 3 1/2” 4” 4”
Jaw
components and will void Moving
warranty. 2 1/4” 2 1/4” 2 1/4” 2 1/4” 3 1/2” 4” 4”
Jaw
*Table represents standard jaw dies used on Vanguard jaw models. If jaw crusher is a
equipped with a non-standard jaw die, jaw wear should be determined using 75-80% of the
tooth depth.
9-6 Maintenance
Side Liners
(50 hours)
Check the side liners for

excessive wear. These liners
must be replaced before they
have worn to the point where
damage may be done to the
crusher base.
Watch especially for wear

in the bottom side liner. The
bottom side liner receives more
impact from material than the
upper two side liners.
Side Liners
Maintenance 9-7
Toggle Plate and Toggle

Seats
(50 hours)
Inspect the toggle plate and Toggle plate
toggle seats for excessive
wear. Replace as required.
Toggle seat
Toggle Plate and Toggle Seat
Flywheel and Bearing Bolts

(200 hours)
Check flywheel and bearing Pillow block

bearing bolts
bolts and make sure they do not
appear loose. If they need to
be tightened, torque the
bearing bolts to 5000 ft.lbs
using a 3-3/4” socket
The flywheel bolts should

be torqued to 850 ft.lbs.
Flywheel bolt
Pillow Block Bearing Bolts

9-8
Maintenance - Wear items

WARNING
Never attempt to service or
adjust this machine until all
energy sources have been
locked out/tagged out.
Refer to Chapter 2 for more
safety information.
Jaw Die Reversal or

Replacement
Jaw die maintenance is

essential for consistent
production as well as for overall New Jaw Die
jaw crusher performance.
Worn jaw dies require NOTICE

higher pressure to crush rock Jaw dies must be checked every ten hours for wear. Failure
and when jaw teeth are worn to to properly monitor and maintain jaw dies reduces
75-80% of new jaw die tooth production, creates unnecessary stress on jaw crusher
depth, the material cannot flow components and will void warranty.
freely causing packing and
crusher overload.
Since most of the crushing

takes place in the bottom part
of the jaw die, many times they
can be reversed to restore
crushing efficiency.
If the jaw dies on both ends

have been worn to a point
where there are pockets, flat
spots, flat parallel zones or
fishhooking they should be
removed and replaced.

Maintenance - Wear Items 9-9
Use the following

1/8”
procedure to remove and
replace the stationary or
moving jaw die.
NOTICE
Shut down engine and
lockout/tagout power.
Moving Jaw Die
1. Unbolt and remove the

retaining wedge head and
wedge clamp at the top of
the jaw.
Add shims
here
Retaining
wedge
WARNING 3. Using a crane or other

suitable lifting device,
Proper procedures must be carefully lift the jaw die
used when welding to the from the crusher.
moving or stationary jaw
Moving Jaw Retaining Wedge
die. Failure to follow
manganese weld NOTICE
procedures could result in Remove any dirt or foreign
2. Tilt the top of the jaw die injury or death. material from the jaw seat
away from the pitman and on the pitman before
attach a chain to the jaw reinstalling the jaw die.
die. Jaw Die Weights
Moving Stationary
Jaw
Jaw Jaw
Refer to the chart in the next 4. If the jaw die can be
2000 lbs. 1764 lbs.
column for moving and 2640
(907.2 kg) (800.13 kg) reversed, turn the jaw die
stationary jaw weights. 2,437 lbs. 2,207 lbs.
over and lower into the
2650 crusher base. If jaw die
(1105 kg) (1001 kg)
Note: Once the plant is 3,450 lbs. 2,940 lbs. cannot be reversed install
received, a lift bracket can be 3055 a new moving jaw die.
(1565 kg) (1334 kg)
welded to the jaw provided 2,540 lbs. 2,600 lbs.
3144
proper manganese weld (1152 kg) (1179 kg)
procedures are followed. 3165 4,746 lbs. 4,413lbs.
(2153 kg) (2002 kg)
See Appendix A for more 3352
4,968 lbs. 5,276 lbs.
information on manganese (2253 kg) (2393 kg)
weld procedures. 4450 6,780 lbs. 6,600 lbs.
(3075 kg) (2994 kg)
9-10 Maintenance - Wear Items
5. Bolt the jaw wedges in 2. Tilt the top of the jaw die 5. Make sure the
place with the retaining away from the pitman and corrugations on the
wedge head contacting the attach a chain to the jaw stationary jaw die mesh
wedge clamp only - not the die. properly with the
moving jaw die. Maintain a corrugations on the
space of 1/8” between the Refer to the chart on page 9-9 moving jaw die. If
wedge clamp and pitman. for stationary jaw die weights. corrugations are not
Shim as needed. aligned properly, damage
to the crusher could result.
6. Tighten the wedge clamp
bolts and check the gap CAUTION
between the wedge clamp Be careful when tilting sta-
and pitman. If the gap is tionary jaw die forward
less than 1/8”, remove the
wedge clamp and install Note: Once the plant is
shims as needed. received, a lift bracket can be Properly Meshed Jaws
welded to the jaw provided
7. Operate the crusher proper manganese weld
under load for a brief
period then retighten
procedures are followed. NOTICE
clamp bolts. Remove any dirt or foreign
3. Using a crane or other material from the jaw seat
suitable lifting device, on the pitman before
Stationary Jaw Die carefully lift the stationary reinstalling the jaw.
jaw from the crusher.
Use the following procedure to
reverse or replace the 6. Tighten the wedge clamp
4. If the jaw die can be bolts and check the gap
stationary jaw die.
reversed, turn the jaw die between the wedge clamp
over and lower into the and base. If the gap is
1. Unbolt and remove the
crusher base. If jaw die less than 1/8”, remove the
retaining clamp bar and
cannot be reversed install wedge clamp and install
upper wedge that hold the
a new stationary jaw die. shims as needed.
upper part of the jaw die.
Retaining
wedge
1/8”
Maintenance - Wear Items 9-11
Side Liners
The side liners protect the

crushing chamber. When they
become worn they should be
replaced to prevent damage to
the crusher base. Use the Side liner
following procedure to remove retaining bolts
and replace the side liners.
1. Remove the top bolt(s) from

side liner plate. Strike the
top of the plate with a
hammer to loosen plate
from base.
2. Attach a chain through
the holes at the top of the
side liner. Loosen bolt
from the bottom of the side
liner.
3. Using a crane or other

suitable lifting device,
carefully lift the plate from
the crusher.
Side Liner Weights Attach chain
Jaw Upper Lower through this hole
2640
73 127
2650
3055 133 189
3144 150 208
3165 146 205
3352 240 338
4450 334 474
4. Attach a chain to the new

plate and using a crane or
other suitable lifting Side Liners
device, carefully lower the
plate into place in the
crusher.
5. Replace and tighten the

side liner retaining bolts.
10-1
Lubrication
Outer Main Bearings
(10 hours)
Add one pint of NLGI00
semifluid grease.
Chevron Ultra-duty HD is a
lithium based semi-fluid grease Lube Point
specially formulated with a high
viscosity base oil, and an
additive package that contains
inhibitors and tackifiers.
Bearing Lube Point
See page 0-8 for information on
cold weather grease.
Pitman Bearings
(10 hours)
Add two pints of NLGI00

semifluid grease
Chevron Ultra-duty HD is a
lithium based semi-fluid grease
Lube Point
specially formulated with a high
viscosity base oil, and an
additive package that contains
inhibitors and tackifiers
**Locations circled in red may have plugs only used on oil circulating
See page 0-8 for information on systems.
cold weather grease.
Lubrication 10-2
Grease Lubrication System

(1000 hours)
Remove pitman and

bearing drain plugs and fill
housings with 10 SAE motor oil
heated to 150O F.
Bring crusher up to
operating speed then
immediately shutdown and
drain housings.
Refill housing with NLGI00

grease.
Drain plug
Pitman Capacities
Jaw Capacity
2640 11 quarts
Bearing Drain Plug
2650 13 quarts
3055 14 quarts
3144 12 quarts
3352 14 quarts
4450 18 quarts
Outer Main Bearing

Capacities
Jaw Capacity
2640 2 quarts
2650 2 quarts
Drain plug
3055 2 quarts
3144 2 quarts
3352 2 quarts
4450 4 quarts
Pitman Drain Plug

11-1
Tr oub leshooting
oubleshooting
Problem Symptom Solution
1. Toggle plate movement 1. Repair or replace toggle
(lateral). seats or toggle plate.
Excessive vibration 2. Crusher speed incorrect. 2. Check speed. Refer to
Specification for RPM
3. Closed side setting 3. Check and adjust as
under recommended needed.
range.

1. V-belts slipping. 1. Check v-belts. Replace if
Crusher speed varies needed.
2. Voltage varies 2. Check power source.

1. V-belts slipping. 1. Check v-belts.
Crusher stops or will not 2. Feed material plugged in 2. Clear material.
start crushing chamber
3. Fuse or breaker out. 3. Replace.

1. Under lubrication/over 1. Lubricate bearings
lubrication according to specifications
High bearing temperature in
in manual.
excess of 180 F
2. Incorrect grease. 2. Use correct grease as
specified in manual.
3. Speed (RPM) too high 3. Check speed and adjust.
Troubleshooting 11-2

1. Not enough rod spring 1. Increase spring tension.
tension.
2. Not enough clearance 2. Increase clearance so jaws
between jaws. do not touch.
Knocking noise when jaw 3. Toggle seats not seated 3. Check toggle seats and
crusher in operation properly. adjust.
4. Loose bolts, jaws, side 4. Adjust and tighten.
liners.
5. Crushing too high in 5. Adjust.
chamber.

1. Lubrication pump not 1. Check power supply to
working. pump.
Lubrication system flow 2. Oil system line plugged. 2. Remove line and clean or
indicators show no flow replace.
3. Oil filter partially blocked 3. Replace filter.
A-1
Appendix A
Welding Lifting Lugs to Jaw Manganese
WARNING
Use the following information to weld lifting lugs
to the jaw manganese.
Proper procedures must be used when
Guidelines welding to the moving or stationary jaw die.
Failure to follow manganese weld
• Locate welder ground as close to the area procedures could result in injury or death.
to be welded. This will help prevent arcing
through the crusher bearings and Weld using Wearshield Mangjet rod.
subsequent bearing failure.
1. Before welding make sure all power is
• Ground off work-hardened base metal or locked out/tagged out. Weld disconnect any
previously deposited weld metal before electrical components.
applying a new deposit. These areas are
more prone to embrittlement and cracking. 2. Use a 1” cold rolled 1018 shaft 20”-24” long
Areas that cannot be easily indented with a to form a loop in the center so that the two
center punch should be removed. legs of the loop will fit into the valley of the
jaw die.
• When joining manganese steel, the joint
should be prepared for 100% penetration. 3. Make three passes on each side of the two
Use a cutting torch to bevel the edges of shafts and to the jaw die using a 5/32 rod at
the plate which can crack if care is not taken approximately 140-150 amps. Each pass will
to prevent overheating the base metal. be 1 to 1-1/2 times the width of the weld
rod.
• Preheat is not necessary unless work is
below room temperature, or if the part is The length of the welds will be 5” long with
unusually massive or complex in design. In complete weld crater fills at the ends of
such cases, heating the piece to room welds.
temperature, or 100-150 degrees
Fahrenheit at the most, should be sufficient. 4. After jaw dies have been installed, remove
lifting lugs for operation.
• As with all austenitic manganese welding
products, interpass temperatures should be
limited to 500 degrees Fahrenheit
maximum. A stringer bead, or a slight weave
is recommended to limit heat build-up.
Excessive heat build-up causes manganese
carbide precipitation which damages the
toughness of austenitic manganese.
Lifting lug
A-2
Typical Operating Procedures:
Rockwell Hardness
• As-welded (2 layers) - 18
• Work hardened (2 layers) - 47
Current (Amps)
• Polarity 5/32 in. (4 mm)
• DC+ 120-180
• AC 125-210
Warranty Registration & Preoperational Check
Jaw Crusher
Kolberg-Pioneer, Inc. Form may be Sent, Faxed or Emailed

700 W 21st. St., Yankton, SD 57078 IMPORTANT
1-800-532-9311 Fax: 1-800-514-6115 Warranty will be void if this registration is not returned
Email: mail@kpijci.com within ten (10) day after the equipment is put into service.
Date Put Into Service Hours on Unit Sale Lease Rental Unit Serial Number Engine Serial Number
Month Day Year
Job Order Dealer Order Number Unit Model Number Engine registered with
manufacturer
Dealer Name Dealer Signature Date City State Zip
Owner/Lessee Name Signature Date City State Zip
The safe operation of this product was explained and a complete operator's manual was with the product.
IMPORTANT
Preoperational Check must be completed as part of warranty registration. The preoperational check
should also be performed any time equipment is moved to a new site, changed renters, or if it has been
in storage for an extended period. Check each component to insure that it is in operational condition.
This check should include, but not be limited to the following items.
PREOPERATIONAL CHECKS OK Adjust OPERATIONAL CHECKS OK Adjust

1.Sheet Metal/Appearance/Paint 1.Unit Vibration
2.Lubrication 2.Jaw Crusher Eccentric Shaft RPM_______
a. Inner Pitman Bearings 3.Crusher Setting_______________
b. Outer Main Bearings 4.Bearings - record bearing temperatures
c. Type of Grease ___________ as indicated below.
3.V-Belts 4 HOURS
4.Jaw Manganese Outer Main Bearing Outer Main Bearing
5.Tension Rod/Auto Adjustment Pressure (float) (held - drive side)
6.Breathers Pitman Bearing
7.General
a. Operator's Manual on Unit
Pitman Bearing
b. Decals in Place & Readable
c. Safety Guards on
8 HOURS
(float) (held - drive side)
Pitman Bearing
Pitman Bearing
If Adjustments are made please note change:
Date Inspection Completed Inspector's Signature

Crushing & Screening Solutions
For Ser vice

KPI -Toll free - 800-532-9311 (605-665-9311)
Fax- 800-514-6115 (605-665-9348)
JCI - Toll free - 866-875-4058 (541-736-1400)
Fax - 541-988-9501
For Parts
KPI - Toll free - 800-766-9793 (605-665-9793)
Fax - 605-665-9348
JCI - 888-474-0115 (541-736-1400)
Fax - 541-988-9487

Mandibulas KPI 2640 - 4450

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OPERATION &

MANUFACTURED BY KOLBERG-PIONEER, INC. YANKTON, SD, U.S.A.

MANUFACTURED BY KOLBERG-PIONEER, INC. YANKTON, SD, U.S.A.

Serial Number Plate

All rights reserved. No part of this manual may be reproduced

This manual contains operating, lubrication and maintenance

Safe and efficient operation requires that you and anyone

Continuing improvement and advancement of KPI-JCI products

KPI-JCI reserves the right to make changes or add

Although care has been taken to assure the accuracy of this

Specifications Chapter 3 3-1

Application Chapter 4 4-1

Site Selection and Setup Chapter 5

Operation Chapter 6 6-1

Preoperation Checklist Chapter 7 7-1

Pressure Adjustment and

Troubleshooting Chapter 11 11-1

Welding Lifting Lugs to Jaw

About This Manual

Serial Number Plates

Jaw Crusher Serial Number

Jaw Crusher Serial Number Plate

Buying Replacement Parts

Typical motor drive assembly parts page.

Typical tail pulley assembly parts page.

Maintenance Techniques and Tools

Grade 5 Grade 8 Grade 1 or 2 Grade 5 Grade 8

Lubricants and Fluids

Jaw Crusher Pitman

Introduction to the Jaw Crusher

Left Side Front View

Right Side Rear View

The following is a brief

The eccentric shaft translates

The pitman carries the moving

The flywheels store energy to

The moving jaw is located

Both jaw dies are reversible to

The stationary jaw fits on the

The side liners, which are made

The tension rod assembly is a

The mechanism sets the

Grease Type System

Operating Safety 3. Always be aware of the counterbalance valve

2. Keep away from discharge 7. Relieve pressure from the

3. Do not place power lines in 3. Do not allow anyone to ride

4. Be sure that all auxiliary 5. Install lighting bar when

Date of review and

Located on inside jaw

Weight: 29,500 lbs.(13,393 kg) A-dimension: 41.370 - 41.380

Base Weight: 8,900 lbs.(4,037 kg) Standard CSS (at factory):

Pitman Assembly Weight: 8,930 lbs. (4,051 kg)

Flywheel Weight (each): 2,650 lbs. (1,202 kg)

Peak to Peak Closed Side Setting - Approximate Capacity

A-dimension: 50.870 - 50.880

Peak to Peak Closed Side Setting - Approximate Capacity

Peak to Peak Closed Side Setting - Approximate Capacity