operator’s manual Doc. no. S 222.

079 en

REAL™ J11
This document is valid for:

Serial no. / Machine no. Sign.

REAL™ J11
© Copyright 2004 Sandvik Rock Processing AB.
All rights reserved. No parts of this document may be reproduced or
copied in any form or by any means without written permission from
Sandvik SRP AB. All data and information in this manual may be
changed without further notice. Reservations for misprints.

Document number: S 222.079 en

00B_Front.fm
Issue: 200411
Version: 3

Sandvik Rock Processing AB

Stationsplan, SE-233 81 Svedala, Sweden
Tel: +46 40-40 90 00, Fax: +46 40-40 92 64
www.sandvik.com
 Table of contents

1. Introduction
1.1 Equipment information.......................................................... 8
1.1.1 Document information............................................ 10
1.1.2 Description ............................................................. 11

2. Safety precautions
2.1 Hazard information ............................................................. 14
2.1.1 General .................................................................. 14
2.2 Personnel............................................................................ 15
2.3 General safety precautions................................................. 16
2.3.1 Electrical safety...................................................... 16
2.3.2 Pressurized systems (hydraulics) .......................... 16
2.3.3 Jaw crusher............................................................ 17
2.3.4 Maintenance work below the jaw crusher .............. 17
2.3.5 Machine safety guards........................................... 17
2.3.6 Equipment for lifting and moving loads .................. 18
2.3.7 Welding .................................................................. 18
2.3.8 Jams ...................................................................... 19
00C_TOC.fm

3. Technical data
3.1 General data ....................................................................... 22
3.2 Processing data .................................................................. 22

4. Start up the jaw crusher

4.1 General ............................................................................... 24
4.1.1 Getting started ....................................................... 24
4.1.2 Running in.............................................................. 25

5. Lubrication of roller bearings

5.1 General ............................................................................... 28
5.1.1 Manual lubrication.................................................. 28
5.1.2 Lubricant requirements .......................................... 29

J11 © Sandvik Rock Processing AB – Doc. no. S 222.079 en Ver. 3 3

Table of contents

6. Inspection and care

6.1 General ............................................................................... 32
6.2 Routine inspection and care ............................................... 33
6.3 Recommended tool box ...................................................... 34
6.4 Crushing chamber............................................................... 35
6.4.1 Jaw plates .............................................................. 35
6.4.2 Deflector plate ........................................................ 36
6.4.3 Clamping bar.......................................................... 36
6.4.4 Wear plate .............................................................. 37
6.4.5 Support bar ............................................................ 37
6.4.6 Cheek plate ............................................................ 37
6.5 Setting adjustment system.................................................. 38
6.5.1 Toggle plate............................................................ 38
6.5.2 Toggle seat............................................................. 38

7. Crushing chamber
7.1 Exchanging clamping bars.................................................. 40
7.1.1 Remove clamping bar ............................................ 40

00C_TOC.fm
7.1.2 Install clamping bar ................................................ 41
7.2 Exchanging jaw plates ........................................................ 42
7.2.1 Remove jaw plate................................................... 42
7.2.2 Install jaw plate....................................................... 44
7.3 Exchanging wear plates...................................................... 46
7.3.1 Remove wear plate ................................................ 46
7.3.2 Install wear plate .................................................... 48
7.4 Exchanging support bars .................................................... 49
7.4.1 Remove support bar............................................... 49
7.4.2 Install support bar................................................... 50
7.5 Exchanging deflector plate.................................................. 50
7.5.1 Remove deflector plate .......................................... 50
7.5.2 Install deflector plate .............................................. 51
7.6 Exchanging cheek plates .................................................... 53
7.6.1 Remove cheek plate .............................................. 54
7.6.2 Install cheek plate .................................................. 55
7.7 Exchanging jaw shim plates................................................ 57
7.7.1 Remove jaw shim plate .......................................... 57
7.7.2 Install jaw shim plate .............................................. 59

4 © Sandvik Rock Processing AB – Doc. no. S 222.079 en Ver. 3 J11

 Table of contents

8. Setting adjustment system

8.1 General ............................................................................... 62
8.2 Setting adjustment .............................................................. 63

9. Setting measurement
9.1 Setting measuring gauge.................................................... 66
9.2 Gauge ................................................................................. 66
9.3 Measuring instructions........................................................ 67

10. Trouble shooting

10.1 Faults and suggested actions ............................................. 70
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Table of contents

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6 © Sandvik Rock Processing AB – Doc. no. S 222.079 en Ver. 3 J11

 1. Introduction
To ensure maximum safety, always read section 2. Safety precautions before
doing any work on the equipment or making any adjustments.
01_Introduction.fm

J11 © Sandvik Rock Processing AB – Doc. no. S 222.079 en Ver. 3 7

1. Introduction

1.1 Equipment information

Purpose
The purpose of this Sandvik equipment is to be a crusher component in a
crushing and screening unit designed, delivered and sold by an independent
manufacturer. This equipment has been exclusively designed for the
application – as defined by the application equipment manufacturer. It is
therefore not the responsibility of Sandvik SRP AB to secure the design and
usage for the complete application. Sandvik SRP AB will not accept any
liability for damage to equipment or injury to personnel caused by
unauthorised or improper use or change of this equipment.
Manufacturer
This Sandvik equipment has been manufactured by:
Sandvik SRP AB
Stationsplan
SE-233 81 Svedala
Sweden
www.sandvik.com
For maintenance
Contact the nearest Sandvik Rock Processing company, agent or
representative or directly:

01_Introduction.fm
Sandvik SRP AB
Service Dept.
SE-233 81 Svedala
Sweden
Telephone +46 40-40 90 00
Telefax +46 40-40 92 64

8 © Sandvik Rock Processing AB – Doc. no. S 222.079 en Ver. 3 J11

 1. Introduction

Identification
The figure below shows an example of the crusher’s identification plate. The
identification plate contains data needed when contacting Sandvik SRP AB
concerning this specific equipment.
Please enter the serial number of the associated machine in the intended field
on the first page of this manual (the copyright page).

8
7

1 2 3 4 5 6

1 Machine type
2 Part number
3 Serial number
4 Mass (kg)
5 Order number
6 Manufacturer
7 Year of manufacture
01_Introduction.fm

8 CE mark

CE marking
This equipment complies with the basic health, environment and safety
regulations of the European Union and European Economic Area.

J11 © Sandvik Rock Processing AB – Doc. no. S 222.079 en Ver. 3 9

1. Introduction

1.1.1 Document information

Purpose of this Operator’s manual
The purpose of this Operator’s manual is to provide the operator with
information on how to handle and operate this Sandvik equipment before,
during, and after operation.
It is important to:
• keep the manual for the lifetime of the equipment
• pass the manual on to any subsequent holder or user of the equipment
Document compliance
The instructions in this document are in accordance with the design and
construction of the equipment at the time it was delivered from the Sandvik
SRP manufacturing plant.
Technical publications
The customer technical publications for this equipment are:
• Installation manual
• Wear part catalogue
• Operator’s manual
When ordering technical publications, always specify the language and quote
the machine serial number.

01_Introduction.fm
Number of pages
This document contains a total of 74 pages.

10 © Sandvik Rock Processing AB – Doc. no. S 222.079 en Ver. 3 J11

 1. Introduction

1.1.2 Description
The following drawings show an overview of the jaw crusher’s nomenclature
and components.
Bottom view
1 Flywheel
2 Eccentric shaft
3 Frame
4 Front frame end
5 Flexible washer for cheek plate
6 Foot 2
7 Hydraulic cylinder – wedge
8 Setting wedge
3
9 Support bar
4
10 Retraction cylinder
11 Back frame end
5
6

7 8 9 10 11
01_Introduction.fm

Top view
12 Bearing housing
13 Moving jaw
14 Counter weight 12
15 Deflector plate 13 14 15 16 17 18 19 20
16 Clamping bar
17 Cheek plate
18 Jaw plate – moving
19 Clamping bar
20 Jaw plate – stationary

J11 © Sandvik Rock Processing AB – Doc. no. S 222.079 en Ver. 3 11

1. Introduction

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01_Introduction.fm

12 © Sandvik Rock Processing AB – Doc. no. S 222.079 en Ver. 3 J11

 2. Safety precautions
To ensure maximum safety, always read this section carefully before doing
any work on the equipment or making any adjustments.
02_Safety precautions.fm

J11 © Sandvik Rock Processing AB – Doc. no. S 222.079 en Ver. 3 13

2. Safety precautions

2.1 Hazard information

2.1.1 General
Failure to observe information marked “DANGER!” puts your life in
danger!

DANGER!

Failure to observe information marked “WARNING!” can result in

personal injury and/or serious damage to, or destruction of,
equipment!
WARNING!

CAUTION! Failure to observe information marked “Caution!” can result in damage

to equipment!

Signs for mandatory actions

02_Safety precautions.fm
Wear ear protection Wear eye protection Wear safety boots

Disconnect current Read the manual Wear safety helmet

before any work

Warning signs

Risk of crushing Dangerous voltage General danger

Heavy load

14 © Sandvik Rock Processing AB – Doc. no. S 222.079 en Ver. 3 J11

 2. Safety precautions

2.2 Personnel
Only skilled or instructed personnel are allowed to work on the equipment.
According to Sandvik SRP an instructed person is:
– An individual adequately advised or supervised by a skilled person to
enable that individual to avoid hazards which this equipment can
create (e.g. operators or service staff).
According to Sandvik SRP a skilled person is:
– An individual with technical knowledge or sufficient experience to
enable that individual to avoid hazards which this equipment can
create (e.g. operators or service staff).

The manufacturer declines all responsibility for injury or damage if the

instructions in this manual are not followed.
Personnel are responsible for:
• the equipment and the work area around the equipment
• all personnel in the vicinity of the equipment
• following local or national safety regulations
02_Safety precautions.fm

• making sure that all safety devices are fully operational

Sandvik SRP strongly recommends that personal safety protection is always

worn when working in the vicinity of the equipment.
The Sandvik SRP recommendation for personal safety protection includes:
• safety boots
• safety helmet
• eye protection
• protective gloves
• mask or breathing apparatus when appropriate

J11 © Sandvik Rock Processing AB – Doc. no. S 222.079 en Ver. 3 15

2. Safety precautions

2.3 General safety precautions

2.3.1 Electrical safety
Dangerous voltage
Personnel must regard all electrical equipment as live until it is proven
dead by proper test procedures. In case of accident call for medical
WARNING! attention immediately.

Work inside the jaw crusher must be performed by skilled or instructed

persons only. Always switch off power to the equipment before any work is
done inside crusher.

Check, repair and replace electrical cables and connectors if they are broken
or damaged in any way, before starting the equipment.

2.3.2 Pressurized systems (hydraulics)

Hydraulic systems
Pressurized oil is dangerous if released incorrectly. Relieve all
pressure in a pressurized system before carrying out maintenance or
WARNING! repair work.

02_Safety precautions.fm
Hydraulic oil can get very hot in operation. Allow the oil to cool before
working on the hydraulic system.
Check, repair and replace defective hoses, valves or fittings before starting
the equipment.
Hydraulic cylinders

Hydraulic cylinders
Never touch hydraulic cylinders when the equipment is in operation.

WARNING!
Hydraulic cylinders in operation are a potential risk for crushing injuries.
The hydraulic cylinders may suddenly change position. Always keep body
parts away from hydraulic cylinders in operation.

16 © Sandvik Rock Processing AB – Doc. no. S 222.079 en Ver. 3 J11

 2. Safety precautions

2.3.3 Jaw crusher

The jaw crusher has been exclusively designed to be the crushing component
in a mineral processing or recycling application, such as crushing asphalt,
concrete and brick material.
CAUTION! Never feed combustible processing material into the jaw crusher.

Any work on the jaw crusher must be performed by skilled or instructed

persons only. Always switch off power to the equipment before any work is
started inside the jaw crusher.

Dangerous work
Do not stand inside the crushing chamber when exchanging jaw plates
and cheek plates.
WARNING!
Always block the position between the moving jaw and the frame cross-
member when the moving jaw is swung forward.

2.3.4 Maintenance work below the jaw crusher

CAUTION! Clear the feed from processing material before any maintenance work
is carried out below the jaw crusher, preventing stones to fall down.
02_Safety precautions.fm

2.3.5 Machine safety guards

Do not remove guards
Make sure that all guards are in place and functioning.

WARNING!
All rotating parts of the equipment shall be protected by guards. Always
attach guards after maintenance work.
The platforms with guard rails shall be installed around the crusher’s feed
opening.
NOTE! The stone hopper shall be equipped with a pivoted stone guard. The stone
guard must not be raised during operation.
Never remove covers while the equipment is in operation.

J11 © Sandvik Rock Processing AB – Doc. no. S 222.079 en Ver. 3 17

2. Safety precautions

2.3.6 Equipment for lifting and moving loads

Hanging load
Make sure that the capacity of the lifting equipment is adequate and
that the equipment itself is in good working order.
WARNING!
If lifting tackle has to be joined to make up the necessary lengths, make sure
that the joints are secure and have the same lifting capacity as the rest of the
tackle.
Always engage the safety clip on lifting hooks to prevent the tackle from
slipping off.
Use ropes or poles to steady and manoeuvre loads. Do not use hands or feet.
Make sure that the route and the destination are free from obstacles before
moving a suspended load. It must be possible to lower the load to the floor
quickly and safely in an emergency.
When depositing loads, keep the lifting equipment in place until the stability
of the load has been checked.

2.3.7 Welding
CAUTION! Always consult with the manufacturer before any welding operation be-
gins on the jaw crusher.

02_Safety precautions.fm
CAUTION! Never let the welding current pass through a roller bearing.
If the working area is earthed on the wrong side of the bearing, the latter
can be so seriously damaged that bearing replacement is necessary.

If welding an item to the jaw crusher, the earth must be attached to the item
itself. If a crusher component is to be welded, the earth should be attached as
near as possible to the welding area. If welding for example on the moving
jaw, the earth must be attached to it and not to the frame or the flywheel.

Toxic gases
Inhalation of welding fumes can be a dangerous to health. Wear
personal safety protection when welding. Always follow instructions
WARNING! provided by the welding equipment supplier.
Several parts of the jaw crusher is made of manganese steel. Long
term exposure to manganese can effect the nervous system.

18 © Sandvik Rock Processing AB – Doc. no. S 222.079 en Ver. 3 J11

 2. Safety precautions

2.3.8 Jams
Dangerous work
Do not use wedges etc. to clear jams in the feed opening. Always wear
personal safety protection. Stones and fragments can be thrown up at
WARNING! high speed from the crushing chamber.

Do not use explosives

Never remove blocking boulders in the jaw crusher’s feed by blasting.
Blasting may seriously damage bearings or other vital components.
WARNING! Sandvik SRP takes no responsibility for damage to personnel or to the
equipment when blasting is used.

It is possible to change the direction of the jaw crushers’s flywheel for a

while to ease a jam. Always return to normal rotation direction when the jam
has been cleared.
It is also possible to increase the CSS (closed side setting) temporarily to
clear a jam.
CAUTION! When the crushing chamber is empty, avoid feeding solitary large boul-
ders in the upper part of the chamber. In unfavourable circumstances
the moving jaw may be pushed forward and bring the toggle plate out
of position.
02_Safety precautions.fm

Sandvik recommends that a jam in the feed opening is cleared by using a

hydraulic hammer.
CAUTION! If a hydraulic hammer is installed, never use it to fracture stones in the
crushing chamber. This may seriously damage bearings or other vital
components.

Use the hydraulic hammer to knock off corners and edges from slightly
oversized stones so that they can enter the crushing chamber. If a “hang”
occurs, use the hydraulic hammer to poke the stones and break the “hang”.

Risk of crushing
Do not fall or stand inside the crushing chamber when a “hang” is
broken up, any objects may be pulled sharply downwards and
WARNING! crushed.

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2. Safety precautions

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02_Safety precautions.fm

20 © Sandvik Rock Processing AB – Doc. no. S 222.079 en Ver. 3 J11

 3. Technical data
03_Technical data.fm

J11 © Sandvik Rock Processing AB – Doc. no. S 222.079 en Ver. 3 21

3. Technical data

3.1 General data

Characteristics Data
Model Real J11
Type Jaw crusher
Application Mineral processing, Recycling
Usage Outdoors
Weight 14 300 kg
Length 2.39 m
Width 2.44 m
Height 2.18 m
Nominal speed 270 rpm
Moment of inertia 388 kg/m2
Max. horizontal dynamic forces FH ± 2 KN at each foot (4×)

Max. vertical dynamic forces FV ± 12 KN at each foot (4×)

3.2 Processing data

Characteristics Data
Max. feed opening 1.10 × 0.70 m
CSS min–max 40 to 175 mm

03_Technical data.fm

22 © Sandvik Rock Processing AB – Doc. no. S 222.079 en Ver. 3 J11

 4. Start up the jaw crusher
This section describes how to start up the jaw crusher when it’s installed in a
crushing and screening unit.
To ensure maximum safety, always read section 2. Safety precautions before
doing any work on the equipment or making any adjustments.
04_Start up the jaw crusher.fm

J11 © Sandvik Rock Processing AB – Doc. no. S 222.079 en Ver. 3 23

4. Start up the jaw crusher

4.1 General
Each jaw crusher delivered by Sandvik Rock Processing has been assembled,
test run and checked in our factory before shipping. The test run is carried
out without load to discover any mechanical faults. This test is performed
before the jaw crusher is installed on the crushing and screening unit.

4.1.1 Getting started

NOTE! Check that the jaw crusher’s CSS (closed side setting) is not smaller than the
recommended value. The minimum setting value can be found in section
3. Technical data.
Start the crusher and let it run for a 1–2 hours without load. In the meantime
check the following:
– That the direction of the crusher’s flywheels is correct (see figure).
right wrong

04_Start up the jaw crusher.fm

– That there is no unusual noise.
– That the bearings do not overheat.
– That the guards are in place.
(Continued)

24 © Sandvik Rock Processing AB – Doc. no. S 222.079 en Ver. 3 J11

 4. Start up the jaw crusher

During this period correct any faults that are discovered. Make sure
everything is OK before starting to feed material carefully to the jaw crusher.
Distribute the feed evenly across the width of the crusher’s feed opening.
Never let the feed rise above the top edge of the stationary jaw plate, marked
in the picture.
04_Start up the jaw crusher.fm

4.1.2 Running in
During the running in period, grease the bearings at shorter intervals than
those given in the care schedule. Check the bearing temperatures regularly.
Check the tightness of all threaded fasteners.
Avoid overloading the jaw crusher.

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4. Start up the jaw crusher

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04_Start up the jaw crusher.fm

26 © Sandvik Rock Processing AB – Doc. no. S 222.079 en Ver. 3 J11

 5. Lubrication of roller
bearings
This section describes how to lubricate the roller bearings and the products to
use.
To ensure maximum safety, always read section 2. Safety precautions before
doing any work on the equipment or making any adjustments.
05_Lubrication of roller bear-

J11 © Sandvik Rock Processing AB – Doc. no. S 222.079 en Ver. 3 27

5. Lubrication of roller bearings

5.1 General
CAUTION! Always use lubricants which fulfil the requirements. The use of wrong
lubricants may damage bearings and block lubricating passages. See
section 5.1.2 Lubricant requirements.
NOTE! Never mix different brands or types of grease. A bad mixture may cause
precipitation and lose its lubricating characteristics. Consult your lubricant
supplier.
The grease has in addition a sealing effect in the labyrinth seals which
prevents dust and other harmful substances entering the bearings. Sandvik
Rock Processing therefore recommends frequent lubrication and larger
grease quantities than are normally required to lubricate roller bearings.
NOTE! To prevent contaminants entering the bearings, always clean the grease
nipples and the grease gun nozzle before lubrication is performed.
CAUTION! Never use contaminated lubricants.

The handling of lubricants is associated with fire and health risks. Always
follow your supplier’s instruction and safety regulations.

05_Lubrication of roller bear-

5.1.1 Manual lubrication
Add at least the following quantity for each roller bearing (per nipple) after
every 40 hours of operation:
Description Qty. Remarks
Grease at each roller bearing 0.26 kg 0.57 lb.

Risk of crushing
Always connect the lubricator nozzle to the grease nipple while the
crusher is standing still.
WARNING!
The jaw crusher must be at normal operating temperature before lubrication
is performed to facilitate the exit of grease.
NOTE! In low temperatures (below 0°C), always run the jaw crusher empty for a
while before greasing the bearings.
(Continued)

28 © Sandvik Rock Processing AB – Doc. no. S 222.079 en Ver. 3 J11

 5. Lubrication of roller bearings

Sandvik recommends running the jaw crusher empty while lubricating, so

that the new grease is evenly distributed throughout the bearings.
To prevent dirt and water entering the bearings, always ensure that the old
grease is forced out of the labyrinth seals, while pumping fresh grease into
the grease nipple.
Use the inner lubrication nozzles (1) to lubricate the inner bearings.
Use the outer lubrication nozzles (2) to lubricate the outer bearings.

1 Inner lubrication nozzles

2 Outer lubrication nozzles
05_Lubrication of roller bear-

NOTE! Run the jaw crusher for a while after lubrication to spread the grease.
When operation begins, the bearing temperature usually rise slightly above
the normal level. If the temperature rise is moderate and the temperature
quickly returns to normal there is no danger to the bearings.

5.1.2 Lubricant requirements

The grease must contain anti-rust and EP additives and fulfil the following
minimum requirements:
Property Test method Requirements
NLGI value DIN 51 818 2 or 3
Drop point DIN ISO 2176 ≥ 180
Base oil viscosity at 40°C in ≥ 170
mm2/s (cSt)
Base oil viscosity at 50°C in ≥ 100
mm2/s (cSt)
Mechanical stability SKF V2F 1000 rpm Approved
Corrosion resistance DIN 51 802 SKF Emcor Approved
Temperature range –30°C to +110°C
Speed range Must lubricate effectively throughout the bearing’s entire operating
speed range
Viscosity index at least 80

(Continued)

J11 © Sandvik Rock Processing AB – Doc. no. S 222.079 en Ver. 3 29

5. Lubrication of roller bearings

Examples of lubricants, which according to their supplier fulfil Sandvik

Rock Processing’s requirements:
Aral Aralub HLP 2 Molub-Alloy Tribol 4020/220-2
BP Energrease LS-EP 2 Shell Ariax Li X 2
ESSO Beacon EP 2 N Statoil UniWay Li X 62
Mobil Mobilgrease HP 222 Texaco Hytex EP 2
If you want to use another type of grease, please consult your lubricant
supplier.

05_Lubrication of roller bear-

30 © Sandvik Rock Processing AB – Doc. no. S 222.079 en Ver. 3 J11

 6. Inspection and care
This section describes the routine inspection and care instructions for the jaw
crusher.
To ensure maximum safety, always read section 2. Safety precautions before
doing any work on the equipment or making any adjustments.
06_Inspection and care.fm

J11 © Sandvik Rock Processing AB – Doc. no. S 222.079 en Ver. 3 31

6. Inspection and care

6.1 General
To ensure optimum performance, the jaw crusher needs to be evenly fed.
Never let the feed rise above the top edge of the crushing chamber, marked in
the picture.

06_Inspection and care.fm

Avoid overloading the crusher. Overloading can be caused by:
– An unfavourable wear pattern on the jaw plates (cavities or “Ski
slopes”)
– Excessive jaw plate wear or jaw plate “arching”
– Too small discharge setting
– Excessive fines content in the feed material

32 © Sandvik Rock Processing AB – Doc. no. S 222.079 en Ver. 3 J11

 6. Inspection and care

6.2 Routine inspection and care

NOTE! Every jaw crusher must be subjected to regular systematic checks. This will
result in fewer and smaller repairs, less downtime and thus lower overall
running costs.

A new machine must be inspected often during the initial operating period.
The intervals between inspections can then be increased until a suitable
frequency is found.
Keep a written log including the crusher’s operating conditions, important
data and details of adjustments made and any repairs carried out.
Since crushers operate under widely differing conditions, it is impossible to
recommend an inspection and care schedule applicable to all crushers.
However, regular inspections are necessary, the following table describes an
example:

Interval Action Remarks See Section

Daily Check bearing temperatures. Perform checks when the jaw –
crusher is running. External
bearing housing temperature
should not exceed 70 °C.
40 operating hours Grease all four bearings. Lubricate when the jaw crusher 5.1
06_Inspection and care.fm

is running empty and is at nor-

mal operating temperature.
Check tightness of all threaded fas- Tighten if necessary. Replace –
teners. damaged bolts.
Check wear on the jaw plates and Excessive wear can result in 6.4
cheek plates. reduced capacity.
80 operating hours Check the toggle plate and the 6.5
toggle seats for wear or damage.
After a long out-of- Lubricate bearings with a grease 5.1
service period gun before starting up.

J11 © Sandvik Rock Processing AB – Doc. no. S 222.079 en Ver. 3 33

6. Inspection and care

6.3 Recommended tool box

The following is a list of recommended tools for use during maintenance
work described in this manual.
Tool Included Used for
in tool kit
Gauge for CSS Yes Setting measurement
Lifting tool Yes Jaw plates / Cheek plates
Slugging wrench 46 mm Yes Jaw plates / Clamping bars
Combination wrench 46 mm Yes Jaw plates / Clamping bars
Combination wrench 30 mm Yes Support bars
Combination wrench 36 mm No Cheek plates
Crow bar No Jaw plates
Props 2 pcs No Jaw plates
Grease gun with hose No Bearings
Hammer with nylon head No Cheek plates
Lifting tackle and chain No –
Mobile crane No –
Protective gloves No –

06_Inspection and care.fm

34 © Sandvik Rock Processing AB – Doc. no. S 222.079 en Ver. 3 J11

 6. Inspection and care

6.4 Crushing chamber

NOTE! See section 7. Crushing chamber for information about how maintenance is
carried out.

To ensure optimum performance for your machine and cost effective

production it’s important to frequently inspect the following parts and to
replace them before they are completely worn out.

6.4.1 Jaw plates

The wear pattern and the adjustment of the jaw plates have a great effect on
the crusher’s capacity. Crushers can be fitted with jaw plates with different
patterns and profiles to suit different crushing duties.
Nip angle α If the jaw plates are worn down at one end there is a risk that the nip angle
becomes too large in the upper part of the crushing chamber when the jaw
plates are reversed. This can create a reduced grip on the material with a
consequent decreased capacity. Sandvik Rock Processing recommends to
exchange the jaw plates if this occurs.
Several factors affect the wear of the jaw plates (3300-1), so it’s impossible
to generalize when and how to reverse or exchange them. Check the wear
pattern regularly and make a judgement of when to reverse or exchange the
06_Inspection and care.fm

jaw plates. In general, if the jaw plates are frequently reversed, the wear will
be more uniform and will have less effect on the nip angle.
A simple rule is:
– If a part of the jaw plate is reduced to 50 % of the tooth height it is
time reverse the first time.
– If a part of the jaw plate is worn down in level with the tooth base it is
time reverse the second time.
– After the jaw plate is worn down in level with the tooth base and
reversing won’t help, it is time to exchange the plate.
(Continued)

J11 © Sandvik Rock Processing AB – Doc. no. S 222.079 en Ver. 3 35

6. Inspection and care

Capacity

3500-0
3400-0
Worn out 3300-1

Jaw plate Wear

change
3100-0
3500-0 Deflector plate (moving jaw only)
3400-0 Clamping bar
3300-1 Jaw plate
3100-0 Wear plate
3200-0 Support bar

3200-0

NOTE! Often it is advantageous to replace the jaw plate (3300-1) before it is

06_Inspection and care.fm

completely worn out.

6.4.2 Deflector plate

The deflector plate (3500-0) is fitted on the upper part of the moving jaw to
protect the crusher’s feed opening from large rocks. Since this part is
exposed to high pressure and heavy wear it is replaceable. The deflector plate
(3500-0) is hollow, if it becomes curved in, or a hole is worn in, it needs to be
replaced.

6.4.3 Clamping bar

The clamping bar (3400-0) is fitted above the jaw plate (3300-1) to lock it to
the jaw. This part is exposed to high pressure and heavy wear so it needs to
be replaceable. When a clamping bar (3400-0) is no longer straight or in full
contact with the jaw plate it is necessary to replace it.

36 © Sandvik Rock Processing AB – Doc. no. S 222.079 en Ver. 3 J11

 6. Inspection and care

6.4.4 Wear plate

A replaceable wear plate (3100-0) is sandwiched between the jaw plate
(3300-1) and the jaw. It protects the jaws from arching under heavy loads.
When a new jaw plate (3300-1) is no longer in contact with the whole
surface of the wear plate (3100-0) it is necessary to replace the wear plate.

6.4.5 Support bar

The support bar (3200-0) supports the bottom edge of a jaw plate (3300-1).
Since this part is exposed to high pressure and heavy wear, it is replaceable.

6.4.6 Cheek plate

The sides of the crushing chamber are protected with cheek plates on the left
side (1103-0) and right side (1104-0). Since these are exposed to high
pressure and heavy wear (especially in the lower part of the crushing
chamber), they are replaceable. Exchange a cheek plate when there is an
obvious cavity in it (especially in the lower part).

1104-0
06_Inspection and care.fm

1103-0

1104-0 Cheek plate, right side

1103-0 Cheek plate, left side

J11 © Sandvik Rock Processing AB – Doc. no. S 222.079 en Ver. 3 37

6. Inspection and care

6.5 Setting adjustment system

NOTE! Maintenance for these parts must be carried out by skilled and trained service
personnel, but the inspection can be performed by the operator.

Worn components should be replaced in good time to avoid damaging the

toggle plate or toggle seats, with a consequent need for expensive repairs.
Sandvik Rock Processing recommends exchanging the toggle plate (5006-0)
and the toggle seats (5004-0), (5005-0) at the same time.

6.5.1 Toggle plate

The toggle plate is a part of the setting adjustment system. It forms a link
between the moving jaw (3000-0) and the setting arrangement (1). The
toggle plate (5006-0) is exposed to high pressure and heavy wear and is
replaceable. If the minimum discharge setting cannot be reached, this could
be an indication that the toggle plate is worn down, check and if necessary
replace it with a new one. Stress can create cracks or bend the toggle plate. If
the toggle plate (5006-0) shows signs of cracks or is bent it is necessary to
replace it with a new one.

6.5.2 Toggle seat

The toggle plate (5006-0) is located by a toggle seat (5004-0), (5005-0) at

06_Inspection and care.fm

each end. The toggle seats (5004-0), (5005-0) are hardened, but exposed to
high pressure and heavy wear and are therefore replaceable. If the toggle
seats (5004-0), (5005-0) loses their shape it is necessary to replace them with
new ones.

1
5003-0
3000-0 Jaw (moving)
5004-0
5005-0 Toggle seat, lower
5006-0 Toggle plate
5003-0 Toggle seat holder
5004-0 Toggle seat, upper
1 Setting arrangement

3000-0 5005-0 5006-0

38 © Sandvik Rock Processing AB – Doc. no. S 222.079 en Ver. 3 J11

 7. Crushing chamber
This section describes the maintenance needed for the crushing chamber of
the jaw crusher.
To ensure maximum safety, always read section 2. Safety precautions before
doing any work on the equipment or making any adjustments.
07_Crushing chamber_JM1208

J11 © Sandvik Rock Processing AB – Doc. no. S 222.079 en Ver. 3 39

7. Crushing chamber

7.1 Exchanging clamping bars

The following wear parts are required:
Description Cat. no. Qty. Remarks
Clamping bar 1210-0 1 stationary jaw, weight 37 kg
Screw M6S M30×280 1211-0 3 stationary jaw
Self-locking nut M6MN M30 1211-1 3 stationary jaw
Washer D95/35×10 1211-5 6 stationary jaw
Flexible washer 1211-6 3 stationary jaw
Clamping bar 3400-0 1 moving jaw, weight 37 kg
Screw M6S M30×760 3401-0 3 moving jaw
Self-locking nut M6MN M30 3401-1 3 moving jaw
Washer D95/35×10 3401-5 6 moving jaw
Flexible washer 3401-6 3 moving jaw

NOTE! These instructions are valid for both moving and stationary jaw. The pictures
describe the moving jaw.

7.1.1 Remove clamping bar

Risk of crushing
Be aware of the weight of the deflector plate, see section

07_Crushing chamber_JM1208
7.5 Exchanging deflector plate. After removing the clamping bar, make
WARNING! sure the deflector plate is properly fastened before doing any more
work in the crushing chamber.

a) Empty the feeder and the crushing chamber from processing material.
NOTE! Put two props between the jaws to prevent the jaw plates below the clamping
bars from falling out.
Recommended tools b) Use a slugging wrench and combination wrench to loosen the nuts
46 mm Slugging wrench (3401-1) that hold the clamping bar (3400-0).
46 mm Combination wrench
c) Remove nuts (3401-1) and the washers (3401-5) and flexible washers
Props
(3401-6).
d) Knock out the screws (3401-0) and the clamping bar (3400-0).

40 © Sandvik Rock Processing AB – Doc. no. S 222.079 en Ver. 3 J11

 7. Crushing chamber

3500-0
3500-0 Deflector plate 3400-0
3400-0 Clamping bar
3401-0 Screw 3401-0
3401-5 Washer 3401-5
3401-6 Flexible washer 3401-6
3401-1 Self-locking nut 3401-5
3401-1

7.1.2 Install clamping bar

NOTE! If more parts are planned to be exchanged in the crushing chamber, please
proceed to the instructions for those parts before installing the new clamping
bar.
a) Clean the slot where the clamping bar fits.
b) Push in the screws (3401-0) and the clamping bar (3400-0).
07_Crushing chamber_JM1208

c) Place the washers (3401-5), flexible washers (3401-6) and nuts (3401-1)
on the screws (3401-0).
d) Use a slugging wrench and combination wrench to tighten the nuts
(3401-1) that hold the clamping bar (3400-0). The flexible washers
(3401-6) must be 10 mm compressed when installation is complete.
e) Remove the props from the crushing chamber.

J11 © Sandvik Rock Processing AB – Doc. no. S 222.079 en Ver. 3 41

7. Crushing chamber

7.2 Exchanging jaw plates

The following wear parts are required:
Description Cat. no. Qty. Remarks
Jaw plate 1208-1 1 stationary jaw, weight 990 kg
Jaw plate 3300-1 1 moving jaw, weight 990 kg

Risk of crushing
Never weld external lifting eyes to the jaw plates. Always use the
referred lifting cavity on the jaw plate and the lifting tool provided with
WARNING! the jaw crusher. Read section 2. Safety precautions for further
information.

NOTE! These instructions are valid for both moving and stationary jaw. The pictures
describe the moving jaw.
NOTE! Remove the clamping bar before removing a jaw plate. See section
7.1.1 Remove clamping bar.

7.2.1 Remove jaw plate

a) Remove the props between the jaws.

07_Crushing chamber_JM1208
Recommended tools b) Release the jaw plate (3300-1) from the jaw by applying a crow bar to
Crow bar the upper edge of the jaw plate. Bend carefully.
Lifting tackle and chain
Mobile crane
c) Position the hook of a mobile crane vertically above the crushing
chamber.
NOTE! Make sure the crane is able to move longitudinally with respect to the jaw
crusher.

Risk of crushing
Be aware of the weight of the jaw plate, see table above. Never stand in
the crushing chamber while uncovering the lifting cavity with a crow
WARNING! bar.

d) Apply a crow bar between the jaw plate (3300-1) and the deflector plate
(moving jaw) (3500-0) or front frame end (stationary jaw) to uncover the
lifting cavity (1).
(Continued)

42 © Sandvik Rock Processing AB – Doc. no. S 222.079 en Ver. 3 J11

 7. Crushing chamber

e) Remove any sponge rubber strip or rags from the lifting cavity (1).
f) Attach the lifting hook (2) to the lifting cavity (1).

Risk of crushing
If the jaw plate is worn down too far, the lifting cavity can be worn away
or deformed. Sandvik Rock Processing strongly recommends
WARNING! exchanging the jaw plates before this occurs.

NOTE! It can be necessary to reinforce a worn away or deformed lifting cavity by

welding on a plate. The electrode used for welding on the jaw plate must
comply with DIN 8555 E8-200 ckZ, for example ESAB’s OK Selectrode
67.45.
g) Take up the slack in the lifting tackle.

Hanging load
Be aware of the weight of the jaw plate, see table above. Handle the jaw
plate with care. The tackle should now be tight but not lifting the jaw
DANGER! plate. Keep clear of hanging loads, see section 2. Safety precautions.

h) Carefully lift the jaw plate (3300-1) out of the crushing chamber.

Risk of crushing
07_Crushing chamber_JM1208

If the wear plate is attached to jaw plate when the jaw plate is lifted out
it can come off while lifting. Keep clear of hanging loads.
WARNING!
i) If the wear plate (3100-0) is attached to the jaw plate (3300-1) when the
jaw plate is lifted out it is necessary to fit a new wear plate (3100-0). See
section 7.3 Exchanging wear plates.
j) Place the jaw plate (3300-1) horizontally on the ground.

2
3500-0
3300-1
3500-0 Deflector plate 1
(moving jaw)
3100-0
3300-1 Jaw plate
3100-0 Wear plate
1 Lifting cavity
2 Lifting hook

J11 © Sandvik Rock Processing AB – Doc. no. S 222.079 en Ver. 3 43

7. Crushing chamber

7.2.2 Install jaw plate

NOTE! If it is planned to exchange wear plates (3100-0), cheek plates, deflector
plate (3500-0) and/or support bars (3200-0) at the same time, please proceed
to the instructions for those parts before installing the new jaw plate.
CAUTION! Replace the support bar bolts if they are broken. Remove the support
bar and clean it carefully. It’s important that the contact faces of the jaw
are clean. Tighten nuts. See section 7.4 Exchanging support bars.
NOTE! Check the condition of the wear plate (3100-0), see section 7.3 Exchanging
wear plates.
a) Clean the wear plate (3100-0), support bar (3200-0) and the corners of
the crushing chamber.
b) Position the hook of a mobile crane vertically above the new jaw plate
(3300-1).

2
3500-0
3300-1
1
3100-0

07_Crushing chamber_JM1208
3500-0 Deflector plate
(moving jaw)
3300-1 Jaw plate
3100-0 Wear plate
3200-0 Support bar
1 Lifting cavity 3200-0
2 Lifting hook

NOTE! Make sure the crane is able to move to the jaw crusher.
(Continued)

44 © Sandvik Rock Processing AB – Doc. no. S 222.079 en Ver. 3 J11

 7. Crushing chamber

c) Attach the lifting hook (2) to the lifting cavity (1) on new jaw plate
(3300-1).
d) Take up the slack in the lifting tackle.

Hanging load
Be aware of the weight of the jaw plate, see table above. Handle the jaw
plate with care. The tackle should now be tight but not lifting the jaw
DANGER! plate. Keep clear of hanging loads, see section 2. Safety precautions.

e) Carefully lift the jaw plate (3300-1) into the crushing chamber.
f) Place the jaw plate (3300-1) on the support bar (3200-0).
g) Adjust the jaw plate (3300-1) into its correct position.
h) Place a crow bar between the jaw plate (3300-1) and the deflector plate
(3500-0) or front frame end.
i) Slacken off the lifting tackle.
j) Remove the lifting hook (2) from the lifting cavity (1).
k) Pack a sponge rubber strip or rags into the lifting cavity (1) to keep out
dust.
NOTE! Do not use cotton waste!
l) Remove the crow bar
07_Crushing chamber_JM1208

m) Put two props between the jaws to fix the jaw plates in place until the
clamping bars above are installed, see section 7.1.2 Install clamping bar.

J11 © Sandvik Rock Processing AB – Doc. no. S 222.079 en Ver. 3 45

7. Crushing chamber

7.3 Exchanging wear plates

The following wear parts are required:
Description Cat. no. Qty. Remarks
Wear plate 1300-0 1 stationary jaw, weight 110 kg
Wear plate 3100-0 1 moving jaw, weight 110 kg

NOTE! These instructions are valid for both moving and stationary jaw. The pictures
describe the moving jaw.
NOTE! Remove the jaw plate before removing a wear plate. See section
7.2.1 Remove jaw plate.

7.3.1 Remove wear plate

NOTE! If a jaw shim plate is used, there is no wear plate. See section 7.7.1 Remove
jaw shim plate.

Recommended tools
a) Position the hook of a mobile crane vertically above the wear plate
Crow bar
(3100-0).
Lifting tackle and chain
Mobile crane
1

07_Crushing chamber_JM1208
3000-0

3100-0

3000-0 Jaw (moving)

3100-0 Wear plate
3200-0 Support bar
1 Lifting eye

3200-0

(Continued)

46 © Sandvik Rock Processing AB – Doc. no. S 222.079 en Ver. 3 J11

 7. Crushing chamber

b) Position the lifting hook in the lifting eye (1) on the wear plate (3100-0).
If the wear plate is stuck to the jaw, use a crow bar to release it.

NOTE! Make sure the crane is able to move longitudinally with respect to the jaw
crusher.
c) Take up the slack in the lifting tackle.

Hanging load
Be aware of the weight of the wear plate, see table above. Handle the
wear plate with care. The tackle should now be tight but not lifting the
WARNING! wear plate. Keep clear of hanging loads, see section 2. Safety
precautions.

d) Carefully lift the wear plate (3100-0) out of the crushing chamber.
e) Place the wear plate (3100-0) horizontally on the ground.

3000-0

3100-0
07_Crushing chamber_JM1208

3000-0 Jaw (moving)

3100-0 Wear plate
3200-0 Support bar
1 Lifting eye

3200-0

J11 © Sandvik Rock Processing AB – Doc. no. S 222.079 en Ver. 3 47

7. Crushing chamber

7.3.2 Install wear plate

a) Clean the support bar (3200-0), jaw (3000-0) and the corners of the
crushing chamber.
b) Position the hook of a mobile crane vertically above the new wear plate
(3100-0).
c) Attach the lifting hook to the lifting eye (1) on the new wear plate
(3100-0).
d) Take up the slack in the lifting tackle.

Hanging load
Be aware of the weight of the wear plate, see table above. Handle the
wear plate with care. The tackle should now be tight but not lifting the
WARNING! wear plate. Keep clear of hanging loads, see section 2. Safety
precautions.

e) Carefully lift the wear plate (3100-0) into the crushing chamber.
f) Place the wear plate (3100-0) on the support bar (3200-0).
g) Adjust the wear plate (3100-0) into its correct position.
h) Place a crow bar between the wear plate (3100-0) and the deflector plate
(moving jaw) or front frame end (stationary jaw).
i) Slacken off the lifting tackle.

07_Crushing chamber_JM1208
j) Remove the lifting hook from the lifting eye (1).
k) Remove the crow bar.

48 © Sandvik Rock Processing AB – Doc. no. S 222.079 en Ver. 3 J11

 7. Crushing chamber

7.4 Exchanging support bars

The following wear parts are required:
Description Cat. no. Qty. Remarks
Support bar 1205-0 1 stationary jaw, weight 37 kg
Screw M6S M20×140 1206-0 6 stationary jaw, recommended exchange
Self-locking nut M20 1206-1 6 stationary jaw, recommended exchange
Washer BRB 21×36 1206-2 6 stationary jaw, recommended exchange
Support bar 3200-0 1 moving jaw, weight 37 kg
Screw M6S M20×140 3201-0 6 moving jaw, recommended exchange
Self-locking nut M20 3201-1 6 moving jaw, recommended exchange
Washer BRB 21×36 3201-2 6 moving jaw, recommended exchange

NOTE! These instructions are valid for both moving and stationary jaw. The picture
describes the moving jaw.
CAUTION! Put two props between the jaws to prevent them from moving.
NOTE! Remove the wear plate before removing the support bar. See section
7.3 Exchanging wear plates.

7.4.1 Remove support bar

a) Use a combination wrench to loosen the nuts (3201-1) on the outside of
07_Crushing chamber_JM1208

Recommended tools
30 mm Combination wrench the crushing chamber that hold the support bar (3200-0).
Props b) Remove the nuts (3201-1) and washers (3201-2).
c) Pull out the screws (3201-0) and remove the support bar (3200-0).

3200-0 Support bar

3201-0 Screw
3000-0 Jaw (moving)
3201-2 Washer
3201-1 Self-locking nut

3200-0 3201-0 3000-0 3201-2 3201-1

Hanging load
Be aware of the weight of the support bar, see table above. Handle the
support bar with care. Keep clear of hanging loads, see section
WARNING! 2. Safety precautions.

J11 © Sandvik Rock Processing AB – Doc. no. S 222.079 en Ver. 3 49

7. Crushing chamber

7.4.2 Install support bar

a) Clean the jaw (3000-0).
b) Put the new support bar (3200-0) into place.
c) Push the screws (3201-0) into the holes in the support bar (3200-0) and
jaw (3000-0).
d) Install the washers (3201-2) and nuts (3201-1).
e) Tighten the nuts (331 Nm).

7.5 Exchanging deflector plate

The following wear parts are required:
Description Cat. no. Qty. Remarks
Deflector plate 3500-0 1 weight 160 kg
Screw M6S M16×50 3502-0 2
Washer BRB 17×30 3502-2 2
Locating bar 3503-0 2

NOTE! Remove the clamping bar before removing the deflector plate. See section
7.1.1 Remove clamping bar.

07_Crushing chamber_JM1208
7.5.1 Remove deflector plate
Recommended tools a) Position the hook of a mobile crane vertically above the deflector plate
24 mm Combination wrench
(3500-0).
Lifting tackle and chain b) Attach the lifting hooks to the two lifting eyes (1) on the top of the
Mobile crane deflector plate (3500-0).

3500-0 Deflector plate 1

3502-0 Screw 3500-0
3502-2 Washer
3502-0
3503-0 Locating bar
3000-0 Jaw (moving)
3502-2
1 Lifting eye 3503-0
3000-0

(Continued)

50 © Sandvik Rock Processing AB – Doc. no. S 222.079 en Ver. 3 J11

 7. Crushing chamber

NOTE! Make sure the crane is able to move longitudinally with respect to the jaw
crusher.
c) Take up the slack in the lifting tackle.

Hanging load
Be aware of the weight of the deflector plate, see table above. Handle
the deflector plate with care. The tackle should now be tight but not
DANGER! lifting the deflector plate. Keep clear of hanging loads, see section
2. Safety precautions.

d) Remove the screws (3502-0), washers (3502-2) and locating bars

(3503-0) that hold the deflector plate (3500-0).
e) Push the deflector plate (3500-0) away from the moving jaw (3000-0).
f) Carefully lift the deflector plate (3500-0) out of the crushing chamber.
g) Place the deflector plate (3500-0) horizontally on the ground.
h) Remove the lifting hooks from the lifting eyes (1).

7.5.2 Install deflector plate

a) Clean the jaw (3000-0) where the deflector plate (3500-0) will be placed.
07_Crushing chamber_JM1208

b) Position the hook of a mobile crane vertically above the new deflector
plate (3500-0).
c) Attach the lifting hooks to the two lifting eyes (1) on the top of the
deflector plate (3500-0).

3500-0 Deflector plate

3502-0 Screw
3502-2 Washer 1
3503-0 Locating bar 3500-0
3000-0 Jaw (moving)
3502-0
1 Lifting eye
3502-2
3503-0
3000-0

(Continued)

J11 © Sandvik Rock Processing AB – Doc. no. S 222.079 en Ver. 3 51

7. Crushing chamber

d) Take up the slack in the lifting tackle.

Hanging load
Be aware of the weight of the deflector plate, see table above. Handle
the deflector plate with care. The tackle should now be tight but not
DANGER! lifting the deflector plate. Keep clear of hanging loads, see section
2. Safety precautions.

e) Carefully lift the deflector plate (3500-0) into the crushing chamber.
f) Centre the deflector plate (3500-0) into its position.
NOTE! The locating bars (3503-0) must be in close contact with the deflector plate
(3500-0) to keep it in place.
g) Fasten the deflector plate (3500-0) with the locating bars (3503-0),
washers (3502-2) and screws (3502-0).
h) Slacken off the lifting tackle.
i) Remove the lifting hooks from the lifting eyes (1).

3500-0 Deflector plate

3502-0 Screw
3502-2 Washer 1
3503-0 Locating bar 3500-0

07_Crushing chamber_JM1208
3000-0 Jaw (moving)
3502-0
1 Lifting eye
3502-2
3503-0
3000-0

52 © Sandvik Rock Processing AB – Doc. no. S 222.079 en Ver. 3 J11

 7. Crushing chamber

7.6 Exchanging cheek plates

The following wear parts are required:
Description Cat. no. Qty. Remarks
Cheek plate 1103-0 1 left-hand side, weight 225 kg
Cheek plate 1104-0 1 right-hand side, weight 225 kg
Screw M6S 24×130 1106-0 10
Self-locking nut M24 1106-1 10
Flexible washer 1106-4 10
Steel washer D105/26×10 1106-5 10

NOTE! The crushing chamber contains two mirror image cheek plates. The
following instructions are for removal of one side. Repeat the procedure for
the other side.
NOTE! The cheek plates can be exchanged without removing the clamping bars and
jaw plates. Sandvik recommends however that you exchange the cheek
plates when these are removed.

Risk of crushing
Never weld external lifting eyes to the cheek plates. Always use the
lifting eye on the cheek plate and the lifting tool provided with the jaw
07_Crushing chamber_JM1208

WARNING! crusher. Read section 2. Safety precautions for further information.

J11 © Sandvik Rock Processing AB – Doc. no. S 222.079 en Ver. 3 53

7. Crushing chamber

7.6.1 Remove cheek plate

The cheek plate (1103-0) is attached with 5 screws (1106-0) to the frame
Recommended tools (1000-0). Each screw has a flexible washer (1106-4), a steel washer (1106-5)
Crow bar and a self-locking nut (1106-1).
Nylon hammer
Lifting tackle and chain a) Remove the upper four nuts (1106-1).
Mobil crane b) Knock out the four screws (1106-0).
36 mm Combination wrench
1 1103-0

1103-0 Cheek plate 1106-0

1106-0 Screw 1106-4
1106-4 Flexible washer 1106-5
1106-5 Steel washer
1106-1 Self-locking nut
1106-1
1000-0 Frame
1 Lifting eye

1000-0

07_Crushing chamber_JM1208
c) Loosen the remaining, lower screw (1106-0) but don’t remove the nut
until the lifting tackle is applied.
d) Position the hook of a mobile crane vertically above the crushing
chamber.
NOTE! Make sure the crane is able to move longitudinally with respect to the jaw
crusher.
e) Position the lifting hook in the lifting eye (1) on the cheek plate.

Risk of crushing
If the cheek plate is worn down too far, the lifting eye can be worn away
or deformed. Sandvik Rock Processing strongly recommends
WARNING! exchanging the cheek plates before this occurs.

(Continued)

54 © Sandvik Rock Processing AB – Doc. no. S 222.079 en Ver. 3 J11

 7. Crushing chamber

NOTE! It can be necessary to reinforce a worn away or deformed lifting eye (1) by
welding on a plate. The electrode used for welding on the cheek plate must
comply with DIN 8555 E8-200 ckZ, like ESAB’s OK Selectrode 67.45
f) Take up the slack in the lifting gear.

Hanging load
Be aware of the weight of the cheek plate, see table above. Handle the
cheek plate with care. The tackle should now be tight but not lifting the
DANGER! cheek plate. Keep clear of hanging loads, see section 2. Safety
precautions.

g) Remove the last self-locking nut (1106-1) and knock out the screw
(1106-0).
NOTE! If the cheek plate gets stuck, apply a crow bar between the frame (1000-0)
and the cheek plate.
h) Carefully lift the cheek plate out of the crushing chamber.
i) Place the cheek plate horizontally on the ground.

7.6.2 Install cheek plate

07_Crushing chamber_JM1208

a) Clean the frame (1000-0) and the corners of the crushing chamber on the
inside.
b) Position the hook of a mobile crane vertically above the new cheek plate.
NOTE! Make sure the crane is able to move to the jaw crusher
(Continued)

J11 © Sandvik Rock Processing AB – Doc. no. S 222.079 en Ver. 3 55

7. Crushing chamber

c) Attach the lifting hook to the lifting eye (1) on the cheek plate.
d) Take up the slack in the lifting gear.

Hanging load
Be aware of the weight of the cheek plate, see table above. Handle the
cheek plate with care. The tackle should now be tight but not lifting the
DANGER! cheek plate. Keep clear of hanging loads, see section 2. Safety
precautions.

e) Carefully lift the cheek plate into the crushing chamber.

f) Position the cheek plate in its place. Use a screw (1106-0) to find the
correct position.
g) Install all of the screws (1106-0). Place a flexible washer (1106-4), steel
washer (1106-5) and self-locking nut (1106-1) on each screw. Do not
tighten.
h) Slacken off the lifting tackle.
i) Remove the lifting hook from the lifting eye (1).
j) Tighten all nuts (1106-1). The flexible washers (1106-4) must be 3 mm
compressed when installation is complete.

1 1103-0

07_Crushing chamber_JM1208
1103-0 Cheek plate 1106-0
1106-0 Screw 1106-4
1106-4 Flexible washer 1106-5
1106-5 Steel washer 1106-1
1106-1 Self-locking nut
1000-0 Frame
1 Lifting eye

1000-0

56 © Sandvik Rock Processing AB – Doc. no. S 222.079 en Ver. 3 J11

 7. Crushing chamber

7.7 Exchanging jaw shim plates

The following accessories are required:
Description Cat. no. Qty. Remarks
Jaw shim plate 1302-0 1 stationary jaw, weight 240 kg
Jaw shim plate 3102-0 1 moving jaw, weight 240 kg

NOTE! The jaws can be equipped with jaw shim plates to decrease the nip angle or
minimum CSS setting.
NOTE! These instructions are valid for both moving and stationary jaw. The picture
describes the moving jaw.
NOTE! Remove the jaw plate before removing a jaw shim plate. See section
7.2.1 Remove jaw plate.

7.7.1 Remove jaw shim plate

3000-0 Jaw (moving)

3102-0 Jaw shim plate 3
3200-0 Support bar 3000-0
07_Crushing chamber_JM1208

1 Double slot
support bar
2 Single slot 1 2
support bar
3 Lifting eye

3102-0

3200-0

NOTE! If a wear plate is used, there is no jaw shim plate. See section 7.3.1 Remove
wear plate.
(Continued)

J11 © Sandvik Rock Processing AB – Doc. no. S 222.079 en Ver. 3 57

7. Crushing chamber

a) Position the hook of a mobile crane vertically above the jaw shim plate
Recommended tools (3102-0).
Crow bar b) Position the lifting hook in the lifting eye (3) on the jaw shim plate
Lifting tackle and chain
(3102-0). If the jaw shim plate is stuck to the jaw, use a crow bar to
Mobile crane
release it.

NOTE! Make sure the crane is able to move longitudinally with respect to the jaw
crusher.
c) Take up the slack in the lifting tackle.

Hanging load
Be aware of the weight of the jaw shim plate, see table above. Handle
the jaw shim plate with care. The tackle should now be tight but not
WARNING! lifting the jaw shim plate. Keep clear of hanging loads, see section
2. Safety precautions.

d) Carefully lift the jaw shim plate (3102-0) out of the crushing chamber.
e) Place the jaw shim plate (3102-0) horizontally on the ground.
Exchange for wear plates
If a thinner wear plate is to be fitted instead of the thicker jaw shim plate,
proceed with the following:

07_Crushing chamber_JM1208
f) Exchange the support bar (3200-0) with double slots (1) for one with a
single slot (2), see section 7.4 Exchanging support bars.

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 7. Crushing chamber

7.7.2 Install jaw shim plate

a) Make sure the support bar (3200-0) has double slots (1) (one for the jaw
shim plate (3102-0) and one for the jaw plate). If not, exchange support
bar according to section 7.4 Exchanging support bars.
b) Clean the support bar (3200-0), jaw (3000-0) and the corners of the
crushing chamber.
c) Position the hook of a mobile crane vertically above the new jaw shim
plate (3102-0).
NOTE! Make sure the crane is able to move to the jaw crusher.
d) Attach the lifting hook to the lifting eye (3) on the new jaw shim plate
(3102-0).
e) Take up the slack in the lifting tackle.

3000-0 Jaw (moving)

3102-0 Jaw shim plate 3
3200-0 Support bar 3000-0
1 Double slot
support bar
2 Single slot 1 2
07_Crushing chamber_JM1208

support bar
3 Lifting eye

3102-0

3200-0

(Continued)

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7. Crushing chamber

Hanging load
Be aware of the weight of the jaw shim plate, see table above. Handle
the jaw shim plate with care. The tackle should now be tight but not
WARNING! lifting the jaw shim plate. Keep clear of hanging loads, see section
2. Safety precautions.

f) Carefully lift the jaw shim plate (3102-0) into the crushing chamber.
g) Place the jaw shim plate (3102-0) on the inner slot of the support bar
(3200-0).
h) Adjust the jaw shim plate (3102-0) into its correct position.
i) Place a crow bar between the jaw shim plate (3102-0) and the deflector
plate (moving jaw) or front frame end (stationary jaw).
j) Slacken off the lifting tackle.
k) Remove the lifting hook from the lifting eye (3).
l) Remove the crow bar.

3000-0 Jaw (moving)

3

07_Crushing chamber_JM1208
3102-0 Jaw shim plate
3200-0 Support bar 3000-0
1 Double slot
support bar
2 Single slot 1 2
support bar
3 Lifting eye

3102-0

3200-0

60 © Sandvik Rock Processing AB – Doc. no. S 222.079 en Ver. 3 J11

 8. Setting adjustment system
This section describes the principle of the setting adjustment system that
gives the jaw crusher the desired setting and also the maintenance needed.
To ensure maximum safety, always read section 2. Safety precautions before
doing any work on the equipment or making any adjustments.
08_Setting adjustment sys-

J11 © Sandvik Rock Processing AB – Doc. no. S 222.079 en Ver. 3 61

8. Setting adjustment system

8.1 General
The setting adjustment system is designed to compensate for jaw plate wear
and to change the discharge setting of the jaw crusher. The setting adjustment
system is built into the back frame end.
The limitation of this chapter is the functionality of the jaw crusher and it
does not include the hydraulic system or the control panel of the setting
adjustment system. However the manufacturer’s manuals for the unit explain
the operation of the hydraulic system and the control panel.
CAUTION! To prevent interruptions in operation, the condition of the toggle plate
and the toggle seats should be checked in accordance with section
6. Inspection and care.

small setting =
smaller fragments

= =

08_Setting adjustment sys-

large setting =
larger fragments

=
=

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 8. Setting adjustment system

8.2 Setting adjustment

A toggle plate (5006-0) is fitted between an upper toggle seat (5004-0) and a
lower toggle seat (5005-0). Behind the toggle seat holder (5003-0), two
hydraulic cylinders (1) can push the setting wedges (2) inwards to decrease
the discharge setting. The moving jaw (3000-0) is pushed closer to the
stationary jaw and when the gap between the two jaws decreases only
smaller fragments of processed material are allowed to pass through. If the
hydraulic cylinders move outwards, the gap increases and larger fragments
of processed material can pass through. The setting adjustment system is
kept in place by a retraction arrangement with a hydraulic cylinder.

1
3000-0 Jaw (moving) 2
5005-0 Toggle seat 5003-0
08_Setting adjustment sys-

5006-0 Toggle plate 5004-0

5003-0 Toggle seat holder
5004-0 Toggle seat
1 Hydraulic cylinder
2 Setting wedge

3000-0 5005-0 5006-0

Never in contact!
The hydraulic system permits stepless setting adjustment over a wide range,
the limits depend on the condition of the jaw plates and length of the toggle
plate.
The setting wedges are self-locking during operation due to the load from the
crushing forces.
CAUTION! Never set the jaw plates so close that they can come in contact with
each other. The jaws must never be set so close that the jaw crusher be-
comes overloaded. See section 3.2 Processing data.

CAUTION! Never lubricate the setting wedges

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8. Setting adjustment system

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08_Setting adjustment sys-

64 © Sandvik Rock Processing AB – Doc. no. S 222.079 en Ver. 3 J11

 9. Setting measurement
This chapter describes the measurement of the CSS, the discharge opening
setting.
To ensure maximum safety, always read section 2. Safety precautions before
doing any work on the equipment or making any adjustments.
09_Setting measurement.fm

J11 © Sandvik Rock Processing AB – Doc. no. S 222.079 en Ver. 3 65

9. Setting measurement

9.1 Setting measuring gauge

The discharge setting is measured on a running jaw crusher and it is the
distance between the jaw plates at the bottom of the crushing chamber. The
measurement is called the Closed Side Setting (CSS). To measure this setting
distance, it is necessary to use a measuring tool, a rod with a disc, at the
bottom end of the stationary and moving jaw plates. The CSS measurement
is the nearest distance between the jaw plates, measured with the largest disc
that is in contact to the opposed jaw plate. The disc simulates the section of a
sphere or an ellipsoid-shaped stone. The measuring device is supplied with
Discharge setting the jaw crusher.

09_Setting measurement.fm
Measuring tool

9.2 Gauge
Characteristics Data
Number of rubber discs 8
Diameter 45 to 135 mm

The measuring tool is composed of a set of rubber discs with different

diameters, one rod with threaded ends and nuts and fixing washer and a
nylon line for gauge lifting. When the rod is suspended by the line, it will
maintain the mounted disc in a horizontal position.

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 9. Setting measurement

9.3 Measuring instructions

NOTE! Run the jaw crusher empty. Clean the feeder from process material, before
measuring begins.
Recommended tools
Gauge for measuring
a) Make an assumption of the diameter of disc to use. Mount it on the rod.
Measuring tape b) Lower the line of the measuring tool along the stationary jaw plate. The
disc should be in contact with two crests.
• If the measuring tool passes the bottom end of the jaw plates, the disc is
too small, but if the measuring tool is stopped before it reaches the
bottom end, the disc is too big.
• When the correct disc is mounted, it is in a horizontal position and
touching two stationary jaw plate crests and barely touching one moving
jaw crest at the bottom end of the jaw plates. This means that the disc
diameter is equal to the CSS opening.
• If a specific CSS opening value is required, use the corresponding disc
diameter and adjust the setting arrangement to the required setting. Read
more in section 8. Setting adjustment system, and in the unit’s operation
manual for the hydraulic system and the control panel.
NOTE! The crusher has accessories to help to adjust the CSS setting to a minimum.
Simply by replacing the wear plates behind the jaw plates with thicker jaw
09_Setting measurement.fm

shim plates (and exchanging the support bars) the minimum CSS setting can
be decreased.

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9. Setting measurement

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68 © Sandvik Rock Processing AB – Doc. no. S 222.079 en Ver. 3 J11

 10. Trouble shooting
This chapter describes a guide for solving different interruptions in
production.
To ensure maximum safety, always read section 2. Safety precautions before
doing any work on the equipment or making any adjustments.
10_Trouble shooting.fm

J11 © Sandvik Rock Processing AB – Doc. no. S 222.079 en Ver. 3 69

10. Trouble shooting

10.1 Faults and suggested actions

The following table shows possible causes and suggested actions. The
symbol “*” denotes a reference to another manual of this machine or a
component.
No. Fault Check Proposed action
1 Jaw crusher will Does the motor run Start motor. If not possible, check motor manual*.
not start Fuses or overload protection Change or reset fuses and overload protection.
Check manual* for action. If the problem persists,
call for electrical service.
V-belt condition and tension Check manual* for action
Is there a jam Remove the objects from the crushing chamber, see
section 2.3.8 Jams
Is the hydraulic pressure Check if the retraction cylinder is disengaged or not
present working. Check hydraulic system. Call for service.
2 Jaw crusher V-belt condition and tension Check manual* for action
stops Fuses or overload protection Change or reset fuses and overload protection.
Check manual* for action. If the problem persists,
call for electrical service.
Is the hydraulic pressure Check if the retraction cylinder is disengaged or not
present working. Check hydraulic system. Call for service.
Is there an unbreakable object Remove the object from the crushing chamber, see

10_Trouble shooting.fm
in the crushing chamber section 2.3.8 Jams
Drive Check motor and V-belt. Check manual* for action.
Is the discharge setting too Widen the setting, see section 8. Setting adjustment
small system
3 Rotation speed Does the V-belt slip Check manual* for action
fluctuates Is the hydraulic pressure vary- Check manual* for action
ing or falling
4 Noise from a run- Are the toggle plate, toggle See section 6. Inspection and care or call for service
ning crusher seats or toggle seat holder
worn
Is the retraction cylinder dam- Replace the retraction cylinder. See section
aged 6. Inspection and care or call for service.
Are the jaw plates loose Check if the screws of the clamping bar are loose or
need exchange, see section 6. Inspection and care
Are the jaw plates in contact Widen the discharge setting, see section 8. Setting
with each other adjustment system
Are nuts and screws loose Fasten nuts and screw or exchange worn parts, see
section 6. Inspection and care
5 Imbalance Are the crusher moving Possible damage in frame or foundation, call for
lengthways or sideways service
6 Vibrations Are there dirt inside the motor Clean the motor pulley or flywheels
pulley or flywheels
7 Bearing tempera- Measure the temperature Rising temperature above 75°C indicates bearing
ture too high failure, call for service.

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 10. Trouble shooting

No. Fault Check Proposed action

8 Jaw plate moves Is a jaw plate loose Attach the jaw plates. If not possible, exchange
them. See section 6. Inspection and care.
Is a jaw plate bent Exchange arching jaw plates, see section
6. Inspection and care
9 Toggle plate Is the jaw crusher or toggle See installation manual*
moves plate not correctly installed
Are the toggle plate, toggle See section 6. Inspection and care or call for service
seats or toggle seat holder
worn
10 Can’t change Is there a jam in the crushing Remove the jam
discharge setting chamber
Retraction cylinder Call for service if disengaged or damaged
Setting wedges Exchange jaw plates or add/remove jaw shim plates
if the wedges have reached their inner/outer limits,
see section 8. Setting adjustment system and sec-
tion 9. Setting measurement
Is the hydraulic pressure Check hydraulic system. Check manual* for action.
present
11 Wrong fragment Is the fragment size too large Reduce the discharge setting, see section 8. Setting
size adjustment system and section 9. Setting measure-
ment
Exchange the jaw plates, see section 6. Inspection
10_Trouble shooting.fm

and care
Add jaw shim plates, see section 6. Inspection and
care
Is the fragment size too small Widen the discharge setting, see section 8. Setting
adjustment system and section 9. Setting measure-
ment

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10. Trouble shooting

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10_Trouble shooting.fm

72 © Sandvik Rock Processing AB – Doc. no. S 222.079 en Ver. 3 J11