Operation & Maintenance Manual

Maintenance Checks

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Model CT-Series Jaw Crushers

Operation & Maintenance Manual

Jaw Crusher Daily Inspection Form

Jaw Crusher Daily Inspection Form

Date __________
Signature _______________________________

7) Flywheel bolts - tight

OK Not OK See Notes
8) Flywheel counterweights - tight
OK Not OK See Notes

Pre-Start-up Checklist

1) Lockout & Tagout - crusher & assoc. equip.

OK Initials ______________________

9) Jaw dies and cheek plate bolts - tight &

jaw dies in good condition
OK Not OK See Notes

2) Under-crusher discharge area - clear of debris

OK Not OK See Notes

10) Pitman tension rod springs tensioned properly

OK Not OK See Notes

3) Belt guards - present, in good condition

OK Not OK See Notes

11) Crusher setting (C.S.S.) checked & adjusted

properly _________Inches _________mm
OK Not OK See Notes

4) Belts - tensioned, clean, in good condition

OK Not OK See Notes
5) Sheaves - aligned, clean, in good condition
OK Not OK See Notes
6) Pitman Shaft:
a. Seals - good condition
OK Not OK See Notes
b. Seals - greased properly
OK Not OK See Notes
c. Bearings - housing bolts tight
OK Not OK See Notes
d. Bearings - greased properly
OK Not OK See Notes
Last Greased at _______________________
Initials ______________________________

Notes:
_____________________________________
_____________________________________
_____________________________________
_____________________________________
_____________________________________

CRSH-OM-0003ENG(OCT-2014)

12) Hydraulic System:

a. Breather cap, control levers & valves - in
place, secure & tight, no leaks, no damage
OK Not OK See Notes
b. Lines & hoses - in place, secure & tight, no
leaks, no damage
OK Not OK See Notes
c. Cylinder(s) - securely pinned, no leaks, no
damage
OK Not OK See Notes
d. Cylinder hydraulic pressure is adequate and
replenished.
OK Not OK See Notes
e. Reservoir - oil clean and at proper level
OK Not OK See Notes
Oil Added - Qts. ______________________
Initials ______________________________
f. Oil & Filter Changed - Qts._____________
Initials ______________________________
Notes:
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________

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Model CT-Series Jaw Crushers

Operation & Maintenance Manual

Jaw Crusher Daily Inspection Form

Start-up Checklist

13) Remove Lockout & Tagout - crusher &

associated equipment
OK Initials ______________________
14) Jog crusher drive motor to verify pitman shaft
rotates in proper direction (See Diagram)
OK Not OK See Notes

20) Crusher run 50% load - 2 hours minimum

OK Not OK See Notes
21) 50% load bearing temperatures checked
(140-160F. / 60-70C.)
OK Not OK See Notes
22) 50% load power draw _____________Amps
OK Not OK See Notes
23) 50% load crusher balance is good
OK Not OK See Notes
24) Crusher run 75% load - 4 hours minimum
OK Not OK See Notes
25) 75% load bearing temperatures checked
(140-160F. / 60-70C.)
OK Not OK See Notes
26) 75% load power draw _____________Amps
OK Not OK See Notes

15) Crusher shaft runs at ______________RPM

OK Not OK See Notes
16) Crusher run no load - 2 hours minimum
OK Not OK See Notes
17) No load bearing temperatures checked
(140-160F. / 60-70C.)
OK Not OK See Notes
18) No load power draw _____________Amps
OK Not OK See Notes
19) No load crusher balance is good
OK Not OK See Notes
Notes:
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________

CRSH-OM-0003ENG(OCT-2014)

27) 75% load crusher balance is good

OK Not OK See Notes
28) 100% load power draw _____________Amps
OK Not OK See Notes
29) 100% load bearing temperatures checked
(140-160F. / 60-70C.)
OK Not OK See Notes
30) Crusher at work
Diesel Engine RPM ____________________
Electric Motor Amps ___________________
Total Crushing Hours Today _____________
Downtime Today ______________________
Notes:
________________________________________
________________________________________
________________________________________
________________________________________

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Model CT-Series Jaw Crushers

Operation & Maintenance Manual

Jaw Crusher Troubleshooting Chart

Table 5 - 6 Jaw Crusher Troubleshooting

ISSUE

POSSIBLE CAUSE

SOLUTION

Bearings overheating

Incorrect grease

Use specified type grease

Over greasing or under

greasing

Use proper quantity of lubricating grease

Crusher is overloaded

Eliminate overload condition

Low oil level in system

Ensure oil reservoir is at proper level

Hydraulic pump not operating

Ensure hydraulic pump has power and is activated

Low hydraulic pressure

Ensure hydraulic system pressure is adequate

Hydraulic lines incorrectly

connected

Check and ensure lines are correctly connected

Air in hydraulic system

Bleed air by removing tension spring tension and

attempting to open and close C.S.S. two full cycles

Damaged wedge surface(s)

Ensure wedge surface(s) are smooth and clear of

debris. Replace as required.

Hydraulic leak

Check and repair leaks

Hydraulic lines incorrectly

connected

Check and ensure lines are correctly connected

Adjustment wedges
will not move

Adjustment wedges
open during
operation

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Model CT-Series Jaw Crushers

Operation & Maintenance Manual

Jaw Crusher Troubleshooting Chart

Table 5 - 6 Jaw Crusher Troubleshooting

ISSUE

POSSIBLE CAUSE

SOLUTION

Crusher loses RPM

Excessive fines in crushing

chamber

Check material feed and remove fines

Low voltage

Check power source

Loose or worn drive belts

Adjust belt tension and replace belts as required

Worn drive sheave

Replace drive sheave as required

Improper jaw dies for

application

Check with TRIO for jaw die options

Electrical power issues

Check power source, wire size, drive motor

Drive belt issue

Check and adjust belt tension and replace belts as

required

Tension springs not equally

adjusted

Check tension springs. Adjust as required.

Worn buffer(s)

Inspect and replace buffer(s) as required

Worn toggle plate

Inspect both ends of toggle plate to check wear

Crusher not level

Check and make sure crusher is level

Material build up on top of

toggle entering lower buffer

Keep toggle plate area free of material build up and

debris

Tension springs not equally

adjusted

Check tension springs. Adjust as required.

Crushing on one side only

Ensure feed is centered and not segregated

Un-crushable object(s) went

through machine

Remove un-crushable object(s) from feed

Exceeding recommended
reduction ratio

Adjust feed size or adjust C.S.S.

Uneven jaw die wear

Improper feed to crusher

Ensure feed is centered and not segregated

Cracked jaw dies

Jaw dies excessively worn

Replace jaw dies at 80% wear

Crusher frame parent steel

worn

Remove dies, inspect and repair crusher frame as

required

Un-crushable object(s) went

through machine

Remove un-crushable object(s) from feed

Application issues

Evaluate crusher application

Poor crusher
performance

Toggle plate drift

Uneven toggle plate

wear

Cracked/broken
toggle plate

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Model CT-Series Jaw Crushers

Operation & Maintenance Manual

Jaw Crusher Troubleshooting Chart

Jaw Crusher Troubleshooting Chart

The following chart outlines some of the issues,
possible causes, and solutions to those issues you
may encounter with the jaw crusher.
Table 5 - 6 Jaw Crusher Troubleshooting
ISSUE

POSSIBLE CAUSE

SOLUTION

Crusher will not start

Incorrect wiring

Check wiring diagram

No power

Check power source

Defective motor

Check motor. Replace if defective.

Soft start issues

Ensure soft start is functioning properly

Crushing chamber full

Clear crushing chamber

Excessive amp draw

Possible voltage drop. Check power source.

Excessive fines in feed

Remove fines from feed.

Un-crushable object in
crushing chamber

Clear crushing chamber

Damaged or worn bearings

Replace bearings

Discharge opening set too

close

Adjust discharge opening to within specifications

Flywheel/Drive sheave turned

on shaft

Re-mount flywheel/drive sheave in proper position

Excessive fines build up in

flywheels

Clean dust or material build up from flywheels

Crusher running too fast

Ensure crusher is running at proper RPM

Crusher not secured to

mounting structure

Ensure crusher foot mounting bolts are secure to

structure

Loose toggle plate

Check tension springs. Adjust as required.

Gap between upper buffer

and upper buffer guide too
large

Add shims to close gap to between .5 ~ 1.0 mm

Loose die bolts

Tighten die bolts as required

Dirt/material buildup in toggle

plate seats

Remove dirt/material buildup

Loose bolts

Tighten all loose bolts as required

Crusher stops under

load

Crusher shakes/
vibrates

Excessive noise
(knocking,
squeaking,
rattling, etc.)

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Model CT-Series Jaw Crushers