H3450 Hydra Jaw Crusher

H3450 Hydra Jaw Crusher
Operation and Maintenance

SN 45215 and Greater
ORIGINAL INSTRUCTIONS - ENGLISH
ISSUE DATE: 04/17 TP651
SAFETY
Be sure to read and fully understand the precautions shown on the inside front cover of this manual before
operating or servicing your Telsmith product. Also refer to Chapter 1 for important safety information.
! WARNING
Failure to follow the safety precautions shown below may result
in serious personal injury or death!
• Never attempt to work on quarry equipment while it is in operation. Always stop the machinery, lockout power
and tag controls:
1. Before performing any lubrication, maintenance, adjustment, or repairs.
2. Before removing spilled materials.
3. Before clearing jams or working inside the machinery.
4. If any unusual noises or sudden changes in operation are noticed.
• Stay clear of feed and discharge areas and other places where falling rock is present. Keep away from loading
vehicles. Wear and use personal protective equipment in accordance with all applicable health and safety
regulations. Safety goggles, hard hat, ear plugs and steel-toed shoes are mandatory when working near
machinery. Wear and use additional personal protective equipment as required.
• Stay clear of springs and other pinch points. Never reach in-between vibrating equipment and its support
structure. Keep a safe distance from all moving components.
• Never attempt to enter the crushing chamber when tramp iron or other uncrushable objects are wedged inside.
These materials are under tremendous pressure and may be propelled upward through the feed opening at any
time. On crushers not equipped with hydraulic clearing, use a pole, hook, grappling device, or breaker bar to
safely dislodge uncrushable objects.
• Do not make equipment modifications that will result in a safety hazard or create a dangerous situation. Never
remove or disable safety devices. Maintain all machinery in accordance with manufacturer’s instructions and
maintenance schedules.
• Read the operator’s manual for the equipment that you operate. Be sure that you fully understand all phases of
operation for each machine. A careful and well-trained operator is the best insurance against an accident.
• Refer to Chapter 1, Safety, for important quarry safety information. If your copy is missing, replacement
copies may be obtained from your local Telsmith Dealer or the Telsmith Parts Department.
• All rotating power products are potentially dangerous and must be properly guarded. Placement of guards and
other safety equipment is the user’s responsibility. Such equipment must be installed wherever appropriate and
maintained as required.
• It is the purchaser’s responsibility to ensure that quarry equipment is installed and used in a safe and lawful
manner. All machinery must be operated in compliance with applicable health and safety laws and general
standards of reasonable care.
Foreword
INTRODUCTION ORDERING REPLACEMENT PARTS
The information, drawings, and pictures provided in this Refer to the prints supplied with your machine when ordering
manual will help you to achieve optimum performance from Telsmith parts. If your prints have been lost or damaged, new
your Telsmith, Inc. product. It contains safety, operation, copies are available from your local approved Telsmith
maintenance, service, and repair information on the machine Distributor or the Telsmith Parts Department.
to assist you in your operation.
To ensure that you receive the correct parts for your machine,
Please note that some features shown in this manual may not always include the model number and serial number when
be present on your machine. Some equipment described may ordering.
be optional at extra cost, or available only on selected
models. MODEL and SERIAL NUMBER PLATE
The data and instructions contained in this manual are based LOCATION
on the latest information at the time of publication. Telsmith's
policy of continuous improvem ents, features and
specifications are subject to change without notice.
Actual dimensions, weights, and clearances may be different
than shown, due to fabrication variables, custom engineering
or optional equipment.
HOW TO CONTACT TELSMITH INC.

Use the following information when you wish to contact
Telsmith:
• General: Phone (262) 242-6600
FAX (262) 242-5812
• Parts: Phone (800) 688-6601
FAX (262) 242-7861
• Written: Telsmith, Inc.
10910 N. Industrial Drive
P.O. Box 539
Mequon, WI 53092-0539
U.S.A.
• Send all e-mail to:
parts@telsmith.com
REQUESTING SERVICE ASSISTANCE

If service assistance is required or you have questions about
maintenance or repair procedures in this manual, please
contact your local approved Telsmith Distributor. If
additional assistance is necessary, contact the Telsmith
Service Department. Model and serial numbers are located on a data plate attached
Service technicians are available by telephone from 8:00 a.m. to the machine main frame. Always lockout power and tag
to 4:30 p.m. CST, Monday through Friday, except holidays. controls before reading data plate!
To ensure faster response, always have your machine’s model
and serial numbers ready when calling. SERVICE BULLETINS
Telsmith periodically issues service bulletins to inform
customers of the latest repair and maintenance procedures.
Service bulletins may have been included separately with this
manual. Always read and understand all service bulletins
before starting any maintenance or service work.
04/17 3
Foreword Operation and Maintenance
Telsmith H3450 Jaw Crusher
SAFETY CONTACTS
All quarry personnel operating or servicing the machine must TELSMITH PARTS DEPARTMENT CONTACTS
read and fully understand the information included in
Chapter 1, Safety of this manual.
Name:
ILLUSTRATIONS Phone (Office):
Phone (Cell):
This manual contains some illustrations in which guards,
access panels and other safety equipment have been removed FAX:
for instructional purposes or to provide greater clarity.
However, to prevent serious personal injury or death, always Name:
be sure all such equipment is installed before operating the
Phone (Office):
product.
Phone (Cell):
INSTALLATION & ASSEMBLY DRAWINGS FAX:
Installation and assembly drawings (blueprints) are provided

with all new Telsmith products. These drawings are normally TELSMITH SERVICE DEPARTMENT CONTACTS
included with the technical manuals but may be shipped
separately for some orders.
Name:
The drawings include specifications, dimensions and other Phone (Office):
information for use during installation and assembly
Phone (Cell):
procedures. Contact your local Telsmith dealer or the
Telsmith Service Department if you have any questions about FAX:
information contained on the drawings.
If the drawings are lost, replacement copies may be ordered TELSMITH APPROVED DISTRIBUTOR CONTACTS
from your local Telsmith dealer or the Telsmith Parts
Department. Name:
Phone (Office):
Phone (Cell):
FAX:
OTHER CONTACTS
Name:
Phone (Office):
Phone (Cell):
FAX:
Name:
Phone (Office):
Phone (Cell):
FAX:
4 04/17
Operation and Maintenance Safety
Telsmith Model 3450 Jaw Crusher
TABLE OF CONTENTS
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
FEATURES, DIMENSIONS and SPECIFICATIONS . . . . . . . . . . . . . . . 2
CRUSHER INSTALLATION and ASSEMBLY . . . . . . . . . . . . . . . . . . 3
CRUSHER OPERATION and ADJUSTMENTS . . . . . . . . . . . . . . . . . 4
CRUSHER LUBRICATION and MAINTENANCE SCHEDULE . . . . . . . . . 5
HYDRAULIC SYSTEM OPERATION & MAINTENANCE . . . . . . . . . . . . 6
CRUSHER TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . 7
WEAR LINER and CHEEK PLATE REPLACEMENT . . . . . . . . . . . . . . 8

7F
REPAIR and OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
04/17 i
Foreword Operation and Maintenance
TABLE OF CONTENTS
(Continued)
APPENDICES
1
APPENDIX A - TORQUE TABLES - SAE Grades . . . . . . . . . . . . . . . . . . A-1
APPENDIX B - CONVERSION TABLES . . . . . . . . . . . . . . . . . . . . . . . B-1
APPENDIX C - TORQUE TABLES - ISO Grades . . . . . . . . . . . . . . . . . . C-1
ii 04/17
1
Chapter 1
Safety
CONTENTS
Page
GENERAL SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
PRECAUTIONARY STATEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Hazard Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Advisory Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
LOCKOUT/TAGOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Who Must Use Lockout/Tagout? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
What Is Lockout/Tagout? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
When Must Lockout/Tagout Occur? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
How Is Lockout/Tagout Performed? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
When Can Lockout/Tagout Devices Be Removed? . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Lockout/Tagout Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Lockout/Tagout Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Additional Lockout/Tagout Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
QUARRY SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Know Your Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Be Prepared for Emergencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Wear Personal Protective Equipment (PPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Observe Personal Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Help Prevent Accidents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
High Operating Temperatures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Avoid Alcohol and Other Drugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Be Aware of Your Surroundings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Practice Good Housekeeping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Falling Rocks or Material. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Inspect and Maintain Machinery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
EQUIPMENT INSTALLATION SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Equipment Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Foundations and Supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
04/17 1–1
Safety Operation and Maintenance
Telsmith 3450 Jaw Crusher
1 Operator Vantage Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Guarding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Customer Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Electrical Installation Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
MAINTENANCE AND REPAIR SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Electrical Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Pressurized Systems
(Hydraulic and Pneumatic) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Welding, Cutting or Grinding on Machinery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Clearing Jammed Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Hazardous Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Disposal of Excess Fuels, Lubricants and Liquids . . . . . . . . . . . . . . . . . . . . . . . 1-15
Flammable and Combustible Liquids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
HOISTING AND HANDLING SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Forming Wire Rope Eyes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Connecting Wire Ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Fiber or Synthetic Slings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
TRANSPORTATION SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

MAINTENANCE INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
SAFETY LABELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
Types of Safety Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
DECOMMISIONING THE 3450 JAW CRUSHER . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
1–2 04/17
GENERAL SAFETY Hazard Statements 1

It is the responsibility of the quarry management team to
develop a comprehensive safety awareness program, and to ! DANGER
ensure that all quarry workers and support personnel receive Danger indicates an imminently hazardous situation
appropriate safety training as required by federal, state and which, if not avoided, will result in death or serious injury.
local regulations.
Be sure all operating, maintenance, service and support ! WARNING
personnel read and understand the contents of this manual,
including the safety information in this Chapter 1. Warning indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
There are standard safety rules, but each situation has its own injury.
conditions that cannot always be covered by these rules.
Therefore, quarry personnel must continually watch for
possible safety hazards and be prepared to take prompt ! CAUTION
corrective action when deficiencies in safety procedures are Caution indicates a potentially hazardous situation which, if
found. not avoided, may result in minor or moderate injury.
Failure to observe the precautions contained in this chapter
can result in serious personal injury and even loss of life. As Advisory Statements
with most industrial work environments, a careful operator is
the best insurance against an accident. NOTE:
The complete observance of one simple rule would prevent A statement used to draw attention to procedures and
many unnecessary injuries and deaths each year. This rule is: practices. Advisory in nature to the operation, maintenance,
service, and repair of the machinery.
“Never attempt to clean, lubricate, repair or adjust any
machinery or equipment unless it is stopped and properly
locked out and tagged out.” IMPORTANT:
Please note that this chapter is intended only as a brief review A statement used to draw attention to procedures and
of basic quarry safety precautions and procedures. The practices that need to be followed to prevent damage to the
general guidelines included in the following paragraphs machine.
should not be considered in lieu of a quarry’s official safety
procedures, insurance company requirements, or applicable
federal, state and local regulations.
PRECAUTIONARY STATEMENTS
Throughout this manual, you will see the following
Precautionary Statements listed below. These are used to
emphasize certain hazards or precautions related to
procedures in this manual.
04/17 1–3
1 There are many maintenance procedures contained LOCKOUT/TAGOUT

throughout this manual. All machinery that is maintained in
good working condition minimizes safety hazards and Who Must Use Lockout/Tagout?
emergencies.
Quarry owners, managers, and safety officers must be aware
Refer to Figure 1-1 for examples of Precautionary of OSHA’s “lockout/tagout” standard: 29 CFR, Section
Statements. 1910.147, The Control of Hazardous Energy. This standard is
also recognized by MSHA.
All mechanics, maintenance personnel, operators, and
electricians must fully understand and comply with this
NOTE: standard to ensure the safety of all employees.
Use a high impact type grout which contains a non-

shrink additive. Be sure to follow manufacturer’s
instructions when handling and pouring grout.
IMPORTANT:
If obvious signs of trouble or unusual noises occur
during start-up, stop the crusher as soon as
possible.
! CAUTION
Failure to install rotor locking pin after upper
rear frame has been opened will allow rotor
to turn. Serious personal injury may occur.
! WARNING
Failure to follow the instructions and
precautions below may result in serious
personal injury or death.
• Stop crusher and lockout/tagout main drive
p o w e r s o u r c e a n d c o n t r o l s . Wa r n a l l
personnel that crusher is being serviced.
! DANGER
HAZARDOUS VOLTAGE! Disconnect and
l o c k o u t / ta g o u t p o w e r s o u r c e b e f o r e
servicing. Failure to observe this precaution
will likely result in serious injury or death.
Figure 1–1. Sample Precautionary Statements
1–4 04/17
What Is Lockout/Tagout? 1
Lockout/tagout is a means to ensure that personnel who
install, operate, repair, maintain, service, or otherwise disable
machines, equipment, or electrical energy systems are
protected from harm due to unexpected energization or start-
up of equipment, or the release of stored energy by:
Lockout. The placement of a lockout device on an
energy isolating device, in accordance with an
established procedure, ensuring that the energy
isolating device and the equipment being controlled
cannot be operated until the lockout device is
removed.
Lockout device. A device that utilizes a positive
means such as a lock, either key or combination
type, to hold an energy isolating device in the safe
position and prevent the energizing of a machine or
equipment. Included are blank flanges and bolted
slip blinds.
Tagout. The placement of a tagout device on an
energy isolating device, in accordance with an
established procedure, to indicate that the energy
isolating device and the equipment being controlled
Figure 1–2. Lockout/Tagout
may not be operated until the tagout device is
removed.
When Must Lockout/Tagout Occur?
Tagout device. A prominent warning device, such
Lockout/tagout of equipment must occur whenever service
as a tag and a means of attachment, which can be
or maintenance is performed, and injury could occur due to
securely fastened to an energy isolating device in
the unexpected energization or start-up of equipment, or the
accordance with an established procedure, to
release of stored energy.
indicate that the energy isolating device and the
equipment being controlled may not be operated In general, lockout/tagout procedures must be performed
until the tagout device is removed. under the following circumstances:
• Before cleaning, lubricating, adjusting or repairing
machinery or equipment.
• Before working on electrical, hydraulic or pneumatic
circuits or devices.
• Before clearing jammed mechanisms, machinery or
equipment.
• Before removing guards or other protective devices.
• Whenever a machine or its controls will be left
unattended.
04/17 1–5
1 How Is Lockout/Tagout Performed? In situations in which lockout or tagout devices must be

temporarily removed to test or position the machinery or
OSHA has identified the following step-by-step lockout/
component thereof, the following sequence of actions shall be
tagout procedure:
followed:
1. Prepare for shutdown – Before shutting down a piece of
1. Clear the machine or equipment of tools and materials.
equipment, know the type and magnitude of the energy that
powers it, the hazards of that energy, and how to control it. 2. Remove employees from the equipment area.
Warn all employees that the machinery is about to be shut
3. Remove the lockout or tagout devices following proper
down.
procedures.
2. Shut down the equipment – After warning all
4. Energize and proceed with testing or positioning.
employees, shut down the machine, equipment, or electrical
system by the normal stopping procedure. 5. De-energize all systems and reapply lockout/tagout
devices to continue the servicing and/or maintenance.
3. Isolate the equipment – Disengage all isolating devices,
both primary and secondary, so that the equipment is isolated
from all of its energy sources (electrical, mechanical,
hydraulic, pneumatic, etc.).
4. Apply lockout/tagout devices – Attach lockout/tagout
devices (according to your company’s safety program) in
such a manner that the isolating device (circuit breaker,
control, etc.) will be held in a safe or off position. Attach tags
to alert others that the machinery is being serviced.
5. Control stored energy – any potentially hazardous
stored energy (electrical, mechanical, hydraulic, pneumatic,
etc.) that remains must be released, dissipated, restrained, or
otherwise rendered safe. If stored energy reaccumulates,
monitor it until the possibility of accumulation no longer
exists.
6. Verify that equipment is isolated – After warning all
employees to stay clear, engage the start button to confirm the
machine is inoperable. Return the control to the OFF position
before proceeding with servicing.
When Can Lockout/Tagout Devices Be

Removed?
Lockout/tagout devices can be removed only after the
following conditions are met:
• All guards and protective devices are properly reinstalled.
• All tools and repair equipment are removed from the
equipment and the immediate area.
• All mechanics and other personnel are clear of the
equipment and its immediate area.
• All personnel have been warned that the equipment is
about to be restarted (sound warning horn or activate
warning lights).
After removing lockout/tagout devices, always use the
normal start-up procedure as described in the operator’s
manual for the machinery.
1–6 04/17
Lockout/Tagout Devices • Your company’s lockout/tagout program may be 1

somewhat different than described in this manual. If so,
Lockout/tagout devices include:
be sure to completely follow your company’s official
1) locks policies and procedures when lockout/tagout is
2) tags and labels necessary. Consult your company’s safety officer if you
3) multiple lockout devices have any questions.
Lockout devices and tagout devices shall be singularly • A lock must have only one user and one key. Anyone who
identified, shall be the only device(s) used for controlling installs a lock must keep the key in their possession at all
energy, shall not be used for other purposes, and shall meet times. Except in an emergency situation, only the person
the following requirements: that installs a lock is authorized to remove it.
• Lockout and tagout devices shall be capable of • To prevent accidental start-up, never give your lock or its
withstanding the environment to which they are exposed key to another employee.
for the maximum period of time that exposure is
• Your key must open your lock only. Your key should not
expected. Tagout devices shall be constructed and printed
be capable of opening any other locks. Keys for other
so that exposure to weather conditions or wet and damp
locks should not be capable of opening your lock.
locations will not cause the tag to deteriorate or the
message on the tag to become illegible. • Except in an emergency situation, never attempt to
remove anyone else’s lock. Do not allow others to remove
• Lockout and tagout devices shall be standardized within
your lock.
the facility in at least one of the following criteria: color,
shape, or size, and additionally, in the case of tagout • When disconnecting power, be sure that the circuit
devices, print and format shall be standardized. breaker handle (or other isolating device) is in the OFF
position. Accidentally locking a control in the ON
• Lockout devices shall be substantial enough to prevent
position could result in serious personal injury or death.
removal without the use of excessive force or unusual
techniques, such as with the use of bolt cutters or other • If two or more people are working on a machine, a
metal cutting tools. multiple lockout device must be used to prevent
accidental start-up in the event that one person finishes
• Tagout devices, including their means of attachment, shall
working before another.
be substantial enough to prevent inadvertent or accidental
removal. Tagout device attachment means shall be of a • Each lock must have a tag. If two or more people are
non-reusable type, attachable by hand, self-locking, and working on a machine, each person must attach a separate
non-releasable with a minimum unlocking strength of no tag to their lock. Never attach a lock without a tag.
less than 50 pounds and having the general design and
• Never use tags alone. A tag should always be
basic characteristics of being at least equivalent to a one-
accompanied by a lock which prevents the isolating
piece, all-environment-tolerant nylon cable tie.
device from becoming energized.
• Lockout devices and tagout devices shall indicate the
identity of the employee applying the device(s).
• Tagout devices shall warn against hazardous conditions if
the machine or equipment is energized and shall include a
legend such as the following: Do Not Start. Do Not Open.
Do Not Close. Do Not Energize. Do Not Operate.
A multiple lockout device must be used when two or more
people are working on a piece of equipment. This allows each
person to install their own lock and tag.
Lockout/Tagout Rules
• Always lockout/tagout any machinery before
performing any adjustment, inspection, lubrication,
maintenance or repair procedures. Failure to observe this
precaution may result in serious personal injury or death.
04/17 1–7
1 Additional Lockout/Tagout Requirements • Become familiar with the controls, functions and settings
of each machine. Fully understand all phases of each
• Be sure that the power is COMPLETELY turned off. A
machine’s operation.
motor may be stopped and locked out. However,
interlocks, starters, and other supplemental electrical • Be sure that you completely understand and follow all
components may still be energized. Use a voltmeter and/ start-up and shutdown procedures as described in the
or ammeter to verify that all electrical circuits are manufacturer’s manuals.
completely dead.
• Be familiar with the safety labels on your equipment, and
• Always be sure that all peripheral equipment, such as feed the hazards against which they warn.
conveyors, grizzly feeders and discharge conveyors, have
• Check the legibility of all safety labels every day. Order
lockout/tagout devices attached. Serious personal injury
new labels from the machinery manufacturer if they
or death can result if any of these items starts
become illegible or worn.
unexpectedly while service work is in progress.
• Although lockout/tagout procedures are most commonly Be Prepared for Emergencies
associated with electrical systems, be aware that
• Know the proper emergency shutdown procedures for the
hydraulic, pneumatic and mechanical systems must also
equipment you operate.
be tagged and locked out before servicing. This may
involve the lockout/tagout of valves, levers and other • Know where fire extinguishers are kept and how to use
non-electrical devices. them. Be sure that fire extinguishers are properly rated,
and that they remain fully charged and ready for use at all
• For machinery powered by internal combustion engines
times.
(diesel, gas, etc.), always disconnect batteries and shut off
fuel supply before servicing the machinery. Lockout/ • Know the procedure for contacting emergency medical
tagout engine controls to ensure that engine is not personnel. Keep a list of emergency phone numbers
accidentally started while the machinery is being handy at all times.
serviced.
• Know where a first-aid kit, stretcher and other emergency
• Always be sure that all hydraulic or air pressure is supplies are kept. Be sure that first aid supplies are
completely relieved before working on hydraulic or properly maintained and ready for use.
pneumatic systems. Dangerous pressures can be present,
• Make sure that a clear path to emergency equipment and
even when equipment is turned off and locked out.
exits is always maintained. Do not allow equipment,
• After maintenance or repairs are completed, always warn spilled materials or other obstructions to get in the way.
all employees that the machinery is about to be restarted.
• Know how to report accidents. Always report all
Be sure no one is on or near the equipment before a lock
accidents immediately to the appropriate supervisor.
and tag is removed.
• As a precaution, always activate a warning horn or light
before restarting the machinery. This will provide
additional warning for personnel to stay clear of
machinery that is about to be started.
QUARRY SAFETY
Know Your Equipment
• Read and understand the manufacturer’s operation and
maintenance manuals for all machinery and equipment
that you operate. Be sure that all hazard statements
contained within the manuals are completely understood.
• Allow only trained and authorized personnel to operate
and maintain machinery.
1–8 04/17
Wear Personal Protective Equipment (PPE) • To avoid back injuries, always use proper lifting 1
techniques to safely lift heavy objects. Lift with your legs
Aggregate processing and handling can be a dangerous
and keep your back straight. Keep the materials or object
process. To reduce the risk of serious injury or death to
close to your body. Have a co-worker assist you if the load
personnel, observe the following precautions:
cannot be lifted safely by one person.
• Wear safety glasses or goggles whenever outside of an
• Before starting the machinery, check that no personnel are
approved operator ’s enclosure. Failure to wear
inside, on, under or beside the equipment. Unless
appropriate eye protection can result in permanent eye
absolutely necessary, do not allow anyone to be on or near
injuries and loss of sight.
the equipment while it is operating.
• During initial start-up of machine, sound pressure levels
• Never attempt to catch falling materials or objects.
should be taken near machine to determine what level of
hearing protection is required. Wear appropriate ear • Be aware of flammable liquids and other potential fire
protection when working within 50 feet of any operating hazards. Do not smoke when refilling engines or using
quarry machine and in other areas where noise levels are cleaning solvents.
high. Prolonged exposure to high noise levels can cause
• Do not stand under equipment or components that are
permanent hearing loss.
being hoisted or suspended. Never allow other quarry
• Wear steel-toe safety boots, heavy-duty gloves and a hard personnel to do so.
hat. This equipment is mandatory in most areas of the
• Before you assemble, operate, clean, lubricate, or adjust
quarry.
machinery, be sure to read and understand all procedures
• Always use authorized respirators when working in and contained in the machinery manufacturer’s manual.
around high-dust areas. Prolonged exposure to dust
• Be sure to operate quarry machinery in compliance with
particles can cause silicosis of the lungs. This, over a long
current OSHA and MSHA regulations, and all applicable
time period, can cause serious illness or death.
federal, state or local regulations.
• Other personal protective equipment may be necessary
• Be sure that all guards and other safety devices are
for your specific job assignment, such as a full face shield
correctly installed and tightly secured before starting the
and safety harness. Wear or use these items when
crusher. Stay clear of rotating or moving parts during
necessary and as required by applicable federal state and
crusher operation.
local regulations.
Observe Personal Safety Precautions

• Never wear loose or ragged clothing when working on or
around rotating power equipment. Avoid wearing
necklaces, rings or other jewelry. These items can become
caught or tangled in the machinery, resulting in severe
• Keep hair short, if possible. Keep long hair securely tied
up to prevent it from becoming caught in the machinery.
• Be especially careful whenever using wet walkways,
platforms, or ramps. The combination of rock dust and
wet metal can create an extremely slippery surface. Keep
all walkways and other access structures clean, dry and
free of grease or oil.
• Use walkways and ladders when working near machinery,
or observing its operation. Use a safety harness when
necessary. Keep handrails and machine contact surfaces
clean.
04/17 1–9
1 Help Prevent Accidents • Be aware of idle machinery that could start up without
warning. Stay clear of such machinery and the immediate
• Do not allow unauthorized personnel in or near the work
area.
area. Never allow unauthorized personnel to operate,
adjust, maintain or repair machinery. • Be aware of overhead obstructions, such as conveyors,
support structures or power lines.
• Allow only properly trained and experienced personnel to
operate machinery. Be sure inexperienced operators are
carefully supervised at all times. Practice Good Housekeeping
• Do not store tools or equipment on walkways.
• Do not allow personnel to be near loading areas, or
anywhere else that falling or ejected material could hit • Be sure that all walkways, platforms, stairs and ramps are
them. kept free of spilled material and trash. A build-up of
material in these areas can cause slips and falls. Make
• Use extreme caution if the machinery must be operated
repairs as required in areas where spillage is present.
for inspection or observation purposes. Stay a safe
distance from the machinery and wear appropriate • Do not allow machinery to become buried under piles of
personal protective devices. spilled material. This will make the machinery more
difficult to inspect and may hide broken welds, loose
• Before making repairs to the machinery, always clear all
fasteners and other serious problems that could cause a
quarry material from the feed and discharge devices
safety hazard.
(feeders, conveyors, chutes, etc.).
• Keep the areas around control panels and machinery free
• In areas that present a danger of falling, use an appropriate
of spilled material. Free access must be maintained at all
fall protection device, such as a safety harness and
times. In the event of an emergency, quick access to
lifeline.
controls could prevent injury or death.
• Always report any unsafe conditions or defective
• Clean up spilled fuel or oil immediately to eliminate
equipment to the appropriate supervisor.
slipping hazards. If necessary, use an oil absorbent.
High Operating Temperatures • Always be sure that power is tagged and locked out before
cleaning spilled material or oils. Never clean up these
• The equipment generates heat during operation resulting
items while the machinery is operating.
in surface temperatures that may sometimes exceed 140
°F (60 °C). For your safety, we recommend you let the
equipment cool before attempting to perform Falling Rocks or Material
maintenance. CAUTION - There is a risk of burn if the • Due to the unpredictable nature of aggregate and mineral
equipment is handled before cooling. handling, rocks may sometimes fall or be ejected from the
equipment. The user is cautioned to prevent potential
Avoid Alcohol and Other Drugs falling debris though intelligent design of the surrounding
structure by using guards and skirting where appropriate.
• Do not operate or work near quarry machinery when
CAUTION - A falling debris hazard exists around the
under the influence of alcohol or other drugs. These
equipment. Maintain a safe distance and wear Personal
substances can result in reduced alertness and impaired
Protective Equipment such as your hard hat, safety shoes
judgement. Serious personal injury or death could result.
and safety glasses. Additional safety warning decals have
• Some prescription and non-prescription medications can been provided for your convenience to post near the
cause drowsiness or other adverse side effects. Do not equipment.
operate or work near quarry machinery when under the
influence of such medications.
Be Aware of Your Surroundings

• The quarry environment contains many situations that are
potentially hazardous. Use extreme caution to avoid being
struck by haul trucks, loaders and other quarry mobile
equipment.
1–10 04/17
Inspect and Maintain Machinery • All support structures designed and manufactured by 1
others must be of adequate strength and size to resist the
• Always perform a safety inspection at the beginning of
weight of loaded machinery and any vibration which may
each shift. Refer to the machinery manufacturer’s
occur.
operation and maintenance manuals for detailed pre-start-
up inspection and maintenance procedures. • Structures and foundations should be designed and
constructed to handle dynamic forces up to 2.5 times the
• Test all warning devices before starting the machinery to
weight of the machinery.
ensure that they are working properly. Never disable or
bypass any alarm systems or interlocks. • All walkways, platforms, handrails, stairs and guards
designed by others must meet all local, state and federal
• Be sure that any defective components or systems are
regulations.
properly repaired by a qualified technician before the
machinery is started. Immediately report any serious Typical installations of Telsmith equipment will include an
problems to the appropriate supervisor. operator's platform. This may be furnished by Telsmith or by
the owner of the equipment. The operator's platform should
• Before performing inspections or maintenance, always
be positioned so that the operator has a clear view to control
lock out and tag power to the machinery, and to all feed
the feed of material to the equipment. Remote cameras can be
and discharge equipment for the machinery. Warn all
located to assist the viewing of feed points that are obstructed
personnel that the equipment is being serviced. Refer to
from the operator's view. An operator's cabin should be
the Lockout/Tagout section of this chapter for additional
provided in environments where the operator would be
information.
exposed to harmful dust, noise, and bad weather conditions.
• Maintenance inspection procedures are included The operator's platform should be isolated from any structure
throughout this manual. Although maintenance is not that might cause the operator to be exposed to excessive
typically a safety concern, machinery that is regularly vibrations.
maintained and in proper working condition will
Typical installations of Telsmith equipment will include
minimize the occurrence of safety hazards and emergency
service platforms. These may be furnished by Telsmith or by
situations.
the owner of the equipment. Since these platforms are
typically installation specific, Telsmith provides several
EQUIPMENT INSTALLATION SAFETY hazard decals to be located at the time of installation. The
placement of these decals is part of the initial start-up
Equipment Vibration checklist for the particular Telsmith equipment. Refer to
Some Telsmith equipment is designed to vibrate during specific Telsmith operator manual for proper placements.
operation. Vibrations are amplified during the start-up and The construction of any platforms shall conform to MSHA
shut-down cycles. There is a risk of a crushing injury if body and OSHA regulations for the area in which the equipment is
parts become pinched by the motion of the equipment. to be operated.
CAUTION - Be advised to keep hands and body parts away
from the moving equipment to avoid injury. Support structures Operator’s Vantage Point
must be suitably designed to accept these vibrational forces.
The dynamic loads generated by the equipment are • Telsmith suggests that the operator of the equipment
referenced on the installation drawing. should have a clear vantage point to view the flow of
material into the primary sections of large capacity plants
(250 tons per hour or more). This will ensure good control
Foundations and Supports
of material flow into the primary and into downstream
Your Telsmith equipment, along with any supporting components. It will also promote quicker reactions to
structure, must be installed on an adequate and proper problems, such as blockages, resulting in improved
foundation. Consider the following when preparing for the overall efficiency.
installation of the equipment:
• An adequate foundation on a solid footing is required.
The load-bearing capacity of the location for the
machinery must be 2500–3000 lb/ft2 ( 17.2- 20.7 MPa).
The location should be as level as possible.
04/17 1–11
1 Guarding • If power and control lines are run overhead, allow for
plenty of clearance for vehicle traffic of all sorts. If there
• Quarry management is responsible for the proper
are multiple cables, a cable tray should be used to support
installation and placement of guards to prevent personnel
all lines.
from coming in contact with rotating or moving parts.
• Maintain adequate overhead clearance from power lines
• In addition to the guards supplied with the machinery,
or other obstructions, particularly when planning to use
additional guards and related safety equipment may be
stacking conveyors for stockpiles.
required to comply with OSHA, MSHA and any
applicable local regulations. The proper fabrication, • Be sure that electrical power supplies are located in an
installation and placement of these items is quarry area that will be safe from accidental contact during
management’s responsibility. operation.
• When fabricating guards, refer to MSHA’s Guide to • All Telsmith machinery is designed with electrical
Equipment Guarding. Additional information can also be components of the proper size and voltage.
provided by the safety officer at your worksite.
• Be sure that all connections are in accordance with the
• Never remove guards until the machinery is stopped, National Electric Code (NEC) and any applicable state or
power is locked out and tagged. Be sure that guards are local codes.
properly reinstalled before reconnecting power. Refer to
• NEVER run computer cables in the same conduit as
the Lockout/Tagout section of this chapter for additional
electrical power cables. This will cause interference with
information.
the computer input/output data.
Customer Modifications • Incoming power and utility company transformers should
be located away from the crushing and screening
• Do not modify quarry machinery in any way without prior
equipment and vehicle travelways. Any modifications to
approval from the manufacturer. Such modifications may
these components or to the power supply must be
include (but are not limited to) changing machine speed or
approved in writing by the Telsmith Engineering
direction of rotation, drilling additional holes and welding
Department.
or bolting additional equipment to the machinery.
• All customer modifications to Telsmith machinery must
be approved in writing by the Telsmith Engineering
Department.
Electrical Installation Safety
! WARNING
When installing any electrical equipment, be
sure to completely follow the manufacturer’s
instructions. Failure to observe this precaution
could result in a dangerous electrical shock
hazard.
• Be sure that all electrical equipment is properly grounded.
• Lay out the power lines, especially those for portable
plants, so that contact with standing water is minimized.
• Do not place power lines in an area where they will be
driven over by transport vehicles or other quarry
equipment. If it is absolutely necessary to extend a power
line across a traffic area, protect the cable with properly
rated bridging.
• Be sure that all auxiliary control panels or power supply
panels can be securely locked out. This type of panel is
mandatary.
1–12 04/17
MAINTENANCE AND REPAIR SAFETY • Do not tamper with machinery alarm components. Never 1
attempt to defeat electrical interlocks or to disable
machine protective devices.
! WARNING
Always lockout/tagout power to the machinery Pressurized Systems
and to all feed and discharge equipment before (Hydraulic and Pneumatic)
performing any maintenance or repairs. Warn all
• Adjust, maintain and repair all pressurized systems only
personnel that the machinery is being serviced.
in accordance with the instructions contained in the
manufacturer’s manuals provided with the machinery.
General Precautions
• Never attempt to work on a pressurized system while it is
• To help ensure safe machine operation, use only genuine
pressurized or in operation.
OEM replacement parts that are sold or approved by the
machine’s manufacturer. Use of non-OEM parts may • Before performing maintenance or repairs on any
adversely affect machine operation and could result in a pressurized system:
hazardous situation.
— Cycle the controls through all operating positions to
• Always tighten all fasteners to the proper torque as relieve any trapped pressure.
described in the repair procedures. When torque
— Check that ALL pressure is relieved from the system.
specifications are not listed, use the values in the torque
Pressure gauges must read zero (0) psi.
table at the back of this manual. Refer to Appendix A of
this manual. — Lockout and tag all controls. Be sure electrical power
is properly locked out and tagged.
• Be sure all replacement fasteners are of the proper grade
and specifications. Replace any worn or damaged
fasteners.
Electrical Systems
• Always read, understand and follow appropriate electrical
system troubleshooting, maintenance and repair
instructions in the machinery manufacturer’s manuals.
• Allow only trained and licensed electricians to install,
troubleshoot and repair electrical equipment. All
procedures must be in compliance with the National
Electric Code and any applicable state or local
regulations.
• When servicing an electrical system, work with the power
locked out and tagged. Always assume that an electrical
system is live until it has been locked out.
• Always lockout and tag power before removing cables
with quick-disconnect plugs.
• Repair any obviously worn or damaged wires and
connectors.
• Inspect power cables and connections daily for signs of
wear, cracked insulation and worn or damaged
connectors. Repair or replace as required.
• Do not store tools inside electrical cabinets.
• Verify that all tools are grounded with a three-wire plug or
double insulated. Be sure that all extension cords are
grounded with a three-wire plug.
04/17 1–13
1 • Allow time for hot hydraulic oil to cool before performing • Be sure to wear the proper welding shield, welding gloves
any maintenance or repairs. Hot oil can cause burns. and clothing. Do not wear synthetic-fabric clothing or
clothing which could be easily ignited by sparks.
• Wear safety glasses or face shield when working on
pressurized systems. • Always follow all standard safety procedures when
welding. Be sure that all systems are locked out and
• Before loosening fittings or removing components,
tagged out. Provide welding screens to protect other
always recheck that ALL pressure is relieved from the
employees working in the area.
system. Pressure gauges must read zero (0) psi.
• Relieve all hydraulic pressure before welding near
• Never attempt to loosen a hydraulic fitting while a
hydraulic components and lines. Cover hydraulic
hydraulic system is pressurized. Serious personal injury
components to protect them from weld spatter and sparks.
could result.
• Do not weld near flammable liquids or hydraulic oils.
• Never have your face near, or stand directly in front of a
hydraulic line when loosening a fitting, even after system • DO NOT weld lifting eyes or hooks to any components.
pressure has been relieved. Always assume that the line Welding lifting eyes or hooks to components made of
has pressure. manganese, cast iron, ductile iron or other alloyed
materials may fail when being hoisted or moved. If it
• Use a piece of cardboard, not your hand, to check for
becomes absolutely necessary, use a stainless steel or
hydraulic oil leaks. Escaping fluid under pressure can
manganese welding rod. Use extreme caution when
penetrate the skin, resulting in serious personal injury.
lifting or moving these items and keep all personnel clear.
• Clean up any spilled hydraulic oil. Hydraulic oil is
• Never ground the welder so that the electrical power will
extremely slippery, and can be especially dangerous if
flow through bearings, hydraulic components or electrical
spilled on an elevated walkway or platform.
equipment. Serious damage could result.
• Repair any leaks immediately. Always relieve system
• Be sure all compressed gas cylinders are stored upright,
pressure and lockout/tagout power before tightening
chained and capped. Turn off all cylinders when not in
fittings or making repairs.
use.
• Never attempt to adjust pressure relief valves to above the
machinery manufacturer ’s recommended settings.
Serious personal injury and/or equipment damage could
result.
• Do not operate any hydraulic or air system with obviously
worn or damaged, or leaking components. Always replace
any defective components immediately.
• Never place hands on hydraulic cylinder rods while
equipment is in operation.
• Refer to manufacturer’s instructions when recharging
hydraulic accumulators or checking accumulator
pressure. Allow only trained hydraulic system technicians
t o d e p r e s s u r i z e , r e c h a rg e o r r e p a i r h y d r a u l i c
accumulators.
Welding, Cutting or Grinding on Machinery

• Be sure to provide adequate ventilation when welding,
cutting or grinding inside enclosed areas to prevent the
buildup of hazardous fumes or dust. Special concern
should be exercised when welding, cutting or grinding
chromium, manganese, cadmium, copper, cobalt, lead
and nickel, as these materials are considered to be
potentially carcinogenic.
1–14 04/17
Clearing Jammed Material Disposal of Excess Fuels, Lubricants and 1

• If material becomes jammed in the machinery: Liquids
— Immediately stop the machinery. Quarry personnel are responsible for the proper disposal of
unused fuels, used lubricating oils, used hydraulic oils, and
— Lockout/tagout power. Warn others that the other toxic materials. DO NOT dispose of these materials in
machinery is being serviced. an unapproved manner. Follow all applicable federal, state
— Follow the instructions in the operation and and local regulations.
maintenance manual of the affected equipment.
Flammable and Combustible Liquids
• To prevent serious personal injury or death, never attempt
to remove jammed material while the machinery is in • Store flammable liquids in a safe place, away from quarry
operation. machinery and personnel. Use approved safety containers
and be sure that they are clearly marked. Containers must
• Always remove all jammed material before restarting the be covered when not in use.
machinery. To prevent damage, never attempt to restart a
stalled machine without first removing the jammed • Keep flammable liquids away from sparks, open flame,
material. and other ignition sources. Do not smoke around
flammable liquids. Always obey posted “no smoking”
• Never use dynamite or other explosives to clear jams. signs.
Explosives are dangerous and can injure or kill personnel.
Damage to machinery could also occur. • Be familiar with the locations of fire extinguishers
throughout the quarry. Be sure they remain accessible at
all times, and are not blocked by obstructions.
Hazardous Materials
• Do not use gasoline or other flammable liquids to clean
• Be aware of potentially hazardous chemicals or materials.
tools or parts. Use only approved non-flammable
Such items can be harmful if they are improperly used,
solvents.
stored, mixed or transported, or if they are inhaled,
swallowed or allowed to contact the skin. • Always shut off engines before refueling. Ground fuel
spout against the filler neck to prevent static electricity.
• Consult your employer’s hazard communications plan for
Never smoke while refueling.
instructions regarding the proper handling and use of
hazardous materials. Read and understand the labels • Use only approved safety containers for storing and
attached to the product containers. Always follow the transporting small quantities of flammable liquids. Keep
instructions carefully. containers covered when not in use.
• Consult the manufacturer’s material safety data sheet
(MSDS) for potential hazards and appropriate medical
procedures should an accident occur.
• Store hazardous materials only in approved containers.
Be sure containers are clearly labeled.
• To avoid potential health hazards, persons in regular
contact with hydraulic oils must be aware of the
importance of thorough hygiene, and the proper methods
for handling mineral oils.
• Always wear suitable protective clothing when handling
hydraulic oil.
• Be sure protective clothing and proper washup facilities
are available to all personnel that may come in contact
with mineral-based hydraulic oils.
• Always dispose of used rags or paper towels in the correct
and safe manner.
04/17 1–15
1 HOISTING AND HANDLING SAFETY Forming Wire Rope Eyes

When forming eyes in wire ropes, use the following method:
General Precautions
• Use the correct size thimble as recommended by the
• Do not allow personnel to work or walk under loads supplier for the wire rope being used. DO NOT use under-
supported by a crane or hoist. or over-sized thimbles.
• Use appropriate lifting devices to secure the load to the • Use the correct size and number of U-bolt/saddle clamps
crane. See the following paragraphs of this section for to fasten the wire rope dead end to the live side of the wire
additional information. rope. Orient the saddle so it sits against the live side of the
• Use the correct lifting hooks to support the load. rope. DO NOT place the U-bolt against the live side of the
wire rope, as this will crush and deform the wire rope.
• Use extreme caution when operating a crane near power
lines or electrical equipment.
Connecting Wire Ropes
• Do not exceed the crane’s rated load capacity. Always When clamping or connecting two separate pieces of wire
include the weight of the hook block, slings, chains, rope together use the following method:
spreader bars and any additional equipment when
determining the maximum load that can be safely lifted. • Lay the two pieces of wire rope side by side with the spiral
of the strands facing or turning in the same direction.
Wire Rope • Have your supplier determine the number of U-bolt/
Wire rope requires careful use, handling and maintenance to saddle clamps required for your size of wire rope.
ensure long life and safe operation. Always observe the Normally, one complete clamp can carry approximately
following precautions. 75–80% of the wire rope capacity.
• Be sure to use the correct size wire rope for the • Install the clamps so that the saddle portion is alternated
application. from one side to the other.
• Be sure wire ropes are inspected regularly following the

manufacturer’s guidelines. Maintain an inspection log.
• When storing wire rope, follow the manufacturer’s
recommendations for applying a protective coating to the
wire ropes.
• Avoid sudden loading in cold weather. Never use frozen
wire rope in weather below 32°F (0°C).
• Do not use wire rope around sharp corners or edges that
may cause a cut or deformation of the wire rope.
• Use suitable padding to protect wire rope from sharp
corners or edges.
• Avoid dragging wire rope underneath loads or over
obstacles, as this may cause damage to the wire rope.
• Never use wire rope that is cut, badly kinked, frayed or
crushed.
• Avoid reverse bends.
• Be sure rope ends are properly sized.
• Use appropriate sized thimbles in eye fittings at all times.
NEVER attempt to use an undersized thimble in forming
a wire rope eye.
• Follow the manufacturer’s instructions for lubrication if
using wire rope for lifting purposes.
1–16 04/17
Chains • Keep slings clean and free of solvents, oils and grease. 1
Chains require careful use, handling and maintenance to • Wet or frozen slings should not be used until thoroughly
ensure long life and safe operation. dried. Have supplier inspect sling before using.
• Be sure to use the correct size chain for the application.
TRANSPORTATION SAFETY
• Be sure chains are inspected regularly following the
General Precautions
• Avoid sudden or shock loading. DO NOT jerk load • Be sure that the machinery or equipment is properly
upright or allow load to fall over if chains have too much secured so that it cannot vibrate or move during transport.
slack. Remove any dirt, stones or other loose material from the
• DO NOT use chains around sharp corners or edges that machinery.
may damage chain. • Install shipping brackets, wood blocking or other
• Use suitable padding to protect the chain from sharp shipping materials as directed in the machinery
corners or edges. manufacturer ’s manuals. Perform any shipment
preparation procedures as indicated in the manuals.
• Avoid dragging the chain under loads or over obstacles, as
this may cause damage to the chain. • Plan your route carefully. Know the clearance height of
the machinery. Be aware of bridges, power lines and steep
• Always place chain hooks over links with the hook point or uneven grades. Be aware of any other conditions which
facing downwards. may present hazards or obstructions.
• Inspect chains for wear. Refer to manufacturer’s • Be sure that all tractor-trailer components are working
recommendations for replacement. and in good condition. Test all systems (brakes, steering,
• Be sure all connections between chain sections are lights, etc.) for proper operation and/or adjustment before
completed with properly sized hardware and lifting beginning the move. Check air pressure in all tires and
hooks. replace any tires that are worn or damaged.
• When storing chains, follow the manufacturer’s • After the machinery has been transported, block the tires
recommendations for applying a protective coating to the if the trailer will remain stationary for an extended period
chains. of time.
! CAUTION MAINTENANCE INSPECTIONS

Always follow proper rigging procedures as • Routine maintenance inspections such as lubrication can
provided by the chain manufacturer. The angle often be conducted when performing a safety inspection.
of rigging may decrease the rated lifting This will help provide a good service routine and increase
capacity. the efficiency of your operation.
Fiber or Synthetic Slings

Slings require careful use, handling and maintenance to
ensure long life and safe operation.
• Be sure slings are rated or coded for the hitch or
application.
• Be sure slings are inspected regularly following the
• DO NOT use fiber or synthetic slings in temperatures
below 32°F (0°C) or temperatures exceeding 150°F
(65.5°C).
• Avoid sudden or shock loading (DO NOT jerk load
upright).
04/17 1–17
1 SAFETY LABELS It should be mentioned here that the ANSI Z535.4-2002

Standards are voluntary standards – they are not a legal
General requirement. However, from a legal point of view, product
manufacturers have the legal “duty to warn” about hazards
Each piece of equipment manufactured by Telsmith, Inc., has associated with the use or maintenance of their products.
undergone a Safety Audit to determine those areas that may
create a potential hazard. These audits were done under the To provide a comprehensive Safety Label, safety labels use
guidelines set forth by the ANSI Z535.4-2002 Standards, EN the “Harmonized” format. The Telsmith “Harmonized”
292-2 European Standards and ISO 3864 Part 2 International format uses the ISO Symbol in a center panel along with
Standards. Hazard audits performed are on file at our English text in the left side panel and the text translation for
facilities. the country of operation in the right side panel of the label.
Where possible, potential hazards have been designed out of To promote a better understanding of the Safety Labels
the equipment. However, when it is impractical to design out specifically designed and used by Telsmith, the following
a potential hazard Telsmith, Inc., applies various safety labels outlines the design of Safety Labels to meet or exceed the
to equipment manufactured to warn of the potential hazard. ANSI Z535.4-2002 and the ISO 3864 Part 2 Standards.
See Figure 1-3 to better understand the parts of a Safety
Types of Safety Labels Label.
Since Telsmith, Inc., furnishes equipment worldwide, Safety
Labels provided comply with the ANSI Z535.4-2002 and the
International ISO 3864 Part 2 Standards.
B
A
C
E
F G H
I
Figure 1–3. Safety Label

A – Safety Alert Symbol D – Consequence of Interaction with Hazard G – ISO 3864-2 Symbol
B – Signal Word in Panel E – How to Avoid the Hazard H – Text Panel – Country of Operation
C – Nature of Hazard F – Text Panel – English I – Label Part Number for Ordering
1–18 04/17
A. “SAFETY ALERT SYMBOL” DECOMMISIONING THE 3450 JAW 1

This symbol is an exclamation mark enclosed in a triangle. It CRUSHER
is placed next to the Signal Word in the Panel and indicates If the 3450 reaches a point in its service life where it will be
that a possible personal (human) injury hazard exists. permanently retired from duty, the following items must be
serviced before the unit is scrapped or dismantled:
B. “SIGNAL WORD in PANEL”
• If the crusher is powered by an electric motor, the drive
The Signal Words for product Safety Labels are DANGER, motor must be removed and recycled at a facility that is
WARNING, CAUTION, and NOTICE. These words call certified for electric motor disposal.
attention to the Safety Label and designate a level of hazard
seriousness. (ANSI 4.13 Standard.) • All hydraulic pressure must be removed from the
hydraulic systems prior to removing components or
• ANSI 4.13.1 DANGER: Indicates an imminently dismantling the machine. When the hydraulic pump is
hazardous situation which, if not avoided, will result in shut off, the 3450 automatically drains pressure through a
death or serious injury. The Signal Word is to be limited check valve. The pressure sensor indicator (E, Fig. 1-4)
to the most extreme situations. must always be checked for a zero pressure reading before
• ANSI 4.13.2 WARNING: Indicates a potentially beginning any removal of hydraulic components. Remove
hazardous situation which, if not avoided, could result in the hydraulic gear pump (A, Fig. 1-4) from it’s mounts
death or serious injury. and dispose of at an appropriate recycling facility after
draining fluid.
• ANSI 4.13.3 CAUTION: Indicates a potentially
hazardous situation which, if not avoided, may result in • Disconnect the network electrical cables at the Electrical
minor or moderate injury. It may also be used to alert connection panel (B, Fig. 1-4) on the hydraulic unit.
against unsafe practices. Remove the sensor blocks from the panel and dispose of
at an electrical recycling facility.
• ANSI Z535.2 NOTICE: Indicates potential equipment
damage may occur if the Safety Label is ignored when • Hydraulic fluid must be drained from the toggle cylinder,
performing maintenance, repair or servicing of the the hydraulic tank and hydraulic hoses and all fluids must
equipment. be disposed of in accordance with local environmental
regulations.
NOTE: • Remove all grease from the swing jaw shaft bearing
housing cavities and dispose of in accordance with local
When the Signal Word “NOTICE” is used on a Safety regulations.
Label the Safety Alert Symbol is removed from the
panel. • Remove all rubber items (drive belts, hydraulic hoses,
etc.) and dispose of at a certified recycling facility.
It is the responsibility of the quarry personnel to replace any
worn or illegible labels. Contact the Telsmith Parts • Take note of the weight of the 3450 components in
Department for replacement labels. Chapter 2 when disassembling the crusher. Proper lift
equipment with ratings to match the components will be
required to safely lift major components (Jaw with Dies,
Frame, Flywheels, Hydraulic Cylinder, Hydraulic Control
Unit etc.) out of the 3450 crusher.
04/17 1–19
1
C
A F
Figure 1–4. 3450 Hydraulic Components

A. Hydraulic Gear Pump B. Network Electrical Panel C. 30 Gallon Hydraulic Tank
D. Tank Drain E. Pressure Sensor F. Electric Motor
1–20 04/17
Chapter 2
Features, Dimensions and Specifications 2
CONTENTS
Page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
MAJOR FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
MOUNTING ARRANGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
EXTERNAL DIMENSION DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
ENVIRONMENTAL REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
04/17 2–1
Features, Dimensions and Specifications Operation and Maintenance
DESCRIPTION The Model 3450’s hydraulic relief feature automatically

allows passage of most uncrushable objects, such as tramp
The Telsmith Model H3450 is a primary jaw crusher intended iron and rebar, without jamming or stalling the crusher. If
for use as a mid-mount crusher on low profile applications needed, the crushing chamber can be manually cleared using
such as portable plants or track chassis. This crusher can also the hydraulic clearing function.
2 be used in a Stationary Application using the mid-mounts.
Discharge setting adjustments may be performed quickly and
The H3450 crusher uses a single hydraulic cylinder (I, Fig 2- easily, using the controls on the crusher’s hydraulic power
1) to provide both crushing pressure and hydraulic relief unit. Discharge settings of approximately 89 to 203 mm
action. (3.5 to 8 inches) are possible.
G
E
M
C I
B L
H
O
A
K
J
Figure 2–1. H3450 Cutaway

A. Main Frame D. Cheek Plate G. Eccentric Shaft J. Toggle Seat M. Clamp Plate
B. Maganese Stationary Die E. Swing Jaw Guard H. Swing Jaw K. Toggle End N. Die Wedge
C. Manganese Swing Jaw Die F. Flywheel, Pulley I. Toggle Cylinder L. Compression Springs O. Adjustable Mounting Foot
2–2 04/17
Operation and Maintenance Features, Dimensions and Specifications
MAJOR FEATURES OPTIONS

• A single oversize hydraulic cylinder (I, Fig. 2-1) allows • Back mounted motor drive arrangement w/drive &
simple crusher adjustment and overload protection. flywheel guards.
• The single hydraulic tensioning toggle cylinder assembly
replaces traditional tension springs, plus the associated
• Hydraulic power unit for stand-alone unit machine
installation. 2
toggle beam and adjustment shims.
• Crusher Feed Box
• AR 400 alloy steel cheek plates (D, Fig. 2-1) provide
• Automatic greasing system.
extended wear.
• Fabricated main frame (A, Fig. 2-1) is FEA designed and MOUNTING ARRANGEMENT
stress relieved for rugged durability.
The Model H3450 is available as a stand-alone unit or as a
• Barrel protection is provided by a replaceable impact component of a complete portable crushing plant.
plate (E, Fig. 2-1).
If your crusher is mounted on a portable plant chassis:
• Reversible and interchangeable jaw dies (B & C, Fig. 2-
1) provide extended wear and allow the use of the same • Refer to the Plant Assembly Drawing for the external
part for both the stationary and swing jaw. dimensions of your portable plant.
• Shut down alarm automatically stops the crusher in the • The H3450 can be mounted with standard mounting
event of low hydraulic pressure. brackets, or with the brackets located in an optional high
mounting position. Refer to the assembly drawings in this
• Linear Position Sensor which automatically maintains the chapter or any additional engineering drawings that have
discharge setting. This allows push button adjustment, been provided separately with this manual.
instead of traditional manual adjustment. Automatically
resets discharge setting after hydraulic relief event. Some portable plants may include additional equipment, such
as vibrating screens or feeders. Separate operation and
maintenance manuals have been provided for this equipment.
Refer to these manuals for installation and start-up
procedures.
04/17 2–3
EXTERNAL DIMENSION DRAWINGS
D
C
B
L
K
J
G S
M
R
E
Q
O
P
Figure 2–2. H3450 Dimension in Millimeters (Inches)

A. 330 mm (13.0 in.) G. 0.33 mm (1.30 in.) Hopper Mount Holes M. 971.0 mm (38.23 in.)
B. 1460.5 mm (57.5 in.) H. 675.0 mm (26.57 in.) N. 2445.0 mm (96.26 in.)
C. 1333.5 mm (52.5 in.) I. 620.0 mm (24.41) in.) O. 172.2 mm (6.78 in.)
D. 1270.0 mm (50.0 in.) J. 1253.5 mm (49.35 in.) P. 749.7 mm (29.51 in.)
E. 56.0 mm (2.20 in) K. 1797.3 mm(70.76 in.) Q. 89mm (3.5 in.) to 203mm (8.0 in) Closed Side Setting Range
F. 12.5o L. 3743.4 mm (147.38 in.) R. 54.0 mm (2.13 in.) Inside Frame
S. 360.9 mm (14.21 in.)
2–4 04/17
B 2
C D
CL
H H
I I
Figure 2–3. 3450 Dimension in Millimeters (Inches)

A. 2322.0 mm (91.42 in.) F. 1450.0 mm (57.09 in.)
B. 2300.7 mm (90.58 in.) G. 3079.2 mm (121.23 in.)
C. 1570.7 mm (61.84 in.) H. 355.6 mm (14.00 in.)
D. 365.0 mm (14.37in.) I. 1146.4 mm (45.13 in.)
E. 182.5 mm (7.19 in.) J. 2292.7 mm (90.26 in.)
04/17 2–5
I STANDARD MOUNT
H K
N M L
C
HIGH MOUNT
B E
A G F
Figure 2–4. Crusher Mounting Options

A. 357.4 mm (14.07 in.) F. 250.8 mm (13.81 in.) K. 150.0 mm (5.91 in.)
B. 178.7 mm (7.04 in.) G. 1862.8 mm (73.34) in. L. 300.0 mm (11.81 in.)
C. 1175.0 mm (46.26 in.) Clearance For Jaw H. 178.7 mm (7.04 in.) M. 1711.4 mm (67.38 in.)
D. 1251.3 mm (49.26 in.) I. 515.0 mm (20.28 in.) Clearance For Jaw N. 357.4 mm (14.07 in.)
E. 175.4 mm (6.91 in.) J. 1911.3 mm (75.25 in.)
2–6 04/17
2
REMOTE V-BELT DRIVE
I
H
D E
CRUSHER MOUNT DRIVE

G
Figure 2–5. 3450 Drive Options

A. 1911.3 mm (75.25 in.) F. 853.3 mm (33.59 in.) K. 381.0 mm (15.00 in.)
B. 799.8 mm (31.49 in.) G. 1625.5 mm (64.00) in. L. 419.1 mm (16.50 in.)
C. 775.0 mm (30.51 in.) H. 1842.6 mm (72.54 in.)
D. 12.0 mm (0.47 in.) I. 2859.5 mm (112.58 in.)
E. 12.0 mm (0.47 in.) J. 2230.9 mm (87.83 in.)
04/17 2–7
WEIGHTS
Model 3450 Kilograms Pounds
Jaw Crusher (kg) (Lbs)
2 Crusher, Assembled and Complete 29,030 64,000
Crusher Main Frame Assembly (Includes Stationary Die and Cheek Plates. Excludes Swing Jaw
Assembly, Flywheels, Toggle Cylinder Assembly and Tension Springs. 13,662 30,118
Swing Jaw Assembly

(Complete weight of assembled swing jaw and shaft assembly, including swing jaw, swing jaw 10,082 22,226
die, eccentric shaft, swing jaw bearings, main frame bearings, and other related components.)
Flywheel Sheave 1243 2741
Flywheel Pulley 1352 2982
Swing Jaw Die 2205 4860
Stationary Jaw Die 1470 3240
Cheek Plate, Upper 199 439
Cheek Plate, Lower 111 245
Toggle Cylinder Assembly 1629 3592
Crusher Motor 1074 2368
V-Belt Drive (STD) 101 222
V-Belt Drive (Back Mount) 85 187
Motor Base ASM (Back Mount) 333 735
Drive Guard (Back Mount) 387 854
Flywheel Guard 261 575
IMPORTANT:
All weights shown are estimated and may vary by +/- 5
percent due to fabrication variables, optional equipment or
custom engineering. When available, always refer to the bill of
lading or packing list for actual weights.
ENVIRONMENTAL REQUIREMENTS
The operating temperature range for the 3450 crusher is -
17oC (0oF) to 43oC (110oF). If the 3450 crusher must be
operated in temperatures that exceed the higher limit, contact
the Telsmith Engineering Department for recommendations.
The 3450 crusher is not designed to be operated below the
minimum temperature.
The maximum elevation for 3450 operation is 1000 M (3280
feet).
2–8 04/17
Chapter 3
Crusher Installation and Assembly
3
CONTENTS
Page
RECEIVING THE SHIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Shipment Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Inspection & Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Reporting Damaged or Missing Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
CRUSHER LIFTING & HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
CLEARANCE REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
MOUNTING THE CRUSHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
LUBRICATION SYSTEM REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Standard Model (Manual Grease). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Auto Grease Models (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Priming. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7
PIN Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7
Pre-Lube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7
Filling The Grease Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . .3-8
Low Level Warning Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8
Monitoring Grease Pump Operation . . . . . . . . . . . . . . . . . . . . . . .3-9
HYDRAULIC SYSTEM PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Hydraulic Supply Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Hydraulic Line Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Hydraulic Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Hydraulic & Sensor Control Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . 3-11
Customer Supplied Electrical Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Plus 1 Electrical Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
SAFETY GUARD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
DIESEL ENGINE PREPARATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
FEED AND DISCHARGE ARRANGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
ALTERNATE MOUNTING LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
NEW CRUSHER START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
INITIAL START-UP CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
04/17 3–1
Crusher Installation and Assembly Operation and Maintenance
Telsmith Model H3450 Jaw Crusher
RECEIVING THE SHIPMENT 2. Compare the total number of pieces received in the
shipment against the quantity shown on the bill of lading.
Shipment Details Check for any missing pieces.
The H3450 Crusher is shipped completely assembled. 3. Check the crusher and any subassemblies for obvious
Standalone 3450 crushers will require final electrical control signs of damage.
3 c o n n e c t i o n s t o t h e h y d r a u l i c c o n t r o l a s s e m b l y.
Recommended crusher starter circuitry and connections to 4. Remove all parts from the shipping crates and check
the control assembly are detailed in Chapter 3. them against the packing list. Make a note of any damaged or
missing items.
Stand alone machines come with a free standing hydraulic
power unit. Machines mounted on a Telsmith Portable Plant Reporting Damaged or Missing Items
are connected to a plant mounted hydraulic power unit. Missing items or non-concealed damage must be noted in
The crusher will require a hydraulic pressure source capable writing on the delivery receipt when the shipment is
of delivering 11 LPM (3 GPM) of hydraulic fluid at a delivered. The carrier will have the right to reject any future
minimum of 172 bar (2500 psi). Maximum hydraulic damage claims if this is not done.
pressure is 206 bar (3000 psi). Hydraulic connections and Report any missing items or non-concealed shipping damage
requirements are detailed in Chapter 3. as follows:
The startup procedure for the grease lubrication system is 1. Provide a brief description of the missing or damaged
located in this chapter (Chapter 3). items in writing on the delivery receipt. Make a copy of the
IMPORTANT: Do not connect electrical power to the delivery receipt for your records.
hydraulic power control assembly until all hydraulic and 2. Notify the carrier immediately and request an inspection
lubrication hose connections have been made. by an authorized representative. Save any damaged items or
Tools and loose parts are packed inside wooden crates or shipping materials so that they are available for examination
fastened to pallets. Refer to the bill of lading and packing list during the inspection.
for a complete description of the components and any 3. File a damage claim with the carrier immediately after
subassemblies supplied with your crusher. the inspection.
Inspection & Unloading IMPORTANT: Immediately report any concealed
1. Always use proper lifting and handling procedures when shipping damage or parts shortages to the Telsmith
unloading and unpacking the shipment. To avoid damage, Service Department or your local Telsmith dealer.
follow the instructions in the Crusher Lifting & Handling
section of this chapter.
CHECK THE ENTIRE SHIPMENT

FOR MISSING OR DAMAGED ITEMS
REFER TO THE BILL OF LADING AND PACKING

LIST WHEN UNLOADING THE SHIPMENT
3–2 04/17
Operation and Maintenance Crusher Installation and Assembly
CRUSHER LIFTING & HANDLING
Figure 3–1. Lifting The H3450 Jaw Crusher

3. Lift the crusher by installing lifting lugs or eyes of correct
! WARNING capacity at the four mounting holes shown in Figure 3-2. Use
Do not allow personnel under the crusher while it is only these lift points and make certain that the crusher is
being supported by a crane or other lifting device. evenly supported. Also note the following precautions:
Always use suitable rigging and hoisting equipment • NEVER attempt to lift the crusher using the swing jaw
to stabilize and lift heavy objects. Lifting heavy lifting lugs. These lugs are not designed to lift the entire
components with inadequate hoisting apparatus crusher. Serious damage could result!
can result in serious injury or death.
• NEVER place slings around the flywheel sheaves or the
1. Read and understand the general hoisting and handling eccentric shaft. These components should never be used as
safety precautions contained in Chapter 1. lifting points.
2. Refer to the bill of lading or packing list for the actual • Handle the crusher with care. Ensure that it remains
weight of the complete H3450 crusher assembly. If these upright and evenly supported at all times. Rough or
documents are not available, refer to Chapter 2 for estimated careless handling can cause serious damage.
weights. Be sure that the lifting device and all other lifting
equipment is of adequate capacity to support the entire load
being lifted.
04/17 3–3
IMPORTANT: Improper lifting procedures can result in CLEARANCE REQUIREMENTS

permanent damage to the crusher and its components.
Such damage is not covered under warranty! Note the following guidelines when planning the crusher
installation. Refer to Chapter 2 for crusher external
dimensions and required clearances.
3 A • Allow adequate room beside the crusher for walkways and

service platforms. Observe all federal, state and local
regulations when designing and constructing such
structures.
• Allow adequate room above the crusher for swing jaw
removal. Any structures or chutes mounted above the
crusher must be designed for easy removability when
repairs are necessary.
A • Allow room above feed hopper for die removal

B
• Allow room above rear of crusher for toggle cylinder
removal.
• Allow adequate room beside the flywheel sheaves to
permit removal of the sheaves when repairs are necessary.
• Allow adequate room beside the drive belt and drive
sheave for routine inspection and maintenance. All belt
A drive components must be easily accessible when the
flywheel and drive guards are removed.
• Allow adequate room around the grease lubrication
system and the hydraulic control unit. All service points
must be easily accessible for routine inspection,
Figure 3–2. H3450 Crusher Frame Lifting Points
lubrication and maintenance activities.
A. Install lift eyes or lugs at these points only.

B. DO NOT use swing jaw eyes to lift complete 3450 crusher
3–4 04/17
MOUNTING THE CRUSHER

IMPORTANT:
• The crusher must be horizontally and vertically level when
mounted. Damage to crusher internal components may When mounting and leveling your crusher, ensure that
result if the crusher is not completely level. all of the crusher feet are tightly shimmed to the support
structure BEFORE tightening the mounting bolts. DO
• Install steel leveling shims as required between the crusher
mounting feet and mounting framework. Then tighten the
NOT leave any feet with an “Air Gap”. An un-shimmed
gap left under a support foot (Fig. 3-3) will cause the
3
crusher mounting nuts to firmly secure the crusher to the crusher to thrust on the foundation leading to foundation
frame. failures, or the crusher foot may fracture, or the
anchoring bolts will frequently loosen leading to failures.
Crusher must be horizontally and vertically level
(Check in all planes as shown)
! CAUTION
Check the position of the lock pins (A, Fig. 3-4)
on both sides of the crusher after the unit is
mounted and before starting the crusher. Lock
pins must be in the storage position (Nose of pin
NOT protruding into the crushing chamber).
Make certain the pins are firmly locked in the
storage position with the locking capscrews.
Sta r t i n g t h e c r u s h e r w i t h t h e l o c k p i n s
protruding into the crushing chamber could
seriously damage the crusher drive
components.
A A
Shim Shim Figure 3–4. Locking Pin Storage Position

Mounting Mounting
Foot A. Locking Pin In Storage Position
Foot
Figure 3–3. Checking Crusher Levelness
04/17 3–5
LUBRICATION SYSTEM
REQUIREMENTS
Standard Model (Manual Grease)
• Start-Up - The H3450 Jaw Crusher uses four separate
3 grease fittings located on one central bracket (Fig. 3-5) to
supply lube to the swing jaw and main frame bearings.
The grease lubrication system is delivered installed on the
crusher frame, with all hoses plumbed to grease zerks
(Fig. 3-5). Apply several strokes of a standard grease gun
at each zerk prior to starting the crusher to ensure the lines
are full.
• Daily Lubrication - Approximately 31 grams (1.2 oz.) of
NLGI 2 grease should be added at all zerks daily at
shutdown while the H3450 is warm. Add approximately
8 strokes of Mobil Delvac Extreme from a standard grease
gun to each zerk (Always verify grease gun volume per
stroke). If the 3450 crusher is used for more than 1 shift a
day, it should be lubed at the end of each 8 hour shift. If
grease is just visible at the grease seal shaft junction
behind the flywheels, grease intervals and amounts are
probably correct. If grease weepage at the seal junction is
excessive and grease is being thrown by the rotating parts,
decrease the grease amount applied at each interval. A A
B B
D C B
D C A
Figure 3–5. Grease Fittings

A. To Swing Jaw Bearing (2) B. To Main Frame Bearing (2)
C. Hose Fitting D. Hyd Fitting
E. Grease Zerk (4)
3–6 04/17
AUTO GREASE MODELS (OPTION) You will need to install the control cables from the Low Level
connector and the Pressure connector to the X67 I/O module
If your 3450 crusher is delivered with the optional automatic
(Fig. 3-7). You must also wire the CPC power cable supplied
8 Liter G1 grease pump (D, Fig. 3-6), it will be necessary to
with the grease pump to 24V power on the Universal Crusher
remove the shipping plug from the fitting on the bottom of the
PLC panel.
flow divider (B, Fig, 3-6) mounted on the back of the crusher.
Remove the shipping cap from the grease line (C, Fig. 3-6) The auto grease pump is delivered with the reservoir pre- 3
and attach the grease line from the pump mounted on the filled with NLGI #2 Mobil Delvac Extreme grease. The PLC
hydraulic unit to the fitting on the flow divider (A, Fig, 3-6). will determine on and off cycles of the pump based on feed
back from the pressure sensor and the low level sensor.
A B
E
D
Figure 3–7. Control Cable Connections

C
A. Low Level Connection (On B. 24V Power Connector (On
Pump) Pump)
Figure 3–6. Grease Line Connections C. Pressure Sensor D. Pressure Sensor Connector
Connection (On Sensor)
A. Flow Divider B. Divider Grease Line Fitting E. Low Level Connector F. X67 I/O Module Link
C. Grease Line D. Grease Pump
E. Grease Pump Fitting
04/17 3–7
Priming Filling The Grease Reservoir

1. Temporarily remove the grease feed hose from the fitting Your grease reservoir should be filled with NLGI #2 grease as
on the grease element (B, Fig. 3-8). follows:
2. Loosen the grease pump element fitting (Fig. 3-8). 1. Use a hand pump, pneumatic pump or electric transfer
3 NOTE: Hold the element with a second wrench (A, Fig. 3-8)
to prevent the pump element from turning as the pump
pump to fill the reservoir. Connect the fill hose at the inlet
fitting zerk A, Fig. 3-8).
element fitting is loosened. A loosened pump element will
change the pump output volume. IMPORTANT:
Always clean the zerk fitting with a clean dry cloth prior
to filling the reservoir. Introducing dirt or debris into the
reservoir could damage the pump or the crusher.
D
! CAUTION
When filling the reservoir with a pneumatic or
electric transfer pump, care must be taken not to
pressurize the reservoir as this could cause it to
break.
2. When the grease level in the reservoir reaches
approximately 1/4 full, start the pump to rotate the stirring
C paddle.
3. Rotating the stirring paddle during filling will help
prevent air pockets from forming in the grease.
4. Fill the reservoir only to the MAX full line (B, Fig. 3-9).
DO NOT use the vent port located on the rear of the reservoir
as a fill indicator.
A
B
C
B
Figure 3–8. Priming The Grease System

A. Hold Element at this point with wrench B. Pump Element Fitting
C. Pump Reservoir D. Reservoir Vent
3. Run the pump until air is no longer being dispensed with

the lubricant coming out of the element fitting (B, Fig. 3-8).
4. Tighten the pump element fitting while holding the pump
element with a second wrench to prevent it from turning.
Reinstall the grease line to the element fitting.
5. Remove the grease line at the divider fitting on the crusher
(B, Fig. 3-6). Restart the grease pump and run it until grease
A
comes out of the full circumference of the supply line.
Reinstall the grease line at the fitting and run the pump for 30
seconds to fill the grease divider.
Figure 3–9. Filling The Reservoir
A. Grease Inlet Zerk Fitting B. MAX fill line
C. Vent Port
3–8 04/17
Low Level Warning Alarm

When the grease level in the reservoir drops to the low level
point a signal will be sent to the controller and a warning
(horn activates on PLC Panel) will occur. To prevent nuisance
low level warnings, the grease pump must detect 3 or more
low level triggers within one minute before the horn sounds. 3
Figure 3–10. Warning Horn Location
! CAUTION
If the low level warning alarm is not
acknowledged a shut down of the crusher will
occur after a set period of time.
04/17 3–9
HYDRAULIC SYSTEM PREPARATION Hydraulic Line Installation

The H3450 Crusher requires installation of three (3)
Hydraulic Supply Requirements hydraulic hoses between the hydraulic power unit and the
The H3450 Jaw Crusher is delivered with a 30 gallon 7.5 HP crusher. Two (2) electrical connections to the hydraulic
(113 L, 75.6 Kw) hydraulic unit capable of producing a control module on the crusher are also required.
3 maximum of 317 bar (4600 psi). A steady hydraulic operating 1. Remove the crusher relief line shipping plug from the
pressure of 41 BAR (600 PSI) is the typical 3450 stand by tank end of the relief line (B, Fig. 3-11).
pressure.
2. Remove the shipping cap from the tank fitting (C, Fig. 3-
11). Remove the plug (B,
E H
G A
C G
A H
I
Figure 3–11. 3450 Hydraulic Tank Hose Connections

A. Relief Line D. Hydraulic Fitting G. Dust Cap
B. Shipping Plug (Hose) E. Quick Coupling (P, Pressure Line) H. Tank Line
C. Shipping Cap (Fitting) F. Quick Coupling (T, Tank Line) I. Pressure Line
3. The pressure supply line must be connected to fitting (P) 5. The pressure line (A, Fig. 3-12) must also be connected to
on the hydraulic tank (E, Fig. 3-11). A return line to the the hydraulic manifold at the crusher.
hydraulic tank must be connected to fitting (T) on the
6. Connect the tank line (B, Fig. 3-12) to the hydraulic
hydraulic tank (F, Fig. 3-11).
manifold on the crusher.
4. The Relief Line (A, Fig. 3-11) from the toggle cylinder
manifold must be connected to the tank fitting (D, Fig. 3-11).
3–10 04/17
3
E
E D
H
B
C I
A
D
I
G
H F
Figure 3–12. Hydraulic Manifold and Toggle Cylinder Hose Connections

A. Pressure Line (To Manifold) D. Relief Line (To Toggle Cylinder) G. Relief Line to Toggle Cylinder
B. Tank Line (To Manifold) E. Toggle Cylinder H. Hydraulic Manifold
C. Relief Line (From Tank)) F. Pressure Line to Toggle Cylinder I. Relief Line Hose Fitting
7. Connect the crusher relief line (C, Fig. 3-12) from the tank
to the relief line hose fitting (I, Fig. 3-12) on the frame.
8. If the manifold to toggle cylinder pressure line (F, Fig. 3-
12 and the relief line (G, Fig. 3-12) are not already installed,
they must be connected at this time.
04/17 3–11
C
D
F E
A B
H I
Figure 3–13. Hydraulic Line Connections

A. P Hydraulic Hose Connection B. T Hydraulic Hose Connection
C. 24V Connector (Solenoid A, D. 24V Connector (Solenoid B,
Retract) Extend)
E.>Counterbalance Valve 5000 F.Counterbalance Valve 6000
PSI PSI
G. Pressure Reducing Valve 600 H. Port B, Pressure Hose
PSI Connection
I. Port A, Relief Hose Connection
3–12 04/17
Hydraulic Control A typical Hydraulic Control Assembly schematic is shown in

Fig. 3-14.
The H3450 crusher is typically delivered with a hydraulic
power unit and electrical control panel. Refer to Chapter 4 for
complete instructions on using the control panel to operate,
troubleshoot and make changes to your H3450 crusher.
H3450 CRUSHER HYDRAULICS

3
Directional Control Valve
G b
HYDRAULIC ADJUST
ASSEMBLY C
P A
T B
G4
HYDRAULIC CONTROL
Retract
Extend
ASSEMBLY
H
a G1 G2
A D E
30 psi 600 psi
spring Charge
Pressure
P T 5000 psi B A 6000 psi P T
B P
4000
psi T
145 psi spring

EXT RET B A
G3 F
T2 T1 P
11 LPM (3 GPM) Minimum Recommended @ P
172 bar (2500 psi) Minimum Supply Pressure @ P
206 bar (3000 psi) Maximum Supply Pressure @ P
Supplied by Telsmith
Figure 3–14. Hydraulic Control Assembly, Hydraulic Schematic

A. Check Valve C. Directional Control Valve E. Pressure Reducing Valve G. Retract Coil
B. Reset Valve D. Counterbalance Valve F. Check Valve H. Extend Coil
Hydraulic & Sensor Control Electrical from the position sensor (C, Fig. 3-15). These cables are
Connections provided with the UC PLC panel located on the back of the
crusher. If an optional auto grease lube unit is used a third
The H3450 Jaw Crusher requires electrical connection at both module will be mounted on the I/O module panel.
the hydraulic control assembly, and the jaw position sensor.
• The jaw position sensor is delivered mounted and adjusted
• 24V must be supplied to the extend and retract solenoids to give a 18 cm (7 in.) detection range. If adjustments to
on the hydraulic control assembly (Fig. 3-13). Connectors the jaw position sensor become necessary, refer to Chapter
are supplied at both coils for the 24V supply. Cables are 4.
provided with the UC PLC panel.
• An X2X cable (Fig. 3-15) delivers signals to the X67DO
module and a Power Cable delivers the incoming 24VDC
power to the module (Fig. 3-15). A return cable returns the
I/O link output signal to the X67D module (Fig. 3-15)
04/17 3–13
A B
E C
D
(To Options)
X2X Cable X2X Cable X2X Cable
Extend “A” Solenoid

Cyl Pressure Sensor
Retract “B” Solenoid

(To Options)
Cyl Position Sensor
Power Cable (To Options)

Power Cable
X67DO X67DS
Figure 3–15. Electrical Connections

A. Solenoid A (Retract) DIN connector B. Solenoid B (Extend) DIN connector C.Jaw Position Sensor Connector
D. Manual Override Retract Button E. Manual Override Extend Button
STOP START TR2-1 CR2-1 MS2

PLUS +1
2-44
C1-P44 PWMOUT/DOUT/PVG 2OUT
From From 2-45
From Oil C1-P45 PWMOUT/DOUT/PVG 3OUT
Pump Alarm Hydraulic Oil Pump 2-46
Panel Controller Starter C1-P46 PWMOUT/DOUT/PVG 3OUT
2-1
Recommended Crusher Starter Circuitry C1-P47 Power Supply +
2-1
C1-P48 Power Supply +
STOP START 2-1
TR1-2 CR3-1 MS1 C1-P49 Power Supply +
C1-P50 Power Supply + 2-1
From Oil From From
Pump Alarm Hydraulic Crusher
Panel Controller Starter
Recommended Starter Circuitry For Device Feeding Crusher Supplied With 3450 Crusher
CR1-1
FROM
HYDRAULIC CONTROLLER
Recommended Starter Circuitry For Hydraulic Power Unit
CR2
2-2 Crusher Interlock
CR3
2-2 Feeder Interlock
CR1 Hydraulic Pump Enable

2-2
CUSTOMER SUPPLIED INTERFACING RELAYS 24VDC, 10 mA UP TO 1A PER RELAY COIL

Figure 3–16. Customer Supplied Components
3–14 04/17
DISCONNECT AND BRANCH CIRCUIT 7

PROTECTION PROVIDED BY OTHERS CUSTOMER SUPPLIED POWER CAN+ 4
USE COPPER CONDUCTORS ONLY 2-1A 2
+ 24VDC- 5
PLUS+1 CAN-
2-2 3
C1-P1
C1-P2
MC050-010
Power Ground -
Power Supply +
2-2
2-1
PE 1
3
C1-P3 Can +
2-3 2
C1-P4 Can -
2-4 2-1 1
PE 2-15 3
C1-P5 AINCAND Shield 2
2-6 C1-P6 DIN 4
2-7 C1-P7 DIN 2-2
C1-P8 5VDC Sensor Power +
Sensor Power Ground 3
2-10
C1-P9
C1-P10 DIN
*NOTE: 2-1 1
2-16 3
2-11 C1-P11 DIN TAPE END OF UNUSED BLACK WIRES, 2
2-12 C1-P12 DIN BUNDLE AND SECURE WITH CABLE TIE 4
2-13 C1-P13 2-2
DIN
C1-P14
C1-P15
DIN/AIN
DIN/AIN
2-15 4
1 C1-P16 2-16 2-1 1
2-1
DIN/AIN
2-17 2-17 3
1 BRN
C1-P17 2
3 BLUE 2-2 DIN/AIN
2 2-18 4
WHT
C1-P18 DIN/AIN/FREQIN
4 BLK
2-19 2-2
C1-P20 CAN1+
C1-P21 CAN1-
C1-P22 AIN/CAN/SHIELD 5
2-23 2-1 1
2-23 C1-P23 DIN/AIN/FREQIN
2-24 2-29 3
2-24 C1-P24 DIN/AIN/FREQIN
2-25 2
2-25 C1-P25 DIN/AIN/FREQIN 4
2-26 2-26 2-2
2-27 2-27
2-28 2-28
C1-P27
C1-P28
AIN/TEMP/RHEO
AIN/TEMP/RHEO 6
2-29 2-1 1
C1-P29 AIN/TEMP/RHEO 2-30 3
Horn 2-30
2-2 C1-P30 AIN/TEMP/RHEO 2
2-31 C1-P31 4
DOUT
2-32 2-2
C1-P32 DOUT
2-33
C1-P33 DOUT
2-34
C1-P34 DOUT/PVG PWR1
2-35
C1-P35
C1-P36
DOUT/PVG PWR2
DOUT/PVG PWR3
2-36
2-36
2-35A 2-35 8
2-37 2-32
C1-P37 PWM/OUT/DOUT/PVG1OUT A
2-38 2-37
C1-P38 PWM/OUT/DOUT/PVG1OUT
2-39 2-38 B
2-40 2-39
C1-P40 PWM/OUT/DOUT/PVG1OUT 2-40 2-33
2-41
C1-P41 PWM/OUT/DOUT/PVG2OUT 2-41 C
2-42
2-43 D
2-44
C1-P44 PWM/OUT/DOUT/PVG2OUT 2-44
2-45 2-34
C1-P45 PWM/OUT/DOUT/PVG3OUT 2-45 E
2-46
C1-P46 PWM/OUT/DOUT/PVG3OUT 2-46
2-1 F
2-1
2-1 G
2-1
C1-P50 Power Supply + H
2-37
PLUS+1 J
DP200 K
C1-P1 Main Power Ground 2-2
C1-P2 Main Power Supply 2-1 2-38
L
C1-P3 CAN0+ CAN+
C1-P4 CAN0- CAN- M
C1-P5 CANSHIELD PE
C1-P6 DIN/AIN 2-56 2-39
N
C1-P7 DIN/AIN 2-57
C1-P8 DIN/AIN 2-58 O
C1-P9 DIN/AIN 2-59
C1-P10 NA 2-40
P
C1-P11 NA
C1-P12 NA Q
2-41
R
S
2-42
CONNECTOR LEGEND T
U
Conn #1 - Cylinder Position Sensor 2-43

V
Conn #2, 3, 4, 5 & 7 NOT USED In This Application W
2-1
Conn #6 - Hydraulic Pressure Sensor X
2-2
Conn #8 - Main Connector (Jaw Extend/Retract,
Feeder Power, Discharge Conveyor, Feeder Speed)
Figure 3–17. Crusher Control Panel, PLUS 1 Electrical Schematic
04/17 3–15
SAFETY GUARD INSTALLATION

If your H3450 crusher was not supplied with factory installed
guards (Fig. 3-18), installation of flywheel and drive belt
safety guards is required after installation of the crusher is
complete.
3
Figure 3–19. Flywheel Guard Mounting Holes
DIESEL ENGINE PREPARATION

• Be certain that the diesel engine is properly sized for the
crusher. The H3450 Crusher requires 149 KW (200 HP) to
drive the swing jaw. Note that diesel horsepower is rated
differently than electric horsepower.
• Read and understand the operator’s manuals provided
with the engine. If present, also refer to any additional
Figure 3–18. Typical Factory Supplied Flywheel and
operator’s manuals for engine accessories (power take-off,
Motor Guards
auxiliary pump drive, etc.).
When fabricating guards, they must completely cover the
• Follow the engine manufacturer’s instructions when
inner and outer face and the rim of each flywheel, the
preparing the diesel engine for use. Check all fluid levels.
complete belt run and the belt drive sheave to prevent
If it is necessary to add fluids, use only recommended
accidental contact with the rotating surfaces by any service
fluids of the proper specifications.
personnel or operators. Flywheel and belt guards should be
designed to prevent accidental intrusion by tools, flying • If the engine is equipped with a power take-off (PTO),
debris and any service equipment that could come in contact read the PTO operator’s manual for start-up checks and
with an operating jaw or the flywheel drive apparatus. adjustments.
Threaded holes are provided in the H3450 frame for
• Prepare the engine for operation in accordance with the
mounting flywheel guards (Fig. 3-19).
engine manufacturer’s initial start-up instructions.
Completely follow all recommended break-in procedures.
! CAUTION Observe all safety precautions as outlined in the operator’s
manuals.
Failure to properly guard Model H3450 Jaw
Crusher flywheels and drive sheaves could IMPORTANT: It is the user’s responsibility to install and
result in entanglement risks to operators and connect an appropriate fuel shut-off device if the
service personnel. Serious injury or death could crusher is diesel powered.
result if contact is made with rotating flywheels,
sheaves or belts. Never operate the H3450
crusher with flywheel, sheave or drive belt
guards removed.
3–16 04/17
FEED AND DISCHARGE ALTERNATE MOUNTING LOCATIONS

ARRANGEMENT The H3450 crusher offers several mounting options that
Adequate surge storage facilities must be provided to ensure allow the crusher to be physically mounted lower in
that the H3450 crusher receives a constant, steady feed at all applications where sufficient clearance above the crusher is
times. It is recommended that a feeder be installed between not available. Front outrigger mounts can be mounted in four
the crusher and the surge storage to allow precise regulation different positions (Fig. 3-20). Rear outrigger mounts are 3
of the feed. available with the mounting feet in locations that match the
front mount locations. For example: If the front outriggers are
A vibrating grizzly feeder placed just ahead of the crusher is placed in the No. 3 position it will be necessary to use
mandatory for most crushing applications. A feeder will matching rear outriggers with the mounting feet in the No. 3
remove most of the undersize or “fine” material from the position.
feed, resulting in improved crushing efficiency.
A feed hopper of appropriate size must be mounted above the
crusher. It is the customer’s responsibility to fabricate a
suitable feed hopper if one was not supplied with the crusher.
Hopper mounting holes are provided at the top of the crusher
frame. Refer to Chapter 2 for mounting hole locations and
dimensions.
A proper discharge arrangement is essential. Be certain that
the discharge chute will not restrict the free flow of material #4
through the crusher. Provide a sufficient amount of clearance #3
between the top of the jaw crusher foundation and the bottom #2
of the discharge area so that crushed material can drop freely
as it exits the crusher. #1 #1
Flat bottom boxes used as discharge chutes should be Low Mount Position
mounted low enough so that crushed material, when piled to
the angle of repose, will not reach the lower portion of the
swing jaw. Any material back-ups in this area can cause
serious damage to the crusher.
Crushed stone can be very abrasive. Whenever possible,
chutes should be constructed in the form of boxes so that
stone runs on stone and wear is reduced. For added durability,
it is recommended that chutes and hoppers be lined with
abrasion resistant steel plate.
#4 #4
High Mount Position
Figure 3–20. Outrigger Mounting Options

When installing front outriggers in a different position, or
new outriggers in the back position all mounting bolts for the
outriggers must be torqued to 1570 Nm (1168 Ft. Lbs.).
Always check outrigger feet after remounting to see if any
shimming between the feet and the mounting base is required.
When all feet are mounted and shimmed, check that the
crusher is level in all planes (Fig. 3-3).
04/17 3–17
NEW CRUSHER START-UP

1. Read and fully understand the crusher operating
instructions contained in this manual. Be familiar with all
crusher features and functions.
3 2. Perform all applicable installation and assembly

procedures as described in the previous sections of this
chapter.
3. Locate the Initial Start-up Checklist. This checklist is
shipped loose with all new crushers. Keep all checklists
handy during the initial start-up period.
NOTE: Refer to the back of this chapter for a duplicate
copy of the Initial Start-up Checklist.
NOTE: Perform all hydraulic system initial start-up
procedures as described in the OEM track plant
manufacturer instructions. Verify that all hydraulic
functions operate properly, and that there are no
obvious problems.
4. If not done previously, adjust the crusher discharge
setting. Refer to Chapter 4 for instructions.
5. Complete section I of the Initial Start-up Checklist.
6. Start the hydraulic pump. Verify that the main system
pressure gauge indicates approximately 172 - 206 bar (2500 -
3000 PSI). The hydraulic pump should turn on when main
system pressure falls below approximately 137 bar (2000 psi)
and turn off when main system pressure rises above 206 bar
(3000 psi).
7. Walk completely around the crusher. Check that no
personnel are on, inside or near the machine. Sound a
warning horn to alert others that the crusher is about to be
started.
8. Start the crusher drive motor or diesel engine.
9. Check crusher speed (RPM) during initial startup with a
handheld tachometer. If crusher RPM is less than or greater
than the specified RPM, adjustments to the flywheel drive
apparatus will be required.
10. Verify that hydraulic adjust cylinder position sensor LED
remains green during complete crusher stroke.
11. Listen for noise at the hydraulic adjust assembly. If a
“thumping” is heard during the test run, spring tension may
need to be adjusted or balanced on the compression springs.
Refer to Chapter 4 for complete spring adjustment
instructions.
3–18 04/17
Mail to: Important:

Telsmith, Inc. Mail Signed Checklist
within 7 days of start-up
Attn.: Service Department
to maintain warranty.
P.O. Box 539
Mequon, WI 53092 3
U.S.A.
INITIAL COMMISSIONING CHECKLIST

Telsmith H3450 Hydra Jaw Crusher
CUSTOMER INFORMATION: SECTION 1- Pre Start-Up Checks cont.
Customer Name / Address BELT DRIVE

Sheaves properly aligned and installed.
All sheave bolts tight.
Dealer Name / Address Drive belt tension adjusted correctly.

Drive and flywheel guards installed.
DIESEL ENGINE (OPTION)

Checklist completed by Engine properly installed and prepared for
operation.
Engine fluid levels checked.
Date Engine manufacturer’s manuals read and
Crusher Model understood.
Serial Number
HYDRAULIC SYSTEM
Customer Signature: Hydraulic reservoir filled
(Name and grade of fluid used _____________).
SECTION 1- Pre Start-Up Checks
Hydraulic supply and relief hoses properly
FOUNDATION connected at hydraulic unit and crusher.
Crusher solidly mounted on machine or Timed delay relay interlocked with crusher starter
structure. or diesel fuel shutoff.
Crusher shimmed level.
Hydraulic pump turns in correct direction.
Crusher mounting nuts tight.
Main system pressure indicator indicates 172 bar
CHUTES AND HOPPERS (2500 psi) to 206 bar (3000 psi).
Feed chute adequately sized and properly Hydraulic filter indicator(s) show no obstruction or
positioned. leaks.
Discharge hopper adequately sized and properly
positioned.
Chutes and hoppers have proper clearance.
Chutes and hoppers free of obstructions.
CRUSHER
Discharge setting correct (________ inches).
Crushing chamber clear.

Tension springs correctly adjusted.
(No knocking or thumping when initial run occurs)
04/17 3–19
START-UP CHECKLIST cont.

SECTION 2- CRUSHER INITIAL START-UP SECTION 3- MATERIAL INTRODUCTION
3 GREASE LUBRICATION SYSTEM FEED ARRANGEMENT
Grease Zerks Serviced. Feed evenly distributed across full width of
crushing chamber.
Swing jaw and eccentric shaft bearing temperatures
Feed free of clay and fines.
checked after 8 hour run-in:
Swing jaw bearings ______oC Crushing chamber remains adequately filled
Eccentric shaft bearings _______oC during normal operation.
No material back-ups or spillage evident in
CRUSHER DRIVE SYSTEM discharge area.
Top of drive side flywheel rotates toward feed
opening. HYDRAULIC SYSTEM
Flywheel speed is ______ RPM with crushing Hydraulic fluid temperature and pressure
chamber empty. remain within acceptable limits.
Jaw position sensor LED shows green. Hydraulic filter indicator(s) show green after fluid
is warm.
DIESEL ENGINE
Fluid heater (if equipped) turns on and off at
Engine starts and operates properly. correct temperatures.
Power take-off engages properly. CRUSHER
Engine gauges and indicators show normal readings. No unusual noises, vibrations or other signs that
would indicate jaw is making contact with solid
objects.
Engine heater turns off and on at the proper
temperature (if equipped). Hydraulic relief action does not occur during
processing of normal feed material.
Engine rpm is _____ rpm with crusher unloaded.
Flywheel sheave speed is ______ RPM after
material feed is started.
BELT DRIVE
Crusher RPM remains constant (within 5%) after
Drive belt tension correct after initial run. material feed is started.
Drive belt and sheave not contacting guards during Position sensor LED remains green during
operation. complete crusher stroke.
Mail to: Important:

Telsmith, Inc. Mail Signed Checklist
Attn: Service Department within 7 days of start-up
P.O. Box 539 to maintain warranty.
Mequon, WI 53092
U.S.A.
3–20 04/17
Chapter 4
Crusher Operation and Adjustments
4
CONTENTS
CONTROL OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Universal Control Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Touch Screen Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
PRE-START-UP CHECKS and ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Selecting Crusher Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Setting The Preliminary Setpoint. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Checking Data Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
DAILY START-UP PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Pre-Start Checks & Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Start-Up Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Crusher Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
AFTER STARTING MATERIAL FEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
FEED RATE AND GRADATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
DAILY SHUTDOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
GOOD HOUSEKEEPING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
MEASURING THE DISCHARGE SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
VIEWING THE CURRENT DISCHARGE SETTING ON THE DISPLAY . . . . . . . . . . . 4-9
SETPOINT ADJUSTMENT FEATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
ADJUSTING THE DISCHARGE SETTING (Setpoint) . . . . . . . . . . . . . . . . . . . . . . . 4-10
CLEARING OBSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Hydraulically Clearing the 3450 Hydra Jaw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Manual Clearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
POSITION SENSOR ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
HYDRAULIC ADJUST ASSEMBLY SPRING TENSION . . . . . . . . . . . . . . . . . . . . . 4-16
04/17 4–1
Crusher Operation and Adjustments Operation and Maintenance
CONTROL OVERVIEW Touch Screen Functions

Adjust Setpoint Keypad (A, Fig. 4-1)- Selects the ADJUST
Universal Control Display SETPOINT option.
The primary control device for the 3450 is a touch screen Open Crusher Keypad (B, Fig. 4-1) - Selects OPEN crusher
located on the cover of the main electrical control cabinet option to allow the jaws to be fully opened to clear material
(Fig. 4-1). A hinged outer cover provides extra protection for backups.
the control device. This control (Fig. 4-1) allows you to
control and monitor functions such as changing the crusher Fault Indicator (C, Fig. 4-1) - This icon will appear on the
4 closed side setting, accessing fault information, monitoring screen when faults are present in the system.
the status of I/O’s and performing manual opening of the Feeder Enable Indicator (D, Fig. 4-1) - If the indicator has
3450 jaw. A touch key at the bottom right hand corner of the turned green the feeder has enabled.
device allows you to select background color options.
Crusher Enable Indicator (E, Fig. 4-1) - If the indicator has
turned green the crusher has enabled.
01/18/17 K Main Page Data Values (F, Fig. 4-1) - Live pressure and
H3450 temperature readouts for system pressure, jaw position
G J
readout, cylinder pressure and hydraulic oil temperature
I
appear here.
F
Model Designator Readout (G, Fig. 4-1) - The currently
selected crusher model is displayed. If the wrong model is
designated, the Startup Selection Screen #1 must be used to
E H select the correct crusher.
D Select Crusher Setup Window Keypad (H, Fig. 4-1) - This
selection opens several Startup Screens that allow changes in
crusher selections, configurations or modes and also current
pressure and temperature readings.
A B C
I/O Status Window Keypad (I, Fig. 4-1) - This selection
opens an I/O Status Window. Analog Outputs, Digital Inputs
Figure 4–1. 3450 Touch Pad Control Components and Digital Outputs can be monitored on this screen.
A. ADJUST SETPOINT selection
Fault Window Keypad (J, Fig. 4-1) - This selection opens
B. OPEN JAW
C. FAULT INDICATOR the fault window which displays all faults on a historical time
D. FEEDER ENABLE Indicator line by month/day/year.
E. CRUSHER ENABLE Indicator
F. DATA VALUE Readings Main Menu Keypad (K, Fig. 4-1). This selection returns
G. CRUSHER MODEL DESIGNATOR you to the Main Menu window from anywhere in the system.
H. CRUSHER SETUP WINDOW selector
I. I/O STATUS Screen Selector NOTE: It may require more than one keypad touch to return
J. FAULT READOUT Screen Selector to the main menu depending on your current location in the
K. MAIN PAGE Screen Selector system.
IMPORTANT:
Your 3450 closed side setting (CSS) should be checked
before operating the crusher for the first time. Failure to
operate the crusher without the correct minimum
clearance could damage the crusher. See Measuring
the Discharge Setting and Adjusting The Discharge
Setting (Setpoint) in this chapter.
4–2 04/17
Operation and Maintenance Crusher Operation and Adjustments
PRE-START-UP CHECKS &

ADJUSTMENTS A Machine Setting
Selecting Crusher Type

If your Main Control Panel is not displaying the correct
model crusher in the center of the screen on startup (G, Fig. B
4-1), it will be necessary to use the Startup Selection Screen
(Fig. 4-2) to select your crusher model. From the Main Screen
press the Setup Menu keypad (H, Fig. 4-1) once to call up the
C 4
Startup Selection Screen (Fig. 4-2)
D
Figure 4–3. Machine Setting Screen

A. Language Selection C. Network Settings
B. Screen Configuration Selections D. Time and Date Selection
Setting The Preliminary Setpoint

You MUST set the crusher setpoint to a correct minimum
value before starting the 3450 crusher for the first time. To
call up the Setpoint Selection Screen (Fig. 4-4) press the
Adjust Setpoint keypad (A, Fig. 4-1) once. Use the Open (A,
A
B Fig. 4-4) and Close (C, Fig. 4-4) keypads to set the new
discharge setting. NOTE: If you have questions about
selecting the correct setpoint value refer to Adjusting The
Figure 4–2. Startup Selection Screen
Discharge Setting (Setpoint) in this chapter. When the
A. Machine Settings selection keypad correct setpoint is reached, press the OK button (B, Fig. 4-4).
B. Alarm Setpoints selection keypad
The example in Figure 4-2 is setup for a 3244 crusher. Use the
keypad selection arrow to select the 3450 crusher. NOTE:
you will need to use the LOG IN window and provide a
password to change selections on this screen.
The Startup Selection screen will also allow you to change the
language from English to Spanish or vice/versa and turn the
automatic grease lubrication system on or off.
Pressing the SETTINGS keypad (A, Fig. 4-2) on the
Selection Screen will bring up a new MACHINE SETTING
screen (Fig. 4-3) that allows you to switch languages from
English to German, or change screen brightness, network
settings or the time and date.
A B C
Figure 4–4. Setpoint Selection Screen

A. Open Setpoint button
B. Save New Setpoint button
C. Close Setpoint button
04/17 4–3
Checking Data Values

The Main Page Data Values (F, Fig. 4-1) supply current
readings on following crusher values: C
1- Current Hydraulic System Pressure in PSI

2 - Current Jaw Position Setting
3 - Cylinder Hydraulic Pressure in PSI
4 - Hydraulic Oil Temperature in oF or oC A
4 You can also check the Alarm Setpoints by activating the
SETPOINTS keypad (B, Fig 4-2) on the Startup Selection
B
Screen. The ALARM SETPOINTS screen (Fig. 4-5) will
now appear allowing you to compare High/Low Pressure
Readings and High/Low Temperature Readings against the
current readings on the Main Page Screen. Figure 4–6. Fault History Screen
A. Up/Down Keypads C. Selection Bar
B. Acknowledgement Keypad
6000 PSI 4000 PSI

Status Indications
Analog inputs are indicated in the status window chart by the
100 PSI 0.10 in current pressure or temperature readings being returned to the
crusher. Digital Inputs and Outputs indicate their status by the
180 o F 0.20 in color of the corresponding box. A green indicator will appear
when digital signals in the correct range are present. A red
41 o F PSI indicator indicates the correct signal is not present or is out of
range.
PSI
A B
Figure 4–5. Alarm Setpoints Screen
Fault Indicator
If the Fault Indicator (C, Fig. 4-1) appears on the main menu,
this indicates that one or more new active faults are currently
present in the crusher. If the fault indicator is not present, it
indicates the crusher is currently enabled with no faults.
C
To access the current or historical faults, push fault keypad (J,
Fig. 4-1) once to access the Fault History Screen (Fig. 4-6).
Use the UP and DOWN arrow keypads to scroll through fault
list using the selection bar (C, Fig. 4-6). The Check keypad Figure 4–7. I/O Status Window
(B, Fig. 4-6) is used to acknowledge a current fault and turn
A. Analog Inputs C. Digital Outputs
off the Fault Indicator on the main control panel.
B. Digital Inputs
4–4 04/17
DAILY START-UP PROCEDURES

Use the following steps as a guide when preparing the crusher
for operation at the beginning of each shift.
Pre-Start Checks and Inspections

Perform the following steps with the 3450 crusher OFF.
! WARNING 4
Lockout/tagout power to the crusher drive before
making the following checks and inspections.
1. Remove any spillage and debris from around the crusher.
Remove any built up material from the crusher frame surfaces
and ledges.
Figure 4–8. 3450 Hydraulic Control Unit
2. Check that the crushing chamber is clear. Be sure that no
material is lodged inside. Crusher Start-Up
3. Check the discharge area for obstructions. If present, Perform the following steps when starting the 3450 crusher:
remove any trash or built-up material.
1. Walk completely around the crusher. Be sure no personnel
4. Inspect all chutes and hoppers for damage or excessive are on, inside or under the machine. Sound a warning horn to
wear. Remove any obstructions. alert others that the crusher is about to be started.
5. Remove any loose dirt or stones from the drive motor 2. Start the hydraulic unit.
cooling fins. Be sure that the motor fan openings are clear.
3. Verify that the plant hydraulic system pressure gauge
indicates approximately 2500 PSI (172 bar).
Lubrication System
Grease zerks for the 3450 swing jaw should be serviced when
! CAUTION
the bearings are warm after a shift shutdown. Refer to Daily
Shutdown in this chapter for suggested grease intervals. The jaw crusher jaw setpoint (discharge setting)
MUST be adjusted before running a new crusher
1. Remove any loose dirt or spillage from the grease zerk for the first time. The H3450 is delivered with the
block. jaws at a minimum clearance setting for
2. Check grease system hoses and fittings for leaks. Repair transport purposes. Follow the instructions in
any leaks before starting crusher. this chapter on adjusting the setpoint before
placing the crusher in the CRUSH mode for the
Start-Up Checks first time. Failure to set the setpoint (discharge
setting) at a 8.00 cm (3.5”) or greater setting
Perform the following steps with the 3450 crusher OFF. Refer before running the 3450 crusher could damage
to Chapter 9 for hydraulic system operation and maintenance the unit.
instructions.
4. If you are starting the 3450 Crusher for the first time,
1. Remove loose dirt or spillage from the hydraulic control adjust the crusher jaw setpoint (discharge setting) to the
unit (Fig. 4-12). desired setpoint as described in Measuring the Discharge
2. Wipe off all gauges and indicators. Setting and Adjusting the Discharge Setting in this chapter.
An initial crusher jaw setpoint MUST be established before
3. Check for hydraulic fluid leaks. Repair any leaks before starting the 3450 crusher for the first time.
starting the hydraulic pump.
5. Place the selector switch controlling the 3450 crusher in
4. Check the plant hydraulic reservoir level indicator. Add the CRUSH position.
fluid if low. Refer to the plant manufacturers hydraulic fluid
specifications for correct hydraulic fluid type. 6. Verify that there are no unusual noises, vibrations or other
indications of improper operation. Stop the crusher
immediately if any obvious problems are detected.
04/17 4–5
AFTER STARTING MATERIAL FEED FEED RATE AND GRADATION

1. Verify that the material feed is evenly distributed and well Regulate the feed rate so that the chamber remains at least
graded. The 3450 crusher should remain at least two thirds two-thirds filled while crushing. This will help ensure proper
full during crushing. work-hardening of the jaw dies and will help prevent uneven
wear from occurring.
2. Be sure there is no material spillage at the crusher feed
hopper. Reduce feed rate if spillage occurs. A well-graded feed - evenly distributed across the full width
of the crushing chamber - will help ensure maximum jaw die
3. Verify that material moves continuously through the
4 crusher without backing up. Check that the discharge
life and the highest quality product.
conveyor is removing crushed material at an adequate rate. The feed should be sized to a top dimension well within the
effective receiving opening of the crusher. Large pieces that
4. Check the ammeter at the drive motor. Power draw should
cannot pass through the crusher without bridging should be
remain within normal limits and must not exceed the full
broken by other means or removed from the feed. Typically,
rated amps of the crusher drive motor.
the feed size of your material should be limited to 80% of the
5. Recheck all gauges and indicators at least every 4 hours. jaw gape or less on your crusher. The gape (jaw feed opening
Stop the crusher immediately if any abnormal or rapidly at entry point) on a 3450 crusher is 34” (86.3 cm). So the
changing readings are observed. maximum feed size on a 3450 jaw should be 27” (68.5 cm) or
less in two of the three dimensions of each feed piece. For
6. When starting a new 3450 crusher for the first time, the
example 27” wide and 27” deep, or 27” wide and 27” long.
swing jaw and eccentric shaft bearings temperatures should
be checked with a heat gun after 2 hours of operation and then
again after the first 4 hours of operation (Fig. 4-13). All 40”
bearings should read 82oC (180oF) or less. After the crusher 27”
is broken in, bearing temperatures should be checked once a 27”
week (40 hours). Excessive temperatures can be due to either
34”
overgreased or undergreased bearings.
27”
27” FEED SIZE EXAMPLES
Occasionally feeding material 80% of the gape is acceptable.

Continuous operation running this large of feed is not
recommended or productive.
Maintaining feed material at less than 80% of gape allows the
material to drop deeper in the chamber where it can be
crushed more effectively by the stronger crushing forces at
the lower two thirds of the jaw.
Operating the crusher with a weak or intermittent feed is not
recommended. Underfeeding will result in a lower quality
product and greatly increased liner wear at the lower portion
of the jaw dies.
Several times each day, check the discharge conveyor to
verify that crushed material is being carried away without any
spillage or back-ups.
Figure 4–9. Checking 3450 Bearing Temperatures

7. If swing jaw relief action occurs frequently, check the
material feed for excessive tramp iron or other uncrushable
objects.
4–6 04/17
DAILY SHUTDOWN
1. Stop the material feed and allow time for the crushing Table 4–1. 3450 Grease Requirements
chamber to clear. Wait until there is no material remaining on
Recommended Recommended
the discharge conveyor. Temperature
Specification Standard Synthetic
Range
Lubricant Lubricant
2. Stop the discharge conveyor.
Below 4oC NLGI 00, with - Mobilith SHC
3. Stop the crusher drive motor (or diesel engine) and allow 40OF* EP Additives 007
the swing jaw to come to a complete stop.
4. Lockout/tagout power to the crusher drive motor (or
Below 38oC
100oF
NLGI 2, with
EP additives
Mobil Delvac
Xtreme Service
Mobilith SHC
460 4
Grease
diesel engine), and to all feed and discharge devices. or: Shell Gadus
S3 V220 C2
5. Lockout/tagout power to the hydraulic system and the
Above 38oC NLGI 2, with - Mobilith SHC
lubrication system. 100oF EP additives 460
6. Do a complete walk-around inspection of the crusher.

Note any maintenance or repair activities which must be GOOD HOUSEKEEPING
performed before the crusher is restarted.
• Keep the crusher clean. Do not allow spilled material to
7. Clean up any spilled material from walkways, stairways, accumulate on or around the crusher. Be sure all
service platforms and other areas near the crusher. walkways, service platforms and stairways remain free of
8. Grease the swing jaw and eccentric shaft bearings while tools and spilled material.
the unit is still warm. Apply five strokes of a standard grease • Do not allow spilled material to accumulate around the
gun to each zerk (Fig. 4-14). Use an NLGI #2 grease with EP hydraulic power or control units. All gauges, indicators
additives such as Mobil Delvac Xtreme Service or Shell and service points must remain accessible for routine
Gadus S3 V220 C2 if the crusher is operating in a temperature inspection and maintenance purposes.
range from 4oC (40oF) to 38oC (100oF). Refer to Table 4-1 for
grease recommendations if the crusher will be operating in • If possible, provide drainage away from the crusher.
extreme heat or cold. If the crusher is used for more than one • When not in use, properly store all spare parts and tools so
8 hour shift per day, grease amounts will need to be adjusted. they are protected from dust and dirt.
A properly greased crusher should show a slight amount of
grease seepage at the grease seal/shaft junction behind the
flywheels after eight hours of use. MEASURING THE DISCHARGE
SETTING
Measure the discharge setting as described in the following
steps.
1. Lockout/tagout power to all feed and discharge devices.
Refer to Chapter 1 for complete lockout/tagout procedures.
2. Visually check that the crushing chamber is completely
empty.
3. Visually check that the flywheel weights are in the UP
position. This indicates that the eccentric shaft is in the
Figure 4–10. 3450 Grease Junction Block DOWN (at rest) position. If the weights are not in the up
position, the drive may need to be engaged momentarily to
rotate the weights.
04/17 4–7
! WARNING ! WARNING
Performing the discharge setting adjustment Once discharge settings are determined, all
requires working under or near the machine with personnel must clear the area beneath or near
h yd r a u l i c p o w er a c ti ve . M a k e c e r tai n al l the crusher before the discharge setting is
personnel are aware that clearance settings are adjusted. Adjusting the discharge opening with
being adjusted. Rope off the work area and personnel under the crusher could result in
install warning tags on the hydraulic control pinch point injuries or injuries due to dislodged
4 panel to prevent inadvertent activation of
controls while service personnel are working
material falling unexpectedly.
under or near the crusher.

4. From beneath the crusher, measure the PEAK to PEAK
distance between the stationary die and the swing jaw die.
Make measurements in at least five different places across the
entire width of the discharge opening. See Figure 4-15.
At Rest Gap
Discharge
Setting
Figure 4–11. Discharge Setting Measurement

5. Subtract approximately 1 inch (25 mm) from the shortest
measurement made in step 4. This dimension is the crusher
discharge setting.
IMPORTANT: The minimum discharge setting for this
crusher is 3.5” (89 mm) or 4.5” (114 mm) as measured
at rest. DO NOT attempt to adjust the discharge setting
below this dimension. Crushing with an excessively
close di scha rge setting may result in serious
mechanical damage to the crusher. The maximum
discharge setting must not be set beyond 8” (203 mm)
or 9” (229 mm) as measured at rest.
4–8 04/17
VIEWING THE CURRENT DISCHARGE

SETTING ON THE DISPLAY D
Check the current discharge (setpoint) setting as described in

89 mm
the following steps.
1. Lockout/tagout power to all feed and discharge devices.
Refer to Chapter 1 for complete lockout/tagout procedures.
2. Visually check that the crushing chamber is completely
empty. 4
! WARNING
Performing the discharge setting adjustment A B C
requires working with hydraulic power active.
Make certain all personnel are aware that Figure 4–13. Jaw Setpoint Screen Readings
clearance settings are being adjusted. Rope off A. Open Jaw Keypad C. Close Jaw Keypad
the work area and install warning tags on the B. Save New Setpoint Keypad D. Current Setpoint Reading
control panel to prevent inadvertent activation of
controls while service personnel are working
crusher is 89 mm (3.5”). DO NOT attempt to adjust the
near the crusher.
discharge setting below this dimension. Crushing with
3. From the startup menu (Fig. 4-12), access the Adjust Jaw an excessively close discharge setting may result in
Setpoint Screen (Fig. 4-13) by pressing the Setpoint Selection serious mechanical damage to the crusher. The
Keypad (A, Fig. 4-12) once. maximum discharge setting must not be set beyond 203
mm (8”).
H3450 ! WARNING
Once discharge settings are determined, all
personnel must clear the area beneath or near
the crusher before the discharge setting is
F adjusted. Adjusting the discharge opening with
personnel under the crusher could result in
pinch point injuries or injuries due to dislodged
material falling unexpectedly.
Figure 4–12. Startup Menu

A. Adjust Setpoint Selection
4. The Adjust Setpoint Screen will now appear (Fig. 4-13).

The current crusher setpoint is located on the first line of the
screen (D, Fig. 4-13).
NOTE:
Step #4 Does Not provide the CSS value, only the
setpoint value. The Closed Side Setting (CSS) must be
measured manually.
04/17 4–9
SETPOINT ADJUSTMENT FEATURE

Your crusher is equipped with a Linear Position Sensor that E
automatically maintains the discharge (setpoint) setting. In
the event of a relief action, the crusher will return the swing
jaw to the previous discharge setting by controlling the
hydraulic cylinder position.
4 NOTE:
As wear occurs to the swing jaw and stationary
maganese crushing dies, the discharge setting will
gradually open beyond it’s original setting. As the
automatic reset feature controls the position of the D
crushing cylinder, not the gap between the dies, it will be
necessary to check the discharge setting periodically. A B C
Refer to Viewing The Current Discharge Setting in
this chapter for instructions on how to determine your Figure 4–14. Adjust Setpoint Screen
current discharge setting. A. Open Jaw Keypad D. Jaw Discharge Setting
B. Save Setpoint Keypad E. Main Menu Keypad
C. Close Jaw Keypad
ADJUSTING THE DISCHARGE
SETTING (Setpoint) 3. Using the Adjust Setpoint screen, open the discharge
setting by pushing the Open Jaw Keypad (A, Fig. 4-14) on the
If the discharge setting is not correct for your crushing main control panel and holding it until the desired setting is
application, or falls outside the 89 mm (3.5 inch) minimum or reached. As you press the key to open the gap, the screen will
203 mm (8 inch) maximum, adjust the setting as follows: reflect the change by incrementing the percentage of change
To change the setpoint (Discharge Setting) on your H3450 and the actual distance the jaw has opened in both inches and
crusher, adjust the jaw opening as follows: millimeters. If you wish to decrease the crusher discharge
opening, press the Close Jaw Keypad (D, Fig. 4-14) and hold
1. Place the Main Circuit Breaker in the ON position. until the desired setting is reached.
4. If the new setting is correct, press the OK Selection
! CAUTION keypad (B, Fig. 4-14) to save the setting. Return to the Main
Inform all personnel working on or in the vicinity Page screen using the Main Page Keypad (E, Fig. 4-14).
of the crusher that a discharge setting 5. When a correct setpoint adjustment is obtained, restore all
adjustment is about to occur. power to the crusher drive and all feed and discharge devices.
2. Press the Setpoint Keypad (A, Fig. 4-1) on the far left of Test the crusher for correct operation and correct size of
the Main Control Panel once to access the Adjust Setpoint crusher output.
screen (Fig. 4-14).
4–10 04/17
CLEARING OBSTRUCTIONS
Feed to the 3450 crusher should be sized to a top dimension A
well within the effective receiving opening dimension (Gape)
of the crusher. Material that is 20 percent smaller than the full 91 mm
rated receiving opening dimension (34” or 86 cm on a 3450)

is recommended. Feed should be regulated so that the
crushing chamber is always about 2/3 full. In most cases, the
hydraulic relief action should allow oversize material or an
overload to pass through the jaw. In some cases if an B 4
oversized piece of material is introduced, the crusher could
stall or cause a backup of input feed due to a bridging
condition that is at the jaw intake above the crushing dies.
Hydraulically Clearing The 3450 Hydra Jaw C D
If it becomes necessary to manually clear the 3450 Jaw using Figure 4–16. Open/Close Jaw Screen
the hydraulic function, use the Main Control Screen and the A. Current Setpoint
Adjust Setpoint Screen to Open/Close the jaw as follows: B. Adjustment +/- Readout as Open/Close Jaw is performed.
C. Open Jaw Keypad D. Close Jaw Keypad
1. Immediately stop all feed devices.
4. Monitor the Adjustment Readout (B, Fig. 4-16) as you
2. From the Main Page (Fig. 4-15) press the Adjust Setpoint
hold the Close Jaw Keypad (D, Fig. 4-16) depressed to close
Keypad (A, Fig. 4-15) once to access the Adjust Setpoint
the jaw 1”. Release the Close Jaw Keypad. Press the Open
Screen (Fig. 4-16).
Jaw Key (C, Fig. 4-16) and open the jaw 1” to return to the
current CSS opening. Continue cycling in this manner until
the chamber is clear.
H3450 IMPORTANT:
B Opening the jaw more than the original Set Point (CSS)
(A, Fig. 4-16) when performing a clear, may fill the
crusher chamber voids with material. In this case, the
hydraulic cylinder may not be able to overpower the full
chamber of material. This could result in manual
clearing of the chamber.
5. Restart the feed devices and observe the crusher operation
as feed is re-introduced to the jaw.
6. If the crusher will not clear using the extend/retract
method, it maybe be necessary to manually break-up or
A
remove the bridged material (See Manual Clearing in this
chapter).
Figure 4–15. Hydraulically Clearing The Jaw
A. Adjust Setpoint Keypad B. Main Menu Keypad Manual Clearing
3. Note the current Setpoint measurement (A, Fig. 4-16) as 1. If your plant or machine is equipped with a rock breaker
you will want to return to the current setpoint when the hammer (Fig. 4-17), it may be possible to breakup or dislodge
clearing action is completed. the bridged piece with the hammer.
2. Align the rock breaker hammer above the crusher jaw
opening. Attempt to use the chisel head to bump or nudge
bridged material into the jaw opening.
04/17 4–11
3. If the material will not dislodge, use the hammer feature

to break up the oversize material into crushable pieces. Use ! WARNING
caution when activating the hammer so that the breaker head Use extreme caution when attempting to
does not plunge too deep into the chamber (Figure 4-17) and dislodge or remove jammed objects from the
contact the rotating or stationary jaw die. 3450 crusher. These objects may be under
tremendous pressure and could dislodge or
fracture at any time.
4 ! WARNING
Never use dynamite or other explosives in an
attempt to clear a crusher jam. Explosives could
damage the crusher or eject material from the
crushing chamber at a high velocity that could
cause injury or death.
! WARNING
Always use a pole, rock hook (Fig. 4-18), breaker
bar or grappling device to safely dislodge
objects jammed inside the crushing chamber.
Always work from the top of the chamber. Never
allow personnel to attempt to break up a jam
from beneath the 3450 crusher. Material could
suddenly release causing possible injury or
death. To prevent serious personal injury, do not
attempt to remove or dislodge jammed objects
by hand.
Figure 4–17. Improper Breaker Hammer Use

4. In some cases, uncrushable material (re-bar, tramp iron
etc.) may be causing a bridge above the crushing dies. In this
type of obstruction situation it will be necessary to remove
the bridged material manually.
5. Before attempting to remove a bridged obstruction
manually, read and understand all of the following warnings:
! WARNING
Lockout/tagout power to the crusher drive, to all
feed and discharge devices and the hydraulic
power unit. Shut off the diesel engine (if
equipped) on the plant.
Figure 4–18. Using A Rock Hook To Dislodge Jams
4–12 04/17
! WARNING A
Always use flywheel blocking to hold the swing
jaw in position. Do Not place timbers or other
blocking devices in the crushing chamber in an A
B
attempt to hold the swing jaw open. Blocking
could crack or be ejected under tremendous B
force causing personal injury or machine
damage. 4
A
! WARNING
Never attempt to walk on jammed or bridged
A
material. The material could break free at any
time sweeping you into the crusher and causing
serious personal injury or death.
C
6. Remove the V-belt drive guard to provide access to the
crusher flywheel. If possible place the swing jaw locking pins
(C, Fig. 4-19) in the extended position. Block the flywheel
sheaves to prevent the jaw from turning during clearing
procedures (Fig. 4-19). Blocking must be installed so that the Figure 4–19. Blocking Swing Jaw Sheaves
weighted portion of the sheave does not rotate to the top as the A. Blocking points (4 places) B. Blocking
chamber is cleared. Block the flywheels by installing C. Lock Pin (2)
blocking through the flywheel cutouts and contacting the top 7. Remove as much loose material from the top of the
of the crusher frame at two points on each flywheel. crushing chamber as possible. When the uncrushable object
becomes accessible, try to loosen it with a pole, rock hook or
breaker bar. If necessary, use a grappling device to remove the
uncrushable object up through the feed opening.
8. After clearing is complete, remove any objects, loose
material or debris from the crusher discharge area.
9. Remove the blocking from the flywheel. Retract the
locking pins to their storage position and secure with locking
bolts.
10. Reinstall the flywheel guard.
! WARNING
Before restarting the crusher, verify that no
personnel are working on, inside or under the
crusher or plant.
11. Start the diesel engine (if equipped), and start the crusher.
Allow the jaw to return to the proper setpoint before resuming
crushing.
04/17 4–13
POSITION SENSOR ADJUSTMENT and forth in relation to the slider magnet (J, Fig. 4-21).
Make certain the slider magnet is oriented towards the
The 3450 Crusher is delivered with a linear position sensor back of the sensor assembly (H, Fig. 4-21) before making
that tracks the hydraulic cylinder movement and position. adjustments.
The sensor is set from the factory to track a cylinder stroke
from 0 mm (0”) to 200 mm (7.87”). • Slide the sensor housing forward or back on the clamps
until the magnet does not run in the red zones.
If you require a different sensor range, or the indicators on the
sensor indicate that the position sensor is no longer tracking • When the dimension is correct, tighten the position sensor
clamp bolts (B, Fig. 4-24) to 11 Nm (8 Ft. Lbs).
4 the correct range, adjust the sensor as follows:
1. An LED located next to the electrical connector on the • Remove the protective cover from the euro connector (A,
end of the position sensor provides diagnostic readings to Fig. 4-21) and re-install the cable to the euro connector.
determine current sensor condition (A, Fig. 4-20). When Restore power to the crusher.
correctly set, the LED will show green to indicate the zone • Retract and extend the jaw through the complete range
that is currently programmed. several times. Observe the LED as the jaw runs through
2. When re-setting the linear position sensor, you must note the range; if it reads GREEN at all times, the programmed
the dead (null) areas on each end of the sensor. At the stroke is correctly set.
connector end of the housing, a 29 mm (1.14”) dead (null)
zone is present. The back end of the housing also has a 29 mm
(1.14”) dead (null) zone. When setting up the position sensor,
the magnet must be adjusted so it does not run in these zones.
If the magnet slides into these zones, the LED will turn red to
alert you that the position sensor cannot be programmed in
these areas.
Figure 4–20. Position Sensor LED Location

A. Sensor Condition LED B. Digital Signal I/O Connector
C. Position Sensor Body D. Slider
3. To replace or reposition a linear position sensor the

following steps are required:
• Disconnect the connector (A, Fig. 4-21) at the front of the
sensor and install the protective cover while adjustments
are being made.
• Loosen the six (6) clamp bolts on the position sensor (B,
Fig. 4-21) enough to allow the sensor body to be slid back
4–14 04/17
B B B
4
D
C E
J
C
H
A
F
Figure 4–21. Position Sensor Components

A. Connector D. Isolator (2) G. Mounting Bracket J. Slider Magnet
B. Sensor Clamp Bolts (6) E. Threaded Slider Rod H. Orient Slider Magnet As Shown
C. Sensor Body F. Mounting Dimension I. Sensor Clamp (2)
4. If it is not possible to correctly program the sensor stroke

by positioning the sensor body, it may be necessary to adjust
the length of the threaded slider rod (E, Fig. 4-21). Loosen the
fitting on one end of the rod and thread the rod in or out to
change the length. If the sensor range cannot be programmed
to yield a green LED over the complete slider range, contact
the Telsmith Service Department.
5. When all settings are correct and the sensor mounts are
tight, reset the jaw discharge setting to the desired opening.
04/17 4–15
HYDRAULIC ADJUST ASSEMBLY 3. Compress the spring with the lower hex nut (G, Figure
SPRING TENSION 4-22) until the compressed dimension is 25 mm [1 in.] less
than the original dimension in step 2. Adjust all four springs
The hydraulic adjuster assembly springs should be checked so they are set at 25mm [1 in.] compression from the original
after the initial 8 hour shift has been run and then on a measurement taken in step 2.
monthly basis. As the toggle seats and wear bars wear over
time, spring tension will require adjustment. With the crusher 4. Reinstall the upper jam nuts (H, Fig. 4-22) and tighten
running, listen at the bottom of the unit to the hydraulic adjust firmly while holding the lower jam nut to prevent it from
assembly (Fig 4-22). If a distinct “Thumping” sound is rotating. When all four springs are set with 25 mm [1 in.]
4 present, the four springs on the unit need to be re-tensioned compression, restart the crusher and run with no load for
after their initial run-in. several minutes to check for further abnormal noises.
To re-tension springs:
1. Shut off all power to the crusher and plant including the
hydraulic system and the diesel engine (If Equipped).
Lock/tagout all controls.
! WARNING
Lockout/tagout power to the crusher drive, to all
feed and discharge devices and the hydraulic
power unit. Shut off the diesel engine on the
plant (if equipped) before performing any service
on the hydraulic adjust assembly.
! CAUTION
When performing the adjustments in steps 2, 3
and 4, loosen and adjust only one spring at a
time so the hydraulic toggle assembly stays
safely secured in the crusher.
2. Remove the upper jam nut (H, Fig. 4-22) and loosen the
lower hex nut (G, Fig. 4-22) until all tension is removed from
the spring. Measure the length of each spring from the spring
cup face to the end of the spring (Fig. 4-22). Record the
measurement for each spring.
! WARNING
Do Not over compress the spring in steps 3 & 4.
Compressing the spring more than the original
recommended compression amount could
cause the springs to go solid. Operating with a
solid spring could lead to failure of the spring
and other toggle end components. If a spring is
suspect, remove the jam nut and back the hex
nut off until all spring tension is relieved. Pull the
upper spring cap back and measure the free
standing length of the spring. If the freestanding
(no compression) length of the spring is less
than 158 mm [6.25 in.] replace with a new spring.
4–16 04/17
Measure
Uncompressed
STEP 1 Distance
STEP 3 Install Upper

Jam Nut
Set Compressed
Distance
1 inch (25 mm)
STEP 2 Less
NOTE: If thumping is heard during the test run

with the springs set to the 1 inch (25 mm)
compressed dimension in Step 2, it is
permissible to compress all four springs an
additional 0.13 in. (3 mm) to quiet the
operation.
Figure 4–22. Spring Compression Measurement
IMPORTANT:
If the cylinder toggle assembly is noisy it is permissible
to tighten the springs an additional 3 mm (0.13 in.) to
quiet the toggle assembly. NEVER attempt to run the
crusher with the tension springs compressed more than
28 mm (1.13 in.) as this could damage the spring or
toggle assembly components. Springs that allow toggle
and toggle seat separation at this dimension (Thumping
Sound) are either extremely worn or defective and
should be replaced with new units.
04/17 4–17
B
D
F
E
I
A
C H G
Figure 4–23. Hydraulic Adjust Assembly

A. Tension Pin (4) D. Toggle Cylinder G. Lower Hex Nut (4)
B. Toggle Wear Bar (2) E. Compression Spring (4) H. Upper Jam Nut (4)
C. Tension Pin Bracket (2) F. Spring Washer (4) I. Upper Spring Cap
5. If the hydraulic toggle unit continues to make noise after

! CAUTION tightening the springs to a matching dimension, look for other
Never operate your 3450 crusher with tension sources for the noise such as the tension pin action in the
springs that are coil bound or adjusted to more toggle ends or loose toggle wear bars (A, Fig. 4-24) in the
than 28 mm [1.13 in.] compression from the toggle ends.
original non-compressed measurement.
Attempting to operate your crusher with coil
bound springs can lead to catastrophic failure of
hydraulic adjuster assembly components.
4–18 04/17
.
A
4
E
Figure 4–24. Hydraulic Assembly (Bottom View)

A. Toggle Wear Bar (Rod Side) B. Toggle Wear Bar (Stationary) C.Tension Spring (4)
D. Tension Pin (4) E. Hex Nut (4) F. Jam Nut (4)
04/17 4–19
4–20 04/17
Chapter 5
Crusher Lubrication
and Maintenance Schedule
Contents
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
TIME INTERVALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
CRUSHER LUBRICATION & MAINTENANCE SCHEDULE . . . . . . . . . . . . .5-3
04/17 5–1
Crusher Lubrication and Maintenance Schedule Operation and Maintenance
INTRODUCTION IMPORTANT: Before performing any service work, read

and completely understand all applicable maintenance
The crusher lubrication and maintenance schedule contains procedures. Always observe the safety precautions and
important lubrication, maintenance and inspection instructions included within the procedures.
procedures which must be performed on a routine basis to
ensure proper H3450 crusher operation.
TIME INTERVALS
All procedures should be performed at the proper time
intervals indicated in the schedule. Do not skip any The time intervals shown in the schedule are based on an 8 to
procedures that apply. 10 hour operating day and are applicable for most crushers.
However, some maintenance items may require more
Always keep a written record of all maintenance activities. frequent attention if one or more of the following conditions
Never rely on memory when performing scheduled are present.
maintenance.
- If the crusher is operated over 10 hours per day.
As indicated in the right hand column of the schedule, refer
to other chapters of this manual for detailed maintenance - If wet, dirty or sticky feed is being processed.
instructions, lubricant specifications and other important - If the feed contains unusually hard or abrasive material.
information.
- If the crusher operates in unusually hot or cold outside
5 ambient temperatures.
! WARNING!!!
DANGER - If the jaw dies are nearing the end of their useful life.
Always stop the crusher and lockout/tagout power The following lubrication and maintenance schedules should
before performing any inspection, adjustment, be considered only as a guide. Environmental conditions, the
lubrication, maintenance or repair procedures. type of material being processed and other factors specific to
Refer to Chapter 1 for complete lockout/tagout your crushing application will dictate the exact amount of
instructions. periodic maintenance required.
LUBRICANT RECOMMENDATIONS FOR JAW CRUSHERS

Lubricant Ambient Recommended Recommended
Temperature Specification Standard Synthetic Quantity Interval
Type
Fo (Co) Lubricant Lubricant
Central Grease NLGI 00
System with EP Mobil SHC 007
Below 40 (4) Additives
GREASE Below 100 NLGI 2 with Mobil Delvac Extreme Mobilith SHC 220 Every 8
21 grams
(Below38) EP Additives or Shell Gadus S3 or Shell Albida 220 (0.08 oz.) Hour Shift
V220 C2
6 Strokes
Above 100 NLGI 2 with (Standard Gun)
(Above 38) EP Additives Mobil SHC 460
Below 40 ISO 100 Mobilgear 600
LUBE (Below 4) Mobilgear SHC 150 Check Daily
GMA 3EP XP 100
OIL Change Every
Above 40 ISO 150 Mobilgear 600 Mobilgear SHC 150 Six Months
(Above 4) XP 150
ISO 32,
Below 40 Mobil DTE 13M Mobil SHC 524
(Below 4) HVI W 75L (20 Gal)
Low Pour Pt. or Shell Tellus 32 or Shell Tellus S4 32
HYDRAULIC Check Daily
OIL Change Yearly
Above 40 ISO 68, Mobil DTE 26 Mobil SHC 526
75L (20 Gal)
(Above 4) Antiwear or Shell Tellus 68 or Shell Tellus S4 68
5–2 04/17
Operation and Maintenance Crusher Lubrication and Maintenance Schedule
CRUSHER LUBRICATION & MAINTENANCE SCHEDULE
Table: 5-1 H3450 Crusher Lubrication and Maintenance Schedule
Monthly
Chapter
Refer to
Weekly
Yearly
Daily
Lubrication or Maintenance Item:
REMOVE SPILLAGE AND DEBRIS FROM AREA AROUND CRUSHER. •
REMOVE ANY BUILT-UP MATERIAL FROM CRUSHER FRAME SURFACES. •
REMOVE DUST AND DIRT FROM CRUSHER DRIVE MOTOR. •
INSPECT ALL CHUTES AND HOPPERS FOR WEAR AND OBSTRUCTIONS. •
VERIFY THAT CRUSHING CHAMBER IS CLEAR. •
LUBRICATE GREASE FITTINGS • 3

5
CHECK JAW DIES AND CHEEK PLATES FOR LOOSENESS, CRACKS OR • 7
WEAR.
CHECK TIGHTNESS OF NUTS AND BOLTS. •
CHANGE HYDRAULIC SYSTEM FLUID •
CHECK THE CRUSHER DISCHARGE SETTING. • 4
REMOVE DUST AND DIRT FROM SHEAVES. •
CHECK SHEAVES FOR DAMAGE OR LOOSENESS. • 8
INSPECT V-BELTS FOR WEAR OR DAMAGE. CHECK V-BELT TENSION. •
CHECK SUPPORT STRUCTURE FOR LOOSE OR DAMAGED MEMBERS. •
CHECK CRUSHER MAIN FRAME FOR CRACKS. •
CHECK CRUSHER SWING JAW FOR CRACKS. •
CHECK LINEAR POSITION SENSOR LED FOR CORRECT OPERATION. • 4
CHECK HYDRAULIC ADJUST ASSEMBLY SPRING TENSION. • 4
CHECK TOGGLE WEAR BARS AND TOGGLE SEATS. •
**PERFORM ENGINE MAINTENANCE (DIESEL ENGINE OPTION). (As Required)
CLEAN OUT ALL CHUTES, HOPPERS, AND ROCK BOXES •
CHECK HYDRAULIC SYSTEM OIL LEVEL. •
*Re-lubricate daily or every 8 hours on machines operated more than one shift a day (Manual Grease Units).
**Refer to manufacturer’s service manuals for recommended time intervals.
Warning: Lockout/tagout power before performing any adjustment, inspection, lubrication, maintenance or repair procedures.
! Disconnect batteries, shut off fuel supply and lockout/tagout engine controls if crusher is powered by a diesel engine.
04/17 5-3
Crusher Lubrication and Maintenance Schedule Operation and Maintenance
NOTES
5–4 04/17
Chapter 6
Hydraulic System Operation, Maintenance
and Troubleshooting
CONTENTS
Page
HYDRAULIC SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
SETPOINT ADJUSTMENT FEATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
RELIEVING SYSTEM PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
HYDRAULIC FILTER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
HYDRAULIC UNIT ELECTRIC DRIVE MOTOR MAINTENANCE . . . . . . . . . . . . . . . 6-6
PERIODIC HYDRAULIC POWER UNIT MAINTENANCE . . . . . . . . . . . . . . . . . . . . . 6-7
Hydraulic Fluid Level-Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
HYDRAULIC SYSTEM MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . 6-8
HYDRAULIC SYSTEM MAINTENANCE SAFETY PRECAUTIONS. . . . . . . . . . . . . . 6-9
HYDRAULIC POWER UNIT MAINTENANCE PROCEDURES . . . . . . . . . . . . . . . . . 6-9
Hydraulic Reservoir - Drain/Clean/Refill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Oil Heater (Option) - Inspect/Clean. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
HYDRAULIC DIRECTIONAL VALVE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Solenoid Coil Replace. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
HYDRAULIC SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
HYDRAULIC POWER UNIT ELECTRICAL CONNECTIONS . . . . . . . . . . . . . . . . . . 6-15
PRELIMINARY TROUBLESHOOTING CHECKS and ADJUSTMENTS . . . . . . . . . 6-16
HYDRAULIC SYSTEM TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . . . . . . 6-17
04/17 6–1
Hydraulic System Operation, Maintenance and Troubleshooting Operation and Maintenance
HYDRAULIC SYSTEM OPERATION uses control valves to set and relieve hydraulic system
pressure. A suction strainer and an in-line filter (Fig. 6-1)
The 3450 crusher uses a remote hydraulic power unit with a mounted on the hydraulic unit clean the supply line fluid. An
30 gallon (114 L) tank. The drive motor and pump are air-oil cooler (L, Fig. 6-1) keeps the fluid with-in the correct
mounted on the power unit (Fig. 6-1) and supply hydraulic temperature range.
fluid under pressure to the swing jaw crushing cylinder. A
control manifold attached to the top of the hydraulic cylinder
D
C
B
F
H
K
L
A
J I
Figure 6–1. Hydraulic Power Unit

A. Hydraulic Gear Pump D. Fill Pipe Cap G. Pressure Sensor J. Coupler
B. Electrical Connection Panel E. Breather H.150 PSI Filter K. Suction Line
C. Hydraulic Tank (30 Gallon) F. Tank Heater I. Electric Drive Motor 7.5 HP L. Cooler Assembly

6 NOTE: 3450 crusher is 89 mm (3.5”). DO NOT attempt to adjust
the discharge setting below this dimension. Crushing
The Hydraulic Unit drive motor will require a motor with an excessively close discharge setting may result
starter, an On/Off push button or switch and a mounting in serious mechanical damage to the crusher. The
panel supplied and wired by the customer. Refer to the maximum discharge setting must not be set beyond 203
electrical schematics supplied with your crusher for mm (8”). Refer to Chapter 4 for detailed instructions on
complete details. setting the crusher discharge opening (setpoint).
6–2 04/17
Operation and Maintenance Hydraulic System Operation, Maintenance and Troubleshooting
H
J
A B
K
E D
G F
Figure 6–2. Control Panel Location

A. Protective Cover C. Horn E. Cord Grip (2) G. Devicenet Receptacle I. Mount K.Hydraulic Unit
B. Power Panel D.120 VAC Interface F. Connectors H. Control Panel Door J. Control Cabinet
SETPOINT ADJUSTMENT FEATURE

Your crusher is equipped with a Linear Position Sensor that
automatically maintains the discharge (setpoint) setting. In
the event of a relief action, the crusher will return the swing
jaw to the previous discharge setting by controlling the
hydraulic cylinder position.
NOTE:
As wear occurs to the swing jaw and stationary

maganese crushing dies, the discharge setting will
gradually open beyond it’s original setting. As the
automatic reset feature controls the position of the
crushing cylinder, not the gap between the dies, it will be
necessary to check the discharge setting periodically. 6
Refer to Viewing The Current Discharge Setting in
Chapter 4 for instructions on how to determine your
current discharge setting.
04/17 6–3
RELIEVING SYSTEM PRESSURE 4. Check the pressure readout (A, Fig. 6-4) on the Pressure
Sensor located near the electric motor (B, Fig. 6-4). Pressure
If it becomes necessary to relieve hydraulic pressure in the should now read 0 Bar (0 PSI).
3450 system perform the following steps in the order shown.
! WARNING !!!
Pressures of up to 262 bar (3800 PSI) may be
present in the hydraulic system even when the A B
hydraulic pump is off and the hydraulic pressure
gauge on the plant power unit indicates zero (0)
PSI (0 bar). Never loosen any hydraulic fittings or
disconnect any hydraulic hoses until after the
0.00 PSI
hydraulic system has been depressurized as
described in the following procedures:
1. Retract the swing jaw to the fully open position using the
Open Jaw (Setpoint) touchpad on the Setpoint Selection
Screen (Fig. 6-3) on the Main Control Panel.
Figure 6–4. Adjust Setpoint Screen

A. Sensor Pressure Readout
B. Sensor Location
C. Electric Motor.
5. If the sensor readout (A, Fig. 6-4) does not register zero,
B attempt to close the jaw with the Close touchpad (C, Fig. 6-3).
A C (If all hydraulic pressure is exhausted, the jaw should not
Figure 6–3. Setpoint Selection Screen move). If enough pressure is present to fully close the jaw,
attempt to open the jaw again with the Open touchpad (A,
A. Open Jaw Touchpad
Fig. 6-3) until all pressure is relieved.
B. Save New Setpoint Touchpad
C. Close Jaw Touchpad 6. Install a hydraulic test gauge at pressure test port G2 (Fig.
2. Stop the crusher. Lockout/tagout power to the hydraulic 6-5) on the hydraulic control assembly to test for remaining
power unit and to all feed and discharge equipment. Power pressure.
must remain connected to the Main Control Panel. 7. Move the test gauge to the G1 pressure test port on the
3. Be sure no personnel are on, inside or under the crusher. hydraulic control assembly (Fig. 6-5).
8. If pressure is indicated at either port, install a pressure test
line at the G1 port and bleed off any remaining pressure and
6 ! CAUTION !!! fluid into a catch receptacle. Install a pressure test line at the
The swing jaw may move during the following G2 port and bleed off any remaining pressure and fluid into a
steps. To prevent serious personal injury, be catch receptacle
sure no personnel are on, inside or under the
H3450 crusher before activating the hydraulic
functions.
6–4 04/17
HYDRAULIC FILTER SERVICE

The 150 PSI automotive style spin off filter is monitored by
an indicator that turns red when the element requires
replacement (Fig. 6-7).
Hydraulic Fluid Filter Element - Replace

G2
1. Lockout/tagout power to the crusher drive, to the
hydraulic power unit, to the lubrication system and to all feed
and discharge devices. Refer to Chapter 1 for complete
lockout/tagout procedures.
G1
2. Make certain the hydraulic pressure sensor (Fig. 6-4)
indicates zero (0) PSI and that the hydraulic pump is OFF.
! WARNING !!!
Figure 6–5. Control Assembly Test Ports
Hot hydraulic oil can cause burns! If necessary,
9. Move the test gauge to the hydraulic adjust assembly and allow oil to cool to a safe temperature before
install the test gauge at both port G3 and G4 (Fig. 6-8) to test replacing the filter element. Wear appropriate
for remaining residual pressure. If any pressure is indicated eye and hand protection when handling the filter
on the gauge, install a pressure test line at the port in question canister.
and bleed off any remaining pressure and fluid into a catch
receptacle. 3. Place a suitable container under the filter assembly to
catch any spilled hydraulic fluid.
NOTE: An alternate method for draining off pressure at
G3 and G4 is to adjust both counterbalance valves all 4. Carefully rotate the spin-off filter canister
the way out (turn LH screw adjusters clockwise) and counter-clockwise and remove it from the filter head (E, Fig.
allow pressure to bleed. Count the number of turns 6-10). Remove the O-rings if they do not come off with the
when turning screw adjusters and return the adjusters Canister.
to the original settings. Recheck pressure at G3 and 5. It may be necessary to use a filter strap wrench to initially
G4. break the filter canister loose from the head.
6. Hold the filter vertical while it is being removed, and tip
G3 G4 it into a suitable pan or bucket to drain the hydraulic fluid that
remains in the filter.
7. Moisten the sealing surface o-ring of the new filter with
a small amount of fluid. Then, carefully spin the filter
clockwise onto the post of the filter head. When the o-ring on
the filter canister contacts the filter head, turn the filter an
additional half turn. If necessary use a strap wrench to fully
tighten the filter.
8. Connect power to the hydraulic unit. Start and run the
hydraulic pump. Check that the hydraulic fluid filter
indicator shows full GREEN and no leaks are apparent.
6
Figure 6–6. Hydraulic Adjust Assembly
04/17 6–5
HYDRAULIC UNIT ELECTRIC DRIVE

B MOTOR MAINTENANCE
The cooling fins on the electric pump motor should be
cleaned of any debris or dust buildup to prevent motor
overheating. Remove the drain plugs every month and
operate the motor for 15 minutes with the plugs removed to
allow any moisture buildup in the case to drain out. Reinstall
the plugs after 15 minutes of operation and wipe all moisture
off the motor and from the hydraulic unit cabinet.
A
C
B
Figure 6–8. Motor

A. Conduit Box C. Lift Eye
B. Cooling Fins
Remove Install
Figure 6–7. 150 PSI Hydraulic Filter

A. Filter Condition Indicator C. Spin Off Replaceable Element
B. Filter Head
6–6 04/17
PERIODIC HYDRAULIC POWER UNIT

MAINTENANCE
Hydraulic Fluid Level - Check
1. Access the Setpoint Selection Screen on the Main Control
Panel (Fig. 6-3).
2. Press the Open Jaw (Setpoint) touchpad (A, Fig. 6-3) to
open the jaw. Hold the touchpad until the jaw has moved fully
rearward and is against the rear frame stops.
3. Stop the hydraulic pump. Be sure that the hydraulic
pressure sensor readout indicates zero (0) PSI (0 bar).
4. Check the fluid level in the hydraulic reservoir sight
gauge. The fluid level should be almost to the top of the upper
sight gauge (Fig. 6-9) with the jaw retracted.
Upper Fluid
Level
Figure 6–9. Reservoir Sight Gauge

5. If the fluid level is below the line, add additional fluid as
required. Refer to Table 6-3 for hydraulic fluid specifications
and Table 6-2 for capacities.
6
! CAUTION !!!
Do not fill the reservoir to the top line unless the
j a w i s f u l l y r e t r a c t e d a g a i n s t t h e s t o ps .
Overfilling with the jaw not fully retracted could
damage the hydraulic system.
04/17 6–7
HYDRAULIC SYSTEM MAINTENANCE

SCHEDULE
Table 6–1. Hydraulic System Maintenance Schedule
Before Crusher Start-up
After Crusher Start-up

(Every 8 hours)
As Required
Monthly
Weekly
Yearly
INSPECT, LUBRICATE OR SERVICE AS FOLLOWS:
Remove all dirt and dust from the hydraulic power unit.
•
Inspect the entire hydraulic system for oil leaks or other obvious prob-
lems.
•
Check hydraulic filter indicator is GREEN.
(Note: Check with power unit in CRUSH mode.)
•
Check the hydraulic pressure sensor readout with unit running. Verify
that pressure is between 600 psi (41 bar) and 3800 psi (262 bar). (Note:
• •
Check with power unit in CRUSH mode.)
Remove dust and dirt from the toggle cylinder.

•
Clean hydraulic pump drive motor fins.
•
Inspect all hydraulic hoses for wear, damage or fatigue. Replace as
required.
•
Clean and inspect the hydraulic reservoir breather cap. Replace if
clogged.
•
Inspect all gauges and indicators. Be sure they are clean and working.
•
Test all hydraulic functions for proper operation.
•
Drain and refill the hydraulic reservoir. Replace the suction strainer.
•
Replace the hydraulic filter element if indicator turns RED.
(Note: Check with power unit in CRUSH mode.)
•
6 1
Replace when indicated by the filter monitor.
6–8 04/17
HYDRAULIC SYSTEM MAINTENANCE • Refer to Chapter 1 for additional safety precautions and
SAFETY PRECAUTIONS warnings which apply to pressurized systems and related
machinery.
! WARNING !!! HYDRAULIC POWER UNIT MAINTENANCE

Failure to observe the following safety precautions PROCEDURES
may result in serious injury or death.
• If the hydraulic dump valve were to malfunction and not ! WARNING !!!
release hydraulic pressure back to the tank, high pressure
may be present in the hydraulic system even when the Lockout/tagout power to the crusher drive, to the
hydraulic pump is off. If you have questions on whether hydraulic power unit, and to all crusher feed and
pressure remains in the system, depressurize the discharge devices before beginning any hydraulic
hydraulic system before loosening any hydraulic fittings system maintenance procedures or service work.
or disconnecting any hydraulic hoses. Refer to
RELIEVING SYSTEM PRESSURE section earlier in this
Chapter for a procedure.
! WARNING !!!
• Always lockout/tagout power to the hydraulic power unit Always make certain the 3450 hydraulic system
before performing any adjustments, maintenance or has depressurized before disconnecting any
repairs. hydraulic hoses or loosening any hydraulic
fittings. Failure to observe this precaution could
• Before beginning any service work, read the following result in the release of high pressure hydraulic
sections of this chapter to become familiar with hydraulic fluid. Serious personal injury or death can occur
system features, adjustments and maintenance items. if hydraulic fluid penetrates the skin.
• Read the hydraulic system operating instructions earlier in
this chapter to become familiar with hydraulic system Table 6–2. Hydraulic Fluid Capacities
operating procedures.
ITEM GALLONS REQUIRED
• Use common sense when observing hydraulic system
operation. Be aware of potential hazards at all times. Stay Fluid Reservoir Capacity 30 (114 L)
clear of cylinder rods, swing jaw, toggle beam and other
moving parts. Additional fluid required Approx. 3 (11 L)
to fill system (required to
• Allow only trained personnel to perform hydraulic system
fill hoses, cylinders etc.)
maintenance. Any repairs or adjustments must be made
only by certified hydraulic specialists. NOTE: Actual oil capacity may vary, depending on
hose lengths and other factors. Capacities for custom
• Be careful when draining hot hydraulic fluid. Hot engineered hydraulic systems may be different than
hydraulic fluid can cause burns. Wear appropriate hand shown.
protection and protective clothing when servicing the Always check oil level with hydraulic power unit OFF.
hydraulic system. Avoid unnecessary contact with Always use new oil poured from a clean container.
hydraulic fluid.
• Dispose of used hydraulic fluids in accordance with
federal regulations and any state or local regulations that
apply. The proper disposal of fluids and other toxic
materials is the user’s responsibility.
• Cleaning solvents must be used only in accordance with 6
manufacturer’s instructions. Always wear appropriate
protective equipment and clothing when using cleaning
solvents and other chemicals.
• Never disable the hydraulic system electrical interlocks.
04/17 6–9
8. Check the condition of the fluid heater element (E, Fig.

Table 6–3. Hydraulic Fluid Specifications 6-10). Remove any carbon build-up or sludge from the
element. Verify that the element is not touching the tank sides
Ambient or baffles.
Standard Synthetic
Temperature Type
o Lubricant Lubricant 9. Rotate the suction strainer counter-clockwise and remove
F (oC)
it from the pump suction line. Used suction strainers must be
Below ISO 32, Mobil Mobil discarded. Do not attempt to clean and reuse an old strainer.
40 (4) HVI AW DTE 13M SHC 524
or: Shell or: Shell 10. Install the new suction strainer into the pump suction line.
Tellus 32 Tellus S4 32 Be careful not to cross thread or overtighten the strainer.
Above ISO 68 Mobil Mobil 11. Secure the cover with the cover bolt (A, Fig. 6-10) and a
40 (4) Antiwear DTE 26 or: SHC 526 new gasket if necessary. To prevent leaks, verify that the
or: Shell or: Shell cover seals tightly against the reservoir and gasket.
Tellus 68 Tellus S4 68
12. Remove the filler cap (F, Fig. 6-10). Slowly fill the
hydraulic reservoir with new fluid of the proper
Hydraulic Reservoir - Drain/Clean/Refill specifications as shown in Table 6-3. Continue filling until
1. Lockout/tagout power to the crusher drive, to the the fluid level is up to the black line at the top of the reservoir
hydraulic power unit, to the lubrication system and to all feed sight gauge. Refer to Figure 6-9.
lockout/tagout procedures.
2. Be sure that the hydraulic pressure sensor indicates zero
(0) PSI (0, bar) and that the hydraulic pump is OFF.
! WARNING !!!
Hot fluid can cause burns! Stay clear of hot fluid
during draining procedures. If necessary, allow
hydraulic fluid to cool to a safe temperature
before draining. Wear appropriate eye and hand
protection during draining procedures.
3. Turn the drain spigot handle to the open position (A, Fig.
6-10) and allow the old fluid to drain into a suitable container.
Use more than one container if necessary to hold all the fluid.
4. After draining is done, inspect the drain pipe and check
for buildup of debris. Remove any particles with a clean
lint-free rag. Then rotate the spigot handle back to the closed
position.
5. Remove the center bolt (D, Fig. 6-10) holding the end
cover (C, Fig. 6-10) to the tank and pull the cover off the tank.
6. Inspect the inside of the reservoir tank and the cover for
dirt, sludge or other contaminants. If contaminants are
present, determine the source and make necessary repairs as
6 required. Inspect the cover gasket (B, Fig. 6-10) for tears or
other damage. Replace if necessary.
7. Wipe all interior surfaces of the reservoir with clean
lint-free rags. Also wipe the interior surface of each access
cover.
6–10 04/17
E C
Figure 6–10. Hydraulic Reservoir End Cover Removal

A. Drain Spigot B. Cover Gasket C. Cover D. Cover Bolt E. Tank Heater (Optional) F. Filler Cap
13. During filling, check the tank end cover to be sure that Oil Heater (Option) - Inspect/Clean
there are no oil leaks.
14. With the crusher OFF, operate all hydraulic functions at hydraulic power unit, to the lubrication system and to all feed
least five times to verify proper operation. Refer to the and discharge devices. Refer to Chapter 1 for complete
Hydraulic System Operation section of this chapter for lockout/tagout procedures.
complete hydraulic system operating instructions. Check
2. Be sure that the hydraulic pressure gauge and sensor both
again for any oil leaks.
indicate zero (0) PSI (0 bar) and that the hydraulic pump is
15. Fully retract the hydraulic relief cylinders. Stop the OFF.
hydraulic fluid pump and recheck the hydraulic fluid level.
3. Drain all hydraulic fluid from the reservoir. Follow the
Add additional fluid if the level has dropped. For complete
instructions, refer to the Hydraulic Fluid Level - Check
procedure earlier in this chapter. 6
paragraph earlier in this chapter. 4. Disconnect the electrical connections at the conduit box.
Unthread the heating element from the fitting on the tank.
5. Inspect and clean the heating element as follows:
04/17 6–11
•Remove any carbon build-up or sludge from the heating

element. (A small amount of carbon on the element
surfaces is normal).
•Check that heating element is not bent or cracked. Verify
that it is not touching the reservoir. Wear spots on the
element or element build-up are an indication of contact.
•If heater replacement is necessary, be certain that the new
heater is of the exact same specifications as the original.
Contact the Telsmith Service Department for additional
information.
6. After cleaning procedures are completed, refill the tank
with new hydraulic fluid of the proper specifications. Follow
the procedure earlier in this section.
7. Check that the fluid heater thermostat is set to the correct
temperature. Figure 6–11. Toggle Cylinder Relief Valves
4. Have a certified hydraulic specialist verify that the new
relief valve(s) is set at 4000 PSI (275 bar).
Relief Valves - Replace 5. Lightly coat the threads and o-rings of the new relief valve
There are two relief valves in the hydraulic system. The relief with hydraulic fluid and insert it into the threaded opening of
valves are mounted on the toggle cylinder manifold (Fig. the manifold. Hand tighten the valve, making sure that it is
6-11). Use the following procedures when relief valve not cross-threaded.
replacement is necessary:
6. Using a hand wrench, tighten the valve the additional
amount until it is snug. Do not overtighten.
Toggle Cylinder Relief Valve
1. Check that both the manual pressure gauge and the HYDRAULIC DIRECTIONAL VALVE
hydraulic pressure sensor readout (Fig. 6-9) read 0 PSI (0 SERVICE
bar). If they do not, refer to Relieving System Pressure earlier
in this chapter. Solenoid Coil - Replace
hydraulic power unit, to the lubrication system and to all feed ! WARNING !!!
lockout/tagout procedures. Never attempt to replace solenoid coils while
electrical power is connected to the hydraulic
power unit. Always lockout/tagout power before
! WARNING !!! beginning any service work.
Before loosening any relief valves, be certain that
Removal
the hydraulic system is completely depressurized
as described earlier in this chapter. Up to 4000 PSI 1. Lockout/tagout power to the crusher drive, to the
(275 bar) may be present in the toggle cylinder hydraulic power unit, to the lubrication system and to all feed
hydraulic relief hoses and cylinder, even when the and discharge devices. Refer to Chapter 1 for complete
hydraulic gauge and sensor readout indicate zero (0 lockout/tagout procedures.
6 PSI (0 bar)). High pressure hydraulic fluid could be
released if all pressure has not be relieved in the
2. Be sure that the hydraulic pressure gauge and hydraulic
pressure sensor both indicate zero (0) PSI (0 bar) and that the
cylinder prior to removing the valve. Serious injury
hydraulic pump is OFF.
could result if high pressure fluid were to penetrate
the skin. 3. Disconnect the 3 prong electrical connection at the coil
being serviced (Fig. 6-12).
3. Using a hand wrench, carefully loosen the old relief valve
(Fig. 6-11) and remove it from the manifold on the toggle
cylinder.
6–12 04/17
4. Remove the knurled nut and O-ring (Fig. 6-12). Check the
condition of the o-ring, replace if worn, damaged or distorted.
C D
E
J
B K
L
A F
Figure 6–12. Solenoid Coil Components

A. Counterbalance Valve D. Extend Coil G. Directional Control Valve J. Coil (2)
B. Pressure Reducing Valve E. Press Sensor (0-5800 PSI) H. Cylinder Hydraulic Manifold K. O-Ring (2)
C. Retract Coil F. Hydraulic Control Manifold II. Control Valve L. Knurled Retaining Nut (2)
5. Gently pull the coil away from the valve body (Fig. 6-12). 3. Slide the actuator coil towards the valve body (Fig. 6-12)
Remove the coil gasket. Check the condition of the gasket
4. Reinstall the O-ring and knurled retaining nut (Fig. 6-12).
and replace if necessary.
Using a hand wrench, carefully tighten the knurled nut until 6
6. Test the coil with an ohmmeter. The coil is defective if an snug.
open condition is indicated.
5. Reconnect electrical leads at the connectors.
Installation 6. Restore power to the crusher and check the directional

control valve for correct operation in both the extend and
1. Be sure that power remains locked-out. retract mode.
2. Install the coil gasket over the actuator.
04/17 6–13
HYDRAULIC SCHEMATIC
H3450 CRUSHER HYDRAULICS

RET COIL
HYDRAULIC ADJUST ASSEMBLY
A
G4
H
B
C
Extend
Retract
HYDRAULIC CONTROL ASSEMBLY
EXT COIL
G
G1 G2
Oriface
C'balance
D
30 psi Valve Pressure Reducing
Check spring E Valve
A
Valve
600 PSI
P T 5000 psi B A 6000 psi P T CHARGE
PRESSURE P
Relief
B
Valves
4000
psi
Check T
F
Valve
psi
145 psi spring
EXT RET B A
G3
T2 T1 P
Figure 6–13. Hydraulic Schematic

A. Check Valve C. Cylinder E. Pressure Reducing Valve G. Retract Coil
B. Relief Valves. D. Counterbalance Valve F. Check Valve H. Extend Coil
6–14 04/17
HYDRAULIC POWER UNIT

ELECTRICAL CONNECTIONS
V W
P Q
N R
D E M S
C F L T
B G K U
A H J V
X67 MODULE X67 MODULE LUBE (OPTIONAL) X67 MODULE

I/O LINK I NODE
0 0
C 4 C 4
8 8
NODE NODE
HIGH LOW
SETTING SETTING
Figure 6–14. Power Unit Electrical Connections

A. Power Cable from UCPLC Panel G. Cap (Spare) M. Spare (Cap) S. Spare (Cap)
B. Hydraulic Pressure Sensor H. Power (Optional Grease or Oil Lube) N. Pressure Control Valve Cable T. Spare (Cap)
C. Tank Temperature Sensor I. Power (Standard Lube) O. X2X Cable U. Spare (Cap)
D. X2X Cable from UCPLC Panel J.Power P. Node Switch - High V. Power Beyond
E. X2X (Optional Grease or Oil Lube) .K. Spare (Cap). Q. Node Switch - Low W. X2X Beyond
F. Spare (Cap) L. Spare (Cap) R. Spare (Cap)
IMPORTANT:
Node switches (P & Q) must be configured to reflect 6
module position (Fig. 6-14). Standard Position: Set High
to [0] / Low to [B].
04/17 6–15
PRELIMINARY TROUBLESHOOTING
CHECKS AND ADJUSTMENTS Table 6–4. Hydraulic System Pressure Settings
Make the following checks and inspections before
Pressure
performing any hydraulic system troubleshooting Component
Settings
procedures:
• Check the hydraulic reservoir fluid level. Reservoir is full Hyd Adjust Assembly 4000 PSI
when the fluid level is up to the black line at the top of the Relief Valves (275 bar)
gauge. Add hydraulic fluid if low. Refer to Table 6-3 for
5000 PSI
fluid specifications.
(344 bar)
• Check for visible external leakage on hydraulic system Control Assembly RETRACT
fittings. Lockout/tagout power and depressurize the Counterbalance Valve
hydraulic system before tightening or replacing any 6000 PSI
fittings. (414 bar)
EXTEND
• Check for visible external leakage on valves, cylinders,
and other hydraulic components. Replace or repair Control Assembly Pressure 600 PSI
defective components as required to eliminate leaks. Reducing Valve (42 bar)
Lockout/tagout power and depressurize the hydraulic
system before making repairs.
• Check that the hydraulic power unit is securely mounted.
Loose mounting hardware or cracked or damaged
hydraulic system framework could indicate vibration
problems in the system.
• Verify that proper voltage is connected to the hydraulic
control panel. Be sure polarity is not reversed.
• Hydraulic system electrical components must be correctly
wired and in proper working order. If electrical problems
are suspected, have a licensed electrician inspect and
troubleshoot the electrical components as required.
• Check the system pressure at each major hydraulic
component (Table 6-4). Incorrect pressure settings or
readings can often help isolate hydraulic system problems
to a specific component.
6–16 04/17
HYDRAULIC SYSTEM
TROUBLESHOOTING CHART
Refer to Table 6-5 for the hydraulic system troubleshooting
chart.
Table 6-5: Hydraulic System Troubleshooting Chart
SYMPTOMS POSSIBLE CAUSE CORRECTIVE ACTION
1. Crusher stops A. X2X cable from UCPLC Panel Reconnect power to the control panel at the A con-
disconnected at the I/O Link X67 nector.
Module
B. X2X cable from the I/O Link Check the X2X cable from B connector on the I/O
X67 Module to the Node Module Link X67 Module to the A connector on the I/O
X67 disconnected at the I/O Link Node X67 Module.
or Node module.
C. Loose connections Check for loose connections inside the hydraulic

control panel.
Be sure that connections to pressure sensors are
fully seated.
Check for loose connections at control modules
(X67 I/O Link, X67 Grease, X67 Node).
2. Main control has deter- A. Pressure sensor on feeder is Check feeder pressure sensor, feeder hydraulic
mined a hydraulic low sending a low hydraulic pressure lines and connectors for leaks. Repair or replace
pressure at the feed signal. defective components.
device exists.
3.High hydraulic fluid A. Low fluid level Check fluid level. Hydraulic reservoir is full when
temperatures. fluid level is up to black line of sight gauge. If fluid
level is low, add additional hydraulic fluid as
required. Refer to Table 6-3 for hydraulic fluid
specifications.
Before checking fluid level, verify that hydraulic
fluid pump is off and that the hydraulic pressure
sensor indicates (0) PSI. For most accurate fluid
level readings, the relief cylinder should be fully
retracted.
04/17 6–17
H i g h H y d r a u l i c F l u i d B. Fluid not the correct specifica- ISO 68 Hydraulic Fluid in synthetic formula may be
Temperatures cont. tion for high ambient tempera- required.
ture conditions.
C. Dirty or unchanged hydraulic Drain and flush the hydraulic reservoir. Replace
fluid. hydraulic filter element.
Refill hydraulic reservoir with new fluid of the
proper viscosity. Refer to Table 6-3 for hydraulic
fluid specifications and recommended change
intervals.
D. Relief valve on cylinder mani- Check for heat build-up at relief valve circuit. Clean
fold is by-passing oil. or replace valve if suspect.
E. Worn pump is creating excess Rebuild or replace pump.

heat.
F. Excess load Check for mechanical binding or excess feed input

above rated design for crusher.
G. Cavitation is causing the fluid Cavitation may be caused by air in system, leaky
to overheat. connections, dirty filters, worn or low fluid, clogged
breathers, worn pump seals etc. Determine cause
and correct.
H. Power Unit Relief Valve Check relief valve setting on hydraulic pump unit.
Pressure relief valve should be set at 3800 PSI
Setting Incorrect.
(262 Bar). Reset pressure setting if greater than
3800 PSI (262 Bar).
6–18 04/17
4. Low hydraulic pressure A. Low fluid level Check fluid level. Hydraulic reservoir is full when
fluid level is up to line of top sight gauge. If fluid
specifications.
Before checking fluid level, verify that the hydraulic
reservoir pump is off and that sensor indicates zero
(0) PSI. For most accurate oil level readings, the
relief cylinders should be fully retracted.
B. Pump turning in wrong direc- Check direction of pump motor fan. Fan must
tion rotate in same direction as arrow on motor fan
housing. Reverse electrical leads if necessary.
C. Pump suction line clogged or Check for loose or cracked suction line fittings.
leaking Tighten or replace fittings as required.
Check suction line for obstructions. Remove if
present.
D. System relief valve stuck Check setting of system relief valve. Readjust or
open or set too low replace as required.
E. Tension cylinder by-passing Check if any fluid is returning from the piston side
oil. of the tension cylinder circuit. Replace or repair cyl-
inder if defective.
F. Defective pressure gauge giv- Install a new pressure gauge and compare read-
ing false reading. ings. If reading are not the same (old gauge read-
ing low) replace pressure gauge if defective.
G. Defective Pressure Sensor Install a new properly programmed pressure sen-

sor into the hydraulic manifold. Verify that pressure
sensor reading is accurate. Replace pressure sen-
sor if old gauge reads lower than new.
H. Low pump output Run a pump test with outlet hose removed. Pump
should flow approximately 4.3 gallons of fluid in
one minute. If GPM flow rate is less than 3 gallons,
repair or replace the hydraulic pump.
I. External system leak Check all hoses and connections for hose damage
or leaking connections. Repair or replace hoses as
necessary.
J. Pump motor not turning cor- Check electric motor for overheating, single phas- 6
rect RPM. ing etc. Check bearings for overheating and make
certain motor is correctly lubed. Replace motor if
necessary.
04/17 6–19
5. Low hydraulic flow A. Low oil level Check fluid level. Hydraulic reservoir is full when
fluid level is up to line of top sight gauge. If fluid
specifications.
Before checking fluid level, verify that reservoir
pump is off and that sensor indicates zero (0) PSI.
For most accurate fluid level readings, the relief
cylinders should be fully retracted.
B. Pump suction line clogged or Check for loose or cracked suction line fittings.
leaking. Tighten or replace fittings as required.
present.
C. Low pump output Repair or replace the hydraulic pump or pump

motor.
6. No hydraulic pressure A. No fluid reaching pump Hydraulic reservoir extremely low, refill fluid to
proper level.
Clogged Inlet line, remove obstruction and change
filters.
B. Main control module (UCPLC) Check that all X2X cables are connected at the
not sending signal to hydraulic hydraulic modules on the hydraulic unit.
unit to start.
If cables are OK, replace X67 modules or main
control module on UCPLC panel.
C. Malfunctioning relief valve is Check relief valve setting and repair or replace
allowing all hydraulic fluid to valve as necessary.
bypass.
6–20 04/17
8. OPEN/CLOSE func- A. Obstruction preventing toggle Check that the crushing chamber is free of tramp
tions not operating beam and swing jaw movement iron or jammed material. Clear the crushing cham-
ber if necessary.
Verify that the toggle beam and tension cylinders
are unobstructed. Remove obstructions if present.
B. No power to solenoid coils Control Valve #1 contains two solenoid coils. One
coil activates the hydraulic RETRACT (Open) func-
tion. The other activates the hydraulic EXTEND
(Close) function.
Check that voltage is present at the appropriate
solenoid coil terminals when the function selector
touchpad is in the OPEN or CLOSE position.
C. Solenoid coil is defective Jog the selector several times between OPEN and
CLOSE with the Function selector keypads on the
Setpoint Selection Screen on the Main Control
Panel (Fig. 6-3). Listen for the valve spool to shift.
If spool does not shift when each function is acti-
vated, one or both solenoid coils may be defective.
To verify a defective solenoid coil, manually shift
the spool in both directions by depressing the
push-button at each end of the valve.
When either button is depressed, the spool will
shift about 1/8 inch. Pressure should build immedi-
ately, and the swing jaw should begin to move.
D. Directional control valve is Manually shift the valve spool as described in step
defective. C.
If the valve spool is stuck and cannot be manually
shifted, repair or replace directional control valve.
E. Hydraulic pressure unit relief Check setting of relief valve on hydraulic power
valve stuck open or set too low. unit. Readjust or replace as required.
F. Toggle cylinder relief valve Check setting of toggle cylinder relief valve. Valve
stuck open or set too low. must be set to 4000 PSI (275 bar). Readjust or
replace as required.
04/17 6–21
8. OPEN or CLOSE func- G. Low pump output or clogged 1. Lockout/tagout power to the hydraulic control
tions do not operate pump intake line. panel.
(con’t)
2. Verify that the pressure gauge indicates zero (0)
PSI.
3. Place a hydraulic flowmeter in the pump outlet
line. The flowmeter must be capable of operating
at pressures of at least 5000 PSI.
4. Restore power and start the hydraulic pump.
The toggle cylinder must be moving (extending or
retracting) while the flowmeter reading is checked
in the next step.
5. Observe the flowmeter reading. The flow rate
should be approximately 3.0 to 4.3 GPM. Go to
next step of troubleshooting if the flow rate is within
acceptable limits.
6. If the flow rate is below acceptable limits
Drain the hydraulic reservoir and inspect the pump
suction line for obstructions or leaks.
Refill the hydraulic reservoir with new oil. Check
the flow rate again as described in steps 4 and 5 of
this procedure. Repair or replace the pump if the
flow rate is still below acceptable limits.
H. Directional control valve is Troubleshoot directional control valve. Verify

defective. proper operation. Repair or replace as required.
I. Toggle tension cylinder defec- Repair or replace the cylinder as required.

tive.
9. Toggle Cylinder is not A. A pressure relief valve stuck Check setting of pressure relief valves on manifold
maintaining correct pres- open or set too low. Check both block (4,000 PSI (276 bar) is correct setting).
sure. valves on cylinder manifold Readjust or replace as required.
block.
6–22 04/17
10. Fluid temperature too A. Fluid heater not working Check that fluid heater is properly connected to a
cold. power source of the correct voltage. Be sure that
power remains connected, even when crusher is
off.
Check that thermostat is set to between 70F
(21C) and 90F (32C).
Check for carbon build-up on heating element.
Clean as required.
Check for defective thermostat or burned-out heat-
ing element. Make repairs as required.
B. Hydraulic fluid heater thermo- Raise the temperature of the fluid heater thermo-
stat set too low stat as required.
The heater thermostat is normally set at 70° to
90°F (21° to 32°C) depending on outside ambient
temperature. It can be set up to 100°F (38°C) for
especially cold climates.
11. Fluid heater failure A. Carbon build-up on heating Periodically clean and inspect the heating element
element to prevent premature failures.
B. Heating element not Check Hydraulic fluid level. Always disconnect

immersed in fluid caused ele- power to heater before draining fluid.
ment burnout.
Always disconnect power to heater during sea-
sonal storage.
C. Heating element touching res- When performing tank maintenance, be careful not
ervoir to bend the heating element. The element must not
touch the inside of the reservoir.
12. Hydraulic system A. Hydraulic reservoir leaking Inspect the hydraulic reservoir for leaks. Make
loses fluid repairs as required.
B. Leaking hydraulic hoses Check all hydraulic hoses and fittings for leaks.
and/or loose fittings Tighten fittings or replace hoses as required.
C. Leaking hydraulic compo- Check hydraulic components for visible leakage.

nents
Repair or replace leaking hydraulic components as
required.
04/17 6–23
13. Noisy pump A. Fluid is cold Pump may be noisy when hydraulic fluid is cold,
but should become quieter as fluid warms up.
B. Low fluid level Check fluid level. Hydraulic reservoir is full when
fluid level is up to top line of upper sight gauge. If
fluid level is low, add additional fluid as required.
Refer to Table 6-3 for hydraulic fluid specifications.
Before checking fluid level, verify that fluid pump is
off and that all gauges indicate zero (0) PSI. For
most accurate fluid level readings, the relief cylin-
ders should be fully retracted.
C. Pump turning in wrong direc- Check direction of pump motor fan. Fan must
tion rotate in same direction as arrow on motor fan
housing. Reverse electrical leads if necessary.
D. Incorrect hydraulic filter Install a new filter of correct micron size.
E. Pump suction line clogged or Check for loose or cracked suction line fittings.
present.
F. Pump damaged Repair or replace the hydraulic pump.
G. Pump cavitating Hydraulic filters dirty or clogged, replace filters.

Breather vent clogged, replace tank cap or clean
filter.
Pump shaft seal worn, replace pump seal.
Inlet line clogged, replace suction filter and clean
obstructions from line.
Inlet line connection loose allowing air into system,
tighten connections and bleed air from system.
Fluid worn out, change fluid
14. Filter element needs A. Fluid poured from an unclean Be sure that hydraulic fluid container is clean to
frequent replacement. container or new fluid from open prevent dirt and other harmful contaminants from
barrel is contaminated. entering the hydraulic system.
Sludge at bottom of
hydraulic reservoir. B. Unchanged fluid Change fluid at the proper time interval. Refer to
hydraulic system maintenance schedule.
6 C. Pump suction line clogged or Check for loose or cracked suction line fittings.
Check suction line for obstructions. Remove
obstructions if present.
6–24 04/17
15.Toggle cylinder A. Directional control valve is Try to manually shift the spool of directional control
extends or retracts when defective. valve in both directions by depressing the
control is on the ADJUST push-button at each end of the valve.
SETPOINT screen and
When the #2 or #3 Key is NOT pressed, the spool
OPEN/CLOSE touchpads
should return to the center position and the relief
are not activated,
cylinders should not move.
If the valve spool is stuck in the EXTEND or
RETRACT position and cannot be manually
shifted, repair or replace the directional control
valve.
16. Toggle cylinder does A. Counterbalance valve car- Pressure is adjusted by turning the adjustment
not remain stationary tridges are set too low or stuck screws on the counterbalance valve cartridges.
(creeps) when the open.
To adjust the pressure setting, loosen the locknuts
ADJUST SETPOINT
on both valve cartridges. Turn each adjustment
screen is activated.
screw fully CLOCKWISE until it stops. Then turn
each adjustment screw COUNTERCLOCKWISE to
set the pressure. Pressure setting is approximately
5000 PSI (344 bar) on counterbalance cartridge B
and 6000 PSI (410 bar) on cartridge A.
With the selector switch in the ADJUST position,
verify that the toggle beam does not move or
creep. Re-tighten the locknuts after making any
additional adjustments.
Replace the counterbalance valve cartridges if
they appear to be stuck open.
To check for correct Keypad operation disconnect
the solenoid electrical connections (B, Fig. 6-19) at
each coil. If tension cylinder continues to creep
with the electrical input to the coils removed, the
problem is hydraulic, not electrical.
17. Excessive hydraulic A. Toggle cylinder relief valve set Check setting of relief valve on tension cylinder.
relief action. too low or stuck open. Re-adjust or replace as required. Valve must be
set to 4000 PSI (276 bar).
04/17 6–25
6–26 04/17
Chapter 7
Crusher Troubleshooting
CONTENTS
Page
CRUSHER TROUBLESHOOTING SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . 7-2
CRUSHER TROUBLESHOOTING CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

1. Crusher will not start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
2. High power draw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
3. Crusher vibrates or shakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
4. Crusher makes knocking sounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
5. Crusher loses RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 7
6. Uneven die wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7. Low production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
8. Broken toggle wear bar(s). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
9. High Bearing Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
POSITION SENSOR TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

1. Position Sensor LED does not light. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
2. Position Sensor LED remains RED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
3. Position Sensor LED remains YELLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
4. Position Sensor LED cycles from RED to GREEN . . . . . . . . . . . . . . . . . . . . . . . 7-6
5. Position Sensor Doesn’t Output Voltage Readings. . . . . . . . . . . . . . . . . . . . . . . 7-6
DISCONNECTING HYDRAULIC HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
DEPRESSURIZING THE 3450 CRUSHER HYDRAULIC SYSTEM . . . . . . . . . . . . . . 7-7
PRELIMINARY HYDRAULIC CHECKS and ADJUSTMENTS . . . . . . . . . . . . . . . . . . 7-8
HYDRAULIC SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
HYDRAULIC SYSTEM TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . . . . . . 7-12
04/17 7–1
Crusher Troubleshooting Operation and Maintenance
CRUSHER TROUBLESHOOTING SAFETY bridged material. The material could break free at any
PRECAUTIONS time.
• Fully retract the jaw when service will occur in the
crushing chamber. Always block the jaw sheaves and
! WARNING!!!
DANGER install swing jaw lock pins before allowing anyone inside
Stop the crusher and lockout/tagout power before the crushing chamber when the swing jaw is in the
performing any adjustment, lubrication, retracted position. Refer to Chapter 4 for procedure.
maintenance or repair procedures. Never attempt to • Do not place timbers or any other blocking devices inside
service the H3450 Jaw Crusher while it is operating. the crushing chamber to hold the swing jaw open. The
Refer to Chapter 1 for complete lockout/tagout blocking could crack or become dislodged. Serious
procedures. personal injury could result.
• Be sure that all guards and other safety devices are
! WARNING!!!
DANGER correctly reinstalled and tightly secured after
troubleshooting procedures are completed.
Failure to observe the following precautions may
result in serious personal injury or death!
CRUSHER TROUBLESHOOTING CHART
• Lockout/tagout power to the crusher drive motor, and all
Refer to Table 7-1 for general crusher troubleshooting
crusher systems before performing any inspection,
procedures. When indicated in the Corrective Action column,
adjustment, lubrication, maintenance or repair procedures.
refer to the other chapters of this manual for additional
Also lockout power to all crusher feed and discharge
maintenance instructions.
equipment. Refer to Chapter 1 for complete lockout/tagout
procedures. Refer to Table 7-2 for problems relating to the position
sensor.
• If the crusher is powered by a diesel engine, disconnect
7 batteries and shut off fuel supply before performing any
inspection, adjustment, lubrication, maintenance or repair
procedures. Lockout/tagout engine controls to prevent
the engine from being accidentally started while the
crusher is being serviced.
• Wear or use appropriate personal protective equipment
(PPE) as required by federal, state or local regulations,
such as hard hats, steel toe shoes, safety glasses and ear
protection.
• Use extreme caution if it is necessary to operate the
crusher for observation purposes. Stay clear of any
rotating or moving parts. Be aware of potential hazards at
all times.
• Allow only authorized personnel near the crusher during
troubleshooting procedures.
• Rock projected upwards through the feed opening can
injure or kill. Stay clear of the feed opening during crusher
operation. Use mirrors or closed-circuit cameras if close
observation of the feed arrangement is necessary for
troubleshooting or evaluation purposes.
• Never place hands on hydraulic cylinder body or rod.
Never stand on hydraulic hoses or use them as steps.
• Always use a safety belt, lifeline, body harness and/or
lanyard if it is necessary to enter the crushing chamber for
inspection purposes. Never attempt to walk on jammed or
7–2 04/17
Operation and Maintenance Crusher Troubleshooting
Table 7–1. Crusher Troubleshooting Chart
1. Crusher will not start A. Material lodged in crushing Remove material from crushing chamber.
chamber.
Refer to Chapter 4 for chamber clearing
procedure.
B. No power to hydraulic Check diesel engine power source. Check

system. diesel output device to hydraulic pump. (If
equipped with Diesel Option).
C. Electrical interlocks or Verify that all interlocked doors (alarm and con-
switches preventing crusher trol panels) are closed.
startup.
Verify that the hydraulic system pump is on.
Verify that hydraulic system pressure is at least

2500 PSI (172 bar).
Verify that crusher is in CRUSH mode.
D. Incorrect wiring or loose Check electrical wiring at switches and

connections. hydraulic power control unit. 7
E. Hydraulic drive motor or drive Check the drive belt condition and tension.
belt defective. Remove belt if necessary and check whether
hydraulic drive motor runs with belt removed.
If motor runs without load, problem may be at
the swing jaw drive sheave or eccentric shaft
bearings. If hydraulic drive motor does not
operate with drive belt removed, a hydraulic
drive motor or hydraulic pressure problem may
be present on the plant.
2. High Power Draw A. Excessive fines in feed Remove excessive fines from feed.
(packing condition).
B. Uncrushable object in Clear the crushing chamber.

crushing chamber.
C. Discharge setting too small. Increase the discharge setting as required.
D. Defective drive motor. Have a licensed electrician test the drive motor
for proper operation.
E. Crusher bearings damaged or Replace bearings as required.

worn.
04/17 7–3
3. Crusher vibrates or A. Support structure bolts loose. Tighten any loose bolts. Check for missing
shakes bolts.
B. Swing Jaw bearing mounting Retorque bolts with Torque Multiplier tool.
flange bolts loose. Refer to Chapter 3.
C. Insufficient support structure. Rebuild or reinforce support structure as

required.
D. Crusher not level. Check crusher for levelness.

If necessary, add shims under the crusher
mounting flange.
E. Crusher speed incorrect. Check speed at the flywheel sheave. Refer to

Chapter 3 for recommended crusher RPM.
F. Dirt buildup on sheaves. Check for a buildup of dirt on the motor and
flywheel sheaves.
Remove dirt if present.
G. Wrong number of Add or remove counterweights as required.

counterweights on sheaves.
Contact Telsmith Service Department for
7 counterweight quantities and locations.
4. Crusher makes A. Hydraulic Adjustment Inspect the tension springs and adjust tension
knocking sounds Assembly tension springs not or replace springs as required. Refer to
providing adequate tension. Chapter 4.
B. Adjuster assembly wear bars Check wear bar mounting hardware. Tighten or
loose or extremely worn. replace as necessary. Check wear bar and
toggle seats for extreme wear or damage.
Replace as necessary.
5. Crusher loses RPM A. Excessive fines in crushing Check feed and remove fines.
chamber.
B. Loose or worn drive belts. Adjust tension and replace belts as required.
C. Sheave grooves worn. Inspect sheave grooves for wear. Replace

sheave(s) if grooves are excessively worn.
D. Swing Jaw Bearings Refer to Chapter 3 for swing jaw grease points
overheating due to insufficient and periodic grease intervals.
lube.
6. Uneven die wear A.Crushing chamber underfilled. The crushing chamber should be kept
approximately two-thirds full for best results.
Increase speed of feeding device as required.
B. Feed directed to one side. Reposition the feeding device so that material
is evenly distributed as it enters the crusher.
7–4 04/17
7. Low production A. Discharge setting too small. Check for proper discharge setting. Refer to
Chapter 4.
B. Crusher rotation incorrect. Check for proper rotation. Crusher flywheels

must turn towards crushing chamber. Refer to
Chapter 3.
C. Low Crusher RPM. Check crusher RPM at the flywheel.

Crusher RPM is a minimum of 242 RPM.
If RPM is below minimum, determine reason for
low RPM and make repairs or adjustment to
raise RPM to 250 RPM.
8. Broken toggle wear A. Excessive amount of Remove uncrushable objects from the feed.
bar(s) uncrushable objects entering the
crushing chamber.
B. Material build up in crusher Check discharge conveyor for proper

discharge area. operation.
Verify that the discharge chute is not restricting

the free flow of material.
C. Fines building up in the

bottom of crushing chamber
Remove fines from the feed. 7
D. Hydraulic relief function not Troubleshoot the hydraulic relief circuit of the
working properly. hydraulic system.
9. High bearing A. Under or overlubricated Determine if grease is the correct volume and
temperatures at swing bearings or grease breakdown. type for current temperatures. Refer to Chapter
jaw and eccentric shaft 4 for grease specifications.
bearings
B. Drive belt is slipping on drive Check belt for contamination or damage that
sheave. may be causing slipping. Install new belt and
tension properly if necessary.
C. Discharge setting too small. Increase discharge setting.
D. Flywheel speed too high. Check speed at the flywheel sheave. Maximum
speed is 260 RPM. Correct if necessary.
E. Bearings worn or damaged. Replace crusher bearings as required.
04/17 7–5
Table 7–2. Position Sensor Troubleshooting
SYMPTOM POSSIBLE CAUSE CORRECTIVE ACTION
1. Position Sensor LED A. 24V input to position sensor Remove input cable and test for 24V input
does not light when connector is not present at pin 1 with a test meter. If voltage is not present,
crusher is started. of the connector. replace input cable and check 24V source.
B. Position sensor is defective. Replace position sensor and reset sensor

range. See Chapter 4.
C. Correct ground is not present Establish that ground path continuity is

at pin 3 (blue wire) on present from connector to the ground point.
connector.
2. Position Sensor LED A. The magnet is not delivering Replace magnet and reset sensor range.
remains RED when swing a signal to the linear
jaw is operating. displacement transducer.
B. Magnet is remaining in a null Check that mounting clamps on the

(dead) zone at the front or back transducer are tight and that the magnet
of the travel range. linkage has not broken or become
disconnected. Make repairs and adjustments
as needed.
3. Position Sensor LED A. “ZERO” and “SPAN” settings Follow instructions in Chapter 4 and set or
7 remains YELLOW or were not set when the linear reset span making certain that “ZERO” and
YELLOW and RED over transducer was mounted. “SPAN” settings are located in the active zone.
the complete span of
magnet while the crusher
is running.
4. Position sensor LED A. Magnet was set with either Reset sensor range, making certain that the
cycles from RED to the “ZERO” or “SPAN” setting in LED is in the active zone when the “ZERO”
GREEN while the jaw is a null zone when the unit was and “SPAN” settings are established.
running. programmed.
5. Position sensor is A. No voltage is being output at Position sensor defective, replace unit and
GREEN during complete pin 4 (black wire) on the position reprogram “ZERO” and “SPAN”.
jaw stroke, but no voltage sensor connector.
readings are being shown
on readout device. B. Correct voltage signals are Check the cable between the output
being output at the position connector and the display device for correct
sensor connector, but are not continuity. If cable checks OK, the display
being displayed at the output device may be defective.
device.
7–6 04/17
DISCONNECTING HYDRAULIC HOSES 1. Retract the swing jaw to the fully open position using the
OPEN JAW (Setpoint) touchpad on the Setpoint Selection
Screen (Fig. 7-1) on the Main Control Panel.
! WARNING!!!
DANGER
Failure to properly depressurize the hydraulic
system before loosening hydraulic fittings or G1
disconnecting hydraulic hoses could result in
G2
the release of high pressure hydraulic fluid.
Serious personal injury or death can occur if
hydraulic fluid penetrates the skin.
• To prevent the release of high pressure hydraulic fluid,
always completely depressurize the hydraulic system
before loosening any hydraulic fittings or disconnecting
any hydraulic hoses during troubleshooting procedures.
Refer to the Depressurizing the Hydraulic System section
of this chapter for instructions and additional information.
B
• Before removing a hydraulic hose, check that the hose is A C
relaxed and not stiff. A stiff hose indicates that pressure
has not been relieved. Figure 7–1. Setpoint Selection Screen
• As hoses are removed, catch any hydraulic oil leakage in A. Open Jaw Touchpad
an appropriate container. B. Save New Setpoint Touchpad
C. Close Jaw Touchpad
2. Stop the crusher. Lockout/tagout power to the crusher

! WARNING!!!
DANGER drive, the hydraulic power unit and to all feed and discharge 7
Always assume that the system is pressurized, equipment. Power must remain connected to the Main
even if pressure appears to have been relieved. Control Panel.
Wear appropriate eye protection and other 3. Be sure no personnel are on, inside or under the crusher.
personal protective equipment when loosening
hydraulic fittings and disconnecting hoses.
Serious personal injury or death can result if ! CAUTION
DANGER !!!
hydraulic oil penetrates the skin.
The swing jaw may move during the following
steps. To prevent serious personal injury, be
DEPRESSURIZING THE 3450 CRUSHER sure no persons are on, inside or under the 3450
HYDRAULIC SYSTEM crusher before activating the hydraulics.
If it becomes necessary to manually relieve system pressure 4. Check the pressure readout (A, Fig. 6-4) on the Pressure
due to a malfunctioning dump valve, depressurize the Sensor located near the electric motor (B, Fig. 6-4). Pressure
hydraulic system as follows: should now read 0 Bar (0 PSI).
Perform all steps in the order shown. Do not skip any steps.
! WARNING!!!
DANGER
Pressures of up to 3800 PSI (262 bar) could be
present in the hydraulic system even when the
hydraulic pump is off. If there is any question
whether hydraulic pressure is present, never
loosen any hydraulic fittings or disconnect any
hydraulic hoses until after the hydraulic system
has been depressurized as described in the
following procedures:
04/17 7–7
8. If pressure is indicated at either port, install a pressure test

line at the G1 port and bleed off any remaining pressure (and
fluid) into a catch receptacle. Install a pressure test line at the
G2 port and bleed off any remaining pressure (and fluid) into
a catch receptacle
A B
9. Move the test gauge to the hydraulic adjust assembly and
install the test gauge at both port G3 and G4 (Fig. 7-4) to test
for remaining residual pressure. If any pressure is indicated
on the gauge, install a pressure test line at the port in question
0.00 PSI and bleed off any remaining pressure (and fluid) into a catch
receptacle.
G3 G4

7 A. Sensor Pressure Readout
B. Sensor Location
C. Electric Motor.
5. If the sensor readout (A, Fig. 7-2) does not register zero, Figure 7–4. Hydraulic Adjust Assembly
attempt to close the jaw with the Close touchpad (C, Fig. 7-1.
NOTE: An alternate method for draining off pressure at
(If all hydraulic pressure is exhausted, the jaw should not
G3 and G4 is to adjust both counterbalance valves all
move). If enough pressure is present to fully close the jaw,
the way out (turn LH screw adjusters clockwise) and
attempt to open the jaw again with the Open touchpad (A,
allow pressure to bleed. Count the number of turns
Fig. 7-1) until all pressure is relieved.
when turning screw adjusters and return the adjusters
6. Install a hydraulic test gauge at test port G2 (Fig. 7-3) on to the original settings. Recheck pressure at G3 and G4.
the hydraulic control assembly to test for remaining pressure.
7. Move the test gauge to the G1 port on the hydraulic PRELIMINARY HYDRAULIC CHECKS
control assembly (Fig. 7-3). AND ADJUSTMENTS
Make the following checks and inspections before
performing any hydraulic system troubleshooting
procedures:
G1
G2 • Check the plant hydraulic reservoir fluid level. Add
hydraulic fluid if low. Refer to plant manufacturer
documentation for fluid specifications.
• Check for visible external leakage on hydraulic system
fittings. Lockout/tagout power and depressurize the
hydraulic system before tightening or replacing any
fittings.
Figure 7–3. Hydraulic Control Assembly
7–8 04/17
• Check for visible external leakage on valves, cylinders,

and other hydraulic components. Replace or repair
defective components as required to eliminate leaks.
Lockout/tagout power and depressurize the hydraulic
system before making repairs.
• Check that the hydraulic control assembly is securely
mounted. Loose mounting hardware could indicate
vibration problems in the system.
• Verify that proper voltage is connected to the solenoid
DIN fittings on control assembly. Be sure polarity is not
reversed.
• Hydraulic system electrical components must be correctly
wired and in proper working order. If electrical problems
are suspected, have a licensed electrician inspect and
troubleshoot the electrical components as required. Refer
to Chapter 3 for the hydraulic system wiring diagram.
• Check the system pressure at each major hydraulic
component (Table 7-3). Incorrect pressure settings or
readings can often help isolate hydraulic system problems
to a specific component.
Table 7–3. Hydraulic System Pressure Settings
Pressure
7
Port Component
Settings
G1 Supply Pressure 172 - 206 Bar

Fig. 7-1 (2500 - 3000 psi)
G2 Charge Pressure 138 Bar

Fig. 7-1 (Cyl Rod) (2000 PSI)
G3 Piston Side 34 - 330 Bar

Fig. 7-2 Pressure (500 - 4800 PSI)
G4 Rod Side 138 - 345 Bar

Fig. 7-2 Pressure (2000 - 5000 PSI)
04/17 7–9
HYDRAULIC SYSTEM • Allow only trained and licensed electricians to

TROUBLESHOOTING troubleshoot hydraulic system electrical components and
wiring.
Hydraulic Troubleshooting Safety • Use common sense when observing hydraulic system
operation during troubleshooting. Be aware of potential
hazards at all times. Stay clear of all rotating or moving
! WARNING!!!
DANGER parts.
Lockout/tagout power to the hydraulic control • Wear or use appropriate personal protective equipment
assembly before performing any inspections, (PPE) as required by federal, state or local regulations,
adjustments, maintenance or repairs. Never such as hard hats, steel toe shoes, safety glasses, face
attempt to service the hydraulic system while it shield and ear protection.
is operating. Refer to Chapter 1 for complete
lockout/tagout procedures. • Never attempt to loosen a hydraulic fitting when the
hydraulic system is pressurized.
• When loosening a hydraulic fitting, keep your face and
! WARNING!!!
DANGER body away from the fitting as much as possible. Always
Pressures of up to 262 bar (3800 PSI) could be assume that the line has pressure.
present in the hydraulic adjust assembly even • Use a piece of cardboard to check for hydraulic fluid
when the hydraulic pump is off. If there is a leaks, not your hand. Escaping fluid under pressure can
question as to whether hydraulic pressure penetrate the skin, resulting in serious personal injury.
remains in the system, never loosen any
hydraulic fittings or disconnect any hydraulic • Clean-up any spilled hydraulic fluid. Hydraulic fluid is
hoses until after the hydraulic system has been extremely slippery and can be especially dangerous if
manually depressurized as described later in spilled on an elevated walkway or platform.
7 this chapter. • Hot hydraulic fluid can cause burns. Wear appropriate
hand protection and protective clothing when servicing
the hydraulic system. Avoid unnecessary contact with
! WARNING!!!
DANGER hydraulic fluid.
Failure to observe the following safety • Refer to Chapter 1 for additional safety precautions and
precautions may result in serious injury or warnings which apply to pressurized systems and related
death. machinery.
• Before beginning any troubleshooting procedures,
become familiar with hydraulic system operation for both
your plant and the H3450 crusher. Refer to Fig. 7-5 in this
chapter to identify hydraulic components and operating
pressure levels.
• Lockout/tagout power to the hydraulic control panel if it
is necessary to perform any adjustments, lubrication,
maintenance or repairs during troubleshooting. Refer to
Chapter 1 for complete lockout/tagout procedures.
• Always depressurize the hydraulic system before
loosening any hydraulic fittings or disconnecting any
hydraulic hoses. Refer to the Depressurizing the
Hydraulic System section of this chapter for additional
information.
• Allow only qualified hydraulic service technicians to
perform hydraulic system troubleshooting. All persons
working on the hydraulic system must have appropriate
training and certification.
7–10 04/17
RET COIL
HYDRAULIC ADJUST ASSEMBLY
HYDRAULIC ADJUST
ASSEMBLY
A
G4
B
HYDRAULIC CONTROL
Extend
Retract
HYDRAULIC CONTROL ASSEMBLY
ASSEMBLY
EXT COIL
G1 G2
Oriface
C'balance
30 psi Valve Pressure Reducing
Check spring Valve
Valve
600 PSI
P T 5000 psi B A 6000 psi P T CHARGE
PRESSURE P
Relief
Valves
4000
psi
Check T
Valve
145 psi spring
EXT RET B A
G3
T2 T P
7
T2 T1 P
P
3648 I.G. 3648 I.G.

4448 I.G. 4448 I.G.
5060 I.G. 5060 I.G.
76 BAR [1100 PSI] 345 BAR [5000 PSI]
3858 3858
317 BAR [4600 PSI] N/A- HIGH PRESSURE FUNCTION NOT
HYDRAULIC POWER UNIT
USED
LP
LowLOW
Pressure Setting
PRESSURE SETTING
6060 IMPACTOR 6060 IMPACTOR
600 PSI (41 Bar) 14 BAR [200 PSI] 207 BAR [3000 PSI]
T P High Pressure Setting 3800 PSI (262 Bar)
HIGH PRESSURE SETTING
HP
SET TO MAX FLOW
LPM @ 60 Hz
13.7 LPM @ 50 Hz
4.5 BAR
STOP Stop
[65 PSI]
16.4 LPM @ 60Hz
13.7 LPM @ 50Hz
P T
SET TO MAX FLOW
Torque Limiter
[3.6 GPM
3.6 GPM
TORQUE LIMITER CARTRIDGE

Volume
[4.3 GPM]
GPM]
Cartridge B
VOLUME
16.4
4.3
M 1.7 BAR BYPASS

25.0 CC 9.3 CC [25 PSI]
[1.53 CU IN] [0.57 CU IN]
5.6 KW
[7.5 HP]
1760 RPM @ 60Hz T
1450 RPM @ 50Hz L2
S
Figure 7–5. H3450 Hydraulic Schematics
04/17 7–11
1. Crusher control mod- A. A low pressure reading has Check that hydraulic unit is running and outputting
ule has stopped the been detected. sufficient pressure. If pressure reading is less than
crusher. 2500 PSI (172 bar) on hydraulic unit pressure sen-
sor, determine cause and make repairs.
B. Connectors at I/O modules Check C connector (Hydraulic Pressure Sensor)

unplugged or modules defective. on Module I/O Link. Replace cable or module(s) as
necessary.
2. High hydraulic fluid A. Low fluid level. Check fluid level. If fluid level is low, add additional
temperatures. hydraulic fluid as required.
Before checking fluid level, verify that hydraulic
fluid pump is off and that the hydraulic pressure
gauge indicates (0) PSI.
B. Fluid not the correct specifica- ISO 68 Hydraulic Fluid in synthetic formula may be
tion for high ambient tempera- required.
ture conditions.
C. Dirty or unchanged hydraulic Drain and flush the hydraulic reservoir. Replace
7 fluid. hydraulic filter element.
Refill hydraulic reservoir with new fluid of the
proper viscosity. Refer to your plant manual or
Chapter 6 for hydraulic fluid specifications and rec-
ommended change intervals.
D. One or more relief valves are Check for heat build-up at individual relief valves in
by-passing oil. circuit. Clean or replace any suspect valves.
3. Low hydraulic pressure A. Low fluid level. Check fluid level. If fluid level is low, add additional
hydraulic fluid as required.
Before checking fluid level, verify that the hydraulic
reservoir pump is off and that all gauges and sen-
sors indicate zero (0) PSI. For most accurate oil
level readings, the relief cylinders should be fully
retracted.
B. Hydraulic pump turning in Check direction of pump motor. Reverse electrical

wrong direction. leads if necessary.
7–12 04/17
Low hydraulic pressure C. Pump suction line clogged or Check for loose or cracked suction line fittings.
cont. leaking. Tighten or replace fittings as required.
present.
D. System relief valve stuck Check setting of system relief valves. Readjust or
open or set too low. replace valves as required.
E. Defective counterbalance Check valve setting. Replace valve if proper set-

valve, or improper valve setting. ting cannot be held.
F. Defective pressure gauge giv- Install a second pressure gauge at the pressure
ing false reading. test coupling (G1, Fig. 7-3) to verify that pressure
gauge is providing an accurate reading. Replace
pressure gauge if defective.
G. Low pump output Run a pump test with outlet hose removed. Pump
should flow approximately 3 - 4.3 gallons of fluid
(11- 16.3 LPM) in one minute. If GPM flow rate is
less than 2.5 gallons (9.5 LPM), repair or replace
the hydraulic pump.
4. Low hydraulic flow A. Low oil level Check fluid level. If fluid level is low, add additional
hydraulic fluid as required.
7
Before checking fluid level, verify that reservoir
pump is off and that all gauges and sensors indi-
cate zero (0) PSI.
B. Pump suction line clogged or Check for loose or cracked suction line fittings.
leaking. Tighten or replace fittings as required.
present.
C. Low pump output Repair or replace the hydraulic pump or pump

motor.
04/17 7–13
5. EXTEND/RETRACT A. Obstruction preventing Check that the crushing chamber is free of tramp
functions do not operate hydraulic cylinder and swing jaw iron or jammed material. Clear the crushing cham-
movement. ber if necessary.
Verify that the adjust assembly hydraulic cylinder is
unobstructed. Remove obstructions if present.
B. No power to solenoid coils. Hydraulic control assembly contains two solenoid

coils. One coil activates the hydraulic RETRACT
function. The other activates the hydraulic
EXTEND function.
Check that voltage is present at the appropriate
solenoid coil terminals when the function selector
switch is in the EXTEND or RETRACT position.
Refer to Chapter 3 or 6 for hydraulic system wiring
diagram.
C. Solenoid coil is defective. Jog the selector switch several times between
EXTEND and RETRACT (Open/Close on Setpoint
Selection Screen). Listen for the valve spool to
shift.
7 If spool does not shift when each function is acti-

vated, one or both solenoid coils may be defective.
To verify a defective solenoid coil, manually shift
the spool in both directions by depressing the
push-button at each end of the valve.
When either button is depressed, the spool will
shift about 1/8 inch. Pressure should build immedi-
ately, and the toggle cylinder rod should begin to
move.
D. Hydraulic control valve is Manually shift the valve spool as described in step
defective. 5C.
If the valve spool is stuck and cannot be manually
shifted, repair or replace hydraulic control valve.
E. System pressure too low. Check system pressure. Correct reading 2500 -
3800 PSI (172 to 262 Bar) (@ Port G1.
F. Cylinder relief valve stuck Check setting of toggle cylinder relief valves.
open or set too low. Valves must be set at 4000 PSI (276 Bar). Read-
just or replace as required.
7–14 04/17
5. EXTEND or RETRACT G. Low pump output or clogged 1. Lockout/tagout power to the hydraulic control
functions do not operate pump intake line. panel.
(cont.)
2. Verify that the pressure gauge indicates zero (0)
PSI.
3. Place a hydraulic flowmeter in the pump outlet
line. The flowmeter must be capable of operating
at pressures of at least 5000 PSI.
4. Activate the switch in the EXTEND or RETRACT
(Open/Close) position and hold. Reconnect power
and start the hydraulic pump.
The hydraulic cylinder must be moving (extending
or retracting) while the flowmeter reading is
checked in the next step.
5. Observe the flowmeter reading. The flow rate
should be approximately 3.0 GPM (11 LPM) or
greater. Go to next step of troubleshooting if the
flow rate is within acceptable limits.
6. If the flow rate is below acceptable limits:
Drain the hydraulic reservoir and inspect the pump 7
suction line for obstructions or leaks.
Refill the hydraulic reservoir with new oil. Check
the flow rate again as described in steps 4 and 5 of
this procedure. Repair or replace the pump if the
flow rate is still below acceptable limits.
I. Relief cylinder defective. Repair or replace the relief cylinder as required.
6. Adjust Assembly A. Pressure leaking down due to Check for leaks at Extend/Retract lines and fittings.
hydraulic toggle cylinder fluid loss. Check for hydraulic leak at cylinder. Repair fittings
does not maintain ade- or replace seals as necessary.
quate tension.
B. Hydraulic toggle cylinder Check hydraulic cylinder and cylinder body for
defective. signs of damage. (Cylinder plating peeling,
scratched, gouged etc., Cylinder body cracked or
dented etc.)
Replace adjust assembly if necessary.
C. Hydraulic cylinder relief Check setting of both cylinder relief valves (4000
valve(s) stuck open or set too PSI). Readjust or replace as required.
low.
04/17 7–15
7. Low hydraulic fluid A. Fluid heater (If used) not Check that fluid heater is properly connected to a
temperature. working. power source of the correct voltage. Be sure that
power remains connected, even when crusher is
off.
Check that thermostat is set to between 70F
(21C) and 90F (32C).
Check for carbon build-up on heating element.
Clean as required.
Check for defective thermostat or burned-out heat-
ing element. Make repairs as required.
B. Hydraulic fluid heater thermo- Raise the temperature of the fluid heater thermo-
stat (if used) set too low. stat as required.
The heater thermostat is normally set at 70° to
90°F (21° to 32°C) depending on outside ambient
temperature. It can be set up to 100°F (38°C) for
especially cold climates.
8. Hydraulic system loses A. Hydraulic reservoir leaking. Inspect the hydraulic reservoir for leaks. Make
oil. repairs as required.
7 B. Leaking hydraulic hoses Check all hydraulic hoses and fittings for leaks.
and/or loose fittings. Tighten fittings or replace hoses as required.
C. Leaking hydraulic compo- Check hydraulic components for visible leakage.

nents.
Repair or replace leaking hydraulic components as
required.
9. Hydraulic cylinder A. Directional control valve is Try to manually shift the spool of directional control
extends or retracts when defective. valve in both directions by depressing the
EXTEND/RETRACT push-button at each end of the valve.
switch is in the center
When either push-button is released, the spool
(neutral) position.
should return to the center position and the relief
cylinders should not move.
If the valve spool is stuck in the EXTEND or
RETRACT position and cannot be manually
shifted, repair or replace the directional control
valve.
10. Excessive hydraulic A. Hydraulic relief cylinder valve Check setting of relief valve. Re-adjust or replace
relief action. set too low or stuck open. as required. Valve must be set to 4000 PSI (276
bar).
B. Crusher discharge setting is Check discharge setting and adjust within recom-
too low. mended limits.
7–16 04/17
Chapter 8
Wear Liner and Cheek Plate Replacement
CONTENTS
Page
REPLACEABLE WEAR COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
WEAR LINER REPLACEMENT PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Swing Jaw Die Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Swing Jaw Die Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Swing Jaw Hub Guard Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Swing Jaw Hub Guard Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Stationary Die Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Stationary Jaw Die Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
CHEEK PLATE REPLACEMENT PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10

Cheek Plate Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Cheek Plate Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
Cheek Plate Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
04/17 8–1
Wear Liner and Cheek Plate Replacement Operation and Maintenance
REPLACEABLE WEAR COMPONENTS
D
E
K
J
8 K
A
C
Figure 8–1. 3450 Crusher Replaceable Wear Components

A. Cheek Plate Upper D. Stationary Die Retainer G. Swing Jaw Guard J. Feedbox Top Liner (2)
B. Cheek Plate Lower E. Swing Jaw Maganese Die H. Jaw Die Retainer (Replaceable) K. Feedbox Bottom Liner (2)
C. Stationary Maganese Die F. Swing Jaw Die Wedge I. Stationary Die Retainer (Replaceable)
8–2 04/17
Operation and Maintenance Wear Liner and Cheek Plate Replacement
WEAR LINER REPLACEMENT

PROCEDURES ! CAUTION
Use extreme caution during jaw die removal
Swing Jaw Die Removal
procedures. Work from the top of the crusher
1. Retract the swing jaw completely using the hydraulic only. Stay clear of areas where the die could tip
controls. or fall. Do not allow any personnel to be inside
the crushing chamber or under the crusher
! WARNING during the lifting procedure.
Lockout/tagout power to the crusher drive, the
hydraulic system, and all feed and discharge
equipment before beginning wear liner
replacement procedures. Refer to Chapter 1 for A
complete lockout/tagout procedures.
2. With all power to the crusher locked out, attach chains to
the jaw at the lower cast in lugs (Fig. 8-2). Secure the chains
to the 3450 frame to prevent the swing jaw from moving
during jaw die removal and replacement.
B
3. Install two (2) jaw die hooks in the upper pockets of the
maganese die (Fig. 8-3). Attach lift chains or harness capable
of lifting approximately 2102 Kg (4634 lbs) to the lift hooks.
4. Attach a hoist of suitable lifting capacity to the jaw die lift
apparatus (Jaw die weighs approx. 2102 Kg (4634 lb.). Apply
slight pressure to the hooks to maintain the jaw die in position
while the retaining wedge is removed.
Figure 8–3. Swing Jaw Die Lift Hook Location

A. Lift Hook (pn AJ-273-2117) B. Die Lift Points (4)
C. Swing Jaw Maganese Die
5. Remove the four (4) hex head capscrews, washers and

locknuts holding the die wedge to the swing jaw (Fig. 8-4).
6. Install a lift strap through the two outer bolt holes on the
die wedge and lift it off the die with a hoist or crane (wedge
weighs 78 Kg (171 lb.)).
7. Tilt the top of the jaw die out slightly from the jaw casting
and lift the die straight up off the retaining lip on the bottom
edge of the jaw casting.
NOTE:
If the jaw die is only worn on one end it can be reversed
180 degrees and reused in the crusher. If wear is
Figure 8–2. Swing Jaw Chain Attachment Point present on both ends, replace the die.
04/17 8–3
Swing Jaw Die Installation

1. Examine the back side of the new or replacement jaw die
and the face of the jaw for any damage. Clean the mating
surfaces and remove any nicks or burrs (Fig. 8-5). Remove
any obvious high spots with a grinder.
A
Figure 8–5. Die Surface Preparation
2. Be sure that all power to the crusher drive, hydraulic
B
system, the lubrication system and all feed and discharge
devices remains tagged and locked out. Continue to keep the
jaw chained in the fully retracted position (Fig. 8-2).
3. Insert two jaw die lift hooks (pn AJ-273-2117) into the
two upper pockets of the new or rotated die (Fig. 8-6). Install
a suitable lift harness or chains and connect a hoist capable of
supporting 1470 Kg (3240 Lb.).
8 B E
Figure 8–4. 3450 Jaw Die Wedge Removal

A. Swing Jaw Maganese Die B. Jaw Retaining Lip
C. Hex Head Capscrew Gr 8.8 (4) D. Jaw Die Wedge
E. Replaceable Jaw Retainer
8. Check the die retaining lip, the die wedge and the wedge
fasteners for wear and damage. If the wedge fasteners or the
wedge show substantial wear, replace the components.
If you are installing a new jaw retainer (E, Fig. 8-4) use a
medium strength thread locker on the hex head capscrew
threads and torque capscrews to 1570 Nm (1168 Ft. Lb)
working in a 1-6, 2-5 and 3-4 alternating pattern starting with
half torque and then applying final torque.
Figure 8–6. Lifting Jaw Die
8–4 04/17
4. Carefully lift the jaw die over the crusher feed opening. 7. Carefully remove the lift apparatus and the two jaw die
Verify that the ribbed surface of the die is facing the hooks while maintaining the die in position on the jaw. Lower
stationary die. the die wedge (78 Kg (171 Lb)) down into position on the die.
5. Slowly lower the bottom end of the jaw die straight down 8. Align the mounting holes in the wedge with the holes in
into the crusher. Align the bottom edge of the die with the the jaw and install all four wedge hex head capscrews (D, Fig.
protruding jaw retainer lip. Seat the die on the lip and rotate 7-7 through the wedge and jaw. If the capscrew mounting
the die back until it is fully supported by the lip. holes on the wedge will not align with jaw mounting holes,
the die is not correctly seated.
! CAUTION 9. Lube the threads of the wedge capscrews with anti-seize
Keep hands and fingers clear of the area and install the washers and locknuts (F, Fig. 8-7) on the
between the jaw die and the swing jaw during the capscrews. Work in an alternating pattern (1-3, 2-4) and
f o l l o w i n g s t e ps . F a i l u r e t o o b s e r v e t h i s tighten the wedge capscrews to 2745 Nm (2043 Ft Lbs).
precaution may result in serious personal injury. 10. Remove the chain holding the jaw to the frame, and run
6. Continue to rotate the top of the die back until it seats the hydraulic cylinder forward to the previous jaw crusher
completely on the face of the jaw (Fig. 8-7). Make certain the setting before resuming crushing.
protruding key in the center of the die seats fully in the pocket
on the face of the swing jaw. IMPORTANT:
Never attempt to run the crusher with the jaw retracted
past the 7” maximum jaw opening. Attempting to crush
material with a fully retracted jaw could damage the
hydraulic cylinder. Always re-establish your crusher jaw
setting before attempting to crush material.
E
11. Recheck the tightness of the wedge fasteners on a daily
basis during the first three days of operation. Re-torque if
D necessary.
F
8
C
Figure 8–7. Seating and Installing Jaw Die

A. Replaceable Jaw Die Retaining Lip B. Jaw Die
C. Jaw Die Pocket D. Wedge Capscrew (4)
E. Wedge F. Locknut and Washer (4)
04/17 8–5
Swing Jaw Hub Guard Removal Swing Jaw Hub Guard Installation
If the swing jaw guard (B, Fig. 8-8) on the H3450 is damaged Install a new or refurbished swing jaw guard as follows:
or excessively worn on the bottom edge, it should be changed
1. Be sure that all power to the crusher drive, hydraulic
at the same time as the swing jaw die. Remove the swing jaw
system and all feed and discharge devices remain tagged and
guard as described in the following steps
locked out.
1. Lockout/tagout power to the crusher drive, hydraulic
2. Carefully inspect the mating surfaces of the jaw guard and
power unit and all feed and discharge devices.
swing jaw. Thoroughly clean all surfaces and remove any
nicks or burrs. Check internal threads on mounting holes for
! WARNING damage or debris. Clean and re-tap as necessary.
Always lock out power and tag controls before 3. Install lift eyes or hooks into the two outside jaw guard
performing any service on the swing jaw. Failure mounting holes on the top row (Fig. 8-9). Lift the guard into
to observe this precaution may result in serious position and align the mounting holes with the threaded holes
personal injury or death. in the swing jaw casting.
2. Loosen the 6 capscrews (C, Fig. 8-8) holding the jaw
guard to the swing jaw casting, but Do Not remove.
! CAUTION
Failure to support the guard when fastening
hardware is removed will allow it to drop into the
crusher.
3. Using a prybar, pry the guard forward until it separates
from the face of the jaw. Remove only the two outer mounting
capscrews on the upper row. Replace the mounting capscrews
with lift hooks or eyes.
4. Support the guard with a lift device capable of supporting
132 Kg (292 lbs). Remove the remaining four mounting
8 capscrews and carefully lift the guard out of the crusher with
the lift device.
Figure 8–9. Swing Jaw Guard Mounting

A 4. Coat the capscrews with medium thread locker and install
D the mounting capscrews and washer at the four open holes,
but Do Not tighten. With the guard correctly aligned and the
four mounting capscrews partially threaded into mounting
holes, remove the lift apparatus and the lift hooks.
5. Install the two remaining mounting capscrews in the
outside mounting holes and torque all fasteners to 1,135 Nm
C (845 Ft.Lb.) in a cross pattern.
6. Recheck the tightness of the fasteners on a daily basis
B
during the first three days of operation. Re-torque if
necessary.
Figure 8–8. Jaw Guard Removal

A. Swing Jaw B. Jaw Guard
C. Mounting Capscrew Gr 8.8 (6) D. Flat Washer (6)
8–6 04/17
Stationary Die Removal 4. Install a suitable lift harness or chains capable of lifting
approximately 2102 Kg (4634 lbs) to the stationary die lift
Remove the stationary die as follows:
hooks and apply slight pressure to hold the die in position
1. Fully retract the swing jaw to provide operating room for while the retainer is removed.
removal of the stationary die. Install a chain to the lower lugs
5. Remove the thread protection bolts (F, Fig. 8-11) from the
(Fig. 8-10) on the swing jaw and secure to the frame to hold
center of the stationary retaining plate. Remove the five hex
the swing jaw stationary.
head capscrews, flat washers and hex nuts holding the die
retainer plate in position (Fig. 8-11).
A
B
F C
D
8
Figure 8–11. Stationary Die Retainer Plate Removal
A. Hex Nut (5) B. Hex Washer (4)
Figure 8–10. Swing Jaw Locking Chain Installation C. Retainer Plate D. Stationary Die
E. Hex Head Capscrew & Washer (5) F. Protector Bolt (2)
2. Lockout/tagout power to the crusher drive, hydraulic G. Flat Washer (5)
power unit and to all feed and discharge devices. Refer to
Chapter 1 for complete lockout/tagout procedures. 6. Tip the retainer plate (C, Fig. 8-11) up on each end using
a pry bar, and install lift eyes in the two outside mounting
holes. Attach a lift apparatus capable of lifting approximately
! CAUTION 54 Kg (120 Lb.) and remove the die retainer plate.
Use extreme caution during stationary die
removal procedures. Work from the top of the NOTE:
crusher only. Stay clear of areas where the die If you are not replacing the retainer plate (D, Fig. 8-12) it is
could tip or fall. Do not allow personnel to be possible to tip the plate up enough to remove the die using
inside the crushing chamber or under the jack bolts. This will allow the retainer plate to remain in
c r u s h e r d u ri n g r e m o v a l a n d i n s ta l l a t i o n position on the frame. Install two M36 x 90 jack bolts in the
procedures. two threaded holes where the protector bolts (B, Fig. 8-12)
3. Install two lift hooks (pn AJ-273-2117 supplied with were removed. Loosen all five hex nuts (C, Fig. 8-12) on the
crusher) in the two upper lift pockets on the face of the die. die retaining capscrews until only two threads are retaining
the nuts. Thread the two jack bolts (A, Fig. 8-12) down evenly
into the protection bolt holes and lift the retainer plate until
enough clearance is available to remove the stationary die.
04/17 8–7
Stationary Jaw Die Installation

1. Be sure that power to the crusher drive, hydraulic system
and all feed and discharge devices remains tagged and
D locked out and that the swing jaw is still fully retracted and
A held in position.
2. Check the lower die retainer (A, Fig. 8-13) on the crusher
B
frame for damage before beginning installation of the new or
replacement die. If the retainer has pieces missing or has lost
the square edge and upward slant necessary to seat and hold
C the die it will need to be replaced. It can be removed and
replaced with a new retainer by unbolting the lower retainer
plate (C, Fig. 8-13) to access the die retainer.
If you are installing a new die retainer, use an anti-seize
compound on lower retainer capscrews (E, Fig. 8-13) and
torque the capscrews to 1350 Nm (1000 Ft. Lb.) working in a
1-6, 2-5, 3-4 alternating pattern. Start at 1/2 torque and then
torque to the final setting.
Figure 8–12. Using Retainer Plate Jack Bolts

A. Jack Bolt M36 x 90 (2) B. Protector Bolt M36 x 50 (2) - Remove
C. Hex Nut (5) D. Upper Retainer Plate
! CAUTION
The top of the stationary die could tip forward
suddenly when the upper die mounting plate is
removed. Keep hands and arms away from the
8 area between the stationary die and the swing
jaw die. Injury to personnel could occur if the die C B
were to suddenly tip.
7. Lift the die straight up out of the frame.
NOTE: D A
If the stationary die is worn only on one end, it can be E

reversed 180 degrees and reinstalled in the crusher. Figure 8–13. Lower Die Retainer Location
However, the jaw die must be replaced if both ends are
worn. A. Lower Die Retainer B. Back Wall
C. Retainer Plate D. Removable Die Retainer
E. Lower Retainer Capscrews (6)
NOTE: 3. Examine the upper die retainer plate (D, Fig. 8-14) for
Frame cheek plates should be examined for wear and wear and damage. An extremely worn or bent retainer should
damage while the stationary die is removed. Access to be replaced.
cheek plates is improved with the stationary die
removed. Renewal and replacement of these parts
should be accomplished in tandem with a stationary die
replacement.
8–8 04/17
E
D
Swing Jaw Removed For Clarity
A
8
Figure 8–14. Stationary Die Installation

A. 3450 Frame B. Stationary Die C. Hex Head Capscrew & Washer (4) D. Die Retainer Plate
E. Flat Washer (4). F. Hex Washer (4) G. Hex Nut (4)
4. Carefully inspect the mating surface of the new or

replacement jaw die for nicks, burrs or high spots. Remove ! CAUTION
any high spots with a grinder (Fig. 8-5). Use extreme caution during die installation
procedures. Work from the top of the crusher
only. Stay clear of areas where the die could tip
or fall. Do not allow personnel to be inside the
crushing chamber or under the crusher.
04/17 8–9
5. Attach lift hooks to the two upper pockets on the front 9. Lube the threads on the thread protector bolt (A, Fig. 8-
side of the die (Fig. 8-14). Use an appropriate lifting device, 15) with anti-seize and install bolt.
carefully lift the die over the crusher feed opening. Be sure
10. Remove the lift hooks and lift device from the stationary
that the ribbed side faces the jaw die.
die.
6. As the die is slowly lowered into the crusher, align the
11. Remove the chains holding the swing jaw in the retracted
bottom of the die with the protruding edge of the lower die
position (Fig. 8-10). Restore power to the crusher.
retainer. When the die is fully supported by the die retainer,
tip the die back so it fits flush against the back wall of the 12. Recheck the tightness of the fasteners on a daily basis
crusher. Make certain the protruding key in the center of the during the first three days of operation. Re-torque if
die aligns with the keyway in the crusher frame. Continue to necessary.
support the die with the lifting hooks.
7. Using an appropriate lifting device, position the upper jaw CHEEK PLATE REPLACEMENT
retaining plate (D, Fig. 8-14) over the stationary die. Lower PROCEDURES
the retaining plate into position aligning the mounting holes
with the holes in the crusher frame. Cheek Plate Removal
8. Install the five (5) hex head capscrews with a washer on
each head up through the frame and the retaining plate. Lube NOTE:
the threads on the capscrews with anti-seize compound. Due to clearance issues, it is easier to remove and
Install a hex head nut and washers on each capscrew. Torque install cheek plates when the stationary die is removed
fasteners to 1350 Nm (1000 Ft. lbs) working in an alternating from the back of the crusher frame.
pattern (2-4, 1-3, 5).
1. Fully retract the swing jaw, and chain in position (Fig. 8-
10) to prevent the swing jaw from moving during cheek plate
IMPORTANT: replacement.
When the retaining plate is correctly installed, the open 2. Lockout/tagout power to the crusher drive, the hydraulic
side of the bolt slots must be on the die side of the plate unit and all feed and discharge devices. Refer to Chapter 1 for
(Fig. 8-15). complete lockout/tagout procedures.
8 ! CAUTION
Use extreme caution during cheek plate removal
and installation procedures. Stay clear of areas
where a cheek plate could tip or fall. Do not allow
personnel to be under the crusher while cheek
A plate removal/installation is in progress. A
dislodged cheek plate could cause injury or
1
B death.
2
3 3. Completely remove the top two flat head screws, washers
4 and crown nuts from the upper cheek plate (A, Fig. 8-16).
5
Figure 8–15. Die Fastener Torque Sequence

A. Thread Protector Bolt B. Bolt Slot Orientation
8–10 04/17
4. Loosen (But Do Not Remove) the remaining crown nut on

the bottom fasteners of the plate. Tip the top of the cheek plate
towards the crushing chamber to allow a lift sling (Fig. 8-17)
or lift eyes to be installed in the top two holes. Attach the sling
to an appropriate lift device (plate weighs approximately 199
D Kg (439 Lb.)).
A C
1 2
Figure 8–17. Upper Cheek Plate Removal 8

5. Support the cheek plate with the lifting device and sling.
Remove the remaining flat head screws and lock washers and
B carefully lift the upper cheek plate from the crushing
chamber.
6. Completely remove the top flat head screws, washers and
Figure 8–16. H3450 Cheek Plates
locknuts from the lower cheek plate.
A. Upper Cheek Plate (2) B. Lower Cheek Plate (2)
C. Mounting Flathead Screw D. Locknut and Washer 7. Loosen (But Do Not Remove) the remaining locknut on
the bottom fastener of the plate. Tip the top of the cheek plate
towards the crushing chamber and install a lift strap or lift eye
in the top mounting hole. Attach the sling to an appropriate
lifting device (cheek plate weighs approximately 111 Kg (245
Lbs)).
8. Support the cheek plate with the lifting device and sling.
Remove the remaining lower flat head screw, washer and
locknut from the cheek plate and carefully remove the plate
from the crushing chamber.
04/17 8–11
Cheek Plate Inspection 6. Insert a flat head screw through the open lower mounting
hole of the cheek plate and the crusher frame. Lube flat head
screw threads with anti-seize compound and loosely install
NOTE: flat washer and locknut.
Cheek plates on the model H3450 crusher are NOT
reversible. Damaged or severely worn plates must be 7. Remove the sling from the cheek plate. Lube the
replaced with new parts. remaining flat head screw threads with anti-seize compound
and loosely install the flat head screws, flat washers and lock
Cheek plates should be checked at each swing jaw and nuts.
stationary die change for wear or damage:
8. Alternately torque all locknuts to 1570 Nm (1168 Ft. lbs).
• Check the face of the plate for deep gouging, cracking
and trenching. Damaged or deeply grooved plates should 9. Insert a sling through the top two bolt holes of the upper
be replaced. cheek plate as shown in Figure 8-16. Attach the sling to an
appropriate lifting device. Carefully lift the cheek plate over
• Check the flat head mounting screws for wear on the the crusher feed opening.
heads. If the head of the fastener is worn away to the point
it can no longer anchor the plate, both the flat head screw 10. Slowly lower the upper cheek plate into the crusher. Align
and the cheek plate should be replaced. the mounting holes on the cheek plate with the mounting
holes in the crusher frame.
• With the cheek plates removed from the crusher frame,
check the width of the plate at several points. If the plate 11. Insert a flat head screw through the open lower mounting
is worn to 1/2” (12 mm) or less at any point, replace the holes of the upper cheek plate and the crusher frame. Lube the
cheek plate. capscrew threads with anti-seize compound and loosely
install flat washers and locknuts.
• Check the mounting side of the plate for flatness. Using
a straightedge, check the mating surface longitudinally 12. Remove the sling from the cheek plate. Lube the
and diagonally for flatness. If any warping or high spots remaining flat head screw threads with anti-seize compound
are evident in the plate, replace it. and loosely install the flat head screws, flat washers and lock
nuts.
Cheek Plate Installation 13. Alternately torque all locknuts to 1570 Nm (1168 Ft. lbs).
1. Be sure that power to the crusher drive, hydraulic system 14. Install the stationary jaw die if previously removed. Refer
and all feed and discharge devices remains tagged and
8 locked out.
to installation sequence in this chapter.
15. Recheck tightness of all nuts and bolts during the first
2. Read and understand all precautionary statements at the three days of operation. Retorque as required.
beginning of this chapter.
3. Carefully inspect the mating surfaces of the new or
replacement cheek plate and the crusher frame. Thoroughly
clean all surfaces and remove any nicks or burrs.
! WARNING
U s e e xt r e m e c a u t i o n d u r i n g c h e e k p l at e
installation procedures. Stay clear of areas
where the cheek plate could tip or fall. Do not
allow personnel to be under the crusher. A
dislodged cheek plate could cause injury or
death.
4. Insert a sling through the top bolt holes of the lower cheek
plate. Attach the sling to an appropriate lifting device.
Carefully lift the cheek plate over the crusher feed opening.
5. Slowly lower the cheek plate into the crusher. Align the
mounting holes on the cheek plate with the mounting holes in
the crusher frame.
8–12 04/17
Chapter 9
Repair and Overhaul
CONTENTS
Page
GENERAL OVERHAUL INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
SWING JAW REPAIR and OVERHAUL PROCEDURES . . . . . . . . . . . . . . . . . . . . . . 9-4

Flywheel Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Hydraulic Adjustment System Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
Swing Jaw Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
Eccentric Shaft Bearing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
Main Frame Bearing Removal . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
Eccentric Shaft Removal From Swing Jaw Housing. . . . . . . . . . . . . . 9-13
Swing Jaw Bearing Removal . . . . . . . . . . . . . . . . . . . . . . . . . 9-15
Eccentric Shaft Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17
Swing Jaw Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . 9-17
Eccentric Shaft Installation In Swing Jaw . . . . . . . . . . . . . . . . . . . 9-18
Swing Jaw Bearing Race Alignment. . . . . . . . . . . . . . . . . . . . . . 9-21
Main Frame Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . 9-22
Installing Swing Jaw in Main Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22
Flywheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25 9
Sheave Flywheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . 9-25
Pulley Flywheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26
HYDRAULIC ADJUSTING ASSEMBLY SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26

Hydraulic Adjustment Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26
Hydraulic Adjustment Component Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 9-31
Toggle Wear Bar Replacement . . . . . . . . . . . . . . . . . . . . . . . . 9-31
Toggle End Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-31
Cylinder Rod Toggle End Replacement . . . . . . . . . . . . . . . . . . . . 9-31
Stationary End Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 9-34
Hydraulic Adjustment Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-34
04/17 9–1
Repair and Overhaul Operation and Maintenance
GENERAL OVERHAUL INSTRUCTIONS

Work Safety
• Refer to Chapter 1 of this manual for important quarry
safety information. Also refer to the Telsmith Quarry
Equipment Safety Guide for additional safety precautions.
• Observe all precautionary statements (DANGER,
WARNING, CAUTION, IMPORTANT, and NOTE) that
are included within the repair and overhaul procedures.
• Keep cleaning solvents and other combustibles away
from heat and open flame. Do not smoke around
flammable liquids.
• Wear appropriate personal protective equipment (PPE).
Keep the work area clean and well organized.
• If service assistance is needed, contact your local
Telsmith dealer or the Telsmith Service Department.
Lockout/Tagout
• Lockout/tagout power (Fig. 9-1) to the crusher drive
motor and to the crusher hydraulic system before
beginning any service work.
• If the crusher is powered by a diesel engine, disconnect
batteries and shut off fuel supply before beginning any
service work. Lockout/tagout engine controls to prevent Figure 9–1. Lockout/Tagout
the engine from being accidentally started while the
crusher is being serviced. Lifting Heavy Components
• Lockout/tagout power to all other quarry equipment in • Refer to Chapter 2 for the weights of major components
the area, such as feeders, conveyors and related and subassemblies. Know the total weight of the entire
machinery. load before beginning the lift.
• Refer to Chapter 1 for complete lockout/tagout • Always practice safe lifting procedures. Refer to the
procedures. Hoisting and Handling Safety section of Chapter 1 for
9 additional information.
! WARNING • Be sure all lifting devices, slings and supports are in good
condition and of adequate rated capacity.
Always lockout power and tag controls before
performing any lubrication, adjustments,
maintenance or repairs. Failure to observe this ! WARNING
precaution may result in serious personal injury Always use suitable rigging and hoisting
or death. equipment to stabilize and lift heavy objects.
Lifting heavy components with inadequate
hoisting apparatus can result in serious
Tools and Supplies

The following common tools, shop equipment and supplies
are required to complete swing jaw repair and overhaul
procedures:
• Chain puller (6000 lb. capacity)
9–2 04/17
Operation and Maintenance Repair and Overhaul
• Impact wrench with a 3/4 inch drive minimum, 1 inch • If shafts, bearings or other machined items are to be
preferred removed from the equipment for more than a few days,
cover them with a protective coating of rust-preventative
• Set of sockets and breaker bars, minimum 3/4 inch drive
lubricant.
with sockets up to 3-1/2 inches
• Be careful not to cut or tear seals as machined components
• Cold chisel, 3/4 inch
are installed and removed.
• Hammers (various sizes)
• Cables, slings, and chains Handling Bearings
• Remove any loose dirt from the machinery before
• Crane or hoist of adequate capacity
exposing bearings. Handle bearings with clean, dry
(Refer to Chapter 2 for component weights)
hands.
• Feeler gauge and inside/outside micrometers
• Use only clean lint-free rags. Use clean tools in clean
• Cleaning solvent surroundings. Use clean solvents and flushing oils.
• Heated Oil bath • Install new bearings as removed from packaging without
washing. Do not remove bearings from packaging until
• Bearing Induction Heater
ready to use.
• Portable Power Pack Jacking Unit
• Soak used bearings in solvent. Then wash the bearings
and blow them dry with filtered, moisture-free
Lubricants and Sealants compressed air. Dip the bearings in oil immediately after
Various lubricants and sealants are used during the repair and drying to prevent rust.
overhaul procedures in this chapter. These items include:
• Lubricating oil ! WARNING
• NLGI #2 Grease Always wear eye protection and face shield
when using compressed air.
• Thread locking compound
• To prevent bearing damage, do not spin the bearings by
• Gasket sealant hand or with compressed air after the bearing surfaces
• Anti-seize compound have dried.
• Pipe sealant
Using Heat
Part Identification and Inspection • Be careful when using heat and handling hot parts. To
prevent burns, always wear appropriate hand, face and
• Tag and mark all parts during removal and disassembly
procedures.
eye protection. 9
• Avoid applying heat to nearby parts that could be
• Clean all parts as removed. Verify that they are free of damaged by excessive heat.
cracks, nicks, burrs and other imperfections.
• Check clearances and dimensions as instructed in the
procedures.
• Replace any excessively worn or damaged parts.
• If possible, take reference photographs of the machinery
as it is disassembled. Use the photographs during
reassembly procedures to verify that all parts are correctly
reinstalled.
Handling Machined Parts

• Handle machined parts carefully to prevent damage. Do
not nick or mar finished surfaces.
04/17 9–3
SWING JAW REPAIR AND OVERHAUL

PROCEDURES ! WARNING
Always use suitable rigging and hoisting
Flywheel Removal equipment to stabilize and lift heavy objects.
1. Lockout/tagout power as described in the previous
hoisting apparatus can damage machinery and
section.
may result in serious personal injury or death.
2. If the crusher is equipped with flywheel guards, remove
4. Remove the two hex head capscrews holding the flywheel
the guards and all brackets and mounting apparatus.
retainer to the end of the swing jaw shaft (Fig. 9-2) and
3. Attach a suitable lifting device and lift chains to the remove the flywheel retainer from the shaft.
flywheel (Fig. 9-3). Flywheel pulleys weigh approximately
5. Remove the four mounting capscrews, washers and
1352 Kg (2982 Lbs) each. Flywheel sheaves weigh
locknuts (Fig. 9-2) holding the flywheel to the eccentric shaft.
approximately 1243 Kg (2741 Lbs).
A
G
B
F
E F
B
9 Figure 9–2. Flywheel Retaining Hardware Removal

A. Flywheel Retainer Washer w B. Weight Mounting Capscrews w/ C. Shaft Key (2) D. Flywheel Mounting Capscrews w/washer
capscrews and washers (2) washer & locknut (4 Total) & locknut (8 Total)
E. Flywheel (Pulley) F. Counterweight G. Eccentric Shaft H. Flywheel (Sheave)
NOTE:
It may be necessary to use wedges in the face and back
of the flywheel hub (Fig. 9-3) to spread the hub and help
separate the flywheel from the shaft.
9–4 04/17
4. As the tube is lifted out of the main frame, note if any

A
shims were used between the tube mounting flanges and the
frame side wall. If shims are present, keep them with their
respective flange for reuse when the tube is re-installed.
Figure 9–3. Flywheel Removal C

B
A. Lift Chain B. Hub Wedges (4)
6. Slide the flywheel hub back off the eccentric shaft and
lower flywheel to the ground with the hoist.
7. Remove the wedges from the hub splits on the flywheel.
8. Remove the shaft key from the eccentric shaft and inspect
for damage or wear. Replace the key if worn, mis-shaped or
otherwise damaged. Inspect the keyway on the shaft for
damage, and reshape with a cutting wheel if edges are worn
rounded or mis-shaped.
9. Repeat the flywheel removal sequence in steps 3 through
8 for the remaining flywheel.
Hydraulic Adjustment Assembly Removal

On 3450 Model Hydra Jaw crushers it is necessary to remove Figure 9–4. Torque Tube Removal
the torque tube located between the main frame walls prior to
A. Lift Strap C. Washer
9
removing the hydraulic adjustment assembly.
B. Hex Head Capscrew (8) D. Torque Tube
1. Attach a lift strap capable of lifting 178 Kg (393 Lb) at the
5. Disconnect the electrical connector at the position sensor
center point of the torque tube (A, Fig. 9-4). Apply slight
(A, Fig. 9-5). Temporarily install the threaded protective cap
pressure to the lift harness with an overhead crane or hoist.
on the position sensor connector.
2. Remove the eight hex head cap screws (B, Fig. 9-4) and
6. Disconnect position sensor bracket and linkage to prevent
washers (C) holding the torque tube assembly to the frame
damage during handling (Fig. 9-5). Disconnect the linkage
walls.
from the cylinder rod toggle end (B, Fig. 9-5). Unbolt the two
3. Apply additional lift pressure to the torque tube and bolts holding the bracket to the side of the hydraulic assembly
attempt to lift it straight up out of the main frame. If the tube (C, Fig. 9-5) and lift the complete assembly with linkage off
will not come free, it may be necessary to use a hydraulic jack the crusher.
between the frame walls to spread the side walls slightly at a
point just below the tube mounting points.
04/17 9–5
! WARNING
B The hydraulic assembly and swing jaw will move
during the following steps. To prevent serious
personal injury, be sure no personnel are on,
inside or under the crusher before restoring
power and activating the hydraulic functions.
8. Restore power to the control panel. Start the hydraulic
pump.
A 9. From the Startup Selection Screen press the SETTINGS
Key once to access the Setpoint Selection Screen (Fig. 9-7).
C Press and hold the OPEN SETPOINT key on the Setpoint
Point Selection screen until the jaw has retracted fully (A, Fig
9-8).
Figure 9–5. Disconnect Sensor Linkage

A. Step 1: Disconnect sensor cable at Euro Connector
B. Step 2: Disconnect linkage at this point
C. Step 3: Remove bracket mounting bolts
7. Attach a hoist and sling (Fig. 9-6) of sufficient capacity

(1629 Kg (3592 Lb)) around the cylinder body of the
adjusting assembly to hold the assembly from dropping
during the following removal steps. Failure to support the
assembly could result in the hydraulic adjust cylinder falling STEP 1
down prior to removal.
9 C
STEP 2 STEP 3
PRESS AND
HOLD
B
Figure 9–7. Jaw Opening Control Sequence
Figure 9–6. Hydraulic Adjusting Assembly Lift Sling 10. When the jaw is fully open, press the OK button. The jaw
will remain in the open position while the hydraulic adjust
A. Lift Strap B. Relief Manifold
C. Hydraulic Cylinder
assembly is removed.
11. Remove the jam nuts, the upper spring cap and the spring
from all four spring tension assemblies on the hydraulic
adjust assembly (Fig. 9-8).
9–6 04/17
12. Remove the lower spring retainer from all four tension 13. Return to the Adjust Setpoint Screen (Step 3, Fig. 9-7) and
spring pockets (Fig. 9-8) and allow the tension pins to swing use the #3 Function Key (Step 3, Fig. 9-7) to extend the jaw
down out of the hydraulic adjust assembly. to the point where lockout pins can be inserted to support the
swing jaw (Fig. 9-9).
I
M
F
D
C G E
9
B TYPICAL 4 PLACES
Figure 9–8. H3450 Tension Spring Removal

A. Swing Jaw Toggle Seat B. Tension Pin (4) C. Rod Side Toggle End D. Lower Spring Retainer (4)
E. Tension Spring (4) F. Upper Spring Cap (4) G. Lower Jam Nut (4) H. Upper Jam Nut (4)
I. Hydraulic Cylinder J. Fixed Toggle Seat K. 3450 Frame L. Swing Jaw Assembly
M. Toggle Wear Bar
04/17 9–7
C B
Figure 9–9. Install Swing Jaw Locking Pins

A. Step 1: Extend Hydraulic Adjust Cylinder B. Step 2: Install Lock-Out Pin on each side of jaw.
14. Using the Setpoint Selection Screen, use the Open

Setpoint Key (Fig. 9-7) to retract the hydraulic adjust
cylinder. The toggle wear bar should now disengage from the
swing jaw toggle seat (Fig. 9-10). Press the OK key (Fig. 9-
7) on the Setpoint Selection Screen to hold the cylinder
retracted. Caution: The hydraulic adjust assembly will now
be supported only by the lift strap.
B
9
Figure 9–10. Hydraulic Adjust Cylinder Retract

15. Depressurize the hydraulic adjust assembly as detailed in
Chapter 6. Lockout power to hydraulic power unit.
9–8 04/17
! WARNING B B
F a i l u r e t o L o c k o u t / Ta g o u t p o w e r a n d
depressurize the hydraulic adjust assembly A A
before attempting to remove hydraulic hoses or
remove the adjuster assembly could result in
16. Disconnect the hydraulic hoses (3) at the relief manifold
on top of the hydraulic adjusting assembly noting the position
of the lines (Fig. 9-11).
Figure 9–12. Grease Line Removal
A. Swing Jaw Grease Line B. Main Frame Grease Line
Fitting (2) Fitting (2)
B
2. Attach chains to the lower swing jaw lugs and attach the
chains to a frame mounted come-along puller (Fig. 9-13)
Figure 9–11. Hydraulic Line Disconnection

A. Hydraulic Adjusting Cylinder B. Hydraulic Pressure Lines (2)
C. Hydraulic Relief Line Pull-Alo
ng
17. Maneuver the hydraulic adjusting assembly so the toggle

wear bar slides out of the fixed toggle seat bolted to the frame
Figure 9–13. Positioning Swing Jaw
(J, Fig. 9-8). Tilt the back of the hydraulic adjust assembly
(the end removed from frame toggle seat) up and carefully lift 3. Remove the locking pins from both sides of the swing
the assembly up out of the H3450 frame. jaw. Use the come-along to slowly move the swing jaw back
to the neutral position. Remove the come-along and chains.
NOTE: 4. Attach a suitable lifting device and cables or chains to the 9
If your H3450 application has sufficient room beneath two lifting lugs at the top of the swing jaw (swing jaw
the crusher to extract the hydraulic assembly from assembly with die weighs approximately 7746 Kg (17076
below, it may be possible to lower the assembly and Lbs)).
remove it from under the crusher. Refer to Hydraulic
Adjustment Assembly Service in this chapter for
additional detailed service and installation/removal
instructions.
Swing Jaw Removal

1. Remove the grease lines at the swing jaw and main frame
bearing fittings (Fig. 9-12).
04/17 9–9
! WARNING
Keep all personnel clear of the work area while
removing the swing jaw with a hoist. Do not
allow personnel to work on or in the crusher until
the swing jaw assembly has been completely
removed from the crusher and secured in a work
area.
5. While maintaining slight pressure on the lift mechanism,
remove the eight capscrews holding each bearing mounting
flange to the crusher mainframe (Fig. 9-14).
Figure 9–15. Swing Jaw Removal

9 A
C 7. Lift the swing jaw assembly straight up out of the frame
and place on suitable supports with the wear surface facing
Figure 9–14. Flange Mounting Bolt Removal down (Fig. 9-16).
A. Flange Mounting Bolt (18) B. Locknut and Washer (18)
C. Mounting Flange
6. Using the hoist, lift the swing jaw assembly straight up

until the bearing mounting flanges clear the crusher frame
(Fig. 9-15). Move the swing jaw assembly slightly forward
toward the stationary die until it is hanging straight down.
Figure 9–16. Swing Jaw Support
9–10 04/17
Eccentric Shaft Bearing Removal 4. Attach a grease gun to the fitting and pump grease into the
shaft until grease begins to flow between the bearing inner
Main Frame Bearing Removal race and the shaft.
1. Remove the main frame bearing spacer and seals from the 5. Fabricate a bearing removal tool using four Grade 8
eccentric shaft (A, Fig. 9-17). threaded rods, a metal plate and a hydraulic jack or portable
power unit (Fig. 9-19). Thread the 4 rods into the face of the
2. Remove the 8 hex head capscrews (C, Fig. 9-17) and main bearing flange spacing the rods evenly around the
washers holding the main frame bearing retainer to the main circumference of the flange. Suspend the plate from a hoist
frame bearing housing (B, Fig. 9-17). Remove the bearing and install the rods through the plate, securing with nuts on
retainer from the shaft. the rods.
B E
Figure 9–17. Bearing Spacer and Retainer Removal B C

A. Bearing Spacer B. Main Frame Bearing Retainer
C. Hex Head Capscrew (8)
3. Remove the threaded plug from the first journal step on

the eccentric shaft and install a grease fitting (M10 x 1.5
A
threads) into the threaded hole in the shaft (Fig. 9-18).
Figure 9–19. Main Frame Bearing Removal 9
A. Hydraulic Jack B. Reinforced Metal Plate
C. Threaded Rod (4) D. Bearing Housing
E. Bearing
! WARNING
Always wear safety glasses or a safety shield
during bearing removal procedures. Parts may
break and be ejected with tremendous force
when removing bearings. To prevent serious
personal injury, remain a safe distance from the
bearings and the removal tools while force is
bring applied.
Figure 9–18. Grease Fitting Location
04/17 9–11
6. Install the portable power tool or hydraulic jack between

the end of the eccentric shaft and the metal plate (Fig. 9-19).
Apply enough force to hold the jacking unit in position. Step
back a safe distance from the bearing and puller and slowly
apply hydraulic pressure to the bearing and bearing housing.
As the hydraulic shaft extends, verify that the bearing has
unseated and is moving off the shaft. If the force of removing
the bearing shows signs of bending the metal plate, it may be
necessary to use a thicker plate, or weld reinforcing straps in
a V-pattern across the face of the plate. Figure 9–20. Bearing Removal From Housing
7. If the hydraulic jacking device does not have sufficient 9. If the bearing will be reused, make certain that a soft
cylinder travel to remove the bearing in one stroke, it may be surface is provided beneath the bearing where it will drop out
necessary to relocate the metal plate inward and repeat the of the housing to prevent bearing damage. Heat the bearing
jacking process until the bearing assembly can be removed housing with a torch (Fig. 9-20), moving around the housing
completely from the shaft journal. When the bearing to heat the area beneath the mounting flange uniformly until
assembly reaches the first step on the shaft, attach a lift the bearing drops out.
harness to the bearing housing and remove the assembly from
10. Repeat steps 1 through 9 to remove the second main frame
the shaft.
bearing/housing from the eccentric shaft.
8. Lower the bearing assembly onto blocking with the open
end of the bearing housing facing down (Fig. 9-20). Eccentric Shaft Removal from Housing
Removing the eccentric shaft from the swing jaw is necessary
! CAUTION to gain access to the swing jaw bearings. Remove the shaft
When tipping the bearing housing onto its face, and bearings as a unit as follows.
be aware that the bearing assembly could slide 1. Remove the outer seal (H, Fig. 9-21), the bearing spacer
out of the housing if the bearing is worn/ (G) and the inner seal (F) from both sides of the eccentric
damaged or a loose fit in the housing bore. shaft.
D
E
C
9 A F
G
Figure 9–21. Eccentric Shaft Seal and Bearing Retainer Removal

A. Capscrew and Washer (8) B. Eccentric Shaft C. Swing Jaw D. Swing Jaw Bearing
E. Bearing Retainer F. Inner Seal (350 mm) G. Spacer H. Outer Seal (350 mm)
9–12 04/17
3. Thread two lift eyes (M24 x 3.0 threads) into the flywheel 5. Attach one lift hoist and chain to the pulling end of the
(expansion) end of the eccentric shaft and attach a chain shaft (Fig. 9-23).
puller to the eyes (Fig. 9-22).
4. Have two hoists and chains of sufficient capacity to
support the shaft assembly at both the center and the end
ready for use. Install a blocking device between the swing jaw
housing and a solid object to prevent the swing jaw from
shifting during the pulling operation (Fig. 9-22).
Figure 9–23. Shaft Lift Hoist Arrangement

6. Heat the swing jaw housing around the circumference of
both swing jaw bearings to approximately 71oC (160oF) to
77oC (170oF). Move around the complete circumference of
Figure 9–22. Shaft Pulling Arrangement the housing with an acetylene torch directly above the swing
jaw bearings (Fig. 9-24). Use a heat gun to check the swing
jaw housing temperature.
Expansion Thrust
9
Figure 9–24. Swing Jaw Housing Heating Areas
7. Apply a small amount of lift tension to the lift chain (Fig.
9-23) to remove swing jaw weight from the swing jaw bore.
04/17 9–13
• Excessive bearing clearance

IMPORTANT: Maximum radial clearance mounted: 0.280 mm (0.0110”)
It is necessary to immediately begin the pulling Maximum radial clearance not-mounted: 0.370 mm
operation when the swing jaw housing has been heated (0.0146”)
to the correct temperature. A delay in beginning the pull • Corrosion
of the swing jaw assembly could allow heat to begin to
transfer to the bearing assemblies. • Spalling or pitting
8. Slowly pull the eccentric shaft and swing jaw bearing • Out-of-round races
assemblies out of the swing housing until both the thrust and 13. If the bearings appear worn or damaged or other problems
expansion side bearings have unseated from their bores in the are suspected, replace the bearings. Remove the bearings
housing and the approximate center of the shaft is exposed. from the shaft as described in the following paragraph of this
Attach the second lift chain at the center of the eccentric shaft chapter.
14. If the shaft and bearings will be stored for a prolonged
period: Coat the bearings and all shaft surfaces with heavy
oil. Wrap both bearings and the shaft in waterproof paper.
Store the entire assembly in a clean dry place until needed for
re-installation.
Swing Jaw Bearing Removal

1. Remove the threaded plug from the second journal step on
both ends of the eccentric shaft (Fig 9-26). Install grease
fittings (M10 x 1.5) in threaded holes.
A
Figure 9–25. Center Lift Chain Location
9. When both bearings are unseated, make certain the thrust
side bearing that remains in the housing is suspended so it is E B
floating in the housing and is not touching the swing jaw
housing at the circumference or face of the bearing.
10. Reheat the expansion side bearing housing to
approximately 71oC (160oF) to 77oC (170oF). Immediately
9 align the thrust side bearing in the expansion side bore and
use the puller to withdraw the eccentric shaft assembly from
C
the swing jaw housing.

D
NOTE:
Figure 9–26. Bearing Grease Fitting Location
It may be necessary to reposition the center lift chain
A. Grease Channel B. Threaded Plug
and/or use support blocking as needed to maintain even C. Bearing D. Swing Jaw Housing
support of the shaft during removal. E. Eccentric Shaft
11. When completely removed from the housing, lower the 2. Install eyebolts on one end of the eccentric shaft and stand
eccentric shaft onto blocking or fixtures of sufficient capacity the shaft on one end supported by cables or slings inserted in
to support the assembly. the eyebolts (Fig. 9-27).
12. Carefully inspect both swing jaw bearings for the
following signs of wear or damage:
• Obvious wear such as worn through plating or
discoloration of rollers and races
9–14 04/17
3. Install wood blocking around the base of the shaft to the

level of the first journal step to prevent the bearing from IMPORTANT:
dropping to the ground when released. Do not apply heat to any ungreased surface. Do Not use
a cutting torch to apply heat.
9. Lift the eccentric shaft free of the bearing and reverse
A
shaft to remove the remaining bearing.
! CAUTION
Allow removed bearing to cool before handling if
heated during the removal process.
Figure 9–27. Swing Jaw Bearing Removal

A. Lift Eyes B. Swing Jaw Bearings
C. Eccentric Shaft D. Wood Block
4. Apply grease to the grease fitting on the lower bearing

until grease is visible around the complete circumference of
the shaft/inner race junction.
! CAUTION
The bearing assembly may drop down suddenly
during the following removal steps. Never place
any part of the body (hands, feet etc.) between
the lower bearing race and the blocking. Failure
9
to comply could lead to serious personal injury.
5. Apply light blows to the top side of the inner bearing race
with a wooden block and a hammer to move the bearing down
the shaft.
6. If the bearing will not come free from the journal using
the grease pressure and hammer method, it may be necessary
to apply some heat to the inner race.
7. Prior to applying any heat, coat all surfaces of the bearing
with heavy grease.
8. Carefully heat the inner bearing race with a rosebud type
heating torch or a welding torch. Continuously move around
the race and apply more grease if needed during heating. The
bearing and inner spacer should drop down onto the blocking
when heated sufficiently.
04/17 9–15
Eccentric Shaft Bearing Installation
Swing Jaw Bearing Installation

1. Place the new or refurbished eccentric shaft on suitable
supports that will prevent the shaft from shifting during
component installation.
2. Be sure that all machined surfaces of the shaft are
completely free of grease and dirt. Remove any nicks, burrs
or scratches with a grinder or emery cloth.
3. Using a micrometer, measure the diameter of the shaft
journals on which the swing jaw bearings will be installed.
The diameter of each shaft journal must be between 300.08
mm and 300.13 mm (11.814 to 11.816 in.).
4. Using a feeler gauge, check the clearance between the top
roller and the outer race on each bearing before installation.
Clearance must be within 0.28 to 0.37 mm (0.0110 to 0.0146
in.).
NOTE: Repeat steps 5 through 11 for both ends of Figure 9–28. Swing Jaw Bearing Installation
shaft. Heat and install bearings one at a time.
8. Assemble a blocking device (Fig. 9-29) using a metal bar
5. Heat the bearing inner race to between 93° and 104°C threaded into the end of the eccentric shaft and two 2x4s.
(200 to 220 degrees °F) using an induction heater. If an Tighten the blocking until the 2x4s are tight against the
induction heater is not available an oil heater may be used. If bearing inner race.
an oil heater is used, slowly bring the oil up to the required
temperature to ensure even heating. Do not allow oil
temperature to exceed 107°C (225°F).
6. Suspend the bearing in a cable or place it in a basket so
that it does not contact the bottom of the oil bath. Direct heat
may permanently damage the bearing.
IMPORTANT:
The following steps must be performed quickly to
9 prevent the bearing from cooling and seizing before it is
fully installed on the shaft. Review the installation steps
before removing the bearing from the heater.
! WARNING
The bearing will be extremely hot when removed
from the bearing heater or oil. Make certain all
personnel involved in the installation have heat
resistant clothing before beginning installation.
Figure 9–29. Blocking Swing Jaw Bearings
Failure to wear heat (and oil resistant) garments
could cause severe burns. 9. Allow the bearing to cool with blocking in place.
Approximately 30 to 60 minutes will be required, depending
7. Remove the bearing from the heater and carefully slide
on bearing temperature. Remove the blocking after the
onto shaft using a sling or hook to lift the bearing (Fig. 9-28).
bearing has cooled.
Make certain that the bearing seats fully against the shaft step.
10. Using a feeler gauge, check the clearance between the top
roller and the outer race on each bearing. Clearance must be
within 0.28 to 0.37 mm (0.0110 to 0.0146 in.).
9–16 04/17
11. Using a feeler gauge, check the clearance between the 2. Using a micrometer, check the inside diameter of the bore
inner race of the bearing and the step on the shaft (Fig. 9-30). on both sides of the swing jaw (Fig. 9-31). Make two
There should be no clearance at this point. measurements 90 degrees apart in each location. Verify that
all measurements are between 499.95 and 499.99
millimeters. (19.683 to 19.685 in.).
Figure 9–30. Race to Shaft Step Clearance Check

Figure 9–31. Checking Swing Jaw Bore I.D.
12. Repeat the installation process for the remaining swing
jaw bearing. 3. Install bearing stop fixture plate pn #1059330 on the
swing jaw expansion side housing with four (4) capscrews.
13. When both bearings have completely cooled, remove the The fixture plate will act as the bearing stop as the eccentric
bearing stop apparatus and prepare the swing jaw housing for shaft assembly is pulled into the housing and provide 1.00
eccentric shaft installation. mm (0.039 in.) clearance when the stop fixture plate is
removed and replaced with the bearing retainer plate.
Eccentric Shaft Installation in Swing Jaw
The installation of the eccentric shaft into the swing jaw
housing will require an overhead hoist with two lift chains of A
sufficient capacity and a chain puller arrangement similar to
what was used to pull the eccentric shaft from the housing.
1. Remove any dirt or grease from the machined surfaces of
the swing jaw bore. Check all machined surfaces for nicks,
burrs or scratches. Remove with emery paper or a stone if 9
present.
Figure 9–32. Bearing Stop Fixture

A. Bearing Stop Fixture Plate B. Mounting Capscrew (4 places)
04/17 9–17
IMPORTANT:
Be sure that both bearings have fully cooled before
continuing with the following steps:
4. Attach a double lifting chain to the center balance point of
the shaft assembly (Fig. 9-33). Thread lift eye bolts into both
ends of the eccentric shaft.
Figure 9–34. Heating Housing Bores
! CAUTION
In the following steps personnel will be working
with and around heated components. Proper
heat resistant safety gear should be worn to
prevent burns if inadvertent contact is made with
Figure 9–33. Center Lift Chain heated components.
5. Horizontally suspend the shaft assembly using an 8. When both bores are properly heated, align the first
appropriate lifting device. Align the leading end of the shaft bearing outer race with the swing jaw bore opening (Fig 9-
with the opening of the swing jaw bore. Refer to Chapter 2 for 35). Coat the swing jaw bearing bores with clean oil.
shaft assembly weights.
9. Check alignment with a T-Square at four locations, 90
6. Coat the swing jaw bearings with clean oil. degrees apart (Fig. 9-35) as the bearing face first enters the
swing jaw housing bore. Adjust the shaft if necessary to
square up housing.
! CAUTION
Do not overheat swing jaw bores in the following
9 step. Overheating can expand the length of the
bore which can lead to bearing seating problems
as the unit cools. A temperature measuring
device must be used in the following sequence.
7. Heat both swing jaw housing bores to 71oC to 76oC
(160oF to 170oF) using a rosebud torch (Fig 9-34). Keep torch
head 3 feet from end of each bore to prevent hotspots and
move the torch around the inner circumference of the bore to
allow heat to penetrate gradually. Use a heat gun to check
temperature periodically.
Figure 9–35. Checking Bearing Alignment

10. Guide the first bearing through the bore until the end of
the eccentric shaft emerges on the far side (bearing stop plate
side) of the housing.
9–18 04/17
11. Block up the end of the shaft that is outside the swing jaw
housing and remove the double lift chain from the center of
the eccentric shaft. Attach one chain to the lift eyes at each
end of the shaft. Attach the pulling device (Fig. 9-23) to the
lift eyes in the eccentric shaft.
12. Support the shaft at both ends with the lift chains and
remove the blocking from the shaft. Immediately begin to
draw the shaft assembly through the bore using the puller.
Monitor both bearings to make certain they are square in the
housing as the pulling operation begins (Fig. 9-36). Continue
to pull the shaft, until the first bearing bottoms on the bearing
stop fixture (Fig. 9-32). Remove the pulling device.
Figure 9–37. Shim Location and Installation

15. When the entire assembly has cooled to room
temperature, check the following:
Figure 9–36. Second Bearing Alignment • Check alignment of the outer bearing race with the inner
13. Move to the other side of the housing (without bearing race. If the radial clearance is not correct it will be
stop plate). Rotate or rock the eccentric shaft back and forth necessary to realign the races. (Refer to Swing Jaw
several times to help center the bearings. Bearing Race Alignment).
14. Insert two (2) brass shims 180 degrees apart on the • Use a feeler gauge to check the radial bearing clearance.
bearing. Matched shims in the range from 0.381 mm to 0.508 Clearance should be in the range from 0.28 to 0.37 mm 9
mm (.015” to .020”) should be used. Use the largest set of (0.011” to 0.0146”).
shims that the bearing will accept. The shims should be 16. If clearances are within tolerance, continue to assemble
inserted at the 3 o’clock and 9 o’clock position between the the swing jaw.
thrust side bearing rollers and the outer race (Fig. 9-36).
Rotate the eccentric shaft several turns to allow all rollers to 17. Remove the bearing stop fixture from expansion side of
run over the shims. This helps work the outer race towards the swing jaw. Replace bearing stop fixture with retainer plate.
end of the swing jaw bore. Leave the shims in place for 30 Install retainer plate (A, Fig. 9-38) on the swing jaw housing
minutes as the assembly cools and then remove. with eight (8) capscrews and washers. Use a medium thread
locker (Loctite #242) on the retainer bolts and torque to 571
Nm (425 Ft. lbs). Repeat the retainer plate installation on the
opposite side of the swing jaw housing.
18. Install set screw (M10 x 1.5 x 12 lg.) in the threaded
grease hole (Fig. 9-18).
04/17 9–19
Swing Jaw Bearing Race Alignment
A D If the swing jaw bearings have less than minimum radial

clearance when the unit has cooled (Step 15), it will be
necessary to reduce preload effect to prevent premature
bearing wear or overheating. The position of the outer races
C can be manipulated by realigning the swing jaw housing in
relation to the outer bearing race as follows:
1. Install four (4) threaded rods (equally spaced around the
circumference) into the face of the swing jaw housing using
the threaded holes that are used for mounting the bearing
retainer plate. The rods must be long enough to reach past the
end of the eccentric shaft by several feet.
2. Secure a fixture plate (or a metal plate with four holes
drilled for the threaded rods) to the end of the rods by
installing nuts and washers on the threaded rods. Install a
hydraulic jack or portable power unit between the end of the
B eccentric shaft and the steel plate (Fig. 9-39).
3. Apply hydraulic pressure and pull the swing jaw housing
and upper bearing race back into alignment. Release
hydraulic pressure and remove the jack (Fig. 9-39).
Figure 9–38. Seal and Retainer Installation
A. Bearing Retainer Plate B. Bearing Spacer
C. Outer Seal (350 mm) D. Bearing Retainer Capscrew (8)
19. Install a 350 mm seal on the inner step of the bearing Expansion
spacer and a 350 mm seal on the outer step of the spacer (Fig. Side
9-38). Completely pack the area above the seals on the spacer
with NLGI #2 grease. Use a putty knife to make certain the
gap above the seal is completely full of grease.
20. Slide the spacer/seal assembly onto the shaft. Repeat the
seal and retainer installation on the opposite side of the shaft.
Figure 9–39. Bearing Race Alignment

4. Rock the shaft back and forth several times to center the
inner races in the bearings. Check both the bearing race
alignment and the radial clearance again.
9–20 04/17
5. If the bearing races are now aligned, move back to the

other side of the swing jaw housing and check that the upper
bearing race to swing jaw housing measurement is still 1.00 B
A
mm (0.039 in). Note: It will be necessary to remove the
bearing retainer plate to check the bearing race/housing
dimension (D, Fig. 9-40). If the bearing to housing face
clearance is correct, check the bearing radial clearance.
C
D
C
Figure 9–41. Seating Main Frame Bearing In Housing

A. Main Frame Bearing Housing B. Main Frame Bearing
Figure 9–40. Bearing Race to Housing Dimension C. Bearing Stop
A. Swing Jaw Housing B. Outer Bearing Race

C. Eccentric Shaft D. Measure Dimension At This Point NOTE:
6. If the outer (upper) bearing race does not have the Before attempting to install the main frame bearing
required 1.00 mm (.039”) clearance with the outer face of the assembly on the eccentric shaft, check the shaft
swing jaw housing, or radial clearance is incorrect, it will be condition. Make certain all high spots are polished off
necessary to move the hydraulic/fixture plate assembly to the with an emery cloth, and check that all machined
thrust side. Pull the thrust side outer race out to re-align the grooves or keyways in the shaft do not have high edges
expansion side bearing outer race. or burrs. Use a stone or file to remove any
imperfections.
Main Frame Bearing Installation 4. Heat the bearing and housing assembly to 120oC to 138oC
Heat the main frame bearing mounting bore to 4oC (40oF) (250oF to 280oF). DO NOT exceed 149oC (300oF).
1.
greater than the current ambient temperature. 5. Install a bearing strap tool with handles around the
9
machined portion of the bearing housing (Fig. 9-42). This
! CAUTION will provide lift points and non-heated handles to aid in
alignment of the heated bearing assembly.
In the following steps personnel will be working
around and with heated components. Proper
heat resistant safety gear should be worn to
prevent burns if inadvertent contact is made with
heated components.
2. Place the heated main frame bearing housing face up on a
work surface. Oil the heated bore of the housing.
3. Lower the main frame bearing down into the housing. Use
a soft faced mallet on the outer race if necessary to fully seat
the bearing in the housing bore. When bearing is fully seated
at the bottom of the bore, install a bearing stop (C, Fig. 9-41)
to prevent the bearing from moving as the housing cools.
04/17 9–21
D
B
C A
Figure 9–43. Blocking Main Frame Bearing

A. Inner Bearing Race B. Wood Blocking
C. Face Bar D. Grease Plug
9. If the eccentric shaft grease plugs (D, Fig. 9-43) were not
fitted in the grease channels previously, install them at this
time.
A
Installing Swing Jaw In Main Frame

Figure 9–42. Main Frame Bearing Assembly When the main frame bearing assemblies have cooled
Installation completely and the bearing blocking assemblies are removed,
A. Main Frame Bearing Housing B. Eccentric Shaft install the swing jaw in the 3450 frame as follows:
C. Bearing Strap Tool
Install the swing jaw as described in the following procedure.
6. Oil the eccentric shaft at the bearing race mounting point Refer to figures as indicated.
before beginning to mount the bearing.
1. Using an appropriate cleaning solvent, completely
7. Lift the bearing assembly up into position with a hoist remove any rust preventative coating, grease, paint
(Fig. 9-42) and quickly (before assembly cools) slide it back overspray, dirt, corrosion etc. from the unpainted machined
on the shaft until it is fitting flush against the bearing spacer surfaces of the swing jaw mounting saddles (Fig. 9-44).
9 (B, Fig. 9-38) installed previously.
8. Install bearing blocks and a face bar at the end of the
eccentric shaft to hold the inner bearing race in place on the
shaft until it cools (Fig. 9-43). Repeat steps 1 through 8 to
install the main bearing assembly on the other side of the
eccentric shaft.
Figure 9–44. Swing Jaw Frame Mounting Saddles
2. After removing any contamination or rust preventative

coating, verify that there are no nicks, burrs, scratches or
damage on the machined surfaces of the frame.
9–22 04/17
4. Slowly lower the swing jaw into the center of the crusher.
! WARNING When the swing jaw is approximately 1/2 depth in the frame,
The complete 3450 swing jaw/die assembly without maneuver the swing jaw directly over the frame mounting
flywheels weighs approximately 9950 Kg (21,935 saddles (Fig. 9-46). Make certain the main frame bearing
Lb.). Always use suitable rigging and hoisting assembly mounting flanges are aligned outside the frame.
equipment to stabilize and lift heavy objects. Lifting
heavy components with inadequate hoisting
apparatus can damage machinery and may result in
serious personal injury or death. Refer to Chapter 2
for actual weight of components. Never attempt to
lift the jaw assembly by slinging around the bearing
housings or the flywheel shafts. Lift only at the lift
eyes built into the upper casting as shown in Figure
9-44. Failure to lift the swing jaw at the correct
points could result in damage to the jaw assembly
or crusher frame.
3. Using a suitable lifting device, carefully lift the swing jaw

at the two lift eyes cast into the top of the bearing housing
(Fig. 9-45) and suspend it over the crusher frame opening.
Make certain that the swing jaw die faces toward the
stationary jaw die. Position the swing jaw assembly over the
center of the frame with the bearing assemblies forward of the
frame mounting saddles.
Figure 9–46. Positioning Swing Jaw in Frame

5. As the jaw assembly begins to seat on the frame, slide two
mounting bolts through the bearing flange mounting holes
and into the frame on each side of the unit to help align the
9
unit with the crusher frame. It may be necessary to align the
flange holes using a hardened drift while maintaining some
tension on the lift hooks before bolts can be fully inserted.
6. When the swing jaw unit is completely seated on the
frame mounting saddles, and at least four mounting bolts can
be installed with no interference on each side of the unit, the
tension can be released from the lift hooks. Remove the
lifting lugs and lift chains at this time.
7. Install all nine mounting bolts on each side of the frame
with a washer on the head of the bolt (Fig. 9-47). Coat the
threads of mounting bolts with high strength thread locker
(10T77). Install a wedge lock washer and the hex nut on all
mounting bolts and hand tighten.
Figure 9–45. Lifting the Swing Jaw Assembly
04/17 9–23
Flywheel Installation
Sheave Flywheel Installation
1. Install a lift sling or chain and a hoist of sufficient
capacity to the sheave (grooved) flywheel (flywheels weigh
approximately 1243 Kg (2741 Lb.)). With the flywheel
supported and standing on end, drive wedges into the hub
splits at both the front and back of the hub (Fig. 9-49).
A
A
B A
C
Figure 9–47. Bearing Mounting Flange Hardware C
A. Mounting Bolt (18) B. Wedge-Lock Washer (36)

C. Hex Nut (12)
B
8. Using a torque multiplier tool (Fig. 9-48), torque each
mounting bolt to a final torque of 2745 Nm (2043 Ft. lb.).
Work in a cross pattern alternating from one side to the other
on the crusher until all fasteners hold the final torque value. B
NOTE:
Failure to properly torque mounting bolts could result in
loosening of the bearing mounting to frame connection
which will cause damage to machine parts.
Figure 9–49. Installing Flywheel Wedges
A. Lift Chain B. Hub Wedge (4)
C. Rotation Arrow
! WARNING
9 equipment to stabilize and lift heavy objects.
may result in serious personal injury or death.
2. Make certain the flywheel weight is facing in (towards the
crusher). Lift the flywheel up and align with the end of the
eccentric shaft. Slide the flywheel back onto the eccentric
shaft until it contacts the spacer.
NOTE:
Figure 9–48. Torquing Mounting Flange Bolts If the flywheel is difficult to slide on the last portion of the
shaft, it may be possible to pull it down with the end cap.
9. Install the grease lube lines at both the swing jaw and
After the drive key is installed in the keyway, finish
main frame bearings (Fig 9-11) when the swing jaw is
seating it on the shaft by drawing down the end cap
completely mounted.
fasteners.
10. Reinstall the hydraulic adjusting assembly as detailed in
the Hydraulic Adjustment Assembly Service in this chapter.
9–24 04/17
3. Align the flywheel with the shaft keyway and install a HYDRAULIC ADJUSTING ASSEMBLY
new key (Fig. 9-50). SERVICE
The hydraulic adjusting assembly removal method will be
dictated by clearances beneath the H3450 crusher. If your
application has sufficient clearance to lower the unit and pull
it out from beneath the back of the crusher, this method is
suggested. If clearances are not available to lower the
hydraulic unit, it is also possible to extend the swing jaw fully
and tilt the hydraulic unit slightly as it is lifted out of the
crushing chamber from the top. If your application has a
discharge conveyor with forward/reverse operation and the
capacity and width to hold the hydraulic adjuster, it may also
be possible to remove and replace the assembly using the
conveyor.
Hydraulic Adjustment Assembly Removal

Figure 9–50. Key Installation 1. Lockout/tagout power to the crusher drive motor and to
4. When the flywheel is correctly aligned, install the the crusher hydraulic system before beginning any service
flywheel retainer on the end of the eccentric shaft. Coat the work.
retainer bolts with medium thread locker (10H50) and torque 2. Disconnect the electrical connector at the position sensor
to 1145 Nm (845 Ft. Lb.) in an alternating pattern. (A, Fig. 9-51). Disconnect position sensor bracket and
5. Remove the hub wedges from the front and rear of each linkage to prevent damage during handling (Fig. 9-50).
hub split. Install the four flywheel retaining capscrews down Disconnect the linkage from the cylinder rod toggle end (B,
through the hub. Coat the threads with medium thread locker Fig. 9-50). Unbolt the two bolts holding the bracket to the
(Loctite #242) and install the flatwashers and locknuts side of the hydraulic assembly (C, Fig. 9-50) and lift the
torquing in a cross pattern to 571 Nm (425 Ft. Lb.). complete assembly with linkage off the crusher.
Pulley Flywheel Installation

Install the pulley flywheel using the same sequence as step 1
through 5 for the sheave flywheel installation. Complete the B
installation by removing the hub wedges and installing the
flywheel retaining capscrews. Use medium thread locker
(Loctite #242) and install the flatwashers and locknuts
torquing in a cross pattern to 571 Nm (425 Ft. Lb.). 9
A
Figure 9–51. Disconnect Sensor Linkage

A. Step 1: Disconnect sensor cable at Connector
B. Step 2: Disconnect linkage at this point
C. Step 3: Remove bracket mounting bolts
04/17 9–25
NOTE:
On 3450 Model Hydra Jaw crushers it is necessary to remove
the torque tube located between the main frame walls prior to H3450
removing the hydraulic adjustment assembly. Refer to Fig. 9-

4 and follow the torque tube removal instructions earlier in
this chapter.
3. Attach a hoist and sling of sufficient capacity (Fig. 9-52)
around the cylinder body of the adjusting assembly to hold
the assembly from dropping during the following removal
steps. Failure to support the assembly could result in the
hydraulic adjust cylinder falling down prior to removal. C
B
B D E F

Figure 9–52. Hydraulic Adjusting Assembly Lift Sling A. Startup Selection Screen B. Setpoint Selection Screen
A. Lift Strap B. Relief Manifold C. Step #1 Press Once D. Step #2 Press and Hold
C. Hydraulic Cylinder E. Step #3 Press Once F. Step #4 Press and Hold
7. Remove the upper & lower jam nuts, the upper spring cap
9 ! WARNING and the spring from all four spring tension assemblies on the
hydraulic adjust assembly (Fig. 9-54).
The hydraulic assembly and swing jaw will move
during the following steps. To prevent serious 8. Remove the lower spring retainer from all four tension
personal injury, be sure no personnel are on, spring pockets (Fig. 9-54) and allow the tension pins to swing
inside or under the crusher before restoring down out of the adjuster assembly.
power and activating the hydraulic functions.
9. Return to the Setpoint Selection Screen (B, Fig. 9-53) and
4. Restore power to the hydraulic control panel. Start the extend jaw using the CLOSE SETPOINT Key (F, Fig. 9-53)
hydraulic pump. until lockout pins can be inserted to support the swing jaw (B,
Fig. 9-55).
5. From the Startup Selection screen (Fig. 9-53), press the
SETTINGS key once (C, Fig. 9-53) to access the Setpoint
Selection Screen. From the Setpoint Selection Screen, press
and hold the OPEN SETPOINT Key (D, Fig. 9-53) until the
swing jaw has completely retracted.
6. When the jaw is fully open, release the Open Setpoint
Key, and then press the OK key once. This will hold the jaw
in the Open position.
9–26 04/17
C D
E
H
F
G
B TYPICAL 4 PLACES
9
A
Figure 9–54. Tension Spring Removal

A. Swing Jaw Toggle Seat B. Tension Pin (4)) C. Rod Side Toggle End D. Lower Spring Retainer (4)
E. Tension Spring (4) F. Upper Spring Cap (4) G. Lower Jam Nut (4) H. Upper Jam Nut (4)
I. Hydraulic Cylinder J. Fixed Toggle Seat K. 3450 Frame L. Swing Jaw Assembly
04/17 9–27
C B
Figure 9–55. Install Swing Jaw Locking Pins

A. Step 1: Extend Hydraulic Adjust Cylinder B. Step 2: Install Lock-Out Pin on each side of jaw.
10. Retract the hydraulic cylinder fully (Fig. 9-56) using the 11. Lockout/Tagout power to the control panel.
#2 Function Key on the Setpoint Screen (D, Fig. 9-53). The
toggle wear bar should now disengage from the swing jaw
toggle seat. CAUTION: The hydraulic adjust assembly will
now be supported only by the lift strap.
Figure 9–56. Hydraulic Adjust Cylinder Retract
9–28 04/17
12. Lockout power to hydraulic power unit. Depressurize the

hydraulic adjust assembly as detailed in Chapter 6. NOTE:
If your 3450 application has sufficient room beneath the
! WARNING crusher to extract the hydraulic assembly from below, it
may be possible to lower the assembly and remove it
F a i l u r e t o L o c k o u t / Ta g o u t p o w e r a n d
from under the crusher. Refer to Hydraulic Adjustment
depressurize the hydraulic adjust assembly
Assembly Service in this chapter for additional
before attempting to remove hydraulic hoses or
detailed service and installation/removal instructions.
remove the adjuster assembly could result in
13. Disconnect the hydraulic hoses (3) at the relief manifold
on top of the hydraulic adjusting assembly noting the position
of the lines (Fig. 9-57). Disconnect the electrical connector at
the position sensor.
Pull-Alo
ng
Figure 9–58. Positioning Swing Jaw

A
Figure 9–57. 3450 Hydraulic Line Disconnection

A. Hydraulic Adjusting Cylinder B. Hydraulic Pressure Lines (2)
C. Hydraulic Relief Line Port 9
14. Attach a chain and come-along puller or hoist to the
bottom swing jaw eyes (Fig. 9-58). Pull the swing jaw fully
forward until it contacts the stationary die to provide
additional room for the hydraulic adjuster assembly removal.
15. Maneuver the hydraulic adjusting assembly so the toggle
wear bar slides out of the fixed toggle seat bolted to the frame
(J, Fig. 9-54). Tilt the back of the hydraulic adjust assembly
(the end removed from frame toggle seat) up and carefully lift
the assembly up out of the 3450 frame.
04/17 9–29
Hydraulic Adjuster Component Replacement Toggle End Replacement

The hydraulic adjuster assembly (Fig. 9-59) can be Both the stationary toggle end attached to the hydraulic
disassembled to replace the toggle wear bars, the toggle ends cylinder body, and the cylinder rod toggle end attached to the
and the hydraulic relief manifold. Telsmith supplies o-rings cylinder rod can be removed from the hydraulic assembly to
as spare parts that will allow you to replace internal seals on allow the hydraulic cylinder assembly to be serviced. Note
the cylinder assembly. If internal cylinder repairs to the ram that the cylinder rod toggle end is a shrink fit and must be
or seals are required, Telsmith suggests that these type of removed using heat.
repairs be carried out by a qualified hydraulic repair facility.
! CAUTION
Toggle Wear Bar Replacement
Personnel will be working with and around
1. Toggle wear bars (and possibly the matching toggle seat heated components in the following removal
end) are worn to replacement depth when only 6.35 mm (1/4”) s t e ps . P r o p e r h e a t r e s i s ta n t s a f e t y g e a r
of clearance remains between the face of the toggle end and including gauntlets and an apron should be
the leading edge of the toggle seat (Fig. 9-59). worn to prevent burns if inadvertent contact is
2. Remove the four hex head capscrews and flatwashers made with heated components.
holding each wear bar retainer (A, Fig. 9-59) in the toggle
end. Cylinder Rod Toggle End Replacement
3. Slide the toggle wear bar out of the toggle end and inspect 1. Remove the eight socket head capscrews (D, Fig. 9-59)
for major wear or damage. Wear bars that are bent, cracked or from the face of the cylinder rod toggle end (N, Fig. 9-59).
missing pieces should be replaced. Wear bars that have worn
in length to allow less than the 6.35 mm (1/4”) of clearance NOTE:
(Fig. 9-58) must be replaced with a new bar.
Cylinder rod toggle end capscrews were assembled
4. Install a new wear bar in the toggle end (Fig 9-59) after with high strength thread locker. It may be necessary to
inspecting the condition of the toggle seat. Toggle seats that use heat when removing the eight (8) socket head
are extremely worn or dished out should be replaced as a capscrews in Step 1.
matched set with a new toggle wear bar.
2. If a portable hydraulic power unit is available attach it to
5. Coat the threads on the retaining bar mounting hex head the hydraulic inputs on the hydraulic manifold (P, Fig. 9-59).
capscrews (G, Fig. 9-59) with medium strength thread locker. Fully extend the cylinder with hydraulic pressure and install
Align mounting eyes on the new wear bar with the matching hardwood blocks or bar stock between the stationary toggle
cutouts in the toggle end and install the four retaining bar end (E, Fig 9-59) and the cylinder rod toggle end (N, Fig. 9-
capscrews w/washers through the toggle end and thread into 59) on both sides of the cylinder assembly.
each retaining bar. Torque to 330 Nm (365 Ft. lbs).
3. Heat the cylinder rod toggle end at the round cylinder seat
9 portion of the casting with a torch. When the toggle end
reaches 121oC (250oF) quickly use the hydraulic pressure
device to retract the piston rod from the toggle end before
heat transfers to the cylinder rod (Fig. 9-60).
9–30 04/17
I I
H
P A
N
L B
M
K D
G F
E G
A
F
O
A B F
G
J
G
F
D
C
9
Toggle Wear Bar New Dimension

12.7 mm (1/2 in.)
Figure 9–59. Toggle Cylinder Components

A. Wear Bar Retainer (4) G. Hex Head Cap Screw (8) M. Check Valve
B. Toggle Wear Bar (2) H. Pressure Relief Valve 4000 PSI (2) N. Cylinder Rod Toggle End
C. Wear Bar Measurement Point I. M20 Hex Bolt (8) O. Dowel Pin (2)
D. Socket Head Capscrew (14) J. Hydraulic Cylinder (16” Bore) P. Hydraulic Manifold
E. Stationary Toggle End K. Pressure Test Port
F. Washer (8) L. Pressure Test Port
04/17 9–31
4. If hydraulic pressure is not available, it will be necessary I
to manually remove the toggle end. Remove the retainers and

wear bar (B, Fig. 9-59) from the stationary toggle end, and
bolt two chains of sufficient capacity to support the hydraulic
adjuster assembly to the stationary toggle end (hydraulic
adjuster assembly weighs approximately 1629 Kg (3592 Lb.).
Lift the hydraulic adjuster assembly up with a suitable hoist
or crane and suspend approximately a foot off the ground by
the lift chains (Fig. 9-60).
! WARNING
B B
equipment to stabilize and lift heavy objects.
may result in personal injury or death. Make
certain all service personnel keep feet and hands
away from the area beneath the cylinder rod
toggle end while heating and removal is in
progress. The toggle end could separate from
the cylinder rod and drop at any time.
A
5. Heat the cylinder rod toggle end at the round cylinder seat
portion of the casting (A, Fig. 9-60) with a torch to Figure 9–60. Cylinder Rod Toggle End Removal
approximately 121oC (250oF). If the cylinder rod toggle end
A. Apply heat at this point.
does not drop down off the cylinder rod using heat only, use B. Install blocking between toggle ends if using the hydraulic
a soft faced mallet to help drive the toggle end down off the pressure removal method.
cylinder rod. Remove the lift chains and hoist after returning
the hydraulic cylinder to a suitable work stand or bench.
! CAUTION
Installation personnel will be working with and
around heated components in the following
installation steps. Proper heat resistant safety
gear including gauntlets and an apron should be
worn to prevent burns if inadvertent contact is
9 made with heated components.
6. Heat the new or replacement cylinder rod toggle end to
121oC (250oF). Square the toggle end on the cylinder rod
making certain the mounting holes in the toggle end are
aligned with the threaded mounting holes on the end of the
cylinder rod. Press the toggle end down onto the cylinder rod
until it is fully seated.
NOTE:
If the toggle end is difficult to press down fully onto the
cylinder rod, use the mounting capscrews in step 7 to
draw the toggle end down onto the rod.
7. Coat the eight capscrews (D, Fig. 9-59) with high strength
thread locker (10T77) and install with washers to fasten the
toggle end to the cylinder. Torque fasteners to 1835 Nm (1365
Ft. Lb.) in a cross pattern.
9–32 04/17
8. Allow the toggle end to cool completely on the cylinder Hydraulic Adjustment Assembly
shaft before installing further components. Replacement
9. Install a new wear bar in the cylinder rod end following 1. If you will be installing the hydraulic adjustment
the instructions in Toggle Wear Bar Replacement. assembly from the top of the crusher, pull the swing jaw fully
forward with chains and a frame mounted come-along puller
Stationary End Replacement and secure in place (Fig. 9-58). Attach a lift harness and hoist
of sufficient capacity around the hydraulic cylinder and lower
1. Remove the eight socket head capscrews (D, Fig. 9-59)
the hydraulic adjustment assembly down until it is positioned
holding the stationary toggle end (F, Fig. 9-59) to the end of
between the swing jaw toggle seat and the fixed toggle seat
the hydraulic cylinder. Support the toggle end to prevent it
on the frame.
from dropping (stationary toggle end weighs 281 Kg (619
lbs)). Remove the toggle end from the dowels (O, Fig. 9-59) 2. If you are installing the hydraulic assembly from below
on the end of the hydraulic cylinder. the crusher, move the assembly into place with a rolling
machine cart or the discharge conveyor (Fig. 9-61). Install a
lift strap of sufficient capacity to lift the complete assembly,
NOTE: around the hydraulic cylinder (Fig. 9-61).
Cylinder rod toggle end capscrews were assembled
with high strength thread locker. It may be necessary to
use heat when removing the eight (8) socket head
capscrews in Step 1.
2. If the dowels (O, Fig. 9-59) on the end of the hydraulic
cylinder are damaged or worn, remove them with locking
pliers. New dowels are a shrink fit and must be chilled to
-40oC (-40oF) before driving into cylinder holes.
3. Check the stationary toggle end for signs of dishing or
extreme wear in the wear bar seat. If the seat is dished out, it
is recommended that the toggle wear bar and toggle seat be
replaced as a set.
4. Slide a new or replacement toggle end onto the mounting
dowels on the face of the hydraulic cylinder. Hold the toggle
in place with a lift sling and hoist and install the eight socket
head capscrews (D, 9-59) through the face of the stationary
end. Coat the threads with high strength thread locker
(10T77) and torque the capscrews to 1835 Nm (1365 Ft. lbs).
5. Remove the lift apparatus and hoist. 9
6. Install a new toggle wear bar in the stationary end
following the instructions in Toggle Wear Bar Replacement.
Figure 9–61. Positioning Assembly Under Crusher

3. Pull the swing jaw fully forward with chains and a frame
mounted come-along puller (Fig. 9-58) to provide more
installation space. Lift the Hydraulic Adjuster Assembly up
with a hoist or crane of sufficient capacity and align the wear
bars between the fixed toggle seat and the swing jaw toggle
seat (Fig. 9-62).
04/17 9–33
7. Secure each tension spring in the spring pocket with a

C lower spring retainer (A, Fig, 9-64). Install the springs (B,
Fig. 9-64) in all four spring pockets.
Figure 9–62. Aligning Wear Bars With Toggle Seats A

A. Toggle Wear Bar (2) B. Cylinder Toggle End (2)
C. Lifting Balance Point D. Swing Jaw Toggle Seat
B
4. Slowly move the swing jaw back into the chamber using
the come-along. Tilt the hydraulic adjuster assembly as
necessary to line up the toggle wear bars with the toggle seats
C
on the frame and swing jaw.
D
5. When both wear bars (A, Fig 9-62) are located in the
E
toggle seats, align all four spring pockets (C, Fig. 9-63) with
the tension pin brackets on the toggle seats (B, Fig. 9-63). Figure 9–64. Spring & Spring Retainer Installation
6. Slide the toggle end of each toggle tension pin (A, Fig. 9- A. Lower Spring Retainer (4) B. Spring (4)
63) into the tension pin bracket (B, Fig. 9-63). Rotate each C. Upper Spring Cap (4) D. Lower Jam Nut (4)
tension pin up into the spring pocket (C, Fig. 9-63). E. Upper Jam Nut (4)
8. Install the upper spring cap and lower jam nut on each
spring (Fig. 9-65). Remove the chains and come-along puller
from the swing jaw.
9
C
B
Figure 9–63. Securing Tension Pins

A. Tension Pin (4) B. Tension Pin Bracket
C. Spring Pocket
9–34 04/17
A B C D
Figure 9–65. Upper Spring Cap and Lower Jam Nut

Installation
A. Lower Jam Nut B. Upper Spring Cap
C. Spring D. Lower Spring Retainer
! WARNING
Do Not over-compress the spring in Steps 9 and
10. Compressing the spring so it is coil-bound
could cause the spring to go solid during
operation. Operating with a solid spring could
lead to failure of the crusher toggle end. Always
replace a spring that will not run without
thumping when it is correctly compressed.
9. Tighten the lower jam nut until the upper spring cap just
contacts the spring and begins to compress it (Step 1, Fig. 9-
66). Take a measurement from the bottom edge of the spring
cap to the face of the lower coil (Step 1, Fig. 9-66). Compress
9
the spring until the spring cap to lower coil face distance is
one inch (25mm) less than the first measurement in Step 1.
10. Install the upper jam nuts (Step 3, Fig. 9-66) when all four
spring dimensions are correctly set. Remove the lift harness
from the adjuster hydraulic cylinder.
04/17 9–35
Measure
Uncompressed
STEP 1 Distance
STEP 3 Install Upper

Jam Nut
Set Compressed
Distance
1 inch (25 mm)
STEP 2 Less
NOTE: If thumping is heard during the test run

with the springs set to the 1 inch (25 mm)
compressed dimension in Step 2, it is
permissible to compress all four springs an
additional 0.13 in. (3 mm) to quiet the
operation.
9
Figure 9–66. Spring Compression Dimension
11. Install the three hydraulic lines to the hydraulic manifold 15. Lower the tube down between the main frame walls. If
on the adjuster assembly hydraulic cylinder (Fig. 9-57). shims were used between the tube and the walls previously,
Install the position sensor assembly and linkage (Fig. 9-51). coat the shims with heavy grease and slide them into their
original position aligning the shim mounting holes with the
12. Apply power to the crusher and check the hydraulic
pad mounting holes on the frame (Fig 9-67).
adjuster assembly and swing jaw for correct operation. Cycle
the cylinder five (5) complete times to remove any air from
the circuit before starting crusher. NOTE:
13. When the hydraulic adjuster assembly is fully installed in If shims were not used previously, and the tube is a tight
the crusher, re-install the torque tube removed from the frame fit between the frame walls, it may be necessary to use
walls earlier. a hydraulic jack to spread the walls slightly while
lowering the tube into position.
14. Attach a lift strap capable of lifting 178 Kg (393 Lb) at the
center point of the torque tube (Fig. 9-4).
9–36 04/17
16. Apply anti-seize compound to the eight hex head

mounting capscrew (A, Fig. 9-67) threads. Install the eight
cap screws with washers through the tube mounting flanges
(D, Fig. 9-67) and into the threaded mounting pads (E, Fig. 9-
67) on the crusher wall with the heads of the cap screws
facing to the inside of the crusher.
B
E
Figure 9–67. Frame Torque Tube Installation

A. Frame Torque Tube B. Hex Head Capscrew (8)
C. Washer (8) D. Tube Mounting Flange (2)
E. Mounting Pad (2)
17. Working in a crossing pattern, use a torque multiplier tool

to torque the frame torque tube mounting cap screws. Torque
the cap screws to 50% torque and then to the final torque of
2745 Nm (2043 Ft. Lbs).
18. Remove the lift harness when torque tube mounting is
complete.
04/17 9–37
9–38 04/17
Telsmith H3450 Jaw Crusher Appendix A - Torque Tables
SAE GRADES
Fastener Information SAE J429 Grade 2 SAE J429 Grade 5
Size Thread Threads Major Dia. Tensile Torque Torque Torque Torque
Type Per Inch (in) Stress Dry Lubricated Dry Lubricated
(n) Area in-lb/ft-lb in-lb/ft-lb in-lb/ft-lb in-lb/ft-lb
(in2) (Nm) (Nm) (Nm) (Nm)
1/4 UNC 20 0.2500 0.0318 66 (7.4) 49 (5.5) 100 (11.2) 76 (8.5)

UNF 28 0.2500 0.0364 75 (8.4) 56 (6.3) 120 (13.5) 87 (9.8)
5/16 UNC 18 0.3125 0.0524 11 (14.9) 8 (10.8) 17 (23.0) 13 (17.6)

UNF 24 0.3125 0.0581 13 (17.6) 9 (12.2) 19 (25.7) 14 (18.9)
3/8 UNC 16 0.3750 0.0775 20 (27.1) 15 (20) 31 (42.0) 23 (31.1)

UNF 24 0.3750 0.0878 23 (31.1) 17 (23) 35 (47.4) 26 (35.2)
7/16 UNC 14 0.4375 0.1063 32 (42.3) 24 (32.5) 49 (66.4) 37 (50.1)

UNF 20 0.4375 0.1187 36 (48.8) 27 (36.6) 55 (74.5) 41 (55.5)
1/2 UNC 13 0.5000 0.1419 49 (66.4) 37 (50.1) 75 (101) 57 (77.2)

UNF 20 0.5000 0.1600 55 (74.5) 41 (55.5) 85 (115) 64 (86.7)
9/16 UNC 12 0.5625 0.1819 70 (94.9) 53 (71.8) 110 (149) 82 (111)

UNF 18 0.5625 0.2030 78 (106) 59 (79.9) 120 (162) 91 (123)
5/8 UNC 11 0.6250 0.2260 97 (131) 73 (98.9) 150 (203) 110 (149)
UNF 18 0.6250 0.2560 110 (149) 83 (112) 170 (230) 130 (176)
3/4 UNC 10 0.7500 0.3345 170 (230) 130 (176) 270 (366) 200 (271
UNF 16 0.7500 0.3730 190 (258) 140 (188) 300 (407) 220 (298)
7/8 UNC 9 0.8750 0.4617 170 (230) 120 (163) 430 (583) 320 (434)
UNF 14 0.8750 0.5095 180 (244) 140 (190) 470 (630) 360 (488)
1 UNC 8 1.0000 0.6057 250 (339) 190 (258) 640 (868) 480 (651)
UNF 12 1.0000 0.6630 270 (366) 210 (285) 710 (963) 530 (719)
1 1/8 UNC 7 1.1250 0.7633 350 (474) 270 (366) 800 (1085) 600 (813)
UNF 12 1.1250 0.8557 400 (542) 300 (407) 890 (1207) 670 (908)
1 1/4 UNC
UNF
7
12
1.2500
1.2500
0.9691
1.0729
500 (677)
550 (746)
380 (515)
420 (569)
1,100 (1491)
1,200 (1627)
840 (1139)
930 (1260) 7F
1 3/8 UNC 6 1.3750 1.1549 660 (895) 490 (664) 1,500 (2033) 1,100 (1491)
UNF 12 1.3750 1.3147 740 (1003) 560 (760) 1,700 (2304) 1,300 (1762)
1 1/2 UNC 6 1.5000 1.4053 870 (1179) 650 (881) 2,000 (2711) 1,500 (2033)
UNF 12 1.5000 1.5810 980 (1328) 730 (989) 2,200 (2982) 1,600 (2169)
ASTM A307 Grade A ASTM A449
1 3/4 UNC 5 1.7500 1.8995 1,400 (1898) 1,000 (1355) 2,300 (3118) 1,700 (2304)
1 3/4 UN 12 1.7500 2.1873 1,600 (2169) 1,200 (1627) 2,600 (3525) 2,000 (2711)
2 UNC 4 1/2 2.0000 2.4982 2,100 (2847) 1,500 (2033) 3,400 (4609) 2,600 (3525)
2 UN 12 2.0000 2.8917 2,400 (3254) 1,800 (2440) 4,000 (5423) 3,000 (4067)
2 1/4 UNC 4 1/2 2.2500 3.2477 3,000 (4067) 2,300 (3118) 5,000 (6779) 3,800 (5152)
2 1/2 UNC 4 2.5000 3.9988 4,100 (5559) 3,100 (4203) 6,900 (9355) 5,200 (7050)
2 3/4 UNC 4 2.7500 4.9340 5,600 (7592) 4,200 (5694) 9,400 (12745 7,000 (9491)
3 UNC 4 3.0000 5.9674 7,400 (10033) 5,600 (7592) 12,000 (16270) 9,200 (12473)
Torque Coefficients Dry: 0.20

Lubricated: 0.15
04/17 A–1
Torque Tables
Alloy Socket Head Cap

Fastener Information SAE J429 Grade 8
Screws ASTM A574
Size Thread Threads Major Dia. Tensile Torque Torque Torque Torque
Type Per Inch (in) Stress Dry Lubricated Dry Lubricated
(n) Area ft-lb ft-lb ft-lb ft-lb
(in2) (Nm) (Nm) (Nm) (Nm)
1/4 UNC 20 0.2500 0.0318 12 (16.2) 9 (12.2) 14 (18.9) 10 (13.5)

UNF 28 0.2500 0.0364 14 (18.9) 10 (13.5) 16 (21.6) 12 (16.2)
5/16 UNC 18 0.3125 0.0524 25 (33.8) 18 (24.4) 29 (39.3) 22 (29.8)

UNF 24 0.3125 0.0581 27 (36.6) 20 (27.1) 32 (43.3) 24 (32.5)
3/8 UNC 16 0.3750 0.0775 44 (59.6) 33 (44.7) 51 (69.1) 38 (51.5)

UNF 24 0.3750 0.0878 49 (66.4) 37 (50.1) 58 (78.6) 43 (58.3)
7/16 UNC 14 0.4375 0.1063 70 (94.9) 52 (71.8) 82 (111) 61 (82.7)

UNF 20 0.4375 0.1187 78 (106) 59 (79.9) 91 (123) 68 (92.1)
1/2 UNC 13 0.5000 0.1419 110 (149) 80 (109) 120 (162) 93 (126)
UNF 20 0.5000 0.1600 120 (163) 90 (122) 140 (188) 110 (149)
9/16 UNC 12 0.5625 0.1819 150 (203) 120 (162) --- ---
UNF 18 0.5625 0.2030 170 (230) 130 (176) --- ---
5/8 UNC 11 0.6250 0.2260 210 (285) 160 (217) 240 (325) 180 (244)
UNF 18 0.6250 0.2560 240 (325) 180 (244) 270 (366) 200 (271)
3/4 UNC 10 0.7500 0.3345 380 (515) 280 (379) 420 (569) 320 (434)
UNF 16 0.7500 0.3730 420 (569) 320 (433) 470 (637) 350 (474)
7/8 UNC 9 0.8750 0.4617 610 (827) 460 (624) 680 (922) 510 (691)
UNF 14 0.8750 0.5095 670 (908) 500 (677) 750 (1017) 560 (759)
1 UNC 8 1.0000 0.6057 910 (1234) 680 (922) 1,000 (1350) 770 (1044)
UNF 12 1.0000 0.6630 1,000 (1356) 750 (1017) 1,100 (1491) 840 (1139)
1 1/8 UNC 7 1.1250 0.7633 1,300 (1762) 970 (1315) 1,400 (1898) 1,100 (1491)
7F UNF 12 1.1250 0.8557 1,400 (1898) 1,100 (1491) 1,600 (2169) 1,200 (1627)
1 1/4 UNC 7 1.2500 0.9691 1,800 (2440) 1,400 (1898) 2,000 (2711) 1,500 (2003)
UNF 12 1.2500 1.0729 2,000 (2711) 1,500 (2003) 2,300 (3118) 1,700 (2305)
1 3/8 UNC 6 1.3750 1.1549 2,400 (3254) 1,800 (2440) 2,700 (3660) 2,000 (2711)
UNF 12 1.3750 1.3147 2,700 (3660) 2,000 (2711) 3,000 (4068) 2,300 (3118)
1 1/2 UNC 6 1.5000 1.4053 3,200 (4338) 2,400 (3254) 3,600 (4881) 2,700 (3660)
UNF 12 1.5000 1.5810 3,600 (4881) 2,700 (3660) 4,000 (5423) 3,000 (4068)
ASTM A354 Grade BD
1 3/4 UNC 5 1.7500 1.8995 5,000 (6779) 3,700 (5017) 5,600 (7592) 4,200 (5694)
1 3/4 UN 12 1.7500 2.1873 5,700 (7728) 4,300 (5830) 6,400 (8677) 4,800 (6508)
2 UNC 4 1/2 2.0000 2.4982 7,500 (10169) 5,600 (7593) 8,400 (11389) 6,300 (8541)
2 UN 12 2.0000 2.8917 8,700 (11796) 6,500 (8813) 10,000 (13588) 7,300 (9897)
2 1/4 UNC 4 1/2 2.2500 3.2477 11,000 (14914) 8,200 (11118) 12,000 (16270) 9,300 (12609)
2 1/2 UNC 4 2.5000 3.9988 15,000 (20338) 11,000 (14914) 17,000 (23049) 13,000 (17626)
2 3/4 UNC 4 2.7500 4.9340 18,000 (24405) 13,000 (17626) 23,000 (31184) 17,000 (23049)
3 UNC 4 3.0000 5.9674 24,000 (32540) 18,000 (24405) 30,000 (40676) 23,000 (31184)
Torque Coefficients Dry: 0.20

Lubricated: 0.15
A–2 04/17
Operation and Maintenance Appendix B - Conversion Tables
Appendix B - Conversion Tables
Telsmith Model H3450 Crusher – Appendix B
LINEAR MEASURE SQUARE MEASURE
To Convert Info Multiply by To Convert Info Multiply by

Inches Centimeters 2.54 Sq. Inches Sq. Centimeters 6.452
Feet Meters 0.3048 Sq. Miles Sq. Kilometers 2.59
Centimeters Inches 0.3937 Sq. Centimeters Sq. Inches 0.15499
Millimeters Inches 0.0394 Sq. Meters Sq. Inches 1549.9
Meters lnches 39.37 Sq. Meters Sq. Feet 10.763
Meters Feet 3.2808
CUBIC MEASURE WEIGHT
To Convert Info Multiply by To Convert Info Multiply by

Kilograms Pounds 2.2046
Cu. Inches Cu. Centimeters 16.387
Pounds Kilograms 0.4536
Cu. Feet Cu. Meters 0.0283
Pounds/Sq. Kilograms/Sq. 0.0703
Cu. Centimeters Cu. Inches 0.06102
Inch Centimeter
Cu. Meters Cu. inches 610233779.0
Pounds/Sq. Kilograms/Sq. 4.8824
Cu. Meters Cu. Feet 35.314
Foot Meter
DEGREES FAHRENHEIT TO DEGREES CENTIGRADE
F C F C F C F C F C
-30 -34.44 +20 -6.67 +55 +12.78 +90 +32.22 +225 +107.22
-28 -33.33 21 -6.11 56 13.33 91 32.78 230 110.00
-26 -32.22 22 -5.56 57 13.89 92 33.33 235 112.78
-24 -31.11 23 -5.00 58 14.44 93 33.89 240 115.56
-22 -30.00 24 -4.44 59 15.00 94 34.44 245 118.33
-20 -28.89 25 -3.89 60 15.56 95 35.00 250 121.11
-18 -27.78 26 -3.33 61 16.11 96 35.56 255 123.89
-16 -26.67 27 -2.78 62 16.67 97 36.11 260 126.67
-14 -25.56 28 -2.22 63 17.22 98 36.67 265 129.44
-12 -24.44 29 -1.67 64 17.78 99 37.22 270 132.22
-10 -23.33 30 -1.11 65 18.33 100 37.78 275 135.00
-8 -22.22 31 -0.56 66 18.89 105 40.55 280 137.78
-6 -21.11 32 0.00 67 19.44 110 43.33 285 140.55
-4 -20.00 33 +0.56 68 20.00 115 46.11 290 143.33
-2
0
-18.89
-17.78
34
35
1.11
1.67
69
70
20.56
21.11
120
125
48.89
51.67
295
300
146.11
148.89 7F
+1 -17.22 36 2.22 71 21.67 130 54.44 305 151.67
2 -16.67 37 2.78 72 22.22 135 57.22 310 154.44
3 -16.11 38 3.33 73 22.78 140 60.00 315 157.22
4 -15.56 39 3.89 74 23.33 145 62.78 320 160.00
5 -15.00 40 4.44 75 23.89 150 65.56 325 162.78
6 -14.44 41 5.00 76 24.44 155 68.33 330 165.56
7 -13.89 42 5.56 77 25.00 160 71.11 335 168.33
8 -13.33 43 6.11 78 25.56 165 73.89 340 171.11
9 -12.78 44 6.67 79 26.11 170 76.67 345 173.89
10 -12.22 45 7.22 80 26.67 175 79.44 350 176.67
11 -11.67 46 7.78 81 27.22 180 82.22 355 179.44
12 -11.11 47 8.33 82 27.78 185 85.00 360 182.22
13 -10.56 48 8.89 83 28.33 190 87.78 365 185.00
14 -10.00 49 9.44 84 28.89 195 90.55 370 187.78
15 -9.44 50 10.00 85 29.44 200 93.33 375 190.55
16 -8.89 51 10.56 86 30.00 205 96.11 380 193.33
17 -8.33 52 11.11 87 30.56 210 98.89 385 196.11
18 -7.78 53 11.67 88 31.11 215 101.67 390 198.89
19 -7.22 54 12.22 89 31.67 220 104.44 395 201.67
04/17 B–1
Appendix B - Conversion Tables Operation and Maintenance
Telsmith H3450 Crusher
NOTES
7F
B–2 04/17
Appendix C- Torque Tables
Telsmith H3450 Portable Plant
ISO GRADES
Fastener Information ISO S98 HHCS Grade 8.8 ISO S98 HHCS Grade 10.9
Size Pitch Major Dia. Tensile Torque Torque Torque Torque

(mm) (mm) Stress Area Dry Lubricated Dry Lubricated
(mm2) Nm Nm Nm Nm
(ft-lb) (ft-lb) (ft-lb) (ft-lb)
M6 1.00 6.00 20.12 11 (8) 8 (6) 15 (11) 11 (8)
M10 1.50 10.00 57.99 50 (36) 38 (28) 72 (54) 54 (40)
M12 1.75 12.00 84.27 68 (65) 66 (49) 126 (94) 94 (72)
M16 2.00 16.00 156.67 218 (162) 164 (122) 312 (232) 234 (174)
M20 2.50 20.00 244.79 441 (326) 330 (246) 610 (454) 457 (340)
M24 3.00 24.00 352.50 761 (567) 571 (425) 1,053 (784) 790 (588)
M30 3.50 30.00 560.59 1,514 (1,126) 1,135 (845) 2,094 (1,588) 1,570 (1,166)
M36 4.00 36.00 816.72 2,646 (1,969) 1,985 (1,477) 3,661 (2,724) 2,745 (2,043)
M42 4.50 42.00 1120.91 4, 237 (3,153) 3,178 (2,364) 5,881 (4,361) 4,396 (3,271)
M48 5.00 48.00 1473.15 6,364 (4,736) 4,773 (3,551) 8,804 (6,550) 6,603 (4,913)
7F
04/17 C–1
Torque Tables cont.
Fastener Information ISO 898 SHCS Grade 12.9
Size Pitch Torque Torque

(mm) Dry Lubricated
Nm Nm
(ft-lb) (ft-lb)
M6 1.00 18 (13) 13 (10)
M8 1.25 43 (32) 32 (24)
M10 1.50 84 (63) 63 (47)
M12 1.75 147 (109) 110 (82)
M16 2.00 365 (271) 274 (204)
M20 2.50 712 (530) 534 (398)
M24 3.00 1,231 (916) 923 (687)
M30 3.50 2,447 (1,821) 1,835 (1,365)
M36 4.00 4, 278 (3,183) 3,208 (2,387)
M42 4.50 6,850 (5,097) 5,137 (3,822)
M48 5.00 10,288 (2,655) 7,716 (5,741)
7F
C–2 04/17

H3450 Hydra Jaw Crusher - Operation and Maintenance

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H3450 Hydra Jaw Crusher - Operation and Maintenance

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Operation and Maintenance

ORIGINAL INSTRUCTIONS - ENGLISH

ISSUE DATE: 04/17 TP651

2. Before removing spilled materials.

3. Before clearing jams or working inside the machinery.

4. If any unusual noises or sudden changes in operation are noticed.

HOW TO CONTACT TELSMITH INC.

REQUESTING SERVICE ASSISTANCE

INSTALLATION & ASSEMBLY DRAWINGS FAX:

Installation and assembly drawings (blueprints) are provided

FEATURES, DIMENSIONS and SPECIFICATIONS . . . . . . . . . . . . . . . 2

CRUSHER INSTALLATION and ASSEMBLY . . . . . . . . . . . . . . . . . . 3

CRUSHER OPERATION and ADJUSTMENTS . . . . . . . . . . . . . . . . . 4

CRUSHER LUBRICATION and MAINTENANCE SCHEDULE . . . . . . . . . 5

HYDRAULIC SYSTEM OPERATION & MAINTENANCE . . . . . . . . . . . . 6

WEAR LINER and CHEEK PLATE REPLACEMENT . . . . . . . . . . . . . . 8

GENERAL SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

PRECAUTIONARY STATEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

QUARRY SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

EQUIPMENT INSTALLATION SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

1 Operator Vantage Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

MAINTENANCE AND REPAIR SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

HOISTING AND HANDLING SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

TRANSPORTATION SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

MAINTENANCE INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

SAFETY LABELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18

DECOMMISIONING THE 3450 JAW CRUSHER . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20

GENERAL SAFETY Hazard Statements 1

1 There are many maintenance procedures contained LOCKOUT/TAGOUT

Use a high impact type grout which contains a non-

Figure 1–1. Sample Precautionary Statements

1 How Is Lockout/Tagout Performed? In situations in which lockout or tagout devices must be

When Can Lockout/Tagout Devices Be

Lockout/Tagout Devices • Your company’s lockout/tagout program may be 1

Observe Personal Safety Precautions

Be Aware of Your Surroundings

Electrical Installation Safety

Welding, Cutting or Grinding on Machinery

Clearing Jammed Material Disposal of Excess Fuels, Lubricants and 1

1 HOISTING AND HANDLING SAFETY Forming Wire Rope Eyes

• Be sure wire ropes are inspected regularly following the

! CAUTION MAINTENANCE INSPECTIONS

Fiber or Synthetic Slings

1 SAFETY LABELS It should be mentioned here that the ANSI Z535.4-2002

Figure 1–3. Safety Label

A. “SAFETY ALERT SYMBOL” DECOMMISIONING THE 3450 JAW 1

Figure 1–4. 3450 Hydraulic Components

MAJOR FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

MOUNTING ARRANGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

EXTERNAL DIMENSION DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

ENVIRONMENTAL REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

DESCRIPTION The Model 3450’s hydraulic relief feature automatically

Figure 2–1. H3450 Cutaway

MAJOR FEATURES OPTIONS

EXTERNAL DIMENSION DRAWINGS

Figure 2–2. H3450 Dimension in Millimeters (Inches)

Figure 2–3. 3450 Dimension in Millimeters (Inches)

Figure 2–4. Crusher Mounting Options

CRUSHER MOUNT DRIVE

Figure 2–5. 3450 Drive Options

2 Crusher, Assembled and Complete 29,030 64,000

Swing Jaw Assembly

Flywheel Sheave 1243 2741