TEREX FINLAY C-1550

CHAMBER MAINTAINENCE

Rev-01

Author: Herbie Jones

Date: 03/03/2011
Subject to change without notice
 TEREX 1300 - COMPONENTS

MANTLE NUT ECCENTRIC CONCAVE LINER

UPPER
FRAME MANTLE LINER
OIL FLINGER WEDGE RING
ASSEMBLY

ROLLER MAIN FRAME

BEARINGS WEAR LINER
LABRYNTH STRIPS
TAPERED
ROLLER
BEARINGS DUMPY JACKS

ANTI-ROTATION
POST
ROTORY
SEAL RING
LUB OIL
FEED C/B

MAINFRAME
COUNTERSHAFT
PINION BOX
BEVEL GEAR GEAR
MAIN SHAFT LUB OIL LUB OIL
FEED IN RETURN x2
 TEREX – 1300 COMPONENTS

Upper Frame & Concave Liner

 One Piece Solid Cast Steel Upper Frame
 Two Separate Upper Frames to Adapt Liner Configurations
 Quick Wedge Locking System for Liner Retention
 Backing Compound Required on Concave Liner
Concave Wear Liner
One Piece Cast Upper Frame

Backing
Compound
 TEREX 1300 - CONCAVES

Coarse Concave Autosand Concave

Has the largest feed opening capable of accepting Designed to accept a feed size from 63mm (2.1/2
220 mm (8.1/2 inch) down material. Ideally suited inch) to 13mm (1/2 inch). Used for applications
for making 40mm (1½ inch) down material. where plenty of fines and small aggregates are
required.
 TEREX 1300 – UPPER FRAME

 There are two types of upper frames, to hold the different profiles of concaves.

 The course concave will only fit in upper frame #1 and the Autosand concave in upper frame #2.

 As the course concave is shallower than the other one the difference in the upper frames are clearly
visible below.
Accepts standard course
concave ONLY!! Accepts autosand concave ONLY!!

Upper frame #1 Upper frame #2

 TEREX 1300 - COMPONENTS
Main Frame & Wedge Ring Assembly
 One piece cast Main Frame
 One piece cast Wedge Ring machined to high specifications
 Full set of Hydraulic Wedge Jacks, Dumpy Jacks Expanding
 Easy access to Dumpy Jacks on Full Assembly Wedge Ring

 Anti-rotation Post, Upper Frame Lock

 Set of Friction Grip Wedge Pads

Wedge Friction Pads

Tramp Relief Cylinder

Main Frame Clevis
Anti-Rotation Post

Dumpy Jack Cylinders

Main Frame Casting

 TEREX 1300 - COMPONENTS
Wedge Locking Mechanism
Dust seal
Upper
Frame
Expanding Wedge Ring

Button
grease
nipple

Dumpy
Mainframe Jack
Cylinder
Hydraulic Dumpy Jacks
 TEREX 1300 - COMPONENTS
Eccentric Assembly

 Steel Cast Eccentric, Machined to the Highest Specification

 Complete Roller Bearing System, Higher Load Tolerance & Less Friction thus Less Power Required to Drive
 Bolt on Rotary Seal Ring & Labyrinth Seal Interface with Head
 Bolt on Machined Bevel Gear Cylindrical Roller Bearings

Cylindrical Roller Bearing Inner Labyrinth Seal, Bakelite

Race Strips

Counter weight

Taper Roller Bearing

One Piece Eccentric
Casting
Bolt on Rotary Seal Ring

Taper Roller Bearing Outer

Bolt on Bevel Gear
Race
 TEREX 1300 – COMPONENTS

 High Specification Machined Steel Cast Head, same for all Configurations
 Main Eccentric Taper Roller Bearing Outer Race Mounted inside Lower Head Section
 Cylindrical Roller Bearing fitted in Upper Head Section
 Standard Mantle Liner for all Configurations
 Quick Liner Removal Technique
Mantle Liner, Wear
 Backing Compound Required for Mantle Plate

Backing compound
Mantle Nut, Wear Part

Torch Ring

Cylindrical Roller Bearing

One Piece Casting Head

Taper roller bearing

 TEREX 1300 - COMPONENTS
Countershaft Box Assembly
Lubrication Oil Feed-In
 High Specification Machined Steel Cast Countershaft Box
Port
 Two Tapered Roller Bearings, Oil Bathed
 Separate Lubrication Oil Feed In Port & Oil Drain Port
 High Grade Machined Steel Countershaft, Keyed on Drive End
 Pressed on Pinion Gear with Friction Lock-ring

High Grade Steel Machined

Countershaft

One Piece Steel Cast

Countershaft Box

Pinion Drive Gear

Keyed Shaft for Direct Drive
Pulley

Taper Roller Bearings

TEREX 1300 – COMPONENTS

The crusher is driven via a PT Tech wet

clutch through a drive shaft and then an
adjustable ‘V’ Belt arrangement.

Counter shaft
box location

‘V’ Belt tension can be checked

through an inspection plate on the
drive belt cover.
 TEREX 1300 - COMPONENTS
Linear Transducer
 The linear transducer is found on the outer body of the chamber.
 This is used to send a value to the PLC and in turn give a measurement of
the CCS on the chamber.
 The CSS gap will be shown on the CONE SET-UP MODE screen in mm.

Buttons F2 & F3 open or

close the cone
Side View
 TEREX 1300 - COMPONENTS
Complete TEREX 1300 Assembly

Upper Frame, Lined with

Course Concave

Complete Head
Assembly, Lined

Complete Eccentric Complete Cone Assembly, with Adjusting Cylinders &

Assembly Dumpy Jacks

Mainframe, Main Shaft & Countershaft

Wedge Ring Box
TEREX 1300 - WORKING
 TEREX 1300 - LUBRICATION

 Cone lubrication oil is pumped to the cone by a

hydraulically driven pump.
 There are 2 inlet points; 1 at the base of the main
shaft and the other above the countershaft box.
 The oil flows down through all the bearings and
gears then back to the lubrication tank via two return
hoses.
 Fitted on the lube oil feed line is an electronic flow
metre which measures the amount of oil flowing to the
cone.
 There is also a temperature transducer, and an
electronic level indicator fitted on the lubrication tank.
 There is an auxiliary heater module, mounted in the
lube tank, to pre-heat the lube oil before operation.

Oil inlet Oil return

TEREX 1300 - LUBRICATION

The counter box shaft has its own

separate lube oil feed in and return
to tank.

Lubrication Oil Feed-In

Port

Oil inlet for the Counter box shaft

counter box shaft lubrication oil return. Lubrication Oil
lubrication oil return port
 TEREX 1300 - LUBRICATION

 There are 2 oil outlets on the main shaft

 One oil port is situated at the top of the main shaft, there is also a stationary oil flinger just below the oil port to
help distribute the oil evenly over the upper bearing.
 The oil from this port lubricates the upper and lower cone head bearings.

Lower Oil
Upper Bearings Port
Inner races

Upper Oil
Port
Upper Bearing
Oil Flinger
Inner race

Lower Bearing
Lower Main
Bearing

Eccentric Assembly Main Shaft Assembly

 CONE CONTROL BLOCK

 The cone control blocks function is primarily to open & close the chambers CCS & to protect the cone
from excessive loads inside the crushing chamber.
 Monitors the crushing pressure i.e. (Hydraulic pressure on the top side of the six clamping cylinders)
also the operation of the wedge ring charge / discharge function, & wedge ring pressure.
 TEREX 1300 WEDGE RING

Upper Wedge Ring pad

Lower Wedge Ring pad

Upper Frame grease nipples (12 off)

Upper Frame greasing position

(Upper frame level with bottom of dumpy jack
cylinder)
Dumpy jack stool

 Once the wedge ring has been released, the upper frame needs to be positioned so that the bottom of the
upper frame is in line with the bottom of the dumpy jack cylinder (Not the stool!!).
 With the upper frame in this position, the grease nipples are situated in between the two wedge ring pads.
 TEREX 1300 – WEDGE RING
 When it comes to the greasing of the wedge ring little is better!!!
 Only grease the wedge ring if the pressure in the clamping cylinders goes above 83Bar as you close the cone
 Lightly grease all 12 of the nipples with Moly Bentone grease. Move the upper frame to its fully open and
closed positions for a number of times to spread the grease within the wedge ring.
 Fully open and close the upper frame and monitor the travel. The ideal wedge ring pressure is between 800 to
1200 Psi (55 - 83 Bar) as you close!! (As pressure is only measured on the upper rod end of cylinder).
 If the travel is not smooth or more likely that the pressure is too high, repeat the greasing procedure.

Wedge ring pressure

Clamping cylinder gauge
pressure gauge
Button type grease
nipple
Grease cavity

Note!!
Use supplied Moly
Correct upper frame Bentone Grease
level for greasing only!!

Dumpy jack stool

 TEREX 1300 FRAME ARM SHIELDS
 It is vitally important that the frame arm shields are checked on a weekly basis to ensure there is no material
build up.
 Potential damage that can occur include the seal ring getting damaged and possible loss of lube oil and lifting
of the complete cone head resulting in dirt ingress and possible bearing failure.
 Access can be gained to the frame arm shield’s by sliding down the main conveyor, via opening the inspection
hatch or the pre-screen chute.
Countershaft Arm Shield Key Frame arm shield

 The main frame arm shields drop over the arm supports as does the countershaft arm shield, but the
countershaft shield locates over a key way to prevent movement.
 The head and eccentric need to be removed from the machine to replace the shields, so it would be good
practice to replace them when the machine is being re-metalled.
 TEREX 1300 – FRAME LINER

 The main frame has liner plates welded inside, on its full circumference.
 The liners should be checked on a weekly basis as with the arm shields.
 Provided all liners and arm shields are replaced before they wear through, no damage or wear should
take place on the main frame.
Cross sectional view of Main Frame Main frame Liner

Countershaft Arm
Shield

Frame Arm Shield

TEREX 1300 – MANTLE NUT
 The mantle nut has a replaceable wear plate bolted to it to pre-long the life of the nut.
 When replacing the wear plate, strike it a number of times with a hammer as this should free it up,
and hence allow it to be removed more easily. The 4 off countersunk bolts can also be struck in the
same manner to release them.
 When the new wear plate has been fitted, it would be good practice to fill the 4 holes with silicon so
it will not build up with dirt and have to be chipped out when replacing the wear plate in the future.

Mantle Nut
REMETAL (SAFETY)

Before any type of work is to be carried out on any machinery ensure all safely precautions
are in place e.g.
Work permits, Risk assessments, Lock out tag out, correct PPE & ensure all lifting
equipment has been certified (Chains, chain blocks ,slings etc).
 REMETAL

Figure1
Minimum pin centers
measurement is 805 mm Wear
32 mm
when the cone is closed
fully touching metal to
metal with fully worn
liners.

 New liners metal to metal pin centre measurement is 910mm (Approx.)

 When the liners are new there is approximately 50mm of wear life between both the Concave & Mantle. Once
the wear level reaches 45 mm the wear display box (Figure1) will turn yellow to indicate that a liner change will
need to happen shortly.
 When 50 mm of wear occurs then the wear display box will turn red as a warning that the maximum allowable
wear has occurred and new metal should be fitted immediately.
 The cone clamping pin centres can also be checked to confirm the maximum allowable wear has been reached
this measurement will be 805mm when the cone is zeroed.
REMETAL
The following procedure covers the complete liner change
 When changing the Mantle and Concave, start the machine and leave at low rpm.
 Close valve B and open valve A, this should allow the pressure to drop to zero on the wedge ring
pressure gauge (Figure ’C’).
 The upper frame should be raised and lowered until there is no pressure registering on the wedge ring
pressure gauge as you close (Gauge C).
 Once this has been carried out, raise the upper frame until approx. 5mm (3/16’’) from being fully open.

Dumpy Jack Bleed valve B

(Normally Open)

Dumpy Jack valve A

(Normally Closed)

Wedge ring pressure

gauge ‘C’

Cone control block

REMETAL

Remove these
Slide the feeder fully forward connections

 Once the pressure in the wedge ring has been released, remove the dust suppression hose and
the cable for the cone level sensor (Magic eye)
 Ensure the machine is sitting level then slide the feed conveyor fully forward and fold the pre-
screen down out of the way.
REMETAL

Figure 1

 Remove the bolts from around the cone feed box & attach four chains at the feed box lift points
(double check that the level sensor cable & dust suppression hose have been disconnected).
 Then lift it clear from the machine (Figure1), again ensure all the proper safely precautions are in
place.
REMETAL

Figure 3
Figure 1 Figure 2

 Once the feed box has been removed attach the four chains to the lift points on the upper frame and take
the weight off the six clamping cylinders (Figure1).
 Remove the split pins on the Rhs of the six clamping cylinders and knock the pins out from a right to left
direction (Figure 2) (To avoid unseating the bearing in the upper frame clevis) (Figure3)
REMETAL - CONCAVE

Figure 1 Figure 2

 Before lifting the upper frame off disconnect the CCS transducer from the side of the upper frame
(Figure 1 & 2)
 Lift the upper frame slowly and make sure its level otherwise it could get stuck!!
REMETAL - CONCAVE

Figure 1 Figure 2
Dowel Retaining wedge

 Once the upper frame has been set on the ground with the gas torch cut through the four retaining legs
on the top of the concave (Figure1) and remove the tapered wedges, dress these up with a grinder to
remove any burrs etc the dowels can be removed later on.
 Once all four lugs have been cut then with a sledge hammer unseat the old concave and knock it out on
the floor (Figure 2).
 Remove the debris from around the dowels etc with a wire brush.
REMETAL - CONCAVE

Figure 2
Figure 1

 Once the old concave has been knocked out then turn the upper frame upside down & knock out
the four dowels.
 Using a wire brush or a grinder with a sanding disc clean all the dust/dirt etc from the upper frame
ensure it is well cleaned before applying the release agent (Figure2).
 If the proper release agent is not available a light smearing of grease will do, the area highlighted
above in Figure 1 shows where the release agent should be applied.
REMETAL - CONCAVE
 The taper part of the concave which contacts the upper frame will need
to be dressed with a grinder to ensure there is no high spots or damage
during transport etc. This is to ensure there is a good metal to metal fit
Figure 1 between the two faces (Figure1).
 A small track of silicon can also be applied to ensure the backing
compound does not leak out when being poured.
 Lower the upper frame down on top of the concave.
 With the aid of the specially designed lifting tool Figure 2), lift the
Figure 2 concave up inside the upper frame carefully guiding the lugs through the
pockets on the upper frame (Figure3).
 Once the lugs have cleared
through the pockets, rotate the
concave clockwise so that the lugs
are approximately half way
between the dowel hole and the
pocket (figure 4).
Figure 3 Figure 4
 REMETAL - CONCAVE
 All three wedges can now be inserted from left to right. Keep the concave in tension on the upper frame by the
lifting mechanism.
 Drive the wedges in first with a hammer to keep them all at even distances, then with the aid of a sledge
hammer and drift, drive them around. The tension on the concave can now be removed and lifting tool taken out.
 It’s a good idea to put a mark where the dowel hole is so that you can make a judgement if you can flog the
wedge past the dowel hole or not.
 If the wedges are very tight & not going to make it past the dowel hole then you will have to remove the wedges
and turn the concave slightly in a anti clockwise direction.
 Safety glasses should be worn when carrying out this procedure due to the possibility of shrapnel!!!

Put a mark beside

all four dowel holes.
 REMETAL - CONCAVE

 Drive in the wedges in tight so that they are flush with the edge of the dowel hole.
 Insert the dowel with some anti seize grease.
 If the wedges are not that tight when it gets to the edge of the dowel hole, continue with the sledge hammer
until the wedge becomes tight, then weld in a fill piece between the dowel and the wedge.
 Once the concave preparation then start work on the mantle as both can be filled with the backing compound
later on.
Ideal situation with
wedges tight.

If wedges are not tight

enough, keep flogging
until tight and then
weld in a fill piece.
 REMETAL - MANTLE
 It’s a good idea to cover around the wedge ring to stop any dirt sticking to it during the work & also to have
some wet material on the belt to prevent hot slag from burning it.
 As the mantle nut operates through its life it will always be turning against the material, therefore continuously
tightening at all time, also as the mantle liner wears it will spread, and hence force itself tight up against the nut
preventing it from being undone easily.
 This force will have to be relived from the nut by cutting the mantle torch ring all the way around approximately
25mm/1’’ from the top of the mantle as shown.
Torch ring
 Ensure full PPE is worn when carrying out this procedure.
 REMETAL - MANTLE

 To unscrew the mantle nut, clean out all dirt in the square hole at the top of the nut.
 Insert the flogging bar which is located on the inside of the chassis below the feed conveyor.
 Using a sledge hammer, strike the flogging bar until the nut becomes undone.
 NOTE; THE NUT IS LEFT HAND THREAD, SO ROTATE CLOCKWISE TO LOOSEN!!!
 Insert a bar through the mantle nut and lift clear using a suitable lifting device.

Flogging bar

Torch ring cut to

relive tension on
mantle nut
 REMETAL - MANTLE
 Firstly loosen the mantle by striking with a sledge hammer around the mantle.
 Ensure that the Isolator is switched off , the engine ECM plugs are removed, the Hetronic receiver antenna &
cables (If fitted) & the PT Tech clutch controller are all disconnected before any welding is to be undertaken!!!.
 Make sure the welding earth clamp is fitted to the part that you intend to weld to protect the bearing journals etc
throughout the machine (See figure 1&2).
 Two heavy duty lifting lugs can be welded onto the side of the mantle (Using Dissimilar steel, Stainless Steel or
Low Hydrogen welding rods only!!) and is carried out by a qualified welder/fitter (Figure 2). Ensure the main belt is
again protected with material during the welding process.
 The mantle can then be lifted clear and placed on the ground (Figure 3)

Figure 1 Figure 2 Figure 3

 REMETAL - MANTLE
 As on the concave the lower taper will need to be a good metal to metal fit to seat properly, it will be necessary
to clean them up with the aid of a sanding disc on a small grinder or wire brush etc to remove paint or damage
that might of occurred during transport. (Ensure the proper PPE is worn)
 The entire cone head should be well cleaned each time a new mantle is to be fitted.
 After cleaning any burrs & paint off the taper on the new mantle the welding of the lifting eyes can then be done.
 REMETAL - MANTLE

 The release agent can now be put on the cone head with an old rag. Wipe a thin film from the bottom of the
threads down to the start of the metal to metal taper (Figure1).
 A small line of silicone can be used to ensure any backing compound from leaking out until it hardens
(Figure 2).
 Once this is done then the new mantle liner & torch ring can be set in place, take care not to damage the
threads when lowering the liner. (Figure 3)

Figure 1 Figure 2 Figure 3

 REMETAL - MANTLE

 Before fitting the mantle nut brush some grease around the threads for easier future nut removal.
 Screw mantle nut down anti clockwise and put the flogging bar through to tighten it up, flog the nut up tight
and then loosen the nut back off again. (This is done to help seat the liner correctly and to also centralise it).
 It’s a good idea to put a mark on the nut and mantle so after the backing compound is filled and the nut re-
tightened you need to go at least to or past the mark.
 REMETAL – BACKING COUMPOUND

 The ideal temperature range for the backing compound to work is between 16° - 32°C
 With a suitable mixing paddle and a drill first mix up the backing compound which is usually harder on the
bottom from settling over time.
 Add the hardener slowly while still mixing the compound thoroughly.
 Once well mixed together begin pouring the backing compound immediately ensure that both mantle &
concave are dry and there is no chance of rain as this will reduce the strength of the filler.
 REMETAL – BACKING COUMPOUND
 Pour the backing compound into the upper frame through all four pockets until it reaches approximately 10
mm from the top edge of the upper frame .(Figure1)
 Holding up the torch ring fill the mantle up to 20mm approximately from the top of the liner (Figure2) (This
space is to allow for the torch ring to seat properly on the liner)
 Tighten the mantle nut down and insert the flogging bar through it, using a sledge hammer tighten the nut as
much as possible until it will tighten no more.
 You will need three buckets of backing compound for the mantle & seven buckets for the standard course
concave.
Fill Levels

Figure 1 Figure 2
 REMETAL – UPPER FRAME

 Lift the upper frame up level and clean any debris that may of stuck to it on the ground smear a thin layer of
Moly Bentone grease around the inside to help slide over the mainframe.
 Slide the upper frame down and line up the anti rotation post and lower down and fit the six clamping
cylinders, again fitting the pins in from a right to left direction.
 The feed box can now be set back on in place and bolted down, grease the bolts for easier removal next time,
re-connect the dust suppression hose and the level bowl sensor (Magic Eye).

Anti rotation post.

 REMETAL - SETUP
The date of the new remetal will
now be displayed.

Figure 1 Figure 2

 Once the remetal is complete then close the crusher down by

pushing & holding button F3 (Figure 2) continue until there is a quick
pressure spike on the crushing pressure gauge (Figure3) as soon as Figure 3
this happens release the button.
 To complete the remetal push button F6 on (Figure 2) you will then be asked to enter a passcode, push F1 to
escape and then enter Configuration mode (Figure 1), enter the passcode 1000 ( Note!!! This is to ensure there
is no confusion between doing a remetal and calibrating zero position) return to the Cone setup page again.
 Push F6 you then see above button F4 ‘Confirm new zero’ push and hold F4 until the wear & date of the new
remetal have changed.
 REMETAL – WEDGE RING
 Recharge the wedge ring circuit by closing valve ‘A’ & opening valve ‘B’ the lower Rhs pressure gauge ’C’
should charge up to 2300Psi approximately.
 Open the cone up and close it down note the pressure on the clamping cylinders this should be between 55 -83
Bar (800 – 1200 Psi) as you close the cone, if the pressure is lower than 55 Bar as you close the cone there is too
much grease around the wedge ring, to help this you should fully open and close the cone several times to spread
the grease thinly ,continue this process until the pressure reaches at least 55Bar.

Dumpy Jack Bleed valve B

(Normally Open)

Dumpy Jack valve A

(Normally Closed)
Clamping cylinders
pressure (Reading only Wedge ring pressure
when cone is closing) gauge ‘C’
REMETAL

 Once the cone has been re-metalled and zeroed, the backing compound will need time to harden
before crushing can start.
 Refer to the manufacturers chart below for approximate curing time for the Korrobond 65 backing
compound.
 Note!! If ambient temperatures are lower than 23°C curing time will have to increase.