JAW CRUSHERS

Installation & Operation Manual

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 Installation & Operating
Instructions

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 TABLE OF CONTENTS

SAFETY CONSIDERATIONS .......................................................................................................................................... 6

GENERAL ......................................................................................................................................................................... 6
HAZARD LEVELS .............................................................................................................................................................. 6
LOCKOUT / TAG OUT PROGRAM ....................................................................................................................................... 6
DRIVE GUARDS ................................................................................................................................................................ 7
JAW CRUSHER SAFETY ..................................................................................................................................................... 7
SAFETY CHECK LIST ......................................................................................................................................................... 8

INTRODUCTION ................................................................................................................................................................ 9
GENERAL ......................................................................................................................................................................... 9
DESCRIPTION .................................................................................................................................................................. 9
MATERIAL APPLICATION ................................................................................................................................................. 9
Feed ......................................................................................................................................................................... 9
Discharge ................................................................................................................................................................. 9
Figure 1 ........................................................................................................................................................... 10
Figure 2 ........................................................................................................................................................... 11
DIES ............................................................................................................................................................................... 12
CHEEK PLATES .............................................................................................................................................................. 12
SPEED............................................................................................................................................................................ 12
HORSEPOWER ............................................................................................................................................................... 12
ROTATION ...................................................................................................................................................................... 12
Table I .............................................................................................................................................................. 13
Jaw crusher capacity in tons per hour .................................................................................................... 13

INSTALLATION ..................................................................................................................................................................14
GENERAL ....................................................................................................................................................................... 14
STRUCTURE & FOUNDATION .......................................................................................................................................... 14
Table II ............................................................................................................................................................ 14
L-Capitan Jaw Crusher approximate weight (in pounds) (-0%, +5%) ................................................. 14
STRUCTURE & FOUNDATION (CONTINUED) ................................................................................................................... 15
CLEARANCES ................................................................................................................................................................. 15
FIELD ASSEMBLY ........................................................................................................................................................... 15
FIELD ASSEMBLY (CONTINUED) .................................................................................................................................... 16
FLYWHEEL INSTALLATION.............................................................................................................................................. 16
INSTALLING FLYWHEELS ON SHAFT .............................................................................................................................. 16
Figure 3 ........................................................................................................................................................... 17
Figure 4 ........................................................................................................................................................... 18
Figure 5 ........................................................................................................................................................... 19
WELDING AND CUTTING PRECAUTION ........................................................................................................................... 19

LUBRICATION .................................................................................................................................................................. 20
GENERAL ....................................................................................................................................................................... 20
Table III ........................................................................................................................................................... 20
oil capacity chart ..................................................................................................................................... 20
Table IV ............................................................................................................................................................ 21
lubrication chart ...................................................................................................................................... 21

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 MANUAL OIL LUBRICATION SYSTEM FOR JAW CRUSHERS ............................................................................................ 21
Figure 6 ........................................................................................................................................................... 22
Figure 7 ........................................................................................................................................................... 22
AUTOMATIC OIL LUBRICATION SYSTEM FOR JAW CRUSHERS ....................................................................................... 23
Figure 8 ........................................................................................................................................................... 23
GENERAL ....................................................................................................................................................................... 23
DESCRIPTION ................................................................................................................................................................ 23
DRAWINGS PROVIDED INCLUDE: ................................................................................................................................... 23
C7003 Auto lube electrical schematic ......................................................................................................... 26
D10233 Auto lube jaw lubrication system (Small Frame Machines) ............................................................ 27
D10232 Automatic oil lube unit (20-Gal) ....................................................................................................... 28
D10337 Auto lube jaw lubrication system (Large Frame machines).......................................................................29
D10336 Automatic oil lube unit (30-Gal).........................................................................................................................30
DQ049-4 Example of a typical plant electrical schematic .................................................................... 30 & 31
INSTALLATION ............................................................................................................................................................... 23
STARTUP ........................................................................................................................................................................ 24
OPERATION .................................................................................................................................................................... 24
LOW-PRESSURE ALARM ................................................................................................................................................ 24
ELECTRICAL .................................................................................................................................................................. 24
MAINTENANCE ............................................................................................................................................................... 25
Motors .................................................................................................................................................................... 25
Filters ..................................................................................................................................................................... 25
Jaw Reservoir ......................................................................................................................................................... 25
Bearings ................................................................................................................................................................. 25
JAW FLUSHING INSTRUCTIONS ...................................................................................................................................... 25

JAW CRUSHER OPERATION ......................................................................................................................................33

GENERAL ....................................................................................................................................................................... 33
STARTING CARE ............................................................................................................................................................. 33
MATERIAL SIZE ADJUSTMENT ........................................................................................................................................ 33
CRUSHERS WITH MANUAL TOGGLE ADJUSTMENT .......................................................................................................... 34
CRUSHER WITH HYDRAULIC TOGGLE BLOCK ADJUSTMENT ........................................................................................... 35
TENSION SPRING, ROD & TOGGLE PLATE ADJUSTMENT PROCEDURE ............................................................................ 35
TENSION ROD, AIR SPRING & HYDRAULIC TOGGLE ADJUSTMENT PROCEDURE ............................................................. 36
CRUSHERS WITH AUTOMATIC HYDRAULIC TOGGLE RELIEF & HYDRAULIC ADJUSTMENT ............................................... 38
INTRODUCTION .............................................................................................................................................................. 39
GENERAL INFORMATION ................................................................................................................................................ 39
Figure 9 ........................................................................................................................................................... 39
REDUCING JAW OPENING .............................................................................................................................................. 40
Figure 10 ......................................................................................................................................................... 40
Figure 11 ......................................................................................................................................................... 40
INCREASING JAW OPENING ........................................................................................................................................... 41
Figure 12 ......................................................................................................................................................... 41
Figure 13 ......................................................................................................................................................... 41

JAW CRUSHER MAINTENANCE ............................................................................................................................... 37

CLEARING CLOGGED CRUSHER ..................................................................................................................................... 37
REVERSE POSITION OF TOGGLE BLOCK TO CHANGE CRUSHING ANGLE ........................................................................ 37
REASSEMBLY OF CRUSHER AFTER REVERSING POSITION OF TOGGLE BLOCK .............................................................. 37
ADJUSTMENTS ............................................................................................................................................................... 37
HYDRAULIC TOGGLE MAINTENANCE .............................................................................................................................. 42
Pump Maintenance ................................................................................................................................................ 42
Figure 14 ......................................................................................................................................................... 42
Figure 15 ......................................................................................................................................................... 42

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 TOGGLE END MAINTENANCE .......................................................................................................................................... 43
Figure 16 ......................................................................................................................................................... 43
HYDRAULIC TOGGLE PARTS INFORMATION .................................................................................................................... 43
Parts Ordering Procedure...................................................................................................................................... 43
HYDRAULIC TOGGLE CYLINDER DISASSEMBLY AND REASSEMBLY ................................................................................ 53
Important ............................................................................................................................................................... 53
Figure 17 ......................................................................................................................................................... 53
Figure 20 ......................................................................................................................................................... 54
Figure 21 ......................................................................................................................................................... 54
Figure 22 ......................................................................................................................................................... 55
Figure 23 ......................................................................................................................................................... 55
Figure 25 ......................................................................................................................................................... 56
Figure 26 ......................................................................................................................................................... 57
Figure 27 ......................................................................................................................................................... 58
Figure 28 ......................................................................................................................................................... 59
Figure 29 ......................................................................................................................................................... 59
Figure 30 ......................................................................................................................................................... 60
Figure 31 ......................................................................................................................................................... 60

IMPORTANT INFORMATION .................................................................................................................................... 6 2

JAW CYLINDER REPAIR .................................................................................................................................................. 62
Figure 34 ......................................................................................................................................................... 62
RELIEF VALVE SETTINGS ................................................................................................................................................ 63
TROUBLESHOOTING ....................................................................................................................................................... 63
ELECTRICAL CIRCUIT .................................................................................................................................................... 64
REPLACMENT PARTS ..................................................................................................................................................... 64

DISASSEMBLY................................................................................................................................................................ 65
GENERAL ....................................................................................................................................................................... 65
TOGGLE ASSEMBLY ........................................................................................................................................................ 65
REMOVING STATIONARY JAW DIE ................................................................................................................................... 65
Figure 36 .................................................................................................................................................................................... 66
DISMANTLING SHAFT ASSEMBLY ................................................................................................................................... 66
Figure 37 ......................................................................................................................................................... 66
Figure 36 ......................................................................................................................................................... 66
Figure 38 ......................................................................................................................................................... 67
FLYWHEEL REMOVAL..................................................................................................................................................... 67
REMOVAL OF FRAME BEARINGS .................................................................................................................................... 67
REMOVAL OF SWING JAW BEARINGS ............................................................................................................................. 68
Figure 39.................................................................................................................................................................... .......... 68

REASSEMBLY .................................................................................................................................................................. 6 9
GENERAL ....................................................................................................................................................................... 69
Figure 40 ......................................................................................................................................................... 69
INSTALLATION OF SWING JAW BEARINGS ...................................................................................................................... 69
INSTALLATION OF FRAME BEARINGS ............................................................................................................................. 70
Table V ............................................................................................................................................................. 70
TORQUE TABLE FOR JAW CRUSHERS ........................................................................................................ 70
LIFTING CHAIN SPECIFICATIONS ................................................................................................................................... 71
Table VI ............................................................................................................................................................ 71
GENERAL V-BELT MAINTENANCE ................................................................................................................................... 72
V-BELT DRIVE TENSIONING GUIDELINES ........................................................................................................................ 74
Table VII ........................................................................................................................................................... 73
TORQUE AND LOAD TABLES ........................................................................................................................................... 73
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 SAFETY CONSIDERATIONS

Always Think Safety

General
This manual is intended to provide your crushing plant personnel with safe and effective procedures for operating
and maintaining your Lippmann-Milwaukee jaw crusher. All personnel working on or around this equipment should read
and understand this manual and follow the instructions and warnings noted herein. They also must pay attention to all
Danger, Warning, Caution, and Notice items in this manual and to the decals applied to the equipment. Failure to follow
sound safety practices and procedures can cause death, severe personal injury, or substantial damage to the equipment.
Please contact Lippmann-Milwaukee, if you do not understand the procedures outlined in this manual or if you have any
questions or comments regarding safe operating or maintenance procedures.

Hazard Levels
The signal words DANGER
ANGER, WARNING
ARNING, CAUTION
CAUTION, and NO TICE are used in this manual and on warning decals on the equip-
NOTICE
ment. They are used to alert personnel to varying levels of hazards. Their meaning is as follows:
DANGER Immediate hazards which WILL result in sever personal injury or death
WARNING Hazards or unsafe practices which COULD result in severe personal injury or death
CAUTION Hazards or unsafe practices which COULD result in personal injury
NOTICE
NOTICE Practices or procedures, that if not followed, COULD lead to serious and costly damage to the equipment

Lockout / Tag out Program

One of the most preventable sources of serious accidents with crushing and screening equipment concerns the
power sources being inadvertently energized while personnel are working on the equipment. OSHA and MSHA regulations
require each employer to establish a Lockout / Tag out Program and train its employees before any employee operates,
maintains, or services a piece of equipment.

ALWAYS
Lockout / Tag out the power source before performing any inspection and maintenance on the equipment.

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Drive Guards

Drive guards are provided on all Lippmann-Milwaukee portable plants and skid mounted units that are supplied
with an onboard drive or motor. Please note that individual jaw crushers are supplied without drive guards, and it is the
purchasers responsibility to provide and install any guards that may be required by local, state, or federal statutes or
regulations.

Jaw Crusher Safety

ALWAYS
Always disconnect the, battery cables from the diesel engine before performing any maintenance on diesel
powered crushers.
Always stand clear of the discharge and feed areas of the Jaw crusher. Material can be ejected from the machine
at high velocities, which can result in serious injury or death.
Always rotate flywheel so weights are at top before working on the jaw crusher
Always know your equipment read the instruction book for complete information on the operation and care of the
various components.
Always keep all the parts tight. Loose bolts will allow parts to cause wear between mating surfaces, and ultimate
breakage will occur. Loose parts on one section of the machine may also cause vibration resulting in
loosening and subsequent wearing of other parts of the unit.
Always keep all bearings lubricated. Refer to the Lubrication instructions in the operators manual.
Always keep the proper tension an all V-belts. Refer to the sheet in the manual on checking the V-belt tension &
alignment, and follow the instructions carefully.
Always keep the equipment clean. Do not allow material to accumulate around vibrating equipment, bearings and
seals. A neat appearing plant inspires the operators to keep it in better running condition. A little diligence
in inspecting and maintaining the equipment can eliminate costly repairs and lossJn production. Maintain-
ing proper clearance on Vibrating Screens and Feeders is especially important, because banging or hitting
on the vibrating frame will cause structural failure in a very short time. Under no circumstances should a
Screen or Feeder be allowed to hit.
NEVER
Never climb on the jaw crusher during operation.
Never clean or repair machinery during operation.
Never overload your equipment. It is important to control the feed, and balance the various units to prevent
overloading any piece of equipment in the plant. Constant overloading of any of the units may cause exces-
sive wear and premature bearing and structural failure, which will result in high maintenance costs.
Never start a crusher with material in the chamber. This could cause slippage, and damage to the V-belts even
though they are properly tensioned for normal operation.
Never operate the equipment unless all guards are in good condition and properly installed. Please contact
Lippmann-Milwaukee if you need assistance in designing or building a drive guard for you jaw crushers

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Safety Check List

Make certain you have established a safety program and all personnel working on or around the
equipment are fully trained in safe operating and maintenance practices
Wear steel toed safety shoes
Use hearing protection devices and safety glasses when equipment is running
Report unsafe conditions and defective equipment immediately
Always disconnect the battery leads on diesel driven plants before working on the equipment.
Use the ladders and walkways provided on plants to access the equipment
Never climb on top of the crusher when it is running
Make certain all personnel are clear of the equipment before starting
Use only qualified electricians to troubleshoot and repair electrical equipment
Never allow personnel to be under a suspended load
Do not operate the equipment until personnel are trained in safety, operation, and maintenance
Wear proper clothing when around the equipment. Do not wear loose clothing, scarves, ties, etc.
that could get caught in v-belt drives, conveyor pulleys, idlers
Wear hard hats at all times
Use breathing masks when dust and fumes are above acceptable limits
Never operate the equipment without all guards in place
Never attempt to clear obstructions from the equipment while it is running
Do not operate the equipment if the walkways, observation platforms, etc. are not in good condition
Make certain all tools and materials are removed from the equipment before starting
Make certain the power sources are properly grounded
Consult the diesel engine manufacturers operation manual, if the plant is diesel powered
Constantly stress safety to your crushing plant personnel
Use only trained personnel to operate and maintain the crushing equipment
Do not walk under conveyor
Shut off engine before refueling
Stay clear of moving conveyor belts

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 INTRODUCTION
General
This manual covers the Lippmann L-Capitan Jaw Crushers. Specific capacities in tons per hour are shown in Table I and
technical characteristics and weights are shown in Table II.
As soon as the crusher is received, inspect carefully for any shortages of parts, or damage. Refer, for this purpose, to the
shipping manifest and to the parts list on the general arrangement drawing and shaft assembly drawing. Any shortage or
damage noted should be called to the attention of the local freight agent for the carrier at once. They should make a proper
statement on the freight bill at this time, so that a claim can be made against the carrier for replacement or adjustment.
After this precaution has been taken, notify the factory, giving full details so that replacements can be furnished promptly to
avoid delay in operating the machine.

Description
The L-Capitan Jaw Crusher is an overhead eccentric shaft type unit and is designed with many features to permit easy
maintenance and longer service life. (See Figure 1 for crusher parts identification.)
High capacity radial thrust taper roller bearings provide the necessary support for shock loading conditions of the jaw
crusher operation. They are built extra large for heavy-duty service and can be adjusted accurately for running clearance
and wear. The bearings are protected by, mechanical labyrinth type seals, with dust flingers to limit contamination from the
normally dusty conditions of a crushing plant. The bearings are lubricated with oil, which is maintained at a level in the jaw
barrel and frame bearing housing to meet the bearing rollers. An optional continuous flow oil circulating system can also
be provided to ease frequency of oil level checks, and to provide filtering and cooling of the oil.
The swing jaw is a rugged heat-treated steel casting. It is supported at the top by the eccentric shaft and bearings. (See
Figure 2 for swing jaw and shaft assembly identification.)
It is also pivoted at the bottom by an adjustable toggle plate and tension rod arrangement. An optional hydraulic toggle can
be provided to permit quick and easy adjustment of the movable jaw die opening. The crusher main frame is a rugged
weldment of steel plate reinforced with heavy ribbing. The stationary jaw die is held in position by the wedging action of the
die extension and high strength bolts.

Material Application
Feed
The jaw crusher can be equipped with a feed hopper or chute. If the feed material contains fines or a wet sticky material,
use a scalping screen or grizzly section ahead of the crusher. On the other hand, if the feed is large and slabby, exercise
care that the material will feed freely and not become jammed. Top size of the feed should generally not exceed 80% of the
feed opening.
Distribute the feed evenly over the full width of the feed opening to equalize wear against the jaw dies and provide closer
control of product size. The material should fall vertically into the crushing cavity. To prevent excessive wear, do not allow
the aggregate to hit and wear against the jaw barrel. Provide some positive means of controlling the rate of feed, such as
an apron or vibrating feeder.
Discharge
Since the discharge arrangement varies with each installation, no discharge chute or attachments are furnished with the
crusher. The slope of the discharge chute should be designed so the material will flow freely under all conditions. Be sure to
provide ample clearance beneath the swing jaw and tension rod. This will prevent material from building up on the chute
and clogging the discharge. A free and unimpeded discharge is essential. Avoid any type of construction that will allow
clogging.

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 FIGURE 1

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FIGURE 1
JAW CRUSHER PARTS IDENTIFICATION
 FIGURE 2

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FIGURE 2
JAW CRUSHER PARTS IDENTIFICATION
Dies Speed
The Jaw Crusher can be furnished with several types of jaw It is important that the crusher be operated at the speed
dies. The proper selection is dependent upon the feed size, recommended. Care should be exercised to obtain a motor
the product size and the type of material to be crushed. pulley of proper diameter, to assure the proper operating
This information should be submitted to the factory before speed. Speed is shown on the nameplate, which is located
making the installation so that the correct dies can be on the swing jaw barrel (see Figure 6). Running the crusher
recommended. Also, consult the factory when any radical too fast will reduce capacity. Running to fast can also cause
change in the feed material is contemplated. Operating with a number of problems: The toggle plate will start scraping
dies unsuited for the material crushed results in uneco- or pounding the toggle bearings causing excess wear in the
nomical wear and poor crushing efficiency. If no information toggle bearings, the toggle plate, and greater impact force
is furnished or where the crusher is to serve a variety of in the jaw crusher. Increased speed also reduces the life of
conditions, jaw dies having a series of longitudinal the roller bearings and the jaw crusher itself.
intermeshing corrugations and a convex longitudinal
curvature are furnished. These dies are special alloy steel Horsepower
and have been designed to be most suitable for the normal
materials and purposes. Always operate the jaw crusher at the recommended
The jaw dies and extensions are reversible, i.e. they can be horsepower. Table I shows the recommended horsepower.
turned end-for-end when worn in order to present new Diesel horsepower recommended is 1.35 times the electric
crushing surfaces in zones of greatest wear. Do not allow horsepower plus the fan horsepower. Excess horsepower
the dies to wear down excessively. Such practice will will void the warranty and can cause damage to the jaw
prevent the complete utilization of the dies, and cause undo crusher.
wear on die supports and greatly increase the power
consumption. Lippmann does not allow flat end dies. Use of Rotation
flat end dies greatly increases the force through out the jaw
and will void the warrenty. It is good practice to keep an The crusher shaft should rotate toward the feed end as
extra set of dies on hand. Order only genuine Lippmann shown by the arrow in the illustration. The rotation should
parts. They are designed to do a better job and are easily impart a forward and downward motion to the swing jaw.
procured from your Lippmann distributor.
The jaw dies are held in position by means of the wedging
action of the jaw die extensions. The extensions are in turn
held in place by jaw die bolts. 1 1/2" jaw die bolts should be
tightened to 750 foot pounds when using 3 rubber washers
and a hardened washer under the nut and jam nut. 1 1/4"
jaw die bolts should be tightened to 450 foot pounds and 1"
jaw die bolts should be tightened to 250 foot pounds. Do not
operate the crusher with loose dies since this will lead to
excessive wear or breakage and will eventually destroy the
die bearing surfaces.

Cheek Plates
The crushers cheek plates are made of manganese steel or
500BHN Alloy steel. Be sure to order only genuine Lippmann
cheek plates, direct from the factory or from your Lippmann
distributor.

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Table I Specifications
Based on tons of 2,000 lbs. of material weighing 100 lbs per cubic foot crushed, which will readily enter the crushing
chamber without bridging the crusher will normally make product 70% of which passes a screen opening of the same
dimension as the given discharge setting. The left most bolded ton per hour values in the table below shows the minimum
closed side setting. The minimum closed side setting for jaw crushers is measured peak to peak in the swing jaw up
position. IMPORT ANT
ANT:: Please note that setting the crusher any tighter than the minimum closed side setting could result in
MPORTANT
serious damage to the machine and will immediately void the warranty.
Discharge opening, peak to peak, up position

Table I
JAW CRUSHER CAPACITY IN TONS PER HOUR
SIZE EE.HP
.HP RPM 1" 1-1/2" 2" 2-1/2" 3" 3-1/2 4" 5" 6" 7" 8" 10" 12" 14" 16
10 x 16 20 325 10 15 20 25 30 35 40
15 x 24 40 275 32 43 54 64 76 88 110
12 x 36 60 275 49 65 83 98 115 130 163
12 x 48 75 275 66 85 110 131 154 173 217
12 x 60 125 275 88 114 146 174 204 229 305
15 x 36 75 275 55 73 91 109 128 147 182 220
20 x 36 100 275 89 110 132 155 176 221 264 308
24 x 36 100 275 115 139 162 185 230 277 322 370
30 x 36 125 275 139 162 186 232 278 324 371 462
22 x 42 125 275 101 126 151 176 202 252 302 353 403
30 x 42 200 230 192 222 252 312 372 432 492 612 732
22 x 48 150 275 115 144 173 202 230 288 346 403 460
30 x 48 200 230 205 235 275 343 412 480 598 685
36 x 50 250 220 310 340 425 520 600 680 840 1030 1130
42 x 48 250 210 4 1/2=400
1/2=400 444 540 624 708 876 1068 1188 1320
46 x 48 250 210 350 444 540 624 708 876 1068 1188 1320
24 x 50 150 275 120 151 186 210 237 296 351 410 466
30 x 62 200 220 220 280 340 420 490 570 650 800
50 x 62 300/350 190 600 700 850 980 1200 1400 1600 1800

NOTES
TES::
NOTES
Capacities shown may vary (25% depending on the type of rock, gradation of feed, horsepower and toggle position. Wet
sticky feeds will adversely affect the capacity, especially at close settings. The horsepowers shown are approximate and
will vary according to the size of product being made, capacity, hardness and toughness of rock or ore, consult the factory
for the ideal setting for your application.
Where no capacity rating is given in the table, it is generally not economical or recommended to operate at such a setting.

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 Table II
L-CAPITAN JAW CRUSHER APPROXIMATE WEIGHT (IN POUNDS) (-0%, +5%)
FRAME COMPLETE TOTAL ** * FLYWHEEL FLYWHEEL CU. FT. FOR
PARTS ASSEMBLY JAW ASSEMBLY WEIGHT FRAME JAW PLAIN GROOVED EXPORT
10 x 16 2,500 3,000 5,500 2,000 1700 700 600 95
15 x 24 5,500 5,800 11,300 4,200 4,000 1000 900 215
12 x 36 8,800 10,800 19,600 6,700 6,400 2,200 2,200 255
12 x 48 12,000 12,900 24,900 8,900 8,900 2,100 1,900 365
12 x 60 15,600 16,800 32,400 10,900 12,300 2,300 2,200 410
15 x 36 11,200 11,200 22,400 8,600 7,500 1,900 1,800 295
20 x 36 14,000 12,700 26,700 10,800 8,300 2,200 2,200 395
24 x 36 15,900 15,100 31,000 12,900 11,100 2,100 1,900 480
30 x 36 16,900 15,100 32,000 13,400 11,100 2,100 1,900 500
22 x 42 20,100 16,200 36,300 15,300 12,200 2,100 1,900 447
30 x 42 36,200 28,500 64,700 29,500 21,100 3,700 3,700 779
22 x 48 20,900 20,800 41,700 15,400 16,800 2,100 1,900 551
30 x 48 33,700 30,500 64,200 24,500 23,100 3,700 3,700 797
36 x 50 46,700 41,300 88,000 36,100 33,900 3,700 3,700 995
42 x 48 70,700 61,700 132,400 54,100 43,000 9,500 9,200 1,487
46 x 48 63,800 58,000 121,800 53,000 38,500 9,500 9,500 1,440
24 x 50 20,800 20,800 41,600 15,400 16,800 2,000 2,000 564
30 x 62 35,100 35,400 70,500 25,600 27,600 4,000 3,800 1,608
50 x 62 111,200 100,600 211,800 85,400 86,100 7,500 7,000 2,330
* Includes jaw die without flywheels ** Bare weldment
NOTE:: Weights in Table II are for standard jaw crushers only. Weight must be added to account for any accessories (I.E.
TE
NOTE
heavy duty dies, hydraulic toggle, frame modifications, etc....).
NOTE
NOTE:: If a crusher with an automatic hydraulic toggle has been purchased, increase weights by at least 3,000 lbs. Increase
TE
weights by at least 5,000 lbs. for the 42 x 48 and the 50 x 62.
NOTE:: If a crusher other than the 42x48 comes equiped with side mounting supports, increase weight by 2,000 lbs. In-
NOTE
TE
crease weights by 3,400lbs. for the 42 x 48.

INSTALLATION
General
Although the jaw crusher is a rough and tough machine ready for heavy-duty service and although it is frequently covered
with rock and excessive dust and otherwise abused, a certain degree of care must be exercised in its maintenance and
operation. Proper caution in operation will pay big dividends in trouble-free service and in longer life.

Structure & Foundation

Before designing a structure and foundation, obtain a copy of the general arrangement drawing for dimensions and design
load information from the Engineering Department. Be sure to obtain an experienced and reputable engineering firm to
design your structure and foundation.

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Structure & Foundation (Continued)
In making the foundation, it is very important to determine the character of the sub foundation. Care should be taken to
provide sufficient bearing area, especially if the subsoil is soft or shifting. Be sure to extend the footings at least 6" below
the frost line. The concrete foundation should be of adequate weight so it reduces vibration to acceptable levels and
spreads the bearing loads to allowable levels. The structure must be adequately braced so a structural frequency is not in
tune with the crusher frequency. This resonant frequency can cause serious vibration problems, and cracking, and even
failure of the structure.

Clearances
Allow proper clearance for convenient servicing of the crusher. Ready accessibility to wearing parts means that they will be
more likely to receive proper attention. Be sure to provide adequate span above the equipment for removal of the jaw dies,
cheek plates, flywheels, and for the jaw assembly so that an overhead crane or other means of lifting can readily service
these parts.

Field Assembly
In order to properly assemble the jaw crusher, adequate crane facilities must be supplied. No attempt should be made to
handle the various parts without a crane or other lifting device capable of handling the crusher sections of the weights
shown in Table II.
Note: Weights in Table II are for standard jaw crushers only. weight must be added to account for any accessories (I.E.
heavy duty dies, hydraulic toggle, frame modifications).
The jaw crusher has been assembled and lubricated at the factory. For convenient shipping and handling at its destination,
it may have been partially disassembled and the unpainted surfaces covered with a rust proofing compound. Rust proofing
can be removed with a cleaning solvent or fuel oil. After cleaning, the surfaces should be wiped with an oil-soaked cloth to
prevent corrosion.
To assemble in the field, the crusher component parts should be moved to the permanent site. Unpack the wooden box
containing parts and tools for use in assembling the crusher, as well as V-belts and, motor and drive sheaves, if ordered.
Refer to Figure 1 before reassembling the crusher. The lifting of the frame should be accomplished by cable slings hooked
in the four (4) lifting holes provided in the frame or ribs at front and rear of crusher frame. The crusher main frame must
be bolted down in position on the footings.
After making sure that all unpainted surfaces are cleaned of rust proofing compound, the frame caps must be checked for
any high spots that may have occurred by bumping while handling. Any high spots on the inside surfaces, toward the frame
bearing retainers, either on the frame caps or the frame bearing retainer saddles in the frame, must be filed off before the
jaw is placed in the frame. The frame bearing retainers must also be inspected for any high spots that may have occurred
in shipment, and these high spots filed off before lowering the jaw into the frame.
The swing jaw can now be lifted by means of the lifting lug on top of the jaw. This assembly must be lowered into the frame
very carefully. Because of the supports for the toggle block, the jaw cannot be lowered directly onto the lower frame
bearing caps; therefore, while the assembly is hanging on the crane the lower end must be tipped toward the feed end for
proper positioning. This tipping can be accomplished by hooking a chain tackle or winch to the tension rod eye location on
the lower end of the swing jaw and pulling the bottom toward the feed end of the jaw, while lowering the assembly slowly
into position. The chain tackle or winch should be well anchored to the feed side of the crusher. Be sure to set the holes in
the bearing retainers over the dowel pins in the lower frame bearing caps. The swing jaw assembly should seat down in the
frame without binding or forcing. If there is any evidence of binding, lift up the assembly again and check the location of
the of the dowel holes in the frame bearing retainer to be certain that they are fitting properly over the dowel pins. After the
jaw assembly is in position, the upper frame bearing caps can be placed in their original position and bolted down. See the
Torque Table VII for torque values.
NOTE
TE:: Be sure to observe the match markings on the upper and lower frame bearing caps, as they are not interchangeable.
NOTE

07/03/08 -15-
Field Assembly (Continued)
To install the toggle plate move the lower part of the swing jaw away from the toggle block. To do this use a chain and
tackle, fastening one end to the tension rod eye on the lower end of swing jaw and the other end should be well anchored
towards the feed end of the crusher. The swing jaw can then be pulled up against the stationary jaw die in one hook up.
The toggle plate can now be lowered through the space between the toggle block and the swing jaw by use of a chain
tackle. A chain or cable passed through the outer cutouts in the toggle plate should be hooked so as to balance the toggle
plate when lifting.
When the toggle plate is placed into operating position, the swing jaw can be released to allow the toggle plate to seat in
the toggle bearings. Before installing the tension rod, check to be sure that the toggle plate is seated in the toggle bearing
in the toggle block.
After the toggle plate is in position, install the tension rod, springs, and washers. Refer to the section on Jaw crusher
operation under the heading of size adjustment for information regarding adjustment of the discharge setting.

Flywheel Installation
The flywheels can be lifted using a cable sling with a loop or hook on one end; this type of sling can be wrapped around the
face of the flywheel. The loop or hook should be at the top and the cable drawn snugly around the face of the flywheel.
The cable should be adjusted so that the wheel is hanging perfectly vertical for ease in starting on the shaft and over the
key. Because of the position of the grooves, it is sometimes not possible to wrap the cable sling directly around the center
of the grooved flywheel. This flywheel can easily be handled by placing several wood blocks across the face. The cable can
then be located in one groove and crossed over the wood blocks to another groove to properly balance the wheel. The
flywheels should be lifted with the counterweights near the top and corresponding to the position of the key in the shaft.
The jaw should be hanging in the frame with the eccentric of the shaft at the bottom. In this position the key way for the
flywheel key will be near the top. The name LIPPMANN on the flywheel should be to the outside or away from the crusher.

Installing Flywheels on Shaft

On crushers with shaft extensions and no tapped holes in shaft, install flywheels on shaft by driving steel wedges into the
slots in the web of the flywheel as close to the hub as possible. The flywheels can then be placed on the shaft extension
tube and jacked on with two (2) studs and plate as shown in Figure 3. After the flywheels are pulled tight against the frame
bearing spacers, install the flywheel clamping washer locknuts. Draw up the flywheel nut securely, and then install the lock
washer and lockout. The four (4) flywheel bolts on each flywheel should now be tightened securely and locked with a
double nut.
On crushers with two holes tapped in the eccentric shaft, place the flywheels on the shaft using two (2) studs and a plate to
pull the flywheel up tight against the frame bearing spacers. (See Figure 4 & 5).

07/03/08 -16-
 Figure 3
FLYWHEEL MOUNTING DIAGRAM

SIZE A B C
10 X 16;10 X 24 3.970 4.250 12"
15 X 24 4.715 5.000 14"
10 X 36; 12 X 36 5.497 5.750 14"
15 X 36 5.497 6.000 14"
20 X 36 5.888 6.500 16"
24 X 36; 30 X 36; 22 X 42 5.888 6.500 16"

07/03/08 -17-
 Figure 4
FLYWHEEL MOUNTING DIAGRAM

SIZE A B C Thread Size

12 X 48 8" 18" 2-1/4" 3/4" X 10 NC
12 X 60 10" 20" 5" 1-1/4" X 7 NC
22 X 48 10" 20" 5" 1-1/4" X 7 NC
30 X 42SB; 30 X 42SA; 30 X 48 14" 24" 7" 1-1/4" X 7 NC
36 X 48 19" 29" 8" 1-1/2 X 6 NC
42 X 48SB; 42 X 48SA; 46 X 48 19" 29" 8" 1-1/2 X 6 NC
50 X 62 22" 32" 10" 1-1/2 X 6 NC

07/03/08 -18-
 Figure 5
FLYWHEEL MOUNTING DIAGRAM, NEW

SIZE A C Thread Size

12 X 48 8" 2-1/4" 3/4" X 10 NC
12 X 60 10" 5" 1-1/4" X 7 NC
22 X 48 10" 5" 1-1/4" X 7 NC
30 X 62; 30 X 42SA; 30 X 48 14" 7" 1-1/4" X 7 NC
36 X 50 19" 7" 1-1/4" X 7 NC
42 X 48SB; 42 X 48SA; 46 X 48 19" 8" 1-1/2" X 6 NC
50 X 62 22" 10" 1-1/2" X 6 NC

Welding and Cutting Precaution

When fitting up the grizzly, feeder, hoppers or chutes around the crusher, be sure that all welders are properly instructed to
observe the welding procedure warnings contained in this manual. The danger of improper placement for ground clamps
cannot be overemphasized and the rules outlined must be followed.
The welders should be instructed to take precautions to avoid any accidental momentary contact of the weld rod or holder
on the flywheels or jaw while preparing to or after completing welding on the frame. Such momentary contact will cause
serious pitting of the bearings at the narrow contact point between the rollers and the races, resulting in premature
bearing failure.
When doing any welding or cutting with an acetylene torch over the jaw crusher be sure to cover the space between the
flywheels and the outer oil seals so that no chips or particles of metal or dirt fall into these spaces. The same protection
should be provided for the spaces between the inner oil seals and the swing jaw bearing retainers.

07/03/08 -19-
 LUBRICATION
General
The swing jaws fill and vent plugs have been shipped in the box with the tools. Remove the plug inserted in the jaw barrel
and install the vent plug. Read this manual carefully, with special attention to the instructions on lubrication before operat-
ing the crusher.
It is a good policy to instruct those who will actually operate the crusher to check all bolts and nuts regularly and to keep
them tight at all times. Also instruct them to periodically review the manual because the information contained it will help
them get maximum performance and longer life from the machine.
The jaw crusher has been lubricated per specifications at the factory. Since speed, pressure and heat are factors to be
considered, oil has many definite advantages over grease, a fact that is recognized by most bearing manufacturers. Since
oil under these conditions remains more constant than grease, it performs a more consistent thorough job of lubrication,
and unlike grease it will not easily channel when cold or readily foam when hot. For these reasons oil is specified for all
Lippmann jaw crushers.
Many jaw crushers are lubricated by the oil-splash system. However some use an oil circulation system. The major
advantage of using the circulating system over the standard oil-splash system are that contaminants associated with
crushing plants are filtered from the oil and a clean supply of oil is fed to the swing jaw barrel and frame bearing reser-
voirs continuously. The flow regulator provides a measured amount of oil to be distributed to each of the bearing reservoirs.
The excess oil spills over the level gauges and returns to the tank through the sight gauges mounted on one end. See the
next section for details of the automatic lubrication system.
When filling a new crusher with lubricant prior to starting up, or in refilling after dismantling for repair, supply oil up to the
level points described below. Pour oil in slowly to allow ample time for it to run into the reservoirs, then close all openings
and run the crusher idle for a few minutes. Recheck the oil level frequently during the first day of operation to be sure that
there is sufficient oil. See capacity chart Table III. After this, check the oil level at these three points twice daily, preferably
at noon and at quitting time. It is very important to drain out all of the oil after the first forty (40) hours of operation and at
suitable intervals there after, depending upon the severity and the amount of continuous duty. Under average conditions,
the oil should be changed every two hundred (200) hours of operation.
The amount of oil to be added at each checking can soon be determined through experience. Great care must be taken to
insure a sufficient oil supply; however, caution must also be employed not to over lubricate since this will cause excessive
leakage. Please note that a small amount of oil should leak through the seals. Caution should be used to see that no dirt or
grit is permitted to get into the oil reservoirs when filling and also that the plugs are tight after filling.
It is good practice to add oil when shutting down at night instead of early morning because then the oil in the crusher is not
congealed, as it would be after a very cold night. Store the oil in a place free from dust, and in winter store it where it is
warm so that it will run freely. When either the oil or the crusher is very cold, it may take more time for the required
amount of oil to enter the oil chambers. To prevent oil from congealing in the jaw crusher during extremely cold weather
operation, attach an electric heater coil or a hot water or steam coil to the outside of the jaw barrel. Never apply direct
flame. Use only the above or similar methods. See Table IV for recommendations on brand and type of oil to use.
Table III
OIL CAPACITY CHART
BEARINGS 10x16 15x24 12x36 10x60 12x48 12x60 15x36 20x36 24x36 30x36
FRAME BEARINGS (each side) .5 pt. .5 pt. .75 pt. 1 pt. 1 qt. 1 qt. 1 pt. 1 pt. 1 qt. 1 qt.
SWING JAW BEARINGS 3 qt. 3 qt. 7.5 qt. 16 qt. 12 qt. 16 qt. 7.5 qt. 8 qt. 12 qt. 12 qt.

BEARINGS 22x42 30x42 22x48 30x48 36x50 42x48 46x48 24x50 30x62 50x62
FRAME BEARINGS (each side) 1 qt. 2 qt. 1.5 qt. 2 qt. 2 qt. 2 qt. 2 qt. 1.5 qt. 2 qt. 1 qt.
SWING JAW BEARINGS 15 qt. 22 qt. 30 qt. 30 qt. 30 qt. 30 qt. 30 qt. 30 qt. 32 qt. 55 qt.

07/03/08 -20-
 Table IV
LUBRICATION CHART
APPLICATION MOBIL TEXACO SHELL CHEVRON
Below 25 degrees F. Mobilgear SHC 150 Pinnacle EP 150 No Product Tegra Syn. Gear EP ISO 150
Above 25 degrees F. Mobilgear 600XP150 Meropa 150 Omala 150 Gear Compound EP ISO 150
Below 80 degrees F. Mobilgear SHC 150 *Multigear 80W90 *Spirax HD 80W90 *RPM Universal GearLube 80W90
Above 40 degrees F. Mobil Gear 600XP220 or Mobilgear SHC 150 Meropa 220 Omala 220 Gear Compound EP ISO 220

* Not recomended (Automotive product)

Manual Oil Lubrication System for Jaw Crushers

NOTE
TE:: Before operating any crusher, check the oil levels carefully.
NOTE

To check the oil level in the jaw barrel (see Figure 6):
1. Remove the center yellow plug in the pipe plug at the bottom of the jaw barrel.
2. If oil flows from this opening, let it drain until the oil stops flowing.
3. If no oil flows from this opening or if only a slight amount flows, remove the filler black plug at the top of the jaw and add
oil slowly until it begins to flow out of the bottom opening.
4. Replace filler cap.
5. Replace center plug (oil level plug).
6. To drain the jaw barrel, remove the large pipe white plug at the bottom of the jaw barrel.

To check the oil level in the frame bearings (see Figure 7):
1. Remove the oil level plugs marked in yellow (long plugs) located near the bottom of each inner oil seal.
2. If oil flows from these openings. Let it drain until the oil stops flowing.
3. If no oil flows from these openings or if only a slight amount flows, remove the filler black plug at the top of each frame
bearing retainer and add oil slowly until it begins to flow out of the bottom openings.
4. Replace filler plugs.
5. Replace bottom oil level plugs.
6. To drain frame bearings, remove the plug marked in white (short plugs) at the bottom of the inner oil seal.

NOTE
TE:: Whenever the oil is changed, wash out breather cap and re-oil if metallic wool type is used.
NOTE

NOTE
TE:: On some crushers, the drain plug is at the bottom of frame bearing retainer next to flywheel.
NOTE

07/03/08 -21-
 Figure 6
OIL LUBRICATION PLATE

JAW CRUSHER LUBRICATION INSTRUCTIONS

To check frame bearing oil level remove oil level plug (at bottom of bearing

retainer on drawing). Remove fill plug (dot directly above) and pour in the
recommended Mobil lubricant (see chart below) until oil flows from bottom opening.
Replace both plugs.

To drain frame bearing remove drain plug only (at bottom of bearing retainer).
To check oil level of jaw bearings remove small plug in center of drain plug (at
bottom center of jaw). Remove fill plug (at top of jaw) and pour in recommended

Mobil lubricant until oil flows from bottom opening. Replace both plugs.
To drain jaw bearings, remove drain plug (at bottom center of jaw).

Application Ambient Temperature Recommended Mobil Lubricant

Crusher Bearing Jaws < 25 F Mobilgear SHC 150
> 25 F to 80 F Mobilgear 600 XP 150 or Mobilgear SHC 150
> 40 F Mobilgear 600 XP 220 or Mobilgear SHC 150

SERIAL H.P. MODEL

R.P.M.
NO. NO.
DO NOT ALLOW DIRT OR GRIT TO ENTER OIL CHAMBER WHEN CHANGING OR
CAUTION: CHECKING OIL. REMOVE DIRT FROM PLUGS BEFORE SERVICING CRUSHER.

For Mobil product availability and technical information, call 1-800-662-4525.

3271 East VVan

an Norman Avenue Cudahy
Cudahy,, Wisconsin 53110 www.lippmann-milwauk
www.lippmann-milwaukee.com
.lippmann-milwaukee.com

Figure 7
FRAME BEARING DRAIN PLUG & OIL LEVEL GAUGE IN INNER OIL SEAL

Breather

Feed line (auto-lube only)

Either 1 location or 2
Always use location located
to the side opposite of the feed end

Return line (auto-lube only)

Either 1 location or 2
Always use location located
to the side opposite of the feed end

3 plugs:
1 drain (center plug)
1 oil level check
(Located to the side opposite of the feed end)
1 not used
Or:
2 plugs:
1 drain
1 oil level check
Receiving hole for guide pin

07/03/08 -22-
Automatic oil lubrication system for jaw crushers
Figure 8
AUTO-LUBE MAIN UNIT DESCRIPTION
Return from non-drive side Pressure gauge
Return from barrel
Pressure valve
Return from drive side
Reservoir fill

Drive motor

Oil heater Feed to jaw

Oil level sight glass (backside)

Oil filter
Non-drive side return oil temp
Barrel return oil temp
Drive side return oil temp

General
This automatic circulating oil lubrication system is designed to lubricate the tapered roller bearings in your jaw crusher.
This system will relieve you of flushing the oil from the bearing system, which normally occurs every 200 operating hours. A
circulating oil lubrication system will reduce operating temperatures and filter the oil thereby increasing the life of the
bearings and reduce downtime. This unit also comes with a heater which will reduce startup time when operating in cold
weather.

Description
The standard unit consists of a reservoir, 3/4 HP, 3 phase, 1200 RPM, 230/460V motor, .5 GPM gear pump, 460v-1.5 KW
heater and 60 degrees to 250 degrees F. controller, low pressure switch, filter, pressure & temperature gauges, sight
glasses, strainer, MX series flow divider, tubing and fittings mounted on the reservoir. A 30 Gal. reservoir is used on 42x48
and 50x62 jaw; all other jaws use a 20 Gal. reservoir.

Drawings Provided Include:

D10233 AUTO LUBE JAW LUBRICATION SYSTEM
D10232 AUTOMATIC OIL LUBE UNIT (20-GAL)
D10336 AUTOMATIC OIL LUBE UNIT (30-GAL)
C7003 AUTO-LUBE ELECTRICAL SCHEMATIC
DQ049-4 TYPICAL PLANT ELECTRICAL SCHEMATIC

Installation
This power unit is mounted on a skid and is carefully packed for shipment. Do not remove the unit from the skid until it has
been carefully checked for damage. Report any damage immediately to the carrier. After inspection, remove the unit from
the skid and locate it at the installation site. The pump should be at least 2-1/2 feet below the bottom of the crusher barrel.
Secure the unit to the base or floor, by using the four (4) mounting holes located in the reservoir legs. Rubber pads should
be placed under the feet. Complete pressure supply and return line connections.
The reservoir has been thoroughly cleaned and treated prior to shipment. Lippmann has filled the reservoir with industrial
grade 150 gear oil, at the factory. When filling the reservoir with oil in the future, fill the reservoir through the filter-
breather with the required oil, to the high level on the gauge. Check the clean out cover for leaks.

07/03/08 -23-
Startup
After all electrical and oil connections are made and the reservoir is full, turn the Chromalox heater to 100 degrees F. Never
turn the heater thermostat above 140 degrees F. Allow reservoir temperature to rise to 50 degrees F. Then jog the pump
motor once and check rotation. If different than indicating arrow on the pump, reverse the electrical leads. Next, jog the
pump motor three (3) times to prime the pump. After the pump is started, run the motor for several minutes and inspect for
leaks. (leaks in fittings and tubes can be caused by vibration during shipping) Tighten all leaks and slowly turn the red
relief valve to increase relief pressure to 150 to 200 PSI at 65 degrees ambient temperature.
Note: Oil may weep out of the labyrinth seals. Inspect for additional leaks, and repair as required.

Operation
It is important to remember that the autolube system is designed to deliver a proper FLOW OF OIL to the jaw bearings,
and that ambient and operating temperatures will affect the viscosity of the oil, thereby increasing or decreasing pressure
or flow. On a cold morning with ambient temperatures of 32 to 60 degrees Fahrenheit, it may be possible that the pressure
regulator will not adjust the pressure lower than 200psi. This is because the viscosity of the oil is high (meaning the oil is
thicker) and the regulator will not compensate for this. But you will also notice that the flow divider may only cycle 15
pulses per minute, meaning the FLOW is very low. However when the jaw oil is at operating temperature after crushing for
hours, the oil may be at 120 degrees Fahrenheit. Now you may not be able to reach a pressure of 200 psi, but the flow
divider may be cycling 120 pulses per minute, meaning the flow is very high.
This is why it is critical to remember that the best indicator of proper oil flow through your jaw and frame bearings is by
physically looking at the return flow through the 3 sight glasses on the autolube unit. It is critical that this be performed 4
to 6 times throughout a 10 hour period, unless a means of shutdown by FLOW has been installed in the crusher run
circuit.

Low-Pressure Alarm
A low-pressure alarm has been provided to prevent operation in the event a hose fails or the motor fails. A qualified electri-
cal contractor can interlock the circuit with the crushing equipment. We provide a square D GAW-5 pressure switch.
The pressure switch can be set to open at 40 PSI and close at 50 PSI the switch should be wired in the N.O. position. This
means the contacts will be set to open and shut down the crusher in an alarm condition. A knurled knob inside the pressure
switch can be turned to set the minimum pressure to 50 PSI. See drawing C7003 for typical electrical schematic.

Electrical
Connect the 230/460V, 60 Hz, 3-phase 3/4 hp electric motor to the starter. Units supplied with starters require connection to
the starter only. Connect the proper 460-volt supply to the pressure switch and heater. Electrical diagrams are supplied on
the inside of the box.

07/03/08 -24-
Maintenance For Manual & Automatic Systems
Motors
Lubricate as recommended by electric motor manufacturer.

Filters
Change or clean filter cartridge after the first 100 hours, thereafter as shown on indicator supplied with the filter.

Bearings
Check bearing temperature daily. If the temperature rises above 150 degrees F. and the ambient temperature is not above
90 degrees F., a new bearing may be required.

Jaw Flushing Instructions For Manual & Automatic Systems

It is recommended that the lubrication system for the jaw be flushed at specified intervals.

Jaw Barrel And Frame Bearing Sump

Drain and flush every 1,000 hours of operation for autolube system, and every 200 hours for manual systems.

Autolube System
Change oil in the autolube reservoir after the first 100 hours of operation. Afterwards, change oil every 1,000 hours de-
pending on application. Maintain proper oil level at all times.

Flushing instructions:
1. Completely drain the reservoir, jaw barrel, and frame bearings. The stand pipe must be removed to drain jaw barrel.
2. Reinstall all plugs and make a solution of 50/50 EP-150 and diesel fuel or kerosene. Refill the autlube reservoir with
this solution, and run the auto-lube until you get the solution returning in all 3 sight glasses. (For manual lubrication
jaws refill the barrel, and both frame bearings with the solution.)
3. Run the jaw for approximately 20-30 minutes (DO NOT CRUSH) to loosen up any sediment which may have accumulated
in the jaw barrel, frame bearings and hoses.
4. Stop the jaw, drain the autolube reservoir, barrel, and frame bearings completely, pull the inspection cover off the
autolube reservoir and wipe the inside of it clean.
5. Reinstall all plugs and refill the autolube reservoir with the recommended oil for the jaw. Run the auto-lube and recheck
your levels. For manual systems refill the swing jaw and frame bearings to specified levels.

07/03/08 -25-
07/03/08 -26-
07/03/08 -27-
07/03/08 -28-
07/03/08 -29-
07/03/08
-30-
30 GAL. JIC RESERVOIR
07/03/08 -31-
07/03/08 -32-
 JAW CRUSHER OPERATION
General
The jaw crusher is a tough machine; its ability to take it should not be used as an excuse for abuse. The crusher should
be shut down immediately when something is wrong. Continued operation may lead to serious trouble and to long shut-
downs and expensive repair bills.
Keep the crusher clean. An occasional coat of paint prevents rust and adds life. A clean looking crusher will receive better
care, will be better maintained and will not depreciate as quickly as one, which is neglected or abused.

Starting Care
After the crusher has been run idle for about 30 minutes and appears to be running smoothly, rock may be fed into the
machine and crushing started. At first, feed only a small quantity of stone into the crusher. Increase the feed gradually until
the crusher is operating under full load. Watch carefully, meanwhile, to be sure that all bolts are tight and that the crusher
does not bind at any point. Before the crusher is started each day, check the bolts for tightness. If this is done and if the
crusher is lubricated as directed and otherwise given reasonable care, it will operate for a longer time without any mainte-
nance, except for the normal wear of such wearing parts as jaw dies, cheek plates and jaw die extension wedges.

Material Size Adjustment

(Refer to Figure 2)
Depending on the size of jaw crusher, it can be used economically for either primary or secondary crushing. However, best
results are obtained if the ratio of reduction, i.e. the ratio between the feed and discharge openings, is kept between 4:1
and 8:1.

07/03/08 -33-
Crushers With Manual Toggle Adjustment
The crusher discharge opening can be easily varied by means of shims at the rear of the crusher frame. To adjust the
crusher to a smaller opening, first loosen the tension rod and the two toggle block wedges (Most crushers have two adjust-
ing screws, however, some smaller size units have only one.); then turn the adjusting nuts counter-clockwise to push the
toggle block forward and decrease the opening between the jaws.
In this procedure it is advisable to turn the adjusting nuts alternately, a small amount at a time, and to avoid cramping the
toggle block and binding the adjustment screws. After the desired opening is achieved (A), insert the necessary amount of
shims behind the toggle block; then tighten the adjusting screws by turning the nuts clockwise until the toggle block bears
firmly against the shims and the shims are bearing solidly against the frame. Next, Retighten the Toggle block wedges so
that the block is held rigidly. Then readjust the tension rod spring height (B), per the jaw general arrangment drawings. See
the section labeled tension spring, rod & toggle plate adjustment procedure for further adjustment procedures. Size of
opening (A) is measured from tip of corrugation on one jaw die to tip of corrugation on opposite jaw die.

07/03/08 -34-
Crusher With Hydraulic Toggle Block Adjustment
The crusher discharge opening can be easily varied by means of two adjusting screws located on the crusher frame. To
adjust the crusher to a smaller opening, first loosen the tension rod and the two toggle block wedges; then loosen the two
adjusting nuts. Push the toggle block forward and decrease the opening between the jaws by using the hydraulic pump.
After the desired opening is achieved (A), insert the necessary amount of shims behind the toggle block; then release
hydraulic pump and tighten the adjusting screws by turning the nuts clockwise until the toggle block bears firmly against
the shims and the shims are bearing solidly against the frame. Make sure sand or small stones are wiped clean behind the
shims, block, and frame to insure a tight fit. Some models have dual acting cylinders. On those models retract the cylinder
to hold the block against the shims. Next retighten toggle block wedges so that the block is held rigidly; then readjust the
tension rod so that the spring dimension (B) is per the jaw general arrangment drawing. The toggle plate and toggle
bearing must be run dry. Grease the thread on the tension rod and the adjusting screws occasionally to prevent rusting.
NO TE
TE:: Be sure to check that the crusher turns freely after making adjustments and maintain sufficient clearance between
NOTE
jaws, (A) especially when the crusher is set for fine crushing. See the section labeled tension spring, rod & toggle plate
adjustment procedure for further adjustment procedures.

Tension Spring, Rod & Toggle Plate Adjustment Procedure

The tension rod nut must be readjusted every time a change in the jaw crusher setting (A) occurs. First loosen the nut or
nuts, if there are 2 tension rods. Then bring the nut up against the tension rod spring so that it is snug in the seat. You may
have to lift up on the spring to seat it properly. Measure the distance (B) from the spring washer to the seat and record this
number. If there are 2 tension rods the numbers may be different. Tighten the spring to the distance specified in the
General arrangement drawing.
Put a guard over the tension rod. Run the jaw crusher and observe the toggle plate in the bearings. The play should be
eliminated between the swing jaw, Toggle bearing, Toggle plate and toggle block, during normal operation. Occasionally, a
very hard round rock in an empty jaw chamber may bounce the pitman and the toggle plate may come out about 1/8" and
go back in, this is normal.
If the toggle plate is coming out of the bearing in normal operation, the tension rod springs should be tightened an addi-
tional 1/2 turn by the tension rod nut. If the toggle plate moves to one side or the other, it can be repositioned in the middle
of the toggle bearing. The spring on the side the toggle plate moves toward should be tightened an additional 1/2 turn, if it
is a 2 toggle spring jaw crusher. After a few days of operation, the toggle plate and bearings will wear in and the toggle
plate side movement will stop.
Never lubricate the toggle plate and bearings with grease or oil. We have found in some instances this can reduce the life
of the toggle plate and bearings by a factor of 10. The toggle plate and bearings must be run dry.
07/03/08 -35-
Tension Rod, Air Spring & Hydraulic Toggle Adjustment Procedure
The air spring tensioning system in conjunction with the automatic hydraulic toggle has greatly reduced the time it takes to
change a jaw crushers settings.In general the air springs should be at a pressure of 90 PSI to 100 PSI with new jaw dies set
at an open side setting (A) that corresponds to the desired closed side setting. The air spring height should be about 13"-
14 or a length suitable that thebellows of the air bags are not permitted to rub against each other. (B) Turn the adjusting
nut to obtain this setting. As the jaw dies wear, the air spring height (B) will be reduced as the cylinders are extended to
keep the closed side setting constant. The bags may need to be lengthened if they become accordianed or so short that
the bellows are rubbing. Once again turn the adjusting nut on the tension rods to achieve a desired air spring length. (B)
The pressure switch is set at 75 PSI, if the pressure falls below this value the interlock will shut down the jaw so the hydrau-
lic toggle does not fall out. Exercise the hydraulic rams forward and backward making sure nothing hits. Also record the
height of the air spring in the retracted and extended positions. The air springs should not be less than 6-1/2" or more than
15" ever (at the open side setting). If they are, reset the air spring height (B) with the adjusting nut to compensate.
Also note the air pressure in the gauge (Item 2, Figure 31) will rise when closing the jaw.
- Start the crusher engine and throttle to the maximum operating speed (rpm).
- Proceed to open the jaw to the maximum opening. If a slapping sound is heard from the cylinder toggle ends this indi-
cates the tension rod forces are insufficient. If this occurs, add additional air until slapping stops. Now slowly close the
jaw to the minmum closed side setting and watch as you close that the pressure does not exceed 120PSI. Pressure can
vary by about 15PSI from minimum to maximum position. It is also critical that the cylinders have at least an inch of
relief travel either extended or retracted in the running position to avoid damaging the cylinders or jaw.
The roller system is preset at the factory. We center the roller gap to a 1/16 to produce a smooth rolling action. Please see
your general arrangement for the exact mounting configuration.

07/03/08 -36-
 JAW CRUSHER MAINTENANCE
Clearing Clogged Crusher
Although the jaw crusher is designed not to stall in operation, there is always the possibility of power failure or tramp metal
becoming caught or wedged in the crusher chamber. Should there be a power failure and the crusher stalls while loaded
with rock, remove any large rocks using winch or hoist that may be in the upper crushing chamber and then rocking the
swing jaw by alternately applying and relieving the power. Care must be taken, however in the case of diesel power not to
burn out the clutch or in the electric motor drive not to burn the V-belts, due to excessive slippage. With an electric motor
drive the rotation can be reversed, running the crusher backward, for short jerks and thereby loosening the rock jammed in
the chamber. Generally, these methods will remove the rock; however, in the case of tramp metal becoming wedged in the
chamber, it may be necessary to use hook bars to pry the rock loose and remove it from the chamber.
WARNING!
In any case, never attempt the use of dynamite to clear a clogged crusher.

Reverse Position of Toggle Block to Change Crushing Angle

(Some Crushers)
1. Remove toggle plate.
2. Loosen and remove toggle block wedge bolts.
3. Remove toggle block wedges.
4. Loosen adjusting screw and remove shims.
5. Remove toggle block cotter pins from nuts and unscrew bolts from nuts (cotter pins not on all crushers).
6. Remove toggle block, reverse position and return to position in the crusher.

Reassembly of Crusher After Reversing Position of Toggle Block

1. Position adjusting screws in toggle block nuts and align holes for pins. Replace cotter pins (cotter pins not on all crush-
ers).
2. Replace shims and tighten adjusting screws.
3. Replace toggle block wedges.
4. Replace and tighten toggle block wedge bolts.
5. Replace toggle plate
NOTE
NO TE:: Upper position toggle blocks are used for limestone or a wider closed side setting. Use the lower position when
TE
operating in extremely hard crushing, or at minimum closed side setting if power draw is to high.

Adjustments
1. Check tightness of all bolts daily.
2. Check tightness of tension rod daily
3. Examine cheek plates, jaw dies and jaw die extensions for wear every several days at first, every week thereafter.
Reverse or replace when necessary.
4. Examine toggle bearing, toggle plate and toggle block for wear at least once a month; replace when necessary.

07/03/08 -37-
Crushers with automatic hydraulic toggle relief & hydraulic adjustment

Jaw Toggle Cylinder

Serial Number

Jaw Toggle Cylinder

Model Number

Jaw Toggle Style

07/03/08 -38-
INTRODUCTION

The purpose of this manual is to provide information for the safe and effective use of your hydraulic toggle cylinders.
The sections of this manual are designed for easy reference.
The topics covered in this manual include:
Operations Procedures
Maintenance Procedures
Parts Information

Before attempting to operate the hydraulic toggle cylinders, you should be familiar with ALL aspects of this manual.
Attempting operation before you are familiar with all aspects of this system could result in damage to the equipment, or
possible danger to operating personnel.

General Information
Your new hydraulic toggle cylinders are designed to save those countless hours required for manually adjusting the jaw
setting for different aggregate sizes or a plugged jaw cavity.
The pair of cylinders are joined together by a cylinder saddle (Figure 9) and are designed to fit into the area normally
occupied by the toggle plate.
Figure 9

Production rates are expected to increase, since operators with very little effort, can adjust the jaw setting as frequently as
jaw wear warrants. In the event uncrushable material falls into the jaw, the system is designed to relieve the high pressure
fluid from the jaw cylinders back to the reservoir.

07/03/08 -39-
REDUCING JAW OPENING
Figure 10

Figure 11

Step 1
Using the control box, turn the motor switch to the
Motor On position (Figure 11).

Step 2
Using the control box (Figure 11) push the switch to the
Close Jaw position. Continue to hold the switch down
until the desired jaw setting is achieved.

Step 3
Using the control box, turn the motor switch to the
Motor Off position.

07/03/08 -40-
Increasing Jaw Opening
Figure 12

Figure 13

Step 1
Using the control box, turn the motor switch to the
Motor On position (Figure 13).

Step 2
Using the control box (Figure 13) push the switch to the
Open Jaw position. Continue to hold the switch down
until the desired jaw setting is achieved.

Step 3
Using the control box, turn the motor switch to the
Motor Off position.

07/03/08 -41-
Hydraulic Toggle Maintenance

Pump Maintenance
To maintain a safe working environment and maximize the life of the hydraulic toggle system, we recommend the following:
1. Periodically check all hydraulic hose and hydraulic fittings for fluid leaks.
2. Check the fluid level indicator (located on pump reservoir, Figure 14). If low, fill the reservoir with (ISO 32 AW) hydraulic
fluid only.

Figure 14
IMPORT
IMPORTANTANT
ANT::
Do not overfill reservoir. Overfilling Reservoir could
result in damaged hydraulic hoses. Before measuring
reservoir, first open the jaw to the maximum setting.
This retracts the jaw toggle cylinder rods, thus return-
ing the cycled fluid back to the reservoir.

Figure 15

NOTE
TE::
NOTE
To increase the life of the hydraulic pump, seals and
valves we recommend the following:
1. Replace the internal filter at least once per year
(Not Shown).
2. For (Item 1, Figure 15), replace the filter if the filter
pressure gauge needle is in the red area. For the filter
(Item 2, Figure 15) replace the filter if the filter
minder (Item 3, Figure 15) indicates change.

07/03/08 -42-
Toggle End Maintenance
1. Periodically check the toggle ends (Item 1, Figure 16) and the toggle seats (Item 2, Figure 16) for excessive wear. If worn
then replace all items.
NOTE
NO TE:: Do not just replace the toggle ends without also replacing the toggle seats.
TE

Figure 16

Hydraulic Toggle Parts Information

Parts Ordering Procedure
When ordering parts, please provide the following information:
a) Hydraulic Toggle Cylinder Serial Number: (example: J94200-A2)
b) Hydraulic Toggle Cylinder Model Number: (example: C3042)
d) Part Description: (example: piston seal)
e) Quantity Required: (example: 6)
NOTE
TE:: When viewing the hydraulic toggle cylinder parts lists, there are various types illustrated in the jaw cylinder assem-
NOTE
bly parts list section. Select the appropriate style when ordering parts.

07/03/08 -43-
 HYDRAULIC TOGGLE CYLINDER ASSEMBLY PARTS LIST
Item No. Quantity (2-Cyl) Description
1 2 Cylinder
2 2 Cylinder Rod
3 2 Retainer Flange
4 See Note 1 Solid Toggle End
5 See Note 1 Cylinder Toggle Extensions
6 See Note 1 Toggle Ends T-type
7 2 Saddle
8 8 Spirol Pins
9 2 Piston Seals
10 4 Piston Wear Rings
11 2 Flange Piston Seal
12 2 Back-up Rings
13 2 Rod Seals
14 2 Back-up Rings
15 2 Wiper Seals
16 4 Rod Wear Rings
17 See Note 2 Hex Head Bolt
18 See Note 2 Hardened Flat washers
19 See (Saddle Assembly Parts List) Hex Head Bolt
20 See (Saddle Assembly Parts List) Flat Washers
21 See (Saddle Assembly Parts List) Hex Nuts
22 See (Saddle Assembly Parts List) Eye Bolt
23 See (Saddle Assembly Parts List) Flat Washer

NOTE
TE::
NOTE
1. Quantities could vary depending upon whether toggle ends are split (Quantity: 4) or toggle ends are continuous span
(Quantity: 2).
2. Bolt sizes & quantities vary. Quantities are usually 12, 16, 18 or 20 per cylinder. Bolt sizes are usually 3/4-10 UNC x 2"
long, 1-8 UNC x 2-1/2" long, 1-1/8-7 UNC x 3" long or 1-1/4-7 UNC x 4" long, (Grade Bowmalloy).
3. When purchasing parts, the unit serial number will be required to obtain accurate part numbers.

07/03/08 -44-
 HYDRAULIC TOGGLE CYLINDER ASSEMBLY PARTS LIST
Item No. Quantity (3-cyl) Description
1 2 Cylinder Body
2 2 Cylinder Rod
3 2 Retainer Flange
4 1 Rod Toggle End
5 2 Toggle Ends
6 3 Piston Seal
7 6 Piston Wear Ring
8 3 Piston Seal
9 3 Back-up Ring
10 3 Rod Seal
11 3 Back-up Ring
12 6 Rod Wear Ring
13 3 Wiper Seal
14 36 5/8-11 UNC x 1-3/4 Lg. Hex Head Bolt
15 36 5/8 Dia Heavy Duty Flatwasher
16 4 0.500 Dia. x 3 Lg. Slotted Spring Pin
17 4 0.313 Dia. x 3 Lg. Slotted Spring Pin
NOTE
TE::
NOTE
1. TORQUE 3/4-10 UNC BOLT HEADS TO 310 FOOT-POUNDS. USE BOWMAN COPPER ANTI-SEIZE COMPOUND ON THREADS.

07/03/08 -45-
 3-CYLINDER HYDRAULIC TOGGLE
NOTE
TE::
NOTE
On 3-cylinder hydraulic toggles replacable toggle ends like item 5 can be provided with a different rod toggle end.

07/03/08 -46-
 2-CYLINDER HYDRAULIC TOGGLE

07/03/08 -47-
 SADDLE ASSEMBLY PARTS LIST
Item No. Quantity Description
1 1 Cylinder Saddle (2 - 1/2 Sections)
2 6 or 8 See Note 1
3 6 or 8 See Note 2
4 6 or 8 See Note 3
5 1 See Note 4
6 2 See Note 5
7 2 See Note 6

NOTES:
1.Depending upon the saddle size, the following sizes are used:
3/4" - 10 UNC x 4-1/2" long hex head bolts (grade Bowmalloy).
1"- 8 UNC x 5-1/2" long hex head bolts (grade Bowmalloy).
1-1/4"- 7 UNC x 6-1/2" long hex head bolts (grade Bowmalloy).
2. Either 3/4", 1", or 1-1/4" diameter lock washers.
3. Either 3/4"- 10 UNC, 1"- 8 UNC or 1-1/4" - 7 UNC hex nuts (grade Bowmalloy).
4. Either 3/4"- 10 UNC, 1"- 8 UNC, 1-1/4" - 7 UNC or 1-1/2" - 6 UNC eye hook.
5. Either 3/4"- 10 UNC, 1"- 8 UNC setscrew.
6. Either 3/4"- 10 UNC, 1"- 8 UNC hex locknut.

07/03/08 -48-
 HYDRAULIC CIRCUIT DIAGRAM

07/03/08 -49-
 HYDRAULIC HOSE PARTS LIST
1/4 NPT PORTS ON CYLINDER
Item No. Quantity Description Part Number
1 1 1/4" Rear Port Hose (11@600 PSI) c/w 2-1/4 NPT Hose Ends ---
2 1 1/4" Front Port Hose (5@000 PSI) c/w 2-1/4 NPT Hose Ends ---
3 2 1/4" Front Port Hose Extensions (5@000 PSI) c/w 2-1/4" NPT Hose H42504
4 2 1/4" Rear Port Hose Extensions (11@250 PSI) c/w 2-1/4" NPT 353-4
5 1 1/4" NPT Female Pipe Tee C3709 x 4

3/8 NPT PORTS ON CYLINDER

Item No. Quantity Description Part Number
1 1 3/8" Rear Port Hose (10@000 PSI) c/w 2-3/8 NPT Hose Ends ---
2 1 3/8" Front Port Hose (4@000 PSI) c/w 2-3/8 NPT Hose Ends ---
3 2 3/8" Front Port Hose Extensions (5@000 PSI) c/w 2-3/8" NPT Hose H42506
4 2 3/8" Rear Port Hose Extensions (10@000 PSI) c/w 2-3/8" NPT 352-6
5 1 3/8" NPT Female Pipe Tee C3709 x 6

NOTES
TES::
NOTES
For 1/4" Hose
For 5,000 PSI hose:
The hose end part number is O4U-104.
For 11,600 PSI hose:
The ferrule part number is JET04-352-BZP.
The male insert part number is
JET04NM04-BZP.
For 3/8" Hose
For 5,000 PSI hose:
The hose end part number is O6U-106.
For 10,000 PSI hose:
The ferrule part number is JET06-352-BZP.
The male insert part number is
JET06NM06-BZP.

07/03/08 -50-
 HYDRAULIC CONTROL PARTS LIST
Item No. Quantity Description
1 1 Reservoir (15 Gallon Standard)
2 1 Electric Motor (See Note 2)
3 1 Pump (Not Shown)
4 1 460V or 575V Control Box
5 1 120V Control Box
6 1 Internal Suction Filter (Not Shown)
7 1 4 Way, 3 Position (Tandem Center) Solenoid Valve (See Note 3)
8 1 Return Filter
9 1 0-5,000 PSI Pressure Gauge
10 1 External Pump Pressure Relief Valve (See Note 1)
11 1 Rotary Valve Actuator
12 Coupling
13 1 10,000 PSI Ball Valve
14 1 Tank Heater
15 1 Hand Control
16 1 Air Breather Filter
17 1 Filler Breather Adaptor Plate
18 1 10,000 PSI Safety Relief Valve (3/8" NPT PORTS)

NO TES
TES::
NOTES
1. This valve is preset to 2800 PSI. DO NO
NOTT adjust this setting.
2. The voltage could vary from 24V, 110V, 220V, 380V, 460V or 575V.
3. The voltage could vary from 24V or 110V.
4. All lines are steel tubing (#8 JIC, 1/2" O.D.). All fittings are JIC to 3/8" NPT.

07/03/08 -51-
07/03/08 -52-
Hydraulic Toggle Cylinder Disassembly and Reassembly
Important
To ensure proper service of your jaw cylinder assembly, we recommend that all repairs be performed by Lippmann-Milwau-
kee, Inc. Lippmann-Milwaukee will not assume responsibility for damage or injury to equipment and /or persons involved
which result from improper customer servicing or repair.

Step 1
Using the hydraulic toggle cylinders (see section on Reducing Jaw Opening); close the jaw until the jaw is at the minimum
opening. This will maximize the clearance between the pitman and the toggle block for removal purposes (Figure 17).
Figure 17

Step 2
To support the weight of the Hydraulic toggle, attach an overhead crane or chain hoist around the cylinder assembly
(Figure 11).

Step 3
When the cylinders require servicing and need to be removed from the jaw crusher, the tension forces on the tension rods
must be reduced to zero. Reduce the air pressure in both air springs until the gauge reads zero (0) PSI. Either press the air
valve to release the air or crack a hose fitting loose with a wrench. After the pressure drops to zero if the hose fitting was
loosened retighten with wrench.

07/03/08 -53-
Step 4
Utilizing a chain hoist (Figure 20); take the weight of the pitman off the hydraulic toggle.

Figure 20

Figure 21
Step 5
Remove both tension rods and yoke
(Items 1 & 2, Figure 20). This will now
provide the necessary space required
to lower the hydraulic toggle cylinder
assembly (Figure 21).

07/03/08 -54-
 Figure 22
Step 6
Using the hydraulic control,
retract the cylinder rods
(Figure 22) all the way (see
section on Increasing Jaw
Opening).

Figure 23
Step 7
Install all safety locking bars
(Item 1, Figure 23) to the
toggle cylinder assembly. This
example shows the bars on
the bottom of the cylinder
assembly. Locking bars are
also located on the top of
some toggle cylinders.

Step 8
Remove all Hydraulic hoses from the cylinders (Items 1-5, Figure 23). Then using either 1/4" or 3/8" NPT hex plugs, plug all
open fittings at the cylinders.

IMPORTANT:
DO NO
NOTT lift the toggle cylinder assembly using the safety
locking bars or eye bolts (Item 1, Figure 24) . Lift the cylinder
assembly by wraping a chain around the saddle.

07/03/08 -55-
Step 9
With the pitman secured, all hydraulic hoses removed and the toggle cylinder secured with locking bars, remove the
cylinder assembly from the jaw crusher (Figure 25).
Figure 25

Step 10
Disassemble the toggle cylinders (Figure 26) for inspection. If the cylinders require new seals, wear rings or toggle ends,
(see section Jaw cylinder assembly parts list).

07/03/08 -56-
 Figure 26
2-CYLINDER HYDRAULIC TOGGLE SEPERATION

3-CYLINDER HYDRAULIC TOGGLE SEPERATION

07/03/08 -57-
Step 11
Before reinstalling the toggle cylinders:
Toggle cylinders are repaired & pressure tested.
The pitman is held secure with a chain hoist (Item 1, Figure 27).
The safety locking bars are fastened to the toggle cylinder assembly (Item 2, Figure 27).

Figure 27

Step 12
Use an overhead crane or chain hoist to raise the cylinder assembly into position.

NOTE:: Insert the cylinder (rear) toggle ends into the toggle seat first (Figure 27).
TE
NOTE

IMPORTANT:
DO NO
NOTT lift the toggle cylinder assembly using the safety
locking bars or eye bolts (Item 2, Figure 21) . Lift the cylinder
assembly by wraping a chain around the saddle.

07/03/08 -58-
 Figure 28
Step 13
With a chain hoist, open the jaw
pitman until the toggle seat of
the pitman comes in contact with
the rod toggle end of the toggle
cylinders (Figure 28).

NO TE
TE::
NOTE
The full weight of the pitman
should now be resting against
the toggle cylinders.

Figure 29
Step 14
Reattach all hydraulic hoses to
the cylinders. Then reinstall the
tension rods and yoke (Items 1 &
2, Figure 29).

07/03/08 -59-
Step 15
To support the weight of the jaw cylinders sufficient tension must be applied to the tension rods. Since the toggle cylinders
where installed in the completely collapsed position, the jaw opening at installation will be the maximum opening (Dimen-
sion - A, Figure 30). The air spring length should be approximately 14"-17" (Dimension - B, Figure 30).
Figure 30

Figure 31
Using an air compressor (not shown), attach the hose to
the filler valve (Item 1, Figure 31). Fill each air spring
until the gauge (Item 2, Figure 31) reads approximately
90 PSI.

07/03/08 -60-
Step 16
Remove the chain hoist holding the pitman and any overhead crane or chain hoist holding the toggle cylinders (Item 1 & 3,
Figure 32).
FIGURE 32

Step 17
Remove all locking bars and locking plates (Items 2, Figure 27) from the toggle cylinder assembly.

Step 18
All air must be removed from the hydraulic circuit. Using the toggle cylinders, open and close the jaw the full range of the
toggle cylinders. (See Reducing Jaw Opening& Increasing Jaw Opening for instructions).
NOTES
NO TES:: 1. Repeat this step 3 or 4 times to cycle the hydraulic fluid thru-out the system.
TES
2. Toggle cyinder rods should always be extended 1 during operation to allow for some tramp relief

Step 19
Set the air springs to the correct position. (See Tension Rod, Air Spring & Hydraulic Adjustment Procedure for
instructions)

07/03/08 -61-
 IMPORTANT INFORMATION
Jaw Cylinder Repair
1. When repairing or servicing hydraulic toggle cylinders ensure all replacement parts are genuine Lippmann-Milwaukee
Inc. parts.
2. When assembling the cylinders, ensure that Bowmalloy hex head bolts are used.
3. Properly torque all bolts to reduce the fatigue stress in the bolt. See Table B below for suggested assembly torque values.

Figure 34

Table B
ASSEMBLY TORQUE (FOOT-POUNDS)
BOLT DIAMETER TIGHTENING BOLT HEAD TIGHTENING NUT
(INCHES) (ITEM 1 - FIGURE 34) (ITEM 2 - FIGURE 34)
3/4" - 10 360 305
1" - 8 875 725
1-1/4" - 7 1700 1450

NO TES
TES::
NOTES
1. All torque values are based on the use of hardened flat washers under the bolt head or nut. This provides a uniform hard
bearing surface. 2. The torque values are based on applying Bowman Anti-Seize Compound to the threads before
assembly.

07/03/08 -62-
Relief Valve Settings
The relief valve is preset from the factory.
JAW SIZE RELIEF VALVE PRESSURE SETTING RELIEF VALVE PRESSURE SETTING
2-CYLINDER SYSTEM 3-CYLINDER SYSTEM
2436 7500 PSI
2248 9500 PSI
2450 9500 PSI
3042 8000 PSI
3048 9500 PSI 9500 PSI
3062 7500 PSI 8000 PSI
3650 6800 PSI 7000 PSI
4248 8500 PSI 9000 PSI
5062 8000 PSI

DO NO
NOTT adjust this pressure setting above the tabulated values without contacting Lippmann-Milwaukee, Inc.

Troubleshooting

PROBLEM PROBABLE CAUSE SOLUTION

Hydraulic Toggle Hydraulic fluid leak in hose or hose See Section Cylinder Hose Parts List and replace
Opens Slowly as Jaw ends. damaged hose.
Setting Increases Replace safety relief valve. Part Number: JC-13.
Leak at safety relief valve. Replace ball valve. Part number: HC-18.
Adjust pressure setting 500 PSI higher than the
Damaged ball valve. existing setting.
IMPORTANT
IMPORT ANT The relief valve is preset tabulated
values from the factory.
Hard crushing where the pressure
exceeds the safety relief valve NOTT adjust this pressure setting above the
DO NO
setting. Thus oil is relieving back to tabulated values without first contacting Lippmann-
the hydraulic reservoir. Milwaukee, Inc.

Air Spring Pressure Air leak in hose or hose ends Replace with new hose assembly.
Loss Gauge Air tank leak. Replace with new air tank.
Air spring leak. Replace with new air spring.

Slapping sound heard Air pressure is too low in the air Charge the air springs to the required pressure.
from toggle ends while
crushing

07/03/08 -63-
Electrical Circuit
ELECTRICAL CIRCUIT DIAGRAM

Replacment parts
Replacment of fuse or relay may be
necessary
Item No. Quantity Description
1 2 Fuses - 10 AMP
2 1 Relay

07/03/08 -64-
 DISASSEMBLY
General
When making preparations to disassemble the jaw crusher, it is necessary to provide adequate lifting equipment for the
heavy assemblies. See technical specifications for approximate weights of parts.
Drain oil from jaw barrel and frame bearing reservoir prior to disassembly. Make sure to have spare parts and new clean
oil on hand to get the crusher back in service after repairs are completed.

Toggle Assembly
Parts of the toggle assembly must be removed before removing the swing jaw from the frame. Proceed as explained under
size adjustment to remove shims from the back of the toggle block. After shims have been removed, the toggle block may
be pulled back to allow room to remove the toggle plate. Remove the tension rod and attach a chain tackle to the bottom of
the swing jaw at some convenient point ahead of it. Support the toggle plate by means of a chain hoist with one end
attached to the toggle plate and the other to the lifting lug on the top of the jaw barrel. Pull the swing jaw toward the
stationary jaw die thereby releasing the toggle plate. The toggle plate can then be lowered out the bottom or raised out
over the top of the back section of the frame. With the swing jaw pulled ahead, the toggle block can be easily removed.
First, remove the cotter pins holding the square nuts on the adjusting screws. The square nuts are in the recess cast into
the toggle block and can be seen when looking down at the toggle block from the rear of the crusher. The adjusting screw
assembly can then be removed from the crusher. On newer model fabricated toggle blocks the adjusting screw is held by a
pin. Remove this pin and pull the adjusting screw out. The toggle block should now be supported by attaching a chain hoist
to it and to the lifting lug at the top of the jaw barrel. Remove the toggle block wedge bolts and toggle block wedges. The
toggle block can then be hoisted out the top of the crusher.
To remove a worn toggle bearing, splitting the bearing down the edge along its full length will facilitate its removal.

Removing Stationary Jaw Die

In order to remove the stationary jaw die, the stationary jaw die extension must first be removed. Tilt the die forward
slightly so that a hook bolt or cable sling can be inserted into two holes on die ribs (see Figure 36).
Occasionally a die extension or a cheek plate may become wedged into place too tightly to remove easily due to the pen-
ning of the metal. To remove the cheek plate, take out the cheek plate bolts; drive a wedge, chisel or pinch bar between the
upper edge of the cheek plate and the frame to loosen the plate; then insert a hook bolt into the slot provided on the upper
edge of the cheek plate and pull upward, prying at the same time if necessary.
The jaw die extensions can be removed by taking out the die bolts and inserting a rod somewhat smaller than the bolt hole
so that it bears against the edge of the bolt hole in the extension. The extension is then forced out by sledging on the rod.
After the die extension is removed the die can be pried forward so that hoisting bolts can be inserted.

07/03/08 -65-
 Figure 36
REMOVING JAW DIE

Dismantling Shaft Assembly

Should it become necessary or desirable to inspect or replace a bearing or other internal part or the shaft assembly, the
jaw must be removed from the frame. It is necessary to first remove the flywheels (see paragraph following on removing
flywheels). The frame cap bolts and the frame caps must be removed. Remove the toggle plate and tension rod. The jaw
and shaft assembly can now be removed from the frame be sure to provide safe and stable support for the jaw in a location
protected from dust and dirt before attempting disassembly. (See Figure 37).

Figure 37
SUPPORTING SWING JAW

07/03/08 -66-
 Figure 38
DISASSEMBLY OF JAW CRUSHER SHAFT ASSEMBLY

Flywheel Removal
To remove the flywheels, remove the lock plate, lock nuts, flywheel clamping washer and four (4) flywheel bolts. Next, use a
puller as shown in Figure 38. To expand flywheel hub for ease in removing flywheels, two wedges may be driven in flywheel
to spread the split hub slightly.

Removal of Frame Bearings

Next remove the frame bearing retainer bolts. Press inner oil seal towards jaw barrel to allow room to insert pry bars to
press off the outer oil seal and the frame bearing retainer. These parts can be pried off with a slight even pressure on two
or more points. Be sure to polish the shaft and oil it before attempting to remove the outer frame bearing spacer.
Remove the frame bearing spacer. This spacer can best be removed by heating it evenly with a torch to expand it suffi-
ciently to slip it off the shaft. Be careful not to overheat or have the heat travel to the shaft and expand it thereby defeating
the expansion of the spacer.
Should the frame bearing be unfit for use, cut off the outer race with a torch. Cut the bearing cage to remove rollers and
heat inner race to expand it sufficiently to pry it off. If the bearings are good, a puller must be used as shown in Figure 39,
using puller bolts and a 2" or 2.5" plate as shown. Tighten evenly on all bolts to loosen the bearing on the shaft. After the
bearing starts moving easier, only half of the bolts may be needed to pull the bearing the remainder of the way. After the
bearings are removed the inner oil seal should be inspected for any war page caused by pulling the bearing. Should this
inner oil seal show signs of war page, it must be refaced to true it up before the new bearings are installed.
Clean and polish the shaft at the frame bearing fit before attempting to remove the inner oil seal collar. This collar can be
removed by the same method as explained for the frame bearing spacer in a preceding paragraph.

07/03/08 -67-
Removal of Swing Jaw Bearings
To remove the swing jaw bearings, proceed as follows:
NO TE
TE:: Support must be provided for the shaft by means of a crane, using a double chain sling or by using a chain hoist on
NOTE
each end of the shaft.
NOTE
NO TE:: Remove the swing jaw bearing retainer bolts. The swing jaw bearing retainer can be removed by inserting round-
TE
pointed setscrews in the tapped holes provided for this purpose.
NOTE
NO TE:: The tapped holes provided for removing the swing jaw bearing retainers are located in the same outer bolt circle as
TE
the swing jaw bearing retainers bolt holes.
After the swing jaw bearing retainers are removed. Proceed to remove the shaft assembly from the swing jaw. Swing the
shaft out one end of the jaw as far as possible or until one chain bears against the swing jaw barrel. The shaft must then be
supported by blocking, or other means to allow a new hook up to be made that will allow the shaft to be removed com-
pletely. Should the swing jaw bearings be worn out, they may be cut off with a torch as explained in removal of frame
bearings. Before using a torch to cut these bearings, the swing jaw bearing collar and the swing jaw bearing slinger must
be removed. Heat the parts evenly with a torch as explained for the frame bearing spacer and remove in the same way. If
the swing jaw bearings are good and it is desirable to save them, a puller must be used. Refer to Figure 39 for type and use
of puller. When using this puller, swing jaw bearing, spacer, slinger and bearing collar will be removed in one operation.

Figure 39
REMOVING SWING JAW BEARING

07/03/08 -68-
 REASSEMBLY
General
Before reassembling, the bearings and retainer should be careful to keep the bearings and retainers clean. Do not allow
grit, sand or dirt to enter the bearings or internal parts of the jaw. After the bearings and retainers have been thoroughly
cleaned, they should be re-oiled with a light oil to prevent oxidation or rusting, and the shaft relubricated with oil before
reassembling.
Figure 40
SHAFT ASSEMBLY

Installation of Swing Jaw Bearings

Since the bearings are fitted to the shaft with a heavy press fit, they must be heated in oil to expand them sufficiently for
easy mounting. The bearings should be heated in oil to approximately 280 degrees F. A suitable thermometer should be
used to ascertain and control the correct temperature.
IMPORTANT
IMPORT NOTE
ANT NO TE::
TE
Great care must be used to insure that oil temperature does not exceed 300 degrees f. Bearing should be suspended in oil
pan or bucket to keep away from direct heat source.
All high capacity finished anti-friction bearings are made of highly tempered and hardened steel. This steel is subject to
annealing and loss of temper at temperatures as low as 350 degrees F. hence, it is very important to control the heating
temperatures.
Be sure to install the spacer on the shaft before the bearings are installed. Heat this spacer in oil as explained in the
following paragraph for installing bearings. Then place it on the shaft with the radius firmly against the radius on the shaft.
After the oil has reached the right temperature, leave the bearing in oil for about 15 minutes, and then place it on the shaft
firmly against the spacer. Hold the bearing in this position until it is sufficiently cooled and contracted to hold tightly to the
shaft. Next, press the bearing cup into the retainer, taking care to avoid cocking.
After both swing jaw bearings are installed on the shaft and cups are inserted into retainers, place the shaft back into the
jaw; then heat the swing jaw bearing slinger in the oil to expand it sufficiently for easy installation onto the shaft. Install the
slinger by holding tightly against the bearing cone until it is sufficiently cooled contracted.
Next, heat the swing jaw bearing collars in oil in the same manner as the slingers and install them on the shaft. Be sure to
make firm contact with the slinger and rotate the collar so that the hole matches with the hole in the slinger.
Great caution must be exercised to maintain the proper clearance between the swing jaw bearings. Install one retainer with
approximately 1/16" of shims and tighten securely. Now start opposite retainer and draw up evenly, rotating the shaft
constantly to insure that bearing rollers are seated properly. When bearings begin to drag, measure the shim gap with a
feeler gauge, add from 0.006" to 0.009" to this measurement and install shims of the total thickness. Tighten bolts securely.
Remove two opposite bolts extending beyond end of shaft. Across these bolts use a steel plate having a setscrew in line with
the center of the shaft. Place a steel ball in center of shaft is being rotated until all play is taken up. Note reading on a dial
indicator set up to record movement and repeat process on opposite side, leaving indicator mounted. Again, take reading
on dial indicator. This will give true clearance of bearings and shims can be added or removed to give proper clearance.
Use 0.001" to 0.006" clearance for all crushers. Tighten all bolts securely. See shaft assembly drawing for actual clearance
requirement.

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Heat the inner oil seal collars in oil and install to butt firmly against the swing jaw bearing collar. Now slip on the inner oil
seals. Place inner frame bearing cup in frame bearing retainer so that the large cup shoulder will butt against the inner oil
seal. Install frame bearing retainer. Next heat frame bearings in oil as directed previously. Be very careful to avoid over-
heating. After the bearings have been heated to 280 degrees F. to 300 degrees F, for about 15 minutes, slip them on the
shaft and into the frame bearing retainer. Then insert outer frame bearing cup into frame bearing retainer.
NO TE:: Some large jaw crushers have a labyrinth type outer seal and slinger collar on frame bearings. For initial assembly,
NOTE
TE
do not install slinger until bearing clearance adjustments are made.

Installation of Frame Bearings

Install the outer oil seal and tighten frame bearing retainer bolts. Be sure to rotate the frame bearing assembly while
tightening to avoid cocking and to seat bearings properly. After the retainers have been tightened so that the bearings bind
slightly, check for play by placing a wooden block on shaft and with a bar pry on retainer, being careful not to burr the oil
groove in oil seal. When all play is removed, check shim gap with a feeler gauge. Be sure to measure to several points on
the circumference and ascertain that there is no gap between inner oil seal and frame bearing retainer while measuring
gap at frame bearing retainer and outer oil seal. Now, remove bolts and add from 0.004" to 0.006" shims and retighten the
bolts. Be sure bolts are tightened securely and rotate shaft to be sure there is no binding. Frame bearing should have 0.004"
to 0.006" endplay (Note: 50x62 is 0.008 to 0.010 endplay). See shaft assembly drawing for actual clearance requirement.
Next install frame-bearing spacer so that it bears firmly against the outer frame bearings cone.
Table V
TORQUE TABLE FOR JAW CRUSHERS
Crusher size Swing jaw bearing retainer cap screws ft. lbs. Outer oil seal cap screws ft. lbs. Frame bearing cap nut ft. lbs.
10 x 16 730 160 500
15 x 24 730 160 2000
12 x 36 730 160 2000
12 x 48 790 160 2000
12 x 60 830 180 2000
15 x 36 730 160 2000
20 x 36 790 160 2000
24 x 36 790 160 2000
30 x 36 1000 160 2000
22 x 42 1000 160 2000
30 x 42 1000 220 2300
32 x 42 1000 220 2300
22 x 48 1000 160 3500
30 x 48 1000 220 2300
36 x 48 1000 300 3500
42 x 48 1000 300 3500
46 x 48 1000 300 3500
24 x 50 1000 160 3500
30 x 62 1000 220 2300
36 x 50 1000 300 3500
50 x 62 1200 600 6800

NO TE
TE:: If frame bearing has outer seal and slinger collar, remove bearing retainer and install slinger collar. Replace bearing
NOTE
retainer and tighten all bolts securely. Never use neversieze on jaw crusher nuts & bolts.

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After the assembly is completed, rotate the shaft to check that it turns freely and does not bind. Before placing jaw assem-
bly into frame, be sure to remove the burrs from retainers and retainer seats in the main frame. This is very important
because the frame-bearing retainer must be kept in perfect alignment.
Frame caps must be free of burrs on surface seating on retainer. Caps are match-marked and must be replaced according
to these marks since they are not interchangeable. Torque the frame bearing cap nuts per the torque table above.
Replace toggle assembly. The tension rod spring must have enough tension to prevent the toggle plate from bumping. Too
much tension will cause early failure of tension rod springs. Then install the flywheels, flywheel clamping washers and lock
washers and lock nuts if required.
Then make sure the oil chambers are filled to the proper level with the recommended lubricant. Rotate the crusher to
check for any binding.
If the crusher is to stand idle for a prolonged time, the machine should be run once every two weeks, or enough to keep
bearings coated with lubricant and prevent corrosion of the bearing surfaces. If a crusher sits for a period of time the oil
will need to be flushed to prevent contamination.

Lifting Chain Specifications

Use safe load strength of heat-treated nickel alloy steel chain slings, (be very sure chains to be used are in excellent
condition not rusted, gouged, nicked, kinked, stretched or worn).

Table VI
LIFTING CHAIN SPECIFICATIONS
ALLOY SINGLE CHAIN DOUBLE BRANCH TYPE USED AT ANGLES OF:
CHAIN SIZE Lbs. on Straight Lbs. on 60 lift Lbs. on 45 Lift Lbs. on 30 Lift
9/32 # 2,750 # 4,763 # 3,889 # 2,750
3/8 # 6,600 # 11,431 # 9,332 # 6,600
1/2 # 11,250 # 19,485 # 15,908 # 11,250
5/8 # 16,500 # 28,578 # 23,331 # 16,650
3/4 # 23,000 # 39,836 # 32,522 # 23,000
7/8 # 28,750 # 49,795 # 40,653 # 28,750
1 # 38,750 # 67,115 # 54,793 # 38,750
1-1/8 # 44,500 # 77,074 # 62,923 # 44,500
1-1/4 # 57,500 # 99,590 # 81,305 # 57,500

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07/03/08 -72-
 Table VII
TORQUE AND LOAD TABLES

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07/03/08 -74-
 WARRANTY
The Company warranties all parts of its equipment against defective material or
workmanship for 90 days from the date of shipment from factory and will repair or replace free
of charge all such defective parts if returned to the factory prepaid providing factory
instructions were followed explicitly in the use of said equipment. The Companys liability for
damage caused by any such defective part shall be limited to such repair or replacement, and in
no event shall the Company be liable for indirect consequential damage. The Company, however,
shall not be not responsible for defects in faulty performance of, or incompetent operation, or
operation with repair or replacement parts not furnished by the Company, or operation with
repair or replacement parts not furnished by the Company, or operation beyond the rated
capacities of the equipment sold, or faulty units, parts, or installations or other equipment not
sold, equipped and installed by this Company. Nor shall the Company be held responsible for
defective parts or damage incurred there from, on any component part or unit not manufactured
by the Company, such as bearing, motors, etc. In instances of this kind, however, the Company
will forward such complaints to the manufacturer for the part or unit for the action. Parts
claimed to be defective under this warranty shall be returned promptly to the Company plant at
Cudahy, Wisconsin, freight charges prepaid, and each part shall be properly tagged, noting
thereon the model and serial number of each unit from which the part was taken. The company
makes no warranties express, implied or statutory other than herein contained, and the Company
is to be wholly discharged of liability hereunder in case the Buyer fails to settle and pay for the
goods promptly and in accordance with the terms of the contract.

PATENTS

We shall defend any suit or proceeding brought against you so far as it is based on claim
that any apparatus, or any part thereof, furnished, when employed in the manner intended by us,
constitutes an infringement of any patent of the United Stats, if notified promptly in writing and
given authority, information and assistance for the defense of same. In case of the apparatus or
any part thereof is in such suit held to constitute infringement and its use, the manner intended
by us is enjoined we haul at our own expense, and at our option, either procure or you the right
to continue using said apparatus or replace same with non-infringing apparatus, or modify it so it
becomes non-infringing or remove said apparatus and refund the purchase price and the
transportation cost thereof. The foregoing states our entire liability for patent infringement by
said apparatus or any part thereof.
07/03/08 -76-
 Lippmann-Milwaukee, Inc.
3271 East Van Norman Ave. Cudahy, WI 53110-0586
(800) 648-0486 (414) 744-2565 Fax: (414) 744-8172
www.lippmann-milwaukee.com

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